Cornelius Blender ICE FROST User Manual

®
ICE FROST  
Post-Mix and Pre-Mix  
Installation, Service, and Operator’s Manual  
Release Date: April 19, 2004  
Publication Number: M620919596OPR  
Revision Date: October 19, 2006  
Revision: C  
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TABLE OF CONTENTS  
Important Warnings and Advice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Plate data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Transportation Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Connecting the Electricity Mains . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2  
Connection Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Ice Frost Generic (Pre-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3  
Ice Frost Generic (Post-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5  
Bowl Loading Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Ice Frost Generic (Pre-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Ice Frost Generic (Post-mix) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
Brix Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8  
Programming Electronic Touch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9  
To Enter Time Programming on Initial Installation or in the Event of Service . . . 9  
Setting COLD Timer (Night Setting) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10  
Operate in Automatic Mode (with COLD Timer Activated) . . . . . . . . . . . . . . . . 10  
Operate in Manual Mode (without COLD Timer Activated) . . . . . . . . . . . . . . . . 10  
Setting the 12 or 24 Hour Display and oF or oC Temperature Display . . . . . . 10  
Viewing the Bowl Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Consistency Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11  
Quarterly Cleaning and Sanitation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Post Mix Systems Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Special Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
Restricted Air Flow Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16  
Electronic Monitoring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Electronic Bowl Monitoring and Safety System . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Pressure and Level Control Card General Features . . . . . . . . . . . . . . . . . . . . . . . . 17  
OFF Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
1st Filling Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
Managing the Bowl Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19  
Safety Probes (only for Ice Frost Generic Pre-mix) . . . . . . . . . . . . . . . . . . . . . 19  
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
VFCB (Pre-Mix) 115V/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21  
VFCB (Post-Mix) 115V/60Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22  
VFCB (Pre-Mix) 230V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23  
VFCB (Post-Mix) 230V/50Hz . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25  
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Ice Frost Operator’s Manual  
IMPORTANT WARNINGS AND ADVICE  
This instruction manual represents an integral part of the equipment and must be kept readily available  
for use.  
Read the warnings contained herein carefully before installing and using this equipment.  
In addition to offering information concerning routine maintenance for the ice slush drinks machine and  
technical back-up for troubleshooting, this manual aims to help the user make the most of the machine’s  
potential, adapting it to suit the specific needs of the various countries it will be used in.  
Modifications or attempts to modify the equipment will not only result in the forfeiture of the guarantee,  
but are also extremely dangerous.  
The maintenance operations must be carried out by qualified professionals. Never attempt to repair the  
machine yourselves as the intervention of non-qualified persons, as well as being hazardous, could also  
lead to serious damage to the machine.  
TECHNICAL DATA  
PLATE DATA  
The voltage and the frequency are indicated on the serial number plate, located on the refrigeration deck  
and the right hand side near the controls.  
TRANSPORTATION INDICATIONS  
To prevent the oil contained in the compressor from flowing out into the cooling circuit, the equipment  
must be transported, stored, and handled in a vertical position, as per the indications given on the  
packing.  
The wooden pallet, equipped with housing for the lifting forks, allows the packed equipment to be moved  
using normal handling and hoisting means.  
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Publication Number: M620919596OPR  
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INSTALLATION  
1. Remove the equipment from the packing, then slide it off  
upwards (see FIGURE 1).  
2. Checking the machine identification after removing the  
packing, you must check that the equipment you have  
received is exactly as you ordered, making sure the  
specifications indicated on the invoice or the delivery note  
are identical to those on the data plate.  
FIGURE 1  
3. Equipment accessories  
The following accessories are included inside the bowls:  
• This instruction manual;  
• 1 tube of Vaseline to be used for the maintenance machine the requires;  
• A drip tray.  
The back-lit cover is packed separately from the machine.  
4. Positioning - make sure the machine’s bodywork is well ventilated, at least 6”, and do not install  
near heat sources.  
We recommend you keep the room temperature at between 59 and 77°F.  
IMPORTANT: All the pieces of packing must be kept out of reach of children as they represent  
potential hazards.  
5. Remove gear motor shipping pins and tags from the rear of the unit prior to installation.  
CONNECTING THE ELECTRICITY MAINS  
Before inserting the plug into the mains socket for your own  
safety you must take careful note of the following precautions.  
The machine’s electrical system can only be considered safe  
when it is connected correctly to a grounded outlet, as  
provided for by the national safety regulations. The  
manufacturer cannot be held responsible for any damages  
that may be caused by failure to earth the system.  
For the system to be installed correctly and safely, it is  
essential to provide a suitable socket having a dedicated 20  
Amp circuit which complies with the national safety  
standards in force (see FIGURE 2).  
FIGURE 2  
Check the power supply cable to make sure it is not being crushed, do not use extension cords and, to  
remove the plug, first turn OFF the switch, then hold the plug tightly and pull gently.  
Do not obstruct the ventilation and the heat dissipation grids as bad airing, in addition to reducing the  
output and causing bad functioning, could also lead to serious damage to the equipment.  
