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VANGUARD 245 SERVICE MANUAL

1. O 2006 IMI Cornelius Inc 50 301135000E Vanguard 245 Service Manual CONDENSER FAN MOTOR REPLACEMENT 301135000E Shut off vvater and CO2 at their sources Disconnect povver to the unit Remove cover by removing tvvo mounting screws Unplug harness Lift up condenser assembly cover by loose four mounting screws Remove four mounting screws of motor bracket remove fan motor by disassembling three motor mounting screws 51 Remove the hood by removing screws on the top and lifting up Mounting screws of cover Harness Mounting screws of condenser assembly Mounting screws of motor bracket Mounting screws of motor Install new fan motor by reversing this procedure 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER REMOTE FIGURE 1 VANGUARD 245 POST MIX DISPENSER REMOTE ASSEMBLY O 2006 IMI Cornelius Inc 52 301135000E C Gru 3 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER REMOTE E panno name L Panno 560002628 Tank Assy 18 560001329 Hood Assy 4083 Harn Wire Not Shown 560003651 Chassis Rfg 120V 60HZ 3 171827615 Swich KevLock 560003652 Chassis Rfg 240V 60HZ G ETE 7 560003653 Chassis Rfg 230V 50HZ 4924 Panel Val 6 Flaver 4 4228 Panel Val 8 Flaver 20 317015000 O Ring 239 I D
2. Before shipping storing or relocating the unit 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 sanitizing solution or water remaining inside the unit to freeze resulting in damage to the internal components EQUIPMENT HANDLING T 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 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 301135000E NS 2006 IMI Cornelius Inc Vanguard 245 Service Manual 2006 IMI Cornelius Inc NOTE 301135000E C Gru 3 Vanguard 245 Service Manual 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 qualified 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 Vanguar
3. Plate Heat Transer 560001415 Receptacle 186154000 Screw SE 8 36 PAPH 12 310780000 Screw MA 4 40 PAPH 20 15682000 y Slinger Water 309645000 Swt Rocker 120V 60HZ 3600 Blade Age Be 8 560001396 Plug Surt 220 230V 50 60HZ 186610000 Pin Sprg 9 188117000 Screw SM 8 TRPH 12 NIL Oo 301135000E 57 2006 IMI Cornelius Inc Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER COLD CARBONATED FIGURE 4 VANGUARD 245 REFRIGERATION COLD CARB ASSEMBLY 301135000E 58 2006 IMI Cornelius Inc C Gru 3 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER COLD CARBONATED Ed tl Pump and Mot Assy 230 V 60HZ 3600 Blade Agit Pump and Mot Assy 230 V 50HZ 186610000 Pin Sprg 200498003 Nut Hex No 8 32 186154000 Screw SE 8 36 PAPH 12 560002107 Panel Back Chassis 560003858 Spacer Evap 311304000 Gasket 3 8 Male Flare 560003071 Holder Ice Bank Probe OLOJO EE 319347016 Rod Support Evap 6 320389000 Bushing Snap 1786 Evap Coil 4680 Screw MA 8 32 PAPH 6 3113 Fan 5 Bid EN 890221201 Platform Rfg 560002108 Shroud Condenser 9 620711936 Insulation Platform 560001537 Holder C Bulb S E he Kit 186770000 Screw MA 10 24 RKPH 20 it Comp 3 4 Washer LK 194 I D Kit Comp 3 4 H P 230V 50HZ 120227000 Washer LK 194 I D 449999999 Transformer 120V 60HZ 24V 2205 02000 Bd cs T9 f
4. Plug in power cord Electrically connect or replace inoperable sensor Replace fuse or reset circuit breaker Note Fuse or circuit breaker are not part of unit Voltage must be 103 volts 115VAC Unit or 208 Volts 220 VAC Unit Tighten connections or replace broken wiring Compressor will cool enough to restart Do not overdraw cooling capacity of unit Refer to Condenser Fan Motor Not Operating in this section 10 Replace inoperative part 11 Replace ice bank probe 12 Replace control board 2006 IMI Cornelius Inc Vanguard 245 Service Manual TROUBLESHOOTING REFRIGERATION SYSTEM Compressor will not stop 1 Ice bank probe location 1 Place probe in proper after sufficient ice bank is produced Compressor operates continuously but does not form sufficient ice bank Agitator motor not operating 2006 IMI Cornelius Inc incorrect Ice temperature sensor inoperative Control board inoperative Cooling capacity is exceeded by overdrawing Unit located in excessively hot area or air circulation through condenser coil is restricted No power source blown fuse or tripped circuit breaker Agitator motor propeller obstructed Low Voltage Loose disconnected or broken wiring Inoperative agitator motor location Replace ice temperature sensor Place power switch in ON position
5. 140135000 Clamp Hose Dispensing Valve Assy 6 113500000 Tank Overflow Hose 2 _ 5318308000 113500000 Tank Drain Hose glee Coven neces bach 5 ars Insulation Tank D egeo 560001881 Coil Wtr No 2 and 3 8 flavor 56 560001449 Cup Rest Optifill Valve 560001876 Coil Wtr No 4 8 Flavor 7 N N 560001886 Retainer Coil 8 77150300 Fitg Drain L 1 2 Barb Coil Wtr No 4 and 5 6 Flavor or 560001877 Coil Wtr No 7 and 8 8 Flavor 560001880 Coil Wtr No 1 188072000 Screw SM 10 TRPH 16 391909000 140135000 200498003 6 oO E EN Es ES 31 EE 301135000E 53 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER COLD CARBONATED FIGURE 2 VANGUARD 245 POST MIX DISPENSER COLD CARB ASSEMBLY O 2006 IMI Cornelius Inc 3 301135000E Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER COLD CARBONATED 1 560002628 Tank Assy 560007415C Tank Carb Assy 71860230 Valve Pres Relief 710660001 Probe Assy Insrt Mold 3 183310000 7 4924 Panel Val 6 Flavor 0 140135000 Insulation Tank 560001874 Coil Wtr No 3 6 Flaver Coil Wtr No 4 8 flavor 560001426 Coil Wtr No 4 6 Flaver Coil VVtr No 5 8 flavor 9 0 1 188072000 35 560001393 Manifold Wtr 6 Flavor Manifold Wtr 8 Flavor 23 560001329 Hood Assy Gl ZL 1 N NI CO N 301135000E
6. 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 O 2006 IMI Cornelius Inc 96 301135000E C Gua 3 Vanguard 245 Service Manual CLEANING CO SYSTEM CO GAS CHECK VALVES The CO regulators CO gas check valves and the Unit CO inlet line CO gas check valve must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO 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 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 301135000E 37 0 2006 IMI Cornelius Inc Vanguard 245 Service Manual 2006 IMI C
