The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possi
ble contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic,
and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and
construction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject to all of the restrictions and limitations contained in the Commercial Warranty.
Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained per
sons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact:
www.cornelius.com
800-238-3600
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Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
This document contains the original instructions for the unit described.
• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit
(decals, labels or laminated cards).
• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations
before operating this unit.
Recognition
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
DIFFERENT TYPESOF ALERTS
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment
damage.
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment
damage.
SAFETY TIPS
• Carefully read and follow all safety messages in this manual and safety signs on the unit.
• Keep safety signs in good condition and replace missing or damaged items.
• Learn how to operate the unit and how to use the controls properly.
• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or
infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING
AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD
RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
This unit has been specifically designed to provide protection against personal injury. To ensure continued protection
observe the following:
Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify
all of the power is off to the unit before any work is performed.
Failure to disconnect the power could result in serious injury, death or equipment damage.
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained
from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.
CO2 (CARBON DIOXIDE) WARNING
CO2 displaces oxygen. Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO2 and
soft drink system. If a CO
contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO
experience tremors which are followed rapidly by loss of consciousness and DEATH.
2 gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the
2 gas
MOUNTINGINORONA COUNTER
When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 615 lbs.to
ensure adequate support for the unit.
FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
NOTE: Many units incorporate the use of additional equipment such as icemakers. When any addition
equipment is used you must check with the equipment manufacturer to determine the additional weight the counter will need to support to ensure a safe installation.
The Ice Drink Cornelius (IDC) series of dispensers solves your ice and beverage service needs in a sanitary, space
saving, economical way. Designed to be manually filled with ice from any remote ice–making source, these dis
pensers will dispense cubes (up to 1–1/4 inch in size), cubelets, and compressed (not flaked). In addition, the units
include beverage faucets, a cold plate, an internal carbonator tank and an external pump for the carbonator, and
are designed to be supplied direct from syrup tanks with 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 8 Intelli Valves
• IDC 255 Progate Drive Thru Unit with 8 UFB-1 Valves
Electrical Connections: 6 ft long power cord with 3-prong plug attached to dispenser.
Power Requirements: 9.3 amps at 120 volts dedicated power supply.
Water Supply Requirements: 100 psi (7 bar) maximum static pressure 40 psi (28 bar) minimum dynamic pres-
sure. 3/8” minimum water 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 dispensers for small/medium, large, and extra large lids
Straw Holder
• Holds up to 140 regular sleeved straws
LID HOLDER COMPATIBILITY
The following template is a guide to validate the compatibility of the cup lids that are used with the Cornelius Lid
Dispensers supplied with the IDC255 Progate Ice Drink Dispenser. The lid dispensers accommodate small lids
3.75" in Dia. ± .032" in the large lid dispensers. The templates below are to scale to check the lids or compatibility.
The lid dispensers are manufactured out of materials that can survive chlorine-based cleaners and warm water
<100°F. Ensure that the parts are thoroughly dried before refilling with lids.
NOTE: Lid dispenser parts should not be soaked in the powersoak washing machine as this will result
in the parts getting scratched. Instead the dispenser parts should be rinsed in warm soap water
and then dried.
PROGATE 2 CONTROL BOX OPERATION
Portion Control Box Functions
The portion control box on the PROGATE 2 has several functions including dispensing 4 programmed ice portions
for 4 cup sizes, programming and a manual dispense mode.
1. Main Power ON/OFF: Turns 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 will 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 Button: The programming button is used with cup size button enabling the user to enter the
portion programming mode to adjust the ice portions. The programming button is used with the directional
arrow buttons to adjust the agitation time.
5. Ice Portion Dispense Buttons: Used to dispense the appropriate ice portion. Can also be used in con-
junction with the program button to program a portion size.
6. Ice Size Program Bar: The program bar is only active in the program mode as a visual aid in setting the
portion size.
7. Light:On start up of the unit or during a mode change (Manual to Progate) this light turns orange to
inform the user that the unit is going through a self diagnostic test. On completion of this test the light turns
green to inform the user that the machine is ready to dispense. If the light remains solid on red and the unit
is not dispensing any ice when an ice portion is pressed this should generate a service call. During ice dis
pense if there is insufficient ice in the ice chute then the light turns red instantaneously to inform the user
that there is insufficient ice. Once the user releases 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 dis-
To change the size of any of the four ice dispense sizes follow the steps below.