IMPORTANT: If the power supply cord is damaged, it must be replaced by qualified persons only  
to prevent any possible risks.  
Publication Number: M620919596OPR  
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CONNECTION DIAGRAMS  
Ice Frost Generic (Pre-mix)  
The diagram shows the sequence for the connection between the ICE FROST GENERIC PRE to an  
existing pre-mix system.  
FIGURE 3  
Description:  
1. Pre-mix product 1 inlet.  
2. Pre-mix product 2 inlet.  
4. Inlet for CO2 (coming from the pressure reducing valve, 12 psi).  
5. CO2 gas cylinder.  
6. Operating pressure gauge.  
7. CO2 pressure regulator.  
8. Gas cylinder pressure gauge.  
9. Pre-mix product 1 container.  
10. Pre-mix product 2 container.  
11. Cooling unit (Optional).  
Connection:  
Connect the points 1, 2, and 4 on the machine to the existing pre-mix system using quick couplings.  
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Ice Frost Generic (Post-mix)  
The diagram shows the sequence for the connection between the ICE FROST GENERIC POST to an  
existing post-mix system.  
FIGURE 4  
Description:  
1. Syrup 1 inlet.  
2. Syrup 2 inlet.  
3. Soda water inlet.  
4. Inlet for CO2 45 to 60 psi.  
5. CO2 gas cylinder.  
6. Operating pressure regulator for carbonation unit.  
7. Carbonation unit operating pressure gauge.  
8. Unit and BIB operating pressure gauges.  
9. Pressure regulator.  
10. Gas cylinder operating pressure gauge.  
11. Water Pressure regulator.  
12. Filter.  
13. Carbonation unit and optional precooling unit.  
14. Syrup 1 pump.  
15. Syrup 2 pump.  
16. Bag-in-box exchanger.  
17. Bag-in-box exchanger.  
18. Bag-in-box.  
Connection:  
Connect the points 1, 2, 3, and 4 on the machine to the existing post-mix system using quick couplings or  
.265 splice connectors.  
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Alarms  
Safety Probe Alarms (only for ICE FROST GENERIC Pre-mix)  
You will remember that the monitoring of the safety probes’ conditions (satisfied/ not satisfied) is only  
active during the bowl loading phase. It follows, then, that a lack of liquid in the tanks during the non-  
loading phases will not be signalled.  
When one of the two safety probes fail to detect the flow (presence) of liquid during the loading phase,  
the system will stop (3-second software filter) the loading phase in progress, while the buzzer on the  
machine emits an intermittent warning signal lasting 6 seconds.  
The fill solenoid connected to the system where the lack of liquid has been detected by the safety probe  
input can only be energized by switching the system OFF then ON again (cycling power resets fill  
operation).  
If both the safety probes fail to detect a presence of liquid while the bowls are loading, the buzzer on the  
card will emit an intermittent sound lasting approximately 20 seconds.  
The bowl fill solenoids are command (OFF). The normal operation conditions can be restored by  
switching the machine OFF then ON again using the main switch.  
The bowl pressure valve solenoid valve is independent of the alarm signal and continues its  
CO2 gas pressure reading function only.  
1st Filling Time-out  
A time limit has been set for the first filling phase which is linked to the level probes detection of the  
presence of liquid.  
When one of the two level probes fails to detect the presence of liquid for more than four seconds, the  
buzzer on the card will emit an intermittent sound for approximately 6 seconds.  
The fill solenoid connected to the system where the lack of liquid has been detected by the safety probe  
input can only be reset by switching the system OFF then ON again.  
When both the level probes fail to detect a presence of liquid for more than four seconds, the buzzer on  
the card emits an intermittent sound lasting approximately 20 seconds.  
All the solenoids linked to the system are inhibited (bowl fill and CO2 gas management valves = OFF).  
The normal operating conditions can be resumed by switching the system OFF and then ON again.  
Filling Time-out  
A time limit has been set for the normal filling phase which is linked to the level probes SLIV 1 and SLIV  
2’s detection of the presence of liquid.  
When one of the two level probes fails to detect the presence of liquid for more than one minute, the  
buzzer on the card will emit an intermittent sound for approximately 6 seconds.  
The fill solenoid connected to the system where the lack of liquid has been detected by the safety probe  
input can only be energized by switching the system OFF then ON again.  
When both the level probes fail to detect a presence of liquid for more than on minute, the buzzer on the  
card emits an intermittent sound lasting approximately 20 seconds.  
The bowl fill solenoids are command (OFF). The normal operating conditions can only be resumed by  
switching the system OFF and then ON again.  
The CO2 gas management valve solenoid valve is independent of the alarm signal and  
continues its CO2 gas pressure reading function only (see relevant paragraph).  
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“FILTER CLEANING” Alarm  
A filter cleaning alarm will activate when the unit is running hot due to insufficient internal air circulation.  
When this occurs a “Filtr” message will appear on the touch pad LED display readout and an intermittent  
tone will also sound to alert the operator of this condition.  
