Cornelius ED 300 BN Operator`s manual

ICE/BEVERAGE DISPENSER
Model: ED 300 BN
Operator’s Manual
Release Date: November 16, 1998
Publication Number: 620913201
Revision Date: August 3, 2010
Revision: E
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 possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(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 subject 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 persons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating, 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 contact:
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 CONTENT
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Recognition. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
2
2
2
Start-up and Operating Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Ice Drink Dispenser. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Cleaning And Maintenance Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Cleaning: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Daily Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Weekly Cleaning: (In addition to daily procedures) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Monthly Cleaning: (In addition to daily and weekly procedures) . . . . . . . . . . . . . . . . . . . . . .
Yearly Maintenance: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Interior Surfaces (Monthly Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cold Plate (Yearly Maintenance). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dispensing Valves: ( Daily Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Product Tubing (Monthly Cleaning) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sanitize Pre-Mix And Post–Mix Tank System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sanitize syrup lines, B–I–B Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replenishing CO2 Supply (As Required) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
4
4
4
5
5
5
5
6
6
6
6
7
Removal And Replacement Of Agitators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
To Remove Agitators For Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Blown Fuse Or Circuit Breaker.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gate Does Not Open. Agitator Does Not Turn.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Gate Does Not Open Or Is Sluggish Agitator Turns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .. 9
Ice Dispenses Continuously. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Beverages Do Not Dispense. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Beverages Too Sweet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Beverage Not Sweet Enough.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Agitators Turn In Opposite Directions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Ice does not dispense from one gate assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
LIST OF FIGURES
FIGURE 1. ENDURO 300 ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
FIGURE 2. MOTER COMPONENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FIGURE 3. GATE SOLENOID ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
FIGURE 4. ELECTRICAL BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
FIGURE 5. VALVE PANEL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
FIGURE 6. GLADDER SCHEMATIC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Ice/Beverage Dispenser Operator’s Manual
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
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.
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.
Publication Number: 620913201
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© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
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:
CO2 displaces oxygen. Strict attention MUST be observed in the prevention of CO2 gas leaks in the entire CO2 and
soft drink system. If a CO2 gas 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 CO2 gas
experience tremors which are followed rapidly by loss of consciousness and DEATH.
MOUNTING IN OR ON A COUNTER
! WARNING:
When installing the unit in or on a counter top, the counter must be able to support a weight in excess of XXX 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 additional weight the counter will need
to support to ensure a safe installation.
© 1998-2010, IMI Cornelius Inc.
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Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
START-UP AND OPERATING INSTRUCTIONS
ICE DRINK DISPENSER
The ice drink dispenser shall be installed by qualified personnel following instruction given in the Installation manual part
number 620913201INS. Fill the hopper with ice. Dispense several large cups of ice (approximately 20 to 30 seconds total
dispensing time) to allow ice to fill the cold plate cabinet. Add ice to the hopper as necessary to refill, then replace the lid. Allow
10 to 15 minutes for the cold plate to cool down. Repeat this procedure whenever the dispenser has run out of ice. Start up the
beverage system and adjust faucets to the proper brix. Contact your local syrup distributor for complete information on the
beverage system.
The ice drink dispenser is designed to operate in ambient temperatures ranging from 40 to 105o F. Do not allow the unit to be
stored or operated in conditions below 32o F. This could cause damage to the unit.
! 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 if 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 and left to “temper” or warm up for a
minimum of 20 minutes in room temperature before loading into the dispenser hopper
In normal operation, pushing the ice dispenser mechanism will cause ice to flow from the ice chute. Ice flow will continue until
the dispenser mechanism is released. Dispensing of any faucet will provide beverage of the appropriate flavor.
! WARNING:
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 on the unit at all times. FAILURE TO CLEAN UP
SPILLS COULD RESULT IN SERIOUS INJURY OR DEATH
If the dispenser fails to dispense ice or beverage, refer to the troubleshooting section in the Installation Manual part number
620913201INS.
NOTE: 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.
NOTE: This appliance is not intended for use by personnel (including children) with reduced physical, sensory or
mental capabilities or lack of experience and knowledge, unless given supervision or instruction concerning use of
the appliance by a person responsible for safety.
Publication Number: 620913201
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© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
CLEANING AND MAINTENANCE INSTRUCTIONS
These instructions are used on all Cornelius ice drink dispensers. Some models may have additional cleaning requirements.
