Cornelius Enduro 150 8 Valve User manual

IMPORTANT:
TOTHEINSTALLER.
Itistheresponsibilityof
theInstallertoensurethat
thewatersupplytothe
dispensing equipmentis
providedwith protection
againstbackflowby anair
gapas definedin
ANSI/ASMEA112.1.2-1979;
oranapprovedvacuum
breakerorothersuch
method as provedeffective
bytest.
Waterpipe connections
and fixtures directly
connectedtoapotable
watersupply shall be
sized, installed,and
maintainedaccording to
Federal, State,and Local
Codes.
Operator’sManual
ICE/BEVERAGEDISPENSER
Model:Enduro-150 8 Valve
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1997-2000Ó
IMICORNELIUSREMCORINC g500 REGENCYDRIVE gGLENDALEHEIGHTS, IL 60139--2268
Telephone [phone] Facsimile(800)519--4423
PartNo.620904402
February,1997
Revised:August, 2000
Revision C
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i620904402
TABLEOFCONTENTS
Page
MAINTENANCE1...........................................................
DAILY(ORAS REQUIRED)1.............................................
WEEKLY(ORAS REQUIRED)1..........................................
MONTHLY1............................................................
START-UP&OPERATINGINSTRUCTIONS1..................................
CLEANINGINSTRUCTIONS1................................................
DISPENSER1..........................................................
BEVERAGE SYSTEM(IFAPPLICABLE)2.................................
TROUBLESHOOTING5......................................................
BLOWNFUSE OR CIRCUITBREAKER.5..................................
GATEDOES NOTOPEN.AGITATOR DOES NOT TURN.5..................
GATEDOES NOTOPENORIS SLUGGISH.AGITATORTURNS.5..........
ICEDISPENSES CONTINUOUSLY.5......................................
SLUSHYICE.WATERIN HOPPER.5.....................................
BEVERAGES DONOTDISPENSE.5......................................
BEVERAGES TOO SWEET.5............................................
BEVERAGES NOTSWEETENOUGH.6...................................
BEVERAGES NOTCOLD(UNITSWITHBUILT-IN COLDPLATE).6...........
PARTSLIST/EXPLODEDVIEW7............................................
CABINETSECTIONPARTSLIST9.......................................
CABINETSECTIONPARTSLIST(CONT’D)10..............................
CABINETSECTIONPARTSLIST(CONT’D)11..............................
ELECTRICALBOX ASSEMBLY12.........................................
SOLENOIDASSEMBLY13................................................
COLDPLATEDRAINFORZSTYLEUNITS14...............................
WARRANTY15..............................................................
LISTOF FIGURES
Page
FIGURE1.CABINETSECTIONEXPLODEDVIEW8........................
FIGURE2.ELECTRICALBOX ASSEMBLY12...............................
FIGURE3.SOLENOIDASSEMBLY13......................................
FIGURE4.COLDPLATEDRAINFORZSTYLEUNITS14....................