The “Filtr” message will appear when the alarm activates (a beeping sound every 4-5 seconds). To  
determine the condition that caused the alarm and correct problem, see list of conditions below:  
Condition  
Corrective Action  
The filter is dirty and needs to be cleaned.  
• Clean and replace filter following instructions  
(Removing and Cleaning Filter).  
The unit is positioned too close to a wall or  
other object restricting air flow and causing  
• Reposition unit to maximize ventilation space  
(Installation Instructions).  
the machine to run at a higher temperature.  
The filter is not properly installed.  
• Properly install filter (Removing and cleaning fil-  
ter).  
• Reposition unit to maximize ventilation space.  
The unit has been installed near a heat  
source, such as a coffee machine, ice maker  
or cold beverage machine which expels hot  
air from its vents, causing the machine to run  
at a high temperature (installation near a  
heat source should be avoided).  
“SYSTEM OVER TEMPERATURE” Alarm  
A system over temperature alarm will activate as a safety precaution when the unit has overheated to  
protect the compressor.  
The system automatically goes to “OFF” status where the compressor’s operations is stopped, while  
augers will keep working to avoid forming ice blocks.  
When this occurs an “Err” message will appear on the touch pad LED readout accompanied by a  
continuous buzzer sound to alert the operator of this condition.  
When this alarm sounds, turn OFF all switches. Then determine the reason for the alarm. (See “Filter  
Cleaning” Alarm Section for Conditions and Corrective Actions).  
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BOWL LOADING OPERATIONS  
Ice Frost Generic (Pre-mix)  
WARNING: If the unit runs out of product and is turned off and turned back on without a new  
(full) product tank installed the sensor will look for product for 4 minutes. During this 4  
minute period CO2 will be purged from the bowl.  
Switch the machine’s main switch to the ON position (1).  
Put the switch (A) into the ON position (1) see FIGURE 5,  
switch A. Controls the flow of the product in the bowls.  
The machine’s bowls will now fill up until the maximum level  
is reached.  
Continue with start up operations.  
FIGURE 5  
Ice Frost Generic (Post-mix)  
Switch the machine’s main switch to the ON position (1).  
Make sure the switch (L1) is in the OFF position (0) -  
FIGURE 6 - (switch L1 controls the flow of the products in the  
bowls).  
Turn mixing motors OFF immediately. Do not run units with  
bowls empty.  
Using an 1/8 inch (8 mm) socket wrench (E1), loosen the nut  
that holds the post-mix valve (D1).  
Twist nozzle counter-clockwise (F1), lift the post-mix valve  
(D1) up slightly and turn it towards the outside. leaving  
nozzle and coupling attached to the bowl.  
FIGURE 6  
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BRIX PROCEDURE  
This will be a two step process. First to adjust the water flow  
rate by adjusting the water flow control and second to obtain the  
proper Brix by adjusting the syrup flow control.  
1. Rotate the valve assembly 90 degrees and slide to the  
outside of the machine. Tighten the 8mm nut using a  
socket wrench (E1), see FIGURE 7.  
2. Checking and adjusting the water flow is most easily done  
by first disconnecting the syrup bib.  
3. Hold the measuring cup below the valve & activate  
dispense using the micro switch on the valve.  
4. Adjust the water flow rate using a stop watch to 13 oz in 10  
seconds. (1.3 oz per sec). Turn the water adjustment  
screw on the flow control clockwise to increase water flow  
FIGURE 7  
or counter clockwise to decrease water flow.  
5. Reconnect the syrup.  
6. Dispense product into a cup by depressing the micro switch on the valve. Check brix using a  
refractometer. The brix should be set to 13% 1%. To increase the brix adjust the syrup adjustment  
screw on the valve clockwise to increase syrup flow or counter clockwise to decrease syrup flow.  
CAUTION: Do not turn the syrup flow control counter clockwise too far.  
7. When the Brix has been set to specification, reposition the  
valve to its original setting and tighten retaining nuts.  
8. Repeat the operation for the second bowl.  
Once the adjustments have been completed for each bowl,  
place the switch (L1) in the “ON” position, see FIGURE 8.  
Both bowls will fill until the level sensor is activated.  
Turn mixing motors “ON” (switch located on the control panel).  
The dispenser has built in delays for compressor and bowl fill  
switch.  
NOTE: During initial filling it is normal for some foaming to  
take place. The bowl level management will adjust as the  
product freezes & the foam will dissipate.  
FIGURE 8  
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PROGRAMMING ELECTRONIC TOUCH PAD  
To lower the control cover, use a coin or other object to turn the keyless lock to the horizontal position, in  
order to access the operating panel (controls are located on the right side of the unit).  
Auger ON/OFF Button  
Main Power Switch  
Turns unit ON.  
• Selects 12/24 time clock or Fo/Co tempera-  
ture display when turned ON while simulta-  
neously depressing the auger button.  
Turns auger ON and OFF when main  
power switch is ON.  
• Must be ON to permit COLD time to be  
reset.  
• Sets current time when turned ON while  
simultaneously depressing the “PRESS TO  
SELECT FUNCTION” button.  