7. be reproduced in any way without permission from Cornelius Printed in the P R C Copyright 2006 All Rights Reserved IMI Cornelius Inc CCD Vanguard 245 Service Manual TABLE OF CONTENT SAFET GE 1 Safety MSU lee mures hein cnt as Dno ice eene outs Pm em et en deis 1 SAC TDS cette sus sU EE 1 Authorized Service Personnel ote o puo tees a Mar tera onn A E nas 2 CO2 Carbon Dioxide ari gre e c stie ees aee eer qud ane 2 Shipping And DIOS eee ere sioe eee coa aeo spe eee e en tbt tinea nue trente 3 Equipment Handling Lai ads nasi A Du a d ette AS AA ees 3 GENERAL INFORMATION cuc Benin ii iii la k eet 5 General Description e NS i A a i ales 5 IDE RI ere oe 5 O ECO AS DEE 7 Design Date unan ei 7 Part CT Lu 7 ele 8 Miscellaneous Information AAA 8 Theory of Operation iii a 8 INSTALLATION oe M 11 Delivery Inspection and Unpacking sss sese 11 INSDECUO ouis i Ee EE 11 UmpackINg Asi sis 11 Identification of Loose Shipped Parts esse 12 Selection Ee ON eR NER LT 12 Installation Procedure tisane ai te telnet aa red S oet 13 Placing Unit in Operating Position sss sese 13 Installing Water Lever Kits see 14 Connecting Drip Tray Drain Hose to a Permanent Drain 15 Connecting Syrup Source Lines to the Unit 15 Connecting Carbonated Water Source Unit Requiring Connection to Remote Carbonator 17 Connecting Plai
8. 1 2 4772 Drip Tray 3 4778 Drip Tray Bracket 5 7 140135000 8 3297 Water Lever Kit see NOTE 9 580000291 Air Filter optional 188072000 1 set 1 EEES EEN ET Br WE 11 301135000E 2006 IMI Cornelius Inc Vanguard 245 Service Manual IDENTIFICATION OF LOOSE SHIPPED PARTS 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 the syrup and water source inlet Lines to be connected to the unit will not be routed through the access hole 3 Drip tray drain hose is to be connected to the drip tray and secured with clamp drip tray drain hose 4 Water lever kit to be installed on dispenser s equipped with UF 1 dispensing valves SELECTING LOCATION 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
9. ESS 560003655 Chassis Rfg 220V 50HZ 5 Dispensing Bave Assy 4123 Cover Access Back 0 331309000 200498003 186207000 150447000 89022240 2 N N GA RY Oo O 00 o 25 99 2006 IMI Cornelius Inc Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER REMOTE FIGURE 3 VANGUARD 245 REFRIGERATION REMOTE ASSEMBLY 301135000E 56 2006 IMI Cornelius Inc CC 3 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER REMOTE EI panno names JE panno names i 3 E 4408 Kit Comp 3 4 H P 230V 60HZ 30 560001537 Holder C Bulb RINGS comp IE 31 186770000 Screw MA 10 24 RDPH 20 ranstormer 449999996 Transformer 240V 60HZ 24V AA 96 MES ee 560002114 Transformer 230V 50HZ 24V 33 320539000 Washer Ft 191 I D 186146000 Nut Hex 5 16 18 34 321484000 5 1560000292 Condenser Coil Motor Fan 35W 120V 60HZ 560000123 Motor Fan 35W 240V 60HZ 560000170 Motor Fan 23W 230V 50HZ El 4182 Rit Comp 3 4 H P 120V 60HZ 29 560002108 Shroud Condenser 7 CA 189723000 8 n v cM m Motor Assy Sgit 230V 50 60HZ 40 DE Motor Agit 25W 120V 60HZ 17 308912000 Motor Agit 25W 240V 60HZ Bja a a RP RP RP B R LR Oo wo wo DNININININ IN Eh NI N o COINIO O oO 309898000 Block Term 318168002 Motor Agit 18W 230V 50 60HZ 5119 Nut Hex NO 4 40 319856000
10. Reduce amount of drinks drawn per given time Relocate unit or check and if necessary clean condenser coil as instructed Replace fuse or reset circuit breaker NOTE Fuse or circuit breaker are not part of unit Remove obstruction Voltage must be 90 135VAC 115 volt unit or 180 260 230 VAC unit at compressor terminals when compressor is trying to start 4 Tighten connections or replace broken wiring 5 Replace agitator motor 301135000E Vanguard 245 Service Manual COMPONENT SERVICE The follovving are procedures for replacing the major components of the Vanguard CARBONATOR PUMP REPLACEMENT 1 Shut off water and CO2 at their sources N Remove the hood by removing screws on the top and lifting up 3 Depressurize carbonator by dispensing drinks from any valve 4 Disconnect power to the unit 5 Disconnect water in and out lines o Loosen the V band clamp and Pump V Band remove pump N Install new pump by reversing this procedure NOTE Be sure there is anti seize compound on the pump Pump Tang 301135000E As O 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Gina gt PuMP MoTOR REPLACEMENT 1 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
11. apply for equipment series no from 89E0630VDXXX IMI CORNELIUS TIANJIN CO LTD
12. deposit build up BONO 7 8 9 Disconnect electrical power from the Unit Remove screw securing the hood then lift the hood straight up to remove from the Unit Remove plug from the drop in refrigeration assembly platform water fill hole 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 ALOCAL 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 CLEANING WATER TANK 1 2 3 4 Disconnect electrical power from the Unit Remove screw securing the hood then lift the hood straight up to remove from the Unit Unplug the drop in refrigeration assembly and electric dispensing valve power cords Unit with integral built in carbonator A Shut off CO and plain water supplies to the Unit 32 2006 IMI Cornelius Inc 301135000E C Gua 3 Vanguard 245 Service Manual B Disconnect carbonated water tank ground wire green with yellow stripe connector protruding up B Disconnect carbonated water tank ground wire green with yellow stripe connec
13. out lines Unplug motor harness N O oO A OO N 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 4 compound on the pump Pump Tang oe 4 drive tang O 2006 IMI Cornelius Inc 48 301135000E Cre is 3 Vanguard 245 Service Manual AGITATOR MOTOR REPLACEMENT 1 Disconnect povver to the unit 2 Shut off vvater and CO2 at their sources 3 Remove the hood by removing screws on the top and lifting up 4 Remove carbonator cover by removing mounting bolts and lifting up 5 Remove mounting screws of condenser kit and lift up slightly Mounting lt Screws 6 Remove motor by reassembling mounting screws Mounting Screws 7 Install new motor by reversing this procedure 49 301135000E 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Gina gt CONTROLLER BOARD 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 It up slightly and push back controller cover Mounting Screws 4 Unplug all connectors Connectors 7 207 5 Remove mounting screws Mounting Screws 6 Install new controller board by reversing this procedure
14. 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 1 Disconnect electrical power from the Unit 2 Shut off CO and plain water supplies to the Unit 3 Remove screw securing the hood then lift hood up an off the Unit 4 Pull up on the carbonated water tank relief valve ring protruding up through the drop in refrigeration deck see Figure 8 to bleed off all CO pressure from the water tank 5 Loosen screen retainer then pull screen retainer and strainer screen from the water pump 6 Pull screen from screen retainer Clean any sediment from the screen retainer and the water pump screen 7 Inspect screen for holes restrictions corrosion and other damage Discard damaged screen 8 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 9 Install screen in screen retainer then screw retainer into the water pump and tighten securely 10 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 serv
