ICE/SOFT DRINK POST-MIX DISPENSER Models: 2230 K4-100 2230 K4PB-100 2230 K6-100 2230 K6PB-100 2230 AK6 2230 AK6 PB Publication Number: 91487 Release Date: November 01, 1999 Revision Date: May 08, 2014 Revision: E THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment CORNELIUS INC; 1989-2014 PRINTED IN U.S.A
TABLE OF CONTENTS Page SAFETY PRECAUTIONS................................................... 1 DESCRIPTION........................................................ 1 INSTALLATION INSTRUCTIONS............................................ 2 KIT 27065............................................................. 3 GATE RESTRICTOR PLATE............................................ 4 ADJUSTMENT........................................................ 4 MAINTENANCE........................................................... 7 PERIODIC CLEANING................................................. 7 DAILY (OR AS REQUIRED)............................................ 7 WEEKLY (OR AS REQUIRED)......................................... 7 MONTHLY........................................................... 7 START-UP & OPERATING INSTRUCTIONS.............................. 7 CLEANING INSTRUCTIONS............................................ 7 DISPENSER......................................................... 7 COLD PLATE........................................................ 8 BEVERAGE SYSTEM................................................. 8 TROUBLESHOOTING...................................................... 10 BLOWN FUSE OR CIRCUIT BREAKER................................... 10 GATE DOES NOT OPEN................................................ 10 GATE DOES NOT OPEN OR IS SLUGGISH. AGITATOR TURNS........... 10 GATE OPENS. AGITATOR DOES NOT TURN............................. 10 ICE DISPENSES CONTINUOUSLY....................................... 10 SLUSHY ICE. WATER IN HOPPER...................................... 10 BEVERAGES DO NOT DISPENSE....................................... 10 BEVERAGES TOO SWEET............................................. 11 BEVERAGE NOT SWEET ENOUGH..................................... 11 BEVERAGES NOT COLD (UNITS WITH BUILT-IN COLD PLATE)............ 11 PARTS LIST.............................................................. 14
TABLE OF CONTENTS (cont d) Page LIST OF FIGURES FIGURE 1. ICE DIVERTER............................................. 3 FIGURE 2. GATE RESTRICTOR PLATE.................................. 4 FIGURE 3. MOUNTING TEMPLATE..................................... 5 FIGURE 4. PLUMBING DIAGRAM....................................... 6 FIGURE 5. WIRING DIAGRAM D150 DISPENSER......................... 12 FIGURE 6. DISPENSER SECTION EXPLODED VIEW..................... 13 FIGURE 7. CABINET SECTION EXPLODED VIEW & PARTS LIST.......... 15 FIGURE 8. SOLENOID ASSEMBLY...................................... 16 LIST OF TABLES TABLE 1. SPECIFICATIONS............................................ 1 Manufactured Under One or More of the Following Patent Numbers: 3,211,336, 3,274,792, 3,393,839, 3,517,860, 3,739,842, 4,215,803, 4,227,377, 4,300,359 4,346,824 Canadian Patent Numbers 912,514 (10/72), 936,855 (11,73), 4,429,543, 4,921,149 Other Patents Pending
SAFETY PRECAUTIONS ALWAYS: disconnect power to the dispenser before servicing or cleaning. NEVER: place hands inside of hopper or gate area without disconnecting power to the dispenser. Agitator rotation occurs automatically when dispenser is energized! This ice dispenser has been specifically designed to provide protection against personal injury and eliminates contamination of ice. To ensure continued protection and sanitation, observe the following: 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: Dispenser cannot be used with crushed or flaked ice. Use of bagged ice which has frozen into large chunks can void 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. DESCRIPTION The 2230 series of ice dispensers solves your ice and beverage service needs in the sanitary, space saving, economical way. Designed to be manually filled with ice from any remote ice making source or top mount ice maker, these dispensers will dispense cubes (up to 1-1/4?in size), cubelets and hard-chipped or cracked ice; and, in addition, several flavors of post-mix beverages. The sink can be easily and quickly removed. The unit must never be lifted or moved by the sink. Dispensers include faucets and cold plates and are designed to be supplied direct from syrup tanks and carbonator, with no additional cooling required. IMPORTANT: For dispensing nugget ice (Model MH750/NM650 Ice Makers), part number 27065 Ice Diverter must be installed on the dispenser (see INSTALLATION INSTRUCTIONS on page 3). Table 1. SPECIFICATIONS Model: 2230 K4-100 2230 K4PB-100 1 2230 K6-100 2230 K6PB-100 2230 AK 2230 AK 6 PB Ice Storage: 100 lbs 100 lbs 100 lbs Maximum Number of Faucets Available: 4 6 6 Built-in Cold Plate: Yes Yes Yes Electrical: 120/1/60 120/1/60 120/1/60 Dimensions: 22IWide X 29-3/4I Deep X 30-1/2IHigh 22I Wide X 29-3/4I Deep X 30-1/2I High 22I Wide X 29-3/4IDeep X 30-1/2I High Shipping Weight: 100 lbs. 100 lbs. 100 lbs. NOTE: Ambient temperature operating range 40 F to 104 F.