• Must be ON to activate the “PRESS TO  
SELECT FUNCTION” button to select manual  
“OFF”, “FREEZE”, or “COLD” functions.  
FIGURE 9  
PRESS TO SELECT FUNCTION Button  
“AUTO TIMER” Button  
• Used to manually select “OFF”, FREEZE”,  
or “COLD” functions when auger is turned  
ON.  
Turns auto COLD mode ON or OFF (light  
on switch indicates when auto COLD mode is  
activated).  
• Accesses COLD timer reset mode when  
depressed for an extended period when  
auger is turned ON.  
• Used to adjust the hours and minutes set-  
tings when readjusting current time or auto  
COLD timer.  
• Locks in hours, minutes and final time set-  
tings after they are reset using the “AUTO  
TIMER” button.  
• Does not function when light on “AUTO  
TIMER” button is illuminated.  
To Enter Time Programming on Initial Installation or in the Event of Service  
1. Turn the power switch OFF.  
2. Press and hold the left “PRESS TO SELECT FUNCTION” button and turn ON the power switch.  
Release the “PRESS TO SELECT FUNCTION” button when the hour digits start blinking.  
3. Set the hour by pressing the “AUTO TIMER” clock button until the appropriate hour is shown.  
NOTE: When using a 12 hour clock the time is P.M. when the dot at the bottom right corner of the  
LED display is lit; A.M. when dot is not lit.  
4. Press the left “PRESS TO SELECT FUNCTION” button to set the minutes, then press the “AUTO  
TIMER” clock button until the appropriate minutes are set.  
5. Press the “PRESS TO SELECT FUNCTION” button one more time to save your settings.  
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Setting COLD Timer (Night Setting)  
1. Turn the power switch ON. Make sure the “AUTO TIMER” is OFF (light on button is not lit).  
2. Press the left hand “Auger ON/OFF” button ON.  
3. Press and hold the “PRESS TO SELECT FUNCTION” button until you hear a long beep and the  
LED, “Cold” and the “AUTO TIMER” clock light begins to blink.  
4. Press the “AUTO TIMER” clock button to set the unit to COLD mode and then press the “PRESS TO  
SELECT FUNCTION” button to save the setting.  
5. Press the “AUTO TIMER” clock button to set the minutes to complete time setting that you want it to  
turn to COLD mode. Then press the “PRESS TO SELECT FUNCTION” button to save the minute  
setting. The “COLD” light will turn off and the “FROZEN” light and “AUTO TIMER” light will begin  
blinking.  
6. Set the time you want the machine to return to FROZEN mode by following steps 1 - 5 above. Then  
press the “PRESS TO SELECT FUNCTION” button to save the time settings. The FROZEN light  
should be blinking.  
7. Repeat steps 1 - 6 for the opposite bowl using the left buttons.  
NOTE: Once the settings have been saved, the unit will keep the settings, even when the power  
switch is turned OFF.  
NOTE: When the light on the “AUTO TIMER” clock button is “ON”, the COLD timer is activated. To  
turn OFF the COLD timer, press the “AUTO TIMER” clock button(s) until the light(s) on the clock  
button(s) turns off.  
Operate in Automatic Mode (with COLD Timer Activated)  
1. Turn power switch ON and wait for LED display to light up.  
2. Press the left hand “Auger ON/OFF” button ON.  
3. To operate in COLD mode press the “AUTO TIMER” button until it is illuminated.  
4. When setting automatic times, please keep in mind it will take time for the frozen product to become  
liquid or vice versa.  
Operate in Manual Mode (without COLD Timer Activated)  
1. Turn the power switch ON and wait for LED display to light up.  
2. Make sure the clock button is OFF (LED light on clock button should not be lit up).  
3. First turn auger ON by pressing the “Auger ON/OFF” button until it beeps.  
NOTE: The auger must be ON before the unit will allow the COLD or FROZEN mode to be  
activated.  
4. Then select COLD or FROZEN mode by pressing the “PRESS TO SELECT FUNCTION” button  
until the light under the selection you desire is lit up.  
NOTE: In the COLD mode, the LED will read the actual temperature of the product (the  
temperature setting is preset to NSF standards and is not adjustable.) In the “FROZEN” or “OFF”  
mode the LED will read the current time.  
o
Setting the 12 or 24 Hour Display and F or oC Temperature Display  
1. Turn the power switch OFF.  
2. Press and hold the left “AUGER ON/OFF” button and turn ON the power switch. Release the  
“AUGER ON/OFF” button when either “12” or “24” are shown (indicates the current hour view).  
3. Press the “PRESS TO SELECT FUNCTION” button until either oF or oC is shown on the display.  
4. Press the “AUTO TIMER” button until the desired temperature display type is shown (oF or oC).  
5. Store the change by pressing the “PRESS TO SELECT FUNCTION” button until the current time is  
displayed. The unit is now ready for use.  
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Viewing the Bowl Temperature  
1. Turn ON the auger on the side that you want to display the bowl temperature (press the “AGER ON/  
OFF” button).  
