Manitowoc CSA-151 series Instruction Manual

CSA-151
SERIES ICE DISPENSERS
INSTALLATION/OWNER’S/SERVICE MANUAL
MANITOWOC EQUIPMENT WORKS
Division of The Manitowoc Company, Inc.
2110 South 26th Street, P.O. Box 1720, Manitowoc, Wl 54221-1720 ® Phone: [phone]
©MANITOWOC 1990
80-0824-3
June, 1990

Two-hand Operation
FREIGHT DAMAGE AND LOSS INFORMATION
A. SHORTAGES
1. Check that the number of cartons delivered matches
the quantity shown on your receipt.
2. If the quantities do not tally, have the driver note the
shortage and file your claim accordingly.
B. NO-FAULT FREIGHT CLAIM PROGRAM
Manitowoc assumes responsibility for all freight damage
claims involving participating carriers, except when:
1. The trucking company loses the equipment.
2. Fire destroys the equipment en route.
3. A traffic accident damages the shipment en route.
C. VISIBLE DAMAGE
1. Open all damaged cartons and inspect their contents.
2. To remove the carton, cut the banding and slide the
carton up and off the unit.
3. Note the location and extent of the damage.
4. Notify your distributor to inspect the merchandise
within 15 days of delivery.
D. CONCEALED DAMAGE
1. If damage is noticed after the equipment is unpacked,
notify the distributor immediately and ask for an
inspection.
2. Save the packing materials until inspection is com¬
plete.
3. Unless these conditions are met, your claim will prob¬
ably be rejected by the distributor.
E. CLAIMS
Satisfaction is between Manitowoc and its distributor to:
1. Arrange to have repairs made, or
2. Replace the merchandise.
MODEL NUMBER DESCRIPTION
C*+150#-
C = Countertop Dispenser
* = Denotes the style of dispense actuator
T — For self-serve or two-hand operation (see Fig. 1B)
S — For glass actuated one-hand operation (see Fig.
1 A)
+ = Model vintage starting with letter A
To change with any major design changes
150 and 151= Model number with cold plate and up to eight
post-mix valves
# = Model variations — Customer options starts with B
- = Cabinet finish
S — Stainless Steel
F — Fawn
This dispenser has a dual purpose actuating lever.
Fig. 1A One-hand Operation
Fig. IB
For the easiest two-hand operation, remove the one-hand lever.
This is accomplished by removing the four screws which secure
the one-hand actuating lever to the two-hand actuating lever.
DISPENSER INSTALLATION
We strongly recommend that the installation and “start and
inspect procedure” be performed by a trained and compe¬
tent technician.
GENERAL
This countertop dispenser dispenses either Manitowoc
“dice” or “half dice” ice cubes.
This dispenser may be manually filled with ice or accept
a top-mounted single Manitowoc Series 200, 400, or 600
model ice machine for automatic fill capability
There is an 11" clearance height between the discharge
chute and grill. The clearance height is 11 W under the drink
dispensing valves.
This dispenser is equipped with up to eight N.S.F. approved,
or listed, post-mix drink dispensing valves (see Fig. 6).
LOCATION
This dispenser is not designed for outdoor installations or
installations where temperatures drop below +40° F or rise
above +110° F. For best performance, select a location away
from radiators, ovens, refrigeration condensers, direct sun¬
light, and other sources of heat. Allow a minimum of five
inches clearance around the dispenser for air circulation.
The dispenser must be located on a flat and level countertop
of sufficient strength to support the dispenser with ice (400
lbs.) and the Manitowoc ice machines (200 lbs.). The
dispenser should be sealed to the counter to comply with
health codes (dispenser set on counter and a minimum of
W radius fillet formed between countertop and dispenser
base with N.S.F. approved silicone sealer). The dispenser
is equipped to accept legs (sold separately), but the counter
must be able to support the weight concentrated on the legs.
Manitowoc recommends that the %" diameter x 11 -thread-
per-inch weld nuts located at the corners of the dispenser
base be used to bolt the dispenser to the countertop to
insure stability. Whenever an ice machine is mounted on
the dispenser, the dispenser must be bolted to the counter.
