in-n-out burger ngf 255 with cold carbonation
Contents
1. Cinellus IN N OUT BURGER NGF 255 WITH COLD CARBONATION Service Manual We A NN Release Date January 25 2011 Publication Number 621058476SER Revision Date April 02 2014 Revision B 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 equipment nor to provide for every possi ble contingency in the installation operation or maintenance of this equipment This manual assumes that the per son s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met in addition to the information contained in this manual This Product is warranted only as provided in Cornelius Commercial Warrant applicable to this Product and is sub ject 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 nor2. Reed switch is not being activated Check the upper ice chute assembly for proper assembly and operation Inoperable reed switch Electrical board driver circuit is defective Replace reed switch Replace main control board Gear motor has open circuit Reed switch is not activated Improper assembly of upper ice chute to lower chute Broken wire in the 2 wire harness leading to the reed switch Replace gear motor Check to make sure tongue of upper chute engages into the back of the lower chute ensure upper chute engages outside the lower chute and snap front of chute into place Repair of replace 2 wire harness Bad connection at main control board J3 pins 2 83 Repair connection or replace 2 wire harness Ice dispenses continuously lce gate mechanism is stuck in open position Inspect gasket for proper position Examine gate plate to see if it slides freely behind the lower ice chute Stuck or bent ice lever does not allow gate to close and open reed switch Examine ice dispense lever to see if it is bent Publication Number 621058476SER 14 2011 2014 Cornelius Inc C Gne In N Out Burger NGF 255 Service Manual Slushy ice or water in hopper Blocked drains in cold plate Remove access covers in cold plate cover amp inspect clean drains Poor ice quality due to water quality or ice maker problems Correct water quality or re
3. AGITATION ADJUSTMENTS When lce is not being dispensed from the machine such as during off hours it is essential to move or agitate the ice to keep it from clumping and to replenish the ice in the cold plate The amount of time the agitator runs and the time between the agitation cycles can be adjusted depending on ice type or application The settings for this function are located on the E Board found in the E Box Using a screwdriver follow the diagram below and set the agitator for the desired settings MOTOR ON TIME FULL CCW 0 5 SECONDS FULL CW 5 SECONDS OFF TIME FULL CCW 10 MINUTES FULL CW 3 HOURS 2 5 2 HRS 3 HRS HRS 2 HRS lt J 1 10 HR 30 MIN SRI Son T TIME OF i TIME j E BOARD AGITATION TIMER Figure 2 E Board Off Cycle Adjustment Diagram Manufacturer Recommended Agitation Settings Model Ice Fill Ice Type Motor ON Time Motor OFF time Manual Hard Ice Cube 4 Seconds 1 Hour 1756215 300 ore TR Mount ice I Io Seconds 20 Minutes B BC Cube Manual amp Automatic Cornelius Chunklet Scotsman amp Hoshizaki Compressed Ice 0 5 Seconds 3 Hours B Beverage C Coldplate NO FLAKED ICE 2011 2014 Cornelius Inc Publica
4. around the unit clean and free of clutter Failure to keep this area clean may result in injury or equipment damage SHIPPING AND STORAGE CAUTION Before shipping storing or relocating the unit the unit must be sanitized and all sanitizing solution must be drained from the system A freezing ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components CO2 CARBON DioxIDE WARNING DANGER 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 concentrations of CO2 gas experience tremors which are followed rapidly by loss of consciousness and DEATH MOUNTING IN OR ON A COUNTER WARNING When installing the unit in or on a counter top the counter must be able to support a weight in excess of 600 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 addi tional weight the counter will need to support to ensure a safe installation Publication Nu
