Cornelius DF250 User manual

Installation Manual
DURAFLEX ICE/BEVERAGE DISPENSER
Model: DF-250 BCP
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.
PRINTED IN U.S.A
IMI CORNELIUS INC; 2001
IMI CORNELIUS REMCOR INC g500 REGENCY DRIVE gGLENDALE HEIGHTS, IL 60139–2268
Telephone [phone] Facsimile (800) 519–4423
Part No. 620919541
Revised: July, 2001
Revision A
Control Code A
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment

i
TABLE OF CONTENTS
Page
SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOWN FUSE OR CIRCUIT BREAKER. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLUSHY ICE. WATER IN HOPPER 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES DO NOT DISPENSE. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES TOO SWEET. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT SWEET ENOUGH. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT COLD (UNITS WITH BUILD-IN COLD PLATE). 11. . . . . . . . . .
NO ICE DISPENSED FROM ICE PORTION CONTROLLER 11. . . . . . . . . . . . . . . .
NO ICE DISPENSED FROM ICE PORTION CONTROLLER (CONTINUED) 12. . .
NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON SWITCH 12
ICE DISPENSING DURING AUTOMATIC AGITATION 12. . . . . . . . . . . . . . . . . . . . . .
WARRANTY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
Page
FIGURE 1. PARTS IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. MOUNTING TEMPLATE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. FLOW DIAGRAM (BEVERAGE VALVE MANIFOLD R TO L 3.1.2.2) 6
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE) 7. . . . . . . . . . . . . . . . . . . .
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT) 8. . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. WIRING SCHEMATIC (115 VOLT UNIT) 9. . . . . . . . . . . . . . . . . . . . . . . .

1620919541
REMOVABLE STRAW
HOLDER PANEL
LID/STRAW
HOLDER
BEVERAGE FAUCET
ON/OFF SWITCH
ICE PORTION
CONTROL MODULE
MANUAL/AUTO ICE
TOGGLE SWITCH
MANUAL ICE DISPENSE
RED PUSH BUTTON SWITCH
DRIP TRAY
CUP REST
LOWER ACCESS
PANEL
BEVERAGE FAUCETS (8)
ICE AGITATOR
RETAINER
ICE BIN COVER
FIGURE 1. PARTS IDENTIFICATION

2
620919541
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 insure 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 “DURAFLEX”series of ice dispensers solves your ice and beverage service needs in a sanitary, space sav-
ing, economical way. Designed to be manually filled with ice from any remote ice making source, these dispensers
will dispense cubes (up to 1-1/4 in. in size), cubelets, and hard-chipped or cracked ice; and in addition, several
flavors of post–mix beverages. The unit includes beverage faucets and a cold plate and is designed to be sup-
plied direct from syrup tanks and a carbonator, with no additional cooling required.
SPECIFICATIONS
Model DF250 BCP
B (Beverage Faucets)
C (Cold Plate)
P (Pneumatic ice portioning system)
Ice storage 250 pounds
Maximum No. of
Beverage Faucets
Available
8
Cold Plate (Built–In) Yes
Electrical 120/1/60, 3.5 Amps
Dimensions 30 in. Wide X 30-11/16 in. Deep X 39-5/8
in. High

3620919541
INSTALLATION INSTRUCTIONS
1. Locate the dispenser indoors on a level counter top.
The ice dispenser must be sealed to the counter. The MOUNTING TEMPLATE (see Figure 3)
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 MOUNTING TEMPLATE. Cut openings in the
counter.
Rotate the line support bracket, located under base, to the up position and route all the lines below the
bracket.
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. The beverage tubes, drain tube and power cord are routed through the large opening in the bottom of the
unit. See the MOUNTING TEMPLATE (see Figure 3), for locating the required clearance hole in the counter
for these utility lines.
3. DRIP TRAY DRAIN ASSEMBLY (see Figure 2). Route the drain tube to an open drain with the end of the
tube above the “flood”level of the drain. Use the tubing, fittings, clamps, and insulation provided with the Dis-
penser to assemble the drain. The completed drain line must pitch continuously downward and contain no
“traps”or improper drainage will result.
NOTE: This equipment must be installed with adequate backflow protection to comply with federal, state,
and local codes.
4. Connect the beverage system product tubes as indicated in the Flow Diagram. This work should be done by
a qualified Service Person. Any non-carbonated water tubing must be connected to the outlet of the check
valve.
Note: See the Flow Diagram (see Figure 4) or decal on lower front panel of the unit for the location of syr-
up and water connections.
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.
5. ICE PORTION CONTROLLER: Regulated CO2gas pressure is required to operate the portion control dis-
pensing system. Proceed as follows to connect the CO2gas pressure source line to the dispenser.
A. Connect and route the CO2line from outlet side of the source regulator assembly up to the dispenser.
NOTE: That the minimum source-regulated pressure is 40 psig.
B. Connect the CO2source line to dispenser inlet line labeled “CO2“.
C. The dispenser regulator outlet pressure is factory preset to 34 psig ±2 psig DO NOT ADJUST.
IMPORTANT: Maximim CO2operating pressure is 50 psig.
6. Clean the hopper interior (see Owner’s Manual P/N 620916502 for cleaning instructions).
7. Connect the power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle.

