Cornelius ED Series Installation guide

ED Series Training Manual
IMI CORNELIUS INC
One Cornelius Place
Anoka, MN 55303-6234
Telephone [phone]
Facsimile [phone]
TD 218
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Page 1TD 218
ED200 & ED250
MODELS
ED200 ED250 ED300
Ice Storage 200 lbs. 250 lbs. 300 lbs.
Max # of Valves 10 10 12
Built-In Cold Plate BC Model Only BC Model Only BC Model Only
Voltage 120 120 120
Phase 111
Hertz 60 60 60
Amp Draw 3.5 3.5 5.2
Dimension A 30I30I44-1/4I
Dimension B 30I30I30I
Dimension C 35-5/8I39-5/8I35-5/8I
C
B
A

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ENDURO 200 & ENDURO 250

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ENDURO 300 (ED300) (POST-MIX)
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4041
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Item
No. Part No. Name
121491 Slide,Gate
222081 Restrictor, Gate
327107 Bracket, Lever Depressor
415213 Agitator, Left
529483 Cover, Rear
Item
No. Part No. Name
629538
29495 Panel,Lower, LEV Panel, Lower, Corco
729496 Extension, Drip Tray
829497 Cover, Electrical Box
929507 Bracket, Motor Support
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4
TD 218
ENDURO 200 & ENDURO 250
Item
No. Part No. Name
10 21491 Slide,Gate
11 22081 Restrictor, Gate
12 53298 Insulation, Panel
13 29541 Plate, Motor Mount
14 29694 Agitator
15 29555 Cover, Rear
16 29551 Panel, Lower Front
17 15093 Support, Drip Tray
18 29655
15013 Cover, Electrical Box – ED250 Cover, Electrical Box – ED200
19 29547
29540 Cabinet, ED250 Cabinet, ED200
20 Contact
Factory Panel/Cold Plate/Valve Ass’y
21 53011 Fitting, Cold Plate
22 31007 Boot, Switch
23 29664 Lever
24 50767 Snap Bushing
25 15211 Pin, Drip Tray
26 15464 Baffle, Beverage Panel
27 50459 Snap Bushing
28 30794 Motor Heater
29 30895 Switch
30 27107 Bracket, Lever
31 31928 Bulb, Florescent
32 33387 Motor
33 32954 Solenoid Ass’y
34 53268 Cover, Foamed Cold Plate
35 33354
33353 Electrical Box Ass’y, ED250 Electrical Box Ass’y, ED200 FIG 2
36 29542 Bracket, Motor Mount
37 53255 Cover, Access (Cold Plate)
38 71010 Washer
39 53020 Shield, Foam
40 50328 Spacer
41 29377 Hinge
42 53199 Seal, Motor
43 51891 Gasket, Gate
44 51908 Plug
45 71025 Strap, Motor
46 52882 Plate, Mounting, Ice Chute
47 52883 Ice Chute
48 15132 Bracket, Motor Mount
49 52912
52911
53000
53001
Merchandiser, ED250 Black
Merchandiser, ED200 Black
Merchandiser, ED250 Gray
Merchandiser, ED200 Gray
Item
No. Part No. Name
50 52950
52949 Panel,Inner – ED250 Panel, Inner – ED200
51 53210
53211 Drip Tray – Black Drip Tray – Gray
52 52909
53108 Lid, Dispenser – Black Lid, Dispenser – Gray
53 52960
52916 Hopper Ass’y – ED250 Hopper Ass’y – ED200
54 52967 Plug, Foot
55 52972 Tab, Retaining
56 70016 Hex Nut, No. 10-32
57 70017 Insert, No. 10-32
58 70100 Locknut, No. 8-32
59 70242 Screw, No. 10-32 By 3/8-In. Long
60 70015 Hex Nut, No. 10-32
61 70056 Washer, No. 10
62 70067 Washer, 7/32 x 7/8 x 3/64 Plated
63 70076 Hex Nut, No. 8-32
64 70104 Nutsert, No. 8-32
65 70164 Screw, No. 8-32 By 3/4-In. Long
66 70171 Screw, No. 8-32 By 3/8-In. Long
67 70204 Screw, No. 8 By 1/2-In. Long
68 71033 Screw, 3/8-16 By 3/4-In. Long
69 70068 Washer, 3/8
70 71061 Washer, 7/16
71 70341 Spring, Gate
72 70478 Clip, Push-on
73 70555 Screw, No. 8-32 By 2 5/8-In. Long
74 15302 Support, Line
75 70959 Nutsert, No. 8-32
76 71011
70970 Leg – Metal (Not Shown) Leg – Metal/Plastic (Not Shown)
77 15087 Retainer, Agitator
78 70847 Spacer, Switch
79 71059 Wing Nut, 3/8-16
80 71028 Shoulder Screw, 1/4-20
81 71039 Grill
82 51288 Adapter, 1-In. Barb By 3/4 MPT (Not
Shown)
83 50952 Adapter, 3/4 Soc By 3/4 FPT (Not
Shown)
84 71089 Shoulder Screw
85 70750 Clamp (Not Shown)
86 53299 Tab, Retaining
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TD 218
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FIGURE 1. ELECTRICAL BOX ASSEMBLY
Item
No. Part No. Name
33353 ElectricalBox/Reflector Ass’y ED200
33354 Electrical Box/Reflector Ass’y ED200
129665 Box, Electrical ED250
29656 Box, Electrical ED200
229657 Clamp, Capacitor
333160 Capacitor
430995 Power Cord
530960 Terminal Board
631620 Starter
731621 Ballast
831763 Timer
932042 Socket, Starter
10 32682 Transformer, 120/24V
11 31375 Relay, Mercury
12 15479 Bracket, Relay
13 33162 Relay, Start
Item
No. Part No. Name
14 32746 Lampholder
15 32958 Rectifier
16 50458 ReliefStrain
17 50475 Bushing
18 50459 Bushing
19 33302 Wire Harness, Solenoid (Not Shown)
20 33626 Wire Harness, Dispense Switch (Not
Shown)
21 33388 Wire Harness, Motor (Not Shown)
22 70147 Screw, No. 6-32 By 1/2-In. Long
23 70153 Screw, No. 6-32 By 3/4-In. Long
24 70215 Screw, No. 8-32 By 1/4-In. Long
25 70217 Screw, No. 8-32 By 1/2-In. Long
26 70120 Screw, No. 10-32 By 1/2-In. Long
27 70075 Hex Nut, No. 6-32
28 70015 Hex Nut, No. 10-32

