Cornelius Enduro-200/250 User manual

INSTALLATION MANUAL
ICE/BEVERAGE DISPENSER
MODEL: ENDURO-200/250
Release Date: March 24, 2004
Publication Number: 92181INS
Revision Date: August 3, 2010
Revision: F
Visit the IMI Cornelius web site at www.cornelius.com for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possi-
ble contingency in the installation, operation or maintenance of this equipment. This manual assumes that the per-
son(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic,
and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and
construction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is sub-
ject to all of the restrictions and limitations contained in the Commercial Warranty.
Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained per-
sons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, oper-
ating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con-
tact:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
Printed in U.S.A.

TABLE OF CONTENTS
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
installation instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
ADJUST WATER -TO-SYRUP RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Gate Restrictor Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 1 - © 2006-2010, IMI Cornelius Inc.
SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
Safety Overview
• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or
laminated cards).
• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before
operating this unit.
Recognition
DIFFERENT TYPES OF ALERTS
!
DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
!
WARNING:
Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment
damage.
CAUTION:
!
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment
damage.
SAFETY TIPS
• Carefully read and follow all safety messages in this manual and safety signs on the unit.
• Keep safety signs in good condition and replace missing or damaged items.
• Learn how to operate the unit and how to use the controls properly.
• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or
infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND
PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN
SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
!

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 2 - Publication Number: 92181INS
SAFETY PRECAUTIONS
This unit has been specifically designed to provide protection against personal injury. To ensure continued protection
observe the following:
!
WARNING:
Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify
all of the power is off to the unit before any work is performed.
Failure to disconnect the power could result in serious injury, death or equipment damage.
CAUTION:
!
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
CAUTION:
!
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained
from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.
CO2(CARBON DIOXIDE) WARNING
!
DANGER:
CO2displaces oxygen. Strict attention MUST be observed in the prevention of CO2gas leaks in the entire CO2and
soft drink system. If a CO2gas leak is suspected, particularly in a small area, IMMEDIATELY ventilate the
contaminated area before attempting to repair the leak. Personnel exposed to high concentrations of CO2gas
experience tremors which are followed rapidly by loss of consciousness and DEATH.
MOUNTING IN OR ON ACOUNTER
!
WARNING:
When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 580 lbs. to
insure adequate support for the unit. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR
EQUIPMENT DAMAGE.
NOTE: Many units incorporate the use of additional equipment such as icemakers. When any addition
equipment is used you must check with the equipment manufacturer to determine the addi-
tional weight the counter will need to support to ensure a safe installation.

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 3 - © 2006-2010, IMI Cornelius Inc.
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) ED250 (Ice Only)
B (Beverage Faucets) B (Beverage Faucets)
C (Cold Plate) C (Cold Plate)
Z (No drip tray) Z (No drip tray)
N (No Lid) N (No Lid)
F (Flavor) F (Flavor)
Ice storage 200 pounds 250 pounds
Maximum No. of Beverage
Faucets Available 10 10
Cold Plate (Built-In) Yes, On BC Model Only Yes, On BC Model Only
Electrical 120/1/60, 3.5 Amps 220--240/1/50--60, 2.0
Amps 120/1/60, 3.5 Amps 220--240/1/50--60, 2.0 Amps
Dimensions 30 in. Wide X 30-11/16 in. Deep X 35-5/8in.
High 30 in. Wide X 30-11/16 in. Deep X 39-5/8 in. High
Z Models 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

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 4 - Publication Number: 92181INS
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 4). 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 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 5, 6, 7, or 8) 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).
!
WARNING:
This unit must be grounded to avoid possible fatal electrical shock or serious injury to the operator. The unit power
cord is equipped with a three prong plug. If a Three-hole (grounded) outlet is not available, use an approved method
to ground the unit. Failure to comply could result in serious injury, death or damage to the equipment.
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 must be provided by the equipment Installer.
7. Maximum and minimum ambient temperature rating for correct operation is 40oto 105oF.
8. The dispenser is not designed for a wash down environment and must not be placed in an area where a water
jet could be used.
9. The unit has to be placed in a horizontal position.
10. If the supply cord is damaged, it must be replaced by the manufacturer, it’s service agent or similarly qualified
person in order to avoid a hazard.

