Cornelius PRO ED FAST GATE Installation guide

®
PRO ED FAST GATE
Training Manual
Release Date: April 17,2003
Publication Number: TP00918
Revision Date: NA
Revision: C
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

PRO ED FAST GATE TRAINING MANUAL
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 varia-
tions 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.
To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:
Trademarks and copyrights:
Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus,
and Vista are registered trademarks of IMI Cornelius Inc.
Optifill trademark is pending.
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2003, All Rights Reserved, IMI Cornelius Inc.
IMI Cornelius Inc.
Corporate Headquarters
One Cornelius Place
Anoka, MN 55303-6234
U.S.A.
Internet:
www.cornelius.com
Email:
[e-mail]
In the U.S.A.:
phone:[phone]
800-238-3600
FAX:[phone]
Outside the U.S.A.:
phone:[phone]
FAX:[phone]

TABLE OF CONTENTS
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Preview Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Key Things To Know / Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
ED 250 Pro Fast Gate Dimensions & Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Electric Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SYSTEM DETAILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Carbon Dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Water . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Syrup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pneumatic Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Controls and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Portion Control Panel: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Ice Dispensing System Trouble Shooting: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Motor Replacement: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
TROUBLE SHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
REVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Pro ED Fast Gate Training Manual
© 2003, IMI Cornelius Inc. - 1 -
INTRODUCTION
1. PREVIEW QUESTIONS
Check your current knowledge by taking a few minutes to answer the following questions:
1. How many transformers are there in this unit?________________________________
2. Is the internal air regulator adjustable _____ Yes _____ No?
3. How many plain water valves can be configured? _____________________________
4. What is the function of the ice chute interlock proximity switch? _________________
____________________________________________________________________
____________________________________________________________________
2. KEY THINGS TOKNOW / DO
• The magnet must be in place to satisfy the ice chute interlock proximity
switch!
• The ice chute refill time is adjustable!
• There are 3 power sources (115 VAC, 24 VAC, 12 VDC)!
• The LED lights indicate both programming modes and operational modes!
• Adjust the ice chute refill times before programming the ice portions.
• If the unit is shorted to ground, perform the transient voltage suppressor test,
refer to page 9.

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3. OVERVIEW
3.1 Product Description
The Pro ED Fast Gate is a beverage dispenser available with programmable, auto-
matic portioning ice dispensing available 250 models. See “Portion Control Panel:”
on page 5 for description of programming.
3.2 ED 250 Pro Fast Gate Dimensions & Capacities
•30”wide, 29”deep, 40”tall
•eight UFB Optifill 2-4 oz. dispensing valves
•250 pound ice capacity
•Drip tray drain has 1”I.D.
•120 VAC, 60 cycle, single phase, 15 amp circuit (3 1/2 amp draw)
3.3 Electric Box
Drip Tray & Cup Rest
Beverage Valves
Beverage Valves On/Off
Rocker Switch
Red Push Button
For Manual Ice
Dispensing
Ice Portion Control Panel
Lid & Straw Holder
Auto/Manual Ice
Dispenser Toggle Switch
Ice Chute
Terminal
board
Pneumatic gate
solenoid valve
Filter
regulator
Manual
override
solenoid
Pressure
gauge Agitator motor
start capacitor
Agitator motor
start relay
Agitator
relay
Interlock
relay
24 VAC
transformers
Typical layout -- ED 200/250 pictured
NOTE: A 12 VDC power rectifier is part of the portion control board.
TABLE OF CONTENTS

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© 2003, IMI Cornelius Inc. - 3 -
SYSTEM DETAILS
1. CARBON DIOXIDE
100 psi maximum to the unit, regulated to 35 psi inside the unit
2. WATER
Plain water inlet pressure of 50 psi minimum, 70 psi maximum
Carbonated water inlet pressure of 80-120 psi minimum
3. SYRUP
60 psi minimum