WATER AND DRAIN REQUIREMENTS AND CONNEC¬
TIONS
This dispenser is equipped with a W pipe female fitting at
the rear for drain connection.

Drain connections must not allow waste water to back up
into the storage bin. The drain lines must be vented to atmos¬
phere and should run separately from the dispenser and
ice machine (when used) to an open trapped, or vented, floor
drain. Drain lines must have VA" drop per five feet of run.
The plumbing for the drain connection can be routed out
of the bottom of the dispenser. The syrup lines and the?
carbonated water lines and power cord can also be routed
out the bottom left hand rear corner of the dispenser.
Syrup lines and carbonated water lines are marked and
extend through the rear of the cabinet. These lines are
capped, and connection from the syrup tanks and
carbonated tank can be made to these using a barbed
connector and oteiker clamps.
NOTE: All connections should be checked for leaks.
There is a separate section on the soda valve operation and
adjustment (see page 9).
All plumbing must meet national and local code
specifications.
ELECTRICAL REQUIREMENTS AND CONNECTIONS
This dispenser is 115-volt, 60-cycle, 1 -phase, cord-connec¬
ted.
The dispenser must be plugged into a 15 amp electrical
outlet.
CAUTION: This dispenser must never be plugged into an
extension cord. If an outlet is not within reach of the dis¬
penser’s power cord, have an electrician install a 15-amp
outlet.
ICE MACHINE INSTALLATION (Automatic Fill)
1. See Ice Machine Use and Care Manual for ice machine
installation.
2. The dispenser’s plastic top cover is purchased
separately if the dispenser is to be manually filled. It is
not needed when an ice machine is top-mounted to the
dispenser.
3. Inside the shipping envelope you will find two flat
mounting plates to secure the ice machine to the
dispenser. Fasten the plates to the lower mounting
screw on the ice machine back panel. Then, using the
plate as a locater, drill two holes ( s /32" diameter) into
the dispenser back panel and fasten the plates to the
dispenser using the screws provided in the envelope
(see Fig. 3).
4. If local codes require this dispenser to be permanently
wired:
L. Connect conduit fitting to control box.
M. Pull three 14 gauge conductors (black, white, and
green) through conduit and connect to pigtails with
wire nuts furnished. (Do not disconnect plastic strain
relief holding pigtails.)
NOTE: Tape over the wire nuts with electrical tape
after nuts are tightened.
Fig. 3
A. Disconnect power supply cord from electrical service
before working on dispenser.
B. Remove rear access panel.
C. To remove original power cord from dispenser,
knock out strain relief from inside out (may use pliers
to squeeze together).
D. Proceed to front of dispenser.
E. Remove drain pan from the dispenser to gain access
to control box and remove control box cover.
F. Disconnect wire nuts from power supply cord.
G. Remove strain relief from control box holding power
cord.
H. From back of dispenser, pull power cord out.
I. Route conduit (flexible) through conduit fitting hole
at lower right-hand rear corner.
J. Pull conduit back through access panel to install %"
conduit fitting.
K. Feed conduit to front of dispenser to control box .
Fasten mounting plate top hole using two screws from back
of ice machine. Using plate as a locater, drill two holes s / 32 "
diameter in the back of dispenser back panel. Avoid drilling
more than W deep to prevent damaging liner. Secure bottom
hole in plate with screw provided.
3

27. Hinge Pin
40. Clip — Spring Hinge Pin
41. Polypropylene (Living Hinge)
42. Insert
48. Ice Chute
FINAL CHECK LIST FOR DISPENSER INSTALLATION
1. Is the dispenser level?
2. Has all internal packing, auger shipping block, and tape
been removed?
3. Are all electrical and water connections complete?
4. Is there a 5" clearance on all sides for air circulation?
(Required when an ice machine is placed on top.)
5. Is there a separate drain for the dispenser, when an ice
machine is placed on top?
6. Are the drains vented?
7. Has the ice machine (when used) been secured to the
dispenser?