1620904402
MAINTENANCE
The following dispensermaintenanceshould be performed at the intervalsindicated:
DAILY(orasrequired)
Removeforeign materialfromvending area driptrayto preventdrain blockage.
WEEKLY(orasrequired)
Clean vending area.Check forproperwaterdrainage fromthe vending area driptray.
MONTHLY
Clean and sanitizethe hopperinteriorand beverage system,ifapplicable(see CLEANINGINSTRUCTIONS).
START-UP&OPERATINGINSTRUCTIONS
Fill the hopperwithice.Dispenseseveral large cupsofice(approximately20 to30secondstotaldispensing time)
to allowicetofill the cold platecabinet. Add icetothe hopperasnecessarytorefill and replacethe lid.Allow10 to
15 minutesforthe cold platetocooldown.Repeat thisprocedurewheneverthe dispenserhasrun outofice.Start
up the beverage systemand adjust faucetstothe properbrix.Contactyourlocalsyrup distributorforcomplete
information on the beverage system.
In normaloperation,pushing the ice dispensermechanismwill causeicetoflowfromthe icechute. Iceflow will
continue until the dispensermechanismisreleased.Dispensing ofanyfaucetwill provide beverage of the ap-
propriateflavor.
CAUTION:Use caution toavoidspilling ice whenfilling dispenser.Cleanupimmediately any
spilledice fromfilling oroperating theunit.To preventcontamination ofice,thelidmustbe
installedontheunitatall times.
If the dispenserfailsto dispenseice orbeverage see troubleshooting guide.
CLEANINGINSTRUCTIONS
WARNING:DisconnectPowerBeforeCleaning!Do notuse metalscrapers,sharp objectsor
abrasives on theice storagehopper,top coverand the agitatordisk,as damagemay result.
Do notuse solventsorothercleaning agents,as they may attack theplasticmaterial.
Soap solution -Useamixture ofmild detergentand warm(100 degreesF)potablewater.
Sanitizing solution -Use 1/2 ounce ofhousehold bleachin 1 gallon ofpotablewater.Preparing the sanitizing
solution tothisratiowill createasolution of200 PPM.
DISPENSER
1.CLEANINGEXTERIORSURFACES
Important: Performthefollowing daily.
A.Removethe cup rest fromdriptray.
B.Washthe driptraywithsoap solution.Rinsewithclean waterand allowsolution torun downthe drain.

2
620904402
C.Washcup restwithsoap solution and rinseinclean water. Install the cup restintothe driptray.
D.Clean all exteriorsurfaceswithsoap solution and rinseinclean water.
2.CLEANINGINTERIORSURFACES
CAUTION:When pouring liquidintothehopper,do notexceedtherateof1/2gallon
perminute.
Important: Performthefollowing atleastonceamonth.
A.Remove agitatorassembly.
B.Using a nylon bristle brush orsponge,clean the interiorof the hopper, top coverand agitatorassembly
withsoap solution.Thoroughlyrinsethe hopper,coverand agitatorsurfaceswithclean potablewater.
C.Reassemble agitatorassembly.Takespecialcareto ensurethat the thumbscrewistight.
D.Usingamechanicalspraybottlefilled withsanitizing solution,spraythe entireinteriorand agitatoras-
sembly.Allowto airdry.
E.Removemerchandiserand icechutecoverfromunit.
F.Withanylon bristle brush orsponge,clean the inside of the icechute,gasket, and coverwithsoap solu-
tion and rinsethoroughlytoremove all tracesofdetergent.
G.Reassembleicechute assembly.
H.Usingamechanicalspraybottlefilled withsanitizing solution,spraythe inside of the icechute.Allowto
airdry.
I. Reinstall merchandiser.
BEVERAGE SYSTEM(IFAPPLICABLE)
WARNING:DisconnectPowerBeforeCleaning!Do notuse metalscrapers,sharp objects
orabrasives on theice storagehopper,top coverand the agitatordisk,as damagemay
result.Do notuse solventsorothercleaning agents,as they may attack theplasticmaterial.
Soap solution -Useamixture ofmild detergentand warm(100 degreesF)potablewater.
Sanitizing solution -Use 1/2 ounce ofhousehold bleachin 1 gallon ofpotablewater.Preparing the sanitizing
solution tothisratio, the required solution of200 PPMwill be obtained.
Cleaning tank-Fill clean,emptytankwithamixture ofmild detergentand five(5)gallonsofwarm
potablewater (120 degreesF).
CAUTION:When pouring liquidintothehopper,do notexceedtherateof1/2gallon
perminute.
1.COLDPLATE
A.Removesplash panel.
B.Remove ormovethe plastic cold platecoverto exposethe cold plate.
C.Locate and remove anydebrisfromthe draintrough.Check that the drain holesare notclogged.
D.Poursmall amountofsoap solution through cold plate openingsin hopper.