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TD 218
ENDURO 300 (ED300) (POST-MIX)
Item
No. Part No. Name
29 29509 Base Ass’y
30 Dispensing Valve Panel Ass’y
31 15214 Agitator, Right
32 29562 Spacer, Drain
33 29664 Lever, Ice Chute
34 29667 Support, Product Lines
35 29668 Baffle, Product Lines
36 53136 Cover
37 29493 Bracket, Motor Mount
38 30895 Switch
39 31007 Boot, Switch
40 53011 Elbow
41 53186 Clamp
42 31622 Bulb, Florescent
43 32954 Solenoid Ass’y
44 32977 Switch, Power
45 33352 Electrical Box Ass’y
46 50328 Spacer
47 50097 Gasket, Hopper
48 52814 Insulation, Cold Plate, Side
49 52815 Insulation, Cold Plate, Back
50 51891 Gasket, Gate
51 51908 Plug
52 52882 Plate, Mounting, Ice Chute
53 52883 Shell, Ice Chute
54 52884 Cover, Cold Plate
55 71024 ”S”–Clip
56 53185 Disk, Agitator
57 52937
52952 Merchandiser, Black Merchandiser, Gray
58 52943 Lens, Inner
59 52932
52938 Drip Tray, Black Drip Tray, Gray
Item
No. Part No. Name
60 52957 Hopper Ass’y
61 52967 Plug
62 52972 Tab, Retaining
63 70016 Hex Nut, No. 10-32
64 70017 Insert, Nylon, No. 10-32
65 70056 Washer, Flat, No. 10
66 70067 Washer
67 70076 Hex Nut, No. 8-32
68 70104 Nutsert, No. 8-32
69 70164 Screw, Phil Truss Hd., No. 8-32 By
3/4-In. Long
70 70171 Screw, Phil Truss Hd., No. 8-32 By
3/8-In. Long
71 70178 Screw, Phil Truss Hd., No. 8-32 By
1/2-In. Long
72 70204 Screw, Phil Truss Hd., No. 8-32
73 70215 Screw, Hex Washer Hd., No. 8-32 By
1/4-In. Long
74 70217 Screw, Hex Washer Hd., No. 8-32 By
1/2-In. Long
75 41459 O–ring
76 70474 Retaining Ring
77 70478 Clip, Pushon
78 70555 Screw, Phil Truss Hd., No. 8-32 By 3-In.
Long
79 70847 Washer, Switch
80 70959 Nutsert, No. 8-32
81 70997 Strike
82 70998 Latch
83 70999 Cup Rest
84 70531 Ball Stud
85 70075 Hex Nut, No. 6-32
86 71010 Washer, No. 8
87 53135 Lid, Cover
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7
TD 218
ENDURO 300 (ED300) (POST-MIX)
Item
No. Part No. Name
129303 Plate, Motor Mount
229654 Plate, Adjustable, Motor
330794 Heater, Motor
432498 Motor
551859 Seal, Motor Shaft
651860 Gasket, Motor
770018 Hex Nut, 1/4-20
870043 Washer, Flat, 1/4
970048 Washer, Lock, 1/4
10 70257 Screw, Phil Truss Hd, 1/4-20 By 1/2-In.
Long
11 70260 Screw, Phil Rd. Hd., 1/4-20 By 1-In.
Long
12 70341 Spring, Gate
13 70992 Receptacle, 1/4-turn
14 70993 Retainer, 1/4-turn
15 70994 Stud, 1/4-turn
9
