IDC 2XX WITH COLD CARBONATION Service Manual Release Date: October 2, 2007 Publication Number: 621057403SER Revision Date: August 3, 2010 Revision: A Visit the IMI 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.
TABLE OF CONTENTS Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Recognize Safety Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Different Types of Alerts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDC 2XX Training Manual SAFETY INSTRUCTIONS READ AND FOLLOW ALL SAFETY INSTRUCTIONS Safety Overview • Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards). • Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit. Recognition Recognize Safety Alerts ! This is the safety alert symbol.
IDC 2XX Training Manual SAFETY PRECAUTIONS 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.
IDC 2XX Service Manual INTRODUCTION DESCRIPTION The IDC series of ice dispensers solves your ice and beverage service needs in a sanitary, space saving, economical way. Designed to be automatically filled with ice from a top mounted ice machine or 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 or extruded style ice.
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Publication Number: 621057403SER S1 1 S2 2 5 S5 CW PLAIN WTR IN CARB WTR IN -5- S7 W2 PW S6 W3 TOTAL FLEX MANIFOLD 5 S8 S9 5 4 3 2 1 S10 PW CW 6 SYRUP BIB'S 60 PSIG SECONDARY REGULATOR 10 9 8 7 6 COLDPLATE ICE CHUTE VALVES CO2 SOURCE 100-110 PSIG 6 TOTAL FLEX MANIFOLD 7 7 9 8 10 9 CO2 CYLINDER FIXED REGULATOR 8 W3 10 W2 PW = PLAIN WATER W1 CARB TANK PRESSURE REGULATOR OR BOOSTER PUMP MAY BE REQUIRED PUMP & MOTOR ASY W3 IN OUT CW = CARBONATED WATER CARB TAN
IDC 2XX Tarining Manual E – BOARD OFF CYCLE AGITATION ADJUSTMENTS When Ice is not being dispensed from the machine such as during off hours it is essential to move or agitate the ice to keep it from clumping and to replenish the ice in the cold plate. The amount of time the agitator runs and the time between the agitation cycles can be adjusted depending on ice type or application. The settings for this function are located on the E-Board found in the E-BOX.
KEY SWITCH RED RED BLK BLK -7- BLK/RED BLK ORG BLK BLK RED WHT TRANSFORMER WHT WHT YEL WHT VALVES WHT BLK WHT YEL WHT/YEL LIGHT SOCKET BLK TRANSFORMER BLK WHT/YEL WHT BLK BRN CAPACITOR J7 J3 J4 WHT ICE GATE SWITCH BLK BLK WHT BLK RED ON OFF TIME TIME L2_AGIT BLU AGIT MAIN ELECTRICAL BOX RED BLK RED/BLK BLK WHT BRN ELETRIC SHOCK HAZARD.
IDC 2XX Service Manual SCHEMATIC L2 L1 EARTH L2_IN L1_1N CARB MOTOR CARB MOTOR CARB_MOTOR_L2 CARB EARTH AGITATOR MOTOR AGITATOR_L2 AGITATOR AGITATOR EARTH OPTIONAL LIGHTING L1_BALLAST FLOURESCENT LIGHT BALLAST BALLAST_L2 STARTER HEATER L1_HEATER XFORMER_L1 HEATER_L2 L2_XFORMER 120V Pri XFRMR1 E-BOARD 80 VA E-BOARD 24V Sec KEY LOC VALVE VALVE 120V Pri XFRMR2 80 VA 24V Sec KEY LOC VALVE VALVE E-BOARD ICE GATE SWITCH J3 BLK J4 WHT BLK RED CARB TANK HIGH LEVEL PROBE LOW LEVE
IDC 2XX Service Manual CLEANING AND MAINTENANCE INSTRUCTIONS These instructions are used on all Cornelius ice drink dispensers. Some models may have additional cleaning requirements. Those models will have addition procedures listed later in the manual. ! WARNING: Disconnect power to the unit before cleaning or servicing following all lock out / tag out procedures established by the user. Verify all of the power is off to the unit before performing any work.
IDC 2XX Service Manual Monthly Cleaning: (In addition to daily and weekly procedures) 1. Flush and sanitize all syrup lines as well as all of the syrup connectors. (See the sanitize syrup lines section shown later in this manual). 2. Remove ice from hopper and clean and sanitize the hopper. (See the Cleaning the interior surfaces section shown later in this manual). 3. While cleaning the hopper use the brush provided with the unit to clean the cold plate surface.
