Cornelius Enduro Ed 250 Bcp Users Manual 620916501INS

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Installation Manual
ENDURO ICE/BEVERAGE DISPENSER
Model: ED-250 BCP
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. 620916501INS
October 19, 2005
Revised: March 10, 2006
Revision: C
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment

© IMI CORNELIUS INC; 2005–2006

TABLE OF CONTENTS
Page
SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

BLOWN FUSE OR CIRCUIT BREAKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

SLUSHY ICE. WATER IN HOPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

BEVERAGES DO NOT DISPENSE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

BEVERAGES TOO SWEET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

BEVERAGES NOT SWEET ENOUGH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

BEVERAGES NOT COLD (UNITS WITH BUILD-IN COLD PLATE). . . . . . . . . . .

11

NO ICE DISPENSED FROM ICE PORTION CONTROLLER . . . . . . . . . . . . . . . .

11

NO ICE DISPENSED FROM ICE PORTION CONTROLLER (CONTINUED) . . .

12

NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON SWITCH 12
ICE DISPENSING DURING AUTOMATIC AGITATION . . . . . . . . . . . . . . . . . . . . . .

12

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

LIST OF FIGURES
Page
FIGURE 1. PARTS IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

FIGURE 2. DRIP TRAY DRAIN ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

FIGURE 3. MOUNTING TEMPLATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

FIGURE 4. FLOW DIAGRAM (BEVERAGE VALVE MANIFOLD R TO L 3.1.2.2)

6

FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE) . . . . . . . . . . . . . . . . . . . .

7

FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT) . . . . . . . . . . . . . . . . . . . . . . . . . .

8

FIGURE 7. WIRING SCHEMATIC (115 VOLT UNIT) . . . . . . . . . . . . . . . . . . . . . . . .

9

i

620916501INS

RETAINER
ICE BIN COVER
ICE AGITATOR

MANUAL ICE DISPENSE
RED PUSH BUTTON SWITCH

ICE PORTION
CONTROL MODULE

BEVERAGE FAUCET
ON/OFF SWITCH

REMOVABLE STRAW
HOLDER PANEL

MANUAL/AUTO ICE
TOGGLE SWITCH

LID/STRAW
HOLDER
CUP REST
DRIP TRAY

BEVERAGE FAUCETS (8)

LOWER ACCESS
PANEL

FIGURE 1. PARTS IDENTIFICATION
1

620916501INS

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.

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.
CAUTION:

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 unit includes beverage faucets and a cold plate and is designed to be supplied direct
from syrup tanks and a carbonator, with no additional cooling required.

SPECIFICATIONS
Model

ED250 BCP
B (Beverage Faucets)
C (Cold Plate)
P (Pneumatic ice portioning system)

Ice storage

250 pounds

Maximum No. of

8

Beverage Faucets
Available
Cold Plate (Built–In)

Yes

Electrical

120/1/60, 3.5 Amps

Dimensions

30 in. Wide X 30-11/16 in. Deep X 39-5/8
in. High

620916501INS

2

INSTALLATION INSTRUCTIONS
1. Locate the dispenser indoors on a level counter top.
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 2). 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: 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 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 the Flow Diagram (see Figure 4) 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. ICE PORTION CONTROLLER: Regulated CO2 gas pressure is required to operate the portion control dispensing system. Proceed as follows to connect the CO2 gas pressure source line to the dispenser.
A.

Connect and route the CO2 line from outlet side of the source regulator assembly up to the dispenser.
NOTE: That the minimum source-regulated pressure is 40 psig.

B.

Connect the CO2 source line to dispenser inlet line labeled “CO2“.

C.

The dispenser regulator outlet pressure is factory preset to 34 psig ± 2 psig DO NOT ADJUST.

IMPORTANT: Maximim CO2 operating pressure is 50 psig.
6. Clean the hopper interior (see Owner’s Manual P/N 620916502 for cleaning instructions).
7. Connect the power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle.

3

620916501INS

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 2. DRIP TRAY DRAIN ASSEMBLY

620916501INS

4

30
26–7/16

1–13/16
1–5/16

23

7/16
12
21–1/4

9

18–5/8
23–1/16

21–1/4

OPENING
29

30–11/16

3–1/2

REMOVABLE DRIP TRAY

Z STYLE

9–3/16

11–5/8

RECOMMENDED COUNTER OPENING SIZE
9.00 X 12.00 FOR UTILITIES AND
BEVERAGE TUBING. OPENING CAN BE LOCATED
ANYWHERE WITHIN THE SHADED AREA.