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4. MECHANICAL
4.1 Pneumatic Controls
CO2Regulator
•Works with CO2only
•Preset to 34 psi (± 2 psi)
Pneumatic Solenoid Valve
•When set to the manual mode, 24 VAC is applied to the manual override
solenoid providing an open chute for direct dispense of ice via the red
manual push button.
•When set to the auto/ice portion control mode, 12 DCV is applied to the
auto pneumatic solenoid when depressing one of the ice portion buttons.
The ice gate closes by spring pressure.
5. COOLING
High performance cold plate accepts cubed and chunklet™compressed ice. Never use
flaked ice in this unit!
MANUAL OVERIDE
SOLENOID 24 VAC.
MANUAL MODE ONLY
FILTER REGULATOR
AND WATER TRAY
WATER
DRAIN
PRESSURE
GAUGE
PNEUMATIC GATE
SOLENOID VALVE
12 VAC PORTION CONTROL
AUTO MODE.
ICE PNEUMATIC
CYLINDER
(SPRING RETURN)
ICE GATE
ADJUSTMENT
ICE GATE
ADJUSTABLE
INTRODUCTION

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© 2003, IMI Cornelius Inc. - 5 -
6. CONTROLS AND ELECTRICAL
6.1 Portion Control Panel:
The portion control panel on the Pro ED Fast Gate has several functions including
dispensing 4 programmed ice portions for 4 cup sizes, programming, and cleaning.
The portion control panel and its functionality are described in the following illustra-
tion:
Portion Control Panel Operations
Light Color Explanation Actions That Can Be Taken
Green Normal
Operation
Press any CUP SIZE for
portioned ice.
—or —
Press INCREASE and then
CUP SIZE for extra ice.
Green -
flashing
Normal
Operation
Chute
Refilling
Wait until chute has refilled
and press desired CUP
SIZE again.
Red then
Yellow
Clean
Mode
To enter Clean Mode simul-
taneously press INCREASE
and DECREASE.
Press any CUP SIZE to
empty chute, then remove
chute for cleaning.
When chute is replaced, unit
will automatically return to
normal operation after one
minute, or INCREASE and
DECREASE can simulta-
neously pressed 3 times.
LIGHT
Indicates mode of
operation or amount
of adjustment
CUP SIZE
Small, Medium, Large or X-Large Cup Size
Press for extra
ice, then press
cup size
INCREASE
DECREASE
INTRODUCTION

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Ice Portion Control Set Up and Adjustment Procedure
Light Color Explanation Actions That Can Be Taken
Step 1.
Fill the
Ice Chute
Yellow
Flashing
Chute
Agitation
Refill
Time
To enter Agitation Adjust-
ment Mode simultaneously
press INCREASE and
DECREASE three times then
press and hold INCREASE
and DECREASE for 3 sec-
onds.
Press any CUP SIZE to
select a preset agitation time
(small=shortest time, X-
Large=longest time, ect)
To exit Agitation Refill Time
Adjustment Mode simulta-
neously press INCREASE
and DECREASE.
NOTE: Once in a mode the
light will blink to indicate
the refill time: 1 blink for the
shortest refill time-4 blinks
for the longest refill. The fac-
tory recommendation is 2
blinks.
NOTE: Larger ice portions
require more time to refill.
SYSTEM DETAILS

Pro ED Fast Gate Training Manual
© 2003, IMI Cornelius Inc. - 7 -
NOTE: Consult store manager on desired ice level in each size cup.
Step 2.
Set por-
tion
level for
each size
cup
Yellow
IcePortion
Adjust-
ment
To enter Portion Adjustment
Mode simultaneously press
INCREASE and DECREASE
twice.
Press and hold CUP SIZE
to be adjusted and while
pressing INCREASE or
DECREASE to change por-
tion size (5 millisecond per
pulse).
NOTE: Make sure the light
blinks as the buttons are
pressed.
The light will flash green for
5 seconds. While the green
light is flashing the ice por-
tion can be tested by pressing
the CUP SIZE again.
To exit Portion Adjustment
Mode simultaneously press
INCREASE and DECREASE
two times.
Step 3.
If
desired,
set the
extra ice
portion
adjust-
ment
Red
Extra Ice
Portion
Adjust-
ment
To enter Extra Ice Adjust-
ment Mode simultaneously
press INCREASE and
DECREASE three times.
Press and hold the CUP
SIZE to be adjusted and
press INCREASE or
DECREASE to change por-
tion size (5 millisecond per
pulse).
NOTE: Make sure the light
blinks as the buttons are
pressed.
To exit Extra Ice Portion
Adjustment Mode simulta-
neously press INCREASE
and DECREASE.
Light Color Explanation Actions That Can Be Taken
SYSTEM DETAILS