2. Press the “PRESS TO SELECT FUNCTION” button until the “Cold” LED is lit. The display will now  
show the current bowl temperature in either oF or oC as applicable.  
CONSISTENCY ADJUSTMENT  
1. To dispense the product, place the cup beneath the  
dispensing valve (Q) and pull the lever (R) very gently  
(FIGURE 10).  
2. Adjusting the viscosity:  
To vary the viscosity of the product, turn the knob (S) as  
shown in FIGURE 11.  
Turning the knob counter-clockwise will increase viscosity  
(make the product denser).  
Turning the knob clockwise will decrease viscosity (make the  
product less dense).  
FIGURE 10  
ATTENTION: This control only changes the viscosity of the  
product dispensed, it does not effect the COLD  
temperature.  
ATTENTION: When the level of the product inside the bowl  
is below the minimum level, you must switch the COLD  
system (OFF position), or refill the bowl, following the  
instructions given in the previous paragraphs.  
An indicator gauge for reference is located on the back of the  
unit approximately 6 inches below the adjustment knob.  
NOTE: This indicator can not be viewed on all models.  
FIGURE 11  
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QUARTERLY CLEANING AND SANITATION  
POST MIX SYSTEMS OPERATIONS  
ATTENTION: The cleaning operations must be performed with the machine disconnected from the  
power supply.  
1. Empty the bowl of any remaining product and switch off the main switch “M”.  
2. Remove the cover (B) - FIGURE 27.  
3. Extract the quick couplings (C2) / (F2) - (FIGURE 12, FIGURE 13, and FIGURE 14).  
Pre-mix version  
Post-mix version  
FIGURE 13  
FIGURE 12  
FIGURE 14  
4. Disconnect the probe fastenings (D2) / (E2) - (FIGURE 12 and FIGURE 13).  
5. Pull the lockpin/safety pin (Y) upwards - FIGURE 15.  
CAUTION: There is a spring below the safety pin. Take  
caution when removing the pin that the spring does not fall  
into the unit or eject the pin.  
FIGURE 15  
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6. Slide the locking bar (Z) - FIGURE 16 - outwards so that  
the bowls are fully released.  
Unlock relief valve on the bowl lid cap and remove  
(FIGURE 17).  
FIGURE 16  
Bowl Lid Cap  
7. Unscrew the knobs (A1) so the bowls can be lowered  
slightly, open the tap to remove any remaining liquids and  
then extract it from its seating, pulling it outwards (FIGURE  
17).  
FIGURE 17  
8. Remove the tap from its seating, pressing the two  
clamping wings at the same time (FIGURE 18) and  
pushing upwards.  
FIGURE 18  
9. Remove the tap, holding the body (R) pressed downwards,  
then slide the lever (L) out of its seating (FIGURE 19).  
Wash all the parts thoroughly with hot water and mild  
detergent, rinse them well, and replace them.  
FIGURE 19  
10. Separate the bowl from its cover, releasing the fastening  
(D1) by pulling them upwards as shown in FIGURE 20.  
FIGURE 20  
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11. Wash the bowl and cover carefully with water and mild  
detergent, rinse them well, and replace them, making sure  
the sealing strip (E1) is positioned correctly between the  
cover and the bowl. To guarantee the seal, the rounded  
part of the said sealing strip (as shown in FIGURE 21)  
must be facing the cover.  
FIGURE 21  
12. Unscrew the fastening knob (F1) clockwise as the  
direction indicated by the arrow (threading to the left) and  
extract the spiral scraper (G1) and the seals (H1) and (I1).  
Clean the individual parts thoroughly (FIGURE 22).  
FIGURE 22  
13. Clean the drip tray (J1) and the evaporator (K1) (FIGURE  
23).  
14. Replace the mixing unit as follows:  
• Dampen the sealing strip (l1) and insert it into its  
seating.  
• Apply a generous amount of Vaseline (supplied with the  
machine) to the suction cup seal (H1) (on the part that  
comes into contact with the evaporator K1) and insert it  
in its spiral seating.  
• Replace the spiral scraper (G1).  
FIGURE 23  
• Fasten all the components in place by screwing the  
knob F1 counter-clockwise.  
15. Replace the bowl by pushing it into its seating.  
16. Fasten the bowl in place by tightening the knobs (A1) -  
FIGURE 24 and the locking bar (Z) - FIGURE 16.  
FIGURE 24  
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17. Replace the tap, remembering to smear both is seating in  
the bowl and the seals (J) with Food Grade Lubricant  
(FIGURE 25).  
FIGURE 25  
18. Remove the drip tray (L1) by rotating it slightly and pulling  
it outwards (FIGURE 26).  
Wash all the parts carefully and reassemble it by following  
the prior operations, remembering to re-insert the  
condensation discharge pipe (M1) in its seating.  
FIGURE 26  
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SPECIAL MAINTENANCE  
ATTENTION: To guarantee peak cooling  
system performance level, the routine cleaning  
of the condenser filter is essential.  