TO FRONT OF DRIP TRAY
ON COUNTERTOP
TO FRONT TOP OF
DRIP TRAY

FIGURE 3. MOUNTING TEMPLATE

5

620916501INS

FAUCETS VIEWED FROM THIS SIDE

FIGURE 4. FLOW DIAGRAM (UNIT WITH EIGHT FAUCETS)

620916501INS

6

S1
S2
S3
S4
W1
W2
W3
W4
S5
S6
S7
S8

W3

W4

W2

W1

COLD PLATE

S8

S7

S6

S5

S4

S3

S2

S1

ITEMS INSIDE BROKEN LINE
INCLUDED WITH UNIT

8

7

6

5

COLDPLATE
INLET
CONNECTIONS

4

3

2

1

FAUCETS

5–15
PSIG

OPTIONAL FOR
DIET DRINKS
OR ROOT BEER

S8

S7

S6

S4

S3

S2

CHECK
VALVE

SYRUP TANKS
15–50 PSIG

S5

CO2

CARBONATOR

Non–Carb Water
Carb Water

S1

PRESSURE
REGULATORS

CO2
Cylinder

Carb Water

INSTALL FOR
NON–CARB AS
REQUIRED

FILTER

OPTIONAL
PRESSURE
REGULATOR

POTABLE
WATER
SUPPLY

PNEUMATIC GATE SOLENOID VALVE
3-WAY NORMALLY CLOSED

FILTER–REGULATOR
(FACTORY-SET OUTLET
PRESSURE TO 32-36 PSIG)
CO2 SUPPLY
50 PSIG MAX.

7
ICE GATE CYLINDER REVERSE
SINGLE ACTING-SPRING EXTENDED

MANUAL OVERIDE SOLENOID VALVE
3-WAY NORMALLY CLOSED

620916501INS

FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE)

ED250 PROGATE WIRING DIAGRAM
MOTOR
HEATER

L

INTERLOCK
RELAY

BLK

7

A

5

B

N

ICE CHUTE
INTERLOCK
SWITCH

INCOMING POWER

E

TO GUSSET
HINGE GROUND
TERMINAL

BLK

TERMINAL
BOARD

GRN/YEL
GRN/YEL

BLK
BLK

BLK

WHT

WHT

BLK

WHT

BLK

YEL

BLK

WHT

BLK

WHT

TO EBOX
GROUND
SCREW

WHT

DIODE

BLK

WHT

BLK

LINE

WHT

LINE

TRANSFORMER

TRANSFORMER

LOAD

YEL

LOAD
RED

YEL/BLK

YEL

ORN/BLK

ORN
1

2

3

4

5

1

2

3

4

5

WHT
WHT

YEL

YEL
RED

YEL/BLK

YEL

BLK

ORN/BLK

WHT

ORN

BLK

AGITATOR
MOTOR

MOTOR START
CAPACITOR

WHT
GRN/YEL

BEVERAGE
VALVE

BLK

BEVERAGE
VALVE

WHT

BLK

BEVERAGE
VALVE

BLK

WHT

TO EBOX
GROUND
SCREW

BEVERAGE
VALVE

WHT

BLK

BEVERAGE
VALVE

WHT

1

WHT

2

GRN

1

BLU

2

MANUAL
OVERRIDE
SOLENOID

BEVERAGE
VALVE

(TYPICAL)

(TYPICAL)

BRN
BLK

RED

BLU

PNEUMATIC
GATE
SOLENOID

RED

1

2

AGITATION
RELAY
3

RED

TO EBOX
GROUND
SCREW

4

BLK
GRN/YEL

BLU
BRN

RED
ORN

1

YEL

ORN

2

3

BLK

4

5

6

YEL

7

8

GRN/YEL

9
BLK

BLK

GRN

RED
1

MANUAL/AUTO ICE
TOGGLE SWITCH

2

WHT
ORN

3

4

5

ORN

6

7

8

BLK
RED

BLU

VIO

WHT

BLU

BRN

9

YEL

1

2

3

4

5

6

7

8

9

1

2

3

4

5

6

7

8

9

YEL
COM

RED
WHT

NO

MANUAL ICE
DISPENSE SWITCH

PORTION CONTROLLER/TOUCH PANEL

BLK

ORN

BEVERAGE
VALVES 25
ON/OFF
SWITCH 12
YEL

ORN

24

WIRE COLOR CHART

11

BLK

YEL

DANGER!
ELECTRIC SHOCK HAZARD. DISCONNECT
POWER BEFORE SERVICING UNIT.

620913001 REV.E

LEGEND

BLACK

WHT

WHITE

YEL

YELLOW

ORN

ORANGE

BRN

BROWN

VIO

VIOLET

SPLICE/QUICK CONNECT CONNECTION

BLU

BLUE

GROUND

RED

RED

MALE HARNESS CONNECTOR

GRN

GREEN

FEMALE HARNESS CONNECTOR

GEN/YEL

GREEN W/YELLOW STRIP

FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT)
620916501INS

8

L
ICE CHUTE INTERLOCk
SWITCH

2

1

BEV
VAL.

120V

24VAC

START CAPACITOR

AGITATOR MOTOR
R
S

3

2

N

620916501INS

MOTOR
START RELAY

4

TOUCH
PANEL

MANUAL OVERIDE
SOLENOID VALVE
MANUAL/AUTO ICE
TOGGLE SWITCH

BEVERAGE
TRANSFORMER

INTERLOCK RELAY

BEV
VAL.

BEV
VAL.

24VAC

BEV
VAL.

BEV
VAL.

24VAC

PORTION CONTROLLER/
TOUCH PANEL

24VAC

BEV
VAL.