Those models will have addition procedures listed later in the manual.
! WARNING:
Disconnect power to the unit before cleaning or servicing following all lock out / tag out procedures established by
the user. Verify all of the power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
!
CAUTION:
Do not use metal scrapers, sharp objects or abrasives on the ice storage hopper, top cover, agitator disc or exterior
surfaces as damage to the unit may result. Do not use solvents or other cleaning agents as they may attack the
material resulting in damage to the unit.
Soap solution – Use a mixture of mild detergent and warm (100° F ) potable water.
Sanitizing Solution – Dissolve 2 packets (4 oz) of Stera Sheen Green Label into 2 gallons of warm (80 – 100° F)
potable water to ensure 200 ppm of chlorine.
Daily Cleaning:
1. Remove cup rest from drip tray and clean with warm soapy water, rinse with clean water and allow to air dry.
2. Wipe down the exterior of the unit with warm soapy water, rinse with clean water and allow to air dry.
3. Remove valve nozzles and diffusers and wash in warm soapy water, rinse in clean water and allow to air dry.
4. Clean the interior of the ice chute using the brush provided with the unit with warm soapy water, rinse with
clean water and allow to air dry.
5. Spray the ice chute inside and out with sanitizer and allow to air dry.
6. Pour warm soapy water down the drains to keep them clean and flowing smoothly.
7. Spray the nozzles and diffusers inside and outside with approved sanitizing solution, reinstall them on the
valves and allow to air dry.
8. Reinstall the cup rest into the drip tray.
9. Pour all remaining sanitizer solution down the drains to help keep the drain clear.
Daily Maintenance:
1.
Check the temperature, smell and taste of the product.
2. Check the water pressure coming to the unit using the pressure gauges on the back room package.
3. Check carbonation of the drink
4. Check level of CO2 supply to the system.
5. Check the date on all of the BIB’s (bags in boxes).
Weekly Cleaning: (In addition to daily procedures)
Remove the ice chute cover and clean it along with the back half with warm soapy using the brush provided with
the unit. Rinse with clean water and reinstall on the unit. Spray the ice chute assembly with approved sanitizer
allowing it to air dry.
© 1998-2010, IMI Cornelius Inc.
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Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
Monthly Cleaning: (In addition to daily and weekly procedures)
1.
Flush and sanitize all syrup lines as well as all of the syrup connectors. (See the sanitize syrup lines
section shown later in this manual).
2. Remove ice from hopper and clean and sanitize the hopper. (See the Cleaning the interior surfaces section
shown later in this manual).
3. While cleaning the hopper use the brush provided with the unit to clean the cold plate surface. To
accomplish this, the brush needs to be extended through the opening in the bottom of the hopper.
Yearly Maintenance:
Have the water pump and check valve inspected and cleaned by a qualified service technician.
Have the CO2 gas check valve inspected and cleaned by a qualified service technician.
Remove the unit’s splash and cold plate cover to clean and sanitize the cold plate surface. (See the cleaning the
cold plate section shown later in this manual).
Cleaning Interior Surfaces (Monthly Cleaning)
! CAUTION:
When pouring liquid into the hopper, do not exceed the rate of 1/2 gallon per minute. Pouring more liquid into the
hopper could result in an overflow situation may result in injury or damage to the equipment.
1. Remove agitator assembly.
2. Using a nylon bristle brush or sponge, clean the interior of the hopper, top cover and agitator assembly with
soap solution. Thoroughly rinse the hopper, cover and agitator surfaces with clean potable water.
3. Reassemble agitator assembly. Take special care to ensure that the thumbscrew is tight.
4. Using a mechanical spray bottle filled with sanitizing solution, spray the entire interior and agitator assembly. Allow to air dry.
5. Remove merchandiser and ice chute cover from unit.
6. With a nylon bristle brush or sponge, clean the inside of the ice chute, gasket, and cover with soap solution
and rinse thoroughly to remove all traces of detergent.
7. Reassemble ice chute assembly.
8. Using a mechanical spray bottle filled with sanitizing solution, spray the inside of the ice chute. Allow to air
dry.
9. Reinstall merchandiser.
Cold Plate (Yearly Maintenance)
1.
2.
3.
4.
5.
6.
7.
8.
Remove splash panel.
