Cornelius IDC 255 Installation Manual Download

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IDC 255 Progate Drive Thru Installation Manual

INSTALLATION MANUAL

IDC 255 PROGATE DRIVE THRU UNIT

Release Date: December 31, 2008

www.cornelius.com

Revision: B

Summary of Contents for IDC 255

Page 1: ...IDC 255 Progate Drive Thru Installation Manual INSTALLATION MANUAL IDC 255 PROGATE DRIVE THRU UNIT Release Date December 31 2008 www cornelius com Revision B ...

Page 2: ...IDC 255 Progate Drive Thru Installation Manual Publication Number 621057419INS 2 2006 IMI Cornelius Inc ...

Page 3: ...s 8 Operation Instructions 9 Lid Dispenser Operation 9 Unit Operation 9 Loading of Lid Dispenser 10 Plastic Wrapped lids 10 Individual lids 11 Lid Dispenser Operation 12 Lid Dispenser Maintenance 12 Progate 2 Control Box Operation 12 Portion Control Box Functions 12 Programming Changing the Ice Portion 13 Agitation Time 14 Programming Changing the Agitation Time 15 Ice Portion Bar 16 Diagrams 17 C...

Page 4: ...IDC 255 Progate Drive Thru Installation Manual ...

Page 5: ...on Young children should be supervised to ensure that they do not play with the appliance Keep your machine in proper working condition and do not allow unauthorized modifications to the machine Qualified Service Personnel CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES CO...

Page 6: ...no additional cooling required VALVE CONFIGURATIONS IDC 255 Progate Drive Thru Unit with 7 Intelli Valves and 1 Variety Valve IDC 255 Progate Drive Thru Unit with 5 Intelli Valves and 3 Variety Valves IDC 255 Progate Drive Thru Unit with 8 Intelli Valves IDC 255 Progate Drive Thru Unit with 8 UFB 1 Valves SPECIFICATION Model Descriptions IDC 255 B Beverage C Coldplate H Internal Carb P Progate Z N...

Page 7: ...line recommended CO2 Requirements 100 psi max to unit regulated to 35 psi 2 4 bar to Progate 2 ice gate system 75 psi 5 2 bar carbonator Progate 2 Features Progate Portion Ice Control Features 4 Programmable ice dispense sizes Automatic Manual Ice Dispense Modes Unit Power On Off Switch Programmable Agitation Time Lid Dispenser 4 lid dispenser locations on the unit 3 Separate removable lid dispens...

Page 8: ...ors 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 COUNTER MOUNTING The ice drink dispenser must be sealed to the counter The template drawing indic...

Page 9: ...M FLOW RATE MUST BE AT LEAST 125 GALLONS PER HOUR If flow rate is less than 125 gallons per hour starving of the carbonator water pump will occur Starving will overheat the carbonator s water pump causing the safety thermostat on the pump outlet to stop the water pump motor Overheating could occur if the plain water supply line flow rate drops below 125 gallons per hour INCOMING PLAIN WATER INLET ...

Page 10: ... a 120 volt 60 cycle 3 wire grounded receptacle For 220 240 Volt International Units a 3 wire power cord is provided An adapter plug for the particular country will need to be provided by the Installer ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY LINE ON 1 Open counterclockwise CO2 cylinder valve slightly to allow lines to slowly fill with gas then open the valve fully to back seat ...

Page 11: ...Use 1 4 tubing capable of handling a minimum of 120 psi 2 Guide CO2 lines from back of machine to front 3 Locate CO2 line and connect to the barb fitting 4 Use Oetiker clamps to secure all lines to barbed fittings 5 Replace lower splash panel to frame FIGURE 4 POWER INSTALLATION The machine is equipped with a 3 Prong plug hot neutral ground and is plugged into any standard wall outlet capable of h...

Page 12: ...rbed fittings FIGURE 5 FIGURE 6 3 Use 3 8 tubing capable of handling a minimum of 120 psi Approved for food applications 4 Guide water lines from back of machine to left front and attach to cold plate lines W1 carbonator water line and W2 plain water or mains water line NOTE W4 is the re circulation line which is connected to a remote tower A W remote tower 5 Turn on pressure and check for leaks F...

Page 13: ...ounded to avoid possible fatal electrical shock or serious injury to the operator The unit power cord is equipped with a three prong plug If a three hole grounded electrical outlet is not available use an approved method to ground the unit CAUTION Never operate the carbonator pump with the water inlet supply line shutoff valve closed Dry running the water pump will burn out the pump A pump damaged...

Page 14: ...w the black plastic bottom Plastic Wrapped lids 1 To remove grab the lid dispenser lifting and pulling away from merchandiser FIGURE 9 FIGURE 10 2 Get fresh sleeve of lids and position so that lid bottom is up 3 Remove lid dispenser top if present 4 Tear open bag FIGURE 11 5 Slide sleeve into tube Pull plastic from stack replace top and place lid dispenser back in position on the merchandiser FIGU...