1. To enter the program mode press the Prog
time and hold for 5 seconds.
2. The Ice Portion Bar will come on
3. Press the RIGHT ARROW button to increase the amount of dispensed ice. The LED will move
towards the right indicating the Ice Portion has been increased.
4. Press the LEFT ARROW button
the left indicating the Ice Portion has been decreased.
5. To exit the program mode press the Desired Size button
return to the dispense mode.
6. Place a cup under the ice chute and press the just programmed dispense size button
pense amount is not the desired amount repeat the process.
7. To exit, repeat Step 1.
ram Button
to decrease the amount of dispensed ice. The LED will move towards
and Desired Size button at the same
or wait 10 seconds and the control will
If amount dis-
Agitation Time
The software coding for the progate system involves a direct relationship between the dispense time and the agitation time.
Dispense Time (mS)Agitation Ra
5010500
7010700
9010900
110101100
130101300
150101500
170101700
190101900
210102100
230102300
Dispense Time (mS)Agitation RatioAgitation Time (mS)
Dispense Time (mS)Agitation RatioAgitation Time (mS)
170162720
19
0163040
210163360
230163680
Dispense Time (mS)Agitation RatioAgitation Time (mS)
50281400
70281960
90282520
110283080
130283640
150284200
170284760
190285320
210285880
230286440
The relationship is expressed below.
Agitation Time (A
The agitation time equals the dispense time m
change the agitation ratio thereby altering the agitation time in order to ensure that the ice chute is always filled with
ice for all ice types.
) = Dispense Time (DT) x Agitation Ratio2 (RA)
T
ultiplied by the agitation ratio. The user is given the flexibility to
Figure 5.
Programming (Changing) the Agitation Time
1. Simultaneously press and hold for 3 seconds, the
to enter the programming mode.
button and also both direction arrow buttons
2. The LED meter turns ON once the programming mode is ente
obtained from the visual programming LED
ratio enabling the user to vary the agitation time using the directional arrow buttons. Left
and right direction arrow button to increase.
The portion bar is 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.
The beverage assembly for the unit comprises of 7 Intelli Valves and 1 Variety valve, 8 Intelli Valves, or 8 UFB-1
valves. Attached are the cold plate diagrams showing the each of the connections.
When Ice is not being dispensed from the machine such as during off hours it is essential to move or agitate the ice
to keep it from clumping and to replenish the ice in the cold plate. The amount of time the agitator runs and the time
between the agitation cycles can be adjusted depending on ice type or application. The settings for this function are
located on the E-Board found in the E-BOX. To access the board to be adjusted refer to sections 5.1 and 5.3. Using
a screwdriver follow the diagram below and set the agitator for the desired settings.
Figure 9.
Manufacturer Recommended Agitation Settings
ModelIce Fill/Ice TypeMotor ON Time Motor OFF time
These instructions are applicable for all Cornelius ice drink dispensers. Some models may have additional cleaning
requirements. Those models will have additional procedures listed later in the manual.
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
Do not use metal scrapers, sharp objects or abrasives on the ice storage hopper, top cover, agitator disc or exterior
surfaces as it may damage the unit. Do not use solvents or other cleaning agents as they may degrade the material
resulting in damage to the unit.
Soap solution – Use a mixture of mild detergent and warm (100° F) potable water.
Sanitizing Solution – Dissolve 2 packets (4 Oz) of Stera Sheen Green Label into 2 gallons of warm (80 – 100° F)
potable water to ensure 200 ppm of chlorine.
Daily Cleaning:
1. Remove cup rest from drip tray and clean with warm soapy water, rinse with clean water and allow to air dry.
2. Wipe down the exterior of the unit with warm soapy water, rinse with clean water and allow to air dry.
3. Remove valve nozzles and diffusers and wash in warm soapy water, rinse in clean water and allow to air dry.
4. Clean the interior of the ice chute using the brush provided with the unit with warm soapy water, rinse with
clean water and allow to air dry.