As explained earlier, an audible signal accompanied by  
the word FILT appearing on the control panel display,  
will warn the operator when the filter is clogged and so  
must be cleaned before the machine comes to an  
automatic stop.  
FIGURE 27  
Disconnect the machine from the power supply;  
Unscrew the nut (C in FIGURE 27).  
Remove the cover (B in FIGURE 27).  
Disconnect the plug (D in FIGURE 28).  
Loosen and rotate the bracket.  
Lift and remove the back (E in FIGURE 28).  
Clean the filter behind the net, then clean the  
condenser with a brush, if necessary.  
WARNING: You are reminded that all the opera-  
tions described above must be carried out with  
the machine switched off and the power cable dis-  
connected.  
FIGURE 28  
FIGURE 29  
FIGURE 30  
RESTRICTED AIR FLOW ALARM  
To protect the entire cooling system, the Ice Frost  
drinks maker is fitted with an electronic system which  
issues an acoustic warning signal in the event of  
insufficient ventilation or if the condenser filter is  
clogged. In addition to this, the words FILT and then  
ERR will appear on the control panel display.  
If the operator does not intervene when the signal is  
issued, restoring normal working conditions (i.e.  
ensuring better ventilation or cleaning the filter), this  
electronic system will stop the machine automatically.  
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ELECTRONIC MONITORING  
ELECTRONIC BOWL MONITORING AND SAFETY SYSTEM  
The diagram shows the electronic pressures and levels  
management system:  
1. Safety valve.  
2. Monitoring card for maximum limit exceeded probes.  
6
1
3. Bowl 1 overpressure discharge relief valve solenoids.  
4. Bowl 2 overpressure discharge relief valve solenoids.  
2
5
5. CO2 inlet solenoid valve.  
3
4
6. Pressure and levels monitoring card.  
7
7. CO2 pressure switch.  
FIGURE 31  
In addition to the product level probes, each bowl is fitted with 2 further ‘overfull’ safety probes.  
In fact, if the level probes should cease functioning and so the product begins to fill up the bowls, these  
safety probes will transmit this information electronically to the monitoring card (2), which will then  
disconnect the pressures and levels monitoring card (6).  
The pressures and levels control cards have various functions, which are described below.  
PRESSURE AND LEVEL CONTROL CARD GENERAL FEATURES  
Via a micro-controller, the μZ4LP allows the operator to manage the levels and the relative safety devices  
linked to the two cold drink bowls. An electronic pressure switch card (amplified, linearized, and  
compensated) is provided for monitoring the pressure of the gas used in the post-mix phase of the said  
drink.  
The Electronic Pressure Switch Card will have the following features:  
Independent level control for each bowl.  
CO2 gas pressure reading.  
Acoustic warning signal in the event of a lack of liquid/s.  
Pressure maintained between two pre-set points by means of a relay.  
The use of these mixed THT and SMD components makes it possible to maximize the services/  
dimensions/quality relationship (better immunity to external troubles).  
The ECU is composed of two main printed circuits:  
Power’ section including transformer, relay, and power supply.  
Logic’ section including (controller and level control circuiting).  
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OFF CONDITION  
In this condition, the electronic control is not connected to the power supply. To connect the ECB to the  
power supply, the main system switch must be put in the ON position.  
1st Filling Condition  
Supposing both the bowls are empty when the power is switched ON, the following situation will occur:  
After a 3 second delay if the four probes, managed by the system, have detected no ‘presence’ of liquid,  
the (μcontroller will energies the bowl fill solenoid 1 and 2 to allow the bowl to fill to begin.  
Bowl Level Probe  
Bowl Level Probe  
Safety Probe Input  
Safety Probe Input  
Bowl Fill Solenoid  
Bowl Fill Solenoid  
Safety Probe Inputs and Bowl Level Probes Uncovered  
FIGURE 32  
Bowl Fill Solenoids = ON  
Explanation of system flow controls, the first probes to be ‘covered’ are the two safety probe inputs.  
However, this recognition of the passage of liquid does not actually stop the filling phase since the main  
‘aim’ of the ECU is to fill the two bowls to the level required. Therefore only the recognition by bowl level  
probes interrupts the inlet of liquid into the bowl/s.  
Safety Probe Inputs Covered and Bowl Level Probes Uncovered  
Bowl Fill Solenoids = ON  
Bowl Level Probe  
Safety Probe Input  
Bowl Level Probe  
Safety Probe Input  
Bowl Fill Solenoid  
Bowl Fill Solenoid  
Safety Probe Inputs Covered and Bowl Level Probes Covered  
FIGURE 33  
Bowl Fill Solenoids = ON  
Once the initial fill is complete, the (μcontroller will command ON the CO2 gas management solenoid  
valve, which has been kept forcibly de-energized.  
NOTE 1: The initial fill must take place within a maximum time lapse which is monitored by the μcontroller  
(see Alarms section).  
NOTE 2: The initial fill might only concern one of the two bowls, but it will maintain the same features.  