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 5 - © 2006-2010, IMI Cornelius Inc.
ADJUST WATER -TO-SYRUP RATIO
Figure 1.Ratio Cup
1. Remove valve cover and install syrup separator over the diffuser and through the nozzle.
2. Hold cup under valve and dispenser beverage for a specific time (i.e. 2 seconds)
NOTE: Water and syrup must be cold before checking ratios.
3. Adjust carbonated water flow to the desired rate (such as 90 to 100 ml (3 to 3.75 oz.) per second). Turn the
flow adjuster 1/4 of a turn at a time and recheck the flow. To increase reading turn clockwise.
4. Set a syrup flow adjuster to get the desired ratio.
5. Test the valve and adjust until a consistent ratio is delivered three consecutive times.
6. Repeat procedure for other valves.
GATE RESTRICTOR PLATE
CAUTION:
!
Disconnect power to dispenser before installing, removing or adjusting restrictor. See Safety Section of this manual.
Figure 2. Gate Restrictor Plate
Separator
Water-To-Syrup Ratio Cup

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 6 - Publication Number: 92181INS
ADJUSTMENT
This plate may be adjusted as shown to reduce or increase the dispensing rate of ice, especially desirable when
using glasses or other containers with small openings. Adjustment can be made by sliding up or down with nuts
loosened, to obtain the desired amount of restriction.
NOTE: Recommended counter opening size 9” X 12” for utilities and beverage tubing. Opening can be
located anywhere within the shaded area.
Figure 3. Mounting Template

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 7 - © 2006-2010, IMI Cornelius Inc.
Figure 4. Drip Tray Drain Assembly

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 8 - Publication Number: 92181INS
Figure 5. Flow Diagram (Unit with Six Faucets)

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Publication Number: 92181INS - 9 - © 2006-2010, IMI Cornelius Inc.
Figure 6. Flow Diagram (Unit with Eight Faucets)

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 10 - Publication Number: 92181INS
Figure 7. Flow Diagram (Unit with Ten Faucets)

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 11 - © 2006-2010, IMI Cornelius Inc.
Figure 8. Flow Diagram (“B” Unit with Eight Beverage Faucets)

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 12 - Publication Number: 92181INS
Figure 9. Wiring Diagram (115 Volts Unit)

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Figure 10. Schematic (115 Volt Unit)

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 14 - Publication Number: 92181INS
Figure 11. Wiring Diagram (220-240 Volt Unit)

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 15 - © 2006-2010, IMI Cornelius Inc.
Figure 12. Schematic (220-240 Volt Unit)

Ice/Beverage Dispenser installation Manual
© 2006-2010, IMI Cornelius Inc. - 16 - Publication Number: 92181INS
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 CO2system, stop dispensing, shut off the
CO2supply, 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 contains ice. If the
unit does not dispense, check the following chart under the appropriate symptoms to aid in locating the defect.
Trouble Probable Cause
BLOWN FUSE OR CIRCUIT BREAKER.
A. Short circuit in wiring.
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.
A. Stuck or bent depressor plate (does not release switch).
B. Defective dispensing switch.
C. Improper switch installation.
SLUSHY ICE. WATER IN HOPPER.
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. A. No 24 volt power to faucets.
B. No CO2 pressure.
BEVERAGES TOO SWEET.
A. Carbonator not working.
B. No CO2 pressure in carbonator.
C. Faucet brix requires adjusting.
BEVERAGE NOT SWEET ENOUGH. A. Empty syrup tank.
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 CO2pressure.
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

Ice/Beverage Dispenser installation Manual
Publication Number: 92181INS - 17 - © 2006-2010, IMI Cornelius Inc.
Contact your local syrup or beverage equipment distributor for additional information and troubleshooting of
beverage system.
FLAVOR DISPENSES FOR MORE THAN 1 SEC.
A. Dip switch settings on control board incorrect.
B. PC board defective.
C. Defective flow control.
FLAVOR DISPENSES MORE THAN .5 OZ.
A. Dip switch settings on control board incorrect.
B. Flow control incorrectly set.
C. PC board defective.
D. Defective flow control.