15. 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 CLEANING DROP IN REFRIGERATION ASSEMBLY CONDENSER COIL CAUTION The refrigeration 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 301135000E 31 O 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Gino gt 1 Disconnect electrical power from the Unit 4 5 6 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 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
16. B 449999996 Transformer 240V 60HZ 24V 321484000 560002114 Transformer 230V 50HZ 24V 560000292 Condenser Coil 186146000 _ Nut Hex 5 16 18 39 960000123 Motor Fan 35W 240V 60HZ 2602 560000170 Motor Fan 23W 230V 50HZ 319941000 Screw TR 8 32 HXWS 12 2944 Brkt Motor Fan 189723000 Grommet Cop 189429000 Nut Hex 1 4 20 187888000 Clip Comp MTg 187394000 Cushion Fan Mount 316727000 Cap Plug 560001720 Cover Terminal Block 18 5600005518 Motor Assy Agit 240V 60HZ 4187 Control Ice Bank 5600004702 Motor Assy Agit 230V 50 60HZ 309898000 Block Term 4932 Brkt Motor Agititor 5119 Nut Hex NO 4 40 Cer Se Motor Agit 25W 240V 60HZ 560001415 Receptacle Motor Agit TEW 200 DUGUNA 310780000 Screw MA 4 40 PAPH 20 180154000 Screw SE 8796 PAPH 12 309645000 Swt Rocker 120V 60HZ 319856000 Plate Heat Transfer 560001396 Plug Swt 220 230V 50 60HZ 188999000 Slinger Water 188117000 Screw SM 8 TRPH 12 301135000E MSS O 2006 IMI Cornelius Inc Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST MIX DISPENSER COLD CARBONATED FIGURE 5 PUMP AND MOTOR COLD CARB ASSEMBLY Pump and Motor 230V 60HZ Pump and Motor 230V 50HZ 361003200 Fitg L 3 8 MPT By 5 8 18 197359000 Control Liquid Level 395098000 Strain Relief 4 320626000 Motor Pump 1 4H P 240V 199020000 Motor Pump 1 4H P 230V 50HZ 560000863 Box Co
17. CGinelius gt VANGUARD 245 POST MIX BEVERAGE DISPENSER SERVICE MANUAL IMI CORNELIUS TIANJIN CO LTD CONTACT INFORMATION The products technical information and instructions contained in this manual are subject to change without notice These instructions are not intended to cover all details or variations of the equipment nor to provide for every possible contingency in the installation operation or maintenance of this equipment This manual assumes that the person s working on the equipment have been trained and are skilled in working with electrical plumbing pneumatic and mechanical equipment Appropriate safety precautions should be followed and all local safety and construction requirements should be met To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact NN IMI Cornelius Inc In the U S A In the P R C Ph 800 238 3600 Ph 022 2529 0858 Fax 763 488 4283 Fax 022 2529 0865 Add 101 Broadway Street West Add No 12 Xintai Road Osseo MN 55369 TEDA Tianjin 300457 Internet www cornelius asia com E mail customerservice cornelius com cn VVS IS NAN ARS Trademarks and copyrights Aurora Cornelius Decade Hydro Boost Olympus Impulse Sitco Spirit UF 1 Vanguard Venture and Vista are registered trademarks of IMI Cornelius Optifill trademark is pending This document contains proprietary information and it may not
18. CO 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 CO 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 carbon ated drink except plain water is substituted for carbonated water 8 2006 IMI Cornelius Inc 301135000E CC 3 Vanguard 245 Service Manual UNIT WITH INTEGRAL CARBONATOR NOTE The unit is factory set to dispense non carbonated water and carbonated water as per customer 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 CO cylinder delivers carbon dioxide CO gas through adjustable CO 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 CO gas pressure also entering the water tank When dispensing valve is opened CO gas pres
19. ENT SERVICE i cross inoran ia sn uas deat ace as cate aac 47 Carbonator Pump Replacement ss 47 Pump Motor Replacement sse eee edet heeded nine 48 Agitator Motor Replacement si ns kasta ae ite cd etaed can 49 Controller Board Replacement 5 setem denied tiens 50 Condenser Fan Motor Replacement eee eee eee e eee eee eee eee 51 ILLUSTRATED PARTS LIST cun oest 52 REFERENCE MATERIAL 1 ania ti 61 WIG Diagrami Zalese RETO 61 Flowing DIAGRAM 2 2 SE a S 62 301135000E 2006 IMI Cornelius Inc Vanguard 245 Service Manual 2006 IMI Cornelius Inc NOTE 301135000E C Gru 3 Vanguard 245 Service Manual SAFETY SAFETY INSTRUCTIONS Read And Follow All Safety Instructions Read and follow all safety instructions in this manual and on the machine decals labels and laminated cards Read and understand all applicable OSHA Occupation Safety and Health Administration safety regulations before operating the machine Recognize Safety Alerts This is the safety alert symbol When you see it in this manual or on the machine be alert to the potential of personal injury or damage to machine Different Types Of Alerts There are three types of safety alerts DANGER Indicates an immediate hazardous situation which if not avoided WILL result in serious injury death or equipment damage WARNING Indicates a potentially hazardous situation which if not avoided COULD result in serious injury death or equipment da
20. EVER 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 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 Un
21. HE 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 3 Install plug in the water fill hole 4 Unit with integral built in carbonator Activate plain water and CO supplies to the Unit Make sure CO inlet pressure to the carbonator is adjusted to a nominal 80 psi CO inlet pressure to the carbonator must not exceed 125 psi 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 9 Place dispensing valves keyed lock out switch on side of the Unit in the OFF position 9 60 Hz Units Make sure Unit power switch if applicable is in ON position 7 Plug the Unit power cord into an electrical outlet with the proper electrical reguirements The compressor condenser 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 ope