5. Spray the ice chute inside and out with sanitizer and allow to air dry.
6. Pour warm soapy water down the drains to keep them clean and flowing smoothly.
7. Spray the nozzles and diffusers inside and outside with approved sanitizing solution, re-install them on the
valves and allow to air dry.
8. Re-install the cup rest into the drip tray.
9. Pour all remaining sanitizer solution down the drain to help keep the drain clear.
Daily Maintenance:
1. Check the temperature, smell and taste of the product.
2. Check the water pressure coming to the unit using the pressure gauges on the back room package.
3. Check carbonation of the drink.
4. Check level of CO2 supply to the system.
5. Check the date on all the BIB’s (bags in boxes).
Weekly Cleaning: (In addition to daily procedures)
Remove the ice chute cover and clean it along with the back half with warm soap water using the brush provided
with the unit. Rinse with clean water and re-install on the unit. Spray the ice chute assembly with an approved
sanitizer and allow it to air dry.
Monthly Cleaning: (In addition to daily and weekly procedures)
1. Flush and sanitize all syrup lines as well as all of the syrup connectors. (See the Sanitize syrup lines
section shown later in this manual).
2. Remove ice from hopper, clean and sanitize the hopper. (See the Cleaning the interior surfaces section
shown later in this manual).
3. While cleaning the hopper use the brush provided with the unit to clean the cold plate surface. To
accomplish this, the brush needs to be extended through the opening in the bottom of the hopper.
Yearly Maintenance:
1. Have the water pump and check valve inspected and cleaned by a qualified service technician.
2. Has the CO2 gas check valve inspected and cleaned by a qualified service technician.
3. Remove the unit’s splash and cold plate cover to clean and sanitize the cold plate surface. (See the
Cleaning the Cold Plate section shown later in this manual).
Lid Dispenser Cleaning
The lid dispensers are manufactured out of materials that can survive chlorine-based cleaners and warm water
<100°F. Ensure that the parts are thoroughly dried before refilling with lids.
Lid dispenser parts should not be soaked in the power soak washing machine as this will result in the
parts getting scratched. Instead the dispenser parts should be rinsed in warm soapy water when dry.
Ice Chute Cleaning
The Ice chute needs to be cleaned daily to remove buildups.
NOTE: The ice chute has an built-in safety feature which disables the unit when the ice chute cover is
removed. If the ice chute cover is not properly installed the agitator and ice chute gate will not
function.
Removing and Reinstalling the Ice Chute:
1. Grab ice chute and slide up until it comes to a
stop.
2. Pull forward.
3. Properly clean the ice chute. The ice chute is
manufactured out of materials that can survive
chlorine-based cleaners and warm water
<100°F.
IMPORTANT: Do not put the ice chute into a
dishwasher.
4. Replace when finished.
5. If agitator or ice chute does not operate
remove and re-install chute cover.
Figure 13.
Cleaning Interior Surfaces (Monthly Cleaning)
When pouring liquid into the hopper, do not exceed the rate of 1/2 gallon per minute. Pouring more liquid into the
hopper could result in an overflow situation which may result in injury or damage to the equipment.
1. Remove agitator assembly.
2. Using a nylon bristle brush or sponge, clean the interior of the hopper, top cover and agitator assembly with
soap solution. Thoroughly rinse the hopper, cover and agitator surfaces with clean potable water.
3. Re-assemble agitator assembly. Take special care to ensure that the thumbscrew is tight.
4. Using a mechanical spray bottle filled with sanitizing solution, spray the entire interior and agitator assembly. Allow to air dry.
5. Remove merchandiser and ice chute cover from the unit.
6. With a nylon bristle brush or sponge, clean the inside of the ice chute, gasket, and cover with soap solution
and rinse thoroughly to remove all traces of detergent.
7. Re-assemble ice chute assembly.
8. Using a mechanical spray bottle filled with sanitizing solution, spray the inside of the ice chute. Allow to air dry.
9. Reinstall the merchandiser.
Cold Plate (Yearly Maintenance)
1. Remove splash panel.
2. Remove or move the plastic cold plate cover to expose the cold plate.
3. Locate and remove any debris from the drain trough. Check that the drain holes are not clogged.
4. Pour small amount of soap solution through cold plate openings in hopper.
5. Using a cloth, wash down the surfaces of the cold plate and plastic cover with soap solution.
6. Install and properly position the access covers on the cold plate.
7. Install the splash panel in the reverse order it was removed.
8. Rinse cold plate surface by pouring potable water through hopper openings.
Dispensing Valves: (Daily Cleaning)
Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed on the unit.
