Cornelius Beverage Dispenser Enduro 200 250 User Manual

Installation Manual  
ICE/BEVERAGE DISPENSER  
Model: Enduro-200/250  
IMPORTANT:  
TO THE INSTALLER.  
It is the responsibility of  
the Installer to ensure that  
the water supply to the  
dispensing equipment is  
provided with protection  
against backflow by an air  
gap as defined in  
ANSI/ASME A112.1.2-1979;  
or an approved vacuum  
breaker or other such  
method as proved effective  
by test.  
Water pipe connections  
and fixtures directly  
connected to a potable  
water supply shall be  
sized, installed, and  
maintained according to  
Federal, State, and Local  
Codes.  
Part No. 92181INS  
March 24, 2004  
Revised: March 2, 2006  
Revision: D  
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION  
This Manual must be read and understood before installing or operating this equipment  
PRINTED IN U.S.A  
© IMI CORNELIUS INC; 2006  
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SAFETY PRECAUTIONS  
Always: Disconnect power to the dispenser before servicing or cleaning.  
Never: Place hands inside of hopper or gate area without disconnecting power to the dispenser. Agitator rotation  
occurs automatically when dispenser is energized!  
This ice dispenser has been specifically designed to provide protection against personal injury and eliminates  
contamination of ice.To insure continued protection and sanitation, observe the following:  
ALWAYS: Be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior  
and possible contamination of the ice.  
ALWAYS: Be sure the upper and lower front panels are securely fastened.  
ALWAYS: Keep area around the dispenser clean of ice cubes.  
CAUTION: Dispenser cannot be used with crushed or flaked ice.  
Use of bagged ice which has frozen into large chunks can void warranty. The  
dispenser agitator is not designed to be an ice crusher. Use of large chunks of  
ice which ”jam up” inside the hopper will cause failure of the agitator motor and  
damage to the hopper. If bagged ice is used, it must be carefully and completely  
broken into small, cube–sized pieces before filling into the dispenser hopper.  
DESCRIPTION  
The ”ENDURO” series of ice 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 in. in size), cubelets, and hard-chipped or cracked ice; and in addition, several flavors  
of post–mix beverages. The “BC” units include beverage faucets and a cold plate and are designed to be supplied  
direct from syrup tanks and a carbonator, with no additional cooling required.  
SPECIFICATIONS  
Model  
ED200 (ice only)  
B (Beverage Faucets)  
ED250 (ice only)  
B (Beverage Faucets)  
C (Cold Plate)  
Z (No drip tray)  
N (No Lid)  
C (Cold Plate)  
Z (No drip tray)  
N (No Lid)  
F (Flavor)  
F (Flavor)  
Ice storage  
200 pounds  
10  
250 pounds  
Maximum No. of  
Beverage Faucets  
Available  
10  
Cold Plate (Built–In) Yes, On BC Model Only  
Yes, On BC Model Only  
Electrical  
120/1/60, 3.5 Amps  
120/1/60, 3.5 Amps  
220–240/1/50–60, 2.0 Amps  
220–240/1/50–60, 2.0 Amps  
Dimensions  
30 in. Wide X 30-11/16 in. Deep X 35-5/8 30 in. Wide X 30-11/16 in. Deep X 39-5/8  
in. High  
in. High  
Z Model  
30 in. Wide X 23-1/16 in. Deep X 35-5/8  
in. High  
30 in. Wide X 23-1/16 in. Deep X 39-5/8  
in. High  
1
92181INS  
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INSTALLATION INSTRUCTIONS  
1. Locate the dispenser indoors on a level counter top.  
A. LEG OPTION  
Note: Before installing legs, the plastic plugs must be removed.  
Unpack the four (4) legs and install them into the threaded holes provided in the bottom of the unit. The  
installer must provide flexibility in the product and utility supply lines to permit shifting the position of the  
dispenser sufficiently to clean the area beneath it.  
Rotate the line support bracket, located under base, to the down position and route all the lines above  
the bracket.  
B. COUNTER MOUNTING  
The ice dispenser must be sealed to the counter. The MOUNTING TEMPLATE (see Figure 3)  
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 MOUNTING TEMPLATE. Cut openings in the  
counter.  
Rotate the line support bracket, located under base, to the up position and route all the lines below the  
bracket.  
Apply a continuous bead of National Sanitation Foundation (NSF) listed silastic sealant (Dow 732 or  
equal) approximately 1/4” 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 (see Figure 3), for locating the required clearance hole in the counter  
for these utility lines.  
3. DRIP TRAY DRAIN ASSEMBLY (see Figure 1). 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 Dis-  
penser to assemble the drain. The completed drain line must pitch continuously downward and contain no  
“traps” or improper drainage will result.  