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6.2 Ice Dispensing System Trouble Shooting:
If the ice system does not dispense ice, follow these procedures.
NOTE: When following these procedures, if a component fails a test, replace it and
test the new component. Then check to see if the dispenser works correctly.
LINE POWER TESTS
NOTE: The control panel harness must be connected during test.
Power cord must be
connected during this test.
1. Outlet & Power Cord Test —
Check for power at the source
first and then across the black
and white wires on the terminal
board (4 tab connector and 6 tab
connector).
Power cord must be
connected during this test.
2. Terminal Board and Interlock
Voltage Test —
A. Check terminal board voltage
across the two six tab connectors.
There should be line voltage.
B. Remove ice chute cover and the
then check voltage –it should be
zero.
White Wire Probe
Black Wire Probe
Diode Assembly Board
Bidirectional transient
voltage suppressor
4 Tab connector
6 Tab connector
Probe the 2 six
tab connectors
bidirectional transient
voltage suppressor
SYSTEM DETAILS

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© 2003, IMI Cornelius Inc. - 9 -
Power cord must be
disconnected during this test.
3. Voltage Suppressor Test
p/n 32714 —
The bidirectional transient voltage
suppressor protects the portion control.
Its normal failure mode is a direct short.
Check by removing it from the board
and using an ohm meter. It should test
open in both directions.
Power cord must be
disconnected during this test.
4. Proximity Switch Test
p/n 32953 —
Check ice chute interlock proximity
switch for continuity by disconnecting
the connector and using probes. There
should be less than 1 ohm of resistance.
24 VOLT POWER TESTS
Power cord must be
connected during this test.
1. Valve Banks Test —
Check the two transformers by
checking one valve in the left bank
and one valve in the right bank of
valves. If both banks operate cor-
rectly, go to step 9.
If either of the banks does not work
correctly, go to the next step.
bidirectional
transient
voltage
suppressor
Probe the
connector
Left
valve
bank Right valve bank
SYSTEM DETAILS

Pro ED Fast Gate Training Manual
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Power cord must be disconnected
during this test.
2. Beverage Valve On/Off Switch Test —
Remove the front panel cover and use an
ohm meter to check the beverage switch
connector pins. Check for continuity on the
front panel connector pins.
Put the meter probes across pins 1 & 3, there
should be continuity with the switch ON and
an open circuit with the switch OFF.
Then put the meter probes across pins 7 & 9,
there should be continuity with the switch
ON and an open circuit with the switch OFF.
Power cord must be
disconnected during this test.
3. Manual / Auto ICE Toggle Switch
Tes t —
A. Remove front panel from unit.
B. Remove the ice chute cover.
C. Use an ohm meter to check the
beverage switch connector pins.
Check the pins on the backside of
the front panel connector.
D. Put the meter probes across pins 1
& 4, there should be continuity
with the switch in MANUAL.
E. Then put the meter probes across
pins 1 & 6, there should be conti-
nuity with the switch in AUTO.
White/
Orange
Black
Red
31
64
97
Beverage
valve
switch
Front panel
connector
9-pin
Connector
layout
White/
Orange
Black
Red
31
64
97
Manual / auto
ice toggle
switch
Front panel connector
Connector
layout
SYSTEM DETAILS

