Cornelius Enduro ED-250 BCP User manual

Operator’s Manual
ENDURO ICE/BEVERAGE DISPENSER
Model: ED-250 BCP
IMI CORNELIUS INC; 2005--2009©
www.cornelius.com
Part No. 620916502OPR
June 7, 1999
Revised: April 15, 2009
Revision: B
Control Code: B
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment

Enduro Ice/Beverage Dispenser Operator’s Manual
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TABLE OF CONTENTS
Page
START--UP AND OPERATING INSTRUCTIONS 2...............................
CONTROLS AND ELECTRICAL 2.........................................
PORTION CONTROL PANEL OPERATIONS 3..............................
ICE PORTION CONTROL SETUP AND ADJUSTMENT PROCEDURE 3.......
MAINTENANCE 5...........................................................
DAILY (OR AS REQUIRED) 5.............................................
WEEKLY (OR AS REQUIRED) 5..........................................
MONTHLY 5............................................................
CLEANING INSTRUCTIONS 5............................................
DISPENSER 5..........................................................
BEVERAGE SYSTEM 7......................................................
CLEANING 7............................................................
CLEANING DISPENSING VALVES 7.......................................
SANITIZING 7..........................................................
TROUBLESHOOTING 9......................................................
WARRANTY 11..............................................................

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SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
CAUTION
DANGER
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.
Safety signs with signal word DANGER or WARNING
are typically near specific hazards. WARNING
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety mes-
sages in this manual.
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to
use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2(Carbon Dioxide) Warning
CO2Displaces Oxygen. Strict Attention must be observed in the prevention of CO2(carbon dioxide)
gas 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 ex-
posed to high concentration of CO2gas will experience tremors which are followed rapidly by loss of
consciousness and suffocation.
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from the
plain and carbonated water systems. A freezing ambient temperature will cause residual water remain-
ing inside the Unit to freeze resulting in damage to internal components of the Unit.
Shipping, Storing, Or Relocating Unit

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REMOVABLE STRAW
HOLDER PANEL
LID/STRAW
HOLDER
BEVERAGE FAUCET
ON/OFF SWITCH
ICE PORTION
CONTROL MODULE
MANUAL/AUTO ICE
TOGGLE SWITCH
MANUAL ICE DISPENSE
RED PUSH BUTTON SWITCH
DRIP TRAY
CUP REST
LOWER ACCESS
PANEL
BEVERAGE FAUCETS (8)
ICE AGITATOR
RETAINER
ICE BIN COVER
FIGURE 1. PARTS IDENTIFICATION

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START--UP AND OPERATING INSTRUCTIONS
Fill the hopper with ice and replace the lid. Allow 10 to 15 minutes for the cold plate to cool down. Repeat this pro-
cedure whenever the dispenser has been standing overnight or other long periods without ice use. Start up the
beverage system and adjust faucets to the proper brix. Contact your local syrup distributor for complete informa-
tion on the beverage system.
To dispense ice, hold cup under ice chute and press the appropriate size button on the ice portion control located
above the ice chute. An extra ice portion may be obtained by pressing the increase key before pressing the button.
For beverage dispensing, place a cup on the cup rest against the faucet lever of the desired flavor. Beverage is dis-
pensed automatically, filling the cup and shutting off. A delay feature is provided in the faucet controller to “top--off”
the drink after shut off.
Maximum and minimum ambient temperature rating for correct operation 40 to 105dF.
CAUTION: Use caution to avoid spilling ice when filling dispenser. Clean up
immediately any spilled ice from filling or operating the unit. To prevent
contamination of ice, the lid must be installed at the unit at all times.
CONTROLS AND ELECTRICAL
Portion Control Panel
The portion control panel on the Pro ED Fast Gate has several functions including dispensing 4 programmed ice
portions for 4 cup sizes, programming, and cleaning. The portion control panel and its functionality are described
in the following illustration:
Press for extra
ice, then press
cup size
LIGHT
Indicates mode of
operation or amount
of adjustment
DECREASE CUP SIZE INCREASE
Small, Medium, Large or X--Large Cup Size