22. N 1 SYRUP 5 1 1 I 1 SYRUP 6 T 3 T i 6 i CARB DRINK CO2 WATER 6 NOTE The indicated CARB DRINR 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 O 2006 IMI Cornelius Inc 62 301135000E C Gru 3 Vanguard 245 Service Manual REFERENCE MATERIAL FLOW DIAGRAM Eight Flavor Unit Requiring Remote Carbonator DISPENSING eso al VALVE 8 son DUAL CARB WATER ds 1 a COOLING COILS 4 i Em i CO2 WATER 1 ds i SARB DRINK a SYRUP 1 r 11 Tr I COOLING STILL CO2 PLAIN WATER 2 3 COILS 8 2 NON CARB OR CARB DRINK SYRUP 2 1 SEE ud ze as L c STILL NON CARB OR CARB DRINK 1 SYRUP 3 1 PLAIN WATER PLAIN WATER COOLING COILS SYRUP 4 34 STILL NON CARB OR CARB DRINK STILL NON CARB OR CARB DRINK CO2 PLAIN WATER 5 6 SYRUP 5 1 i STILL NON CARB OR CARB DRINK CARB DRINK Mm Se Um SYRUP 7 i CARB DRINK SYRUP 8 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 301135000E 63 O 2006 IMI Cornelius Inc Vanguard 245 Service Manual REFERENCE MATERIAL FLOW DIAGRAM Six Flavor Unit vvith Integral Carbonator d
23. TING UNIT Probable Cause Adjustment of dispensing 1 Dirty or inoperative Disassemble and valve syrup flow regulator dispensing valve syrup clean dispensing does not decrease to desired flow control valve syrup flow water to syrup ratio control Dispensed product Primary CO2 regulator Adjust primary CO2 carbonation too low out of adjustment for regulator As existing water conditions instructed or temperature Air in carbonator water Vent air out of tank carbonator water tank through relief valve 3 Water oil or dirt in CO2 Remove contaminated supply CO Clean CO2 system lines regulator etc using a mild detergent Install a clean CO2 supply 4 CO2supply depleted Replenish CO2 supply Dispensed product comes 1 Oil film or soap scum in Use clean cups or out of dispensing valve clear cups or glasses glasses but foams in cup or glass 2 Ice used for finished Do not use ice drink is sub cooled directly from freezer Allow 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 301135000E 41 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Geha 3 TROUBLESHOOTING UNIT Probable Cause Dispensed product 1 Recovery rate of refrigeration of Allow ice bank to produces foam as it system exceeded ice bank recover leaves dispe
24. aining 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 ON for 15 seconds OFF then ON for 15 seconds 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 sanitizing 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 mixture must not exceed 200 PPM of chlorine Stir sanitizing solution to thoroughly mix 29 301135000E 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD 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 dispe
25. 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 301135000E 23 O 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD 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 CO gas check valves must be inspected and serviced as instructed at least once a year under normal conditions and after any CO system servicing or disruption Servicing of the CO gas check valves should be performed by qualified Service Personnel Refer to SERVICE AND MAINTENANCE section of this manual for CO gas check valve inspecting and servicing procedure O 2006 IMI Cornelius Inc 24 301135000E C Gua gt Vanguard 245 Service Manual SERVICE IMPORTANT Only qualified personnel should service the internal components or electrical wiring WARNING Disconnect electrical power from the Unit to prevent personal injury before attempting any internal maintenance Only qualified personnel shou
26. d 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 CO 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 301135000E RR 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Gina gt 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 Six or Eight Valves Removable Refrigeration deck Removable Cladding Removable Drip Tray VANGUARD 245 DISPENSER EIGHT FLAVOR UNIT SHOWN The Vanguard 245 over the counter post mix beverage dispenser off
27. d soft drink system If a CO gas leak is suspected particularly in a small area imme diately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of CO 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 CO regulator regulator controls carbonator CO pressure as instructed in manual provided with the remote carbonator UNIT WITH INTEGRAL BUILT IN CARBONATOR Adjust CO regulator regulator controls Unit built in carbonator CO pressure to a nominal 80 psi CO inlet pressure to the carbonator must not exceed 125 psi ADJUSTING SYRUP SUPPLIES CO REGULATOR SUGAR SYRUP TANKS CO REGULATOR Adjust syrup tanks CO regulator to a minimum of 45 psi LOW CALORIE DIET SYRUP TANK CO REGULATOR Adjust low calorie diet syrup tank secondary CO 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 CO pressure may cause low calorie syrup carbonation resulting in foam SYRUP PUMPS BAG IN BOX SYSTEM Adjust the syrup pumps CO2 regulator to 70 psi DO NOT EXCEED MAXIMUM PRESSURE SPECIFIED ON THE SYRUP PUMPS 18 2006 IMI Cornelius Inc 301135000E C Gua gt Vanguard 245 Service Manual FILL WATER TANK AND START T
28. 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 O 2006 IMI Cornelius Inc 12 301135000E C Gru 3 Vanguard 245 Service Manual CAUTION Do not place or store anything on top of the Unit 2 Clearance above top of the Unit must be open to the ceiling 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 CAUTION This Unit is intended for indoor installation only Do not install this Unit in an outdoor environment which would expose it to the outside elements The water tank drain hose drip t
29. e LAIN dNUAS I po El Ana agavo 9 1 Se ee E t LIN 7 YAIVM NIVId i n i 2 MNIMO HV S C1O4INYA YALVM BHVO ANIYA TILLS di Ad HSIVM ANIYA TILLS r 1 B ANIYO dyv9 ian SE Lio M31VM NIV Td ANI HV 1 LA NI ZOO 301135000E 64 2006 IMI Cornelius Inc Vanguard 245 Service Manual REFERENCE MATERIAL Eight Flavor Unit vvith Integral Carbonator FLOW DIAGRAM MNINO TILLS 1 I 1 E B LIINI HAS L qae o NNIXQ THLS n Kass db L ANIJO SVO 9 A SE EE ET a Geck ANIJO SEVO Ens 1 GE az s HOLVNOSHVO d NWA EE ra din A HAIVM I TE ESCENA QU MESE EE I 1 YANIYA TILLS rum JL a H93H9 1vna o ss EE SE m I BE Es N mM lf Tr Y I l a nnn 1 Y HNIHQ guvo EUR tuas IE L Wull 7 G y i V 2 KL Kg UUU nnn I iren et LL YANIYA EVO con K WI El RR al Z dg E 13N ZOO ANIJO SVO I I L3NI v P Res EE ccce n galv Nivid I Q IOJINIVIA LAINI U1I1VM NIV Id 2006 IMI Cornelius Inc 65 301135000E Release Date July 2006 Publication Number 301135000E Visit the IMI Cornelius Web Site at www cornelius asia com for all your Literature needs This manual is
