Cornelius IDC255 Service Manual

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IDC 255 PROGATE DRIVE THRU
Service Manual
Release Date: June 27, 2006
Publication Number: 621057419SER
Revision Date: April 02, 2014
Revision: F
Visit the Cornelius web site at
www.cornelius.com for all your Literature needs.
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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.
CORNELIUS INC
101 Regency Drive
Glendale Heights, IL
Tel: + 1 800-238-3600
Printed in U.S.A.
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TABLE OF CONTENTS
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unit Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Valve Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Progate 2 Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Progate Portion Ice Control Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Lid Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Straw Holder . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
LID HOLDER COMPATIBILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Small Lid Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Medium Lid Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Large Lid Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Lid Dispenser Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Progate 2 Control Box Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Portion Control Box Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Programming (Changing) the Ice Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Agitation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Programming (Changing) the Agitation Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ice Portion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Cold Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
7 Intelli Valves and 1 Variety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8 Intelli Valves or 8 UFB-1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
E – Board Off Cycle Agitation Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Main Electrical Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Interconnect Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
CLEANING AND MAINTENANCE INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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Daily Cleaning: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Daily Maintenance:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Weekly Cleaning: (In addition to daily procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Monthly Cleaning: (In addition to daily and weekly procedures) . . . . . . . . . . . . . . . . . . . . . . . . 18
Yearly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Lid Dispenser Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Ice Chute Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Removing and Reinstalling the Ice Chute: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cleaning Interior Surfaces (Monthly Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Cold Plate (Yearly Maintenance) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Dispensing Valves: (Daily Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Product Tubing (Monthly Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sanitize Pre-Mix And Post–Mix Tank System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Sanitize syrup lines, B-I-B Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Replenishing CO2 Supply (As Required). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Merchandiser Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Main Electrical Box Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Ice Chute Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Diagnostics Guide for the Main Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Motor Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Power Light Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
No Ice Dispense in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
No Ice Dispense in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Beverage Not Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Flat Drinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
No Carbonated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
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IDC 255 Progate Drive Thru Service Manual
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DANGER:
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WAR NING:
CAUTION:
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SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
Safety Overview
• 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 TYPES OF 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.
© 2006-2014, Cornelius Inc. - 1 - Publication Number: 621057419SER
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IDC 255 Progate Drive Thru Service Manual
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WAR NING:
CAUTION:
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CAUTION:
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DANGER:
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WAR NING:
SAFETY PRECAUTIONS
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
MOUNTING IN OR ON A 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.
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IDC 255 Progate Drive Thru Service Manual
UNIT SPECIFICATION
DESCRIPTION
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
SPECIFICATION
Model Descriptions IDC 255
B=Beverage C=Coldplate H=Internal Carb P=Progate
Z=No Drip Tray Unit Weight 368 Pounds Ice Storage 255 Pounds Maximum Number of Faucets 10 Built-in Cold Plate Yes Electrical 120/1/60
9.3 Amps of Total Unit Draw
OR
220/1/50
4.7 Amps of Total Unit Draw
Dimensions Width 29.90 inch (.76 m)
Height 39.75 inch (1.0 m)
Depth 36.90 inch (.94 m) CO
2 Operating Pressure 75-psig (max)
Water 100 psi (7 bar) maximum static pressure.
40 psi (2.8 bar) minimum dynamic pressure.
3/8” minimum water line recommended.
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IDC 255 Progate Drive Thru Service Manual
20.756
39.750
36.901
30.000
PCX OUT OF RATIO LABEL
CORNELIUS LOGO
UNIT SERIAL NUMBER
Figure 1.
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.
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Small Lid Template
3.750
IDC 255 Progate Drive Thru Service Manual
Figure 2.
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IDC 255 Progate Drive Thru Service Manual
4.350
Medium Lid Template
Figure 3.
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Large Lid Template
4.700
IDC 255 Progate Drive Thru Service Manual
Figure 4.