Remove or move the plastic cold plate cover to expose the cold plate.
Locate and remove any debris from the drain trough. Check that the drain holes are not clogged.
Pour small amount of soap solution through cold plate openings in hopper.
Using a cloth, wash down the surfaces of the cold plate and plastic cover with soap solution.
Install and properly position the access covers on the cold plate.
Install the splash panel in the reverse order it was removed.
Rinse cold plate surface by pouring potable water through hopper openings.
Publication Number: 620913201
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© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
Dispensing Valves: ( Daily Cleaning)
Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed on the
unit.
Product Tubing (Monthly Cleaning)
IMPORTANT: Only trained and qualified persons should perform these cleaning and sanitizing procedures.
Sanitize Pre-Mix And Post–Mix Tank System
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 potable water
(120oF).
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 CO2 system.
8. Energize beverage faucet until chlorine sanitizing solution is dispensed through the faucet. Flush at least
two (2) cups of liquid to ensure 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. Remove the nozzle and syrup diffuser and clean them in a mild soap solution.
Rinse with clean water and reassemble the nozzle and syrup diffuser on the valve.
12. Rinse the parts in clean water, reassemble the valve and reconnect it to the dispenser.
13. Discard the tank of sanitizing solution and reconnect the product syrup tanks. Operate the valves until all
sanitizer has been flushed from the system and only product syrup is flowing.
Sanitize syrup lines, B–I–B Systems
1. Remove all the quick disconnects from all the B–I–B 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 B–I–B disconnects in the sanitizing solution.
6. Sanitizing fittings must be attached to each B–I–B disconnect. If these fittings are not available, the fittings
from empty B–I–B bags can be cut from the bags and used. These fittings open the disconnect so the sanitizing solution can be drawn through the disconnect.
7. Place all the B–I–B 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 B–I–B disconnects and connect the disconnects to the appropriate 
B–I–B container. Operate the valves until all sanitizer has been flushed from the system and syrup is flowing freely.
© 1998-2010, IMI Cornelius Inc.
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Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
Replenishing CO2 Supply (As Required)
NOTE:When indicator on the 1800-psi gage is in the shaded (“change CO2 cylinder”) portion of the dial, CO2 cylinder is almost empty and should be changed.
1. Fully close (clockwise) the CO2 cylinder valve.
2. Slowly loosen the CO2 regulator assembly coupling nut allowing CO2 pressure to escape, then remove the
regulator assembly from the empty CO2 cylinder.
3. Unfasten safety chain and remove the empty CO2 cylinder
! WARNING:
To avoid personnel injury and/or property damage, always secure the CO2 cylinder with a safety chain to prevent it
from falling over. Should the valve become accidently damaged or brokenoff, a CO2 regulator can cause serious
personnel injury or death could occur.
4. Position the full CO2 cylinder and secure with a safety chain.
5. Make sure gasket is in place inside the CO2 regulator assembly coupling nut, then install the regulator
assembly on the CO2 cylinder.
6. Open (counterclockwise) the CO2 cylinder valve slightly to allow the lines to slowly fill with gas, then open
the valve fully to back-seat the valve (back-seating the valve prevents gas leakage around the valve shaft).
7. Check CO2 connections for leaks. Tighten any loose connections
Publication Number: 620913201
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© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
REMOVAL AND REPLACEMENT OF AGITATORS
To Remove Agitators For Cleaning
1.
2.
3.
4.
Lift agitator and disc from unit..
Remove O-Ring starting at notch. Warm the O-Ring with water to ease removal.
Lift the plastic agitator disc off of the stainless-steel agitator.
Replace by reversing steps.
NOTE: Refer to Sanitize Procedure in the Owners Instruction for complete cleaning and sanitizing
instructions.
© 1998-2010, IMI Cornelius Inc.
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Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
TROUBLESHOOTING
IMPORTANT:Only qualified personnel should service internal components or electrical wiring.
! WARNING:
If repairs are to be made to the 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 CO2 system, stop dispensing, shut
off the CO2 supply, 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.
! WARNING:
If repairs are to be made to the ice dispensing system, make sure electrical power is disconnected from the unit.
Trouble
Probable Cause
A.
B.
C.
D.
GATE DOES NOT OPEN. AGITATOR DOES NOT A.
TURN.
B.
C.
GATE DOES NOT OPEN OR IS SLUGGISH.
