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Installation Manual
ENDURO ICE/BEVERAGE DISPENSER
Model: ED-250 BCP
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of
the Installer to ensure that
the water supply to the
dispensing equipment is
provided with protection
against backflow by an air
gap as defined in
ANSI/ASME A112.1.2-1979;
or an approved vacuum
breaker or other such
method as proved effective
by test.
Water pipe connections
and fixtures directly
connected to a potable
water supply shall be
sized, installed, and
maintained according to
Federal, State, and Local
Codes.
Part No. 620916501INS
October 19, 2005
Revised: March 10, 2006
Revision: C
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 2005–2006©
TABLE OF CONTENTS
SAFETY PRECAUTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DESCRIPTION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BLOWN FUSE OR CIRCUIT BREAKER. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SLUSHY ICE. WATER IN HOPPER 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES DO NOT DISPENSE. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES TOO SWEET. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT SWEET ENOUGH. 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BEVERAGES NOT COLD (UNITS WITH BUILD-IN COLD PLATE). 11. . . . . . . . . .
NO ICE DISPENSED FROM ICE PORTION CONTROLLER 11. . . . . . . . . . . . . . . .
NO ICE DISPENSED FROM ICE PORTION CONTROLLER (CONTINUED) 12. . .
NO ICE DISPENSED FROM MANUAL ICE DISPENSE PUSHBUTTON SWITCH 12
ICE DISPENSING DURING AUTOMATIC AGITATION 12. . . . . . . . . . . . . . . . . . . . . .
WARRANTY 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Page
LIST OF FIGURES
Page
FIGURE 1. PARTS IDENTIFICATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. MOUNTING TEMPLATE 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. FLOW DIAGRAM (BEVERAGE VALVE MANIFOLD R TO L 3.1.2.2) 6
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE) 7. . . . . . . . . . . . . . . . . . . .
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT) 8. . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. WIRING SCHEMATIC (115 VOLT UNIT) 9. . . . . . . . . . . . . . . . . . . . . . . .
i
620916501INS
MANUAL ICE DISPENSE
RED PUSH BUTTON SWITCH
ICE PORTION
CONTROL MODULE
BEVERAGE FAUCET
ON/OFF SWITCH
RETAINER
ICE BIN COVER
ICE AGITATOR
REMOVABLE STRAW
HOLDER PANEL
LID/STRAW
HOLDER
MANUAL/AUTO ICE
TOGGLE SWITCH
CUP REST
DRIP TRAY
LOWER ACCESS
PANEL
FIGURE 1. PARTS IDENTIFICATION
BEVERAGE FAUCETS (8)
1
620916501INS
SAFETY PRECAUTIONS
Always: Disconnect power to the dispenser before servicing or cleaning.
Never: Place hands inside of hopper or gate area without disconnecting power to the dispenser. Agitator rotation
occurs automatically when dispenser is energized!
This ice dispenser has been specifically designed to provide protection against personal injury and eliminates
contamination of ice.To insure continued protection and sanitation, observe the following:
ALWAYS: Be sure the removable lid is properly installed to prevent unauthorized access to the hopper interior
and possible contamination of the ice.
ALWAYS: Be sure the upper and lower front panels are securely fastened.
ALWAYS: Keep area around the dispenser clean of ice cubes.
CAUTION: Dispenser cannot be used with crushed or flaked ice.
Use of bagged ice which has frozen into large chunks can void warranty. The
dispenser agitator is not designed to be an ice crusher. Use of large chunks of
ice which ”jam up” inside the hopper will cause failure of the agitator motor and
damage to the hopper. If bagged ice is used, it must be carefully and completely
broken into small, cube-sized pieces before filling into the dispenser hopper.
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 unit includes beverage faucets and a cold plate and is designed to be supplied direct
from syrup tanks and a carbonator, with no additional cooling required.
