Cornelius IDC PRO 255 Installation Manual

IDC PRO 255
Installation Manual
Release Date: August 05, 2016
Publication Number: 621058578INS
Revision Date: June 20, 2018
Revision: B
Visit the Cornelius web site at
www.cornelius-usa.com for all your Literature needs.
The products, technical information, and instructions contained in this manual are subject to change without notice.
RECYCLE
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible 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 con struction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warranty 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 persons 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.
Correct Disposal of this Product
This marking indicates that this product should not be disposed with other household wastes throughout the EU. To prevent possible harm to the environment or human health from uncontrolled waste disposal, recycle it responsibly to promote the sustainable reuse of material resources. To return your used device, please use the return and collection systems or contact the retailer where the product was purchased. They can take this product for environmental safe recycling.
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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
System Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Features. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Direct Counter Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Adjusting the Carbonator CO2 Regulator and Turning on the Water Inlet Supply Line . . . . . . . . . . . 8
Gate Restrictor Plate Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Connecting Product to the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water & Syrup Line Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Product Line Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Preparing for Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Service Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Adding Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Mapping Brands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Purging The Syrup Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Syrup Line Cleaning & Sanitizing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Adjusting the Water to Syrup Ratio (BRIX) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Cleaning Interior Surfaces . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Unit Shutdown/Restart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Editing the Media Playlist. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Updating Software Revisions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Plumbing Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Unit Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Carbonator Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
SAFETY INSTRUCTIONS
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DANGER:
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WARNING:
CAUTION:
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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 and/or national and local codes 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
IDC Pro 255 Installation Manual
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.
NOTE: The dispenser is not designed for a wash-down environment and MUST NOT be placed in an area
where a water jet could be used.
© 2016-2018, Cornelius Inc. - 1 - Publication Number: 621058578INS
IDC Pro 255 Installation Manual
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WARNING:
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WARNING:
CAUTION:
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CAUTION:
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DANGER:
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WARNING:
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.
IF THE SUPPLY CORD IS DAMAGED, IT MUST BE REPLACED BY THE MANUFACTURER, ITS SERVICE AGENT OR SIMILARLY QUALIFIED PERSONS IN ORDER TO AVOID A HAZARD.
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 1,000 lbs. (454 kg.) to insure adequate support for the unit. Failure to comply could result in serious injury, death or damage to the equipment.
NOTE: Many units incorporate the use of additional equipment such as ice makers. 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 Pro 255 Installation Manual
NOISE LEVEL
This unit emits acoustical noise with an A-weighted sound pressure level no greater than 75dB, as measured in accordance with ED 60335-2-75.
© 2016-2018, Cornelius Inc. - 3 - Publication Number: 621058578INS
IDC Pro 255 Installation Manual
CAUTION:
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SYSTEM OVERVIEW
The IDC PRO 255 unit solves your ice and beverage service needs in a sanitary, space saving, economical way. It is designed to be manually filled with ice from any remote ice making source. The unit distributes cubes (up to 1-1/4 inch in size), Cubelet and compressed (not flaked) ice. Also, the unit includes beverage valves, a cold plate, an internal carbonator tank and an external pump for the carbonator.
The unit cannot be used with crushed or flaked ice. Use of bagged ice which has frozen into large chunks can void warranty. The unit agitator is not designed to be an ice crusher. Use of large chunks of ice which “jam up” inside the hopper will cause failure of the agitator motor and damage to the hopper. If bagged ice is used, it must be carefully and completely broken into small, cube-sized pieces and left to “temper” or warm up for a minimum of 20 minutes in room temperature before loading into the unit hopper.
FEATURES
• Brand density - 10 brands on each side, 7 chilled, 3 ambient and up to 8 flavor shots (4 per side) for over 320 drink combinations.
• Large HD promotional display
• 255 lb. capacity ice cube hopper
• Internal cold carbonation with remote pump
• Total carb/mid-carb flexibility on each brand
• Dispenses cubed or chewable soft ice
• UI Touch screen.
SPECIFICATIONS
Model IDC Pro 255
Maximum Number of Valves available 36 Total; 20 brands, 8 flavors, 4 Pain & 4 Carb
Built-in Cold Plate Yes
Voltage
Height 39-3/16 in. (.955 m) to top of Adapter lid
Depth 32-3/8 in. (0.823 m)
Width 30 in. (0.762 m)
Screen Dimensions 32 in. Diagonally
2 Operating Pressure
CO
Water Pressure 50-60 psi (345-414 Kpa) at pump
Water Volume Minimum flow rate, 125 gal/hr. (0.473 cubic meters/hr.)