A.
BLOWN FUSE OR CIRCUIT BREAKER.
Short circuit in wiring.
Defective gate solenoid.
Defective agitator motor.
Defective gate rectifier
No power.
Bent depressor plate (does not actuate switch).
Defective dispensing switch.
Defective gate solenoid.
AGITATOR TURNS.
ICE DISPENSES CONTINUOUSLY.
SLUSHY ICE. WATER IN HOPPER.
BEVERAGES DO NOT DISPENSE.
B.
C.
A.
B.
C.
A.
B.
C.
D.
A.
B.
Excessive pressure against gate slide.
Defective Rectifier.
Stuck or bent depressor plate (does not release switch)
Defective dispensing switch
Improper switch installation.
Blocked drain.
Unit not level.
Poor ice quality due to water quality or icemark problem.
Improper use of flaked ice.
No 24 volt power to faucets.
No CO2 pressure.
BEVERAGES TOO SWEET
A. Carbonator not working.
B.
C.
BEVERAGE NOT SWEET ENOUGH.
A.
B.
AGITATORS TURN IN OPPOSITE DIRECTIONS A.
Publication Number: 620913201
No CO2 pressure in carbonator
Faucet brix requires adjusting.
Empty syrup tank.
Faucet brix requires adjusting.
This is normal and is necessary for uniform ice agitation.
-9-
© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
Trouble
ICE DOES NOT DISPENSE FROM ONE GATE
ASSEMBLY
Probable Cause
A. Agitators reversed.
B. Defective gate solenoid or rectifier.
C. Motors wired incorrectly
Contact your local syrup or beverage equipment distributor for additional information and troubleshooting
of beverage system.
© 1998-2010, IMI Cornelius Inc.
- 10 -
Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
ENDURO 300 (ED300) (POST-MIX)
Figure 1. ENDURO 300 ASSEMBLY
Publication Number: 620913201
- 11 -
© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
ENDURO 300 (ED300) (POST-MIX)
Item
No.
Part No.
Item
No.
Name
Part No.
Name
1
21491
Slide, Gate
30
620307401
Hopper/Cabinet Ass’y
2
22081R
Restrictor, Gate
31
620031609
Panel, Access Front
3
27107
Bracket, Lever Depressor
32
52967
Plug
4
15213
Agitator, Left
33
620404201
Dispensing Valve Panel Ass’y
(SeeFigure 5)
5
620031608
Panel, Access Rear
34
70016
Hex Nut, No. 10-32
6
620044541
Panel, Lower
35
70017
Insert, Nylon, No. 10-32
7
15196
Extension, Drip Tray
36
32682
Transformer, 24V
8
620031605
Bracket, Electrical Box
37
70056
Washer, Flat, No. 10
9
29507
Bracket, Motor Support
38
70067
Washer
10
15808
Base Ass’y
39
70076
Hex Nut, No. 8-32
11
15214
Agitator, Right
40
70055
Tinnerman Clip, No. 8-32
12
15500
Lever, Ice Chute
41
70171
Screw, Phil Truss Hd., No. 8-32 By
3/8-In. Long
13
29667
Support, Product Lines
42
70178
Screw, Phil Truss Hd., No. 8-32 By
1/2-In. Long
14
620031607
Cover, Electrical Box
43
70204
Screw, Phil Truss Hd., No. 8-32
15
29493
Bracket, Motor Mounting
44
41459
O--Ring
16
30895
Switch
45
70478R
Clip, Pushon
17
31007
Boot, Switch
46
70555
Screw, Phil Truss Hd., No. 8-32 By
3-In.Long
18
*32498
Agitator Motor (See Figure 2)
47
70847
Washer, Switch
19
32954
Solenoid Ass’y (See Figure 3)
48
71038
Cup Rest
20
620307101
Electrical Box Ass’y
(See Figure 4)
49
71010
Washer, No. 8
21
51908
Plug
50
10145
Pin, Drip Tray
22
51891
Gasket, Gate
51
51455R
Panel, Base
23
620500901
Ice Chute
52
70250
Screw, Phil Truss Hd, 1/4-20
By 1/2-In.Long
24
53168
Cover, Ice Chute
53
70060
Lockwasher, 1/4 Ext, Tooth
25
53185
Disk, Agitator
54
70121
Lockwasher, No. 8 Ext Tooth
26
620031601
Panel, Side, Right-Hand
55
70959
Nutsert, No. 8-32
27
620031610
Panel, Side, Left-Hand
56
620704101
Strainer, Drip Tray Drain
28
53230
Drip Tray
29
620031603
Panel, Upper Front
NOTE: * Not Shown
© 1998-2010, IMI Cornelius Inc.