30. ers the following features Six or eight valves Built in carbonator optional Removable refrigeration deck Removable drip tray Removable cladding O 2006 IMI Cornelius Inc 85 301135000E C Gru 3 Vanguard 245 Service Manual SPECIFICATIONS DESIGN DATA Unit With Built In To Remote Carbonator Carbonator Valve Valve Positions No 3 amp No 4 6 Valves Convertible To Water No 4 No 7 amp No 8 8 Valves Nominal Ice Bank Weight Water Bath Capacity 80 L 21 25 gal 78 L 20 5 gal no ice bank Overall Height 788 mm 31 in 788 mm 31 in GA 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 Ibs 97 8 kg 215 lbs empty water bath Shipping Weight 109 kg 240 pounds 116 kg 255 pounds Counter Weight 97 7 kg 215 pounds 104 6 kg 230 pounds filled water bath valves numbered right to left facing the front of the dispenser PART NUMBER Unit requiring connection to Remote carbonator six flavor unit 115 VAC 60 Hz 417306XXXXX eight flavor unit 115VAC 60Hz 417308XXXXX six flavor unit 208 230 VAC 60 Hz 471 306XXXXX eight flavor unit 208 230 VAC 60 Hz 471 308XXXXX six flavor unit 230 VAC 50 Hz 497 306XXXXX 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
31. icing 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 CHECK VALVE ASSEMBLY 301135000E 35 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD 4 Wipe each part with clean lint free cloth Inspect each part especially the ball for burrs nicks corrosion deterioration and other damage Discard ball seat and any damaged or suspicious parts and replace with new parts during reassembly CONTROL BOX Sa d p jos gt NS O RING P N 315349000 SCREEN RETAINER 7 WATER STRAINER SCREEN PIN 315348000 _ WATER PUMP DOUBLE LIQUID CHECK VALVE 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 check valve 6 Assemble check valves together DO NOT OVER TIGHTEN 7 Install double liquid check valve in water pump outlet port then connect plain water outlet line to the double liquid check valve outlet 8 Restore CO and plain water supplies to the Unit 9 Connect electrical power to the Unit The water pump will cycle on and fill the carbonated water tank with carbonated water Check for water leaks and tighten any loose connections 10
32. 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 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 7 Place Unit in operating position on the countertop 8 To comply with NSF International NSF requirements within the United States the Unit base must be sealed to the countertop and all access holes in the Unit base must be closed and sealed Proceed as follows to seal the Unit base to the countertop an equivalent A Tilt the Unit up to expose the bottom of its base B Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent 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 countertop 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 O 2006 IMI Cornelius Inc 14 301135000E C Gru 3 Vanguard 245 Service Manual INSTALLING WATER L
33. in the drop in refrigeration assembly platform water fill hole 15 Plug drop in refrigeration assembly and electric dispensing valve power cords into their mating connectors 16 Install Unit hood and secure with screw 17 Connect electrical power to the Unit CARBONATOR WATER PuMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM DISRUPTIONS 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 CO 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 circumstances and after any water system disruption plumbing work earthquake etc Refer to manual provided with the remote carbonator for servicing procedure O 2006 IMI Cornelius Inc ede 301135000E C Gru 3 Vanguard 245 Service Manual UNIT WITH INTEGRAL BUILT IN CARBONATOR The carbonator water pump water inlet strainer
34. ing Unit for Shipping or Relocating Hood and Front Access Panel Removal Periodic InspectiOr Kininis ai HUE MORI nes ee CO Regulators Adjustment AAA Adjusting Dispensing Valves for Water Flow Rate Adjusting Dispensing Valves for Water to Syrup Ratio Brix of Dispensed Product eee eee 2006 IMI Cornelius Inc 301135000E CCD Vanguard 245 Service Manual TABLE OF CONTENT Cleaning and enger Ech eege 27 Daily Gleanirig OF UML Les s pei des en Pene eh toit en bcn eeu a i 27 Sanitizing Post Mix Syrup Systems een 28 Cleaning Drop In Refrigeration Assembly Condenser Coil 31 Checking Tee Water Ballets a a adc A a lead EKET 32 Cleaning Water Talk Sisu is ia aa iso ke oa 32 Carbonator Water Pump Yearly Maintenance or After Water System Disruptions uoce tenth ere ida 34 Unit Requiring Connection to Remote Carbonator sese eee eee eee eee 34 Unit with Integral Built In Carbonator 35 Cleaning CO System CO Gas Check Valves ese eeeeeeeeeee 37 Converting Still Non Carbonated Drink Dispensing Valve to Dispense d Carbonated DEHDK 1625 de ia 37 TROUBLE SHOOTING aa 39 Troubleshosting HNL due dires aa o ette eto eere Mak de rata ra 39 Troubleshooting Carbonator iio ee z eee eee 43 Troubleshooting Refrigeration System see eee 44 COMPON
35. into syrup system Replenish syrup supply Replace inoperable syrup pump Adjust syrup tanks CO2 regulator as instructed Repair dispensing valve Adjust dispensing valve syrup flow control Water to Syrup ratio as instructed Turn power OFF for 15 second Correct water supply problem Connect electrical wiring to water level probe see note Replace probe see note Replace pump or motor Replace control board 301135000E Vanguard 245 Service Manual TROUBLESHOOTING REFRIGERATION SYSTEM Probable Cause Refrigeration compressor does 2 not operate 301135000E Ice bank sufficient No water in water tank Control board power Switch on top of unit in OFF position Unit power cord un plugged or drop in refrigeration assembly power cord unplugged Ice sensor electrically disconnected No power source blown fuse or tripped circuit breaker Low high voltage Loose disconnected or broken wiring Overload protector cut out overheated compressor Condenser fan motor not operating as required Inoperative overload protector or start relay Ihoperative ice bank probe Inoperative control board 45 1 Fill water tank with water as Remedy No refrigeration called for instructed Place control board power switch in ON position will be a built in 3 minute time delay before refrigeration compressor starts
36. irculating 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 qualified 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 CARBONATOR WATER PUMP YEARLY MAINTENANCE OR AFTER WATER SYSTEM 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