5. clean and sanitize the hopper See the Cleaning the interior surfaces section shown later in this manual While cleaning the hopper use the brush provided with the unit to clean the cold plate surface To accom plish this the brush needs to be extended through the opening in the bottom of the hopper Yearly Maintenance Have the water pump and check valve inspected and cleaned by a qualified service technician Have the CO2 gas check valve inspected and cleaned by a qualified service technician Remove the unit s splash and cold plate cover to clean and sanitize the cold plate surface See the cleaning the cold plate section shown later in this manual Cold Plate Yearly Maintenance 1 oN up wo Remove splash panel Remove or move the plastic cold plate cover to expose the cold plate Locate and remove any debris from the drain trough Check that the drain holes are not clogged Pour small amount of soap solution through cold plate openings in hopper Using a cloth wash down the surfaces of the cold plate and plastic cover with soap solution Install and properly position the access covers on the cold plate Install the splash panel in the reverse order it was removed Rinse cold plate surface by pouring potable water through hopper openings Dispensing Valves Daily Cleaning Refer to addendum supplied with the unit that is applicable to the manufacturer of the valves installed on the unit Product Tubing M
6. 3 16 hex wrench 5 Replace the motor with the 2 screws removed in step 1 using a 1 4 socket 2011 2014 Cornelius Inc 13 Gear Remove 4 q Screws 4 E Agitator J Motor Shaft Seal Shaft Gasket Gear Box Motor Publication Number 621058476SER In N Out Burger NGF 255 Service Manual WARNING C Gies D TROUBLESHOOTING IMPORTANT Only qualified personnel should service internal components or electrical wiring If repairs are to be made to a product system remove quick disconnects from the applicable product tank then relieve the system pressure before proceeding If repairs are to be made to the CO2 system stop dispensing shut off the CO2 supply then relieve the system pressure before proceeding If repairs are to be made to the refrigeration system make sure electrical power is disconnected from the unit Should your unit fail to operate properly check that there is power to the unit and that the hopper contains ice If the unit does not dispense check the following chart under the appropriate symptoms to aid in locating the defect Dispenser Troubleshooting Symptom Blown fuse or circuit breaker Cause Short circuit in electrical wiring Remedy Repair Wiring Inoperable agitator motor shorted motor Replace gear motor Agitator does not turn No power Restore power or plug in unit Improperly installed upper ice chute assembly
7. ANCE INSTRUCTIONS NOTE These instructions are used on all Cornelius ice drink dispensers Some models may have additional cleaning requirements Those models will have addition procedures listed later in the manual WARNING Disconnect power to the unit before 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 CAUTION Do not use metal scrapers sharp objects or abrasives on the ice storage hopper top cover agitator disc or exterior surfaces as damage to the unit may result Do not use solvents or other cleaning agents as they may attack the material resulting in damage to the unit Soap solution Use a mixture of mild detergent and warm 100 F potable water Sanitizing Solution Dissolve 2 packets 4 oz of Stera Sheen Green Label into 2 gallons of warm 80 100 F potable water to ensure 200 ppm of chlorine Daily Cleaning Remove cup rest from drip tray and clean with warm soapy water rinse with clean water and allow to air dry Wipe down the exterior of the unit with warm soapy water rinse with clean water and allow to air dry Remove valve nozzles and diffusers and wash in warm soapy water rinse in clean water and allow to air dry Bog Clean the interior of the ice chute using the brush provided with the unit with warm soap
8. Main Control Board 17 Troubleshooting s oio ro aa pa S Un PES E Reges 18 Beverage Not Dispensing 18 Flat DriniKe exer cette teed Sas pa aS eed oe ES Reb aa k a eRe at Q ees 19 No Carbonated Water 20 C inet In N Out Burger NGF 255 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 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 foll
9. RR ER 1 Different OF ALG S aa israiska E 1 ric L i a d i ra a a SE S eeu 1 Qualified Service Personnel 1 Safely Precautions se a OY ER RA RR A SS 2 Shipping And L ben ai Ra eee ee p Su luas 2 CO2 Carbon Dioxide Warning kas 2 Mounting imoron a COUNIer 264 3 RENE es E rt Dee ee RM Aden RU wu ES 2 IitFOd UC HOT a ed iae aed c ted Varr Send aba a an i aed ava Me aa ed Cata 3 DESENPUON d is uiro dete ted ur e diuo fid ds ed 3 Theory of cM rc Ee Ead cM e 3 Speciflcalloris cbe X ERG A ERE dde eel 3 Flow Diagrami ER SAO s Xue nam a dap aeu wae gre afa 4 E Board Off Cycle Agitation Adjustments LLP ka 5 Mirino Diagram S e FR IR de unha a e ERIS Ert ps Ed rete e he Xii Rene T 6 eg rude sd Ree rs wan Leone Sal A ee eR See ewes ee GE ES 7 Cleaning and Maintenance Instructions lees nnn 8 Daily Cleaning dore u tase She sted Soe ieu meld d erar tot Ed 8 Daily occ ow ss bade por veo emm te E Rte quee dene ewe 8 Weekly Cleaning In addition to daily procedures 8 Monthly Cleaning I
