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Installation/Service Manual [ 000995 ]

1. ten Part No Description en Part No Description a No 23 186599000 Slinger Water 1 Pump and Mot Assy 230 V 60 24 3600 Blade Agit Pump and Mot Assy 230 V 50HZ 25 186610000 Pin Sprg 2 200498003 Nut Hex No 8 32 26 186154000 Screw SE 8 36 PAPH 12 3 1560002107 Panel Back Chassis 27 560003858 Spacer Evap 4 311304000 Gasket 3 8 Male Flare 28 560003071 Holder Ice Bank Probe 5 1560000754 Inlet Pump 29 319347016 Rod Support Evap 6 1320389000 Bushing Snap 30 4786 Evap Coil 7 4680 Screw MA 8 32 PAPH 31 3113 Fan 5 Bid 8 890221201 Platform Rfg 32 560002108 Shroud Condenser 9 1620711936 Insulation Platform 33 560001537 Holder C Bulb 4182 Kit Comp 3 4 H P 120V 60HZ Kit 34 186770000 Screw MA 10 24 RKPH 20 10 4408 Comp 3 4 H P 240V 60HZ 35 120227000 Washer LK 194 I D 4407 Kit Comp 3 4 H P 230V 50HZ 36 320539000 Washer Ft 191 I D 449999999 Transformer 120V 60HZ 24V 37 321484000 Grommet 11 449999996 Transformer 240V 60HZ 24V 38 560000292 Condenser Coil 560002114 Transformer 230V 50HZ 24V 560000123 Motor Fan 35W 240V 60HZ 12 186146000 Nut Hex 5 16 18 e 560000170 Motor Fan 23W 230V 50HZ 13 2602 Dryer 40 2944 Brkt Motor Fan 14 319941000 Screw TR 8 32 HXWS 12 41 189429000 Nut Hex 1 4 20 15 189723000 Grommet Cop 42 187394000 Cushion Fan Mount 16 187888000 Clip Comp Mtg 43 560001720 Cover Terminal Block 17 316727000 Cap Plug 44 4187 Control Ice Ba
2. 46 Vanguard 245 Post Mix dispenser cold carbonated 47 Pump and Motor cold carb Assembly 48 Reference Material Jura tk va ba k simi IE ER ba k ue maca ges 49 Wiring Es cote hoe o te ati n tuts e CE oe ra Rer eT Var 49 Flow Diagram pesce ots darts Sel EES Same dot Senes i a Su Desc ust u goi eee 50 Six Flavor Unit Requiring Remote Carbonator 50 Flow Diagram aa d e es sa be Wee a ss a Rees 51 Eight Flavor Unit Requiring Remote Carbonator 51 Flow Diagrami ee am L LAS US eh S edd A L orbi SALA 52 Six Flavor Unit with Integral Carbonator 52 Flow Diagram e ducta se tte EN oe Edu net is en de te ne 53 Eight Flavor Unit with Integral Carbonator 5 Cinek D Vanguard 245 Service Manual SAFETY INSTRUCTIONS READ AND FoLLow ALL SAFETY INSTRUCTIONS Safety Overview e Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning caution labels on the unit decals labels or laminated cards e Read and understand ALL applicable OSHA Occupational Safety and Health Administration safety regulations before operating this unit Recognition Recognize Safety Alerts
3. HAYO Q IO3INVIA 1 ANIYA TILLS HOIVNOSHVO ANIYA TILLS gdVo I31NI S31VM NIV Id ANIYA 88VO I3INI ZOO 52 Publication Number 301135000SER 2006 2014 Cornelius Inc Vanguard 245 Service Manual FLow DIAGRAM Eight Flavor Unit with Integral Carbonator ANIYA 1115 ANIYA TILES NING ddv9 NING ANIYA TILES NING ANIYA gUvo NING 88V9 MOJ4 6Z Q IO3INIVIA HH HUAIVM gSuvo HUOIVNOSHVO AA IVA allt dWnd UIIVM 2 A 1 1 1 1 1 191 dAUAS I3INI U31VM NIV Id QO lam zoo 2006 2014 Cornelius Inc 53 Publication Number 301 135000SER CGinctius gt Vanguard 245 Service Manual 2006 2014 Cornelius Inc 54 Publication Number 301135000SER Cornelius Inc www cornelius com
4. 47 309645000 Swt Rocker 120V 60HZ 13 1187888000 Clip Comp Mtg 14 316727000 Cap Plg 48 560001396 Plug Swt 220 230V 50 60HZ 49 188117000 Screw SM 8 TRPH 12 Motor Assy Sgit 120V 60HZ 15 Motor Assy Sgit 240V 60HZ Motor Assy Sgit 230V 50 60HZ 16 4932 Brkt Mtr Agit 111778000 Motor Agit 25W 120V 60HZ 17 308912000 Motor Agit 25W 240V 60HZ 318168002 Motor Agit 18W 230V 50 60HZ 18 1319856000 Plate Heat Transfer 19 186154000 Screw SE 8 36 PAPH 12 20 186599000 Slinger Water 21 3600 Blade Agit 2 Bld 22 186610000 Pin Sprg 23 186154000 Screw SE 8 36 PAPH 12 24 560003858 Spacer Evap 25 1560003071 Holder Bank Probe 26 319347016 Rod Support Evap 27 4786 Evap Coil 28 3113 Fan 5 Bid 29 560002108 Shroud Condenser 30 560001537 Holder C Bulb 31 186770000 Screw MA 10 24 RDPH 20 Publication Number 301135000SER 45 2006 2014 Cornelius Inc Vanguard 245 Service Manual VANGUARD 245 POST MIX DISPENSER COLD CARBONATED LG Figure 23 46 Publication Number 301135000SER 2006 2014 Cornelius Inc Vanguard 245 Service Manual Gent VANGUARD 245 POST MIX DISPENSER COLD CARBONATED Table 4 Vanguard 245 post mix dispenser cold carb Table 4 Vanguard 245 post mix dispenser cold carb
5. 7 INSDEC ON ME P EMI ED 7 Unpacking f e ew Euer te RAPERE Ee DEUM E S 7 Identification Of Loose shipped Parts 7 Selecting Locations ss eas y o ny kere ui Ene 8 Installation DES aa EL 8 Placing Unit in Operating Position 8 Installing Water Lever Kits PASS i 9 Connecting Drip Tray Drain Hose to a Permanent Drain 9 Connecting Syrup Source Lines to the Unit 9 Connecting Carbonated Water Source Unit Requiring Connection to Remote Carbonator 10 Connecting Plain Water Source Line to 10 Unit Requiring Connection to Remote Carbonator 11 Unit with Integral built in Carbonator 11 Connecting CO2 Source Line Unit With Integral Carbonator 11 Adjusting Carbonator CO2 Regulator 11 Adjusting Syrup Supplies CO2 Regulator 11 Fill Water Tank and Start the Refrigeration System 12 Preparation for Operation esac ps ena ae Swe Ee ee eo SER Dek MAE Sek Pee Rees 13 Operator s Instructions ae ERE op des 14 Operatin
6. ON for 15 seconds OFF then ON for 15 sec onds Repeat ON and OFF cycles for 15 cycles 10 Connect potable water source to the remaining syrup systems and flush detergent solution out of the syrup systems as instructed in step 9 preceding 11 Remove potable water source from the syrup system SANITIZE SYRUP SYSTEMS 12 Using a clean syrup tank syrup tanks system or a five gallon container bag in box system prepare sanitiz ing solution using 70 F 21 C to 100 F 38 C potable water and 0 5 oz 15 ml of non scented household liquid bleach that contains a 5 25 sodium hypochlorite concentration to one gallon of potable water This mix ture must not exceed 200 PPM of chlorine Stir sanitizing solution to thoroughly mix 13 Syrup Tank Systems Connect sanitizing solution tank pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup System Place all bag in box syrup containers syrup outlet tubes in container containing sanitizing solution 14 Sanitize the syrup system and dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all water from and install sanitizing solution in the syrup system and dispensing valve C Continue to activate the dispensing valve in cycles ON for 15 seconds OFF then ON for 15 sec onds Repeat ON and OFF cycles for 15 cycles
7. CO2 gas through adjustable CO2 regulators to the applicable syrup tanks or bag in box syrup pumps and also the integral built in carbonator Plain water enters the integral carbonator carbonated water tank and is carbonated by CO2 gas pressure also entering the water tank When dispensing valve is opened CO2 gas pressure exerted upon the applicable syrup tank contents or bag in box syrup pump pushes syrup from the syrup supply through the Unit syrup cooling coil and on to the dispensing valve Carbonated water is pushed from the integral carbonator carbonated water tank by CO2 gas head pressure and is pushed through the carbonated water manifold to the dispensing valve Syrup and carbonated water meet simultaneously at the dispensing valve resulting in a carbonated drink being dispensed Still non carbonated drink is dispensed in the same manner as the carbonated drink except plain water is substituted for carbonated water Publication Number 301135000SER 6 2006 2014 Cornelius Inc Vanguard 245 Service Manual INSTALLATION A 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 A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off
8. Six or Eight Valves m Removable Refrigeration deck Pa Removable Cladding Removable Drip Tray Figure 1 Vanguard 245 Dispenser Eight flavor Unit Shown Publication Number 301135000SER 4 2006 2014 Cornelius Inc Vanguard 245 Service Manual The Vanguard 245 over the counter post mix beverage dispenser offers the following features Six or eight valves Built in carbonator optional Removable refrigeration deck Removable drip tray Removable cladding SPECIFICATIONS DESIGN DATA Unit Requiring Connection to Convertible To Water Description Remote Carbonat r Unit with Built In Carbonator Valve 6 or 8 valves 6 or 8 valves Valve Positions No 3 amp No 4 6 Valves All No 4 No 7 amp No 8 8 Valves Nominal Ice Bank Weight 27 kg 50 pounds 27 kg 50 pounds Water Bath Capacity no ice bank 80 L 21 25 gal 78 L 20 5 gal Overall Height 788 mm 31 in 788 mm 31 in filled water bath 97 7 kg 215 pounds Overall Width 622 mm 24 1 2 in 622 mm 24 1 2 in Overall Depth 746 mm 29 3 8 in 746 mm 29 3 8 in Counter Weight 87 7 kg 193 lbs 97 8 kg 215 lbs empty water bath Shipping Weight 109 kg 240 pounds 116 kg 255 pounds Counter Weight 104 6 kg 230 pounds NOTE Valves numbered right to left facing the front of the dispenser PART NUMBER Unit requiring connection to
9. 22208 VANGUARD 245 BEVERAGE DISPENSER This manual is applicable for eguipment series number from 89E0630VDXXX SERVICE MANUAL 8 B lt gt Release Date September 26 1996 Publication Number 301135000 Revision Date March 17 2014 Revision G Visit the 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 eguipment nor to provide for every possible contingency in the installation operation or maintenance of this eguipment This manual assumes that the person s working on the eguipment 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 con struction 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 prope
10. A 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 A DANGER Indicates an immediate hazardous situation which if not avoided WILL result in serious injury death or equipment damage A WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or equipment damage A CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage SAFETY TIPS e 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 e Keep your unit in proper working condition and do not allow unauthorized modifications to the unit QUALIFIED SERVICE PERSONNEL A 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
11. IN SERIOUS INJURY DEATH OR EQUIPMENT DAMAGE 2006 2014 Cornelius Inc 1 Publication Number 301135000SER Vanguard 245 Service Manual Giner D SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury To ensure continued protection observe the following A 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 A 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 A 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 A DANGER displaces oxygen Strict attention MUST be observed in the prevention of gas leaks in the entire 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 concentration