14
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7
89
10
11
12
13
15
8
MOTOR COMPONENTS
Item
No. Part No. Name
32954 Gate Solenoid Ass’y
128172 Plate, Solenoid Mounting
229173 Arm, Gate Lift
332957 Solenoid
450752 Isolator
550754 Bearing, Gate Arm
670162 Screw, No. 8-32 By 1/4-In. Long
770015 Hex Nut, No. 10-32
1
2
34
5
6
7
GATE SOLENOID ASSEMBLY
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8
TD 218
ENDURO 300 (ED300) (POST-MIX)
25 123
4
5
67
8
9
10 11
12
13 14
15 2317
1920 21
22
2324 26
27
2318 23
28
ELECTRICAL BOX ASSEMBLY
Item
No. Part No. Name
33352 ElectricalBox and Reflector Ass’y
129494 Box, Electrical
230514 Clamp, Capacitor
330774 Capacitor
430995 Power Cord
531107 Terminal Block
631620 Starter
731621 Ballast
831763 Timer, Repeat Cycle
932042 Socket, Starter
10 32579 Harness, Motor
11 32682 Transformer, 120/24V
12 32746 Holder, Lamp
13 32782 Harness, Dispenser Switch
14 32958 Rectifier
15 33302 Harness, Solenoid
Item
No. Part No. Name
16 50458 Strain Relief
17 50459 Bushing, Harness
18 50475 Bushing, Jumper
19 70015 Hex Nut, No. 10-32
20 70131 Screw, Sl Rd Hd, No. 4-40 By 3/8-In.
Long
21 70147 Screw, Phil Rd Hd, No. 6-32 By 1/2-In.
Long
22 70153 Screw, Phil Rd Hd, No. 8-32 By 3/4-In.
Long
23 70215 Screw, Sl Washer Hd, No. 8-32 By
1/4-In. Long
24 70217 Screw, Sl Washer Hd, No. 8-32 By
1/2-In. Long
25 31206 Relay
26 70120 Screw, No. 10-32 By 1/2-In. Long
27 70075 Hex Nut, No. 6-32
28 70152 Screw, No. 6-32 By 3/8-In. Long
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9
TD 218
ENDURO 300 (ED300) (POST-MIX)
12
3
4
5
6
VALVE PANEL ASSEMBLY
Item
No. Part No. Name
29647
29648
29645
29646
29510
29539
Valve Panel Ass’y, 8 Corco
Valve Panel Ass’y, 8 LEV
Valve Panel Ass’y, 10 Corco
Valve Panel Ass’y, 10LEV
Valve Panel Ass’y, 12 Corco
Valve Panel Ass’y, 12LEV
129316 Manifold Ass’y, 2-Flavor
229317 Manifold Ass’y, 1-Flavor
329315 Manifold Ass’y, 3-Flavor
Item
No. Part No. Name
440502 Clamp
552792
50299 Tube, LEV Tube, Corco
629641
29642
29643
29644
29490
29532
Panel, Dispensing Valve, 8 Corco
Panel, Dispensing Valve, 8 LEV
Panel, Dispensing Valve, 10 Corco
Panel, Dispensing Valve, 10 LEV
Panel, Dispensing Valve, 12 Corco
Panel, Dispensing Valve, 12 LEV
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10
TD 218
FIGURE 2. FLOW DIAGRAM (UNIT WITH TEN DISPENSING VALVES)
Syrup Tanks