10. ain in lines for fifteen 15 minutes Repeat the step above applying a different product tube each time until all tubes are filled with the sanitiz ing solution Remove the nozzle and syrup diffuser and clean them in a mild soap solution Rinse with clean water and reassemble the nozzle and syrup diffuser on the valve Rinse the parts in clean water reassemble the valve and reconnect it to the dispenser Discard the tank of sanitizing solution and reconnect the product syrup tanks Operate the valves until all sanitizer has been flushed from the system and only product syrup is flowing Sanitize syrup lines B I B Systems 1 2 3 Remove all the quick disconnects from all the B I B containers Fill a suitable pail or bucket with soap solution Submerge all disconnects gas and liquid in the soap solution and then clean them using a nylon bristle brush Do not use a wire brush Rinse with clean water Using a plastic pail prepare approximately five 5 gallons of sanitizing solution Rinse the B I B disconnects in the sanitizing solution Sanitizing fittings must be attached to each B I B disconnect If these fittings are not available the fittings from empty bags can be cut from the bags and used These fittings open the disconnect so the sani tizing solution can be drawn through the disconnect Place all the B I B disconnects into the pail of sanitizing solution Operate all the valves until the sanitizing so
11. and at connector J4 on the main control board Broken wires between carbonator tank and main control board Replace wire harness Defective liquid level probes Replace both liquid level probes Contact your local syrup or beverage equipment distributor for additional information and troubleshooting of beverage system Publication Number 621058476SER 16 2011 2014 Cornelius Inc DIAGNOSTICS GUIDE FOR THE MAIN CONTROL BOARD In N Out Burger NGF 255 Service Manual continuously for 5 minutes CONDITION Observed State of State Red LED Sensor Input Control Response Service Remedy 0 Flash rate 3 sec Both probes read wet mode Pump No service required Pump is OFF and HIGH Waiting for level to drop 1 Flash rate 1 2 sec probe reads dry and LOW below LOW probe Pump service required probe reads wet OFF Both HIGH and LOW probes Normal mode 2 Flash rate 1 2 sec read dry Pump ON No service required Entered when HIGH probe does not detect liquid and Normal mode 3 Flash rate 1 2 sec LOW probe does detect Pump ON No service required liquid and pump is ON Check electrical connections at the carbonator tank and at connector J4 on the main G control board Entered when HIGH probe Black wire should be 4 Flash rate 1 sec reads wet and LOW probe D dH connected to the LOW probe reads dry and also to Pin 4 of C
12. ction to the E Board in the E Box Publication Number 621058476SER Is the incoming water restricted No Is there power connection to the carbonator pump Restore the recommended water flow No 1 Carbonator 2 Check fitting on the total flex manifold 1 Check whether or not there is power across the carbonator power cord on the E Board in the E Box 2 Change carbonator power cord on the E Board in the E Box Replace carbonator pump 20 2011 2014 Cornelius Inc Cornelius Inc www cornelius com
13. ended Replace CO tank or fix compressor Carbonator Troubleshooting Symptom Cause Remedy Carbonator pump does not start to fill tank Power cord for the carbonator pump motor is not connected Carbonator pump is powered off the main control board inside the electrical box of the unit Check that the umbilical cord is connected from the unit to the pump motor terminal box Power cord is connected but carbonator pump does not run Carbonator pump motor is disabled Check the enable disable switch on the carbonator pump terminal box and enable it if necessary Probes were dry unit was powered up water was not turned on and carbonator did not fill This results in a 5 minute timeout Unplugging the unit and plugging it in will reset the unit and start the carbonator pump Water service was interrupted for more than 5 minutes Unplugging the unit and plugging it in will reset the unit and start the carbonator pump Carbonator pump is short cycling with every drink drawn Lower liquid level probe reads dry while upper probe reads wet Check color of leads going to probes Black should go to bottom probe and white to top probe Reverse if incorrect Carbonator tank overfills overflows through relief valve and pump shuts off after 5 minutes Poor electrical connections between carbonator tank and main control board Check connections at carbonator tank