Product Tubing (Monthly Cleaning)
IMPORTANT: Only trained and qualified persons should perform these cleaning and sanitizing procedures.
Sanitize Pre-Mix And Post–Mix Tank System
1. Remove all the quick disconnects from all the tanks. Fill a suitable pail or bucket with soap solution.
2. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
3. Prepare sanitizing solution and using a mechanical spray bottle, spray the disconnects and allow to air dry.
4. Using a clean, empty tank, prepare five (5) gallons of the sanitizing solution. Rinse the tank disconnects
with approximately 9 oz. of the
5. Prepare cleaning tank by filling clean five (5) gallon tank with a mixture of mild detergent and potable water
o
(120
F).
6. Connect a gas disconnect to the tank and then apply one of the product tubes to the cleaning tank. Operate the appropriate valve until liquid dispensed is free of any syrup.
7. Disconnect cleaning tank and hook up the sanitizing tank to syrup line and CO2 systems.
8. Energize beverage faucet until a chlorine sanitizing solution is dispensed through the faucet. Flush at least
two (2) cups of liquid to ensure that the sanitizing solution has filled the entire length of the syrup tubing.
sanitizing solution. Close the tank.
9. Allow sanitizer to remain in lines for fifteen (15) minutes.
10. Repeat the step above, applying a different product tube each time until all tubes are filled with the sanitizing solution.
11. Remove the nozzle and syrup diffuser and clean them with a mild soap solution.
12. Rinse with clean water and reassemble the nozzle and syrup diffuser on the valve.
13. Rinse the parts with clean water, reassemble the valve and reconnect it to the dispenser.
14. Discard the tank of sanitizing solution and reconnect the product syrup tanks. Operate the valves until all
sanitizer has been flushed from the system and the only product syrup is flowing.
1. Remove all the quick disconnects from all the B-I-B containers.
2. Fill a suitable pail or bucket with soap solution.
3. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
4. Using a plastic pail, prepare approximately five (5) gallons of sanitizing solution.
5. Rinse the B-I-B disconnects in the sanitizing solution.
6. Sanitizing fittings must be attached to each B-I-B disconnect. If these fittings are not available, the fittings
from empty B-I-B bags can be cut from the bags and used. These fittings open the disconnect so the sani
tizing solution can be drawn through it.
7. Place all the B-I-B disconnects into the pail of sanitizing solution. Operate all the valves until the sanitizing
solution is flowing from the valve. Allow sanitizer to remain in lines for fifteen (15) minutes.
8. Remove the nozzle and the syrup diffuser from each valve and clean them with a soap solution. Rinse with
clean water and re-assemble the nozzle and syrup diffuser to the valve.
9. Remove the sanitizing fittings from the B-I-B disconnects and connect the disconnects to the appropriate
B-I-B container. Operate the valves until all sanitizer has been flushed from the system and the syrup is
flowing freely.
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Replenishing CO2 Supply (As Required)
NOTE: When indicator on the 1800-psi gauge is in the shaded (“change CO2 cylinder”) portion of the
dial, CO
1. Fully close (clockwise) the CO2 cylinder valve.
2. Slowly loosen the CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove the
regulator assembly from the empty CO
3. Unfasten safety chain and remove the empty CO2 cylinder.
To avoid personnel injury and/or property damage, always secure the CO2 cylinder with a safety chain to prevent it
from falling over. Should the valve become accidently damaged or broken off, a CO
sonnel injury or death.
4. Position the full CO2 cylinder and secure with a safety chain.
5. Make sure gasket is in place inside the CO2 regulator assembly coupling nut, then install the regulator
assembly on the CO
6. Open (counter-clockwise) the CO2 cylinder valve slightly to allow the lines to slowly fill with gas, then open
the valve fully to back-seat the valve (back-seating the valve prevents gas leakage around the valve shaft).
7. Check CO2 connections for leaks. Tighten any loose connections.