Shipping Weight 545 lb. (247.2 kg)
Counter Weight 440 lb. (199.6 kg)
Ice Storage Weight 255 lbs. (115.7 kg)
Cup Clearance 9-3/4 in. (24.77 cm)
Ambient Operating Temperature 65 to 95° F (18.3 to 35° C)
Table 1.
120 V 60 Hz, single phase; 8.5A. of total unit draw
220 -240V 50 - 60Hz, single phase; 5.5A of total unit draw
More than 80 psig (5.52 bar) feeding carbonator pump (75 psig (5.17 bar) fixed regulator on pump deck)
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IDC Pro 255 Installation Manual
Figure 1.
© 2016-2018, Cornelius Inc. - 5 - Publication Number: 621058578INS
IDC Pro 255 Installation Manual
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WARNING:
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WARNING:
INSTALLATION
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit.
ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
This equipment must be installed to comply with the International Plumbing Code of the International Code Council and the Food Code Manual 01 the Food and Drug Administration (FDA). For models installed outside the U.S.A., you must comply with the applicable Plumbing/Sanitation Code for your area.
Failure to comply could result in serious injury, death or damage to the equipment.
UNIT LOCATION
The unit must be sealed to the counter or placed on the included 4” legs (drip tray style unit only). The template drawing indicates where openings can be cut in the counter. Locate the desired position for the unit, then mark the outline dimensions on the counter using the template drawing, shown in Figure 2.. Cut the necessary openings in the counter.
DIRECT COUNTER INSTALLATION
To install the unit on a counter, perform the procedure in Table 2.
Table 2.
Step Action
1 Locate the unit indoors on a level counter top.
When the unit is mounted directly on the counter top, the b cord are routed through the large opening in the bottom of the unit. See the mounting template shown in Figure 2. for locating the required clearance openings in the counter.
2
NOTE: Recommended counter opening size 9X12 for utilities and beverage tub-
ing. Opening can be located anywhere within the shaded area.
Apply a continuous bead of NSF International (NSF) silastic sealant (Dow 732 or equal) approxi­mately 1/4-inch inside of the unit outline dimensions and around all openings. Then, position the
3
unit on the counter within the outline dimensions. All excess sealant must be wiped away
immediately.
4 Install the drain tube on to the drip tray, as shown in Figure 3..
Route the drain tube to an open drain with the end of the tube above the “flood” level of the drain.
se the tubing, fittings, clamps, and insulation provided with the unit to assemble the drain. The
U
5
completed drain line must pitch continuously downward and contain no “traps” or improper drain­age results.
Locate the carbonator pump assembly and connect the po The cord is connected to the unit’s electrical box and has an electrical connector on the end that plugs into a receptacle in the junction box at the carbonator pump assembly. Connect inlet water to the
6
pump and the pump outlet to the unit using 3/8-inch food-grade tubing. Disable the pump from oper­ating by switching the switch in the carbonator pump assembly junction box to the OFF position.
Connect the beverage system product
7
NOTE: See the Plumbing Diagram (Figure 9.) or the decal on the lower front of
the unit for the location of syrup and water connections.
8 Clean the hopper interior (see “Cleaning Interior Surfaces” section on page 24).
Connect the unit power cord to a 120 volt, 60 cycl Volt units, a 3-wire power cord is provided. An appropriate power cord for the particular country
9
may need to be provided by the installer.
tubes as indicated in the Plumbing Diagram, Figure 9..
everage tubes, drain tube and power
wer cord from the dispenser to the pump.
e, 3-wire grounded receptacle. For 220-240
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IDC Pro 255 Installation Manual
CAUTION:
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CAUTION:
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NOTE: Cornelius Inc. recommends that a water shutoff valve and water filter be installed in the plain water
inlet supply line. A Cornelius Water Filter (P/N 313860000) and Quick Disconnect Set (P/N
313867000) are recommended.
Check the minimum flow rate and the maximum pressure of the plain water inlet supply line. MINIMUM FLOW RATE MUST BE AT LEAST 125-GALLONS PER HOUR. If flow rate is less than 125-gallons per hour, starving of the car
bonator water pump can occur. Starving causes the carbonator stat on the pump outlet to stop the water pump motor.
INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE MUST REMAIN A MINIMUM OF 10 psi BELOW THE CARBONATED CO2 OPERATING PRESSURE. (Example: Carbonator CO sure is 75 psi and the maximum water pressure can be no more t
2 operating pressure) can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve.
CO If water is exceeding maximum pressure specifications, a Water Pressure Regulator Kit must be installed in the plain water inlet supply line. If a fitting connector is not available, tap into the plain water supply line with a 3/8 flare saddle valve.
water pump to overheat, causing the safety thermo-
2 operating pres-
han 65 psi, etc.). Water over pressure (higher than
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© 2016-2018, Cornelius Inc. - 7 - Publication Number: 621058578INS
Figure 2.