NOTE 3: If all the probes are covered when the system is switched ON, the CO2 gas management  
solenoid valve functioning is command ON.  
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Managing the Bowl Levels  
When one of the two level probes fails to detect the presence of liquid in the bowl, the Fill solenoid valve  
is activated to refill the correct level.  
The probes relating to each bowl are completely independent, therefore the following situation will occur:  
Bowl Level Probe  
Bowl Level Probe  
Safety Probe Input  
Safety Probe Input  
Bowl Fill Solenoid  
Bowl Fill Solenoid  
Bowl Level Probes Uncovered  
Bowl Fill Solenoids = ON  
FIGURE 34  
Bowl Level Probe  
Safety Probe Input  
Bowl Level Probe  
Safety Probe Input  
Bowl Fill Solenoid  
Bowl Fill Solenoid  
Bowl Level Probes Covered  
Bowl Fill Solenoids = ON  
FIGURE 35  
NOTE 1: The level/s refill phase must take place within a maximum time lapse which is controlled by the  
(controller (see Alarms chapter).  
NOTE 2: The level/s refill phase may only concern one of the two bowls, but it will maintain the same  
features.  
NOTE 3: It is essential that the safety probes are covered for the bowl/s filling phase to take place.  
Safety Probes (only for ICE FROST GENERIC Pre-mix)  
In addition to the two level probes relating to the two bowls (see FIGURE 32 through FIGURE 35), the  
μZ4LP system also monitors the two ‘safety’ probes designed to monitor the presence of liquid in the  
external tanks.  
The monitoring of the probes (covered/uncovered) is only active during the bowl loading phase. It  
follows, then, that a lack of liquid in the tanks during the non-loading phases will not be signalled.  
If:  
Safety probe inputs uncovered when bowl fill solenoids = OFF -  
no signal  
Example of how the safety system works:  
Supposing the safety probe is uncovered and the solenoid valve is de-energized. In this case there will be  
no signal.  
Then the level probe located in the bowl is uncovered. The solenoid valve is enabled to allow the bowl to  
fill correctly.  
3 seconds after the activation of the solenoid valve, the safety signal is activated as the probe has been  
identified as uncovered. The fill solenoid valve is deactivated and the buzzer emits an intermittent signal  
lasting 6 seconds.  
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NOTE 1: the same intervention methods are applied when the safety probe  
is uncovered after the solenoid valve has been activated.  
NOTE 2: the 3-second software filter activated when it detects the safety probe is uncovered and the  
relevant signal have been introduced to prevent the probe recognizing the “tank-bowl” conduit as “empty”  
when there is residual gas in it.  
Summing Up:  
When one of the two safety probes fails to detect the passage (presence) of liquid during the fill, the  
system will stop (3-second software filter) the fill cycle in progress, while the buzzer on the machine  
emits an intermittent warning signal lasting 6 seconds.  
If the safety probes is uncovered when there is no loading phase in progress (is de-energized), no  
alarm signal is emitted.  
This signal is activated as soon as the system starts to load the bowl.  
If:  
Bowl fill solenoid = ON and Safety probe input = Covered  
bowl filled as usual  
If:  
Bowl fill solenoid = ON and Safety probe input = Uncovered  
after 3 seconds - Bowl fill  
solenoid = OFF and buzzer is activated  
ATTENTION: After the no liquid alarm signal has been activated (safety probe inlet uncovered),  
the actuators for the bowl whose safety probe is uncovered cannot be re-activated. Full  
functioning conditions can only be restored by switching the machine OFF then ON again and re-  
starting from the 1st filling phase. When the second safety probe is also identified as uncovered,  
all the charges relating to the system are inhibited (with the exception of CO2 gas management  
valve) and the buzzer emits an intermittent sound for approximately 20 seconds. Full functioning  
conditions can only be restored by switching ON and OFF the machine starting from the 1st filling  
phase.  
The CO2 gas management valve solenoid valve is independent of the alarm signal and continues  
its CO2 gas pressure reading function only (see relevant paragraph).  
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WIRING DIAGRAM  
VFCB (PRE-MIX) 115V/60HZ  
FIGURE 36  
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VFCB (POST-MIX) 115V/60HZ  
FIGURE 37  
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VFCB (PRE-MIX) 230V/50HZ  
FIGURE 38  
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VFCB (POST-MIX) 230V/50HZ  
FIGURE 39  
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TROUBLESHOOTING  
NOTE: The following procedures must be performed by a qualified service technician.  