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PORTION CONTROL PANEL OPERATIONS
Light Color Explanation Actions That Can Be Taken
Green Normal Operation
Press andy CUP SIZE for portioned
ice.
-- o r --
Press INCREASE and then CUP
SIZE for extra ice.
Green --
flashing
Normal Operation Chute Refil-
ling
Wait until chute has refilled and press
desired CUP SIZE again.
Red then
Yellow Clean Mode
To enter Clean Mode simultaneously
press INCREASE and DECREASE.
Press any CUP SIZE to empty chute,
then remove chute for cleaning.
When chute is replaced, unit automat-
ically returns to normal operation after
one minute, or INCREASE and DE-
CREASE can simultaneously pressed
3times.
ICE PORTION CONTROL SETUP AND ADJUSTMENT PROCEDURE
Light Color Explanation Actions That Can Be Taken
Step 1. Fill the Ice
Chute Yellow Flashing Chute Agitation Refill Time
To enter Agitation Adjustment Mode
simultaneously press INCREASE
and DECREASE three times then
press and hold INCREASE and DE-
CREASE for 3 seconds.
Press any CUP SIZE to select a
preset agitation time (small=short-
est time, X--Large=longest time,
ect)
To exit Agitation Refill Time Adjust-
ment Mode simultaneously press
INCREASE and DECREASE.
NOTE: Once in a mode the light
blinks to indicate the refill time: 1
blink for the shortest refill time and
4 blinks for the longest refill. The
factory recommendation is 2 blinks.
NOTE: Larger ice portions require
more time to refill.

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Light Color Explanation Actions That Can Be Taken
Step 2. Set portion
level for each size
cup
Yellow Extra Ice Portion Adjust-
ment
To enter Portion Adjustment Mode
simultaneously press INCREASE
and DECREASE twice.
Press and hold CUP SIZE to be ad-
justed and while pressing IN-
CREASE or DECREASE to change
portion size (5 millisecond per
pulse).
NOTE: Make sure the light blinks as
the buttons are pressed.
The light will flash green for 5 sec-
onds. While the green light is flash-
ing the ice portion can be tested by
pressing the CUP SIZE again.
To exit Portion Adjustment Mode si-
multaneously press INCREASE and
DECREASE two times.
Step 3. If desired,
set the extra ice
portion adjustment
Red Extra Ice Portion Adjust-
ment
To enter Portion Adjustment Mode
simultaneously press INCREASE
and DECREASE three times.
Press and hold CUP SIZE to be ad-
justed and while pressing IN-
CREASE or DECREASE to change
portion size (5 millisecond per
pulse).
NOTE: Make sure the light blinks
as the buttons are pressed.
To exit Extra Ice Portion Adjustment
Mode simultaneously press IN-
CREASE and DECREASE.
NOTE: Consult store manager on desired ice level in each size cup.
CAUTION: The gate closes immediately when the toggle switch is moved to the auto position. Do not
place fingers or foreign objects into the ice chute when operating the toggle switch.

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MAINTENANCE
The following dispenser maintenance should be performed at the intervals indicated.
DAILY (OR AS REQUIRED)
Remove foreign material from vending area drip tray to prevent drain blockage.
WEEKLY (OR AS REQUIRED)
Clean vending area. Check for proper water drainage from the vending area drip tray.
MONTHLY
Clean and sanitize the hopper interior and beverage system if applicable (see CLEANING INSTRUCTIONS).
CLEANING INSTRUCTIONS
WARNING: Disconnect Power Before Cleaning! Do not use metal scrapers, sharp objects or abrasives
on the ice storage hopper, top cover, ice chute, and air cylinder access cover as damage may result. Do
not use solvents or other cleaning agents, as they may attack the plastic material.
Soap solution -- use a mixture of mild detergent and warm 100dF potable water.
Sanitizing solution -- use 1/2 ounce of household bleach in 1 gallon of potable water. Preparing the sanitizing
solution to this ratio will create a solution of 200 PPM.
DISPENSER
1. CLEANING EXTERIOR SURFACES
IMPORTANT: Perform the following daily.
A. Remove the cup rest from drip tray.
B. Wash the drip tray with soap solution. Rinse with clean water and allow solution to run down the drain.
C. Wash cup rest with soap solution and rinse in clean water. Install the cup rest into the drip tray.
D. Clean all exterior surfaces with soap solution and rinse in clean water.
2. CLEANING INTERIOR SURFACES
CAUTION: When pouring liquid into the hopper, do not exceed the rate of 1/2 gallon per minute.
CAUTION: It will be necessary to have electrical power on to the unit in order to remove any remaining
ice from the storage hopper and ice chute. After the ice has been removed, disconnect electrical power
to the unit before proceeding with cleaning and sanitizing.
A. Dispense all ice from the hopper and ice chute by switching the auto/manual toggle switch to the
“manual” position. The gate slide will then be held open to empty the ice chute. Depress the red
manual pushbutton switch to dispense all remaining ice from the hopper. Discard the ice. Return the
toggle switch to the auto position to close the gate slide.
B. IMPORTANT: Disconnect electrical power to the unit for the remainder of the cleaning and sanitizing
procedure.
C. Cold plate inspection before cleaning.