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IDC 255 Progate Drive Thru Service Manual
1
2
3
6
5
7
8
4
1. MAIN POWER ON/OFF
2. AGITATOR PUSH ON
3. MODE SWITCH MANUAL/PROGATE
4. PROGRAM BUTTON
5. ICE PORTION DISPENSE BUTTONS
6. ICE PORTION BAR
7. PROGATE ON LIGHT
8. PORTION SIZE LEFT/RIGHT KEYS
LID DISPENSER MAINTENANCE
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-
pense program size.
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IDC 255 Progate Drive Thru Service Manual
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 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
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
tio Agitation Time (mS)
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IDC 255 Progate Drive Thru Service Manual
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10 14 16 1812
24
20 22 26 28
Dispense Time (mS) Agitation Ratio Agitation Time (mS)
170 16 2720
19
0 16 3040
210 16 3360
230 16 3680
Dispense Time (mS) Agitation Ratio Agitation Time (mS)
50 28 1400
70 28 1960
90 28 2520
110 28 3080
130 28 3640
150 28 4200
170 28 4760
190 28 5320
210 28 5880
230 28 6440
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.
3. To exit, repeat Step 1.
Publication Number: 621057419SER - 10 - © 2006-2014, Cornelius Inc.
red. Visual feedback of ratio/agitation time is
. The LED meter shows the existing agitation
to decrease
Page 15
IDC 255 Progate Drive Thru Service Manual
=20mS
50mS
230mS
“S” Small
80mS
260mS
“M” Medium
150mS
330mS
“L” Large
230mS
410mS
“XL” XLarge
Ice Portion Bar
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.
Figure 6.
© 2006-2014, Cornelius Inc. - 11 - Publication Number: 621057419SER
Page 16
IDC 255 Progate Drive Thru Service Manual
INCLUDED WITH UNIT
COLDPLATE
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
910
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
S8
S9
S10
FILTER REGULATOR
TO PROGATE
SYSTEM
ELECTRICAL-BOX
SHUT-OFF
VALVE
DIAGRAMS
COLD PLATE
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.
7 Intelli Valves and 1 Variety Valve
Figure 7.
Publication Number: 621057419SER - 12 - © 2006-2014, Cornelius Inc.
Page 17
8 Intelli Valves or 8 UFB-1 Valves
INCLUDED WITH UNIT
COLDPLATE
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
7
8
10
9
11
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
S8
FILTER REGULATOR
TO PROGATE
SYSTEM
ELECTRICAL-BOX
SHUT-OFF
VALVE
PW
CW
5
6
7
8
CW
PW
REG A&W OUT
DUAL TOWER
DIET A&W OUT
DUAL TOWER
IDC 255 Progate Drive Thru Service Manual
Figure 8.
© 2006-2014, Cornelius Inc. - 13 - Publication Number: 621057419SER
Page 18
IDC 255 Progate Drive Thru Service Manual
E-BOARD AGITATION TIMER
2
HRS
1.5
HRS
1
HR
30
MIN
10
MIN
3
HRS
MOTOR ON TIME
OFF TIME
4.5
4
3.5
3
2.5
2
1.5
1
.5
5
2.5
HRS
FULL CCW - 0.5 SECONDS
FULL CW - 5 SECONDS
FULL CCW - 10 MINUTES
FULL CW - 3 HOURS
ON
TIME
OFF
TIME
ON
TIME
OFF
TIME
E – BOARD OFF CYCLE AGITATION ADJUSTMENTS
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
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
0.5 Seconds 20 Minutes
Maker/Hard Ice (Cube)
Manual & Automatic/Cornelius
0.5 Seconds 3 Hours
Chunklet, Scotsman &
Hoshizaki Compressed Ice
B - Beverage C-Coldplate *NO FLAKED ICE*
Publication Number: 621057419SER - 14 - © 2006-2014, Cornelius Inc.
