Cornelius Beverage Dispenser ED 250 BCP User Manual

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  
 
RETAINER  
ICE BIN COVER  
ICE AGITATOR  
MANUAL ICE DISPENSE  
RED PUSH BUTTON SWITCH  
ICE PORTION  
CONTROL MODULE  
BEVERAGE FAUCET  
ON/OFF SWITCH  
REMOVABLE STRAW  
HOLDER PANEL  
MANUAL/AUTO ICE  
TOGGLE SWITCH  
LID/STRAW  
HOLDER  
CUP REST  
DRIP TRAY  
BEVERAGE FAUCETS (8)  
LOWER ACCESS  
PANEL  
FIGURE 1. PARTS IDENTIFICATION  
1
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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  
8
Cold Plate (Built–In) Yes  
Electrical  
120/1/60, 3.5 Amps  
Dimensions  
30 in. Wide X 30-11/16 in. Deep X 39-5/8  
in. High  
2
620916501INS  
 
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 Dis-  
penser 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: Regulated CO gas pressure is required to operate the portion control dis-  
2
pensing system. Proceed as follows to connect the CO gas pressure source line to the dispenser.  
2
A. Connect and route the CO line from outlet side of the source regulator assembly up 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 CO operating pressure is 50 psig.  
2
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
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SOLVENT BOND  
HOSE CLAMP  
DRIP TRAY DRAIN  
FITTING  
COUPLING  
3/4 SOCKET X 3/4 FPT  
BARB ADAPTER  
1 BARB X 3/4 MPT  
DRAIN LINE  
1-IN. I.D. PLASTIC TUBING  
(6 FT) WITH INSULATION  
FIGURE 2. DRIP TRAY DRAIN ASSEMBLY  
4
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30  
26–7/16  
1–13/16  
1–5/16  
23  
7/16  
12  
21–1/4  
9
21–1/4  
18–5/8  
23–1/16  
OPENING  
29  
30–11/16  
3–1/2  
Z STYLE  
REMOVABLE DRIP TRAY  
11–5/8  
9–3/16  
TO FRONT OF DRIP TRAY  
ON COUNTERTOP  
TO FRONT TOP OF  
DRIP TRAY  
RECOMMENDED COUNTER OPENING SIZE  
9.00 X 12.00 FOR UTILITIES AND  
BEVERAGE TUBING. OPENING CAN BE LOCATED  
ANYWHERE WITHIN THE SHADED AREA.  
FIGURE 3. MOUNTING TEMPLATE  
5
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FAUCETS VIEWED FROM THIS SIDE  
FIGURE 4. FLOW DIAGRAM (UNIT WITH EIGHT FAUCETS)  
620916501INS  
6
 
PNEUMATIC GATE SOLENOID VALVE  
3-WAY NORMALLY CLOSED  
FILTER–REGULATOR  
(FACTORY-SET OUTLET  
PRESSURE TO 32-36 PSIG)  
CO2 SUPPLY  
50 PSIG MAX.  
MANUAL OVERIDE SOLENOID VALVE  
3-WAY NORMALLY CLOSED  
ICE GATE CYLINDER REVERSE  
SINGLE ACTING-SPRING EXTENDED  
FIGURE 5. FLOW DIAGRAM (PNEUMATIC ICE GATE)  
 