14. erage dispense valve NO to ensure that they are functioning 3 Change beverage valve 4 Check the water line to the valve and the syrup line to the valve v 1 Check the transformer 2 Change the transformer 2011 2014 Cornelius Inc C Greta In N Out Burger NGF 255 Service Manual Flat Drinks PM FLAT DRINK S drink temperature above 40 degrees Fahrenheit Is CO2 being supplied to the carbonator tank No Y 1 Check CO2 supply tank 2 Check CO2 supply lines 3 Change CO2 tank 2011 2014 Cornelius Inc Yes Yes Is there Yes ice on the cold plate No Y 2 Dispense some ice to ensure that the agitator spreads ice on the cold plate 1 Fill the hopper with ice Is the CO2 pressure in the system correct No Y Adjust CO2 pressure accordingly Yes 19 Check ice coverage on the cold plate the carbonator cycle when a 20oz drink is dispensed No Y Refer to carbonator flow chart Replace Yes carbonator pump Publication Number 621058476SER In N Out Burger NGF 255 Service Manual No Carbonated Water No CARBONATED WATER Does the carbonator pump start when the unit is turned on Yes Check the carbonator pump conne
15. kwise the cylinder valve slightly to allow the lines to slowly fill with gas then open the valve fully to back seat the valve back seating the valve prevents gas leakage around the valve shaft Check CO2 connections for leaks Tighten any loose connections Publication Number 621058476SER 10 2011 2014 Cornelius Inc In N Out Burger NGF 255 Service Manual MAINTENANCE The following dispenser maintenance should be performed at the intervals indicated DAILY OR AS REQUIRED Remove foreign material from vending area drip tray to prevent drain blockage Clean vending area Check for proper water drainage from the vending area drip tray Checking CO2 Supply Make sure cylinder regulator assembly 1800 psi gage indicator is not in shaded change cylinder portion of the dial If so the CO2 cylinder is almost empty and must be replaced Checking for CO2 and water leak Check the Unit for CO2 and water leaks and if found call a qualified Service Person to repair as necessary MONTHLY Clean and sanitize the hopper interior and beverage system if applicable see CLEANING INSTRUCTIONS YEARLY Water Pump Maintenance or after water system disruption The water pump water strainer screen and the liquid dual 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 Call a qualified Service Person to ins
16. lution is flowing from the valve Allow sanitizer to remain in lines for fifteen 15 minutes Remove the nozzle and syrup diffuser from each valve and clean them in a soap solution Rinse with clean water and reassemble the nozzle and syrup diffuser to the valve Remove the sanitizing fittings from the B I B disconnects and connect the disconnects to the appropriate B I B container Operate the valves until all sanitizer has been flushed from the system and syrup is flowing freely Replenishing CO gt Supply As Required NOTE When indicator on the 1800 psi gage is in the shaded change CO2 cylinder portion of the 3 dial CO2 cylinder is almost empty and should be changed Fully close clockwise the cylinder valve Slowly loosen the regulator assembly coupling nut allowing pressure to escape then remove the regulator assembly from the empty cylinder Unfasten safety chain and remove the empty CO2 cylinder WARNING To avoid personnel injury and or property damage always secure the CO2 cylinder with a safety chain to prevent it from falling over Should the valve become accidently damaged or broken off a CO2 regulator can cause serious personnel injury or death could occur 4 5 Position the full CO2 cylinder and secure with a safety chain Make sure gasket is in place inside the CO2 regulator assembly coupling nut then install the regulator assembly on the CO2 cylinder Open countercloc