Page 15: ...c 11 Publication Number 621057419INS Individual lids 1 Stack lids on clean flat surface with lid top facing down FIGURE 14 2 Turn dispenser upside down and trap lids in the tube FIGURE 15 3 Place your hand over the top to capture lids and turn it right side up FIGURE 16 ...

Page 16: ...ns power to the entire machine off Lights Orange when ON 2 Agitator Push ON Turns on agitator and opens ice gate allowing continuous dispense This button will turn green in the manual mode and be off in PROGATE automatic This button will also agitate in the automatic mode but not dispense ice 3 Mode Switch Manual Progate Turns on agitator and opens ice gate allowing unlimited ice portion 4 Program...

Page 17: ...es the portioned button then the red light goes out 8 Portion Up Down Buttons The program bar is only active in the program mode to change the ice dispense program size Programming Changing the Ice Portion To change the size of any of the four ice dispense sizes follow the steps below 1 To enter the program mode press the Program Button and Desired Size button at the same time and hold for 5 secon...

Page 18: ...gitation Ratio2 RA Dispense Time mS Agitation Ratio Agitation Time mS 50 10 500 70 10 700 90 10 900 110 10 1100 130 10 1300 150 10 1500 170 10 1700 190 10 1900 210 10 2100 230 10 2300 Dispense Time mS Agitation Ratio Agitation Time mS 50 16 800 70 16 1120 90 16 1440 110 16 1760 130 16 2080 150 16 2400 170 16 2720 190 16 3040 210 16 3360 230 16 3680 Dispense Time mS Agitation Ratio Agitation Time m...

Page 19: ...ferent ice types FIGURE 17 Programming Changing the Agitation Time 1 Simultaneously Press and hold for 3 seconds the button and also both direction arrow buttons to enter the programming mode 2 The LED meter turns ON once the programming mode is entered Visual feedback of ratio agitation time is obtained from the visual programming LED The LED meter shows the existing agitation ratio enabling the ...

Page 20: ...s used to determine the amount of time programmed for each size button Each button has a minimum and maximum amount of time that can be programmed If a button cannot be adjusted to the size desired use another button to get the desired results FIGURE 18 20mS 50mS 230mS S Small 80mS 260mS M Medium 150mS 330mS L Large 230mS 410mS XL XLarge ...

Page 21: ...PLATE PW CW TO BE POST CHILLED PRE CHILLED WATER 2 3 5 4 6 W2 W3 W2 W1 W4 W1 5 4 3 2 1 12 11 10 9 8 PW PLAIN WATER CW CARBONATED WATER 1 2 3 4 CW PW PW CW 7 8 10 9 11 W2 W3 6 7 8 PW W4 W3 12 1 6 7 IN 5 PW CW SYRUP 1 OUT SINGLE TOWER SYRUP 2 OUT RECIRC IN RECIRC OUT 9 10 NOTES PLUMBING TO FITTINGS OF DIFFERENT DIAMETER MAY BE ACCOMPLISHED BY SPLICING THE TUBE AND USING APPROPRIATE CONNECTORS CITY W...

Page 22: ...CARB TANK CW PW CW PW PW CW PLAIN WATER INLET FOR CARB VALVES PLAIN WATER INLET FOR NON CARB VALVES RECIRC LINE IN OPTIONAL RECIRC LINE OUT OPTIONAL CW PW CW PW TF1 MANIFOLD TF1 MANIFOLD APPLY 90862 LABEL APPLY 90863 LABEL APPLY 90864 LABEL CITY WATER PRESSURE REGULATOR OR BOOSTER PUMP MAY BE REQUIRED PUMP MOTOR ASY CO2 CYLINDER WATER FILTER SECONDARY REGULATOR 60 PSIG FOR BRAND SYRUP PRIMARY REGU...

Page 23: ... W2 W3 W4 W3 12 1 6 7 IN REG A W OUT SINGLE TOWER SYRUP 2 OUT RECIRC IN RECIRC OUT NOTES PLUMBING TO FITTINGS OF DIFFERENT DIAMETER MAY BE ACCOMPLISHED BY SPLICING THE TUBE AND USING APPROPRIATE CONNECTORS CITY WATER PRESSURE REGULATOR OR BOOSTER PUMP MAY BE REQUIRED PUMP MOTOR ASY CO2 CYLINDER WATER FILTER SECONDARY REGULATOR 60 PSIG FOR SYRUP BIBS PRIMARY REGULATOR 110 PSIG S1 S2 S3 S4 S5 S6 S7 ...

Page 24: ...he E Board found in the E BOX Using a screwdriver follow the diagram below and set the agitator for the desired settings FIGURE 22 Manufacturer Recommended Agitation Settings Model Ice Fill Ice Type Motor ON Time Motor OFF time 175 215 255 300 B BC Manual Hard Ice Cube 4 Seconds 1 Hour Automatic Top Mount Ice Maker Hard Ice Cube 0 5 Seconds 20 Minutes Manual Automatic Cornelius Chunklet Scotsman H...