ED250 PROGATE WIRING DIAGRAM  
L
MOTOR  
HEATER  
INTERLOCK  
N
E
INCOMING POWER  
RELAY  
ICE CHUTE  
INTERLOCK  
SWITCH  
BLK  
TO GUSSET  
HINGE GROUND  
TERMINAL  
7
5
A
TERMINAL  
BOARD  
GRN/YEL  
B
GRN/YEL  
BLK  
BLK  
BLK  
BLK  
TO EBOX  
GROUND  
SCREW  
WHT  
BLK  
BLK  
BLK  
YEL  
BLK  
WHT  
WHT  
WHT  
WHT  
WHT  
DIODE  
BLK  
WHT  
BLK  
WHT  
LINE  
LINE  
TRANSFORMER  
LOAD  
TRANSFORMER  
LOAD  
YEL  
RED  
YEL/BLK  
YEL  
ORN/BLK  
ORN  
1
1
2
2
3
3
4
4
5
5
WHT  
WHT  
YEL  
YEL  
RED  
YEL/BLK  
BLK  
YEL  
ORN/BLK  
BLK  
ORN  
AGITATOR  
MOTOR  
MOTOR START  
CAPACITOR  
WHT  
WHT  
GRN/YEL  
BEVERAGE  
VALVE  
BEVERAGE  
VALVE  
BLK  
WHT  
BLK  
WHT  
TO EBOX  
GROUND  
SCREW  
BEVERAGE  
VALVE  
BEVERAGE  
VALVE  
RED  
WHT  
1
2
MANUAL  
OVERRIDE  
SOLENOID  
BLK  
WHT  
BLK  
WHT  
BEVERAGE  
VALVE  
BEVERAGE  
VALVE  
(TYPICAL)  
(TYPICAL)  
GRN  
BLU  
1
2
PNEUMATIC  
GATE  
SOLENOID  
BRN  
BLU  
RED  
BLK  
1
2
AGITATION  
RELAY  
TO EBOX  
GROUND  
SCREW  
3
4
RED  
BLK  
GRN/YEL  
BLU  
BRN  
RED  
YEL  
BLK  
ORN  
ORN  
ORN  
ORN  
YEL  
GRN/YEL  
1
1
2
2
3
3
4
4
5
5
6
6
7
7
8
8
9
9
BLU  
BLK  
BLK  
GRN  
VIO  
RED  
WHT  
BLU  
BRN  
1
1
2
2
3
3
4
4
5
6
6
7
7
8
8
9
9
WHT  
BLK  
YEL  
ORN  
RED  
YEL  
MANUAL/AUTO ICE  
TOGGLE SWITCH  
5
COM  
NO  
RED  
WHT  
BLK  
MANUAL ICE  
DISPENSE SWITCH  
PORTION CONTROLLER/TOUCH PANEL  
ORN  
BEVERAGE  
25  
24  
11  
WIRE COLOR CHART  
VALVES  
ON/OFF  
SWITCH12  
BLK  
WHT  
YEL  
BLACK  
WHITE  
YEL  
YEL  
YELLOW  
ORANGE  
BROWN  
ORN  
BRN  
DANGER!  
LEGEND  
SPLICE/QUICK CONNECT CONNECTION  
ELECTRIC SHOCK HAZARD. DISCONNECT  
POWER BEFORE SERVICING UNIT.  
VIO  
VIOLET  
BLU  
BLUE  
GROUND  
RED  
RED  
MALE HARNESS CONNECTOR  
FEMALE HARNESS CONNECTOR  
GRN  
GEN/YEL  
GREEN  
620913001 REV.E  
GREEN W/YELLOW STRIP  
FIGURE 6. WIRING DIAGRAM (115 VOLT UNIT)  
8
620916501INS  
 
FIGURE 7. WIRING SCHEMATIC (115 VOLT)  
 
THIS PAGE LEFT BLANK INTENTIONALLY  
10  
620916501INS  
 
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 CO2 system, stop dispensing, shut off the CO2 supply, 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.  
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.  
A. Blocked drain.  
B. Replace agitator motor.  
A. Open–up/flush out drain.  
B. Level unit.  
SLUSHY ICE. WATER IN  
HOPPER  
B. Unit not level.  
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.  
B. No CO2 pressure.  
A. Check that beverage switch is  
“on”. Check 24V transformers.  
B. Check CO2 regulator. Check CO2  
tank pressure.  
BEVERAGES TOO SWEET.  
A. Carbonator not working.  
A. Check carbonator.  
B. No CO2 pressure in  
carbonator.  
B. Check CO2 regulator. Check CO2  
tank pressure.  
C. Faucet brix requires adjusting. C. Brix Faucet.  
A. Empty syrup tank. A. Refill syrup tank.  
B. Faucet Brix requires adjusting. B. Brix Faucet.  
BEVERAGES NOT SWEET  
ENOUGH.  
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.  
11  
620916501INS  
 