NOTE: This equipment must be installed with adequate backflow protection to comply with federal, state,  
and local codes.  
4. Connect the beverage system product tubes as indicated in the applicable Flow Diagram. This work should  
be done by a qualified Service Person. Any non-carbonated water tubing must be connected to the outlet of  
the check valve.  
Note: See applicable Flow Diagram (see Figure 4 through 7) or decal on lower front panel of the unit for  
the location of syrup and water connections.  
Note: 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.  
5. Clean the hopper interior (see Owner’s Manual P/N 92108 for cleaning instructions).  
6. Connect the power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle. For 220–240 volt units, a  
3–wire power cord is provided. An adapter plug for the particular country will need to be provided by the  
equipment Installer.  
92181INS  
2
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GATE RESTRICTOR PLATE ADJUSTMENT  
CAUTION: Disconnect power to dispenser before installing, removing or adjusting  
restrictor.  
The restrictor plate may be adjusted up or down as shown in Figure 2 to reduce or increase the ice dispensing  
rate, especially desirable when using glasses or other containers with small openings. Adjustment can be made  
by sliding the restrictor plate up or down with nuts loosened, to obtain the desired ice dispensing rate.  
SOLVENT BOND  
HOSE CLAMP  
DRIP TRAY DRAIN  
FITTING  
COUPLING  
3/4 SOCKET X 3/4 FPT  
BARB ADAPTER  
1 BARB X 3/4 MPT  
DRAIN LINE  
1-IN. I.D. PLASTIC TUBING  
(6 FT) WITH INSULATION  
FIGURE 1. DRIP TRAY DRAIN ASSEMBLY  
3
92181INS  
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INSTALL PLATE ON  
STUDS AS SHOWN  
FIGURE 2. GATE RESTRICTOR PLATE  
7/16 DIA.  
30  
1 13/16  
26 7/16  
1 5/16  
12  
9
18 5/8  
21 1/4  
30 11/16  
23 1/16  
29  
3 1/2  
9 3/16  
11 5/8  
Z Style  
23  
REMOVABLE SINK  
TO FRONT OF DRIP  
TRAY ON COUNTERTOP  
RECOMMENDED COUNTER OPENING SIZE  
9 X 12 FOR UTILITIES AND BEVERAGE  
TUBING. OPENING CAN BE LOCATED  
ANYWHERE WITHIN SHADED AREA.  
TO FRONT TOP  
OF DRIP TRAY  
FIGURE 3. MOUNTING TEMPLATE  
92181INS  
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1
2
3
4
FAUCETS VIEWED FROM THIS SIDE  
FIGURE 4. FLOW DIAGRAM (UNIT WITH SIX FAUCETS)  
5
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1
2
3
4
FAUCETS VIEWED FROM THIS SIDE  
FIGURE 5. FLOW DIAGRAM (UNIT WITH EIGHT FAUCETS)  
92181INS  
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1
2
3
4
FAUCETS VIEWED FROM THIS SIDE  
FIGURE 6. FLOW DIAGRAM (UNIT WITH TEN FAUCETS)  
7
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1
2
3
4
FAUCETS VIEWED FROM FRONT OF UNIT  
FIGURE 7. FLOW DIAGRAM (”B” UNIT WITH EIGHT BEVERAGE FAUCETS)  
92181INS  
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MOTOR  
HEATER  
T’STAT  
1
LIGHT  
AGITATOR  
MOTOR  
WIRING DIAGRAM  
CAP  
2
BLUE  
GRN  
ICE LEVEL SIGNAL  
OPTION  
R
E
D
Y
E
L
N
L
Q.C. CONNECTOR  
SERVICE INFORMATION  
TO 24V  
TRANSFORMER  
TO BEVERAGE VALVES  
TO HINGE  
ELECTRIC SHOCK HAZARD. DISCONNECT  
DISPENSE  
SWITCH  
KEY SWITCH  
GATE  
SOLENOID  
(106VDC)  
DANGER!  
POWER BEFORE SERVICING UNIT.  