SPECIFICATIONS
Model ED250 BCP
B (Beverage Faucets)
C (Cold Plate)
P (Pneumatic ice portioning system)
Ice storage 250 pounds
Maximum No. of
Beverage Faucets
Available
Cold Plate (Built–In) Yes
Electrical 120/1/60, 3.5 Amps
8
Dimensions 30 in. Wide X 30-11/16 in. Deep X 39-5/8
in. High
620916501INS
2
INSTALLATION INSTRUCTIONS
1. Locate the dispenser indoors on a level counter top.
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 2). 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 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 the Flow Diagram (see Figure 4) or decal on lower front panel of the unit for the location of syr-
up 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. ICE PORTION CONTROLLER:
pensing system. Proceed as follows to connect the CO
A. Connect and route the CO
Regulated CO
line from outlet side of the source regulator assembly up to the dispenser.
2
gas pressure is required to operate the portion control dis-
2
gas pressure source line to the dispenser.
2
NOTE: That the minimum source-regulated pressure is 40 psig.
B. Connect the CO
source line to dispenser inlet line labeled “CO
2
“.
2
C. The dispenser regulator outlet pressure is factory preset to 34 psig ± 2 psig DO NOT ADJUST.
IMPORTANT: Maximim CO2 operating pressure is 50 psig.
6. Clean the hopper interior (see Owner’s Manual P/N 620916502 for cleaning instructions).
7. Connect the power cord to a 120 volt, 60 cycle, 3–wire grounded receptacle.
3
620916501INS
SOLVENT BOND
HOSE CLAMP
1-IN. I.D. PLASTIC TUBING
DRIP TRAY DRAIN
FITTING
COUPLING
3/4 SOCKET X 3/4 FPT
BARB ADAPTER
1 BARB X 3/4 MPT
DRAIN LINE
(6 FT) WITH INSULATION
620916501INS
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY
4
1–5/16
1–13/16
7/16
30
26–7/16
23
12
23–1/16
21–1/4
18–5/8
OPENING
3–1/2
Z STYLE
9–3/16 11–5/8
RECOMMENDED COUNTER OPENING SIZE
9.00 X 12.00 FOR UTILITIES AND
BEVERAGE TUBING. OPENING CAN BE LOCATED
ANYWHERE WITHIN THE SHADED AREA.
REMOVABLE DRIP TRAY
9
TO FRONT OF DRIP TRAY
TO FRONT TOP OF
DRIP TRAY
21–1/4
29
30–11/16
ON COUNTERTOP
FIGURE 3. MOUNTING TEMPLATE
5
620916501INS
POTABLE
WATER
SUPPLY
CO2
Cylinder
Non–Carb Water
OPTIONAL
PRESSURE
Carb Water
REGULATOR
CHECK
VALVE
FILTER
INSTALL FOR
CARBONATOR
Carb Water
REQUIRED
NON–CARB AS
CO2
OPTIONAL FOR
DIET DRINKS
OR ROOT BEER
PRESSURE
S1S2
S3
S5 S4
15–50 PSIG
SYRUP TANKS
S7 S6
S8
REGULATORS
1
FAUCETS
S1
W1
2
5–15
W4
S5
6
5
S2
W2
S6
S7
S1S2S3
S3
S4
3
4
S4
W1W2W3
COLDPLATE
W4
INLET
CONNECTIONS
S5
S8
FAUCETS VIEWED FROM THIS SIDE
FIGURE 4. FLOW DIAGRAM (UNIT WITH EIGHT FAUCETS)
PSIG
S6
W3
S7
7
COLD PLATE
S8
8
INCLUDED WITH UNIT
ITEMS INSIDE BROKEN LINE
6620916501INS
PNEUMATIC GATE SOLENOID VALVE
3-WAY NORMALLY CLOSED
FILTER–REGULATOR
(FACTORY-SET OUTLET
PRESSURE TO 32-36 PSIG)