12. PUMPS BAG IN BOX SYSTEM Adjust the syrup pumps regulator to 70 psi DO NOT EXCEED MAXIMUM PRESSURE SPECIFIED ON THE SYRUP PUMPS 2006 2014 Cornelius Inc 11 Publication Number 301135000SER Vanguard 245 Service Manual Giner D FILL WATER TANK AND START THE REFRIGERATION SYSTEM 1 Make sure plug in end of the water tank drain hose is secure NOTE Use a low mineral content water where a local water problem exists 2 Remove plug from drop in refrigeration assembly platform water fill hole Fill the water tank with clean water until water flows out of the water tank overflow hose USE A LOW MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS Install plug in the water fill hole Unit with integral built in carbonator Activate plain water and CO2 supplies to the Unit Make sure CO2 inlet pressure to the carbonator is adjusted to a nominal 80 psi CO2 inlet pressure to the carbonator must not exceed 125 psi A WARNING The Unit must be electrically grounded to avoid possible fatal electrical shock or serious injury to the operator The power cord is equipped with a three prong plug If a three hole grounded electrical outlet is not available use an approved method to ground the Unit 5 Place dispensing valves keyed lock out switch on side of the Unit in the OFF position 6 60 Hz Units Make sure Unit power switch if applicable is in ON position 7 Plug the Unit power cord into an elect
13. Proceed as follows to seal the Unit base to the countertop an eguivalent A Tilt the Unit up to expose the bottom of it s base B Liberally apply silastic sealant such as Dow Corning RTV 731 or eguivalent on Unit base bottom edges NOTE Do not move the Unit after positioning or the seal from the base to the countertop will be broken C Lower the Unit into operating position on the countertop to complete seal from the Unit base to the counter top D Apply additional sealant around bottom of the Unit base The seal must have a minimum radius of 13 mm 1 2 inch to prevent crevices and to ensure a complete seal E All access holes to inside of the Unit must be closed and sealed INSTALLING WATER LEVER KITS The water lever kits are loose shipped only with dispenser s equipped with UF 1 dispensing valves The water lever kits may be installed on dispensing valves to dispense plain or carbonated water only Refer to instructions included with the kits for installation instructions CONNECTING DRIP TRAY DRAIN HOSE TO A PERMANENT DRAIN NOTE Connection of drip tray drain hose to a permanent drain is recommended Drip tray drain hose routed to a waste container is not recommended due to sanitation and cleaning problems The drip tray drain hose must be attached to the drain to allow a 76cm 3 inch air gap between the drain and the end of the hose All connections must comply with local plumbing codes and health codes 1 Connect
14. Remote carbonator six flavor unit 115 VAC 60 Hz 417306XXXXX eight flavor unit 115VAC 60Hz 417308XXXXX six flavor unit 208 230 VAC 60 Hz 477306XXXXX eight flavor unit 208 230 VAC 60 Hz 477308XXXXX six flavor unit 230 VAC 50 Hz 497306XXXXX eight flavor unit 230 VAC 50 Hz 497308XXXXX Unit with built in carbonator six flavor unit 230 VAC 60 Hz 497316XXXXX eight flavor unit 230 VAC 60 Hz 497318XXXXX six flavor unit 230 VAC 50 Hz 497316XXXXX eight flavor unit 230 VAC 50 Hz 497318XXXXX 2006 2014 Cornelius Inc Publication Number 301135000SER Vanguard 245 Service Manual D CAPABILITY Dispensing rate 12 OZ drinks 4 min or fewer 1000 NOTE Number of drinks dispensed 4 C 40 F or below 24 C 75 F syrup and water inlet tem perature and 24 C 75 F ambient MISCELLANEOUS INFORMATION Refrigerant 404A Compressor HP 3 4 H P Standard Valve LEV LVV FFV UF 1 298 mm 11 3 4 inches Cup Clearance 197 mm 7 3 4 inches optional Agency Listing CE NSF UL Electronic Controls Electronic ice bank and liquid level control THEORY OF OPERATION UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR NOTE The unit is factory set to dispense non carbonated water and carbonated water as per cus tomer s requirement It is available to convert carbonated waters to non carbonated water valve s Non carbon
15. Service i a a as 32 Carbonator Pump Replacement sheet edo 26 Ot page T ep HAR A C a d 32 Pump Motor Replacement 33 Agitator Motor Replacement 34 Controller Board Replacement 80 35 Condenser Fan Motor 36 Asse 1022 Compliant Vented Check Valve Option 37 Instruction for Conversion of Chudnow Valve with Anderson Valve 37 Changed Pans LIST 32 sento ges que E IEE eet EE ES ee ey Rees 38 Olympus Vented Double Check Valve Installation 39 illustrated parts IST Is ins al ar a a e wi eA OP a la Sei ele a ES Ed Ed 40 Vanguard 245 Post Mix dispenser remote 40 Vanguard 245 Post Mix dispenser remote 41 Vanguard 245 Post Mix dispenser cold carbonated 42 Vanguard 245 Post Mix dispenser cold carbonated 43 Vanguard 245 Post Mix dispenser remote 44 Vanguard 245 Post Mix dispenser remote 45 Vanguard 245 Post Mix dispenser cold carbonated
16. Unit power cord unplugged or drop 4 Plug in power cord in refrigeration assembly power cord unplugged 5 Ice sensor electrically disconnected 5 Electrically connect or replace inoperable sensor 6 No power source blown fuse or 6 Replace fuse or reset circuit breaker Refrigeration compressor does not tripped circuit breaker Note Fuse or circuit breaker are not operate part of unit 7 Low high voltage 7 Voltage must be 103 volts 115VAC Unit or 208 Volts 220 VAC Unit 8 Loose disconnected or broken wir 8 Tighten connections or replace broken ing wiring 9 Overload protector cut out over 9 Compressor will cool enough to restart heated compressor Condenser fan Do not overdraw cooling capacity of unit motor not operating as required Refer to Condenser Fan Motor Not Operating in this section 10 Inoperative overload protector or 10 Replace inoperative part start relay 11 Inoperative ice bank probe 11 Replace ice bank probe 12 Inoperative control board 12 Replace control board 1 Ice bank probe location incorrect 1 Place probe in proper location Compressor will not stop after suffi 3 _ 2 Ice temperature sensor inoperative 2 Replace ice temperature sensor cient ice bank is produced 3 Control board inoperative 3 Place power switch in ON position 1 Cooling capacity is exceeded by 1 Reduce amount of drinks drawn overdrawing given time Compressor operat
17. and electric dispensing valve power cords 3 Unit with integral built in carbonator A Shut off CO2 and plain water supplies to the Unit B Disconnect carbonated water tank ground wire green with yellow stripe connector protruding up B Dis connect carbonated water tank ground wire green with yellow stripe connector protruding up through hole in drop in refrigeration assembly deck from mating ground wire connector on top of the refrigeration assembly deck C Disconnect two conductor wiring harness connector from electrical terminals on top of the carbonated water tank D Pull up on the carbonated water tank relief valve ring protruding up through hole in the drop in refrigeration deck see Figure 8 to bleed off all pressure from the water tank E Disconnect plain water inlet and outlet lines from the carbonator water pump 4 Extend the water tank drain hose to a waste container or floor drain Remove plug from end of the drain hose and allow the water tank to drain 5 Allow the ice bank to melt Hot water may be used to speed melting 6 Very carefully lift the drop in refrigeration assembly up and out of the Unit CAUTION Never use an ice pick or other instrument to remove ice from the drop in refrigeration assembly evaporator coils Such practice can result in a punctured refrigeration circuit 7 Use a fiber brush and carefully clean mineral deposit build up from the agitator motor shaft and the ice bank sensing b
18. carbonator water pump E Restore and plain water supplies to the Unit 11 Remove plug from the drop in refrigeration assembly platform water fill hole 12 Fill the water tank with clean water until water runs out of the water tank overflow hose USE LOW MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS 13 Install plug in the drop in refrigeration assembly platform water fill hole 14 Plug drop in refrigeration assembly and electric dispensing valve power cords into their mating connectors 15 Install Unit hood and secure with screw 16 Connect electrical power to the Unit CARBONATOR WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS A WARNING The carbonator water pump water inlet strainer screen and the double liquid check valve must be inspected and cleaned at least once a year under normal circumstances and after any disruptions plumbing work earthquake etc to the water supply system that might cause turbulent erratic flow of water through the system A carbonated water pump with no screen or a defective screen in the strainer would allow foreign particles to foul the double liquid check valve CO2 gas could then back flow into the water system and create a health hazard in the water system UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR The remote carbonator water pump water inlet strainer screen and the double liquid check valve must be inspected and cleaned at least once a year under normal
19. ce Ret E i hen EE EG OE AE 19 Flush Syrup Systems ccs k aed D eee Sees E Rae 20 Sanilize Syr p SYSTEMS uu deed esd eds VE wp rd be See a ale Rake 20 Water Flush Syrup Systems xs RE d Steins deter mete Siew DRIN eee 21 Purge Water out of Syrup Systems Restore Operation 21 Cleaning Drop in Refrigeration Assembly Condenser Coil 22 Checking Ice Water Bath iv sve Ste as Uae ie a i eee A 22 Cleaning Water Tank Lies asaul ala tu pea a rona ESE a ks SRS qas 23 Carbonator Water Pump Yearly Maintenance or After Water System Disruptions 24 Unit Requiring Connection to Remote Carbonator 24 Unit with Integral Built In Carbonator 24 Servicing Water Pump Water Inlet Strainer Screen 24 Servicing Double Liquid Check Valve ee eu ua aa LL 25 Cleaning Co2 System Co2 Gas Check Valves 26 Converting Still Non carbonated Drink Dispensing Valve To Dispense A Carbonated Drink 26 Units Requiring Connection to Remote Carbonator 26 Unit with Integral Built In Carbonator 26 Trouble ShODHN ss sia k ie eens a EE GI EE De a S ae EG ESA GE ee ee 27 Component
20. established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment 1 Remove screw securing the hood then lift the hood straight up to remove from the Unit 2 Remove plug from the drop in refrigeration assembly platform water fill hole 3 Using a flashlight inspect the ice water bath and ice bank for cleanliness The ice water bath should be clear and the ice bank should be free of foreign particles If cleaning of the water tank is necessary refer to CLEANING WATER TANK in this section Fill the water tank with clean water until water runs out of the water tank overflow hose USE LOW MINERAL CONTENT WATER WHERE A LOCAL WATER PROBLEM EXISTS Install plug in the drop in refrigeration assembly platform water fill hole Install Unit hood and secure with screw Connect electrical power to the Unit Publication Number 301135000SER 22 2006 2014 Cornelius Inc CGinc ius gt Vanguard 245 Service Manual CLEANING WATER TANK A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment 1 Remove screw securing the hood then lift the hood straight up to remove from the Unit 2 Unplug the drop in refrigeration assembly