INSTALLATION INSTRUCTIONS 1. Locate the dispenser indoors on a level counter top. A. LEG OPTION Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The installer must provide flexibility in the product and utility supply to permit shifting the position of the dispenser sufficiently to clean the area beneath it. NOTE: and Before installing legs, the plastic plugs must be removed. Remove by pushing the center in then removing the plugs. B. COUNTER MOUNTING The ice dispenser must be sealed to the counter. The MOUNTING TEMPLATE (See Figure 3) drawing indicates where openings can be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in counter. Apply a continuous bead of National Sanitation Foundation (NSF) listed silastic sealant (Dow 732 or equal) approximately 1/4?inside of the unit outline dimensions and around all openings. Then, position the unit on the counter within the outline dimensions. All excess sealant must be wiped away immediately. 2. Utilities routing may be made through the rear of the cabinet by removing the plastic rear panel by the inlet of the cold plate and removing the kock-out for the drain hose. Optional routing through the bottom of the cabinet: A. Tip unit to the side to access the drain block located behind the drip tray. B. Replace the straight fitting with the 90 fitting that is in the drain kit supplied with the unit. 3. Beverage System: Connect the beverage system product lines as indicated in Figure 4. This work should be done by a qualified service person. Note that the hoses are marked with numbers (1 through 6) for syrup connections and CW for carbonated water connections. The plain water is marked W. 4. Clean the hopper interior (see CLEANING INSTRUCTIONS on page 7). 5. Connect the power cord to a 120 volt, 60 cycle, 3-wire grounded receptacle. 6. If the legs are not used, the dispenser must be sealed to the counter with RTV. NOTE: 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. 2
KIT 27065 NOTE: For dispensing Scotsman MH 750 nugget style ice and Wilshire MCC550 and MCC700 compressed ice cubes: 1. Disconnect power to dispenser. 2. Remove upper front panel from dispenser. 3. Remove ice chute and discard gate restrictor. 4. Reinstall front panel and connect power to unit. GATE MOUNTING PLATE STORAGE HOPPER ICE DIVERTER FLANGE EXTENDS INTO STORAGE HOPPER THROUGH GATE OPENING ICE CHUTE GASKET APPLY RTV TO THIS SURFACE TO SEAL TO HOPPER GATE MOUNTING PLATE FIGURE 1. ICE DIVERTER 3
GATE RESTRICTOR PLATE CAUTION: Disconnect power to dispenser before installing, removing or adjusting restrictor. INSTALL PLATE ON STUDS AS SHOWN FIGURE 2. GATE RESTRICTOR PLATE ADJUSTMENT This dispenser is provided with a gate restrictor plate, installed in it s highest position. This plate adjusts the rate of ice flow from the dispenser. In applications using buckets, carafes, or other large containers, the plate may be removed entirely for maximum ice flow. For glasses and cups, the plate may be adjusted downward to reduce the flow of ice. The best position depends on the type of ice being used and the size container and must be found by trial and error. Adjustment is made by loosening the upper two ice chute retaining nuts, sliding the restrictor plate to the desired position and retightening the nuts. If the dispenser fails to dispense the ice when operated, check that the hopper has ice in it and that power is being supplied to the unit. If the problem persists, check the following: 1. Determine if the agitator is rotating (check for the sound of ice movement in the hopper) 2. Observe whether the gate is opening. 4
22I 1I 3-15/16I 14I *1-1/8 I 4-1/2I Opening in cabinet bottom for drain & beverage hoses 18-3/4I Optional location for counter top cut-out 16-1/4I *18-25/32 I 29-3/4I Front of Unit 1-1/8I 19-3/4I * NOTE: Leg mounting locations for ref. (5/16-18 threads) FIGURE 3. MOUNTING TEMPLATE 5
6 FIGURE 4. PLUMBING DIAGRAM