4
620919541
DRAIN LINE
1-IN. I.D. PLASTIC TUBING
(6 FT) WITH INSULATION
SOLVENT BOND
HOSE CLAMP
BARB ADAPTER
1 BARB X 3/4 MPT
COUPLING
3/4 SOCKET X 3/4 FPT
DRIP TRAY DRAIN
FITTING
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY

5620919541
12
OPENING
30
23
21–1/4
29
9–3/16 11–5/8
18–5/8
1–5/16 1–13/16 26–7/16
7/16
30–11/16
21–1/4
23–1/16
RECOMMENDED COUNTER OPENING SIZE
9.00 X 12.00 FOR UTILITIES AND
BEVERAGE TUBING. OPENING CAN BE LOCATED
ANYWHERE WITHIN THE SHADED AREA.
REMOVABLE DRIP TRAY
TO FRONT OF DRIP TRAY
ON COUNTERTOP
TO FRONT TOP OF
DRIP TRAY
Z STYLE
9
3–1/2
FIGURE 3. MOUNTING TEMPLATE

6620919541
INSTALL FOR
NON–CARB AS
REQUIRED
CHECK
VALVE
OPTIONAL FOR
DIET DRINKS
OR ROOT BEER
SYRUP TANKS
15–50 PSIG
PRESSURE
REGULATORS
COLD PLATE
CARBONATOR
FILTER
OPTIONAL
PRESSURE
REGULATOR
CO2
CYLINDER
FAUCETS
POTABLE
WATER
SUPPLY
COLDPLATE
INLET
CONNECTIONS
FAUCETS VIEWED FROM FRONT OF UNIT
ITEMS INSIDE BROKEN LINE INCLUDED WITH UNIT
5–15
PSIG
NON–CARB WATER
CARB WATER
CARB WATER
CO2
NOTE: Refer to plumbing schematic located behind
lower splash panel.
WATER
WATER
WATER
WATER
WATER
WATER
WATER
WATER
FIGURE 4. FLOW DIAGRAM (BEVERAGE VALVE MANIFOLD R TO L 3.1.2.2)

7620919541
ICE GATE CYLINDER REVERSE
SINGLE ACTING-SPRING EXTENDED
PNEUMATIC GATE SOLENOID VALVE
3-WAY NORMALLY CLOSED FILTER–REGULATOR (FACTORY-SET OUTLET
PRESSURE TO 32-36 PSIG)
MANUAL OVERIDE SOLENOID VALVE
3-WAY NORMALLY CLOSED
CO2 SUPPLY
50 PSIG MAX.
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE)

