Cornelius Enduro 200 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:Enduro200/250
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1995 -- 2000Ó
IMICORNELIUSREMCORINC g500 REGENCYDRIVE gGLENDALEHEIGHTS, IL 60139--2268
Telephone [phone] Facsimile(800)519--4423
PartNo.92108
January31,1995
Revised:September26,2000
Revision F
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i92108
TABLEOFCONTENTS
Page
MAINTENANCE1...........................................................
DAILY(ORAS REQUIRED)1............................................
WEEKLY(ORAS REQUIRED)1.........................................
MONTHLY1...........................................................
START-UP&OPERATINGINSTRUCTIONS1..............................
CLEANINGINSTRUCTIONS1............................................
DISPENSER2..........................................................
BEVERAGE SYSTEM(IFAPPLICABLE)3.....................................
CLEANING3............................................................
CLEANINGDISPENSINGVALVES 3.....................................
SANITIZING3.........................................................
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............................................
BEVERAGENOTSWEETENOUGH.6....................................
BEVERAGES NOTCOLD(UNITSWITHBUILT--IN COLDPLATE).6..........
SOLENOIDASSEMBLY12................................................
DRAIN13................................................................
WARRANTY14..............................................................
LISTOF FIGURES
FIGURE1.CABINETSECTIONEXPLODEDVIEW7........................
FIGURE2.ELECTRICALBOX ASSEMBLY11...............................
FIGURE3.SOLENOIDASSEMBLY12......................................
FIGURE4.DRAINFORZSTYLEUNITSWITH COLDPLATES 13.............

192108
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 systemifapplicable(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
appropriateflavor.
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 warm100 degreesFpotablewater.
Sanitizing solution -use 1/2 ounce ofhousehold bleachin 1 gallon ofpotablewater.Preparing the sanitizing
solution tothisratiowill createasolution of200 PPM.

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92108
DISPENSER
1.CLEANINGEXTERIORSURFACES
Important: Performthefollowing daily.
A.Removethe cup rest fromdriptray.
B.Washthe driptraywithsoap solution.Rinsewithclean waterand allowsolution torun downthe drain.
C.Washcup restwithsoap solution and rinseinclean water. Install the cup restintothe driptray.
D.Clean all exteriorsurfaceswithsoap solution and rinseinclean water.
2.COLDPLATEINSPECTION BEFORECLEANING
A.Removesplash panel.
B.Removethe plastic cold platecoverto exposethe cold plate.
C.Locate and remove anydebrisfromthe cold plate,draintrough and makecertainthat the drain holes
are notclogged.
D.Reinstall the cold platecover.
E.Reinstall the splash panel inthe reverse orderinwhichitwasremoved.
3.CLEANINGINTERIORSURFACES
CAUTION:When pouring liquidintothehopper,do notexceedtherateof1/2gallon per
minute.
Important: Performthefollowing atleastonceamonth.
A.Remove agitatorassembly.
B.Usingalong handle nylon bristle brush,clean the interiorof the hopper, top,coverand cold platewith
soap solution.The cold platecan be reached bygoing through the ice opening on the hopperbottom.
Makecertaintoreachthe entiresurface of the cold plateincluding the corners.Clean the agitator
assemblywithsoap solution using a nylon brush orasponge.Thoroughlyrinsethe hopper, top cover,
agitatorand cold platesurfaceswithclean potablewater.
C.Removemerchandiserand icechutecoverfromdispenser.
D.Withanylon bristle brush orsponge,clean the inside of the icechute,gasketand coverwithsoap
solution and rinsethoroughlytoremove all tracesofdetergent.
E.Re-assemble agitatorassembly.Takespecialcareto ensurethat the thumbscrewistight.
F.Usingamechanicalspraybottlefilled withsanitizing solution,spraythe entireinteriorand agitator
assembly.Allowto airdry.
G.Re-assembleicechute assembly.
H.Usingamechanicalspraybottlefilled withsanitizing solution,spraythe inside of the icechute.Allowto
airdry.
I. Reinstall merchandiser.