17. mal and proper use and normal service conditions with respect to the Product 2 improper voltage 3 inadequate wiring 4 abuse 5 accident 6 alteration 7 misuse 8 neglect 9 unauthorized repair or the failure to utilize suitably qualified and trained per sons to perform service and or repair of the Product 10 improper cleaning 11 failure to follow installation oper ating 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 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 CG TABLE OF CONTENTS Safety Instructions coe a tac a Ta aa Si A 1 Read and Follow ALL Safety Instructions 7 1 Safety Overview 2 4 05 ar s metere Eso Mee S S add d a Be ee AS 1 Hecogntllon 23 toe i r a i i m a Q E
18. mber 621058476SER 2 2011 2014 Cornelius Inc CG DESCRIPTION The NGF series of ice dispensers solves your ice and beverage service needs in a sanitary space saving economical way Designed to be automatically filled with ice from a top mounted ice machine or manually filled with ice from any remote ice making source these dispensers will dispense cubes up to 1 1 4 inch in size cubelets and compressed or extruded style ice In addition the units include beverage faucets a cold plate an internal carbonator tank and an external pump for the carbonator and are designed to be supplied direct from syrup tanks with no additional cooling required THEORY OF OPERATION The rate of CO2 solubility increases with cold water NGF System provides pre chilled cold water from the cold plate and mix with CO2 in the carbonator tank The water is introduced into the tank with a high volume 125gph Procon pump and high torque motor The amount of carbonated water reserve is controlled by a probe mounted in the tank The probe is called a liquid level probe The liquid level probe senses the water level in the tank Probe controls the pump ON and In N Out Burger NGF 255 Service Manual INTRODUCTION OFF cycle through the liquid level board located on the main control board NOTE The probe works on a 5 mVDC current that continually reverses direction to prevent probe corro sion SPECIFICATIONS Model Descrip
19. n addition to daily and weekly procedures 8 Yearly Maintenance sese seq eR de vene ire Rae PS VES 9 Cold Plate Yearly 9 Dispensing Valves Daily 9 Product Tubing Monthly Cleaning lt kaka 9 Replenishing CO2 Supply As Required 10 Maintenance axes x REG ERR ER CRUCERO RR ROO CAIRO RC RE DIR RR R CORD RR 11 Dally or ds m de n t Ee DE ba pe 11 Checking CO2 Supply 6 eost alu eode ai aa Us a rd x age 11 Checking for CO2 and water leak 11 11 NCAR as disce S quia ib i ure Quee qu dida E 11 Water Pump Maintenance or after water system disruption 11 Cleaning CO2 Gas Check Valve ons Ei Rut ex aee eet V Ru det RD ERR ete 11 Change out Procedures orco E una BAe Ree eee ee Me eee EET 12 Motor Replacement ii ect xut hex P e een xr ek d ea we bie a a 12 Gearbox Heplacemelnbe eoe em tede VO Ris I Laie LE Re ER eS 13 Troubleshooting ssa sos ER Ras s eG Rees 14 Diagnostics Guide for the
20. nator pump starts and runs continuously then shuts off on the 5 minute timeout 1 low water pressure switch deactivates carbonator pump 2 after 5 minutes reset and retry carbonator pump If water supply is restored the 5 minute timeout will not occur Repeat reset a second time but on a third time then lockout carbonator pump which will generate a service call Carbonated drinks are flat low on carbonation is out Replace CO2 Carbonator tank is 10096 filled because the city water pressure exceeds the carbonator tank CO2 pressure regulator setting CO setting for the carbonator tank is 75 psig max water pressure is 60 psig If necessary install a water pressure regulating valve 2011 2014 Cornelius Inc 15 Publication Number 621058476SER In N Out Burger NGF 255 Service Manual C inet D Low water pressure Could be caused by excessively long runs over 40 ft of 3 8 water supply line Increase line size to 1 2 Low water pressure Add water pressure booster pump Plugged water filter Change water filter Water booster bladder has burst Replace water booster tank bladder No Syrup or Watered down drink dispensed Syrup supply is empty Replace B I B BIB pump not working Replace B I B pump No CO or compressed air supply to B I B pump or not enough pressure Check pressure regulator setting 65 psig recomm