8. Is the lower back panel assembly (Item 69, Fig. 13) on
the dispenser? This should be in place before the
dispenser is operated.
9. When the actuator is depressed, is the dispenser
operational.
10. Has the dispenser been sealed and fastened to the
countertop?
11. Have the carbonated water and syrup lines been
checked for leaks?
NOTE: When installing a Manitowoc ice machine on top of
this dispenser, it is important to correctly set the ice
machine’s ice bridge thickness. The thinner the ice bridge
on the ice machine, the better the ice will break up for
dispensing. Too thick a bridge will allow ice chunks to fall
into the bin and prevent cubes from breaking up for easy
dispensing. This will cause a slower dispensing rate.
If using a small-mouthed glass, 2W diameter, or smaller,
it is recommended that “dice” size cubes be used.
SERIAL NUMBER AND ELECTRICAL DATA
An identification plate detailing serial number and electrical
data is located on the dispenser’s front cover.
OPERATION PRINCIPLES (Countertop)
This dispenser’s electric motor is coupled directly to a right
angle gear box that drives through a W pitch positive
displacement belt, the dispensing auger, and an agitator
auger.
The dispensing auger turns at approximately 35 revolutions
per minute, and the agitator turns at approximately 17
revolutions per minute (see Fig. 5).
The dispenser motor is activated by an ice delivery switch
located in a switch control box enclosure behind the upper
front panel of the dispenser. The ice delivery switch is closed
by the ice delivery actuator lever, which is activated by the
customer, or attendant, when ice is required (see Fig. 6A).
This switch controls a solid state relay that controls power
to the dispenser motor (see Fig. 9).
The ice deliver rate ranges from 1.8 oz./sec. to 0.8 oz./sec.,
depending on cube size and bin fullness.
NOTE: Always be sure electrical power is disconnected
before cleaning or performing maintenance on this
dispenser.
Fig. 5
24. Washer 1%" OD
25. Tensioner Bearing
35. Gear Motor Lock Bracket
38. Cover — Base Hole
49. Belt Tensioner Mtg. Bracket Weld
75. Bracket Spring Belt Tightener
76. Spring Belt Tensioner
5. Key Stock
11. Small Drive Pulley Assembly
26. Drain Fitting Assembly
33. Drain Fitting Bracket
36. Gear Box Angle Bracket Tie Strap
58. Drive Motor/Gear Reducer
4

54. Lower Front Panel
79. Control Box
80. Transformer Box
CLEANING INSTRUCTIONS
1. Remove all ice from dispenser.
2. Disconnect the dispenser’s electrical power.
3. Remove top cover on manually filled dispensers, or ice
machine front panel, if an ice machine is assembled
on top of dispenser.
4. Remove upper front panel’s two screws.
5. Remove three thumbscrews holding the auger upper
bearing bracket in place and remove the auger upper
bearing bracket, along with the auger.
6. Remove the ice chute and actuator lever assembly by
removing thumbscrews (see Fig. 6A). The assembly
must be slid down while holding the ice outlet door
open.
7. Remove the lower front panel’s four screws and lay
forward in drain area (see Fig. 6B).
8. Remove the ice outlet door, switch box, and mounting
bracket (see Fig. 6C) by lifting up and forward. This
assembly can be laid on top- of the lower front panel
removed in Step 6.
9. Remove auger access panel by removing four
thumbscrews (see Fig. 6E).
10. Remove lower agitator coupling and agitator flight
extension (see Fig. 6D).
11. The dispenser liner and cold plate can now be cleaned
and sanitized with a solution of 3 oz. of Manitowoc Ice
Machine Cleaner per gallon of water (see Fig. 6D).
12. The agitator flights, upper bearing, shaft, and upper
bearing bracket assemblies can be cleaned and
sanitized with same solution (see Fig. 6E).
13. The dispensing auger can be disassembled by
removing the stainless steel pin at the top of the auger.
Remove the pin, and the auger flights will slide off the
shaft for cleaning (see Fig. 6E).
14. Rinse all parts with clean water before assembling.
WARNING: Do not use metal scrapers or abrasives on the
bin liner or plastic parts. These will destroy the smooth
surfaces.