392108
BEVERAGE SYSTEM
(IFAPPLICABLE)
CLEANING
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 warm100 degreesFpotablewater.
Sanitizing solution -Use 1/2 ounce ofhousehold bleachin 1 gallon ofpotablewater.Preparing the sanitizing
solution tothisratiowill provide the required solution of200 PPM.
Cleaning tank-Fill clean,emptytankwithamixture ofmild detergentand five(5)gallonsofwarm120 degreesF
potablewater.
CLEANING DISPENSING VALVES
Referto addendumsupplied withthe unit thatisapplicabletothe manufacturerof the valvesinstalled on the unit.
SANITIZING
IMPORTANT:Onlytrainedand qualified persons should performthese cleaning and sanitizing
procedures.
Sanitizetank systems,Post-Mix and Pre-Mix
1.Remove all the quick disconnectsfromall the tanks.Fill asuitable pail orbucketwithsoap solution.
2.Submerge all disconnects(gasand liquid)inthe soap solution and then clean themusing a nylon bristle
brush.(Do notuseawirebrush).Rinsewithclean water.
3.Preparesanitizing solution and usingamechanicalspraybottle,spraythe disconnects.Allowto airdry.
4.Usingaclean,emptytank,preparefive(5)gallonsof the sanitizing solution.Rinsethe tankdisconnectswith
approximately9 oz.of the sanitizing solution.Closethe tank.
5.Preparecleaning tankbyfilling clean five(5)gallon tankwithamixture ofmild detergentand 120 degreesF
potablewater.
6.Connecta gasdisconnect tothe tankand then applyone of the product tubestothe cleaning tank.Operate
the appropriatevalve until liquid dispensed isfree ofany syrup.
7.Disconnectcleaning tankand hookup sanitizing tanktosyrup line and CO2system.
8.Energize beverage faucetuntil chlorine sanitizing solution isdispensed through the faucet. Flush atleast two
(2)cupsofliquidtoinsurethat the sanitizing solution hasfilled the entirelength of the syrup tubing.
9.Allowsanitizertoremaininlinesforfifteen (15)minutes.
10.Repeat the step above,applying a differentproduct tube eachtime until all tubesarefilled withthe sanitizing
solution.

4
92108
11.Forpost-mix valves,removethe nozzle and syrup diffuserand clean theminamildsoap solution.Rinse
withclean water, then reinstall the nozzle and syrup diffuseron the valve.
12.Forpre-mix valves,disconnectall product tubesfromthe tankofsanitizing solution and then open the valves
to allowthe pressuretoberelieved.Removethe valvesfromthe dispenser,disassemble and wash
thoroughlyinamildsoap solution.
13.Rinsethe partsinclean water,reassemblethe valve and reconnectit tothe dispenser.
14.Discardthe tankofsanitizing solution and reconnect the product(syrup orpre-mix)tanks.Operatethe
valvesuntil all sanitizerhasbeen flushed fromthe systemand onlyproduct(syrup orpre-mix)isflowing.
Sanitize syrup lines,B-I-BSystems
1.Remove all the quick disconnectsfromall the B-I-Bcontainers.
2.Fill asuitable pail orbucketwithsoap solution.
3.Submerge all disconnects(gasand liquid)inthe soap solution and then clean themusing a nylon bristle
brush.(Do notuseawirebrush).Rinsewithclean water.
4.Using a plasticpail,prepare approximatelyfive(5)gallonsofsanitizing solution.
5.Rinsethe B-I-Bdisconnectsinthe sanitizing solution.
6.Sanitizing fittingsmustbe attached to eachB-I-Bdisconnect. If thesefittingsare notavailable, the fittings
fromemptyB-I-Bbags can be cut fromthe bagsand used.Thesefittingsopen the disconnectsothe
sanitizing solution can be drawnthrough the disconnect.
7.Place all the B-I-Bdisconnectsintothe pail ofsanitizing solution.Operate all the valvesuntil the sanitizing
solution isflowing fromthe valve.Allowsanitizertoremaininlinesforfifteen (15)minutes.
8.Removethe nozzle and syrup diffuserfromeachvalve and clean theminasoap solution.Rinsewithclean
waterand reassemblethe nozzle and syrup diffusertothe valve.
9.Removethe sanitizing fittingsfromthe B-I-Bdisconnectsand connect the disconnectstothe appropriate
B-I-Bcontainer.Operatethe valvesuntil all sanitizerhasbeen flushed fromthe systemand syrup isflowing
freely.

592108
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.
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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.

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92108
TroubleProbableCause
BEVERAGENOTSWEETENOUGH.A.Empty syrup tank.
B.Faucetbrixrequiresadjusting.
BEVERAGES NOTCOLD(UNITSWITHBUILT--IN
COLDPLATE).A.Unitstanding withnoicein hopper -- no icein cold platecabinet.
NOTE:Contactyourlocalsyrup orbeverage equipmentdistributorforadditional information and
troubleshooting ofbeverage system.

