Cornelius IDC 255 Progate Drive Thru Unit Installation Manual

IDC 255 PROGATE DRIVE THRU UNIT

Installation Manual

Release Date: June 27, 2006

Publication Number: 621057419INS

Revision Date: February 19, 2014

Revision: F

Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

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 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 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 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-usa.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.

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Small Lid Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Medium Lid Template. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Large Lid Template . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Mounting and Placement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Adjust Carbonator CO2 Regulator and Turn Water Inlet Supply Line ON . . . . . . . . . . . . . . . . . . . . 10

CO2 Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Power Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Water Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

To access cold plate water inlets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Lid Dispenser Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Unit Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Loading of Lid Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Plastic Wrapped lids. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Individual lids . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Lid Dispenser Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Progate 2 Control Box Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Portion Control Box Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Programming (Changing) the Ice Portion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Agitation Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Programming (Changing) the Agitation Time. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Ice Portion Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Cold Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

7 Intelli Valves and 1 variety Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

5 Intelli Valves and 3 Variety Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

8 Intelli Valves or 8 UFB-1 Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

E-Board off Cycle Agitation Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Electrical Schematic. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Main Electrical Box Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

Interconnect Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Power Light Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

No Ice Dispense in Manual Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

No Ice Dispense in Automatic Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Beverage Not Dispensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Flat Drinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

No Carbonated Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

IDC 255 Progate Drive Thru Installation Manual

SAFETY INSTRUCTIONS

R

EAD AND

F

OLLOW

ALL S

AFETY

I

NSTRUCTIONS

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.

D

IFFERENT

T

YPES OF

A

LERTS

!

DANGER:

Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment damage.

!

WARNING:

Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment damage.

!

CAUTION:

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment damage.

S

AFETY

T

IPS

• 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.

Q

UALIFIED

S

ERVICE

P

ERSONNEL

!

WARNING:

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: 621057419INS


S

AFETY

P

RECAUTIONS

This unit has been specifically designed to provide protection against personal injury. To ensure continued protection observe the following:

!

WARNING:

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.

!

CAUTION:

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.

S

HIPPING

A

ND

S

TORAGE

!

CAUTION:

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.

CO

2

(C

ARBON

D

IOXIDE

) W

ARNING

!

DANGER:

CO 2 displaces oxygen. Strict attention MUST be observed in the prevention of CO 2 gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO 2 gas experience tremors which are followed rapidly by loss of consciousness and DEATH.

M

OUNTING IN OR ON A

C

OUNTER

!

WARNING:

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 insure 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.

Publication Number: 621057419INS - 2 © 2006-2014, Cornelius Inc.


UNIT SPECIFICATION

D

ESCRIPTION

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 dispensers 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.

V

ALVE

C

ONFIGURATIONS

• IDC 255 Progate Drive Thru Unit with 7 Intelli Valves and 1 Variety Valve

• IDC 255 Progate Drive Thru Unit with 5 Intelli Valves and 3 Variety Valves

• IDC 255 Progate Drive Thru Unit with 8 Intelli Valves

• IDC 255 Progate Drive Thru Unit with 8 UFB-1 Valves

S

PECIFICATION

Model Descriptions

Unit Weight

Ice Storage

Maximum Number of Faucets

Built in Cold Plate

Electrical

Dimensions

CO

2

Operating Pressure

Water

IDC 255

B=Beverage



C=Coldplate



H=Internal Carb



P=Progate



Z=No Drip Tray

368 Pounds

255 Pounds

10

Yes

120/1/60



9.3 Amps of Total Unit Draw



OR



220/1/50



4.7 Amps of Total Unit Draw

Width 29.90 inch (.76 m)



Height 39.75 inch (1.0 m)



Depth 36.90 inch (.94 m)

75-psig (max)

100 psi (7 bar) maximum static pressure.



40 psi (2.8 bar) minimum dynamic pressure.



3/8” minimum water line recommended.