IDC 2XX Service Manual 9. 10. Allow sanitizer to remain in lines for fifteen (15) minutes. Repeat the step above, applying a different product tube each time until all tubes are filled with the sanitizing solution. 11. Remove the nozzle and syrup diffuser and clean them in a mild soap solution. Rinse with clean water and reassemble the nozzle and syrup diffuser on the valve. 12. Rinse the parts in clean water, reassemble the valve and reconnect it to the dispenser. 13.
IDC 2XX Service Manual MAINTENANCE The following dispenser maintenance should be performed at the intervals indicated: DAILY (OR AS REQUIRED) Remove foreign material from vending area drip tray to prevent drain blockage. Clean vending area. Check for proper water drainage from the vending area drip tray. Checking CO2 Supply Make sure CO2 cylinder regulator assembly 1800-psi gage indicator is not in shaded (“change CO2 cylinder”) portion of the dial.
IDC 2XX Service Manual CHANGE-OUT PROCEDURES CARBONATED WATER/NON CARBONATED WATER CHANGE-OUT 1. Depressurize the system. IMPORTANT: Both the syrup and water must be depressurized. 2. Push the valve lock down on the valve that needs the water type change and pull the valve off the back block. 3. Remove the 4 screws holding the back block in place and remove the back block. Remove Screws 4. Pull the Y-fitting out by moving it from side to side until it releases. 5.
IDC 2XX Service Manual MOTOR REPLACEMENT 1. Remove the 4 screws with a 1/4” socket to seperate the agitator motor from the gear box. Gear Box Remove (4) Screws Agitator Motor 2. Remove the agitator motor. 3. Install the new agitator motor and replace the screws removed in step 1 with a 1/4” socket. © 2007-2010, IMI Cornelius Inc.
IDC 2XX Service Manual GEARBOX REPLACEMENT 1. Remove the 4 screws with a 1/4” socket to seperate the agitator motor from the gear box. 2. Remove the 4 screws holding the gear box in place with a 3/16 hex wrench. Gear Box Remove (4) Screws Agitator Motor 3. Pull the gear box, seal, and gasket off the machine. 4. Install the new gear box, seal, and gasket. Screw it in place with the 4 screws removed in step 4 using a 3/16 hex wrench. 5.
IDC 2XX Service Manual TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. WARNING: If repairs are to be made to a product system, remove quick disconnects from the applicable product tank, then relieve the system pressure before proceeding. If repairs are to be made to the CO2 system, stop dispensing, shut off the CO2 supply, then relieve the system pressure before proceeding.
IDC 2XX Service Manual Slushy ice or water in hopper Beverage does not dispense Beverage is too sweet Unit will not dispense carbonated drinks. Dispenses syrup only. Unit will not dispense carbonated drinks. Spurts CO2 and syrup only.
IDC 2XX Service Manual Low water pressure No Syrup or Watered down drink dispensed Could be caused by excessively long runs (over 40 ft.) of 3/8” water supply line. Increase line size to 1/2” Low water pressure Add water pressure booster pump Plugged water filter.
IDC 2XX Service Manual DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD State Observed State of Red LED Sensor Input Control Response Service Remedy 0 Flash rate 3 seconds Both probes read “wet” Standby mode. Pump = OFF No service required 1 Flash rate 1/2 second Pump is OFF and HIGH probe reads “dry” and LOW probe reads “wet” Waiting for level to drop below LOW probe. Pump = OFF No service required 2 Flash rate 1/2 second Both HIGH and LOW probes read “dry” Normal mode.
IDC 2XX Service Manual TROUBLESHOOTING Beverage Not Dispensing BEVERAGE NOT DISPENSING Is the key switch on/off? On Is there power on the line side of the transformer? Yes Is there power on the load side of the transformer? Yes Off No Check the key switch. 1. Check the transformer connections to the E-Board in the E-Box. 2. Check the E - Board in the EBox ensuring that power is being supplied to the board. No 1.Check the wire harness from the beverage valves to the terminal board. 2.
IDC 2XX Service Manual Flat Drinks FLAT DRINK(S) Is the drink temperature above 40 degrees Fahrenheit? Yes Is there ice on the cold plate? Check ice coverage on the cold plate. Yes No 1. Fill the hopper with ice. 2. Dispense some ice to ensure that the agitator spreads ice on the cold plate. No Is CO2 being supplied to the carbonator tank? Yes No 1. Check CO2 supply tank. 2. Check CO2 supply lines. 3. Change CO2 tank.
IDC 2XX Service Manual No Carbonated Water NO CARBONATED WATER Does the carbonator pump start when the unit is turned on? No Check the carbonator pump connection to the E-Board in the EBox. Yes Is the incoming water restricted? Yes No Is there power connection to the carbonator pump? Yes Is the pump motor running? Yes 1. Replace Carbonator pump. 2. Check Y fitting on the total flex manifold. No No 1.
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