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TD 218
FIGURE 3. FLOW DIAGRAM (UNIT WITH EIGHT DISPENSING VALVES)
Syrup Tanks

12
TD 218
Coldplate Coldplate
S2 S3S4 S5S6 S7 S8S1 W1 W2 W3 W4 W5 W6 W7 W8
12 34 56 78
Valves as viewed from the front of the dispenser
Left Right
Syrup Inlets are 1/4IBarb. Water Inlets are 3/8IBarb and may be Carbonated or Non-Carbonated
ED300 Plumbing Schematic – 8 Valve
Coldplate Coldplate S2 S3S4S5 S6S7S8S1 W1 W2 W3
W4W5 W6W7
W8
123478
Valves as viewed from the front of the dispenser
Left Right
Syrup Inlets are 1/4IBarb. Water Inlets are 3/8IBarb and may be Carbonated or Non-Carbonated
ED300 Plumbing Schematic – 10 Valve
56910
W9 W10 S9S10
234 78
Valves as viewed from the front of the dispenser
ED300 Plumbing Schematic – 12 Valve
56 910
111 12

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TD 218
FIGURE 4. WIRING DIAGRAM
ELECTRIC SHOCK HAZARD. DISCONNEC
T
POWER BEFORE SERVICING UNIT.
DANGER!
T'STAT LIGHT
2
WHT
ICE LEVEL SIGĆ
NAL
OPTION
WHITE
B L U E
B L U E
B L A C K
B L U E
BLACK
WHITE
W H I T E
R E D
GRN
L
WHITE
BLACK
OPTIONAL
OPTIONAL
OPTIONAL
B L K
Y E L
B L U E
TO TERMIĆ NAL BOARD
B L U E
G R E E N
3
2
L2
N
COMNO
NC
L1
NC NO
YELLOW
B L A C K
B L A C K
AGITAĆ
TOR
MOTOR
MOĆ
TOR
HEATĆ
ER
TO BEVERAGE VALVES
KEY SWITCH
R E D
BLACK
TO HINGE
G R E E N
G R E E N
W H I T E
WHITE
BLACK
DISĆ
PENSE
SWITCH
BLACK
BLACK
RED
WHITE
GATE SOLEĆ NOID (106VD C)
BLACK
B L U E
1
W H I T E
B L A C K
W H I T E
Y E L L O W
BLACK
B L A C K
B L A C K
W H I T E
R E DCOM
WHITE BLACK
W H I T E
B L U E
G R E E N
RED
BLACK
WHITE
WHITE
WHITE
Y E L L O W
B L A C K
W H I T E
BLACK
W H I T E
BLACK
B L A C K
R E D
B L A C K
R E D
Q.C. CONNECTOR

14TD 218
REMOVAL AND REPLACEMENT OF AGITATORS
92089
Retai
n
Agitator Disk, R.H., With 2
Th mb Screw
Agitator Disk, L.H., With Center Hole
Front View
Valve Side
Top of Dispenser
Left
TO REMOVE LEFT, CCW AGITATOR
1. Remove center thumb screw by turning it counterclockwise.
2. Lift plastic agitator disk off of stainless steel agitator.
3. Grip agitation arms at the center and lift up.
4. Replace by reversing steps.
TO REMOVE RIGHT, CW AGITATOR
1. Remove the (2) retaining pins.
2. Lift plastic agitator disk off of stainless steel agitator.
3. Grip agitation arms at the center and lift up.
4. Replace by reversing steps.
Note: Refer to Sanitize Procedure in the Owners Instruction for complete cleaning and sanitizing
instructions.

WHT
BLUE GATE
SOLENOID
WHT
RECTIFIER
AC
AC
WHT STARTER
LIGHT
BALLAST
LIGHTED DISPLAY
OPTION
WHT WHT
BLUE
RECTIFIER
AC
AC
YEL
WHT
BRN
BRN
RED RELAY
R
C
NO
NC
WHT
BLK
WHT
BLK
WHT WHT
BLK
WHT
BLK
WHT WHT
BLK
WHT
BLK
TRANSFORMER
KEY SWITCH OPTION
BEVERAGE SYSTEM
DISPENSE
SWITCH
RED
LNGROUND
GRN
Q.C. CONNECTOR
WHT
RED
-+ -BLUE
BLK
PNK
AGITATION TIMER
NC
NO
C
BLUE
PNK
+
BLK
BEVERAGE SYSTEM
KEY SWITCH OPTION
BEVERAGE FAUCET (TYPICAL)
TRANSFORMER
BLK
WHT
CW
AGITATOR
MOTOR
RED
BLK
ORN
BLU
CAPACITOR
CONNECTION
MOTOR HEATER
ICE LEVEL SIGNAL
OPTION
WHT
LIGHTT'STAT
LIGHTED DISPLAY
OPTION
BALLAST
LIGHT
STARTER
BLK
2 V.
TERMINAL BOARD
TERMINAL BOARD
2 V.
BLK
MOTOR HEATER
CONNECTION
CAPACITOR
BLU
ORN
BLK
RED
CCW
AGITATOR
MOTOR
WHT
Q.C. CONNECTOR
DISPENSE
SWITCH
RED
12
RED
GATE SOLENOID
BEVERAGE FAUCET (TYPICAL)
920594
WHT
WHT
WHT
15TD 218