21. s Unit with Integral Built In Carbonator Non Carbonated Drink Dispensing Valve s can be converted into Carbonated Drink Dispensing Valve s by connecting a carbonated water rather than a plain line to the unit plain water line connected to either No 3 and No 4 dispensing valve s six flavor unit or the No 4 No 7 and No 8 dispensing valve s eight flavor unit Publication Number 301135000SER 26 2006 2014 Cornelius Inc Vanguard 245 Service Manual TROUBLE SHOOTING A 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 A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment A WARNING Water and CO2 to the system must be turned off and the system depressurized prior to performing this service Failure to comply could result in serious injury death or damage to the equipment IMPORTANT If repairs are to be made to one of the syrup circuits disconnect applicable syrup tank and bleed pressure from the system before proceeding IMPORTANT If repairs will be made to the CO2 or carbonated water sys
22. to the unit before performing any work Failure to comply could result in serious injury death or damage to the eguipment DELIVERY INSPECTION AND UNPACKING INSPECTION Upon delivery inspect the unit for damage or irregularities and immediately report problems to the delivering carrier and file a claim with that carrier UNPACKING Remove shipping tape and other packing material Remove four shipping nuts that secure the drop in refrigeration assembly in the lower cabinet Unpack the loose parts and make sure all items are present and in good condition Item No Part No Loose Part No Quantity 1 4771 Cup Rest 1 2 4772 Drip Tray 1 3 4778 Drip Tray Bracket 2 4 4123 Rear Access Cover 1 5 317784000 Screw Thread Cutting 6 6 113500000 Drip Tray Drain Hose 1 7 140135000 Clamp Drip Tray Drain Hose 1 8 3297 Water Lever Kit see NOTE 2 9 560000291 Air Filter optional 1 10 188072000 Screw 6 11 as request Valve Stickers 1 Set 12 301135000E Service Manual 1 IDENTIFICATION OF LOOSE SHIPPED PARTS 1 Drip tray brackets to be installed on the unit then drip tray to be installed on the drip tray brackets and secured with screws thread cutting Cup rest is then to be installed in the drip tray 2 Rear access cover is used to cover the rear access hole on back of the Unit and secured with screws thread cutting if drip tray and water tank drain hoses water tank overflow hose and t
23. 15 Repeat steps 13 and 14 to flush water out of and install sanitizing solution in the remaining syrup systems and dispensing valves 16 Remove sanitizing solution source from the syrup system 17 Allow sanitizing solution to remain in the syrup systems for not less than 10 or no more than 15 minutes max contact time Publication Number 301135000SER 20 2006 2014 Cornelius Inc 2 Vanguard 245 Service Manual WATER FLUSH SYRUP SYSTEMS A WARNING Flush sanitizing solution from the syrup systems as instructed Residual sanitizing solution left in the syrup systems could create a health hazard 18 Fill syrup tank syrup tank system or a five gallon container bag in box system with potable water 19 Syrup Tank Systems Connect syrup tank containing potable water pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup System Place all bag in box syrup containers syrup outlet tubes in container containing potable water 20 Flush sanitizing solution from the syrup system and the dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all sanitizing solution out of the syrup system and the dispensing valve C Continue to activate the dispensing valve in cycles ON for 15 seconds OFF then ON for 15 sec onds Repeat ON and OFF cycles for 15 cycles 21 Repeat steps 19 and 20 precedin
24. 72 Drip Tray 12 1560001882 Coil Wtr No 4 and 5 6 Flavor or 30 4778 Brkt Mtg Drip Tray No 5 and 6 8 Flavor 31 331309000 Screw 13 14763 Retainer Coil Front 32 140135000 Clamp Hose 44 560001875 Coil Wtr 6 6 Flavor 33 1113500000 Tube Vynl 500 I D 560001877 Coil Wtr No 7 and 8 8 Flavor 34 1200498003 Nut Hex No 8 32 15 560000862 Coil Syr Assy RH 35 186207000 Washer Ft 219 I D 16 1560001880 Coil Wtr No 1 36 188072000 Screw 17 188072000 Screw SM 10 TRPH 16 2006 2014 Cornelius Inc Vanguard 245 Service Manual VANGUARD 245 POST MIX DISPENSER COLD CARBONATED Figure 21 42 Publication Number 301135000SER 2006 2014 Cornelius Inc Vanguard 245 Service Manual VANGUARD 245 POST MIX DISPENSER COLD CARBONATED Table 2 Vanguard 245 post mix dispenser cold carb Table 2 Vanguard 245 post mix dispenser cold carb Item K Part No Description No Part No Description 24 560003654 Chassis Rfg 230V 60HZ 1 1560002628 Tank Assy 25 317015000 O Ring 560007415C Tank Carb Assy 26 Dispensing Balve Assy 2 71860230 Valve Pres Relief 27 318308000 Screw 710660001 Probe Assy Insrt Mold 28 40407 Retainer S Prod Line 3 311304000 Gasket Male Flare 29 4123 Cover Access Back 4 178025100 Gaske
25. G VALVES FOR WATER TO SYRUP RATIO BRIX OF DISPENSED PRODUCT The dispensing valves are each equipped with adjustable syrup flow regulators The Water To Syrup Ratio Brix of the dispensed product is controlled by adjustment of these syrup flow regulators Consult the dispensing valve manufacturer for the proper adjustment procedure Publication Number 301135000SER 18 2006 2014 Cornelius Inc CGinc ius gt Vanguard 245 Service Manual CLEANING AND SANITIZING DAILY CLEANING OF UNIT 1 Remove cup rest from the drip tray 2 Wash drip tray in place on the Unit then rinse drip tray with hot water allowing water to drain out through the drain hose Wash cup rest then rinse the cup rest with clean water Install cup rest in the drip tray Clean all external surfaces of the Unit with a sponge Rinse out the sponge with clean water then wring excess water out of the sponge and wipe off all external surfaces on the Unit Wipe Unit dry with a clean soft cloth DO NOT USE ABRASIVE CLEANERS 5 Remove nozzle and syrup diffusers from the dispensing valves Place nozzles and syrup diffusers in sanitizing solution 6 Wash the nozzles and syrup diffusers in sanitizing solution then rinse them with potable water Re install nozzles and syrup diffusers back on the dispensing valves SANITIZING POST MIX SYRUP SYSTEMS A WARNING Only trained and certified electrical plumbing and refrigeration technicians should service
26. OARD REPLACEMENT 1 Shut off water and CO2 at their sources 2 Remove the hood by removing screws on the top and lifting up 3 Remove controller cover by following remove mounting screw Mounting e lift up slightly and push back controller cover Connectors 4 Unplug all connectors Mounting 5 Remove mounting screws Screws Figure 14 6 Install new controller board by reversing this procedure 2006 2014 Cornelius Inc 35 Publication Number 301135000SER Vanguard 245 Service Manual CONDENSER FAN REPLACEMENT 1 Shut off water and CO2 at their sources 2 Remove the hood by removing screws on the top and lifting up Mounting screws of 3 Remove cover by removing two mounting screws cover Harness 4 Unplug harness Mounting screws of 5 Lift up condenser assembly cover by loose four condenser mounting screws assembly Mounting screws 6 Remove four mounting screws of motor bracket of motor bracket Mounting screws 7 Remove fan motor by disassembling three motor of motor mounting screws Figure 19 8 Install new fan motor by reversing this procedure Publication Number 301135000SER 36 2006 2014 Cornelius Inc 2 Vanguard 245 Service Manual ASSE 1022 COMPLIANT VENTED CHECK VALVE OPTION INSTRUCTION FOR CONVERSION OF CHUDNOW VALVE WITH ANDERSON VALVE CHANGE 1 The water inlet fitting of Carb Tank is chan
27. R REMOTE Figure 22 44 Publication Number 301135000SER 2006 2014 Cornelius Inc Vanguard 245 Service Manual VANGUARD 245 POST MIX DISPENSER REMOTE Table 3 Vanguard 245 post mix dispenser remote Table 3 Vanguard 245 post mix dispenser remote Item Part No Description Item RAS PartNo Description 32 120227000 Washer LK 194 I D 33 320539000 Washer Ft 191 1 0 2 560002107 Panel Back 34 321484000 Grommet 1320389000 Bushing Snap 35 560000292 Condenser Coil 4 4680 Screw MA 8 32 PAPH 6 4197 Motor Fan 35W 120V 60HZ 5 1560001722 Platform 36 560000123 Motor Fan 35W 240V 60HZ Br TEES Ins GT ROA 560000170 Motor Fan 23W 230V 50HZ 4182 Kit Comp 3 4 H P 120V 60HZ Brit Motor Fan 7 4408 Kit Comp 3 4 H P 230V 60HZ 38 189429000 Nut Hex 1 4 20 4407 Kit Comp 3 4 230V 50HZ 39 187394000 Cushion Fan Mount 449999999 Transformer 120V 60HZ 24V 29 1 8 449999996 Transformer 240V 60HZ 24V 14187 Control Ice Bank 560002114 Transformer 230V 50HZ 24V das Her Retainer 9 186146000 Nut Hex 5 16 18 A 9098999000 44 5119 Nut Hex NO 4 40 10 2602 Dryer 11 319941000 Screw TR 8 32 HXWS 12 45 960001415 Receptacle 12 189723000 Grommet Comp 46 310780000 Screw 4 40 PAPH 20
28. ated water dispensing valve s may be converted to also dispense carbonated drink s A cylinder delivers carbon dioxide CO2 gas through adjustable CO2 regulators to the applicable syrup tanks or bag in box syrup pumps and also the remote carbonator Plain water enters the remote carbonator water tank and is carbonated by gas pressure also entering the water tank When dispensing valve is opened gas pressure exerted upon the applicable syrup tank contents or bag in box syrup pump pushes syrup from the syrup supply through the Unit cooling coils and on to the dispensing valve Carbonated water is pushed from the remote carbonator by CO2 gas head pressure and is pushed through the Unit cooling coils to the dispensing valve Syrup and carbonated water meet simultaneously at the dispensing valve resulting in a carbonated drink being dispensed Still non carbonated drink is dispensed in the same manner as the carbonated drink except plain water is substituted for carbonated water UNIT WITH INTEGRAL CARBONATOR NOTE The unit is factory set to dispense non carbonated water and carbonated water as per cus tomer s requirement It is available to dispense at most 2 non carbonated waters 6 Flavours or 3 non carbonated waters 8 Flavors with carbonated water dispensing from the remaining valve s Non carbonated water dispensing valve s may be converted to also dispense carbonated drink s A cylinder delivers carbon dioxide