CO2 SUPPLY
50 PSIG MAX.
7
ICE GATE CYLINDER REVERSE
SINGLE ACTING-SPRING EXTENDED
MANUAL OVERIDE SOLENOID VALVE
3-WAY NORMALLY CLOSED
620916501INS
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE)
MOTOR
HEATER
WHT
BLKBLK
ED250 PROGATE WIRING DIAGRAM
INTERLOCK
7A
5B
BLK
RELAY
WHT
ICE CHUTE
INTERLOCK
SWITCH
BLK
BLK
BLK
BLK
BLK
WHT
DIODE
TERMINAL
BOARD
WHT
YEL
WHT
WHTBLK
GRN/YEL
L
N
E
HINGE GROUND
GRN/YEL
TO EBOX
GROUND
SCREW
INCOMING POWER
TO GUSSET
TERMINAL
BLK WHT
BLK WHT
BEVERAGE
VALV E
BLK WHT
BEVERAGE
VALV E
BLK WHT
BEVERAGE
VALV E
(TYPICAL)
BLK
1
AGITATION
RELAY
34
RED
BRN
BLU
RED
2
BLK
LINE
TRANSFORMER
LOAD
YEL
BLK WHT
LINE
TRANSFORMER
LOAD
ORN/BLK
ORN/BLKYEL/BLK ORNYEL
BLK WHT
BEVERAGE
VALV E
BLK WHT
BEVERAGE
VALV E
BLK WHT
BEVERAGE
VALV E
(TYPICAL)
ORN
WHT
WHT
YELYEL/BLK
YEL
RED
12345
12345
YEL
RED
AGITATOR
MOTOR
GRN/YEL
TO EBOX
GROUND
SCREW
RED
WHT
GRN
BLU
1
2
1
2
BLU
BRN
MOTOR START
CAPACITOR
MANUAL
OVERRIDE
SOLENOID
PNEUMATIC
GATE
SOLENOID
TO EBOX
GROUND
SCREW
GRN/YEL
620916501INS
ORN ORN
123456789
123456789
BEVERAGE
VALVES
ON/OFF
SWITCH
DANGER!
ORN
25 24
12 11
YEL YEL
MANUAL/AUTO ICE
TOGGLE SWITCH
RED
WHT
BLK
ELECTRIC SHOCK HAZARD. DISCONNECT
POWER BEFORE SERVICING UNIT.
620913001 REV.E
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT)
RED
YEL
BLK
YEL
GRN/YEL
BLK
RED
WHT
123456789
ORN
RED
ORNORN
YELWHT
BLK
YEL
123456789
PORTION CONTROLLER/TOUCH PANEL
VIOBLK
GRN
BLU
LEGEND
SPLICE/QUICK CONNECT CONNECTION
GROUND
MALE HARNESS CONNECTOR
FEMALE HARNESS CONNECTOR
BLU
BRN
COM NO
MANUAL ICE
DISPENSE SWITCH
WIRE COLOR CHART
BLK BLACK
WHT WHITE
YEL YELLOW
ORN ORANGE
BRN BROWN
VIO VIOLET
BLU BLUE
RED RED
GRN GREEN
GEN/YEL GREEN W/YELLOW STRIP
8
L
AGITATOR
RELAY
ICE CHUTE INTERLOCk
MANUAL ICE DISPENSE
1
2
SWITCH
VAL.
BEV
4
3
VAL.
AGITATOR MOTOR
PNEUMATIC ICE GATE
HEATER
9
START CAPACITOR
O/L
AGITATOR MOTOR
R
S
SOLENOID VALVE
PORTION CONTROLLER/
TOUCH PANEL
24VAC
BEV
VAL.
VAL.
BEV
BEV
VAL.
VAL.
BEV
BEV
VAL.
BEV
VAL.
BEV
MANUAL/AUTO ICE
TOGGLE SWITCH
SOLENOID VALVE
BEV ON/OFF
SWITCH
MANUAL OVERIDE
24VAC
24VAC
24VAC
TRANSFORMER
BEVERAGE
TRANSFORMER
BEVERAGE
SWITCH
INTERLOCK RELAY
120V
START RELAY
MOTOR
620916501INS
TOUCH
2
4
3
PANEL
N
FIGURE 7. WIRING SCHEMATIC (115 VOLT)
THIS PAGE LEFT BLANK INTENTIONALLY
620916501INS
10
TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
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 CO
system, stop dispensing, shut off the CO
2
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.
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.
supply, then
2
BLOWN FUSE OR CIRCUIT
BREAKER.
SLUSHY ICE. WATER IN
HOPPER
BEVERAGES DO NOT
DISPENSE.
BEVERAGES TOO SWEET.
A. Short circuit in wiring (115V
A. Replace defective wiring.
circuit).