BLUE  
YELLOW  
R
G
OPTIONAL  
LIGHT BALLAST  
W
H
I
T
E
R
E
D
B
L
A
C
K
B
B B  
G
R
E
E
N
Y
E
R
L L  
L
G
R
E
E
N
E
L
G
R
E
E
N
D
E
E
N
A
C
K
A
C
A
C
BEVERAGE  
TRANSFORMER  
(OPTIONAL)  
BEVERAGE  
TRANSFORMER  
(OPTIONAL)  
L
O
W
BLACK  
BLACK  
K K  
W
H
I
WHITE  
BLACK  
T
E
B
L
B
L
WHITE  
WHITE  
WHITE  
W
H
I
T
E
B
L
A
C
K
U
E
U
E
B
L
WHITE  
WHITE  
A
C
K
Y
E
L
NC  
NC  
NO  
NO  
COM  
J10  
L2  
L
AGITATION  
TIMER  
BLACK  
O
W
B
L
A
C
K
W
H
I
W
H
I
T
E
B
L
B
L
U
E
B
L
U
E
OPTIONAL  
LIGHT  
STARTER  
J9  
A
C
K
COM  
L1  
T
E
BLACK  
BLACK  
R
E
D
BLACK  
BLACK  
B
L
R
E
D
U
E
BLACK  
WHITE  
BLACK  
WHITE  
OPTIONAL  
LIGHT SOCKET  
OPTIONAL  
LIGHT SOCKET  
620904701 REV.D  
FIGURE 8. WIRING DIAGRAM (115 VOLT UNIT)  
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G
L
N
TIMER  
L2  
L1  
RECTIFIER  
MOTOR HEATER  
AGITATOR MOTOR  
3
N.O.  
N.C.  
O/L  
C
R
S
2
4
START CAPACITOR  
VEND SWITCH  
CAPACITOR  
MOTOR  
START  
RELAY  
GATE  
SOLENOID  
BALLAST  
LIGHT  
STARTER  
OPTIONAL  
BEVERAGE TRANSFORMER  
OPTIONAL FLAVOR VLVS  
OPTIONAL LOW ICE LEVEL LIGHT  
T’STAT  
PCB  
BOARD  
VLV  
SOLENOIDS  
KEYPAD  
OPTIONAL  
BEVERAGE  
VALVES  
OPTIONAL  
BEVERAGE  
VALVES  
BEVERAGE PANEL  
FIGURE 9. SCHEMATIC (115 VOLT UNIT)  
92181INS  
10  
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WIRING DIAGRAM  
SERVICE INFORMATION  
(220–240 VAC)  
DANGER! ELECTRIC SHOCK HAZARD. DISCONNECT  
POWER BEFORE SERVICING UNIT.  
MOTOR  
HEATER  
T’STAT  
LIGHT  
AGITATOR  
MOTOR  
B
L
TO  
B
L
2
BEVERAGE  
PANEL  
1
U
E
K
BROWN  
BROWN  
1
2
3
BLUE  
POWER  
SWITCH  
BLK  
YEL  
BLU  
RED  
BRN  
WHT  
ICE LEVEL SIGNAL  
OPTION  
E
N
PCB BOARD  
Q.C. CONNECTOR  
L
TO BEVERAGE VALVES  
TO 24V  
TRANSFORMER  
TO HINGE  
GUSSET  
DISPENSE  
SWITCH  
KEY SWITCH  
WHT  
BLK  
KEYPAD  
ESD  
GATE  
SOLENOID  
4
BLUE  
(WATER–5)  
YELLOW  
GRN/YEL  
FLAVOR OPTION  
BGBBGY R G B L GGBB  
R
B
LAMP  
LINE  
L RL LR E R R T RRL L  
E
E
L
G
OPTIONAL  
LIGHT  
LT BLUE  
N
N
UNUANL D N O  
NAAA D  
WB / / CCC  
KYO Y N L YYKK  
BLACK  
RED  
R
G
N
MOTOR START  
CAPACITOR  
E/ EC/ L  
/
BEVERAGE  
BEVERAGE  
R
N
/
L
Y
E
L
G
R
N
/
K
/
GRN  
O
E
E
EE  
POWER LINE  
W
U
G
R
N
/
TRANSFORMER  
(OPTIONAL)  
Y
E
L
TRANSFORMER  
(OPTIONAL)  
A
BALLAST  
L
L
E LL  
G
R
N
/
Y
E
L
D
FILTER  
Y
E
L
LT BLUE  
L
Y
E
L
W
H
I
Y
E
L
T
E
BROWN  
WHITE  
BROWN  
WHITE  
WHITE  
WHITE  
W
BLACK  
B
L
B
L
H
I
BLACK  
A
C
K
A
C
K
T
E
WHITE  
MOTOR  
START  
RELAY  
B
L
FILTER  
ASY  
LT BLUE  
A
C
K
NC  
NC  
NO  
NO  
COM  
L2  
J10  
J9  
3
2
AGITATION  
TIMER  
N
B
L
W
H
I
4
A
C
K
OPTIONAL  
LIGHT  
COM  
L1  
T
E
L
BROWN  
W
H
I
STARTER  
BLACK  
BLACK  
BROWN  
R
E
D
R
E
T
E
D
BLACK  
BLACK  
B
L
BROWN  
U
E
LT BLUE  
BROWN  
BLACK  
WHITE  
BLACK  
WHITE  
OPTIONAL  
LIGHT  
OPTIONAL  
LIGHT  
SOCKET  
SOCKET  
FIGURE 10. WIRING DIAGRAM (220–240 VOLT UNIT)  
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G
L
N
EMI FILTER  
LINE  
FILTER  
TIMER  
L2  
L1  
RECTIFIER  
MOTOR HEATER  
POWER SWITCH  
AGITATOR MOTOR  
3
N.O.  