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1. Remove splash panel.
2. Remove the plastic cold plate access cover to expose the cold plate.
3. Remove any remaining ice from the cold plate surface and discard.
4. Locate and remove any debris from the cold plate, drain trough and make certain that the drain
holes are not clogged.
5. Reinstall the cold platecover.
6. Reinstall the splash panel.
D. Remove the plastic lid, agitator retainer (turn counterclockwise to unscrew), and agitator from the ice
storage hopper.
E. Using a long handle nylon bristle brush, clean the interior of the hopper and cold plate with the soap
solution. The cold plate can be reached by going through the ice opening on the hopper bottom. Make
certain to reach the entire surface of the cold plate including the corners. Thoroughly rinse the hopper
interior and cold plate with clean potable water.
F. Clean the agitator, agitator retainer, and lid with the soap solution. Thoroughly rinse with clean potable
water. Reassemble the agitator and retainer in the hopper. Make sure that the retainer is secured
tightly (turn clockwise to screw in place).
G. Clean and sanitize the ice chute as described below:
1. Remove the ice chute cover (snap-fit) by spreading the sides apart slightly to disengage the tabs
in the cover from the ice chute and sliding down to remove the cover. The ice chute (rear half)
and the ice gate are now exposed for cleaning.
2. Remove the black plastic access cover for the air cylinder from the splash panel (2 thumb-
screws).
3. Wash the ice chute cover, ice chute (rear half), ice gate, and air cylinder access cover with the
soap solution. Thoroughly rinse with clean potable water.
4. Using a mechanical spray bottle filled with sanitizing solution, spray these parts with sanitizer.
Allow to air dry.
5. Reassemble the ice chute cover and air cylinder access cover.
H. Using the mechanical spray bottle filled with sanitizing solution, spray the entire hopper interior, agita-
tor assembly, and hopper lid. Allow to air dry. Replace the lid on the unit.