29. circumstances and after any water system disruption plumbing work earthquake etc Refer to manual provided with the remote carbonator for servicing procedure UNIT WITH INTEGRAL BUILT IN CARBONATOR The carbonator water pump water inlet strainer screen and double liquid check valve must be inspected and cleaned at least once a year under normal circumstances and after any water system disruption plumbing work earthquake etc This service procedure must be performed by a qualified Service Person SERVICING WATER PUMP WATER INLET STRAINER SCREEN A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment 1 Shut off CO2 and plain water supplies to the Unit 2 Remove screw securing the hood then lift hood up an off the Unit 3 Pull up on the carbonated water tank relief valve ring protruding up through the drop in refrigeration deck to bleed off all CO2 pressure from the water tank Loosen screen retainer then pull screen retainer and strainer screen from the water pump Pull screen from screen retainer Clean any sediment from the screen retainer and the water pump screen Inspect screen for holes restrictions corrosion and other damage Discard damaged screen Publication Number 301135000SER 24 2006 2014 Corn
30. d REG RGSS ad qu e io Re De 1 1 Different Types of Alerts 145655 y Da DE a i RAW AREA E 1 Safety TIPS acria Pe EE ES 1 Qualified Service Personnel ee Obs Sere ene ow Ge eee ORS Ert ene a 1 Safety Preca tions La ces oi ad e AM 2 Shipping And Storage cae EG Ed PRU Det na 2 CO2 Carbon Dioxide Warning 32 2364 455 GES RE od Ret El 2 Mounting in or on a Counter ias pee hee SES L 2 Equipment Handling 2 RE REIN euh bM Pa ERU ee caw DE i et 3 General Information osa spun aaa A ala 4 General Description Lisa Es a r eter one rr eae tert eee oes 4 Warranty Reference Information 4 Unit Description TT 4 SUSCHIGAHONS S 5 Desig Data EE iu ES ENS eee eS 5 Part Number o r caren i ES esco ES os da pt 5 Capability ot abs dette hou a i DO lia a eA 6 Miscellaneous Information cv Les De em bem oh iem i EC rs x E as He Hei ONE 6 Theory of Operation Met afte et i uo a B aa sai ass tem AR Sia COR td B LLA EO 6 Unit Requiring Connection to Remote Carbonator 6 Unit with Integral Carbonator beens eas ates 6 ET 7 Delivery Inspection And Unpacking
31. drip tray hose to nipple on the drip tray Secure connection with clamp 2 Route lower end of drip tray drain hose to and attach to the drain allowing a 76cm 3 inch air gap between the drain and end of the drain hose CONNECTING SYRUP SOURCE LINES TO THE UNIT NOTE The Unit barbed stainless steel syrup inlet tubes located on the front of the Unit are labeled to identify the dispensing valves they serve For example the barbed syrup inlet stainless steel tube labeled 1 provides syrup to be dispensed from the No 1 dispensing valve Proceed as follows to connect syrup source lines to the Unit 1 Route the syrup source lines numbered for identification from the syrup source location up to the Unit barbed stainless steel syrup inlet tubes on front of the Unit 2 Connect the numbered syrup source lines to the corresponding labeled Unit barbed stainless steel syrup inlet tubes 2006 2014 Cornelius Inc 9 Publication Number 301135000SER Vanguard 245 Service Manual eet D E 82 mm al Qm oe mm 102 mm MINIMUM DRIP TRAY AREA Figure 2 Vanguard 245 Counter Cutout CONNECTING CARBONATED WATER SOURCE UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR Proceed as follows to connect carbonated water source line to Unit requiring connection to a remote carbonator 1 Route carbonated water source line from the remote carbonator up to the Unit 2 Connect the carbonated water source line to the lab
32. driver pry bar into cap openings doing so may damage the valve and cause a leak Use an adjustable strap wrench to remove over tight or rusted caps Open valve slowly If valve is hard to open discontinue use and contact your supplier Never apply flame or localized heat directly to any part of the cylinder High temperatures may damage the cylinder and could cause the pressure relief device to fail prematurely and venting the cylinder contents Never strike an arc on a compressed gas cylinder or make a cylinder part of an electrical circuit For additional information on storage and handling refer to Compressed Gas Association CGA pamphlet P 1 Safe Handling of Compressed Gases in Containers available from the CGA EQUIPMENT HANDLING A CAUTION This equipment is NOT suitable for installation in an area where a water jet could be used and MUST NOT be cleaned by water jet A CAUTION This equipment is top heavy and unstable when empty and MUST NOT be operated unless the unit is in place and the water bath is filled 2006 2014 Cornelius Inc 3 Publication Number 301135000SER Vanguard 245 Service Manual eines D GENERAL INFORMATION GENERAL DESCRIPTION This manual is a guide for installing operating and maintaining this equipment This section gives the Unit Description Theory of Operation and Design Date for Vanguard 245 Post Mix Beverage Over Counter Dispenser This Unit must be installed and serviced by a qua
33. duct into cup or glass NOTE Dispensing of a portion control drink may be stopped by pressing the CANCEL POUR switch Drinks may be manually dispensed non portion control by pressing and holding the CANCEL POUR switch Unit POWER Switcu 50 Hz Units EXCLUDED The Unit power switch must be in ON position before the Unit will operate DISPENSING VALVES KEYED LOCR OUT SWITCH The dispensing valves keyed lock out switch located on side of the Unit must be in the ON vertical position to operate the electric dispensing valves The keyed lock out switch in the OFF horizontal position turns off electrical power to the dispensing valves only but the refrigeration system will continue to operate Publication Number 301135000SER 14 2006 2014 Cornelius Inc Cines gt Vanguard 245 Service Manual DAILY PRE OPERATION CHECK 1 The supply should be checked daily to make sure there is an adequate supply of CO2 If necessary replenish the supply 2 Make sure there is sufficient syrup supply If necessary replenish the syrup supply 3 Make sure the drip tray is clean and clean cup rest is in place in the drip tray UNIT OPERATION 1 Make sure the Unit power switch if applicable is in the ON position 2 Make sure the dispensing valves keyed lock out switch located on side of the Unit is in the ON vertical position 3 Hold cup or glass under the dispensing valve nozzle then activa
34. e all air from the carbonated water and the plain water systems Check entire system for plain water carbonated water and CO2 leaks and repair any leaks IMPORTANT All syrup systems must be sanitized before the Unit is put into operation Sanitize all syrup systems as instructed in the SERVICE AND MAINTENANCE section of this manual Activate syrup supplies to the Unit Dispense from all dispensing valves to purge all air from the syrup systems NOTE The dispensing valves adjustable water flow regulators are factory adjusted and should reguire no further adjustment If re adjustment should become necessary consult the dispensing valve manufacturer for the proper adjustment procedure Adjusting Dispensing Valves For Water To Syrup Ratio Brix Of Dispensed Product The dispensing valves are each eguipped with adjustable syrup flow regulators The Water To Syrup Ratio Brix of the dispensed product is controlled by adjustment of these syrup flow regulators Consult the dispensing valve manufacturer for the adjustment procedure If your dispenser is eguipped with portion control dispensing valves consult the dispensing valves manufac turer for the proper portion control adjustment procedure Recheck entire installation for CO2 plain water carbonated water and syrup leaks and repair any leaks Install Unit front access panel on Unit and secure with two screws 12 Slide tray all the way up on the drip tray brackets then secu
35. eck valve Assemble check valves together DO NOT OVER TIGHTEN Install double liquid check valve in water pump outlet port then connect plain water outlet line to the double liq uid check valve outlet Restore and plain water supplies to the Unit Connect electrical power to the Unit The water pump will cycle on and fill the carbonated water tank with car bonated water Check for water leaks and tighten any loose connections 10 Pull up on the carbonated water tank relief valve ring protruding up through the drop in refrigeration deck to release trapped air from inside the water tank 11 Install hood on Unit and secure with screw 2006 2014 Cornelius Inc 25 Publication Number 301135000SER Vanguard 245 Service Manual CC gt CLEANING CO2 SYSTEM Co2 GAS CHECK VALVES The regulators CO2 gas check valves and the Unit CO2 inlet line CO2 gas check valve must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO2 system ALWAYS REPLACE BALL SEAT QUAD RING SEAL EACH TIME GAS CHECK VALVES ARE SERVICED CONVERTING STILL NON CARBONATED DRINK DISPENSING VALVE TO DISPENSE A CARBONATED DRINK Units Requiring Connection to Remote Carbonator Non Carbonated Drink Dispensing Valve s can be converted into Carbonated Drink Dispensing Valve s by connecting a carbonated water rather than a plain line to the unit plain water line connected to dispensing valve
36. eled barbed stainless steel carbonated water inlet tubes on front of the Unit CONNECTING PLAIN WATER SOURCE LINE TO UNIT NOTE Cornelius Inc recommends that a water shutoff valve and a water filter be installed in the plain water source to be connected to the Unit The plain water source water pressure must not be less than 35 psi or more than 45 psi If water pressure exceeds 45 psi a water pressure regulator must be used to regulate the water pressure The plain water source to the equipment shall be installed with adequate back flow protection to comply with applicable Federal State and local codes Publication Number 301135000SER 10 2006 2014 Cornelius Inc Cinek gt Vanguard 245 Service Manual UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR Proceed as follows to connect plain water source line to No 3 six flavor Unit or No 4 eight flavor Unit dispensing valve on Unit requiring connection to a remote carbonator 1 Route plain water source line from plain water source up to the Unit 2 Connect plain water source line to barbed stainless steel plain water inlet tube labeled WTR 3 six flavor Unit or WTR 4 eight flavor Unit on front of the Unit UNIT WITH INTEGRAL BUILT IN CARBONATOR Proceed as follows to connect plain water source line to Unit with an integral built in carbonator 1 Route plain water source line from plain water source up to the Unit 2 Connect plain water source line to carb