36.901

39.750

20.756

PCX OUT OF RATIO LABEL

30.000

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 pressure.

3/8” minimum water line recommended.

CO 2 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



L

ID

H

OLDER

C

OMPATIBILITY

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.

Small Lid Template

3.750

Figure 2.




Medium Lid Template

4.350

Figure 3.


Large Lid Template


4.700

Figure 4.




INSTALLATION

M

OUNTING AND

P

LACEMENT

!

WARNING :

It is the responsibility of the installer to ensure that the water supply to the dispensing equipment is provided with protection back flow by an air gap as defined in ANSI A 112.1.2-1979; or an approved vacuum breaker or other such method as proved effective by test and must comply with all federal, state and local codes.

Failure to comply could result in serious injury, death or damage to the equipment.

Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed and maintained according to Federal, State and Local laws.

1.

Locate the dispenser indoors on a level counter top.

A.

LEG OPTION



Unpack the four (4) legs and install them into the threaded holes provided at the bottom of the unit. The installer must provide flexibility in the product and utility supply to permit shifting the position of the dispenser sufficiently to clean the area beneath it.

COUNTER MOUNTING



The ice drink dispenser must be sealed to the counter. The template drawing indicates where openings can be cut in the counter. Locate the desired position for the dispenser, then mark the outline dimensions on the counter using the template drawings. Cut openings in counter.

7/16 DIA.

30

26 3/8 1 13/16

1 5/16

12

9

18 5/8

21 1/4

30

31 1/2

23 1/16

Z Style

3 1/2

9 1/2 11

23

REMOVABLE SINK

RECOMMENDED COUNTER OPENING SIZE

9 X 12 FOR UTILITIES AND BEVERAGE

TUBING. OPENING CAN BE LOCATED

ANYWHERE WITHIN SHADED AREA.

Figure 5.

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 unit on the counter within the outline dimensions. All excess sealant must be wiped away immediately.



2.

The beverage tubes, drain tube and power cord are routed through the large opening in the bottom of the unit.

See the MOUNTING TEMPLATE for locating the required clearance opening in the counter for these utility lines.

DRIP TRAY DRAIN ASSEMBLY: Route the drain tube to an open drain with the end of the tube above the “flood” level of the drain. Use the tubing, fittings, clamps, and insulation provided with the Dispenser to assemble the drain.

The completed drain line

must

pitch continuously downward and contain no “traps” or improper drainage will result.

HOSE CLAMP

DRAIN LINE

1" I.D. PLASTIC TUBING

(6') WITH INSULATION

Figure 6.

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.

!

CAUTION :

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 carbonator water pump will occur. Starving will overheat the carbonator’s water pump, causing the safety thermostat on the pump outlet to stop the water pump motor. Overheating could occur if the plain water supply line flow rate drops below 125 gallons per hour. INCOMING PLAIN WATER INLET SUPPLY LINE WATER TO PUMP PRESSURE

MUST REMAIN A MINIMUM OF 10 psi BELOW THE CARBONATED CO

2

OPERATING PRESSURE. (Example: The

Carbonator CO

2

operating pressure is 75 psi and the maximum water pressure can be no more than 65 psi, etc.).

Static water pressure higher then the static CO

2

pressure can cause carbonator flooding, malfunction, and leakage through the carbonator relief valve. If water is exceeding maximum pressure specifications, a Water Pressure

Regulator Kit must be installed in the plain water inlet supply line.

3.

Cut power to the carbonator by turning off its power switch, the switch is located on the junction box of the pump and motor assembly. Locate the carbonator pump assembly and connect to power cord from the Ice/

Drink Unit to the pump. 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 pump and pump outlet to Ice/Drink Unit using 3/8-inch food-grade tubing.




4.

Connect the beverage system product tubes as indicated in applicable Flow Diagram in this manual or on the back of the splash panel. This work should be done by a qualified service person.