B. Defective agitator motor. B. Replace agitator motor.
A. Blocked drain. A. Open–up/flush out drain.
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).
A. No 24 volt power to faucets. A. Check that beverage switch is
“on”. Check 24V transformers.
B. No CO2 pressure. B. Check CO
regulator. Check CO
2
tank pressure.
A. Carbonator not working. A. Check carbonator.
B. No CO2 pressure in
carbonator.
B. Check CO2 regulator. Check CO
tank pressure.
C. Faucet brix requires adjusting. C. Brix Faucet.
2
2
BEVERAGES NOT SWEET
ENOUGH.
BEVERAGES NOT COLD
(UNITS WITH BUILD-IN COLD
PLATE).
A. Empty syrup tank. A. Refill syrup tank.
B. Faucet Brix requires adjusting. B. Brix Faucet.
A. Unit standing with no ice in
A. Refill hopper with ice.
hopper - no ice in cold plate
cabinet.
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.
B. Ice in ice bin bridged (stuck
A. Replenish ice supply as required.
B. Gently tap on ice to break it loose.
together).
C. No electrical power to
dispenser.
11
C. Plug in dispenser power cord, or
check fuse or circuit breaker.
620916501INS
Trouble RemedyProbable Cause
NO ICE DISPENSED FROM
ICE PORTION CONTROLLER
(CONTINUED)
D. Insufficient or no CO
to dispenser.
supply
2
D. Restore CO2 supply to dispenser.
E. Ice chute cover not properly
Installed.
F. Defective ice chute interlock
E. Make sure that cover is “snapped”
into place.
F. Replace interlock switch.
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
I. Replace controller.
J. Replace cylinder.
K. Replace solenoid valve.
valve.
L. Agitation relay wiring incorrect.
L. Red wire should be connected to
“+” terminal (no. 3) of relay coil.
M. Defective agitation relay.
N. Defective agitator motor or
M. Replace relay.
N. Replace defective component.
start capacitor or start relay.
NO ICE DISPENSED FROM
MANUAL ICE DISPENSE
PUSHBUTTON SWITCH
ICE DISPENSING DURING
AUTOMATIC AGITATION
A. Manual/Auto toggle switch in
“Auto” position.
B. Insufficient or no CO2 supply to
dispenser.
C. Defective 24V transformer.
D. Defective manual override
solenoid valve.
E. Defective manual ice dispense
pushbutton switch.
F. Defective agitator motor or
start capacitor or start relay.
G. Defective ice gate cylinder.
A. Manual/Auto toggle switch in
“manual” position.
B. Defective ice gate cylinder.
C. Defective ice gate solenoid
valve.
A. Move toggle switch to “Manual”
position.
B. Restore CO2 supply to dispenser.
C. Replace transformer.
D. Replace valve.
E. Replace switch.
F. Replace defective component.
G. Replace cylinder
A. Move toggle switch to “auto”
position.
B. Replace cylinder.
C. Replace valve.
620916501INS
D. Defective portion controller.
12
D. Replace controller.
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 D P. O. 210, D RIVERWOOD, D NSW 2210, AUSTRALIA D (61) 2 533 3122 D FAX (61) 2 534 2166
D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930
AUSTRIA
D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, B ELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307
BELGIUM
D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829
BRAZIL
D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644
ENGLAND
D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PAR IS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201
FRANCE
GERMANY
GREECE
HONG
ITALY
NEW
SINGAPORE
SPAIN
USA
D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, WEST GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438
D 488 MESSOGION AVENUE D AGIA PAR ASK EV I D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491
KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222
D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814
ZEALAND D 20 LANSFORD CRES. D P. O . BOX 19-044 AVONDALE D AUCKLAND 7, NEW ZEALAND D (64) 9 8200 357 D FAX (64) 9 8200 361
D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604
D POLIGONO INDUSTRAIL D RIERA DEL FONOLLAR D E-08830 SANT BOI DE LLOBREGAT D BARCELONA, SPAIN D (34) 3 640 2839 D FAX (34) 3 654 3379
D ONE CORNELIUS PLACE D
OSSEO
MN
,
(800) 238–3600
13
620916501INS
IMI CORNELIUS INC.
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