8
620919541
WHT
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT)
FEMALE HARNESS CONNECTOR
MALE HARNESS CONNECTOR
GROUND
SPLICE/QUICK CONNECT CONNECTION
LEGEND
GEN/YEL GREEN W/YELLOW STRIP
GRN GREEN
RED RED
BLU BLUE
VIO VIOLET
BRN BROWN
ORN ORANGE
YEL YELLOW
WHT WHITE
BLK BLACK
WIRE COLOR CHART
DANGER!
ELECTRIC SHOCK HAZARD. DISCONNECT
POWER BEFORE SERVICING UNIT
DIODE
MOTOR
HEATER
WHT
3
24
STARTING
RELAY
AGITATOR
MOTOR
VIO
YEL
WHT
MOTOR START
CAPACITOR
BLK
WHT
TERMINAL
BOARD
MANUAL ICE
DISPENSE
SWITCH
MANUAL/AUTO ICE
TOGGLE SWITCH
AGITATION
RELAY
34
2
PORTION CONTROLLER/
TOUCH PANEL
123456789
MANUAL
OVERRIDE
SOLENOID
RED
BEVERAGE VALVES
ON/OFF SWITCH 25 24
12 11
WHT
TRANSFORMER
BLK WHT
VIO
BLK
RED
GRN BLU
ORN
GRN/YEL
BLK
BRN
BLU
RED
BLK
123456789
WHT
ORN
RED
YEL
ORN
BLK YEL
COM NO
BLK
WHT
RED
TO EBOX
GROUND
SCREW
BLU BRN
GRN/YEL
123456789
123456789
1
2
BLU
ORN
RED
YEL
YEL/BLK
LINE
LOAD
BEVERAGE
VALVE
BLK
WHT
YEL/BLK YEL
ORN/BLK
INCOMING POWER
BLK
BLK
WHT
WHT
YEL
BLK
YEL
RED
BLK
GRN/YEL
GRN/YEL
TO GUSSET
HINGE GROUND
TERMINAL
YEL
L
N
E
12345
ICE CHUTE INTER-
LOCK SWITCH
INTERLOCK
RELAY
7A
5B
BLK
WHT
1
BLK
WHT
WHT
WHT
WHT
BLK
BLK
BLK
BLK
WHTBLK
LINE
LOAD
TRANSFORMER
BLKRED
12345
TO EBOX
GROUND
SCREW
BEVERAGE
VALVE
BEVERAGE
VALVE
BEVERAGE
VALVE
BEVERAGE
VALVE TYP.
BEVERAGE
VALVE TYP.
BLK WHT
BLK WHT
ORN/BLK
BLK WHT
BLK WHT
BLK WHT
TO EBOX
GROUND
SCREW 1
2PNEUNATIC
GATE SOLENOID
TO EBOX
GROUND
SCREW
TO EBOX
GROUND
SCREW
GRN/YEL
BLU
BRN
BLK
YEL
YEL
YEL
BLK
RED
ORN
ORN
ORN
ORN ORN
YEL

9620919541
FIGURE 7. WIRING SCHEMATIC (115 VOLT)
120V
INTERLOCK RELAY
MANUAL ICE DISPENSE
SWITCH
MANUAL/AUTO ICE
TOGGLE SWITCH
ICE CHUTE INTERLOCk
SWITCH
BEV ON/OFF
SWITCH
24VAC
AGITATOR
RELAY PORTION CONTROLLER/
TOUCH PANEL TOUCH
PANEL
BEV
VAL.
4
24VAC
PNEUMATIC ICE GATE
SOLENOID VALVE
LN
BEVERAGE
TRANSFORMER
3
AGITATOR MOTOR
HEATER
1
3
S
R
AGITATOR MOTOR
O/L
MOTOR
START RELAY
START CAPACITOR 24
2
MANUAL OVERIDE
SOLENOID VALVE
24VAC
BEVERAGE
TRANSFORMER
24VAC
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.
BEV
VAL.

10
620919541
THIS PAGE LEFT BLANK INTENTIONALLY

11 620919541
WARNING: If repairs are to be made to the beverage system, remove quick disconnects
from the applicable product tank, then relieve the system pressure before proceeding. If
repairs are to be made to the CO2system, stop dispensing, shut off the CO2supply, then
relieve the system pressure before proceeding. If repairs are to be made to the ice dispensing
system, make sure electrical power is disconnected from the unit.
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
Trouble Probable Cause Remedy
NOTE: 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(s) to aid in locating the defect.
BLOWN FUSE OR CIRCUIT
BREAKER. A. Short circuit in wiring (115V
circuit). A. Replace defective wiring.
B. Defective agitator motor. B. Replace agitator motor.
SLUSHY ICE. WATER IN A. Blocked drain. A. Open–up/flush out drain.
HOPPER B. Unit not level. B. Level unit.
C. Poor ice quality due to water
quality or ice maker problems. C. Install water filter system. For Icemaker problems, consult
icemaker manual.
D. Improper use of flaked ice. D. Replaced flaked ice with “cube
style ice (see page 2, Unit
Description).
BEVERAGES DO NOT
DISPENSE. A. No 24 volt power to faucets. A. Check that beverage switch is
“on”. Check 24V transformers.
B. No CO2pressure. B. Check CO2regulator. Check CO2
tank pressure.
BEVERAGES TOO SWEET. A. Carbonator not working. A. Check carbonator.
B. No CO2pressure in
carbonator. B. Check CO2regulator. Check CO2
tank pressure.
C. Faucet brix requires adjusting. C. Brix Faucet.
BEVERAGES NOT SWEET A. Empty syrup tank. A. Refill syrup tank.
ENOUGH. B. Faucet Brix requires adjusting. B. Brix Faucet.
BEVERAGES NOT COLD
(UNITS WITH BUILD-IN COLD
PLATE).
A. Unit standing with no ice in
hopper - no ice in cold plate
cabinet.
A. Refill hopper with ice.
NOTE: Contact your local syrup or beverage equipment distributor for additional information and
trouble shooting of beverage system.
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER A. Insufficient ice supply in ice bin. A. Replenish ice supply as required.
B. Ice in ice bin bridged (stuck
together). B. Gently tap on ice to break it loose.
C. No electrical power to
dispenser. C. Plug in dispenser power cord, or check fuse or circuit breaker.