3620904402
E.Usingacloth,wash downthe surfacesof the cold plate and plastic coverwithsoap solution.
F. Install and properlyposition the coveron the cold plate.
G. Install the splash panel inthe reverse orderitwasremoved.
H.Rinsecold platesurface bypouring potablewaterthrough hopperopenings.
2.DISPENSINGVALVES
Referto addendumsupplied withthe unit thatisapplicabletothe manufacturerof the valvesinstalled
on the unit.
3.PRODUCT TUBING
Onlytrainedand qualified persons should performthese cleaning and sanitizing procedures.
A.Sanitizetank systems,Post-Mix and Pre-Mix
a.Remove all the quick disconnectsfromall the tanks.Fill asuitable pail orbucketwith
soap solution.
b.Submerge all disconnects(gasand liquid)inthe soap solution and then clean themusing a nylon
bristle brush.(Do notuseawirebrush).Rinsewithclean water.
c.Preparesanitizing solution and usingamechanicalspraybottle,spraythe disconnects.
Allowto airdry.
d.Usingaclean,emptytank,preparefive(5)gallonsof the sanitizing solution.Rinsethe tankdiscon-
nectswith approximately9 oz.of the sanitizing solution.Closethe tank.
e.Preparecleaning tankbyfilling clean five(5)gallon tankwithamixture ofmild detergentand pota-
blewater (120_F).
f. Connecta gasdisconnect tothe tankand then applyone of the product tubestothe cleaning tank.
Operatethe appropriatevalve until liquid dispensed isfree ofany syrup.
g.Disconnectcleaning tankand hookup sanitizing tanktosyrup line and CO2system.
h.Energize beverage faucetuntil chlorine sanitizing solution isdispensed through the faucet. Flush
atleast two(2)cupsofliquidto ensurethat the sanitizing solution hasfilled the entirelength of the
syrup tubing.
i.Allowsanitizertoremaininlinesforfifteen (15)minutes.
j.Repeat the step above,applying a differentproduct tube eachtime until all tubesarefilled withthe
sanitizing solution.
k.Forpost-mix valves,removethe nozzle and syrup diffuserand clean theminamildsoap solution.
Rinsewithclean waterand reassemblethe nozzle and syrup diffusertothe valve.
l.Forpre-mix valves,disconnectall product tubesfromthe tankofsanitizing solution and then open
the valvesto allowthe pressuretoberelieved.Removethe valvesfromthe dispenser,disas-
semble and washthoroughlyinamildsoap solution.
m.Rinsethe partsinclean water,reassemblethe valve and reconnectit tothe dispenser.
n.Discardthe tankofsanitizing solution and reconnect the product(syrup orpre-mix)tanks.Operate
the valvesuntil all sanitizerhasbeen flushed fromthe systemand onlyproduct(syrup orpre-mix)
isflowing.
B.Sanitize syrup lines,B-I-BSystems
a.Remove all the quick disconnectsfromall the B-I-Bcontainers.
b.Fill asuitable pail orbucketwithsoap solution.

4
620904402
c.Submerge all disconnects(gasand liquid)inthe soap solution and then clean themusing a nylon
bristle brush.(Do notuseawirebrush).Rinsewithclean water.
d.Using a plasticpail,prepare approximatelyfive(5)gallonsofsanitizing solution.
e.Rinsethe B-I-Bdisconnectsinthe sanitizing solution.
f. Sanitizing fittingsmustbe attached to eachB-I-Bdisconnect. If thesefittingsare notavailable, the
fittingsfromemptyB-I-Bbags can be cut fromthe bagsand used.Thesefittingsopen the discon-
nectsothe sanitizing solution can be drawnthrough the disconnect.
g.Place all the B-I-Bdisconnectsintothe pail ofsanitizing solution.Operate all the valvesuntil the
sanitizing solution isflowing fromthe valve.Allowsanitizertoremaininlinesforfifteen
(15)minutes.
h.Removethe nozzle and syrup diffuserfromeachvalve and clean theminasoap solution.Rinse
withclean waterand reassemblethe nozzle and syrup diffusertothe valve.
i.Removethe sanitizing fittingsfromthe B-I-Bdisconnectsand connect the disconnectstothe ap-
propriateB-I-Bcontainer.Operatethe valvesuntil all sanitizerhasbeen flushed fromthe system
and syrup isflowing freely.