Trouble  
Probable Cause  
Remedy  
NO ICE DISPENSED FROM  
ICE PORTION CONTROLLER  
(CONTINUED)  
D. Insufficient or no CO2 supply  
to dispenser.  
D. Restore CO2 supply 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.  
H. Defective 24V transformer.  
G. Replace relay.  
H. Replace transformer.  
I.  
Defective portion controller.  
I.  
Replace controller.  
J. Defective ice gate cylinder.  
J. Replace cylinder.  
K. Defective ice gate solenoid  
valve.  
K. Replace solenoid valve.  
L. Agitation relay wiring incorrect. L. Red wire should be connected to  
“+” terminal (no. 3) of relay coil.  
M. Defective agitation relay.  
M. Replace relay.  
N. Defective agitator motor or  
start capacitor or start relay.  
N. Replace defective component.  
NO ICE DISPENSED FROM  
MANUAL ICE DISPENSE  
PUSHBUTTON SWITCH  
A. Manual/Auto toggle switch in  
“Auto” position.  
A. Move toggle switch to “Manual”  
position.  
B. Insufficient or no CO2 supply to B. Restore CO2 supply to dispenser.  
dispenser.  
C. Defective 24V transformer.  
C. Replace transformer.  
D. Replace valve.  
D. Defective manual override  
solenoid valve.  
E. Defective manual ice dispense E. Replace switch.  
pushbutton switch.  
F. Defective agitator motor or  
start capacitor or start relay.  
F. Replace defective component.  
G. Defective ice gate cylinder.  
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.  
B. Replace cylinder.  
C. Replace valve.  
C. Defective ice gate solenoid  
valve.  
D. Defective portion controller.  
D. Replace controller.  
12  
620916501INS  
 
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  
AUSTRIA D AM LANGEN FELDE 32 D A-1222 D VIENNA, AUSTRIA D (43) 1 233 520 D FAX (43) 1-2335-2930  
BELGIUM D BOSKAPELLEI 122 D B-2930 BRAASCHAAT, BELGIUM D (32) 3 664 0552 D FAX (32) 3 665 2307  
BRAZIL D RUA ITAOCARA 97 D TOMAS COELHO D RIO DE JANEIRO, BRAZIL D (55) 21 591 7150 D FAX (55) 21 593 1829  
ENGLAND D TYTHING ROAD ALCESTER D WARWICKSHIRE, B49 6 EU, ENGLAND D (44) 789 763 101 D FAX (44) 789 763 644  
FRANCE D 71 ROUTE DE ST. DENIS D F-95170 DEUIL LA BARRE D PARIS, FRANCE D (33) 1 34 28 6200 D FAX (33) 1 34 28 6201  
GERMANY D CARL LEVERKUS STRASSE 15 D D-4018 LANGENFELD, WEST GERMANY D (49) 2173 7930 D FAX (49) 2173 77 438  
GREECE D 488 MESSOGION AVENUE D AGIA PARASKEVI D 153 42 D ATHENS, GREECE D (30) 1 600 1073 D FAX (30) 1 601 2491  
HONG KONG D 1104 TAIKOTSUI CENTRE D 11-15 KOK CHEUNG ST D TAIKOKTSUE, HONG KONG D (852) 789 9882 D FAX (852) 391 6222  
ITALY D VIA PELLIZZARI 11 D 1-20059 D VIMARCATE, ITALY D (39) 39 608 0817 D FAX (39) 39 608 0814  
NEW 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  
SINGAPORE D 16 TUAS STREET D SINGAPORE 2263 D (65) 862 5542 D FAX (65) 862 5604  
SPAIN 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  
USA D ONE CORNELIUS PLACE D  
OSSEO, MN (800) 238–3600  
13  
620916501INS  
 
IMI CORNELIUS INC.  
 

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