Cornelius IDC255 Service Manual

Download

Page 1

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.

Page 2

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

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.

Page 3

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

Page 4

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

Page 5

IDC 255 Progate Drive Thru Service Manual

DANGER:

WAR NING:

CAUTION:

WAR NING:

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.

Page 6

IDC 255 Progate Drive Thru Service Manual

WAR NING:

CAUTION:

DANGER:

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.

Page 7

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.

Page 8

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.

Page 9

Small Lid Template

3.750

IDC 255 Progate Drive Thru Service Manual

Figure 2.

Page 10

IDC 255 Progate Drive Thru Service Manual

4.350

Medium Lid Template

Figure 3.

Page 11

Large Lid Template

4.700

IDC 255 Progate Drive Thru Service Manual

Figure 4.

Page 12

IDC 255 Progate Drive Thru Service Manual

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.

Page 13

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)

Page 14

IDC 255 Progate Drive Thru Service Manual

10 14 16 1812

20 22 26 28

Dispense Time (mS) Agitation Ratio Agitation Time (mS)

170 16 2720

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)

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.

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.

Page 16

IDC 255 Progate Drive Thru Service Manual

INCLUDED WITH UNIT

COLDPLATE

TO BE POST-CHILLED

PRE-CHILLED WATER

PW = PLAIN WATER

CW = CARBONATED WATER

SYRUP 1 OUT

(SINGLE TOWER)

SYRUP 2

OUT

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

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.

Page 17

8 Intelli Valves or 8 UFB-1 Valves

INCLUDED WITH UNIT

COLDPLATE

TO BE POST-CHILLED

PRE-CHILLED WATER

PW = PLAIN WATER

CW = CARBONATED WATER

REG A&W OUT

(SINGLE TOWER)

SYRUP 2

OUT

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

FILTER REGULATOR

TO PROGATE

SYSTEM

ELECTRICAL-BOX

SHUT-OFF

VALVE

REG A&W OUT

DUAL TOWER

DIET A&W OUT

DUAL TOWER

IDC 255 Progate Drive Thru Service Manual

Figure 8.

Page 18

IDC 255 Progate Drive Thru Service Manual

E-BOARD AGITATION TIMER

HRS

1.5

HRS

MIN

HRS

MOTOR ON TIME

OFF TIME

4.5

3.5

2.5

1.5

2.5

HRS

FULL CCW - 0.5 SECONDS

FULL CW - 5 SECONDS

FULL CCW - 10 MINUTES

FULL CW - 3 HOURS

TIME

OFF

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,

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*

Page 19

LINE VOLTAGE

BLK

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

HEATER L2

ICE AGITATION

HEATER

BALLAST L2

BALLAST L1

BLK

WHT

FLOURENSCENT

XFORMER L2

XFORMER L1

BLK

WHT

KEY SWITCH

BLUE

BLK

LEFT

TOTAL FLEX

SOLENOID BLOCK

TOTAL FLEX

SOLENOID BLOCK

RIGHT

WHT

RED

BLK

CARBONATOR

WHT

BLK

RED

CARBONATOR PROBES

BALLAST

STARTER

WHT

BLK

WHT

BLK

SW2

LIGHTS

SOL1

VALVE TIMED SOLENOID

PNEUMATIC

KEYPAD

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

LEFT RIGHT PROGRAM

"AGITATOR GND"

315

MTR

PB1

COVER SWITCH

ENABLE/DISABLE

ICE CHUTE

CR1

AUTO/MANUAL

MODE SWITCH

SW1

CR1

ON/OFF

YLW

OFF CYCLE AGITION MOTOR

CR2

BY PASS

CR2

YLW

BLK

YLW

BLK

YLW

WHT

YLW

BLK

YLW

18AWG

WHT

11 12

GRN/YEL

6203141825

86 68

COMPONENTS LOCATED IN CONTROL BOX

CR3

P1-2

P1-3

4-1P3-1P

P1-1

ORG

GRN

ORG

YLW

BLK

PURP

GRN

PURP

P1-4

P1-5

P1-6

P1-7

PURP

LIGHT

(50 VA)

RED

LIGHT

ELECTRICAL SCHEMATIC

IDC 255 Progate Drive Thru Service Manual

Figure 10.

Page 20

IDC 255 Progate Drive Thru Service Manual

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

J2 J1

CR2

CR1

CR3

PUR

WHT

BLK

YLW

PUR

BLK MODE SW

BLK

YLW

BLK

YLW

BLK

YLW

AIR INPUT

PUSH

TO PNUEMATIC CYLINDER

RETRACT

KEY SWITCH

RED

BLK

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.

Page 21

INTERCONNECT SCHEMATIC

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

J2 J1

CR2

CR1

CR3

PUR

WHT

BLK

YLW

PUR

BLK MODE SW

BLK

YLW

BLK

YLW

BLK

YLW

AIR INPUT

PUSH

TO PNUEMATIC CYLINDER

RETRACT

KEY SWITCH

RED

BLK

BLU

YEL

TRANSFORMER

CAPACITOR

PNEUMATIC SOLENOID

TERMINAL

BOARD

NO/NC RELAY

POWER

CORD

AGITATOR CONTROL

GND

ICE GATE

24 VAC1

24 VAC2

SW1

SW3

PB1

INTERFACE BOARD

31 2

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.

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).

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.

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

(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.

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-

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.

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.

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.

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

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

- 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.

Page 30

IDC 255 Progate Drive Thru Service Manual

Figure 29.

Page 31

POWER LIGHT OFF

Is the unit plugged

into a socket

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

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

Page 32

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

Is lighted green push

button on

Do drink valves

operate

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

Is Ice chute

switch enabled or

disabled

Disabled

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

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

Page 33

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

Does the agitator

work when the green push

buon is pressed

1. Check the red LED on the E-Box pc board.

2. Ensure that relay 2 in the E-box is acted

1. Ensure that the ice maker is funconing properly.

2. Check ice in hopper ensuring that it is loose

Yes

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

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

Box.

IDC 255 Progate Drive Thru Service Manual

Page 34

IDC 255 Progate Drive Thru Service Manual

BEVERAGE NOT DISPENSING

Is the key switch

on/off

1. Check the key switch

Off

there power on

the line side of the

transformer

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.

there power on the

load side of the

transformer

Yes

1. Check the transformer.

2. Change the transformer.

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

Page 35

FLAT DRINKS

FLAT DRI NK(S)

Is the

drink temperature

above 40 degrees

Fahrenheit

Is there

ice on the cold

plate

Yes

Is CO

being supplied to

the carbonator tank

1. Check CO2 supply tank.

2. Check CO2 supply lines.

3. Change CO2 tank

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.

1. Check ice coverage on the cold plat e

Yes

Is the

pressure in

the system

correct

Yes

1. Adjust CO2 pressure accordi ngly

Does

the carbonator

cycle when a 20oz

drink is dispensed

Yes

Refer to

carbonator ow

chart.

Replace carbonator pump

Yes

IDC 255 Progate Drive Thru Service Manual

Page 36

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.

Is the

incoming water

restricted

Yes

Restore the recommended water ow

Yes

Is there

power connection to

the carbonator

pump

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

Is the

pump motor

running

Replace carbonator pump

Yes

1. Replace Carbonator

pump.

2. Check Y tting on the total ex manifold

Yes

NO CARBONATED WATER

Page 37

Page 38

Cornelius Inc.

www.cornelius.com