Page 19
LINE VOLTAGE
BLK
T1
GRN/YEL
"CARB MOTOR GND"
L1 PWR
L2 PWR
GND
120VAC
CARBONATOR
"L2 CARB MOTOR"
GRN/YLW
BLU
BRN
"L1 CARB MOTOR"
BOARD AGITATION/ CARBONATOR
YLW
BRN
GRN/YLW
ICE AGITATION
MTR
"L2 AGITATOR"
"L1 AGITATOR"
BLK
ORG
HEATER L1
BLK
BLK
J2
J1
HEATER L2
ICE AGITATION
HEATER
HT
BALLAST L2
BALLAST L1
BLK
WHT
FLOURENSCENT
XFORMER L2
XFORMER L1
BLK
WHT
KEY SWITCH
BLUE
BLUE
BLK
BLK
LEFT
TOTAL FLEX
SOLENOID BLOCK
TOTAL FLEX
SOLENOID BLOCK
RIGHT
J4
C1
WHT
RED
BLK
CARBONATOR
WHT
BLK
RED
CARBONATOR PROBES
BALLAST
STARTER
WHT
BLK
BLK
WHT
BLK
SW2
LIGHTS
SOL1
VALVE TIMED SOLENOID
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
"AGITATOR GND"
J5
2
315
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
ICE CHUTE
CR1
AUTO/MANUAL
MODE SWITCH
SW1
CR1
CR1
ON/OFF
YLW
OFF CYCLE AGITION MOTOR
CR2
BY PASS
CR2
YLW
BLK
BLK
YLW
YLW
YLW
BLK
BLK
BLK
YLW
WHT
YLW
BLK
YLW
YLW
18AWG
18AWG
18AWG
18AWG
18AWG
18AWG
WHT
WHT
11 12
GRN/YEL
6203141825
86 68
S3
COMPONENTS LOCATED IN CONTROL BOX
0
1
0
1
2
4
5
73
1
2
1
3
CR3
0
1
6
CR3
8
4
3
CR3
P1-2
P1-3
4-1P3-1P
P1-1
34
34
ORG
GRN
GRN
ORG
ORG
YLW
BLK
PURP
GRN
PURP
PURP
P1-4
P1-5
P1-6
P1-7
PURP
LIGHT
(50 VA)
RED
RED
25
LIGHT
ELECTRICAL SCHEMATIC
IDC 255 Progate Drive Thru Service Manual
Figure 10.
© 2006-2014, Cornelius Inc. - 15 - Publication Number: 621057419SER
Page 20
IDC 255 Progate Drive Thru Service Manual
6
1
7
8
0
12345
L2 IN
L1 IN
L2 BALLEST
L1 BALLEST
L2 XFORMER
L1 HEATER
L1 XFORMER
L2 HEATER
CARB MOTOR
WHT
L2 CARB MOTOR
CARB MOTOR EARTH
EARTH IN
AGITATOR L2
AGITATOR
AGITATOR EARTH
J5
J2 J1
2
4
3
4
6
8
1
0
2
1
8
4
6
2
0
CR2
CR1
CR3
PUR
WHT
BLK
YLW
PUR
BLK MODE SW
BLK
BLK
YLW
BLK
P1
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 60569001
RELAY NO
P/N 620052685
CONTROL BOX BRACKET
P/N 325192000
BUSHING 1.093
P/N 70959
TSN NUTS
P/N 620314025
RELAY NO NC
P/N 620313711
SOLENOID ASY
P/N 620052503
BRACKET
P/N 325192000
BUSHING
P/Ns: 07052009 - SCREW
0720603-NUT
MAIN ELECTRICAL BOX ASSEMBLY
Figure 11.
Publication Number: 621057419SER - 16 - © 2006-2014, Cornelius Inc.