IDC Pro 255 Installation Manual
CAUTION:
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CAUTION:
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Figure 3.
ADJUSTING THE CARBONATOR CO2 REGULATOR AND TURNING ON THE WATER
NLET SUPPLY LINE
I
Before connecting the CO2 regulator assembly to a CO2 cylinder, turn the regulator adjusting screw to the left (coun­terclockwise) until all tension is relieved
1. Open (counterclockwise) the CO the valve fully to back-seat it. (Back-seating the valve on the CO shaft).
2. The source CO
Never operate the carbonator pump with the water inlet supply line shutoff valve closed. “Dry running” the water pump will burn out the pump. A pump damaged in this manner is not covered by the warranty.
3. Open the water inlet supply line shutoff valve.
4. Exercise one of the dispensing valves to exhaust trapped air inside the carbonator tank.
2 regulator must be adjusted to a minimum setting of 80 psi.
from the adjusting screw spring.
2 bulk cylinder valve slightly to allow the lines to slowly fill with gas, then open
2 bulk tank prevents leakage around the valve
GATE RESTRICTOR PLATE ADJUSTMENT
The rate at which ice is dispensed is adjusted by adjusting the opening of the gate Restrictor plate as illustrated in Fig­ure 4.
To adjust the gate Restrictor plate, loosen the four (4) nuts that hold the ice chute assembly to the hopper. The Restrictor plate can the maximum rate of ice dispense is available (approximately 3 oz/sec). Re-tighten the four (4) nuts to set the desired Restrictor plate opening. DO NOT EXCEED 35 IN-LB of torque.
now be moved up or down. When the Restrictor plate is fully up, the ice gate opening is 2-1/2” in height, and
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IDC Pro 255 Installation Manual
Figure 4.
CONNECTING PRODUCT TO THE UNIT
Refer to the “Plumbing Diagram” section on page 33 for details of the hook-up.
Any unused lines must remain capped.
NOTE: All inlet connections are clearly marked with a label adjacent to the inlet connections.
Always check for leaks on all connections.
WATER & SYRUP LINE CONNECTIONS
The standard unit supports the following:
• 1-water line from carbonator pump
• 1-water line for non-carbonated drinks
• 20-Syrup lines
• 8-Flavor Shots
Product Line Connections
To connect the syrup, water and flavor shot lines from the backroom package to the unit, perform the procedure in Table 3.
NOTE: If lines are to be cut, mark the line numbers above the cut with a marker. If syrup lines are mixed up
hey can be mapped later in the control. Make sure that syrup lines and flavor lines are NOT mixed.
t
© 2016-2018, Cornelius Inc. - 9 - Publication Number: 621058578INS
IDC Pro 255 Installation Manual
!
WARNING:
Step Action
1
2
3
4
5 Adjust the CO
Basic Pressure Syrup Valves 75 PSI (5.17 bar)
Basic Pressure Flavor Shot Valves 45 PSI (3.1 bar)
Table 3.
Locate the water, syrup and flavor inlets are marked S1- S14 included lines labeled, A1-A6 for ambient (non chilled) syrup and F1 - F8 for flavor lines, CW for Carbonated Water, PW for plain water
Connect syrup lines 1-14 from the unit to th backroom package.
Connect the carbonated lines CW from the Connect carbonator pump to backroom water supply.
Connect the plain water lines PW from the from the backroom package.
2 regulator for syrup BIB pumps as indicated in Table 4.
Table 4.
Regulator Pressure Settings
lines under the counter. The cold plate
e appropriate lines from the
unit to the carbonator pump.
unit to the appropriate lines
UNIT OPERATION
This unit must be grounded to avoid possible electrical shock to the operator. The unit power cord is equipped with a three pronged plug. If a three pronged (grounded) outlet is not available use an appropriate method to ground the unit.
Failure to comply could result in serious injury, death or damage to the equipment.
To initially start up the unit for operation, perform the procedure in Table 5.
Table 5.
Step Action
1 Connect electrical power to the unit.
Locate the switch on the juncti
2
3 Check for water and CO
4
5
water pump will start and fill the carbonator tank with carbonated water. The water pump stops when the carbonator tank is full.
Dispense Carbonated water drinks until the carbonator pu time for the carbonator should be about 5-7 seconds.
If the carbonator pump appears to be short-cycling seconds) refer to the “Troubleshooting” section on page 36.
on box of the carbonator pump and turn it ON. The
2 leaks, and tighten any loose connections.
mp cycles on. The refill
(meaning a refill time of 1-2
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