37. elius Inc Cines gt Vanguard 245 Service Manual 7 Check O Ring on the screen retainer Replace worn or damaged O Ring NOTE A screen should always be used otherwise particles could foul the double liquid check valve 8 Install screen in screen retainer then screw retainer into the water pump and tighten securely 9 Proceed to servicing double liquid check valve and service the double liquid check valve as instructed SERVICING DOUBLE LIQUID CHECK VALVE 1 Service water inlet strainer screen as instructed in previous paragraph before servicing the double liquid check valve 2 Disconnect plain water outlet line from double liquid check valve outlet then remove double liquid check valve from the water pump outlet port 3 Disassemble each check valve as shown in Figure 3 Wipe each part with clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion dete rioration and other damage Discard ball seat and any damaged or suspicious parts and replace with new parts during reassembly CONTROL BOX O RING P N 315349000 SCR EEN RETAINER WATER STRAINER SCREEN P N 315348000 WATER PUMP DOUBLE LIQUID CHECK VALVE Figure 3 Water Strainer Screen and Double Liquid Check Valve 5 Re assemble check valves ALWAYS INSTALL NEW BALL SEAT O RING AND FLAT WASHER NOTE Make sure when assembling the check valves together the FLAT WASHER is in place inside female end of the ch
38. ensed shut off valve closed off valve Carbonator regulator not prop Adjust carbonator regulator as erly adjusted instructed Inoperative carbonator liquid level Replace inoperative component control module or water tank liquid level probe Inoperative water pump or water Replace inoperative pump or motor pump motor Dispensing valve syrup flow regula 1 Adjust Water to Syrup Ratio as tor not properly adjusted instructed Syrup Tanks System 2 ER CO gas pressure to syrup tanks Adjust regulator for syrup tanks as Moe EN Patio too low ortoo insufficient to push syrup out of instructed tank 3 Adjust syrup pumps regulator as Bag In Box System CO gas pressure to syrup pumps insufficient to operate pump instructed Adjustment of dispensing valve syrup flow regulator does not decrease to desired water to syrup ratio Dirty or inoperative dispensing valve syrup flow control Disassemble and clean dispensing valve syrup flow control Primary CO2 regulator out of adjust ment for existing water conditions or temperature Adjust primary CO2 regulator As instructed Air in carbonator water tank 2 Vent air out of carbonator water tank Dispensed product carbonation too through relief valve low Water oil or dirt in supply 3 Remove contaminated CO2 Clean system lines regulator etc using a mild detergent Install a clean CO2 supply suppl
39. er normal conditions and after any system servicing or disruption Servicing of the CO2 gas check valves should be performed by qualified Service Personnel Refer to SERVICE AND MAINTENANCE section of this manual for CO2 as check valve inspecting and servicing procedure Publication Number 301135000SER 16 2006 2014 Cornelius Inc Vanguard 245 Service Manual SERVICE A 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 A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment A CAUTION Do not place or store anything on top of the Unit PREPARING UNIT FOR SHIPPING OR RELOCATING A 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 environment will cause residual water in the Unit to freeze resulting in damage to internal components HOOD AND FRONT ACCESS PANEL REMOVAL Hoop REMOVAL Remove screw secu
40. es continuously but does not form sufficient ice bank 2 Unit located in excessively hot area 2 Relocate unit or check and if necessary or air circulation through condenser clean condenser coil as instructed coil is restricted 1 No power source blown fuse or 1 Replace fuse or reset circuit breaker tripped circuit breaker NOTE Fuse or circuit breaker are not part of unit 2 Agitator motor propeller obstructed 12 Remove obstruction 3 Low Voltage 3 Voltage must be 90 135VAC 115 volt Agitator motor not operating unit or 180 260 230 VAC unit at com pressor terminals when compressor is trying to start 4 Loose disconnected or broken wir 4 Tighten connections or replace broken ing wiring 5 Inoperative agitator motor 5 Replace agitator motor 2006 2014 Cornelius Inc 31 Publication Number 301135000SER Vanguard 245 Service Manual Giner D COMPONENT SERVICE The follovving are procedures for replacing the major components of the Vanguard CARBONATOR PUMP REPLACEMENT Shut off water and CO2 at their sources Remove the hood by removing screws on the top and lifting up Depressurize carbonator by dispensing drinks from any valve Disconnect povver to the unit 9v dco qe Disconnect water in and out lines Pump V Band 6 Loosen the V band clamp and remove pump 7 Install new pump by reversing this procedure NOTE Be sure there is anti seize compound Pump Tang
41. g Controls cia os e ere hte ES DE DE de 14 Dispensing Valve Operation 14 Push Button Dispensing Valve 14 Dispensing Valve with Dispense 14 Portion Control Dispensing Valve 14 Unit Power Switch 50 Hz Units Excluded 14 Dispensing Valves Keyed Lock out Switch 14 Daily Pre Operation Check ES Ls EARS 15 Unit Op ration es Sess E EAR east ee Sake CR RA DR doe Ate ua 15 Cleaning and Sanitizing s vx s seen a a a ees we va ERE Or ira rec ET 15 Daily Cleaning ot ans ous ais entia eo ba S Farms ed OSA OTI Up ed e EN pun 15 Sanitizing Syrup Systems en ques 15 Checking Drop in Refrigeration Assembly Condenser Coil for Restrictions 15 Checking Ice Water Bath V Rn 15 Carbonator Water Pump Yearly Maintenance or After Water System Disruptions 16 Unit Requiring Connection to Remote Carbonator 16 Unit with Integral built in Carbonator 16 Cleaning CO2 Gas Check Valves 9 16 DEAN S 17 Preparing Unit for Shipping or Re
42. g to purge sanitizing solution out of the remaining syrup systems and dis pensing valves 22 Remove potable water source from the syrup system PURGE WATER OUT OF SYRUP SYSTEMS RESTORE OPERATION 23 Syrup Tank Systems A Noting syrup tanks CO2 regulator pressure setting observed in step 4 preceding readjust CO2 regulator to the observed pressure setting B Connect tanks containing syrup into syrup systems Bag in Box Syrup System C Remove all bag valves from bag in box syrup containers outlet tubes connectors D Connect bag in box syrup containers into the syrup systems 24 Place waste container under dispensing valves Dispense from all dispensing valves to permit syrup to purge all potable water from the syrup systems and the dispensing valves Continue to dispense from the dispensing valves until only syrup is dispensed from the syrup systems and valves A WARNING To avoid possible personal injury or property damage do not attempt to remove the syrup tank cover until CO2 pressure has been released from the tank 25 Dispose of waste sanitizing solution in a sanitary sewer not in a storm drain then thoroughly rinse the inside and the outside of the container that was used for sanitizing solution to remove all sanitizing solution residue 2006 2014 Cornelius Inc 21 Publication Number 301135000SER Vanguard 245 Service Manual Giner D CLEANING DROP IN REFRIGERATION ASSEMBLY CONDENSER COIL A CAUTION The refri
43. ged as below picture and the p n of Carb Tank is changed from 560007415C to 890516707 Remove this dual check valve New Carb Tank 890516707 Orginal Carb Tank 560007415C Figure 21 2006 2014 Cornelius Inc 37 Publication Number 301135000SER Vanguard 245 Service Manual CHANGE 2 The Transformer is moved from the Carb Motor Deck to the Refrigeration Deck as below picture Figure 22 CHANGE 3 To assemble the Anderson Check Valve on the Carb pump Outlet as below picture 890212504 U 890216706 OonLh o3933 DZUDUO 1 1 890212414 Figure 23 CHANGED PARTS LIST Part Number Description Qty Unit 620608773 Valve CHK Vent Anderson 1 EA 890216706 Fitg 3 8MPT 5 8 18NPT 1 EA New Parts Added 891212504 Coil Water Outlet Pump to Anderson Valve 1 EA 890212414 Coil CHK Valve to main Water Coil 1 EA NOTE This option is available for markets which demand the use of ASSE compliant vented dou ble check valves in the syste Based on the local plumbing laws this option can be made available on customer discretion Publication Number 301135000SER 38 2006 2014 Cornelius Inc 2 Vanguard 245 Service Manual OLYMPUS VENTED DOUBLE CHECK VALVE INSTALLATION NEN Vented Double Check Valve Vented Double Check valve 1 Ni k 4 NS gt gt le Cal Figure 25 Olympus 5V Installation DCV 2006 2014 Cornelius Inc 39 P
44. geration assembly condenser coil must be cleaned every 30 days Excessive accumulation of dust lint and grease on the condenser coil will restrict air flow through the coil and cause the refrigeration system to overheat Operating the refrigeration system in an overheated condition will eventually lead to compressor failure and will automatically void the factory warranty Clean the condenser coil and air filter as follows A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment 1 Remove screw securing the hood then lift the hood straight up to remove from the Unit Vacuum or use a soft brush to clean the condenser coil If available use low pressure compressed air Clean dust and dirt from around top of the drop in refrigeration assembly Install hood on the Unit and secure with screw a Connect electrical power to the Unit CHECKING ICE WATER BATH A gurgle heard from the Unit indicates water level in the water tank is low and more water should be added for maximum cooling Before adding more water check the ice water bath for cleanliness and check the water tank coils for excessive mineral deposit build up A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures
45. he syrup and water source inlet Lines to be connected to the unit will not be routed through the access hole Drip tray drain hose is to be connected to the drip tray and secured with clamp drip tray drain hose Water lever kit to be installed on dispenser s equipped with UF 1 dispensing valves 2006 2014 Cornelius Inc 7 Publication Number 301135000SER Vanguard 245 Service Manual Giner D SELECTING LOCATION A DANGER To avoid possible fatal electrical shock or serious injury to the operator it is required that a GFI ground fault circuit interrupt be installed in the electrical circuit for the domestic Units It is required that an ELCB earth leakage circuit breaker be installed in the electrical circuit for the export Units This Unit may be installed on a countertop as a self serve Unit or the Unit may be installed in a drive through or a center island installation Locate the Unit so the following requirements are satisfied 1 Near a properly grounded electrical outlet with proper electrical requirements The electrical circuit must be properly fused slow blow type fuse or circuit must be connected through an equivalent HACR circuit breaker The electrical outlet must be accessible for ease of connecting and disconnecting the Unit power cord No other electrical appliance should be connected to this circuit ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES A CAUTION Do not place or st