Page 21
INTERCONNECT SCHEMATIC
6
1
7
8
0
12345
L2 IN
L1 IN
L2 BALLEST
L1 BALLEST
L2 XFORMER
L1 HEATER
L1 XFORMER
L2 HEATER
CARB MOTOR
WHT
L2 CARB MOTOR
CARB MOTOR EARTH
EARTH IN
AGITATOR L2
AGITATOR
AGITATOR EARTH
J5
J2 J1
2
4
3
4
6
8
1
0
2
1
8
4
6
2
0
CR2
CR1
CR3
PUR
WHT
BLK
YLW
PUR
BLK MODE SW
BLK
BLK
YLW
BLK
P1
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
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
31 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 620314527
HARNESS SENSOR ICECHUTE
DISABLE SWITCH
P/N 620317414
HARNESS CHUTE COVER
DISABLE SWITCH
P/N 620316456
CARBONATOR MOTOR
P/N 30794
HARNESS MOTOR HEATER
P/N 620316455
HARNESS AGITATOR MOTOR
P/N 620314720
HARNESS POWER CORD
P/N 620316455
HARNESS CARB PROBE
P/N
620314765
IDC 255 Progate Drive Thru Service Manual
Figure 12.
© 2006-2014, Cornelius Inc. - 17 - Publication Number: 621057419SER
Page 22
IDC 255 Progate Drive Thru Service Manual
!
WAR NING:
CAUTION:
!
CLEANING AND MAINTENANCE INSTRUCTIONS
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).
Publication Number: 621057419SER - 18 - © 2006-2014, Cornelius Inc.
Page 23
IDC 255 Progate Drive Thru Service Manual
CAUTION:
!
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.
© 2006-2014, Cornelius Inc. - 19 - Publication Number: 621057419SER
Page 24
IDC 255 Progate Drive Thru Service Manual
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.
Publication Number: 621057419SER - 20 - © 2006-2014, Cornelius Inc.
Page 25
IDC 255 Progate Drive Thru Service Manual
!
WAR NING:
Sanitize syrup lines, B-I-B Systems
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.
-
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.
2 cylinder is almost empty and should be changed.
2 cylinder
2 cylinder.
.
2 regulator can cause serious per-
© 2006-2014, Cornelius Inc. - 21 - Publication Number: 621057419SER
Page 26
IDC 255 Progate Drive Thru Service Manual
MERCHANDISER REMOVAL
1. Remove all lid holders and straw dispenser.
SERVICE
Figure 14.
2. Remove screws holding merchandiser to con­trol box.
3. Grab panel by sides, lift up to disengage locking tabs and rotate forward past.
Figure 15.
Figure 16.
Figure 17.
Figure 18.
Publication Number: 621057419SER - 22 - © 2006-2014, Cornelius Inc.
Page 27
CONTROL BOX REMOVAL
1. With cover removed locate and remove 4 screws from Control box flange.
2. Pull box forward exposing control board, wiring and switches.
IDC 255 Progate Drive Thru Service Manual
Figure 19.
MAIN ELECTRICAL BOX ACCESS
1. Remove screw-locking cover to electrical box.
2. Lift cover up and then rotate forward.
Figure 20.
Figure 21.
Figure 22.
© 2006-2014, Cornelius Inc. - 23 - Publication Number: 621057419SER
Page 28
IDC 255 Progate Drive Thru Service Manual
ICE CHUTE REMOVAL
1. Remove 4 nuts attaching ice chute to hopper.
2. Disconnect ice chute switch harness located behind the control box.
Figure 23.
Figure 24.
3. Pull assembly away form hopper. Do not loose or damage gasket. If damaged or missing replace.
4. Pull ice chute assembly out of splash panel and disconnect the CO2 lines.
NOTE: Mark the CO2 lines to avoid improper
assembly.
5. View of underside of ice chute assembly show­ing gate and pneumatic cylinder.
Figure 25.
Figure 26.
Figure 27.