NOTE: See applicable Flow Diagram or Decal on the lower front of the unit for the location of syrup and water connections.

5.

Clean the hopper interior.

6.

Connect the unit power cord to a 120 volt, 60 cycle, 3-wire grounded receptacle. For 220-240 Volt International

Units, a 3-wire power cord is provided. An adapter plug for the particular country must be provided by the

Installer.

A

DJUST

C

ARBONATOR

CO

2

R

EGULATOR AND

T

URN

W

ATER

I

NLET

S

UPPLY

L

INE

ON

1.

Open (counterclockwise) CO 2 cylinder valve slightly to allow lines to slowly fill with gas, then open the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve shaft).

2.

The carbonator CO 2 regulator is fixed at a nominal 75 psi.

3.

Open one of the post-mix dispensing valves to exhaust trapped air inside the carbonator tank.

4.

Open the water inlet supply line shutoff valve.

CO

2

I

NSTALLATION

!

WARNING :

The machine is designed to work only with CO 2 . Store air supplied from a compressed air system could contain moisture and oils that could damage and/or cause the Ice Gate to loose performance or malfunction.

1.

Use 1/4” tubing capable of handling a minimum of 120 psi.

2.

Guide CO

2

lines from back of machine to front.

3.

Locate the CO 2 line and connect to the barb fitting.

4.

Use Oetiker clamps to secure all lines to barbed fittings.

5.

Replace lower splash panel to the frame.



CARBONATOR FEED

Figure 7.

P

OWER

I

NSTALLATION

The machine is equipped with a 3 Prong plug (hot, neutral, ground) and is plugged into any standard wall outlet capable of handling 9.3 amps at 120 volts. The Cord may be wrapped and stored under machine for shipment.

W

ATER

I

NSTALLATION

To access cold plate water inlets

1.

Remove screws holding attaching lower splash panel to frame and slide panel away from the machine.

2.

Use Oetker clamps to secure lines to barbed fittings.


Figure 8.

- 11 -

Figure 9.

Publication Number: 621057419INS


3.

Use 3/8” tubing capable of handling a minimum of

120 psi. Approved for food applications.

4.

Guide water lines from back of machine to left front and attach to cold plate lines W1 (carbonator water line) and W2 (plain water or mains water line).

NOTE: W4 is the re-circulation line which is connected to a remote tower (A&W remote tower).

5.

Turn on pressure and check for leaks.

Figure 10.

W1

W2

DETAIL A SCALE 1.500

SEE DETAIL A

W4

Figure 11. [Note: Shown without Total Flex 1 (TF 1)]



OPERATION INSTRUCTIONS

L

ID

D

ISPENSER

O

PERATION

The lid holder assembly is designed to help with lid storage and dispensing in a crew serve environment. The holder comes in several sizes to accommodate different size lids.

• Small/Medium holder accommodates both small and medium size lids.

• Large holder accommodates only large lids.

• Extra large holder accommodates only extra large lids.

The lid dispensers are designed to be removed from the front of the merchandiser to make loading the dispensers simpler and allow for cleaning of the merchandiser and lid dispensers. The dispensers can be arranged in any configuration with room for four on the merchandiser face.

U

NIT

O

PERATION

!

WARNING :

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.

NOTE: 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 warranty.

1.

Connect electrical power to the unit.

2.

Locate the switch on the junction box of the carbonator pump, and turn it ON. The water pump will start and fill the carbonator tank with carbonated water. The water pump will stop when the carbonator tank is full.

3.

Check for water and CO 2 leaks, and tighten any loose connections

4.

Dispense several drinks until the carbonator pump cycles on. The refill time should be about 5-7 seconds.

5.

If the carbonator pump appears to be short-cycling, meaning a refill time of 1-2 seconds, refer to the Troubleshooting section in the back of this manual.




L

OADING OF

L

ID

D

ISPENSER

IMPORTANT: To assure best operation lids should be replaced when the last lid is below the black plastic bottom.