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BEVERAGE SYSTEM
CLEANING
Soap solution -- Use a mixture of mild detergent and warm 100dF potable water.
Sanitizing solution -- Use 1/2 ounce of household bleach in 1 gallon of potable water. Preparing the sanitizing
solution to this ratio provides the required concentration of 200 PPM.
Cleaning tank -- Fill clean, empty tank with a mixture of mild detergent and five (5) gallons of warm 120dF potable
water.
CLEANING DISPENSING VALVES
Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed on the unit.
SANITIZING
IMPORTANT: Only trained and qualified persons should perform these cleaning and sanitizing proce-
dures.
Sanitize tank systems, Post-Mix and Pre-Mix
1. Remove all the quick disconnects from all the tanks. Fill a suitable pail or bucket with soap solution.
2. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
3. Prepare sanitizing solution and using a mechanical spray bottle, spray the disconnects. Allow to air dry.
4. Using a clean, empty tank, prepare five (5) gallons of the sanitizing solution. Rinse the tank disconnects
with approximately 9 oz. of the sanitizing solution. Close the tank.
5. Prepare cleaning tank by filling clean five (5) gallon tank with a mixture of mild detergent and 120dF potable
water.
6. Connect a gas disconnect to the tank and then apply one of the product tubes to the cleaning tank. Operate
the appropriate valve until liquid dispensed is free of any syrup.
7. Disconnect cleaning tank and hook up sanitizing tank to syrup line and CO2system.
8. Energize beverage faucet until chlorine sanitizing solution is dispensed through the faucet. Flush at least
two (2) cups of liquid to insure that the sanitizing solution has filled the entire length of the syrup tubing.
9. Allow sanitizer to remain in lines for fifteen (15) minutes.
10. Repeat the step above, applying a different product tube each time until all tubes are filled with the sanitizing
solution.
11. For post-mix valves, remove the nozzle and syrup diffuser and clean them in a mild soap solution. Rinse
with clean water, then reinstall the nozzle and syrup diffuser on the valve.
12. For pre-mix valves, disconnect all product tubes from the tank of sanitizing solution and then open the
valves to allow the pressure to be relieved. Remove the valves from the dispenser, disassemble and wash
thoroughly in a mild soap solution.
13. Rinse the parts in clean water, reassemble the valve and reconnect it to the dispenser.
14. Discard the tank of sanitizing solution and reconnect the product (syrup or pre-mix) tanks. Operate the
valves until all sanitizer has been flushed from the system and only product (syrup or pre-mix) is flowing.

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Sanitize syrup lines, BIB Systerms
1. Remove all the quick disconnects from all the BIB containers.
2. Fill a suitable pail or bucket with soap solution.
3. Submerge all disconnects (gas and liquid) in the soap solution and then clean them using a nylon bristle
brush. (Do not use a wire brush). Rinse with clean water.
4. Using a plastic pail, prepare approximately five (5) gallons of sanitizing solution.
5. Rinse the BIB disconnects in the sanitizing solution.
6. Sanitizing fittings must be attached to each BIB disconnect. If these fittings are not available, the fittings
from empty BIB bags can be cut from the bags and used. These fittings open the disconnect so the sanitiz-
ing solution can be drawn through the disconnect.
7. Place all the BIB disconnects into the pail of sanitizing solution. Operate all the valves until the sanitizing
solution is flowing from the valve. Allow sanitizer to remain in lines for fifteen (15) minutes.
8. Remove the nozzle and syrup diffuser from each valve and clean them in a soap solution. Rinse with clean
water and reassemble the nozzle and syrup diffuser to the valve.
9. Remove the sanitizing fittings from the BIB disconnects and connect the disconnects to the appropriate BIB
container. Operate the valves until all sanitizer has been flushed from the system and syrup is flowing free-
ly.
WARNING: If repairs are to be made to the beverage system, remove quick disconnects from the appli-
cable 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 proceed-
ing. If repairs are to be made to the ice dispensing system, make sure electrical power is disconnected
from the unit.

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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 CO2system, stop dispensing, shut off the CO2supply, 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.
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
Trouble Probable Cause Remedy
NOTE: 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.
SLUSHY ICE. WATER IN
H
O
P
P
E
R
A. Blocked drain. A. Open-up/flush out drain.
HOPPER 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).
BEVERAGES DO NOT
DISPENSE.
A. No 24 volt power to faucets. A. Check that beverage switch is
“on”. Check 24V transformers.
B. No CO2pressure. B. Check CO2regulator. Check CO2
tank pressure.
BEVERAGES TOO SWEET. A. Carbonator not working. A. Check carbonator.
B. No CO2pressure in
carbonator.
B. Check CO2regulator. Check CO2
tank pressure.
C. Faucet brix requires adjusting. C. Brix Faucet.
BEVERAGES NOT SWEET
E
N
O
U
G
H
A. Empty syrup tank. A. Refill syrup tank.
ENOUGH. 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.
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.