MAINTENANCE PERIODIC CLEANING The following dispenser maintenance should be performed at the intervals indicated: DAILY (or as required) Remove foreign material from vending area drip tray to prevent drain blockage. WEEKLY (or as required) Clean vending area. Check for proper water drainage from the vending area drip tray. MONTHLY Clean and sanitize the hopper interior (see CLEANING INSTRUCTIONS). START-UP & OPERATING INSTRUCTIONS Fill the hopper with ice. Dispense several large cups of ice (approximately one (1) minute total dispensing time) to allow ice to fill the cold plate cabinet. Add ice to the hopper as necessary to refill then replace the lid. Allow 10 to 15 minutes for the cold plate to cool down. Repeat this procedure whenever the dispenser has been standing overnight or other long periods without ice use. Start up the beverage system and adjust faucets to the proper brix. Contact your local syrup distributor for complete information on the beverage system. In normal operation, pushing the ice dispenser lever will cause ice to flow from the ice chute. Ice flow will continue until the dispenser lever is released. Dispensing of any faucet will provide beverage of the appropriate flavor. CAUTION: Use caution to avoid spilling ice when filling dispenser. Clean up immediately any spilled ice from filling or operating the unit. To prevent contamination of ice, the lid must be installed on the unit at all times. CLEANING INSTRUCTIONS WARNING: DISCONNECT POWER 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. Dispenser 1. Clean the ice storage hopper at least once a month. 2. Lift off the agitator and the agitator disk. Wash with a mild detergent solution and rinse them thoroughly to remove all traces of detergent. 7
3. Wash down the inside of the hopper and top cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent. 4. Replace the agitator. 5. Sanitize the inside of the hopper and agitator with a solution of 1 ounce of household bleach in 2 gallons of water. (200 PPM) 6. Replace the agitator disk. Sanitize as described in Step 5. Be sure the center screw is replaced and the screw is tight. 7. Remove ice chute cover as follows: A. Flex sides outward to disengage lower pins. B. Lift ice chuted cover to disengage upper pins. C. Lower ice chute cover down out of unit. Note: it may be helpful to twist cover slightly. 8. Clean the inside of the ice chute and ice chute cover with a mild detergent solution and rinse thoroughly to remove all traces of detergent. 9. Reverse steps above to reassemble ice chute. 10. Sanitize as described in Step 5. Cold Plate 1. Remove splash panel and merchandiser. 2. Remove bottom two (2) screws on the ice chute and loosen the top two (2) screws. You do not have to remove the ice chute. (During reassembly, make sure the ice gate restrictor is relocated to its correct position). 3. Remove the screws; hold the beverage faucet panel and bring forward. 4. Remove the tape holding the lower cold plate cover to the top cold plate cover. 5. Lift the lower cold plate cover up into the top cover. 6. Remove any debris from the drain trough and spring. Check that the drain hole is not clogged. 7. Wash down the inside of the cold plate, tray and cover with a mild detergent solution and rinse. A small, long-handled brush is helpful in reaching the corners. 8. Slide the cover forward, taking care that it is securely positioned on the cold plate. 9. Reassemble. BEVERAGE SYSTEM CLEANING AND SANITIZING INSTRUCTIONS 1. Prepare the following cleaning, rinsing and sanitizing solutions using a clean, empty figal (5 gallon syrup tank) for each solution. CLEANING TANK -- Fill with a solution of 1/2 ounce of a mild liquid detergent (for example, Ivory liquid) to 1 gallon of warm (120_F) potable water. RINSING TANK -- Fill with warm (120_F) potable water. SANITIZING TANK -- Fill with a chlorine sanitizing solution in the strength of 1/2 ounce of household bleach (sodium hypochlorite) to 1 gallon of cold (ambient) potable water to obtain a solution strength of 200. 8