21. onnector J4 Reverse the connections if incorrect Replace harness if necessary Check the harness Able to continue to function connections of the red signal ON continuous Poor signal connection to but carbonator pump short wire at both ends 5 but flickers ae the carbonator tank May cycles Pump will come on 1 at the carbonator ring 3 sec y result in short cycling ofthe each time a drink is drawn terminal and carbonator pump THIS SITUATION SHOULD 2 at Pin 5 of the BE CORRECTED connector at the main control board Unplug the unit and plug it 6 ON continuously Entered when pump has run THIS IS AN ERROR back in This will reset the unit s main control board and restart the carbonator pump 2011 2014 Cornelius Inc Publication Number 621058476SER In N Out Burger NGF 255 Service Manual TROUBLESHOOTING Beverage Not Dispensing eveRaee NOT DISPENSING the key switct on off Check the key switch Is there power on the line side of the transformer Yes No v 1 Check the transformer connections to the E Board in the E Box 2 Check the E Board in the E Box ensuring that power is being supplied to the board Publication Number 621058476SER 18 Is there power on the load side of the transformer Yes 1 Check the wire harness from the beverage valves to the terminal board 2 Check the bev
22. onthly Cleaning IMPORTANT Only trained and qualified persons should perform these cleaning and sanitizing procedures Sanitize Pre Mix And Post Mix tank System Remove all the quick disconnects from all the tanks Fill a suitable pail or bucket with soap solution Submerge all disconnects gas and liquid in the soap solution and then clean them using a nylon bristle brush Do not use a wire brush Rinse with clean water Prepare sanitizing solution and using a mechanical spray bottle spray the disconnects Allow to air dry Using a clean empty tank prepare five 5 gallons of the sanitizing solution Rinse the tank disconnects with approximately 9 oz of the sanitizing solution Close the tank Prepare cleaning tank by filling clean five 5 gallon tank with a mixture of mild detergent and potable water 1209F Connect a gas disconnect to the tank and then apply one of the product tubes to the cleaning tank Oper ate the appropriate valve until liquid dispensed is free of any syrup Disconnect cleaning tank and hook up sanitizing tank to syrup line and CO2 system 2011 2014 Cornelius Inc 9 Publication Number 621058476SER In N Out Burger NGF 255 Service Manual C Ga 12 13 Energize beverage faucet until chlorine sanitizing solution is dispensed through the faucet Flush at least two 2 cups of liquid to ensure that the sanitizing solution has filled the entire length of the syrup tubing Allow sanitizer to rem
23. ow 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 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 2011 2014 Cornelius Inc 1 Publication Number 621058476SER In N Out Burger NGF 255 Service Manual C Ga SAFETY PRECAUTIONS This unit has been specifically designed to provide protection against personal injury To ensure continued protection observe the following WARNING Disconnect power to the unit before servicing following all lock out tag out procedures established by the user Verify all of the power is off to the unit before any work is performed Failure to disconnect the power could result in serious injury death or equipment damage CAUTION Always be sure to keep area
24. pair ice maker Beverage does not dispense No 24VAC to valves Restore 24 VAC to valves No pressure Restore pressure Beverage is too sweet Valve brix requires adjustment Adjust valve brix Carbonator is not operating Repair carbonator No in carbonator Restore pressure in carbonator City water pressure supply low or inconsistent Booster pump must be used if dynamic water pressure drops below 40 psig Unit will not dispense carbonated drinks Dispenses syrup only pressure in carbonator tank is too high Check CO2 pressure regulator setting 75 psig recommended Relieve pressure from carbonator tank Water valve will not open Check electrical connection to water valve Check resistance of coil should be 9 ohms Check for voltage at coil when brand button is depressed Unit will not dispense carbonated drinks Spurts CO2 and syrup only Carbonator tank is empty because tank was emptied while power was applied to unit 5 minute time out of carbonator pump motor occurred and carbonator pump is locked off Unplug the unit and reconnect the unit Main control board will reset ice agitation will occur and carbonator tank will refill to normal level Note that this can occur while the water filter System is serviced or water supply is shutoff If drinks are drawn from the dispenser while water pressure is shutoff the carbo