46. ied Service Person CHECKING ICE WATER BATH A gurgle heard from the Unit indicates the water level in the water tank is low and more water should be added for maximum product cooling Water should be added to the water tank as instructed in SERVICE AND MAINTENANCE section This procedure should be performed by a qualified Service Person 2006 2014 Cornelius Inc 15 Publication Number 301135000SER Vanguard 245 Service Manual CC gt CARBONATOR WATER Pump YEARLY MAINTENANCE OR AFTER WATER SYS TEM DISRUPTIONS Unit Requiring Connection to Remote Carbonator The remote carbonator water pump water inlet strainer screen and the liquid double check valve must be inspected and cleaned by a qualified Service Person at least once a year under normal circumstances and after any water system disruption plumbing work earthquake etc Refer to manual provided with the carbonator for the liquid double check valve inspection and cleaning procedure Unit with Integral built in Carbonator The water pump water strainer screen and the liquid double check valve must be inspected and cleaned as instructed at least once a year under normal circumstances and after any water system disruption plumbing work earthquake etc Refer to SERVICE AND MAINTENANCE section of this manual for inspecting and cleaning procedure CLEANING CO2 Gas CHECK VALVES The CO2 gas check valves must be inspected and serviced as instructed at least once a year und
47. inks by connecting plain water instead of carbonated water to the valves water inlet lines 2006 2014 Cornelius Inc 50 Publication Number 301135000SER Vanguard 245 Service Manual Giner gt FLow DIAGRAM Eight Flavor Unit Requiring Remote Carbonator DISPENSING 5 VALVE 8 DUAL CARB WATER 2 COOLING COILS 4 i 1 CO2 WATER 1 SYRUP 1 T m SYRUPCOOLING STILL COILS 8 2 NON CARB OR CARB DRINR CO2 PLAIN WATER 2 3 ki STILL NON CARB i 1 SYRUP 3 7 OR CARB DRINK PLAIN WATER 1 PLAIN WATER COOLING COILS SYRUP 4 STILL NON CARB r n OR CARB DRINK i 0 0 5 M STILL CO2 PLAIN WATER 5 6 NON CARB I 1 OR CARB DRINK SYRUP 5 1 4 SYRUP 6 yf CO2 WATER 7 8 i i SYRUP 7 STILL NON CARB OR CARB DRINK CARB DRINK 8 cars DRINK SYRUP 8 Figure 27 Flow Diagram NOTE The indicated CARB DRINK dispensing valves may be made to dispense still non carb drinks by connecting plain water instead of carbonated water to the valves water inlet lines Publication Number 301135000SER 51 2006 2014 Cornelius Inc Vanguard 245 Service Manual FLow DIAGRAM Six Flavor Unit with Integral Carbonator MOJ4 82 ANIYA gt LAIN dNdUAS La J31NI NIVId me a ee me J
48. lified Service Person This Unit Contains no User serviceable parts WARRANTY REFERENCE INFORMATION Warranty Registration Date to be filled out by customer Unit Part Number Serial Number Install Date Local Authorized Serviced Center UNIT DESCRIPTION The Vanguard 245 over the counter post mix beverage dispenser is compact and may be installed on a counter top as a self service Unit or the Units are equipped with drop in type refrigeration assemblies that are easily removed for service and maintenance Adjustable water flow regulators and syrup flow regulators located on the dispensing valves are easily accessible to control the water flow rate of the dispensing valves and Water to Syrup Ratio of the dispensed product The only requirements for operation are installation of the Unit on a counter top installation of LOOSE SHIPPED PARTS filling water tank with water connection to a remote carbonator Unit requiring connection to a remote carbonator connections to plain water and syrup supplies adjustment of regulators plugging unit power cord into an electrical outlet and adjusting the dispensing valves water and syrup flow regulators for proper water flow rate and Water to Syrup Ratio of the dispensed product The units are available in two sizes both sizes can be ordered with or without built in carbonator Medium six valve Large eight valve Removable Top Panel N
49. locating 17 Hood and Front Access Panel Removal eee 17 Flood Removal 2455 ue Eis LL SNL eee Reet oe ee Bol ru Res El EA ES 17 Front Access Panel Removal 17 Periodic INS DECUON cauere tA Ue os a AS Pop eat Ge d MOD at oe ew hate ee 17 ADJUSTMENTS estors ee les ag ened Dre a ete DE ego espa ees 18 CO2 Regulators Adjustments kasa k ik ak eee y ea eee DEL RE eS RE ERR me 18 Adjusting Carbonator CO2 Regulator ete La 18 Unit Requiring Connection to A Remote Carbonator 18 Unit With Integral Built In Carbonator 18 Sugar Syrup Tanks CO2 Regulator 18 Low calorie Diet Syrup Tank CO2 Regulator 18 Syrup Pumps Bag in box 18 Adjusting Dispensing Valves for Water Flow Rate 18 Adjusting Dispensing Valves for Water to Syrup Ratio Brix of Dispensed Product 18 Cleaning and Sanitizing o EL ae E 19 Daily Cleaning of Unit x e ease ie CAR State mei wee eae RP CR DE a ees 19 Sanitizing Post Mix Syrup Systems Ma at 19 Wash Sylb SVSIOIS 4 2 25 Meda cee
50. nk 18 5600005518 Motor Assy Agit 240V 60HZ 45 309898000 Block Term 5600004702 Motor Assy Agit 230V 50 60HZ 46 5119 Nut Hex NO 4 40 19 4932 Brkt Motor Agititor 47 560001415 Receptacle 20 308912000 Motor Agit 25W 240V 60HZ 48 310780000 Screw MA 4 40 PAPH 20 318168002 Motor Agit 18W 230V 50 60HZ 49 309645000 Swt Rocker 120V 60HZ 21 186154000 Screw SE 8 36 PAPH 12 50 560001396 Plug Swt 220 230V 50 60HZ 22 319856000 Plate Heat Transfer 51 188117000 Screw SM 8 TRPH 12 Publication Number 301135000SER 47 2006 2014 Cornelius 1 Vanguard 245 Service Manual Pump AND MOTOR COLD CARB ASSEMBLY Figure 24 Table 5 Pump and Motor cold carb assembly Table 5 Pump and Motor cold carb assembly Item m No Part No Description Item Part No Description 8 319453000 Strain Relief Pump and Motor 230V 60HZ 9 319941000 Screw TR 8 32 HXWS 12 Pump and Motor 230V 50HZ 10 1313438000 Switch Toggle 361003200 Fitg L 3 8 MPT By 5 8 18 11 3175 Harn Wire Carb Not Shown 197359000 Control Liquid Level 12 312996000 Pump Water 395098000 Strain Relief 13 187483000 Clamp Pump and Motor 300626000 Motor Pump 1 4H P 240V 50 EE Vee Dual 4 60HZ 15 1151 Fitg L 3 8 NPT 199020000 Motor Pump 1 4H P 230V 50HZ 16 200498003 Nut Hex No 8 32 Not Shown 5 1560000863 Box Contr
51. ol 17 317989555 Clip Thermo Thermostat Control 4967 Cover Elec Box 18 1318039000 Thermostat Control 560001630 Cord Jump 19 1168049000 Fitg Chase Conduit 2006 2014 Cornelius Inc 48 Publication Number 301135000SER Vanguard 245 Service Manual REFERENCE MATERIAL WIRING DIAGRAM sz XINO SLINN A gyvo 0102 T3A NHO MO NYO a HO LHM 1 HO ONIMVHQ AIEWASSV IVNIS 33S SAATWA OL A J qo H9014 NY1L oa HOLIMS H3MOd TANHO SRO 30 NUO IOHLNOO 391 ALIHM OL Q388lH yay LUVLS L HOSSIHdINOI 2006 2014 Cornelius Inc 49 Publication Number 301135000SER CGinc ius gt Vanguard 245 Service Manual FLow DIAGRAM Six Flavor Unit Requiring Remote Carbonator DISPENSING VALVE 6 DUAL CARB WATER COOLING COILS 5 p i 1 CARB DRINK SYRUP 1 SYRUP COOLING COILS 6 CARB DRINK 1 1 SYRUP 2 1 i PLAIN WATER STILL COOLING COILS I 3 NON CARB CO2 PLAIN WATER OR CARB DRINR ds iu CARB DRINK sues TI 1 2 WATER 4 5 TE CARB DRINK SYRUP 5 1 CARB DRINK CO2 WATER 6 T 1 SYRUP 6 1 din ee Ss Figure 26 Flow Diagram NOTE The indicated CARB DRINK dispensing valves may be made to dispense still non carb dr
52. on the pump Figure 5 Publication Number 301135000SER 32 2006 2014 Cornelius Inc CGinc ius gt Vanguard 245 Service Manual Pump MOTOR REPLACEMENT Shut off water and CO2 at their sources Remove the hood by removing screws on the top and lifting up Depressurize carbonator by dispensing drinks from any valve Disconnect power to the unit Disconnect water in and out lines Unplug motor harness DO CON PP GO NS Remove control box Pump V Band 8 Loosen the V band clamp and remove pump 9 Remove nuts from bolts and remove the motor Mounting Bolts 10 Install new motor by reversing this procedure NOTE Be sure there is anti seize com pound on the pump drive tang Pump Tang Figure 8 2006 2014 Cornelius Inc 33 Publication Number 301135000SER Vanguard 245 Service Manual AGITATOR MOTOR REPLACEMENT 1 Shut off water and at their sources 2 Remove the hood by removing screws on the top and lifting up 3 Remove carbonator cover by removing mounting bolts and lifting up Mounting Bolts Figure 9 4 Remove mounting screws of condenser kit and lift up Mounting slightly Screws Mounting 5 Remove motor by reassembling mounting screws Screws Figure 11 6 Install new motor by reversing this procedure Publication Number 301135000SER 34 2006 2014 Cornelius Inc CGinc ius gt Vanguard 245 Service Manual CONTROLLER B
53. onator barbed stainless steel plain water inlet tube labeled CARB WTR and No 4 No 7 and No 8 dispensing valves barbed stainless steel plain water inlet tubes labeled WTR 4 WTR 7 and WTR 8 CONNECTING SOURCE LINE UNIT WITH INTEGRAL CARBONATOR Proceed as follows to connect source line to Unit with integral built in carbonator 1 Route CO2 source line connected to an adjustable CO2 regulator up to the Unit 2 Connect CO2 source line to CO2 check valve on end of the Unit inlet tube labeled CO2 ADJUSTING CARBONATOR REGULATOR UNIT REQUIRING CONNECTION TO A REMOTE CARBONATOR Adjust CO2 regulator regulator controls carbonator CO2 pressure as instructed in manual provided with the remote carbonator UNIT WITH INTEGRAL BUILT IN CARBONATOR Adjust regulator regulator controls Unit built in carbonator pressure to a nominal 80 psi inlet pressure to the carbonator must not exceed 125 psi ADJUSTING SYRUP SUPPLIES REGULATOR SUGAR SYRUP TANKS CO2 REGULATOR Adjust syrup tanks regulator to a minimum of 45 psi LOW CALORIE DIET SYRUP TANK CO2 REGULATOR Adjust low calorie diet syrup tank secondary CO2 regulator to 10 psi for syrup lines up to 30 feet in length Syrup lines longer than 30 feet in length may require a slightly higher setting of 12 psi maximum Excessive pressure may cause low calorie syrup carbonation resulting in foam SYRUP
54. ore anything on top of the Unit 2 Clearance above top of the Unit must be open to the ceiling A minimum clearance of 300 mm 12 inches must be maintained on the back side of the Unit and a minimum of 150 mm 6 inches clearance to the nearest obstruction must be maintained on both sides of the Unit These clearances must be provided to allow for proper air flow through the Unit to cool the refrigeration system The Unit must be located close to a permanent drain to route and connect the Unit drip tray drain hose INSTALLATION PLACING UNIT IN OPERATING POSITION NOTE This Unit is intended for indoor installation only Do not install this Unit in an outdoor envi ronment which would expose it to the outside elements The water tank drain hose drip tray drain hose and the water tank overflow hose may either be routed out through access hole on back of the Unit or they may be routed down through hole cut in the countertop under front of the Unit The carbonated water Unit with integral carbonator plain water and the syrup source inlet lines that are to be connected to the Unit may either be routed in through the back access hole or they may be routed up through hole cut in the countertop under front of the Unit Proceed to applicable installation instructions 1 Remove Unit front access panel by removing two screws securing the panel then remove the panel Install drip tray brackets on front of Unit and secure with screws installed in the b