NOTE: Repeat the following procedure on each of the unit s syrup product lines and beverage faucets. 2. Using a suitable pail or bucket, fill one with a detergent solution and a second container with a sanitizing solution in the strengths as described in step 1. A. Remove the syrup line quick disconnect fitting from the product tank and submerge in the detergent solution. Clean with a nylon bristle brush (do not use a wire brush). Rinse with clean potable water. B. Wearing sanitary gloves, next submerge the quick disconnect fitting in the sanitizing container for 15 minutes. Remove and air dry. 3. Hook-up the sanitized product line fitting (step 2) to the cleaning tank. Hook-up a gas disconnect fitting to the tank and pressurize with 60 to 80 psig CO 2. Energize the beverage faucet continuously for 1 minute to remove all air bubbles. Continue to operate the faucet until liquid dispensed is free of any syrup. Cycle the faucet for 15 seconds on, off and then immediately on again. Repeat this procedure for 15 cycles. Then energize the faucet to remain flowing for 3 minutes. 4. Hook-up the rinsing tank and pressurize with 60 to 80 psig CO 2. Flush the cleaning solution from the product line by cycling the faucet as described in step 3 and then energize the faucet to flow continuously for 3 minutes. 5. Hook-up the sanitizing tank and pressurize with 60 to 80 psig CO 2. Flow the sanitizing solution through the beverage faucet by cycling the faucet as described in step 3. Next energize the faucet continuously to flush at least 2 cups of the sanitizing solution through the system. Finally deenergize the faucet and allow the sanitizer to remain pressurized in the line to 20 minutes. 6. Wearing sanitary gloves. remove the faucet nozzle and diffuser. Repeat the cleaning and sanitizing procedures as described in step 2, then reassemble to the faucet. 7. Disconnect the sanitizing tank. Hook-up the product tank to the unit and to the CO 2 system. Energize the faucet to flush the sanitizing solution from the syrup line and the faucet. Continue flow on the faucet until only syrup is dispensed. 9
TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to carbonated water system, disconnect electrical power to Cooling Unit, shut off plain water and CO 2 supplies, and relieve the carbonated water system pressure before proceeding. If repairs are to be made to syrup system, remove quick disconnects from applicable syrup tank, then relieve the system pressure before proceeding. If repairs are to be made to CO 2 system, stop dispensing, shut off CO 2 supply, then relieve the system pressure before proceeding. If repairs are to be made to an existing Remote Condensing unit, disconnect the power to the condensing 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 10 Probable Cause BLOWN FUSE OR CIRCUIT BREAKER. A. Short circuit in wiring. B. Defective gate solenoid. C. Defective agitator motor. GATE DOES NOT OPEN. A. No power. GATE DOES NOT OPEN OR IS SLUGGISH. AGITATOR TURNS. B. Bent depressor plate (does not actuate switch). C. Defective dispensing switch. D. Blown/defective fuse or jammed gate solenoid. A. Defective gate solenoid. B. Excessive pressure against gate slide. C. Weak gate spring. GATE OPENS. AGITATOR DOES NOT TURN. A. Ice solidified in hopper. B. Defective agitator motor. C. Defective capacitor. D. Defective agitation timer. ICE DISPENSES CONTINUOUSLY. A. Stuck or bent depressor plate (does not release switch). B. Defective dispensing switch. C. Improper switch installation. SLUSHY ICE. WATER IN HOPPER. A. Blocked drain. B. Unit not level. C. Poor ice quality due to water quality or ice maker problems. D. Improper use of flaked ice. BEVERAGES DO NOT DISPENSE. A. No 24 volt power to faucets. B. No CO 2 pressure.
Trouble Probable Cause BEVERAGES TOO SWEET. A. Carbonator not working. B. No CO 2 pressure in carbonator. C. Faucet brix requires adjusting. BEVERAGES NOT SWEET ENOUGH. A. Empty syrup tank. BEVERAGES NOT COLD (UNITS WITH BUILT-IN COLD PLATE). B. Faucet brix requires adjusting. A. Unit standing with no ice in hopper -- no ice in cold plate cabinet. Contact your local syrup or beverage equipment distributor for additional information and troubleshooting of beverage system. 11