12
620919541
Trouble RemedyProbable Cause
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER
(CONTINUED) D. Insufficient or no CO2supply
to dispenser. D. Restore CO2supply to dispenser.
E. Ice chute cover not properly
Installed. E. Make sure that cover is “snapped” into place.
F. Defective ice chute interlock
switch. F. Replace interlock switch.
G. Defective interlock relay. G. Replace relay.
H. Defective 24V transformer. H. Replace transformer.
I. Defective portion controller.
J. Defective ice gate cylinder.
K. Defective ice gate solenoid
valve.
L. Agitation relay wiring incorrect.
M. Defective agitation relay.
N. Defective agitator motor or
start capacitor or start relay.
I. Replace controller.
J. Replace cylinder.
K. Replace solenoid valve.
L. Red wire should be connected to
“+”terminal (no. 3) of relay coil.
M. Replace relay.
N. Replace defective component.
NO ICE DISPENSED FROM
MANUAL ICE DISPENSE
PUSHBUTTON SWITCH
A. Manual/Auto toggle switch in
“Auto”position.
B. Insufficient or no CO2supply to
dispenser.
A. Move toggle switch to “Manual”
position.
B. Restore CO2supply to dispenser.
C. Defective 24V transformer.
D. Defective manual override
solenoid valve.
E. Defective manual ice dispense
pushbutton switch.
C. Replace transformer.
D. Replace valve.
E. Replace switch.
F. Defective agitator motor or
start capacitor or start relay.
G. Defective ice gate cylinder.
F. Replace defective component.
G. Replace cylinder
ICE DISPENSING DURING
AUTOMATIC AGITATION A. Manual/Auto toggle switch in
“manual”position. A. Move toggle switch to “auto” position.
B. Defective ice gate cylinder.
C. Defective ice gate solenoid
valve.
D. Defective portion controller.
B. Replace cylinder.
C. Replace valve.
D. Replace controller.

13 620919541
IMI CORNELIUS INC.
ONE CORNELIUS PLACE
ANOKA, MN.55303–6234
TELEPHONE [phone]
FACSIMILE (763) 422–3232
WARRANTY
IMI Cornelius Inc. warrants 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.
IMI Cornelius Offices
AUSTRALIA DP.O. 210, DRIVERWOOD, DNSW 2210, AUSTRALIA D(61) 2533 3122 DFAX (61) 2534 2166
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GERMANY DCARL LEVERKUS STRASSE 15 DD-4018 LANGENFELD, WEST GERMANY D(49) 2173 7930 DFAX (49) 2173 77 438
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ITALY DVIA PELLIZZARI 11 D1-20059 DVIMARCATE, ITALY D(39) 39 608 0817 DFAX (39) 39 608 0814
NEW ZEALAND D20 LANSFORD CRES. DP.O. BOX 19-044 AVONDALE DAUCKLAND 7, NEW ZEALAND D(64) 98200 357 DFAX (64) 98200 361
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USA DONE CORNELIUS PLACE DANOKA, MINNESOTA D(763) 421-6120 DFAX [phone]

One Cornelius Place
Anoka, Minnesota 55303-6234
[phone]
[phone]
Corporate Headquarters:
IMI CORNELIUS INC.