Plastic Wrapped lids

1.

To remove, grab the lid dispenser lifting and pulling away from the merchandiser.

Figure 12.

2.

Get the fresh sleeve of lids and position so that lid bottom is up.

3.

Remove lid dispenser top if present.

4.

Tear open bag.

Figure 13.

Figure 14.

5.

Slide sleeve into tube, Pull the plastic from stack, replace top and place lid dispenser back in position on the merchandiser.

Figure 15.

Publication Number: 621057419INS - 14 -

Figure 16.


Individual lids

1.

Stack lids on clean flat surface with lid top facing down.


2.

Turn dispenser upside down and trap lids in the tube.

Figure 17.

3.

Place your hand over the top to capture lids and turn it right side up.

Figure 18.


- 15 -

Figure 19.



L

ID

D

ISPENSER

O

PERATION

To dispense a lid:

1.

Place hand in finger slot

2.

Grab edge of lid and pull.

BASE

LID

FINGER

GUIDE

LID SUPPORT

LID PIVOT POINT

POSITION 1

POSITION 2

POSITION 3

P

ROGATE

2 C

ONTROL

B

OX

O

PERATION

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.

4

1

2 3

6

7

5

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

8

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 is 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 an 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.

I ce Portion Dispense Buttons : Used to dispense the appropriate ice portion. Can also be used in conjunction 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 dispense 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 dispense program size.

Programming (Changing) the Ice Portion

To change the size of any of the four ice dispense sizes follow the steps below.

1.

Desired Size button and hold for 5 seconds.

at the same time

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 to decrease the amount of dispensed ice. The LED will move towards the left indicating the Ice Portion has been decreased.

5.

To exit the program mode press the Desired Size button the dispense mode.

or wait 10 seconds and the control will return to

6.

Place a cup under the ice chute and press the just programmed dispense size button amount is not the desired amount repeat the process.

7.

To exit, repeat Step 1

If amount dispense




Agitation Time

The software coding for the progate system involves a direct relationship between the dispense time and the agitation time.

Dispense

Rime (mS)

50

70

90

110

130

150

170

190

210

230

Dispense

Rime (mS)

50

70

90

110

130

150

170

190

210

230

The relationship is expressed below.

Dispense

Rime (mS)

50

70

90

110

130

150

170

190

210

230

Agitation

Ratio

28

28

28

28

28

28

28

28

28

28

Agitation Time (A

T

) = Dispense Time (D

T

) x Agitation Ratio

2

(R

A

)

Agitation

Ratio

10

10

10

10

10

10

10

10

10

10

Agitation

Ratio

16

16

16

16

16

16

16

16

16

16

Agitation

Time (mS)

500

700

900

1100

1300

1500

1700

1900

2100

2300

Agitation

Time (mS)

800

1120

1440

1760

2080

2400

2720

3040

3360

3680

Agitation

Time (mS)

1400

1960

2520

3080

3640

4200

4760

5320

5880

6440



The agitation time equals the dispense time multiplied by the agitation ratio. The user is given the flexibility to change the agitation ratio there by altering the agitation time in order to ensure that the ice chute is always filled with ice for all the different ice types.

2

10 12 14 16 18 20 22

Figure 20.

24 26 28

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 entered. Visual feedback of ratio/agitation time is obtained from the visual programming LED. The LED meter shows the existing agitation ratio enabling the user to.

3.

Vary the agitation time using the directional arrow buttons. Left to decrease and right to increase.

4.

To exit, repeat Step 1.




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.

=20mS

“S” Small

“M” Medium

50mS

“L” Large

80mS

“XL” XLarge

150mS

230mS

230mS

260mS

330mS

410mS

Figure 21.



