Cornelius IDC 255 Service Manual
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Cornelius IDC 255 Service Manual

Progate drive thru
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IDC 255 PROGATE DRIVE THRU
Service Manual
Release Date: June 27, 2006
Publication Number: 621057419SER
Revision Date: August 27, 2013
Revision: E
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

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Summary of Contents for Cornelius IDC 255

  • Page 1 IDC 255 PROGATE DRIVE THRU Service Manual Release Date: June 27, 2006 Publication Number: 621057419SER Revision Date: August 27, 2013 Revision: E Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.
  • Page 2 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...

  • Page 3: Table Of Contents

    TABLE OF CONTENTS Safety Instructions..............1 Read and Follow ALL Safety Instructions .
  • Page 4 Daily Cleaning: ............. . 18 Daily Maintenance:.

  • Page 5: Safety Instructions

    IDC 255 Progate Drive Thru Service Manual SAFETY INSTRUCTIONS ALL S EAD AND OLLOW AFETY 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).

  • Page 6: Safety Precautions

    IDC 255 Progate Drive Thru Service Manual AFETY 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.

  • Page 7: Unit Specification

    UNIT SPECIFICATION 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 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.

  • Page 8: Progate 2 Features

    OLDER OMPATIBILITY The following template is a guide to validate the compatibility of the cup lids that are used with the IMI 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

    IDC 255 Progate Drive Thru Service Manual Small Lid Template 3.750 Figure 2. © 2006-2013, IMI Cornelius Inc. - 5 - Publication Number: 621057419SER...

  • Page 10: Medium Lid Template

    IDC 255 Progate Drive Thru Service Manual Medium Lid Template 4.350 Figure 3. Publication Number: 621057419SER - 6 - © 2006-2013, IMI Cornelius Inc.

  • Page 11: Large Lid Template

    IDC 255 Progate Drive Thru Service Manual Large Lid Template 4.700 Figure 4. © 2006-2013, IMI Cornelius Inc. - 7 - Publication Number: 621057419SER...

  • Page 12: Lid Dispenser Maintenance

    IDC 255 Progate Drive Thru Service Manual ISPENSER AINTENANCE 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.

  • Page 13: Programming (Changing) The Ice Portion

    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 Program Button and Desired Size button at the same time and hold for 5 seconds.

  • Page 14: Programming (Changing) The Agitation Time

    IDC 255 Progate Drive Thru Service Manual Dispense Time (mS) Agitation Ratio Agitation Time (mS) 2720 3040 3360 3680 Dispense Time (mS) Agitation Ratio Agitation Time (mS) 1400 1960 2520 3080 3640 4200 4760 5320 5880 6440 The relationship is expressed below.

  • Page 15: Ice Portion Bar

    IDC 255 Progate Drive Thru Service Manual Ice Portion Bar The portion bar is used to determine the amount of time programmed for each size button. Each button has a min- imum 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.

  • Page 16: Diagrams

    IDC 255 Progate Drive Thru Service Manual DIAGRAMS LATE 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.

  • Page 17: Intelli Valves Or 8 Ufb-1 Valves

    IDC 255 Progate Drive Thru Service Manual 8 Intelli Valves or 8 UFB-1 Valves PRE-CHILLED WATER TO BE POST-CHILLED Figure 8. © 2006-2013, IMI Cornelius Inc. - 13 - Publication Number: 621057419SER...

  • Page 18: E - Board Off Cycle Agitation Adjustments

    IDC 255 Progate Drive Thru Service Manual E – B OARD YCLE GITATION 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.

  • Page 19: Electrical Schematic

    IDC 255 Progate Drive Thru Service Manual LECTRICAL CHEMATIC LEFT TOTAL FLEX 18AWG SOLENOID BLOCK RIGHT TOTAL FLEX 18AWG SOLENOID BLOCK Figure 10. © 2006-2013, IMI Cornelius Inc. - 15 - Publication Number: 621057419SER...

  • Page 20: Main Electrical Box Assembly

    IDC 255 Progate Drive Thru Service Manual LECTRICAL SSEMBLY L1 BALLEST L1 XFORMER L1 HEATER CARB MOTOR L2 CARB MOTOR CARB MOTOR EARTH EARTH IN AGITATOR EARTH AGITATOR L2 AGITATOR BLK MODE SW Figure 11. Publication Number: 621057419SER - 16 -...