Part # Corrections/Update Document
Unit Type/Model # Manual #
ED200/250
ICE/BEVERAGE
DISPENSER
92108
Revision 2 8/11/06
Page Item Old
Part
Desc. New Part Desc. Agent Date Notes
8 8 15093 Sink Extension Jls 1/16/03 Use this number for
units manufactured on
and before 11/15/98.
After this date use
620028702. Serial
number cut off: DF
units ZRM1013131, ED
units 62A9841ED343
8 22 30895 Dispense Switch 02070 Dispense Switch
Kit
Jls 1/16/03 Includes actuator
switch, boot, & spacer
(items 14,22,& 91)
8 25 33387 Agitator Motor
120V
629088531
629088782
Kit, Agitator Motor
Replacement
Agitator Motor
Service
SRV 2/1/06 For units prior to serial#
62A0540ED248
For units beginning with
serial #62A0540ED248
9 54 52949 White Lens ED200 Jls 1/16/03 24.81x11.11
Use 52950 for ED250
24.81x15.11
9 57 53290 Hopper Foamed
Assy Non Cold
Plate Unit
SRV 1/6/06 For ED200
9 57 53292 Hopper Foamed
Assy Non Cold
Plate Unit
SRV 1/6/06 For ED250
10 89 71011 4” Caster Leg 70970 4” Black Plastic
Leg
Jls 1/16/03 Sold individually
10 95 71094 Cup-Rest Optifill
(slanted)
Jls 1/16/03 29.1x7.5
10 100 Graphics 92183 Coca-Cola
Graphics ED200
Jls 1/16/03 Must order thru Coke
USA Parts
10 100 Graphics 92184 Coca-Cola
Graphics ED250
Jls 1/16/03 Must order thru Coke
USA Parts
10 100 Graphics 92046 Pepsi Graphics
ED200
Jls 1/16/03 11.083x24.794
10 100 Graphics 92047 Pepsi Graphics
ED250
Jls 1/16/03 15.083x24.794
10 100 Graphics 92079 Generic Graphics
ED200
Jls 1/16/03 11.083x24.794
3 Cups Refreshing
10 100 Graphics 92080 Generic Graphics
ED250
Jls 1/16/03 15.083x24.794
3 Cups Refreshing
10 100 Graphics 92081 Dr. Pepper
Graphics ED200
Jls 1/16/03 11.083x24.794

10 100 Graphics 92082 Dr Pepper
Graphics ED250
Jls 1/16/03 15.083x24.794
10 100 Graphics 92085 7-Up Graphics
ED200
Jls 1/16/03 11.083x24.794
10 100 Graphics 92086 7-Up Graphics
ED250
Jls 1/16/03 15.083x24.794
10 100 Graphics 92083 RC Cola Graphics
ED200
Jls 1/16/03 11.083x24.794
10 100 Graphics 92084 RC Cola Graphics
ED250
Jls 1/17/03 15.083x24.794
11 10 31763 Agitator Timer
120V
629087448 Agitator Timer Kit
120V
Jls 1/16/03
11 10 32828 Agitator Timer
220-240V
629087451 Agitator Timer Kit
220-240V
Jls 1/16/03
12 70485 Gate Slide Spring Jls 1/16/03 Attaches to gate lift
arm on Solenoid Assy.
Need qty 2
n/a n/a 91978 Coca Cola Side
Decal ED200/250
Jls 1/16/03 Must order thru Coke
USA Parts
n/a n/a 91974 Pepsi Side Decal
ED200/250
Jls 1/16/03 20.97x14.75 Cup
Splash
n/a n/a 08052 Splashguard Kit Jls 1/16/03 Two clear side guards
n/a n/a 33666 Low Ice Indicator
Light
Jls 1/16/03 Red light
n/a n/a 31001 Thermostat Jls 1/16/03 For low light indicator
n/a n/a 629080104 Kit Sink to Z Style
ED2XX
Jls 1/16/03 Z = No drip tray or cup-
rest. Kit removes drip
tray/cup-rest. Allows
unit to sit on counter
with built in tray and
cup-rest.
n/a n/a 629080304 Kit Z Style to Sink
ED2XX GRAY
Jls 1/16/03 Z = No drip tray or cup-
rest. Kit adds drip tray
and cup-rest to unit.
n/a n/a 629080303 Kit Z Style to Sink
ED2XX BLACK
Jls 1/16/03 Z = No drip tray or cup-
rest. Kit adds drip tray
and cup-rest to unit.
n/a n/a 32977 Keylock Switch
w/Keys
Jls 1/17/03
n/a n/a 70739 Key Jls 1/17/03 Key is marked D001