ICE LEVEL SIGNAL OPTION T STAT LIGHT WHT MOTOR HEATER L N GROUND GRN LIGHTED DISPLAY OPTION BALLAST LIGHT BLK WHT GATE SOLENOID STARTER WHT BLK 1 1/4 AMP TIME DELAY FUSE WHT AGITATION TIMER KEY SWITCH OPTION PORTION CONTROL OPTION TO TERMINAL BOARD 24 V. WHT TRANSFORMER BEVERAGE SYSTEM PORTION TIMER RED BLK BEVERAGE FAUCET (TYPICAL) OR RED TD SW DISPENSE SWITCH WHT RED TERMINAL BOARD CONNECTION RED BLK DISPENSE SWITCH BLK PNK WHT ORG BLK BLU RED Q.C. CONNECTOR CCW AGITATOR MOTOR CAPACITOR C NO NC SERVICE INFORMATION DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT POWER BEFORE SERVICING UNIT. 7 8 SOLENOID ADJUSTMENT WHEN REPLACING SOLENOID, ADJUST TO 7/8 AS SHOWN BEFORE TIGHTENING MOUNTING SCREWS. FIGURE 5. WIRING DIAGRAM D150 DISPENSER 12
31 30 29 28 6 32 16 14 5 16 27 2 1 4 8 9 7 15 12 11 10 13 18 17 26 19 20 21 23 24 3 25 22 FIGURE 6. DISPENSER SECTION EXPLODED VIEW 13
DISPENSER SECTION PARTS LIST Index No. Part No. Description 1 91498 Wiring Diagram 2 91546 Ice Gate Restrictor Instructions 3 70439 Leg, 4? 4 70855 Sink Grill 5 52030 Sink 6 52028 Lid 7 31007 Switch Boot 8 30895 Dispenser Switch 9 70847 Switch Spacer 10 215150 Depressor, Cup Activated 11 22644 Depressor Retainer (for 21515) 12 27126 Depressor Push Lever 13 27107 Depressor Retainer (for 27136) 14 52026* Merchandiser Frame 52939** Merchandiser Frame 15 27638 Splash Panel 16 10145 Sink Mtg. Pin 17 70545 Clamp 18 51775 Flexible Drain Fitting 19 51801 Cold Plate Drain Insulation 20 52049 Drain Insulation 21 27470 Mounting Bracket 22 52037 Plastic Drain Fitting 23 52044 O-Ring (2 required) 24 50997 Straight Fitting 25 50249 Armaflex, 1/2 ID x 3/8 W x 72? 50279 Armaflex, 1-1/8 ID x 3/8 W x 72? 26 28035 Beverage Panel, 4 Valve 28036 Beverage Panel, 6 Valve 27 51455 Rear Cover Plate 28 27363 Lower Mounting Bracket 29 27345 Upper Mounting Bracket 30 Graphics Calls Parts Dept. 31 51996* Plexiglass Panel 52941 Plexiglass Panel 32 333000 Key Switch and Lock Nut * For Models 2230AK and 2230AK6PB only ** For Models 2230K4-100, 2230K4PB-100, 2230K6-100 and 2230K6PB-100 only 14
14 15 13 2 4 5 3 8 6 16 7 17 11 10 9 12 19 20 1 18 FIGURE 7. CABINET SECTION EXPLODED VIEW & PARTS LIST Item No. Part No. Description 1 30794 Agitator Motor Heater 2 31406 Fuse, 1-1/4 Amp 3 31093 Solenoid Assembly (See page 16) 4 31763 Agitator Timer 5 30774 Capacitor 6 51891 Gate Gasket 7 53015 Ice Chute Back Section 8 53016 Ice Chute Cover 9 50842 Motor Plate Insulation 10 51860 Motor Gasket 11 51859 Motor Shaft Seal 12 32498 Agitator Motor 13 31091 Transformer 14 51916 Agitator Disk 15 26591* Agitator 29026** Agitator 16 214910 Gate Slide 17 23062 Foam Shield 18 70341 Heater Spring 19 70260 1/4-20 x 1?Phil Rd Hd Screw 20 70815 1/4-20 Hex Motor Mounting Screw * For Models 2230AK6 and 2230AK6PB ** For Models 2230K4-100, 2230K4PB-100, 2230K6-100 and 2230K6PB-100 only. 15
22 1 2 3 4 5 4 22 6 19 22 21 16 15 14 18 20 8 11 10 17 19 13 9 12 7 FIGURE 8. SOLENOID ASSEMBLY Index No. Part No. Quantity Description 1 21493 1 Solenoid Mounting Plate 2# 31551 1 Solenoid Service Kit 3 70171 2 8--32 x 3/8 Phil Tr HD Screw 4 70121 2 No. 8 Lockwasher 5 50752 3 Isolator 6* 50789 2 Bumper Assembly 7* 70423 1 Cotter Pin 8* 10080 1 Gate Lift Rod 9 10081 1 Gate Lift Rod Bushing 10 50754 1 Gate Arm Bearing 11 21492 1 Gate Lift Arm 12 70043 1 Flatwasher 13* 70422 1 Spring 14 70263 1 1/4-20 x 3/4 Hex Hd Screw 15 70048 1 1/4 Lockwasher 16 70066 1 1/4 Flatwasher 17 10077 1 Pivot Bearing 18 30227 1 1/4 Quick Connect Tab 19 50305 ---- Lubricant 20* 21592 1 Solenoid Linkage Pin 21* 70433 2 Retainer Ring 22 51088 ---- Loctite ----* 70438 ---- Rebuilding Kit NOTE: * Parts supplied with rebuilding kit. # 31551 solenoid supplied with items 20 & 21. 16
CORNELIUS INC. Corporate Headquarters: One Cornelius Place Anoka, Minnesota 55303-6234 Telephone (800) 238-3600 Facsimile (612) 422-3246