37. is manual 6 Activate syrup supplies to the Unit 7 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 require no further adjustment If re adjustment should become necessary consult the dispensing valve manufacturer for the proper adjustment procedure 8 Adjusting Dispensing Valves For VVater 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 adjustment procedure 9 If your dispenser is equipped with portion control dispensing valves consult the dispensing valves manufacturer for the proper portion control adjustment procedure 10 Recheck entire installation for CO plain water carbonated water and syrup leaks and repair any leaks 11 Install Unit front access panel on Unit and secure with two screws 12 Slide drip tray all the way up on the drip tray brackets then secure drip tray to brackets with two screws thread rolling O 2006 IMI Cornelius Inc 20 301135000E C Gua gt Vanguard 245 Service Manual OPERATOR S INSTRUCTIONS WARNING Disconnect electrical power to the Unit to prevent personal injury before attempting any internal maintenance On
38. it 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 301135000E Ss 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD 822 mm 8 102 mm MINIMUM DRIP TRAY AREA VANGUARD 245 COUNTER CUTOUT 16 2006 IMI Cornelius Inc 301135000E C Gua 3 Vanguard 245 Service Manual 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 labeled barbed stainless steel carbonated water inlet tubes on front of the Unit CONNECTING PLAIN WATER SOURCE LINE TO UNIT NOTE IMI 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 UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR Proceed as follow
39. ld service the internal components or electrical wiring PREPARING UNIT FOR SHIPPING OR RELOCATING 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 HOOD REMOVAL T CAUTION Do not place or store anything on top of the Unit Remove screw securing 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 301135000E 25 2006 IMI Cornelius Inc Vanguard 245 Service Manual Cina 3 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 Restricti
40. ll external surfaces on the Unit Wipe Unit dry with a clean soft cloth DO NOT USE ABRASIVE CLEANERS 301135000E 27 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD 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 7 Re install nozzles and syrup diffusers back on the dispensing valves SANITIZING POST MIX SYRUP SYSTEMS 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 CO pressure setting on the s
41. ly qualified personnel should service the internal components or electrical wiring 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 M Medium L Large or XL Extra Large dispense switch to dispense product 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 SWITCH 50 Hz UNITS EXCLUDED The Unit power switch must be in ON position before the Unit will operate 301135000E 21 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Gino gt DISPENSING VALVES KEYED LOCK 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 ke
42. mage CAUTION Indicates a potentially hazardous situation which if not avoided MAY result in minor or moderate injury or equipment damage gt SAFETY TIPS Carefully read all safety messages in this manual and safety signs on the machine Keep safety signs in good condition and replace missing or damaged safety signs Learn how to operate the machine and how to use the controls properly Do not let anyone operate the machine without proper training Keep your machine in proper working condition and do not allow un authorized modifications to the machine 301135000E Eq 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Gino gt AUTHORIZED SERVICE PERSONNEL T CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES CARBON DIOXIDE WARNING WARNING CO2 Displaces Oxygen Strict Attention must be observed in the prevention of CO2 gas leaks in the entire CO 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 of CO gas will experience tremors which are followed rapidly by loss of consciousness and death CAUTION PRECAUTIONS TO BE TAKEN IN STORAGE Store and use with adequate ventilation Firmly secure cylinde
43. n Water Source Line to Unit 17 Unit Requiring Connection to Remote Carbonator 17 Unit with Integral Built In Carbonator 17 301135000E 2006 IMI Cornelius Inc Vanguard 245 Service Manual TABLE OF CONTENT CO Source Line Unit with Integral Carbonator CO Regulators Adjustments 2 Adjusting Carbonator CO Regulator Adjusting Syrup Supplies CO Regulator Fill Water Tank and Start the Refrigeration System Preparation for Operation eee eee eee OPERATOR S INSTRUCTIONS ns Operating Controls ei ee ip Dispensing Valve Operation Unit ReWwer re aaa Dispensing Valves Keyed Lock Out Switch Daily Pre Operation Check Uni Opera onades ad Cleaning and Sanitizing Lesia eee eee otra caen tenebant i est Daily Cleaning of Unit anus Sanitizing Syrup Systems Checking Drop In Refrigeration Assembly Condenser Coil for Restrictions J Checking Ice Water Bath sse Carbonator Water Pump Yearly Maintenance or After Water System Disruptions Unit Requiring Connection to Remote Carbonator Unit with Integral Built In Carbonator Cleaning CO Gas Check Valves AAA SERVICE CC OO Prepar
44. ng 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 ADJUSTMENTS CO REGULATORS ADJUSTMENTS WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO 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 of CO 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 CO regulator regulator controls carbonator CO pressure as instructed in manual provided with the remote carbonator Unit With Integral Built in Carbonator Adjust CO regulator regulator controls Unit built in carbonator CO pressure to a nominal 80 psi CO inlet pressure to the carbonator must not exceed 125 psi Adjusting Syrup Supplies CO Regulator 26 2006 IMI Cornelius Inc 301135000E C Gru 3 Vanguard 245 Service Manual SUGAR SYRUP TANKS CO REGULATOR Adjust syrup tanks CO regulator to a minimum of 45 psi Low calorie Diet Syrup Tank CO Regulator Adjust low calorie diet syrup tank secondary CO regulator to 10 psi for syrup lines up to 30 fee
45. nsing depleted valve Primary CO2 regulator pressure Reduce primary CO too high for existing water regulator pressure conditions or temperature settings Tanks System Syrup over Remove syrup tanks carbonated with CO2 as quick disconnects indicated by bubbles in inlet Relieve tank CO2 syrup lines leading to unit pressure as many times as necessary to remove over carbonation Dispensing valve restricted or Sanitize syrup system dirty as instructed in Service and Maintenance Manual Tapered gasket inside carbonated 5 Replace tapered gasket water line swivel nut connector Make sure it is properly distorted restricting carbonated seated water flow Dirty water supply Check water filter Replace cartridge Finished drink above Check refrigeration 4 4 C 40 F system O 2006 IMI Cornelius Inc 42 301135000E Vanguard 245 Service Manual TROUBLESHOOTING UNIT No product dispensed Dispensing valves keyed 1 Place keyed lock out Dispensed product carbonation too low 301135000E lock out switch in OFF position No electrical power to dispenser Disconnected dispensing valves power cord Disconnected or broken wiring to dispensing valve Inoperative transformer or dispensing valve solenoids Primary CO2 regulator out of adjustment for existing water conditions or temperature Air in carbonated water tank water oil or di