25. pect and clean the strainer screen and the liquid dual check valve Cleaning CO2 Gas Check Valve The CO2 gas check valve located on the carbonated water tank must be inspected and serviced at least once a year under normal conditions and after any CO2 system servicing disruption Call a qualified Service Person to inspect and clean the gas check valve NOTE If the power cord is damaged it must be replaced by the manufacturer its service agent or sim ilar qualified persons in order to avoid a hazardous situation 2011 2014 Cornelius Inc 11 Publication Number 621058476SER In N Out Burger NGF 255 Service Manual CHANGE OUT PROCEDURES Motor REPLACEMENT 1 Remove the 4 screws with a 1 4 socket to seperate the agitator motor from the gear box Gear Box Remove 4 pp Screws Agitator Motor 2 Remove the agitator motor 3 Install the new agitator motor and replace the screws removed in step 1 with a 1 4 socket Publication Number 621058476SER 12 2011 2014 Cornelius Inc Guli In N Out Burger NGF 255 Service Manual GEARBOX REPLACEMENT 1 Remove the 4 screws with a 1 4 socket to seperate the agitator motor from the gear box 2 Remove the 4 screws holding the gear box in place with a 3 16 hex wrench 3 Pull the gear box seal and gasket off the machine 4 Install the new gear box seal and gasket Screw it in place with the 4 screws removed in step 4 using a
26. tion Number 621058476SER In N Out Burger NGF 255 Service Manual q3O05 MNVI devo 38044 BAST TN BAN AA a 1HM NOLLO3NNOO TVNOILdO 391 WIRING DIAGRAM xa NOLLO3NNOO TVNOILdO HOLIMS 31V9 321 m Er oOLIovdvo Xog 1VOIH LO3T3 NIVIN BALHM SLINN ONIAH3S 30338 H3MOd LOANNOOSIG QHVZVH MOOHS OI L3 T3 xa S3ATVA xa aadpna J c HOLIMS AM aas 1HM 3WdO4JSNV3L TA AHM 1HM xa Figure 3 Wiring Diagram 2011 2014 Cornelius Inc Publication Number 621058476SER In N Out Burger NGF 255 Service Manual ScHEMATIC L1 L2 EARTH L1_1N L2_IN OPTIONAL CARB MOTOR __ CARB MOTOR CARB MOTOR L2 CARB EARTH AGITATOR MOTOR AGITATOR AGITATOR_L2 AGITATOR EARTH HEATER L1_HEATER O HEATER L2 XFORMER L1 120V Pri XFRMR1 80 E BOARD E BOARD KEY 24V Sec LOCK VALVE VALVE E BOARD ICE GATE SWITCH BLK OPTIONAL CARB TANK HIGH LEVEL PROBE E BLK LOW LEVEL PROBE RED GROUND Figure 4 Wiring Schematic 2011 2014 Cornelius Inc 7 Publication Number 621058476SER In N Out Burger NGF 255 Service Manual C Ga CLEANING AND MAINTEN
27. tions NGF 255 B Beverage C Coldplate H Internal Carb Z No Drip Tray Ice Storage 255 Pounds Maximum Number of Faucets Available 10 Built in Cold Plate Yes Electrical Oa Ampa of Total Unit Draw 30 inch Dimensions 30 11 16 inch 39 inch to top of bin 39 3 4 inch to top of lid CO2 Operating Pressure 75 psig max 2011 2014 Cornelius Inc 3 Publication Number 621058476SER In N Out Burger NGF 255 Service Manual FLOW DIAGRAM OW MNVL auvo ino NI SSVd A8 MNVLIHOIVNO8NHVO ALIO zoo Qauino3s 38 AYN dnd diedi MolvInO3 sala dns gs 4S 95 95 rS S cS 3uHnssadud uar YILYM AHVqNOO3S DISd 0 00 IONNOS ZOD ASV 8 dNnd TWNOILdO ON aes 969569956 928 Lot v 9 e o 9 aiviaqi0o MNV L E z suvo oj 9 o x 1no z m NI g X314 X313 WLOL 3LnHo WLOL Md 301 GALWNOSYV9 MO S3ATVA JalvNANIVId Ad LINN 1115 31901199 1dNOO OL NOILOALOYd MO 1330 V8 ALVNOAGV H LIM GATIVLSNI 38 LSNW LNAWdINOA SIHL MO LS PLAIN WTR IN CARB WTR IN Figure 1 Flow Diagram 2011 2014 Cornelius Inc Publication Number 621058476SER C Greta In N Out Burger NGF 255 Service Manual E BoARD Orr CYCLE
28. y water rinse with clean water and allow to air dry Spray the ice chute inside and out with sanitizer and allow to air dry Pour warm soapy water down the drains to keep them clean and flowing smoothly Spray the nozzles and diffusers inside and outside with approved sanitizing solution reinstall them on the valves and allow to air dry Reinstall the cup rest into the drip tray Pour all remaining sanitizer solution down the drains to help keep the drain clear Daily Maintenance Check the temperature smell and taste of the product Check the water pressure coming to the unit using the pressure gauges on the back room package Check carbonation of the drink Check level of CO2 supply to the system Qv NB Check the date on all of the B I B s bags in boxes Weekly Cleaning In addition to daily procedures Remove the ice chute cover and clean it along with the back half with warm soapy using the brush provided with the unit Rinse with clean water and reinstall on the unit Spray the ice chute assembly with approved sanitizer allowing it to air dry Publication Number 621058476SER 8 2011 2014 Cornelius Inc G gt In N Out Burger NGF 255 Service Manual Monthly Cleaning In addition to daily and weekly procedures 1 Flush and sanitize all syrup lines as well as all of the syrup connectors See the sanitize syrup lines sec tion shown later in this manual Remove ice from hopper and
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