Fig. 6
Fig. 6A
67. Soda Manifold
Fig. 6C
37. Electrical Box
Switch
41. Door — Living Hinge
46. Bracket Ice Outlet
Door Mounting

Fig. 6D
13. Agitator Drive Coupling
21. 'A-20 x 1
29. Weldment Agitator Shaft Paddle
Fig. 6E
12. Upper Bearing Coupling
14. Agitator Flight 8" OD
15. Agitator Bearing 1.625 ID
16. Auger Bearing 1.334 ID
28. Auger Access Panel
43. Agitator Bearing Bracket Weld
44. 4" OD Auger Assembly
45. Auger Bearing Bracket
SWITCH ADJUSTMENTS AND REPLACEMENT
NOTE: Before removing the switch control box cover,
disconnect electrical power to the dispenser.
The actuator switch is located in a switch control box behind
the upper front panel (see Fig. 6 and 6A).
The actuator switch is normally open but closes as the
actuator lever is pushed back or down. It can be adjusted
by bending the flat, or round, arm on the switch. The switch
should make contact just before the ice delivery door is
completely open, and the switch contacts should open as
the ice delivery door starts to close. The switch can be
adjusted by listening for clicks as the switch is opened and
closed (with power disconnected).
AUGER AND AGITATOR DRIVE ASSEMBLY REMOVAL
1. Remove all ice from dispenser.
2. Disconnect the dispenser’s electrical power.
3. Remove top cover on manually filled dispensers, or ice
machine front panel, if an ice machine is assembled on
top of dispenser.
4. Remove upper front panel’s two screws.
5. Remove three thumbscrews holding the auger upper
bearing bracket in place and remove the auger upper
bearing bracket, along with the auger.
6. Remove the ice chute and actuator lever assembly by
removing thumbscrews (see Fig. 6A). The assembly
must be slid down while holding the ice outlet door open.
7. Remove the lower front panel’s four screws and lay
forward in drain area (see Fig. 6B).
8. Remove the ice outlet door, switch box, and mounting
bracket (see Fig. 6C) by lifting up and forward. This
assembly can be laid on top of the lower front panel
removed in Step 6.
9. Remove auger access panel by removing four
thumbscrews (see Fig. 6E).
10. Remove lower agitator coupling and agitator flight
extension (see Fig. 6D).
11. The drive assembly is now accessible for bearing
removal (see Bearing Removal).
BELT TIGHTENING AND REPLACEMENT
NOTE: Before tightening or replacing the belt, disconnect
the electrical power to the dispenser.
The belt is held snug by a tensioner that is located between
the gear motor pulley and ice dispensing auger pulley. This
is accessible by removing the dispenser’s rear panel.
Access is also available from the dispenser front by
removing the drain pan wrapper, drain pan, and front panels.
Working from the front is more difficult.
The belt is tensioned by an extension spring (see Fig 8).
Any time a belt is replaced or the tensioner is loosened,
grease should be reapplied between the tension wheel
bracket and the cabinet base. This grease will insure that
the tensioner bracket can move freely. Be sure wedge is
correctly positioned under the gear box (see Fig. 8).
Fig. 7
18. Thumbscrew #8 x % Type A
22. Thumbscrew — Plastic
6

SERVICE
NOTE: All service should be performed by a Manitowoc
Service Representative.
TROUBLESHOOTING
TROUBLE
POSSIBLE CAUSE
CORRECTIVE MEASURES
Dispenser will not dispense Bin empty.
Fill manually or check ice machine operation.
ice.
Large clusters of ice in bin.
Check and adjust ice bridging. Do not use
bagged ice, or be sure ice is broken up before
putting in dispenser.
Ice jammed in ice chute opening. Check and clear opening.
Defective switch.
Check and adjust or replace.
Drive belt broken or loose.
Tighten or replace.
Drive motor defective.
Check or replace motor. Check start capac¬
itor or replace. Check electronic motor
starting switch or replace.
Drive motor operates, but
doesn’t turn.