DIAGRAMS

C

OLD

P

LATE

The beverage assembly of the unit can be one of the following configurations: 7 Intelli Valves and 1 Variety valve; 5

Intelli Valves and 3 Variety valves; 8 Intelli Valves; or 8 UFB-1 valves. Following are the cold plate diagrams showing the each of the configurations.

7 Intelli Valves and 1 variety Valve

PRE-CHILLED WATER

TO BE POST-CHILLED

PW

CW

OUT

RECIRC


PW

CW

IN

RECIRC

(SINGLE TOWER)

SYRUP 1 OUT

OUT

SYRUP 2

Figure 22.



5 Intelli Valves and 3 Variety Valves


Figure 23.

- 22 © 2006-2014, Cornelius Inc.

8 Intelli Valves or 8 UFB-1 Valves



PRE-CHILLED WATER

TO BE POST-CHILLED

PW

CW

DUAL TOWER

REG A&W OUT

OUT

RECIRC

DUAL TOWER

DIET A&W OUT

PW

CW

IN

RECIRC

(SINGLE TOWER)

REG A&W OUT

OUT

SYRUP 2

Figure 24.



E-B

OARD OFF

C

YCLE

A

GITATION

A

DJUSTMENTS

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. Using a screwdriver follow the diagram below and set the agitator for the desired settings.

MOTOR ON TIME

FULL CCW - 0.5 SECONDS

FULL CW - 5 SECONDS

OFF TIME

FULL CCW - 10 MINUTES

FULL CW - 3 HOURS

Model

3.5

3

2.5

2

1.5

4 4.5

1 .5

5

E-BOARD AGITATION TIMER

ON

TIME

OFF

TIME

TIME

OFF

TIME

ON

2

HRS

1.5

HRS

2.5

HRS

3

HRS

1

HR

30

MIN

10

MIN

Figure 25.

Manufacturer Recommended Agitation Settings

Ice Fill/Ice Type Motor ON Time Motor OFF time

Manual/Hard Ice (Cube) 4 Seconds 1 Hour

175, 215, & 255,

300, B, BC

Automatic (Top-Mount Ice Maker/Hard Ice

(Cube)

0.5 Seconds

Manual & Automatic/Cornelius Chunklet,

Scotsman & Hoshizaki Compressed Ice

0.5 Seconds

*NO FLAKED ICE*

B - Beverage C-Cold plate

20 Minutes

3 Hours


E

LECTRICAL

S

CHEMATIC



CR3 0

RED

BLUE

RED

BLUE

BLK

LEFT

TOTAL FLEX

SOLENOID BLOCK

RIGHT

TOTAL FLEX

SOLENOID BLOCK

YLW

18AWG

YLW

18AWG

Figure 26.



M

AIN

E

LECTRICAL

B

OX

A

SSEMBLY

L1 BALLEST

L1 XFORMER

L1 HEATER

CARB MOTOR

L2 CARB MOTOR

CARB MOTOR EARTH EARTH IN

AGITATOR EARTH

J5

AGITATOR L2

J2

AGITATOR

J1

BLU

BLU

RED

RED

BLK MODE SW

BLK

YLW

BLK

BLK

YLW

YLW

YLW

YLW

PUR

BLK

WHT

Figure 27.


I

NTERCONNECT

S

CHEMATIC


L1 BALLEST

L1 XFORMER

L1 HEATER

CARB MOTOR

L2 CARB MOTOR

CARB MOTOR EARTH EARTH IN AGITATOR EARTH

J5

AGITATOR L2

J2

AGITATOR

J1

BLU

BLU

RED

RED

BLK MODE SW

YLW

BLK

BLK

BLK

YLW

YLW

YLW

YLW

PUR

BLK

WHT

11 24

12 25

24 VAC2

24 VAC1

ICE GATE

AGITATOR CONTROL

GND


Figure 28.



TROUBLESHOOTING

P

OWER

L

IGHT

O

FF

POWER LIGHT OFF

Is the unit plugged into a socket

Yes

No

1. Plug unit into a socket.

Are there other equipments on the same circuit

No

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.