46. nsing 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 seconds Repeat ON and OFF cycles for 15 cycles 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 WATER FLUSH SYRUP SYSTEMS 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 minu
47. ntrol CS 4967 Cover Elec Box 560001630 Cord Jump 8 319453000 Strain Relief 9 319941000 Screw TR 8 32 HXWS 12 O 2006 IMI Cornelius Inc 5905 Leen names 11 Harn Wire Carb Not Shown 12 13 14 15 16 200498003 Nut Hex No 8 32 Not Shown 17 317989555 Clip Thermo Thermostat Control 318039000 Thermostat Control 168049000 Fitg Chase Conduit 301135000E Vanguard 245 Service Manual REFERENCE MATERIAL VVIRING DIAGRAM NINO S LINA A gavo 102 TBA NHO HO NYO DES 7 nia HO LHM A LL 39078 NL aq ol d y re g M ns E HOLMS NIMOA JOHLNOO ANVA 391 TAMNYO O ONIMVHQ ATAWASSV TVNIA 338 YO Nuo LIHM OL 099919 oy uo 19919 Ovdvo SJAA OL ue m NH gt B B C ZA Y ATH IL r YOSSIYANOI ia YOLOW NV4 2LIHM OL 029919 2006 IMI Cornelius Inc 61 301135000E Vanguard 245 Service Manual CCD REFERENCE MATERIAL FLow DIAGRAM Six Flavor Unit Requiring Remote Carbonator DISPENSING VALVE 6 DUAL CARB WATER COOLING COILS 5 d I CO2 WATER 1 CARB DRINK SYRUP 1 1 F i i doa I COOLING IN CO2 WATER 2 CARB DRINK I SYRUP 2 ri I i PLAIN WATER a STILL T COOLING COILS NON CARB CO2 PLAIN WATER SON a SYRUP 3 CARB DRINR I 1 I 1 SYRUP 4 r4 j ta i l CO2 WATER 4 5 D F j 5 CARB DRINK I
48. ornelius Inc NOTE 38 301135000E Vanguard 245 Service Manual TROUBLE SHOOTING IMPORTANT Only a service person should service internal components or electrical vviring 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 systems disconnect electrical power to the carbonator shut off CO2 and water supplies then bleed systems before proceeding WARNING To avoid personal injury disconnect electrical power to the unit before attempting any electrical repairs or working on the internal parts of the unit TROUBLESHOOTING UNIT Probable Cause Adjustment of dispensing 1 No syrup supply 1 Replenish syrup supply valve syrup flow regulator 2 Syrup supply container not 2 Securely connect syrup supply container into system syrup system Gen EE securely connected into desired vvater to syrup ratio 3 Tants System Syrup tants secondary CO2 regulator out of adjustment Adjust syrup tanks secondary CO2 regulator as instructed Bag in Box System Primary CO regulator out of adjustment Adjust primary CO2 regulator as instructed Inoperative dispensing Repair dispensing valve valve syrup flow control 5 Tapered washer inside syrup flow control Replace tapered gasket tube swivel nut connection Make su
49. rate circulating ice water bath in the water tank 00 Unit With Integral Carbonator Place carbonator motor power switch in ON position The Unit integral carbonator 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 301135000E SE O 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD PREPARATION FOR OPERATION 1 Unit requiring connection to a remote carbonator Activate plain water and carbonated water supplies to the Unit 2 Place dispensing valves keyed lock out switch on side of the Unit in the ON position 3 Dispense from all dispensing valves to purge all air from the carbonated water and the plain water systems 4 Check entire system for plain water carbonated water and CO leaks and repair any leaks IMPORTANT All syrup systems must be sanitized before the Unit is put into operation 5 Sanitize all syrup systems as instructed in the SERVICE AND MAINTENANCE section of th
50. ray 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 2 Install drip tray brackets on front of Unit and secure with screws installed in the brackets 3 Temporarily install the drip tray on the Unit by sliding the drip tray up on the drip tray brackets 4 Place the Unit in operating position on the countertop 301135000E wie 2006 IMI Cornelius Inc Vanguard 245 Service Manual CCD 5 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 countertop Cutting hole
51. re it seats 301135000E distorted from being over tightened restricting syrup flow 39 properly 2006 IMI Cornelius Inc Vanguard 245 Service Manual TROUBLESHOOTING UNIT Only syrup dispensed 1 Remote Carbonator Unit 1 Open plain water inlet Water to syrup Ratio too low or too high 2006 IMI Cornelius Inc Plain water inlet supply line shutoff valve closed Carbonator not operating Integral built in Carbonator Unit Unit plain water inlet supply line shut off valve closed Carbonator CO2 regulator not properly adjusted Inoperative carbonator liquid level control module or water tank liquid level probe Inoperative water pump or water pump motor Dispensing valve syrup flow regulator not properly adjusted Syrup Tanks System CO gas pressure to syrup tanks insufficient to push syrup out of tank Bag In Box System CO gas pressure to syrup pumps insufficient to operate pumps 40 supply line shutoff valve Refer to manual provided with carbonator Open plain water inlet supply line shutoff valve Adjust carbonator CO2 regulator as instructed Replace inoperative component Replace inoperative pump or motor Adjust Water to Syrup Ratio as instructed Adjust CO2 regulator for syrup tanks as instructed Adjust syrup pumps CO2 regulator as instructed 301135000E C Gru 3 Vanguard 245 Service Manual TROUBLESHOO
52. rs 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 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 screvvdriver 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 2006 IMI Cornelius Inc 2 301135000E CC 3 Vanguard 245 Service Manual SHIPPING AND STORAGE CAUTION