Auger not properly seated on lower
bearing drive shaft.
Check and reseat correctly.
Keys not in place on shafts.
Replace Key.
Belt loose. (If belt is loose, you will hear a
ratcheting noise.)
Grease base under tensioner bracket. Verify
wedge is located under gear box.
Defective gear
Check and replace reducer.
Motor running continuously.
Ice jammed in door opening.
Clear door. This can usually be done by
dispensing a glass of ice.
Switch.
Adjust or replace.
Fig. 8
3. Positive Drive Belt
10. Large Pulley Assembly
36. Gear Box Angle Bracket
75. Spring — Belt Tightener
76. Bracket — Spring Belt Tightener
BEARING ASSEMBLY REMOVAL
1. See Auger and Agitation Drive Assembly Removal to
gain access to lower bearing and drive shaft assemblies.
2. Loosen belt by loosening the belt tensioner and remove
the belt (refer to Belt Tightening and Replacement).
3. Remove lower bearing drive pin and the plastic drive
coupling on the agitator drive shaft (see Fig. 10).
4. Remove three bolts that hold the upper bearing housing
assembly to the lower bearing housing assembly. Note:
Bolt heads are #7 Torx head and have been filled with
silastic that should be cleaned out to insure good
wrench engagement.
5. Withdraw the three bolts from inside the bin and lift
upper bearing assembly out of dispenser.
6. Withdraw the lower bearing assembly from the gear-
and-motor compartment side.
BEARING ASSEMBLY INSTALLATION
1. Install upper drive shaft housing assembly gasket to
insure a water-tight seal between upper bearing
housing and cold plate. Then position bearing assembly
in bottom of bin.
2. From inside the bin, insert the three mounting bolts
through the upper bearing housing. Use food grade
silastic under the bolt heads to insure no water leakage.
3. Install the lower bearing housing and shaft from the
gear-and-motor drive compartment side.
NOTE: Start all three bolts and tighten together to assure
alignment. Tighten to 95 ±5 in.-lbs. of torque.
4. Insert the pin into the lower bearing drive shaft and insert
the bolt and washer. The plastic drive coupling must
be replaced on the agitator drive shaft.
5. Install the auger and agitator assemblies (refer to Auger
Assembly).
TROUBLESHOOTING ELECTRONIC START WINDING
SWITCH
Item 57 (Sinpac Switch), Fig. 12 (see Wiring Diagram, Fig.
9)
This device switches the start winding in and out of the
circuit.
This device replaces the mechanical/centrifugal switch on
the Vt, hp capacitor start motor. The electronic switch (Item
57) monitors the voltage wave forms across the start
winding. The wave form displays a slight dip followed by
a rise at the motor shaft speed where proper switch
operation should occur (75-80% of synchronous speed).
The electronic switch will usually fail with the switch (Triac)
in the open mode (nonconducting). If the motor won’t start
and run, the switch can be tested by momentarily jumping
the device across terminal number 3 and 2. This will engage
the start winding.
7

Fig. 9
If for some reason the electronic switch failed in the closed
mode (conducting), the motor overload should trip, and the
device (Item 57) can be checked with an amp probe on the
line coming off terminal number 2. The amp draw should
decrease within one second, if start winding drops out.
NOTE: Anytime a problem occurs with the motor, the start
capacitor (Item 72, Fig. 12) should be suspected and
checked.
Fig. 10
6. Pin
7. Upper Drive Shaft Housing Assembly
19. Capscrew ’A-20
21 .'A-20 x 1
65. Lower Drive Shaft/Housing Assembly
74. Gasket — Upper Drive Shaft Housing
SODA OPERATION
This dispenser is equipped with post mix N.S.F. approved
soda-dispensing valves and a cold plate. This cools the
soda water and syrup before dispensing the product through
the valves (see Fig. 14).
The dispenser is fitted with a Class 2 step-down transformer
to provide 24 volt AC current to operate the soda valve
solenoids (see Fig. 9, Wiring Diagram, and Fig. 17). This
transformer is located : in the dispenser bottom and is
accessible by removing the drain pan (see Fig. 15).