  • Page 21: Interconnect Schematic

    IDC 255 Progate Drive Thru Service Manual NTERCONNECT CHEMATIC L1 BALLEST L1 XFORMER L1 HEATER CARB MOTOR L2 CARB MOTOR CARB MOTOR EARTH EARTH IN AGITATOR EARTH AGITATOR L2 AGITATOR BLK MODE SW Figure 12. © 2006-2013, IMI Cornelius Inc.

  • Page 22: Cleaning And Maintenance Instructions

    IDC 255 Progate Drive Thru Service Manual 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. WARNING: Disconnect power to the unit before servicing.

  • Page 23: Yearly Maintenance

    IDC 255 Progate Drive Thru Service Manual 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.

  • Page 24: Cold Plate (Yearly Maintenance)

    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.

  • Page 25: Sanitize Syrup Lines, B-I-B Systems

    IDC 255 Progate Drive Thru Service Manual 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.

  • Page 26: Service

    IDC 255 Progate Drive Thru Service Manual SERVICE ERCHANDISER EMOVAL 1. Remove all lid holders and straw dispenser. Figure 15. Figure 14. 2. Remove screws holding merchandiser to con- trol box. Figure 16. 3. Grab panel by sides, lift up to disengage locking tabs and rotate forward past.

  • Page 27: Control Box Removal

    IDC 255 Progate Drive Thru Service Manual ONTROL EMOVAL 1. With cover removed locate and remove 4 screws from Control box flange. Figure 19. 2. Pull box forward exposing control board, wiring and switches. Figure 20. LECTRICAL CCESS 1. Remove screw-locking cover to electrical box.

  • Page 28: Ice Chute Removal

    IDC 255 Progate Drive Thru Service Manual HUTE EMOVAL 1. Remove 4 nuts attaching ice chute to hopper. Figure 23. 2. Disconnect ice chute switch harness located behind the control box. Figure 24. Figure 25. 3. Pull assembly away form hopper. Do not loose or damage gasket.

  • Page 29: Diagnostics Guide For The Main Control Board

    IDC 255 Progate Drive Thru Service Manual OTOR EMOVAL NOTE: Apply anti-seizing lubricant to the threads of mounting bolts when service is required. Figure 28. IAGNOSTICS UIDE FOR THE ONTROL OARD NOTE: Refer to Figure 23. Observed State State Sensor Input...
  • Page 30 IDC 255 Progate Drive Thru Service Manual Figure 29. Publication Number: 621057419SER - 26 - © 2006-2013, IMI Cornelius Inc.

  • Page 31: Troubleshooting

    IDC 255 Progate Drive Thru Service Manual TROUBLESHOOTING OWER IGHT POWER LIGHT OFF 1. Remove all other equipment Are there other Is the unit plugged from the machine circuit. equipments on the into a socket 2. Install a new dedicated circuit same circuit for the machine.

  • Page 32: No Ice Dispense In Manual Mode

    IDC 255 Progate Drive Thru Service Manual ISPENSE IN ANUAL NO ICE DISPENSE IN MANUAL 1. Check the connector between the MODE Is the control box and the E-Box. machine inlet 2. Check relay 3 in the E-Box for power pressure greater (terminal 3&4).

  • Page 33: No Ice Dispense In Automatic Mode

    IDC 255 Progate Drive Thru Service Manual ISPENSE IN UTOMATIC NO ICE DISPENSE IN AUTOMATIC MODE Can you 1. Check all conne ns to dispense ice from all the ice Some sizes por on control pc board sizes 1. Check the connector between the control box and the E-Box.

  • Page 34: Beverage Not Dispensing

    IDC 255 Progate Drive Thru Service Manual EVERAGE ISPENSING BEVERAGE NOT DISPENSING there power on there power on the Is the key switch the line side of the load side of the on/off transformer transformer 1. Check the key switch 1.

  • Page 35: Flat Drinks

    IDC 255 Progate Drive Thru Service Manual RINKS FLAT DRINK(S) Replace carbonator pump Is the the carbonator Is CO Is the cycle when a 20oz drink temperature being supplied to the carbonator tank pressure in drink is dispensed above 40 degrees...

  • Page 36: No Carbonated Water

    IDC 255 Progate Drive Thru Service Manual ARBONATED ATER NO CARBONATED WATER Does the Is the carbonator pump start Restore the recommended incoming water when the unit is water flow restricted turned on Check the carbonator pump Is there 1. Replace Carbonator...
  • Page 38 IMI Cornelius Inc. www.cornelius.com...

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