53. rt in CO2 supply 43 switch in ON position Plug in dispenser povver cord or check for blown power fuse or tripped circuit breaker Connect dispensing valves power cord Connect or replace wiring Replace inoperative part Adjust primary CO2 regulator as instructed Vent air from carbonated water tank by dispensing from No 1 dispensing valve to make carbonator water pump motor cycle on Have service person remove contaminated CO supply then clean CO system lines regulator etc using a mild detergent install a clean CO2 supply 2006 IMI Cornelius Inc Vanguard 245 Service Manual TROUBLESHOOTING CARBONATOR Only carbonated vvater dispensed Carbonator pump not operating 2006 IMI Cornelius Inc 1 Probable Cause Syrup supply container not securely connected into syrup system No syrup supply Bag in Box System Inoperable syrup pump Tants System Syrup tanks CO2 regulator not properly adjusted Inoperable dispensing valve Dispensing valve syrup flow control not properly adjusted 3 minutes run limit exceeded Water supply to carbonator disrupted Carbonated water tank water level probe electrical wiring disconnected Inoperative carbonated water tank water level probe Inoperative carbonator pump or motor Inoperative control board 44 1 Securely connect syrup supply container
54. s 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 carbonator 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 301135000E 17 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Geha 3 CONNECTING CO SOURCE LINE UNIT WITH INTEGRAL CARBONATOR Proceed as follows to connect CO source line to Unit with integral built in carbonator 1 Route CO source line connected to an adjustable CO regulator up to the Unit 2 Connect CO source line to CO check valve on end of the Unit CO inlet tube labeled CO CO REGULATORS ADJUSTMENTS WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO an
55. sure 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 CO 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 301135000E son 2006 IMI Cornelius Inc Vanguard 245 Service Manual 2006 IMI Cornelius Inc NOTE 10 301135000E Cinks 3 Vanguard 245 Service Manual INSTALLATION U CAUTION Only trained and certified electrical plumbing and refrigeration technicians should service this unit ALL VVIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES 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 4771 Cup Rest
56. t in length Syrup lines longer than 30 feet in length may require a slightly higher setting of 12 psi maximum Excessive CO pressure may cause low calorie syrup carbonation resulting in foam Syrup Pumps Bag in box System Adjust the syrup pumps CO regulator to 70 psi DO NOT EXCEED MAXIMUM CO 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 DISPENSING 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 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 3 Wash cup rest then rinse the cup rest with clean water Install cup rest in the drip tray 4 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 a
57. t 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 301135000E 33 O 2006 IMI Cornelius Inc Vanguard 245 Service Manual Cre is 3 A Referring to previous IMPORTANT note very carefully lovver 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 D Connect plain water inlet and outlet lines to the carbonator water pump E Restore CO and plain water supplies to the Unit 12 Remove plug from the drop in refrigeration assembly platform water fill hole 13 Fill the water tank with clean water until water runs out of the water tank overflow hose USE LOW MINERAL CONTENT WATER WHERE ALOCAL WATER PROBLEM EXISTS 14 Install plug
58. te to purge all sanitizing solution out of the syrup system and the dispensing valve O 2006 IMI Cornelius Inc 305 301135000E Cinks 3 Vanguard 245 Service Manual C Continue to activate the dispensing valve in cycles ON for 15 seconds OFF then ON for 15 seconds Repeat ON and OFF cycles for 15 cycles 21 Repeat steps 19 and 20 preceding to purge sanitizing solution out of the remaining syrup systems and dispensing 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 CO regulator pressure setting observed in step 4 preceding readjust CO 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 WARNING To avoid possible personal injury or property damage do not attempt to remove the syrup tank cover until CO pressure has been released from the tank 25 Dispose of waste sanitizing solution in a sanitary
59. tor protruding upthrough 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 5 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 6 Allow the ice bank to melt Hot water may be used to speed melting 7 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 8 Use a fiber brush and carefully clean mineral deposit build up from the agitator motor shaft and the ice bank sensing bulb 9 Wash inside of the water tank and the drop in refrigeration assembly evaporator coils then rinse with clean water 10 Install plug in end of the water tank drain hose 11 Unit with integral built in carbonator IMPORTANT For proper alignment when lowering drop in refrigeration assembly into the Uni
60. unit 230 VAC 50 Hz 497316XXXXX eight flavor unit 230 VAC 50 Hz 497318XXXXX 301135000E SES 2006 IMI Cornelius Inc Vanguard 245 Service Manual C Geha 3 CAPABILITY Dispensing rate 12 OZ drinks 4 min or fewer 1000 NOTE Number of drinks dispensed 4 C 40 E or below 24 C 75 F syrup and water inlet temperature and 24 C 75 F ambient MISCELLANEOUS INFORMATION Refrigerant 404A Compressor HP 3 4 H P Standard Valve LEV LVV FFV UF 1 Cup Clearance 298 mm 11 3 4 inches 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 customer s requirement It is available to convert carbonated waters to non carbonated water valve s Non carbonated water dispensing valve s may be converted to also dispense carbonated drink s A CO cylinder delivers carbon dioxide CO gas through adjustable CO 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 CO gas pressure also entering the water tank When dispensing valve is opened
61. yed 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 DAILY PRE OPERATION CHECK 1 The CO supply should be checked daily to make sure there is an adequate supply of CO If necessary replenish the CO 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 activate 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 O 2006 IMI Cornelius Inc 22 301135000E C Gru 3 Vanguard 245 Service Manual CHECKING DROP IN REFRIGERATION ASSEMBLY CONDENSER COIL FOR RESTRICTIONS CAUTION C
62. yrup tanks CO regulator then re adjust CO 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 outlet 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 28 2006 IMI Cornelius Inc 301135000E CC gt Vanguard 245 Service Manual C Continue to activate the dispensing valve in cycles ON for 15 seconds OFF then ON for 15 seconds 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 cont

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