Fig. 11
2. Grill — Wire
20. #8-32 x 1V4 Phil Tr MS/Zinc
50. Drain Pan Wrapper
51. LH Lower Front Trim
52. RH Lower Front Trim
53. Top Cover (Black)
54. Lower Front Panel
66. Drain Pan Assembly
68. Front Panel Assembly
8

Fig. 12
56. Relay — Electronic
57. Sinpac Switch
60. Start Capacitor Bracket
72. Start Capacitor
79. Control Box
Fig. 13
31. Product Inlet Lines
63. Drain Fitting Filler Plate
69. Lower Back Panel Assembly
OPERATION THEORY
A C0 2 cylinder delivers carbon dioxide (C0 2 ) gas through
adjustable C0 2 regulators to a carbonator tank and syrup
tanks. None of the above are furnished with this dispenser.
Plain water is piped into the carbonator tank, and the
regulated C0 2 gas is also piped into the carbonator tank.
A pump is used to carbonate the water with the C0 2 gas
and is then pumped to a cold plate where the water is cooled
by use of the ice in the dispenser. The syrup is also routed
through the cold plate to be cooled, and when a valve is
opened, the syrup is forced through the valve by the
regulated C0 2 pressure or by bag in box pumps. Syrup and
carbonated water meet at the dispensing valve resulting in
a carbonated drink being dispensed (see Fig. 19 and 19A
for plumbing schematic).
CONNECTING DRINK LINES
Syrup lines and one carbonated water line have been
connected to the cold plate and extended out the rear of
the cabinet (see Fig. 13). All internal syrup and carbonated
water lines are internally connected between the cold plate
and the dispensing valves at the factory.
NOTE: Lines can be routed through the unit’s base by
removing cover inside rear panel.
Field connections of the syrup lines and carbonated water
lines can be made to the lines extending out the rear of
the dispenser by use of a straight hose connector and
crimping tube clamps (O-clamps) (see Fig. 20). Check
connection for leaks.
PREPARING THE SODA SYSTEM FOR OPERATION
1. Plug dispenser into power source.
2. Momentarily push each dispensing valve lever and note
if electric solenoid valve on each valve is opening.
3. Adjust C0 2 regulators primary to carbonator and
secondary C0 2 regulator to syrup tanks.
C0 2 regulators to syrup (sugar) tanks should be adjusted
to 40 psig for syrup lines up to ten feet long and one
psig for each additional ten feet in length plus one psig
for every two feet in vertical rise.
On low calorie (diet) syrup tanks, the secondary C0 2
regulator should be adjusted to ten psig for up to 30
feet of line. The low calorie regulator should never be
adjusted above 12 psig because this may cause excess
foaming.
The primary C0 2 regulator should be adjusted at 60 to
100 psig.
NOTE: To readjust a 0O 2 regulator to a lower setting,
loosen the adjusting screw locknut and then turn the
screw to the left (counterclockwise) until pressure
gauge reads ten psig below what the new setting will
be. Turn the adjusting screw to the right (clockwise) until
the new setting is obtained and then tighten the locknut.
9

Fig. 15
Fig. 18
66. Drain Pan Assembly 66. Drain Pan Assembly
78. Drain Pan Hose Seal
Fig. 16
Fig. 19
81. t ransformer — Stepdown 24V
67. Soda Manifolds
IMPORTANT All syrup systems must be sanitized before the
dispenser is put into operation.
Only qualified persons should perform sanitizing
procedures.
When washing dispensing valve, care must be taken not
to get water on electrical solenoids.
SANITIZING SYRUP SYSTEM AS REQUIRED BY LOCAL
HEALTH CODES
1. Remove disconnect from syrup tank.
2. With a nylon brush and detergent soap solution, scrub
both halves of the disconnect and rinse with clean water.
3. Using a sanitizing solution of one once per gallon of
Chlor-Tergent (Oaklite Products Inc.), or Chlorox, mixed
with water (resultant, concentration 300 PPM chlorine),
sanitize both halves of the connectors and allow to air
dry.
10