5620904402
WARNING:Ifrepairs areto bemadetoaproductsystem,remove quick disconnectsfrom
the applicableproduct tank,thenrelieve the systempressurebeforeproceeding. Ifrepairs
areto bemadetotheCO2system,stop dispensing,shutoff theCO2supply,thenrelieve the
systempressurebeforeproceeding. Ifrepairs areto bemadetotherefrigeration system,make sure
electricalpowerisdisconnectedfromtheunit.
T
R
O
U
B
L
E
S
H
O
O
T
I
N
G
IMPORTANT:Onlyqualified personnelshouldservice internalcomponentsorelectricalwiring.
Shouldyourunit fail to operateproperly,check that thereispowertotheunitand that thehoppercon-
tainsice. If theunitdoes notdispense,check thefollowing chartunderthe appropriate symptomstoaid
inlocating thedefect.
TroubleProbableCause
BLOWNFUSE OR CIRCUITBREAKER.A.Shortcircuitinwiring.
B.Defective gatesolenoid.
C.Defective agitatormotor.
GATEDOES NOTOPEN.AGITATOR DOES
NOT TURN.A.No power.
B.Bentdepressorplate(doesnotactuateswitch).
C.Defective dispensing switch.
GATEDOES NOTOPENORIS SLUGGISH.
AGITATORTURNS.A.Defective gatesolenoid.
B.Excessive pressure againstgateslide.
C.Defectiverectifier.
ICEDISPENSES CONTINUOUSLY.A.Stuck orbentdepressorplate(doesnot
releaseswitch).
B.Defective dispensing switch.
C. Improperswitchinstallation.
SLUSHYICE.WATERIN HOPPER.A.Blocked drain.
B.Unitnotlevel.
C.Poorice qualitydue towaterqualityor
icemakerproblems.
D. Improperuse of flaked ice.
BEVERAGES DONOTDISPENSE.A.No24voltpowertofaucets.
B.NoCO2pressure.
BEVERAGES TOO SWEET.A.Carbonatornotworking.
B.NoCO2pressureincarbonator.
C.Faucetbrixrequiresadjusting.

6
620904402
TroubleProbableCause
BEVERAGES NOTSWEETENOUGH.A.Empty syrup tank.
B.Faucetbrixrequiresadjusting.
BEVERAGES NOTCOLD(UNITSWITHBUILT-IN
COLDPLATE).A.Unitstanding withnoicein hopper -- no icein cold platecabinet.
Contactyourlocalsyrup orbeverage equipmentdistributorforadditional information and troubleshoot-
ing ofbeverage system.

7620904402
PARTSLIST/EXPLODEDVIEW

8620904402
63
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96
87

9620904402
CABINETSECTIONPARTSLIST
Index
No.PartNo.Name
1 21491 GateSlide
2 22081RGateRestrictor
3NotUsed
4**29303RPlate,MotorMounting
5 15346 AgitatorAssy
6 620021201 Cover,RearWrapper
7 629080213 LowerPanelAssy (ForDripTray)
629080215 LowerPanelAssy (ZModel)
8 620020101 SinkExtension Assy,DripTray
9NotUsed
10 620020001 Wrapper
11 NotUsed
12 ContactSalesPanelColdPlate/FaucetAssy
13 27107 RetainerLever, IceDispenser
14 10145 PinSinkExt.
15 31007 SwitchBoot
16 50335 Insulation,ColdPlateDrain
17 50767 HeycoSnap Bushing
18 NotUsed
19 15087 Retainer,Agitator
20 NotUsed
21 30794 MotorHeater,115 Volt
32826 MotorHeater,220-240 Volt
22 30895 DispenseSwitch
23 53011 Elbow ColdPlateDrain
24 31622 Bulb-Daylight18”
25 **620307901 AgitatorMotor,120 Volt
**620307902 AgitatorMotor,220-240 Volt
26 32954 SolenoidAssembly,115 Volt
33409 SolenoidAssembly,220-240 Volt
27 NotUsed
28 NotUsed
29 NotUsed
30 620302001 ElectricalBoxAssy,120 Volt(B&BCModels)
620303301 ElectricalBoxAssy,120 Volt(IceOnly)
620302301 ElectricalBoxAssy,220-240 Volt(B&BCModels)
620303302 ElectricalBoxAssy,220-240 Volt(IceOnly)
31 NotUsed
32 620022201 Bracket, MotorMounting
33 NotUsed
34 71010 Washer,No.8