Yes

1. Remove all other equipment from the machine circuit.

2. Install a new dedicated circuit for the machine.



N

O

I

CE

D

ISPENSE IN

M

ANUAL

M

ODE

NO ICE DISPENSE IN MANUAL

MODE

Is the machine inlet pressure greater than 35 PSI

Yes

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.

No

1. Check air supply shut off outside the E-Box

2. Check air supply line

3. Check pneumatic cylinder for free movement

Yes

Is manual/ automatic rocker switch in the manual position

Yes

Is lighted green push button on

Yes

Is ice present in the ice chute

No

1. Set the machine to manual

mode by pressing the manual

/automatic rocker switch

No

No

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

Yes

1. Check the connector

between the control

box and the E - Box

Does the agitator run when push button is pressed

Is ice being dispensed in auto mode

No

No

1. Check the red LED on the

E - Box board

2. Ensure that relay two in the

E-Box is activating

Is Ice chute switch enabled or disabled

Enabled

1. Check the electrical

connection from the

portion control board to

the solenoid valve

2. Check pneumatic solenoid

3. Check relief valve

1. Check relay 1 in the E-Box.

The small post on the right hand

side should be retracted

Disabled

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




N

O

I

CE

D

ISPENSE IN

A

UTOMATIC

M

ODE

NO ICE DISPENSE IN AUTOMATIC MODE

Can you dispense ice from all the ice sizes

None of the Sizes

Is the green power light on the keypad on

Yes

Is there ice

present in the ice chute

Some sizes

1. Check all connens to

poron control pc board

Yes

Check for proper air pressure going to the ter regulator in the E- Box

(35PSI or greater)

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 pneumasolenoid

Yes

Is the air pressure to the lter regulater above

35PSI

No

Does the agitator

work when the green push buon is pressed

No

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

2. Ensure that relay 2 in the E-box is acted

Yes

1. Ensure that the ice maker

is funconing properly.

2. Check ice in hopper

ensuring that it is loose

No

1. Check air supply shut

ooutside the E-

Box.

2. Check air supply to

the unit.

3. Check gate cylinder

for free movement.

Do the drink valves operate

No

1. Check key lock out switch.

2. Check transformer for power.

3. Check all electrical connecons.

Yes

1. Check the connector

between the control

box and the E-Box.

Does manual mode work

Yes

1. Check mode selector switch.

2. Ensure relay 2 is aated.

No

Is ice

chute switch disabled

No

1. Relay 1 in the E-Box should

be aated by small post on

the side of the relay being

retracted

Yes

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 acvated.

6. Check transformer power output to

control circuit


B

EVERAGE

N

OT

D

ISPENSING

BEVERAGE NOT DISPENSING


Is the key switch on/off

Off

1. Check the key switch

On

Is there power on

the line side of the transformer

No

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.

Yes

Is there power on the load side of the transformer

Yes

No

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.




F

LAT

D

RINKS

FLAT DRINK(S)

Replace

carbonator

pump

Is the

drink temperature above 40 degrees

Fahrenheit

No

Yes

Is CO 2 being supplied to the carbonator tank

Yes

No

1. Check CO2 supply tank.

2. Check CO2 supply lines.

3. Change CO2 tank

Is the

CO 2 pressure in the system correct

No

1. Adjust CO2 pressure

accordingly

Yes

Does the carbonator cycle when a 20oz drink is dispensed

No

Refer to carbonator ow chart.

Yes

Is there ice on the cold plate

No

1. Fill the hopper with ice.

2. Dispense some ice to

ensure that the agitator

spreads ice on the cold

plate.

Yes

1. Check ice coverage

on the cold plate


N

O

C

ARBONATED

W

ATER


cord on E-Board in E-Box.





Cornelius Inc.

www.cornelius.com

No results