- 12 -
Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
ENDURO 300 (ED300) (POST MIX
Item
No
Part No.
1
29303R
Name
Bracket, Gear Box
2
15218
Plate, Motor Mount
3
29493
Bracket, Motor Mount
4
30794
Heater, Motor
5
32498
Motor
6
651859
Seal, Motor Shaft
7
52876
Gasket, Motor
8
70018
Hex Nut, 1/4-20
9
70260
Screw, Phil Rd. Hd., 1/4-20
By 1-In.Long
10
70341
Spring, Motor Heater
11
70992
Receptacle, 1/4-turn
12
70993
Retainer, 1/4-turn
13
70994
Stud, 1/4-turn
14
70048
Washer, Lock, 1/4
15
70250
Screw, Phil Truss Hd, 1/4-20
By 1/2- In.Long
Figure 2. MOTER COMPONENTS
Ite
m
No
Part No.
Name
32954
Gate Solenoid Ass’y
1
28173
Arm, Gate Lift
2
50754
Bearing, Gate Arm
3
32957
Solenoid
4
28172
Plate, Solenoid Mounting
5
50752
Isolator
6
70015
Hex Nut, No. 10-32
7
70162
Screw, No. 8-32 By 1/4-In.
Long
8
70165
Screw, No. 8-32 By 5/8-In.
Long
9
71007
Spring, Solenoid Arm
10
51348
Spacer
11
70067
Washer
12
70057
Lockwasher, No. 10
Figure 3. GATE SOLENOID ASSEMBLY
Publication Number: 620913201
- 13 -
© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
ENDURO 300 (ED300) (POST-MIX)
Figure 4. ELECTRICAL BOX ASSEMBLY
Item
No
Part No.
Name
Item
No
620307101
Electrical Box Ass’y
9
33617
Harness, Motor
1
620031606
Box, Electrical
10
32782
Harness, Dispenser Switch
2
32958
Rectifier
11
70147
Screw, Phil Rd Hd, No. 6-32
By 1/2-In.Long
3
30514
Clamp, Capacitor
12
70219
Screw, No. 8, Type B
4
30774
Capacitor
13
70215
Screw, Sl Washer Hd, No. 8-32 By
1/4-In. Long
5
31107
Terminal Block
14
50459
Bushing, Harness
6
31763
Timer, Repeat Cycle
15
50458
Strain Relief
7
30995
Power Cord
16
50475
Bushing, Jumper
8
33615
Harness, Solenoid
© 1998-2010, IMI Cornelius Inc.
- 14 -
Part No.
Name
Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
ENDURO 300 (ED300) (POST-MIX)
Figure 5. VALVE PANEL ASSEMBLY
Item
No.
Part No.
Name
Item
No.
Part No.
Name
620404201
Valve Panel Ass’y, 12 Flavor
8
15356
Panel, Valve Mount
1
40502
Clamp
9
40483
Dispensing Valve
2
40439
Fitting, Valve Inlet
10
620700602
Screw, No. 10
3
50249
Insulation, Beverage Tubing
11
50014
Tubing, Water, 1/2 I.D.
4
52792
Beverage Tubing, 1/4 I.D.
12
50130
Insulation, Water Tubing
5
40649R
Fitting, Syrup Inlet, 1/4 Barb
13
32977
Switch, Valve, on/off
6
40949
Manifold, 6-Valve
14
40731R
Fitting, Water Inlet, 1/2 Barb
7
40657
Clamp
15
41209
Manifold, 4-Valve
Publication Number: 620913201
- 15 -
© 1998-2010, IMI Cornelius Inc.
Ice/Beverage Dispenser Operator’s Manual
Figure 6. LADDER SCHEMATIC
© 1998-2010, IMI Cornelius Inc.
- 16 -
Publication Number: 620913201
Ice/Beverage Dispenser Operator’s Manual
Publication Number: 620913201
- 17 -
© 1998-2010, IMI Cornelius Inc.
IMI Cornelius Inc.
www.cornelius.com