10620904402
CABINETSECTIONPARTSLIST(CONT’D)
35 NotUsed
36 NotUsed
37 NotUsed
38 NotUsed
39 620019701 Hinge,Gusset
40 NotUsed
41 NotUsed
42 NotUsed
43 NotUsed
44 **51859 Seal,AgitatorMotorShaft
45 NotUsed
46 51891 Gasket, Gate
47 ***51908 Plug (120VModelsOnly)
48 **52876 Gasket, MotorShaft
49 620500901 IceChute
50 53168 IceChuteCover
51 53241 Access Cover (ColdPlateModelsOnly)
52 53227 AgitatorDisk
53 ContactSalesMerchandiser,Black
ContactSalesMerchandiser,Gray
620024118 Merchandiser,S.S.
620024117 Merchandiser,S.S.(ForLid and Straw Holder)
620024116 Merchandiser,S.S.(ForMedallion)
620024115 Merchandiser,S.S.(ForLowIce Light)
54 620502801 Lens,Merchandiser
55 620502701 Foamed SinkAssy,Black
620502702 Foamed SinkAssy,Gray
56 52879 Lid,Dispenser,Black
53019 Lid,Dispenser,Gray
57 52872 HopperAssy
58 620021901 Baffle
59 52967 Plug,Plastic
60 52972 Tab Retaining
61 53236 Cover (ColdPlateModelsOnly)
62 70016 HexNut, No.10-32 S.S.
63 70017 HexNut, No.10-32 Nylon InsertLocknut
64 **70018 HexNut, 1/4-20 Keps
65 NotUsed
66 **70048 Washer, .255 I.D.
67 70056 Washer,No.10, .219 I.D.

11 620904402
CABINETSECTIONPARTSLIST(CONT’D)
68 70067 Washer, .218 I.D.
69 70076 HexNut, No.8-32
70 70104 NutsertNo.8-32
71 ContactSalesGraphics
72 70171 Machine Screw,Phil Truss Hd,No.8-32 By3/8-In.Long
73 70178 Machine Screw,Phil Truss Hd,No.8-32 By1/2-In.Long
74 70204 SheetMetalScrew,Phil Truss Hd,No.8By1/2-In.Long
75 620503401 Spacer,Cabinet
76 51334 AdhesiveTape
77 15500 Dispense Lever,Short(Cup Activated)
15488 Dispense Lever,Long (Cup Activated)
15501 Push Lever (IceDispense)
78 NotUsed
79 70260 Machine Screw,Phil RdHd,1/4-20 By1-In.Long
80 70320 Pop Rivet, 1/8
81 70341 Spring,HopperGateSlide
82 620701601 Thread Forming Screw,Phil Pan hd,No.10-16 By1/2-In.Long
83 70478R Clip,PushOn
84 70555 Machine Screw,Phil Truss Hd,No.8-32 By3 1/4-In.Long
85 70750 HoseClamp,Worn
86 71006 Machine Screw,Phil Truss Hd,No.8-32 By2 1/4-In.Long
87 53299 Clip,Black
88 70959 HexNutsert, No.8-32
89 70970 Leg,Black
90 70992 Receptacle,1/4Turn
91 **70993 Retainer,1/4Turn
92 **70994 Stud Wing Hd,1/4Turn
93 70847 Spacer,DispenseSwitch
94 70456 3/16 Pop Rivet
95 620700301 Cup Rest
96 71089 ShoulderScrew,No.8-32
*97 51288 Adapter,1”Barbx3/4M.P.T.(ForDripTrayDrain)
*98 50952 Adapter,3/4socx3/4F.P.T.(ForDripTrayDrain)
*99 620702201 ColdPlateCleaning Brush
NOTES:*NOTSHOWN
**PARTSINCLUDEDIN AGITATORMOTOR KIT.
***FOR220-240VMODELS,51908 PLUGREPLACED BY620303001
PUSH-BUTTONSWITCH ACTUATOR AND 620303002 SWITCH BLOCK.

