Cornelius IDC255 ProGate Post-Mix Drink Dispenser Instruction Manual

IDC 255 PROGATE DRIVE THRU UNIT
Installation Manual

Release Date: June 27, 2006
Publication Number: 621057419INS
Revision Date: September 22, 2022
Revision: H
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

IDC255 ProGate Post-Mix Drink Dispenser

Notice
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 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.

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.

Trademarks and Copyrights
This document contains proprietary information and it may not be reproduced in any way without permission from Marmon Food Service Technologies Inc. This document contains the original instructions for the unit described.

MARMON FOODSERVICE TECHNOLOGIES INC
355 Kehoe Blvd
Carol Stream, IL
Tel: + 1 800-238-3600
Printed in U.S.

Contact Information
To inquire about current revisions of any documentation or assistance with any Cornelius product, contact: www.marmonfoodservice.com
www.cornelius.com
800-238-3600

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 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.

VALVE CONFIGURATIONS

• IDC 255 Progate Drive Thru Unit with 7 UFB-1 Valves and 1 Prism Valve
• IDC 255 Progate Drive Thru Unit with 6 UFB-1 Valves and 2 Prism Valve
• IDC 255 Progate Drive Thru Unit with 5 UFB-1 Valves and 3 Prism Valves
• IDC 255 Progate Drive Thru Unit with 8 Intelli Valves
• IDC 255 Progate Drive Thru Unit with 8 UFB-1 Valves
• IDC 255 Progate Drive Thru Unit with 8 SFV-1 Valves

SPECIFICATION

Model Descriptions| IDC 255
B=Beverage
C=Coldplate
H=Internal Carb
P=Progate
Z=No Drip Tray
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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
220-240/1/50
5.5 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)
CO2 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.

Electrical Connections: 6 ft long power cord with 3-prong plug attached to dispenser.
Power Requirements: 9.3 amps at 120 volts or 5.5 amps at 220 – 240 volts (International Units) 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.
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.

Small Lid Template

Medium Lid Template

Large Lid Template

INSTALLATION

MOUNTING AND PLACEMENT
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.
   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.
   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 CO2 OPERATING PRESSURE. (Example: The  Carbonator CO2 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 CO2 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 3wire power cord is provided. An adapter plug for the particular country must be provided by the Installer.

ADJUST CARBONATOR CO2 REGULATOR AND TURN WATER INLET SUPPLY LINE ON

1. Open (counterclockwise) CO2 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 CO2 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.

CO2 INSTALLATION
WARNING:
The machine is designed to work only with CO2. 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 CO2 lines from back of machine to front.
3. Locate the CO2 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.

POWER INSTALLATION
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 or 5.5 amps at 220 – 240  volts (International Units). The Cord may be wrapped and stored under machine for shipment.

WATER INSTALLATION
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.
   |
   ---|---

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 emote tower).

5. Turn on pressure and check for leaks.
   

ADAPTER BRACKETS INSTALLATION ON TO FRONT PANEL – STRAIGHT (90) VERSION
NOTE: In order to install right adapter brackets, Refer Figure 17. in page no.14 for all possible configurations of Lid holder, Cup dispenser, Straw holder & VESA mount.

1. Figure 12 & Figure 13. shows the location of adapter brackets, suitable for Option-1 & Option-4. Assemble Cup/Lid dispenser adapter bracket part no.620071540 at the two left and two right positions. If Lid holders are to be installed in the center area, use Lid holder bracket part no.620070916. This Lid holder bracket should be held and slide into the two shoulder screws such that it stays there. Rotate the thumb screw clockwise to tighten it.
   

2. Figure 14. shows the location of adapter brackets, suitable for Option-3 & Option-6. Assemble Cup/Lid dispenser adapter bracket part no.620071540 at the two left and two right positions. If Straw holder is to be installed in the center area, use Straw holder adapter bracket part no.620071541 in the center area.

3. Figure 15. shows the location of adapter brackets, suitable for Option-2, Option-5 & Option-7. Assemble Cup/Lid dispenser adapter bracket part no.620071540 at the two left and one extreme right positions. If VESA mount hinge arm is to be installed in the center area, unscrew two screws part no.70692 and put them back with VESA mount.

4. If any of the adapter brackets are unused, ensure respective screws holes are covered with suitable screws as shown in Figure 16.
   

CUP DISPENSER/LID HOLDER/STRAW HOLDER/VESA MOUNT COMBINATIONS

MAX]
6| 620046723| HOLDER STRAW
7| 9110-8.5-4| VESA MOUNT HINGE ARM

NOTE: There are only seven combinations of Cup Dispenser/Lid Holder/Straw Holder/VESA Mount as mentioned above and part no.9110-8.5-4 must be ordered separately through  KES.

OPERATION INSTRUCTIONS

LID DISPENSER OPERATION
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.

UNIT OPERATION
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 CO2 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.

LOADING OF LID DISPENSER
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.
   

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.

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

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.

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

LID DISPENSER OPERATION
To dispense a lid:

1. Place hand in finger slot
2. Grab edge of lid and pull.

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
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
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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. Ice 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. To enter the program mode press the Program Button  and  Desired Size button at the same 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 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   or wait 10 seconds and the control will return to the dispense mode.
6. Place a cup under the ice chute and press the just programmed dispense size button  If amount dispense amount is not the desired amount repeat the process.
7. To exit, repeat Step 1

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

The relationship is expressed below.
Agitation Time (AT) = Dispense Time (DT) x Agitation Ratio2 (RA)

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.

Programming (Changing) the Agitation Time

1. Simultaneously Press and hold for 3 seconds, the   button and also both direction arrow buttons    to enter the programming mode.
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.

DIAGRAMS

COLD PLATE
The beverage assembly of the unit can be one of the following configurations: 7 UFB-1 Valves and 1 Prism Valve; 5 UFB-1 Valves and 3 Prism Valves; 6 UFB-1 Valves and 2 Prism  Valves; 8 Intelli Valves; or 8 UFB-1 Valves; or 8 SFV-1 Valves..

7 UFB-1 Valves and 1 Prism Valve Figure 28.

5 UFB-1 Valves and 3 Prism Valves
Figure 29.

6 UFB-1 Valves and 2 Prism Valves
Figure 30.

8 Intelli Valves or 8 UFB-1 Valves or 8 SFV-1 Valves
Figure 31.

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

Manufacturer Recommended Agitation Settings

Model| Ice Fill/Ice Type| Motor ON Time| Motor OFF time
175, 215, & 255, 300, B, BC| Manual/Hard Ice (Cube)| 4 Seconds| I Hour
Automatic (Top-Mount Ice Maker/Hard Ice (Cube)| 0.5 Seconds| 20 Minutes
Manual & Automatic/Cornelius Chunklet, Scots-man & Hoshizaki Compressed Ice| 0.5 Seconds| ; I low.
B – Beverage C-Cold plate| NO FLAKED ICI:
‘

ELECTRICAL SCHEMATIC

MAIN ELECTRICAL BOX ASSEMBLY

INTERCONNECT SCHEMATIC

TROUBLESHOOTING

POWER LIGHT OFF

NO ICE DISPENSE IN MANUAL MODE

NO ICE DISPENSE IN AUTOMATIC MODE

BEVERAGE NOT DISPENSING

FLAT DRINKS

NO CARBONATED WATER

Cornelius Inc.
www.cornelius.com

References

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