Problem  
Possible Cause  
Solution  
“Filt” or “Err” message appears on  
the touchpad LED readout  
• The filter is dirty and needs to  
be cleaned  
• Clean and replace filter follow-  
ing instructions (Removing and  
Cleaning Filter)  
• The unit is positioned too close  
to a wall or other object restrict-  
ing air flow and causing the  
machine to run at a higher tem-  
perature  
• Reposition unit to maximize  
ventilation space (see installa-  
tion figures)  
• The filter is not properly  
installed  
• Properly install filter see  
“Removing and cleaning filter”  
• The unit has been installed  
near a heat source, such as a  
coffee machine, ice maker or  
cold beverage machine which  
expels hot air from its vents,  
causing the machine to run at a  
high temperature. (Installation  
near a heat source should be  
avoid)  
• Reposition unit to maximize  
ventilation space (see installa-  
tion figures)  
The machine does not cool, or  
cools only partially, but the com-  
pressors are running  
• The space around the machine  
is inadequate for ventilation  
• Allow at least 8” (20cm)  
between the machine and any-  
thing next to it; keep away from  
heat sources  
• Freezer is in COLD mode  
• Return to FROZEN mode  
• The condenser fins are clogged  
with airborne particles  
• Remove the side panels. Using  
a brush or compressed air  
clean the condenser  
• Fan motor is not running  
• Check the fan motor’s electrical  
connections and, if discon-  
nected, reconnect. If still not  
operating, replace the motor  
• Refrigerant is low  
• Locate the leak, eliminate it and  
recharge the system  
The machine does not cool or  
cools only partially, but one or  
more of the compressors are not  
running  
Defective Electrical components  
Loose wire connections  
Replace the malfunctioning compo-  
nents  
Check the contacts and correct  
those that are incomplete  
One or more of the compressors  
are malfunctioning  
Replace the compressor(s)  
No current is coming to the  
“compressor delay” PC board  
Check the electrical connections to  
the PC board as well as the trans-  
former feeding the PC board and  
correct  
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Problem  
Possible Cause  
Solution  
The machine over-freezes making  
the auger movement slow or  
stopped  
The product Brix/ratio is too low  
Check the product Brix/ratio and  
correct  
The screw setting for the product  
consistency control system is set  
too far toward the “+” position  
Reset the screw toward the “-”  
position to produce a thinner con-  
sistency product  
The limit switch arm is bent away  
from the gearmotor and prevents  
contact  
Using pliers, straighten the limit  
switch arm  
The level of the product in the bowl  
is too low, exposing the auger  
Add more product or turn the refrig-  
eration “Off”  
The compressor PC board contacts  
don’t open  
Replace the PC board  
The machine is noisy  
• The fan motor blades are hitting  
internal components  
• Check and correct  
The main power switch is “On”.  
The unit is not running.  
The fuse(s) are blown  
Replace the fuse(s)  
The pressure cutout switch has  
activated  
Clean the condenser or add venti-  
lation space around the machine  
(the cutout switch reset is auto-  
matic when the conditions are cor-  
rected)  
Some electrical connections are  
not complete  
Check the contacts and correct  
those that are incomplete  
The main power is not functioning  
Replace the switch  
Product is leaking out of the bowl  
• One of the bowl seals is not in  
place  
• Replace or reposition the seals  
Product is leaking from the dis-  
pensing valve  
The dispensing valve has been  
incompletely or incorrectly replaced  
in its position  
Reassemble and replace  
The free movement of the dispens-  
ing valve is impeded  
Clean and lubricate the valve and  
valve cylinder with the lubricant  
provided with the machine  
Dispensing valve o-rings are dam-  
aged  
Replace the o-rings  
Product is flowing into drain tray  
through drainage tube  
The bell shaped “shaft” seal  
between the front of the cylinder  
and the auger hub has not been  
reinstalled properly  
Find the seal and put it back in  
place  
The bell shaped “shaft” seal or the  
spindle bushing seal is damaged or  
worn  
Replace the damaged/worn seal  
and check the condition of the  
driveshaft.  
The auger is not turning  
Auger not turned on  
Turn auger on  
Some electrical connections are  
not complete  
Check the contacts and correct the  
ones that are incomplete  
The gear motor(s) are malfunction-  
ing  
Replace the gear motor(s)  
The auger is creating noises as it  
rotates  
The large red bowl seal is not in  
position, causing the gear teeth not  
to mesh  
Check and correct  
The product brix is incorrect  
Check the product brix and correct  
The bell shaped “shaft” seal has  
been replaced without lubrication  
or is damaged  
Replace or Clean and lubricate  
with the lubricant provided with the  
machine  
The auger has been incompletely  
or incorrectly reassembled (ie the  
auger’s gear pins are not properly  
seated)  
Check and correct  
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Problem  
Cap is leaking  
Possible Cause  
• The nut is loose  
Solution  
• Tighten the nut  
Bowl not refilling  
• Out of syrup  
• Out of CO2  
• Replace  
• Replace  
• Open  
• Valves are shut off or blocked  
• Foam covering probes  
• Wait  
Turn on  
• Replace  
• Replace  
• Fill Switch in off position  
• Defective syrup pressure switch  
• Defective CO2 shut off  
Bowl is overfilling  
• Bad Pressure and Levels Card  
• Replace the card  
CO2 leaking from back of unit  
• Proper function of bowl over  
pressure discharge solenoids  
• If not continuous leak it is nor-  
mal operation  
• Poor connection  
• Repair leak  
WARNING: Relief valve venting is normal, a continuous leak is not and must be corrected immedi-  
ately. Repair the solenoid valve.  
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