Page 25: ...WHT BLK SW2 LIGHTS SOL1 VALVE TIMED SOLENOI PNEUMATIC KEYPAD J1 25 VAC SECONDARY 120 VAC PRIMARY 100 VA 50 60 HZ BOARD KEYPAD AGITATION TIMER PROGATE 2 PB1 MANUAL MODE DISPENSE OPTIONAL GND 24 VAC2 24 VAC1 AGITATOR CONTROL ICE GATE PROBES 1 2 3 4 5 6 7 8 S LEFT RIGHT PROGRAM M L XL AGITITATOR GND J5 2 3 1 5 4 MTR 2 1 1 2 2 1 1 2 2 1 1 2 1 2 2 1 1 2 2 1 J3 1 2 3 PB1 S2 COVER SWITCH ENABLE DISABLE I...

Page 26: ...1 YLW YLW BLK BLK YLW AIR INPUT PUSH TO PNUEMATIC CYLINDER RETRACT KEY SWITCH RED RED BLK BLU BLU YEL TRANSFORMER CAPACITOR PNEUMATIC SOLENOID TERMINAL BOARD NO NC RELAY POWER CORD P N 92305 LABEL 6 PLCS 2 PLCS P N 70217 8 32 SCEW SS P N 31107 TERMINAL BOARD P N 620314152 BOX ELECTRIC PROGATE P N 720500795 X FORMER P N 30514 STRAP CAPAC P N 30774 CAPAC MOTOR AGIT P N 620314825 TIMER BOARD P N 6056...

Page 27: ...EMATIC CYLINDER RETRACT KEY SWITCH RED RED BLK BLU BLU YEL TRANSFORMER CAPACITOR PNEUMATIC SOLENOID TERMINAL BOARD NO NC RELAY POWER CORD 25 24 11 12 AGITATOR CONTROL 4 5 GND 3 2 1 ICE GATE 24 VAC1 24 VAC2 SW1 SW3 PB1 INTERFACE BOARD 3 4 4 X2 3 X1 J1 1 J4 3 1 2 P1 P N 32229 HARNESS ASSY AC INPUT P N 620317417 HARNESS CONTROL BOX MAIN ASSEMBLY P N 620317452 P N 620313669 JUMPER 18 BLACK P N 6203145...

Page 28: ... No 1 Plug unit into a socket 1 Check the external power supply breakers 2 Open the e box and check that the power cord wires black and white are connected to the e board 3 Check the connector between control box and the e box Are there other equipments on the same circuit Yes No Yes 1 Remove all other equipment from the machine circuit 2 Install a new dedicated circuit for the machine ...

Page 29: ...itch housing 2 Check for magnet in ice chute cover 3 Validate magnet distance from magnetic switch for activation to occur 4 Check ice chute disable switch ensuring that relay 1 is activating 5 Check transformer outputs wiring Yes Is the machine inlet pressure greater than 35 PSI 1 Check air supply shut off outside the E Box 2 Check air supply line 3 Check pneumatic cylinder for free movement 1 Ch...

Page 30: ... is functioning properly 2 Check ice in hopper ensuring that it is loose Yes No Check for proper air pressure going to the filter regulator in the E Box 35PSI or greater Is the air pressure to the filter regulater above 35PSI 1 Check the connector between the control box and the E Box 2 Check terminals 6 and 8 on relay 3 in the E Box 3 Check the pneumatic solenoid 1 Check air supply shut off outsi...

Page 31: ...ormer connections to the E Board in the E Box 2 Check the E Board in the E Box ensuring that power is being supplied to the board No Is there power on the load side of the transformer Yes 1 Check the transformer 2 Change the transformer No 1 Check the wire harness from the beverage valves to the terminal board 2 Check the beverage dispense valve to ensure that they are functioning 3 Change beverag...

Page 32: ...he carbonator tank 1 Check CO2 supply tank 2 Check CO2 supply lines 3 Change CO2 tank No 1 Fill the hopper with ice 2 Dispense some ice to ensure that the agitator spreads ice on the cold plate No 1 Check ice coverage on the cold plate Yes Is the CO2 pressure in the system correct Yes 1 Adjust CO2 pressure accordingly No Does the carbonator cycle when a 20oz drink is dispensed Yes 1 Refer to carbo...

Page 33: ...ed into a carbonated water port on TF1 No Carbonated Water Plug water line into carb water port on TF1 Is incoming water restricted Is there a power connection to carbonator pump 1 Check whether or not there is power across carbonator power cord on E Board in E Box 2 Change carbonator power cord on E Board in E Box 1 Restore recommended water flow 1 Replace carbonator pump 1 Check lines 2 Replace ...

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