O/L  
C
R
S
2
4
START CAPACITOR  
VEND SWITCH  
N.C.  
MOTOR  
START  
RELAY  
GATE  
SOLENOID  
OPTIONAL  
BALLAST  
OPTIONAL LIGHT  
OPTIONAL STARTER  
OPTIONAL  
BEV. TRANSFORMER  
OPTIONAL BEV. TRANSFORMER  
OPTIONAL FLAVOR VLVS  
PCB  
BOARD  
VLV  
SOLENOIDS  
KEYPAD  
BEV. FAUCETS  
BEVERAGE PANEL  
FIGURE 11. SCHEMATIC (220–240 VOLT UNIT)  
92181INS  
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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. If repairs are to be made to the refrigeration system, make sure  
electrical power is disconnected from the unit.  
Should your unit fail to operate properly, check that there is power to the unit and that the hopper con-  
tains ice. If the unit does not dispense, check the following chart under the appropriate symptoms to aid  
in locating the defect.  
Trouble  
Probable Cause  
A.Short circuit in wiring.  
BLOWN FUSE OR CIRCUIT BREAKER.  
B.Defective gate solenoid.  
C.Defective agitator motor.  
GATE DOES NOT OPEN. AGITATOR DOES NOT  
TURN.  
A.No power.  
B.Bent depressor plate (does not actuate switch).  
C.Defective dispensing switch.  
GATE DOES NOT OPEN OR IS SLUGGISH.  
AGITATOR TURNS.  
A.Defective gate solenoid.  
B.Excessive pressure against gate slide.  
C.Defective Rectifier.  
ICE DISPENSES CONTINUOUSLY.  
SLUSHY ICE. WATER IN HOPPER.  
A.Stuck or bent depressor plate (does not release  
switch).  
B.Defective dispensing switch.  
C.Improper switch installation.  
A.Blocked drain.  
B.Unit not level.  
C.Poor ice quality due to water quality or icemaker  
problems.  
D.Improper use of flaked ice.  
BEVERAGES DO NOT DISPENSE.  
BEVERAGES TOO SWEET.  
A.No 24 volt power to faucets.  
B.No CO pressure.  
2
A.Carbonator not working.  
B.No CO pressure in carbonator.  
2
C.Faucet brix requires adjusting.  
13  
92181INS  
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Trouble  
Probable Cause  
A.Empty syrup tank.  
BEVERAGE NOT SWEET ENOUGH.  
B.Faucet brix requires adjusting.  
BEVERAGES NOT COLD (UNITS WITH BUILT-IN  
COLD PLATE).  
A.Unit standing with no ice in hopper or no ice in cold  
plate cabinet.  
FLAVOR SYRUPS DO NOT DISPENSE.  
A.No 24 volt power to PC board.  
B.No CO2 pressure.  
C.Empty syrup tank.  
D.Kinked tubing.  
E.Clogged inner nozzle.  
F. Defective PC board.  
G.Defective harness from keypad.  
H.Defective Flow control.  
I. Defective solenoid harness.  
J. Defective keypad.  
FLAVOR DISPENSES FOR MORE THAN 1 SEC.  
FLAVOR DISPENSES MORE THAN .5 OZ.  
A.Dip switch settings on control board incorrect.  
B.PC board defective.  
C.Defective flow control.  
A.Dip switch settings on control board incorrect.  
B.Flow control incorrectly set.  
C.PC board defective.  
D.Defective flow control.  
Contact your local syrup or beverage equipment distributor for additional information and troubleshoot-  
ing of beverage system.  
92181INS  
14  
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WARRANTY  
IMI Cornelius Inc. warrants that all equipment and parts are free from defects in material and  
workmanship under normal use and service. For a copy of the warranty applicable to your Cornelius  
product, in your country, please write, fax or telephone the IMI Cornelius office nearest you. Please  
provide the equipment model number and the date of purchase.  
IMI Cornelius Offices  
AUSTRALIA D P.O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166  
AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930  
BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307  
BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829  
ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644  
FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201  
GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, WEST GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438  
GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491  
HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222  
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814  
NEW ZEALAND D 20 LANSFORD CRES. D P.O. BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361  
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604  
SPAIN D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379  
USA D ONE CORNELIUS PLACE D ANOKA, MINNESOTA D (763) 421-6120 D FAX (763) 422-3255  
15  
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92181INS  

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