Publication Number: 621057419SER - 24 - © 2006-2014, Cornelius Inc.
Page 29
IDC 255 Progate Drive Thru Service Manual
MOTOR REMOVAL
NOTE: Apply anti-seizing lubricant to the
threads of mounting bolts when service is required.
DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD
NOTE: Refer to Figure 23.
Figure 28.
State
Observed State
of Red LED
0 Flash rate 3
seconds
1 Flash rate
1/2 second
2 Flash rate
1/2 second
3 Flash rate
1/2 second
4 Flash rate 1
second
5ON
continuously, but “flickers” every 3 seconds
6 ON continuously Entered when pump has run
Both probes read “wet” Standby mode. Pump =
Pump is OFF and HIGH probe reads “dry” and LOW probe reads “wet”
Both HIGH and LOW probes read “dry”
Entered when HIGH probe does not detect liquid, and LOW probe does detect liquid, and pump is ON
Entered when HIGH probe reads “wet” and LOW probe reads “dry”
Poor signal connection to the carbonator tank. May result in short cycling of the carbonator pump.
continuously for 5 minutes
Sensor Input Control Response Service Remedy
OFF Waiting for level to drop
below LOW probe. Pump = OFF
Normal mode. Pump = ON
Normal mode. Pump = ON
This is an error condition.
Able to continue to function but carbonator pump short-cycles. Pump will come on each time a drink is drawn. THIS
SITUATION SHOULD BE CORRECTED.
THIS IS AN ERROR CONDITION.
No service required
No service required
No service required
No service required
- Check electrical connections at the carbonator tank, and at connector J4 on the main control board
- Black wire should be connected to the LOW probe and also to Pin 4 of Connector J4
- Reverse the connections if incorrect
- Replace harness if necessary
Check the harness connections of the red signal wire at both ends:
1) at the carbonator ring terminal and
2) at Pin 5 of the J4 connector at the main control board
Unplug the unit and plug it back in. This will reset the unit's main control board and restart the carbonator pump.
© 2006-2014, Cornelius Inc. - 25 - Publication Number: 621057419SER
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IDC 255 Progate Drive Thru Service Manual
Figure 29.
Publication Number: 621057419SER - 26 - © 2006-2014, Cornelius Inc.
Page 31
POWER LIGHT OFF
POWER LIGHT OFF
Is the unit plugged
into a socket
No
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.
IDC 255 Progate Drive Thru Service Manual
TROUBLESHOOTING
© 2006-2014, Cornelius Inc. - 27 - Publication Number: 621057419SER
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IDC 255 Progate Drive Thru Service Manual
NO ICE DISPENSE IN MANUAL
MODE
Is manual/
automatic rocker switch
in the manual position
Set the machine to manual mode by pressing the manual/automatic rocker switch
No
Is lighted green push
button on
Do drink valves
operate
No
1. Check key lock out switch
2. Check transformer for power
3. Check all connections from the terminal board to the push button
Is ice
present in the
ice chute
Check the connector between the control box and the E - Box
Is ice being
dispensed in
auto mode
No
Is Ice chute
switch enabled or
disabled
Disabled
No
Yes
Enabled
1. Check magnetic switch in switch 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. Check the connector between the control box and the E-Box.
2. Check relay 3 in the E-Box for power (terminal 3&4).
3. Check pneumatic solenoid.
Does the agitator run
when push button is
pressed
1. Check the red LED on the E - Box board
2. Ensure that relay two in the E-Box is activating
1. Check the electrical connection from the portion control board to the solenoid valve
2. Check pneumatic solenoid
3. Check relief valve
No
Yes
No
No
Yes
Check relay 1 in the E-Box. The small post on the right hand side should be retracted
Yes
NO ICE DISPENSE IN MANUAL MODE
Publication Number: 621057419SER - 28 - © 2006-2014, Cornelius Inc.