55. r 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 con tact www cornelius usa 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 This document contains the original instructions for the unit described CORNELIUS INC 101 Regency Drive Glendale Heights IL Tel 1 800 238 3600 Printed in U S A TABLE OF CONTENTS Safety INSIUCHIONS 2e sania a cree aria ara tie Owe Lac aa NS nats a ae Su 1 Read and Follow ALL Safety Instructions 1 Safety OVOIVIBW died Gia eos PRE Pet pa oe
56. rackets Temporarily install the drip tray on the Unit by sliding the drip tray up on the drip tray brackets Place the Unit in operating position on the countertop Su B ox Out Unit base back access hole Route water tank drain hose drip tray drain hose and water tank overflow hose out Unit base back access hole The carbonated water plain water and the syrup inlet lines that are to be connected to the Unit will be routed through the back access hole up to the front of the Unit for connection to the stainless steel inlet tubes 6 Through hole cut in the countertop cut hole in countertop as indicated then place Unit in position on the coun tertop Cutting hole in the countertop allows routing the drip tray drain hose water tank drain hose and the water tank overflow hose down through the hole and syrup and water source inlet lines up through the hole to the stainless steel inlet tubes on front of the Unit Publication Number 301135000SER 8 2006 2014 Cornelius Inc Cinek D Vanguard 245 Service Manual Route water tank and drip tray drain hoses and the water tank overflow hose down through hole in the countertop Install rear access cover over Unit back access hole N Place Unit in operating position on the countertop comply with NSF International NSF reguirements within the United States the Unit base must sealed to the countertop and all access holes in the Unit base must be closed and sealed
57. re drip tray to brackets with two screws thread rolling 2006 2014 Cornelius Inc 13 Publication Number 301135000SER Vanguard 245 Service Manual Ginelius gt OPERATOR S INSTRUCTIONS A WARNING Disconnect power to the unit before servicing Follow all lock out tag out procedures established by the user Verify all power is off to the unit before performing any work Failure to comply could result in serious injury death or damage to the equipment A 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 A CAUTION Do not place or store anything on top of unit OPERATING CONTROLS Dispensing Valve Operation Push Button Dispensing Valve The push button on front of the dispensing valve need only to be pressed and held until the cup or glass is full of product then release the button DISPENSING VALVE WITH DISPENSE LEVER The dispensing valve lever located below the dispensing valve need only to be pressed with a cup or glass to dispense product PORTION CONTROL DISPENSING VALVE A Place desired amount of ice in appropriate cup or glass B Hold cup or glass under dispensing valve nozzle C Press appropriate S Small Medium L Large or XL Extra Large dispense switch to dispense pro
58. rical outlet with the proper electrical requirements The compressor denser fan motor and agitator motor will start and begin forming an ice bank When full ice bank has been formed the compressor and condenser fan motor will stop but the agitator motor will continue to operate circu lating ice water bath in the water tank 8 Unit With Integral Carbonator Place carbonator motor power switch in ON position The Unit integral carbon ator water pump motor will start and begin filling the carbonated water tank when the Unit is put into operation The carbonator water pump motor will stop after the water tank has been filled with carbonated water IMPORTANT Circulating air required to cool the refrigeration assembly condenser coil is drawn in through grille on back of the hood and is exhausted out through grille on top of the hood For proper cooling of the condenser coil the hood back grille must be positioned over the condenser coil on back side of the Unit 9 Install hood on the Unit and secure with screw Publication Number 301135000SER 12 2006 2014 Cornelius Inc CGinellus gt Vanguard 245 Service Manual PREPARATION FOR OPERATION 1 2 3 4 91 10 11 Unit reguiring connection to a remote carbonator Activate plain water and carbonated water supplies to the Unit Place dispensing valves keyed lock out switch on side of the Unit in the position Dispense from all dispensing valves to purg
59. ricting carbonated water flow Dirty water supply 6 Check water filter Replace cartridge Finished drink above 4 4 C 40 F 7 Check refrigeration system Dispensing valves keyed lock out 1 Place keyed lock out switch in ON posi switch in OFF position tion No electrical power to dispenser 2 Plugin dispenser power cord or check for blown power fuse or tripped circuit breaker No product dispensed Disconnected dispensing valves 3 Connect dispensing valves power cord power cord Disconnected or broken wiring to 4 Connect or replace wiring dispensing valve Inoperative transformer or dispens 5 Replace inoperative part ing valve solenoids Primary regulator out of adjust 1 Adjust primary regulator as ment for existing water conditions or instructed temperature Air in carbonated water tank 2 Vent air from carbonated water tank by Di dibriod b dispensing from No 1 dispensing ed ee to make carbonator water pump motor Qw cycle on water oil or dirt in CO2 supply 3 Have service person remove contami nated supply then clean sys tem lines regulator etc using a mild detergent install a clean CO2 supply 2006 2014 Cornelius Inc 29 Publication Number 301135000SER Vanguard 245 Service Manual C Gne Syrup supply container not securely connected into syrup system Securely connect syrup supply container into syrup sy
60. ring the hood then lift the hood straight up off the Unit to remove IMPORTANT Circulating air required to cool the refrigeration assembly condenser coil is drawn in through grille on back of the hood and is exhausted out through grille on top of the hood For proper cooling of the condenser coil the hood back grille must be positioned over the condenser coil on back side of the Unit FRONT ACCESS PANEL REMOVAL Remove two screws securing the front access panel then remove the panel PERIODIC INSPECTION 1 Clean the drop in refrigeration assembly condenser coil every 30 day as instructed in this manual section Cleaning the condenser coil should be performed by a qualified Service Person DO NOT place objects on top of or on back side of the Unit hood Restricting circulating air in and out of the Unit hood will cause the refrigeration system to overheat 2 Check the dispensing valves for dripping that indicates leakage and repair as necessary 2006 2014 Cornelius Inc 17 Publication Number 301135000SER Vanguard 245 Service Manual Ginelius gt ADJUSTMENTS CO2 REGULATORS ADJUSTMENTS A WARNING displaces oxygen Strict attention must be observed in the prevention of carbon dioxide 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 concen
61. s of CO2 gas experience tremors which are followed rapidly by loss of consciousness and DEATH MOUNTING IN OR ON A COUNTER A WARNING When installing the unit in or on a counter top the counter must be able to support a weight in excess of 230 Ibs 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 A CAUTION PRECAUTIONS TO BE TAKEN IN STORAGE Store and use with adequate ventilation Firmly secure cylinders upright to keep from falling or being knocked over Screw valve protection cap firmly in place by hand Store only where temperature will not exceed 52 C 125 F Store full and empty cylinders separately Use a first in first out inventory system to prevent storing full cylinders for long periods Publication Number 301135000SER 2 2006 2014 Cornelius Inc Cines gt Vanguard 245 Service Manual CAUTION PRECAUTIONS TO BE TAKEN IN HANDLING Protect cylinders from damage Use a suitable hand truck to move cylinders do not drag roll slide or drop cylinders Never attempt to lift a cylinder by its cap the cap is intended solely to protect the valve Never insert an object e g wrench screw
62. stem No syrup supply 2 Replenish syrup supply Bag in Box System 3 Replace inoperable syrup pump Only carbonated water dispensed Inoperable syrup pump Tanks Sys Adjust syrup tanks CO2 regulator as tem Syrup tanks CO2 regulator instructed not properly adjusted Inoperable dispensing valve 4 Repair dispensing valve Dispensing valve syrup flow control 5 Adjust dispensing valve syrup flow con not properly adjusted trol Water to Syrup ratio as instructed 3 minutes run limit exceeded 1 Turn power OFF for 15 second Water supply to carbonator dis 2 Correct water supply problem rupted Carbonated water tank water level Connect electrical wiring to water level probe electrical wiring disconnected probe see note Carbonator pump not operating Inoperative carbonated water tank 4 Replace probe see note water level probe Inoperative carbonator pump or 5 Replace pump or motor motor Inoperative control board 6 Replace control board Publication Number 301135000SER 30 2006 2014 Cornelius Inc Vanguard 245 Service Manual Ice bank sufficient No refrigeration called for 2 No water in water tank 2 Fill water tank with water as instructed 3 Control board power switch on top of 3 Place control board power switch in ON unit in OFF position position will be a built in 3 minute time delay before refrigeration compressor starts 4
63. t 1 4 Male Flare 30 317784000 Screw 5 1183310000 Valve Chk Blkhd 31 3982 Panel Access 6 4083 Harn Wire 32 4771 Cup Rest 7 71827619 Switch Keylock 33 77150200 Fitg Drain 1 2 20 8 620717788 Tube Inlet CO2 34 177150300 Fitg Ddrain L 1 2 Barb 9 4924 Panel Val 6 Flavor 35 4772 Drip Tray 4228 Panel Val 8 Flavor 36 4778 Brkt Mtg Drip Tray 10 560001487 Tube Conn 375 I D 37 331309000 Screw 11 140135000 Clamp Hose 38 140185000 Clamp Hose 12 113500000 Tank Over Flow Hose 39 113500000 Tube Vynl 500L D 13 140594000 Tank Drain Hose 40 1200498003 Nut Hex No 8 32 Pr 1173 Insulation Tank 41 186207000 Washer Ft 2191 0 15 560001874 Coil Wtr No 3 6 Flaver 42 1188072000 Screw 560001876 Coil Wir No 4 8 flavor 43 150447000 Washer 406 I D Drain Fitting 16 560002983 Retainer Coil 44 1890222401 Tube Soda 47 560001426 Coil Wtr No 4 6 Flaver 45 620717789 P Tube Water 560000753 Coil Wtr No 5 8 flavor 46 620050381 P Support Carb Tank 18 4763 Retainer Coil Front 47 174292000 Tube FlexCor 19 560000862 Coil Syr Assy RH 48 77050200 Plug 20 300000874 Coil Water Assy 49 560006959 Fitg Val Dole 3 8 Barb STGT 21 198072900 Screw 50 560006957 Retainer Prod Line 20 560001393 Manifold Wtr 6 Flavor 51 560006956 Manifold Block 560001342 Manifold Wtr 8 Flavor 52 398023208 Screw 23 560001329 Hood Assy Publication Number 301135000SER 43 2006 2014 Cornelius Inc Vanguard 245 Service Manual VANGUARD 245 POST MIX DISPENSE