12620904402
1
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16
7
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17
18
RIGHTSIDE
L2
L1
COM
COMNO
NO
NC
NC
FRONT
2
FIGURE2.ELECTRICALBOXASSEMBLY EXPLODEDVIEW
ELECTRICALBOXASSEMBLY
Item
No.PartNo.Name
1 620019001 ElectricalBox
2 620019101 ReflectorPanel
3NotUsed
4 30514 Clamp,Capacitor,120 Volt
620308102 Clamp,Capacitor,220-240 Volt
5 30774 Capacitor,120 Volt
620308101 Capacitor,220-240 Volt
6NotUsed
7 31107 TerminalBoard
8NotUsed
9 31620 Starter
10 31621 Ballast, 120 Volt
33662 Ballast, 220-240 Volt
11 31763 Timer,RepeatCycle,120 Volt
32828 Timer,RepearCycle,220-240 Volt
12 620302201 Socket, Starter
13 32682 Transformer,120 Volt
32829RTransformer,220-240 Volt
14 620302101 Lamp-holder
15 32958 Rectifier,10A,. Body
16 620304601 Varistor,220-240 Volt
17 620307301 Filter,220-240 Volt
18 32244 TermiinalStrip,220-240 Volt

13 620904402
SOLENOID ASSEMBLY
10
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11
15
7
4
1
3
5
5
2
8
6
14
FIGURE3.SOLENOID ASSEMBLY
Item
No.PartNo.Name
1 28173 Arm,Gate Lift
2 50754 Bearing,GateArm
3 32957 Solenoid,120 Volt
33397 Solenoid,220-240 Volt
4 28172 Plate,SolenoidMounting
5 50752 Isolator
6 70015 HexNut, No.10-32
7 51689 Locktite
8 70162 Screw,No.8-32 By1/4-In.Long
9 50705 TieCable
10 70165 Screw,No.8-32 By5/8-In.Long
11 71007 Spring,SolenoidArm
12 51348 Spacer
13 70067 Washer, .218 I.D.By.875 O.D.
14 70057 Lockwasher,No.10
15 70052 Flatwasher,No.8

14620904402
DRAIN
1
1
1
1
2
3
3
4
TOCOLDPLATE
DRAINELBOW
1
TOCOLDPLATE
DRAINELBOW
FIGURE4.COLDPLATEDRAINFORZSTYLEUNITS
Item
No.PartNo.Name
1 70750 HoseClamp
2 53170 DrainTube
3 51280 Elbow
4 53293 Coupler

15 620904402
IMICORNELIUSINC.
ONECORNELIUS PLACE
ANOKA,MN.55303--6234
TELEPHONE [phone]
FACSIMILE (612)422--3232
WARRANTY
IMICorneliusInc.and RemcorProductsCompany warrant thatall equipmentand partsarefree fromdefectsin
materialand workmanship undernormaluse and service.Fora copy ofthewarrantyapplicableto your
Corneliusand orRemcorproduct,in yourcountry,pleasewrite,fax ortelephonetheIMICorneliusoffice near-
estyou.Pleaseprovidethe equipment modelnumberand thedateofpurchase.
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IMICORNELIUSINC.