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11 620916502OPR
Trouble RemedyProbable Cause
NO ICE DISPENSED FROM
I
C
E
P
O
R
T
I
O
N
C
O
N
T
R
O
L
L
E
R
ICE PORTION CONTROLLER
(CONTINUED) D. Insufficient or no CO2supply
to dispenser.
D. Restore CO2supply 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.
J. Defective ice gate cylinder.
K. Defective ice gate solenoid
valve.
L. Agitation relay wiring incorrect.
M. Defective agitation relay.
N. Defective agitator motor or
start capacitor or start relay.
I. Replace controller.
J. Replace cylinder.
K. Replace solenoid valve.
L. Red wire should be connected to
“+” terminal (no. 3) of relay coil.
M. Replace relay.
N. Replace defective component.
NO ICE DISPENSED FROM
MANUAL ICE DISPENSE
PUSHBUTTON SWITCH
A. Manual/Auto toggle switch in
“Auto” position.
B. Insufficient or no CO2supply to
dispenser.
A. Move toggle switch to “Manual”
position.
B. Restore CO2supply to dispenser.
C. Defective 24V transformer.
D. Defective manual override
solenoid valve.
E. Defective manual ice dispense
pushbutton switch.
C. Replace transformer.
D. Replace valve.
E. Replace switch.
F. Defective agitator motor or
start capacitor or start relay.
G. Defective ice gate cylinder.
F. Replace defective component.
G. Replace cylinder
ICE DISPENSING DURING
AUTOMATIC AGITATION
A. Manual/Auto toggle switch in
“manual” position.
A. Move toggle switch to “auto”
position.
B. Defective ice gate cylinder.
C. Defective ice gate solenoid
valve.
D. Defective portion controller.
B. Replace cylinder.
C. Replace valve.
D. Replace controller.

Enduro Ice/Beverage Dispenser Operator’s Manual
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620916502OPR
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 DP.O. 210, DRIVERWOOD, DNSW 2210, AUSTRALIA D(61) 2 533 3122 DFAX (61) 2 534 2166
AUSTRIA DAM LANGEN FELDE 32 DA-1222 DVIENNA, AUSTRIA D(43) 1 233 520 DFAX (43) 1-2335-2930
BELGIUM DBOSKAPELLEI 122 DB-2930 BRAASCHAAT, BELGIUM D(32) 3 664 0552 DFAX (32) 3 665 2307
BRAZIL DRUA ITAOCARA 97 DTOMAS COELHO DRIO DE JANEIRO, BRAZIL D(55) 21 591 7150 DFAX (55) 21 593 1829
ENGLAND DTYTHING ROAD ALCESTER DWARWICKSHIRE, B49 6 EU, ENGLAND D(44) 789 763 101 DFAX (44) 789 763 644
FRANCE D71 ROUTE DE ST. DENIS DF-95170 DEUIL LA BARRE DPARIS, FRANCE D(33)134286200DFAX (33) 1 34 28 6201
GERMANY DCARL LEVERKUS STRASSE 15 DD-4018 LANGENFELD, WEST GERMANY D(49) 2173 7930 DFAX (49) 2173 77 438
GREECE D488 MESSOGION AVENUE DAGIA PARASKEVI D153 42 DATHENS, GREECE D(30) 1 600 1073 DFAX (30) 1 601 2491
HONG KONG D1104 TAIKOTSUI CENTRE D11-15 KOK CHEUNG ST DTAIKOKTSUE, HONG KONG D(852) 789 9882 DFAX [phone]
ITALY DVIA PELLIZZARI 11 D1-20059 DVIMARCATE, ITALY D(39) 39 608 0817 DFAX (39) 39 608 0814
NEW ZEALAND D20 LANSFORD CRES. DP.O. BOX 19-044 AVONDALE DAUCKLAND 7, NEW ZEALAND D(64) 9 8200 357 DFAX (64) 9 8200 361
SINGAPORE D16 TUAS STREET DSINGAPORE 2263 D(65) 862 5542 DFAX (65) 862 5604
SPAIN DPOLIGONO INDUSTRAIL DRIERA DEL FONOLLAR DE-08830 SANT BOI DE LLOBREGAT DBARCELONA, SPAIN D(34) 3 640 2839 DFAX (34) 3 654 3379
USA DONE CORNELIUS PLACE DOSSEO,MN (800) 238--3600

IMI CORNELIUS INC.