Pro ED Fast Gate Training Manual
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Power cord must be
disconnected during this test.
4. Manual Push For Ice Button Test —
Disconnect the power cord from the
front panel. Use an ohm meter to check
the two outside receptacles on the cable
connector going to the front panel.
There should be an open circuit except
when the switch is pressed.
Check the two line wires running to the
Manual Push For Ice button for
continuity.
Front
panel
Electric &
pneumatic
box
Manual Push For
Ice button power
cord/connector
Manual
Push For
Ice button
Outside
receptacles
Female plug on cable
from electrical box
SYSTEM DETAILS

Pro ED Fast Gate Training Manual
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Power cord must be
disconnected during this test.
1 A. Additional 24 Volt Circuit Tests —
Remove front panel cover.
NOTE: The magnetic proximity switch on
the ice chute must be closed (satis-
fied).
1 B. Manual Override Solenoid
Tes t —
Use an ohm meter to check pins 3
& 6,
there should be 93 ohms.
1 C. Pneumatic Gate Solenoid Test —
Use an ohm meter to check pins 5 & 6,
there should be 79 ohms.
1B.
1C.
White/
Orange
Black
Red
31
64
97
Manual override
solenoid
Low voltage
connector
layout
Pneumatic gate
solenoid
Portion
control
panel
connector
White
wire
Blue
wire
SYSTEM DETAILS

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AGITATOR MOTOR TESTS
Power cord must be
connected during this test.
1 A. Motor Test p/n 08049 —
Check motor reset by pressing the
button and trying the motor.
NOTE: The magnetic proximity
switch on the ice chute
must be closed (satisfied).
Power cord must be
connected during this test.
2 A. Relay Test p/n 32503 —
Check voltage from terminal # 1
on agitation relay to white
(neutral) wire on terminal board.
There should be line voltage.
2 B. Then press any size cup on the
portion control panel and the
voltage should drop to
approximately 5-9 VDC across
terminals # 3 and # 4.
Power is disconnected
3 A. Agitator Motor Run Winding Test- Use
an ohm meter to check pin 2 on the
agitator relay and pin 3 on the motor start
relay, there should be approximately 6
ohms.
3 B. Agitator Motor Start Winding Test- Use
an ohm meter to check pin 2 on the
agitator relay and the black wire on the
start capacitor, there should be
approximately 14 ohms.
Power cord must be
connected during this test.
4 A. Agitator Relay Test —
Check for line voltage across terminals 1 & 2.
Motor Reset
Button
Black
wire
Blue
wire
Agitator
relay
Start
relay
Start
capacitor
S
TARTIN
G
RELAY A
G
ITAT
O
R RELAY
12
3
24
31
SYSTEM DETAILS

Pro ED Fast Gate Training Manual
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.Power cord must be
disconnected during this test.
4 B. Agitator Relay Test —
Use an ohm meter to check across
pins 1 & 2 of the portion control touch
panel connector, there should be 7
ohms.
NOTE: Connector may be installed
with notches up or down.
Portion
control
panel
connector
White
wire
Blue
wire
SYSTEM DETAILS

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© 2003, IMI Cornelius Inc. - 15 -
Power cord must be
connected during this test.
5 A. Portion Control Test
p/n 32839 —
Check by placing probes on the red
and black wires on the agitator
relay across terminals 3 and 4
when the portion control is
activated. There should be
approximately 5-9 VDC to the
agitation relay.
5 B. Relay Test p/n 32503-
Check voltage from terminal #1
on agitation relay to white
(neutral) wire on terminal board.
There should be line voltage.
5 C. Then press any size cup on the
portion control panel and the
voltage should drop
approximately 10 volts.
5 D. Repeat this procedure on the red
wire at the solid state relay. The
voltage should drop
approximately 5 volts.
5 E. If the unit fails either of these
tests, replace the portion
controller.
Agitator
relay
Agitator
relay
Start
relay
Start
capacitor
AGITATOR RELAY
24
31
Black
wire
Blue
wire
SYSTEM DETAILS

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6.3 Motor Replacement:
OFF
ON
Note: When replacing the gear motor always replace the starting components.
SYSTEM DETAILS