64. te the valve to dispense product CLEANING AND SANITIZING Daily Cleaning of Unit Daily cleaning procedure for the Unit should be performed at the end of daily operation as instructed in SERVICE AND MAINTENANCE section of this manual Sanitizing Syrup Systems The syrup systems should be sanitized every 90 days following Sanitizer Manufacturer s recommendations as instructed in SERVICE AND MAINTENANCE section of this manual The sanitizing procedures should be performed by a qualified Service Person CHECKING DROP IN REFRIGERATION ASSEMBLY CONDENSER COIL FOR RESTRICTIONS A CAUTION Circulating air required to cool the refrigeration assembly condenser coil is drawn in through grille on back of the hood and is exhausted out through grille on top of the hood Restricting air in or out of the Unit will decrease the refrigeration system cooling efficiency Failure to clean and allowing the condenser coil to become clogged will cause the refrigeration system to overheat which will eventually result in refrigeration compressor failure and will automatically void the factory warranty Area on top and back side of the hood must be kept free of obstructions at all times Make sure nothing is stored on top of the hood The Condenser coil must be cleaned every 30 days as instructed in SERVICE AND MAINTENANCE section of this manual to maintain proper cooling of the condenser coil The condenser coil cleaning procedure should be performed by a qualif
65. tems disconnect electrical power to the carbonator shut off CO2 and water supplies then bleed systems before proceeding TROUBLESHOOTING UNIT Trouble Probable Cause Remedy Adjustment of dispensing valve syrup flow regulator does not increase to desired water to syrup ratio No syrup supply Syrup supply container not securely connected into system Tanks System Syrup tanks second ary CO2 regulator out of adjustment Bag in Box System Primary CO2 regulator out of adjustment Inoperative dispensing valve syrup flow control Tapered washer inside tube swivel nut connection distorted from being over tightened restricting syrup flow Replenish syrup supply Securely connect syrup supply container into syrup system Adjust syrup tanks secondary CO 2 regu lator as instructed Adjust primary CO 2 regulator as instructed Repair dispensing valve syrup flow con trol Replace tapered gasket Make sure it seats properly 2006 2014 Cornelius Inc 27 Publication Number 301135000SER Vanguard 245 Service Manual C ines 3 Remote Carbonator Unit Plain water inlet supply line shutoff valve closed Carbonator not operating Open plain water inlet supply line shutoff valve Refer to manual provided with carbon ator Integral built in Carbonator Unit 2 Unit plain water inlet supply line Open plain water inlet supply line shut Only syrup disp
66. 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 IMPORTANT Only qualified Service Personnel should perform sanitizing procedure on the post mix syrup systems The post mix syrup systems should be sanitized every 90 days using a non scented household liquid bleach containing a 5 25 sodium hypochlorite concentration Proceed as follows to sanitize the post mix syrup systems WasH Syrup SYSTEMS 1 Disconnect syrup supplies from syrup systems 2 Rinse quick disconnects syrup tanks systems or bag in box connectors syrup bag in box systems in warm potable water 3 Using a clean syrup tank syrup tank system or a five gallon container bag in box system prepare a full tank or container of liquid dishwasher detergent by using 70 F 21 C to 100 F 38 C potable water and 0 5 oz 15 ml of liquid dishwasher detergent to one gallon of potable water Stir detergent solution to thoroughly mix the solution 4 Syrup Tank Systems A Observe and note CO2 pressure setting on the syrup tanks CO2 regulator then re adjust CO2 regulator to 60 to 80 psi Pressurize syrup tank containing detergent solution to 60 to 80 psi B Connect detergent solution tank pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup Systems A Install bag valves cut from empty bag in box syrup containers on ends of syrup containers syrup ou
67. tlet tubes connectors B Place all syrup outlet tubes with bag valves on their ends in container containing detergent solution 5 Flush the syrup system and dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all syrup and flush out the syrup system 2006 2014 Cornelius Inc 19 Publication Number 301135000SER Vanguard 245 Service Manual CC gt C Continue to activate the dispensing valve in cycles ON for 15 seconds OFF then for 15 sec onds Repeat ON and OFF cycles for 15 cycles 6 Connect detergent solution to the remaining syrup systems and flush syrup out of the syrup systems as instructed in step 5 preceding 7 Remove detergent solution source from the syrup system FLUSH SYRUP SYSTEMS 8 Syrup Tank Systems Connect syrup tank containing potable water pressurized at 60 to 80 psi into one of the syrup systems Bag in Box Syrup System Fill five gallon container with potable water then place all bag in box syrup containers syrup outlet tubes in container containing potable water 9 Flush detergent solution out of the syrup system and dispensing valve as follows A Place waste container under applicable dispensing valve B Activate the dispensing valve for one minute to purge all detergent solution and flush out the syrup system C Continue to activate the dispensing valve in cycles
68. tration of gas will experience tremors which are followed rapidly by loss of consciousness and suffocation ADJUSTING CARBONATOR CO REGULATOR Unit Requiring Connection to A Remote Carbonator Adjust CO2 regulator regulator controls carbonator CO2 pressure as instructed in manual provided with the remote carbonator Unit With Integral Built In Carbonator Adjust CO2 regulator regulator controls Unit built in carbonator CO2 pressure to a nominal 80 psi CO2 inlet pressure to the carbonator must not exceed 125 psi Adjusting Syrup Supplies CO2 Regulator SUGAR SYRUP TANKS CO2 REGULATOR Adjust syrup tanks regulator to a minimum of 45 psi Low calorie Diet Syrup Tank COz Regulator Adjust low calorie diet syrup tank secondary regulator to 10 psi for syrup lines up to 30 feet in length Syrup lines longer than 30 feet in length may require a slightly higher setting of 12 psi maximum Excessive CO2 pressure may cause low calorie syrup carbonation resulting in foam Syrup Pumps Bag in box System Adjust the syrup pumps regulator to 70 psi DO NOT EXCEED MAXIMUM CO2 PRESSURE SPECIFIED ON THE SYRUP PUMPS ADJUSTING DISPENSING VALVES FOR WATER FLOW RATE The dispensing valves adjustable water flow regulators are factory adjusted and should require no further adjustment If readjustment should become necessary consult the dispensing valve manufacturer for the proper adjustment procedure ADJUSTING DISPENSIN
69. ublication Number 301135000SER Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER REMOTE Figure 20 2006 2014 Cornelius Inc 40 Publication Number 301135000SER Vanguard 245 Service Manual VANGUARD 245 POST MIX DISPENSER REMOTE Table 1 Vanguard 245 post mix dispenser remote Table 1 Vanguard 245 post mix dispenser remote Cinku Publication Number 301135000SER 41 tem Part No Description rm Part No Description dus No 18 560001329 Hood Assy 560002628 Tank Assy 560003651 Chassis Rfg 120V 60HZ 4083 Harn Wire Not Shown 19 560003652 Chassis Rfg 240V 60HZ 71827615 Swich KeyLock 560003653 Rfg 230V 50HZ 4 4924 Panel Val 6 Flaver 20 317015000 O Ring 239 I D 4228 Panel Val 8 Flaver 21 Dispensing Valve Assy 5 1140135000 22 318308000 Screw 6 113500000 Overflow Hose 23 4123 Cover Access Back 7 113500000 Tank Drain Hose 24 1317784000 Screw 8 14173 Insulation Tank 25 3982 Panel Accs d 560001878 Coil Wtr No 2 6 Flaver 4771 Cup Rest 560001881 Coil Wtr No 2 and 3 8 flavor 560001449 Cup Rest Optifill Valve 560001874 Coil Wtr No 3 6 Flavor 27 177150200 Fitg Drain 1 2 20 560001876 Coil Wtr No 4 8 Flavor 28 77150300 Fitg Drain L 1 2 Barb 11 560001886 Retainer Coil 29 47
70. ulb 8 Wash inside of the water tank and the drop in refrigeration assembly evaporator coils then rinse with clean water 9 Install plug in end of the water tank drain hose 10 Unit with integral built in carbonator IMPORTANT For proper alignment when lowering drop in refrigeration assembly into the Unit lower housing steel tube welded on top of the carbonated water tank must align with alignment funnel fastened into top of the refrigeration assembly deck The carbonated water tank ground wire green with yellow stripe must also be routed up through hole in the refrigeration assembly deck and be connected to mating ground wire connector on top of the refrigeration assembly deck Failure to connect the carbonated water tank ground wire will cause erratic operation of the carbonator water pump motor A Referring to previous IMPORTANT note very carefully lower drop in refrigeration assembly down into the Unit lower housing Make sure carbonated water tank ground wire connector is routed up through hole in the refrigeration assembly deck B Connect carbonated water tank ground wire connector to mating ground wire connector on top of the refrigeration assembly deck C Connect two conductor wiring harness connector to electrical terminals on top of the carbonated water tank 2006 2014 Cornelius Inc 23 Publication Number 301135000SER Vanguard 245 Service Manual Giner D D Connect plain water inlet and outlet lines to the
71. y depleted 4 Replenish CO2 supply Oil fil scum in cups or 1 Use clean cups or glasses Dispensed product comes out of dis dd P P 9 9 2 Do not use directly from freezer Allow pensing valve clear but foams in cup or glass Ice used for finished drink is sub cooled ice to become wet before using refer to following NOTE NOTE Crushed ice also causes dispensing problems When finished drink hits sharp edges of ice carbonation is released from dispensed drink Publication Number 301135000SER 28 2006 2014 Cornelius Inc Vanguard 245 Service Manual Recovery rate of refrigeration of sys tem exceeded ice bank depleted Allow ice bank to recover Primary regulator pressure too 12 Reduce primary regulator pressure high for existing water conditions or settings temperature Tanks System Syrup overcarbon 3 Remove syrup tanks quick disconnects ated with CO2 as indicated by bub Relieve tank pressure as many bles in inlet syrup lines leading to times as necessary to remove over car Dispensed product produces foam unit bonation as it leaves dispensing valve Dispensing valve restricted or dirty 4 Sanitize syrup system as instructed in Service and Maintenance Manual Tapered gasket inside carbonated 5 Replace tapered gasket Make sure it is water line swivel nut connector dis properly seated torted rest

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