BEV
VAL.

3
4

O/L

PNEUMATIC ICE GATE
SOLENOID VALVE

BEV
VAL.

BEV ON/OFF
SWITCH

BEVERAGE
TRANSFORMER

AGITATOR
RELAY

MANUAL ICE DISPENSE
SWITCH

AGITATOR MOTOR
HEATER

9

FIGURE 7. WIRING SCHEMATIC (115 VOLT)

THIS PAGE LEFT BLANK INTENTIONALLY

620916501INS

10

TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
WARNING: If repairs are to be made to the beverage 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 ice dispensing
system, make sure electrical power is disconnected from the unit.

Trouble
NOTE:

Probable Cause

Remedy

should your unit fail to operate properly, check that there is power to the unit and that the
hopper contains ice. If the unit does not dispense, check the following chart under the
appropriate symptoms(s) to aid in locating the defect.

BLOWN FUSE OR CIRCUIT
BREAKER.

A.

Short circuit in wiring (115V
circuit).

A.

Replace defective wiring.

B.

Defective agitator motor.

B.

Replace agitator motor.

A.

Blocked drain.

A.

Open–up/flush out drain.

B.

Unit not level.

B.

Level unit.

C.

Poor ice quality due to water
quality or ice maker problems.

C.

Install water filter system. For
Icemaker problems, consult
icemaker manual.

D.

Improper use of flaked ice.

D.

Replaced flaked ice with “cube
style ice (see page 2, Unit
Description).

A.

No 24 volt power to faucets.

A.

Check that beverage switch is
“on”. Check 24V transformers.

B.

No CO2 pressure.

B.

Check CO2 regulator. Check CO2
tank pressure.

A.

Carbonator not working.

A.

Check carbonator.

B.

No CO2 pressure in
carbonator.

B.

Check CO2 regulator. Check CO2
tank pressure.

C.

Faucet brix requires adjusting.

C.

Brix Faucet.

BEVERAGES NOT SWEET
ENOUGH
ENOUGH.

A.

Empty syrup tank.

A.

Refill syrup tank.

B.

Faucet Brix requires adjusting.

B.

Brix Faucet.

BEVERAGES NOT COLD
(UNITS WITH BUILD-IN COLD
PLATE).

A.

Unit standing with no ice in
hopper - no ice in cold plate
cabinet.

A.

Refill hopper with ice.

SLUSHY ICE. WATER IN
HOPPER

BEVERAGES DO NOT
DISPENSE.

BEVERAGES TOO SWEET.

NOTE: Contact your local syrup or beverage equipment distributor for additional information and
trouble shooting of beverage system.
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER

A.

Insufficient ice supply in ice
bin.

A.

Replenish ice supply as required.

B.

Ice in ice bin bridged (stuck
together).

B.

Gently tap on ice to break it loose.

C.

No electrical power to
dispenser.

C.

Plug in dispenser power cord, or
check fuse or circuit breaker.

11

620916501INS

Trouble
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER
(CONTINUED)

NO ICE DISPENSED FROM
MANUAL ICE DISPENSE
PUSHBUTTON SWITCH

ICE DISPENSING DURING
AUTOMATIC AGITATION

620916501INS

Probable Cause

Remedy

D.

Insufficient or no CO2 supply
to dispenser.

D.

Restore CO2 supply to dispenser.

E.

Ice chute cover not properly
Installed.

E.

Make sure that cover is “snapped”
into place.

F.

Defective ice chute interlock
switch.

F.

Replace interlock switch.

G.

Defective interlock relay.

G.

Replace relay.

H.

Defective 24V transformer.

H.

Replace transformer.

I.

Defective portion controller.

I.

Replace controller.

J.

Defective ice gate cylinder.

J.

Replace cylinder.

K.

Defective ice gate solenoid
valve.

K.

Replace solenoid valve.

L.

Agitation relay wiring incorrect.

L.

Red wire should be connected to
“+” terminal (no. 3) of relay coil.

M.

Defective agitation relay.

M.

Replace relay.

N.

Defective agitator motor or
start capacitor or start relay.

N.

Replace defective component.

A.

Manual/Auto toggle switch in
“Auto” position.

A.

Move toggle switch to “Manual”
position.

B.

Insufficient or no CO2 supply to
dispenser.

B.

Restore CO2 supply to dispenser.

C.

Defective 24V transformer.

C.

Replace transformer.

D.

Defective manual override
solenoid valve.

D.

Replace valve.

E.

Defective manual ice dispense
pushbutton switch.

E.

Replace switch.

F.

Defective agitator motor or
start capacitor or start relay.

F.

Replace defective component.

G.

Defective ice gate cylinder.

G.

Replace cylinder

A.

Manual/Auto toggle switch in
“manual” position.

A.

Move toggle switch to “auto”
position.

B.

Defective ice gate cylinder.

B.

Replace cylinder.

C.

Defective ice gate solenoid
valve.

C.

Replace valve.

D.

Defective portion controller.

D.

Replace controller.

12

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 OSSEO, MN (800) 238–3600

13

620916501INS

IMI CORNELIUS INC.



---

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