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NO ICE DISPENSE IN AUTOMATIC MODE
NO ICE DISPENSE IN AUTOMATIC MODE
1. Check all connens to poron control pc board
Can you
dispense ice from all the ice
sizes
Some sizes
Is the green
power light on the
keypad on
Do the
drink valves
operate
1. Check key lock out switch.
2. Check transformer for power.
3. Check all electrical connecons.
1. Check the connector between the control box and the E-Box.
Yes
Does manual mode
work
Is there ice
present in the ice
chute
Yes
Yes
Does the agitator
work when the green push
buon is pressed
No
1. Check the red LED on the E-Box pc board.
2. Ensure that relay 2 in the E-box is acted
No
1. Ensure that the ice maker is funconing properly.
2. Check ice in hopper ensuring that it is loose
Yes
No
Check for proper air pressure going to the ter regulator in the E- Box (35PSI or greater)
Is the air
pressure to the lter
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 pneumasolenoid
1. Check air supply shut ooutside the E-
2. Check air supply to the unit.
3. Check gate cylinder for free movement.
Yes
None of the Sizes
No
Is ice
chute switch
disabled
1. Check mode selector switch.
2. Ensure relay 2 is aated.
1. Check magn switch in chute housing.
2. Check for magnet in chute cover.
3. Validate magnet distance from ice chute disable switch.
4. Check ice chute disable switch.
5. Ensure that relay 1 is acvated.
6. Check transformer power output to control circuit
1. Relay 1 in the E-Box should be aated by small post on the side of the relay being retracted
Yes
No
Yes
No
Box.
IDC 255 Progate Drive Thru Service Manual
© 2006-2014, Cornelius Inc. - 29 - Publication Number: 621057419SER
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IDC 255 Progate Drive Thru Service Manual
BEVERAGE NOT DISPENSING
Is the key switch
on/off
1. Check the key switch
Off
Is
there power on
the line side of the
transformer
On
1. Check the transformer 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 beverage valve.
4. Check the water line to the valve and the syrup
line to the valve.
Yes
BEVERAGE NOT DISPENSING
Publication Number: 621057419SER - 30 - © 2006-2014, Cornelius Inc.
Page 35
FLAT DRINKS
FLAT DRI NK(S)
Is the
drink temperature
above 40 degrees
Fahrenheit
No
Is there
ice on the cold
plate
Yes
Is CO
2
being supplied to
the carbonator tank
1. Check CO2 supply tank.
2. Check CO2 supply lines.
3. Change CO2 tank
No
1. Fill the hopper wit h i ce.
2. Dispense some ice to ensure t hat the agitator
spreads i ce on the col d plate.
No
1. Check ice coverage on the cold plat e
Yes
Is the
CO
2
pressure in
the system
correct
Yes
1. Adjust CO2 pressure accordi ngly
No
Does
the carbonator
cycle when a 20oz
drink is dispensed
Yes
Refer to
carbonator ow
chart.
Replace carbonator pump
Yes
No
IDC 255 Progate Drive Thru Service Manual
© 2006-2014, Cornelius Inc. - 31 - Publication Number: 621057419SER
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IDC 255 Progate Drive Thru Service Manual
NO CARBONATED WATER
Does the
carbonator pump start
when the unit is
turned on
Check the carbonator pump connection to the E-Board in the E­Box.
No
Is the
incoming water
restricted
Yes
Restore the recommended water ow
Yes
Is there
power connection to
the carbonator
pump
No
1. Check whether or not there is power across the carbonator power cord on the E-Board in the E-Box.
2. Change carbonator power cord on the E-Board in the E-Box
No
Is the
pump motor
running
Replace carbonator pump
Yes
No
1. Replace Carbonator
pump.
2. Check Y tting on the total ex manifold
Yes
NO CARBONATED WATER
Publication Number: 621057419SER - 32 - © 2006-2014, Cornelius Inc.
Page 37
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Cornelius Inc.
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