Cornelius Vanguard 245 Service Manual
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Cornelius Vanguard 245 Service Manual

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VANGUARD 245
POST-MIX BEVERAGE DISPENSER
SERVICE MANUAL
IMI CORNELIUS ( TIANJIN ) CO., LTD

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Summary of Contents for Cornelius Vanguard 245

  • Page 1 VANGUARD 245 POST-MIX BEVERAGE DISPENSER SERVICE MANUAL IMI CORNELIUS ( TIANJIN ) CO., LTD...

  • Page 2: Contact Information

    Internet: www.cornelius-asia.com E-mail: customerservice@cornelius.com.cn 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 be reproduced in any way without permission from Cornelius.

  • Page 3: Table Of Contents

    Vanguard 245 Service Manual TABLE OF CONTENT SAFETY ........................1 Safety Instructions ....................1 Safety Tips ......................1 Authorized Service Personnel ................2 (Carbon Dioxide) Warning ................2 Shipping And Storage ..................3 Equipment Handling ...................3 GENERAL INFORMATION ..................5 General Description ....................5 Unit Description ....................5 Specification .......................7...
  • Page 4 Vanguard 245 Service Manual TABLE OF CONTENT Source Line (Unit with Integral Carbonator) ........18 Regulators Adjustments ...............18 Adjusting Carbonator CO Regulator ...........18 Adjusting Syrup Supplies CO Regulator ..........18 Fill Water Tank and Start the Refrigeration System ........19 Preparation for Operation ................20...
  • Page 5 Vanguard 245 Service Manual TABLE OF CONTENT ..................27 Cleaning and Sanitizing ................27 Daily Cleaning of Unit ............28 Sanitizing Post-Mix Syrup Systems ......31 Cleaning Drop-In Refrigeration Assembly Condenser Coil .................32 Checking Ice Water Bath ..................32 Cleaning Water Tank Carbonator Water Pump Yearly Maintenance or After ................34...
  • Page 6 Vanguard 245 Service Manual NOTE © 2006, IMI Cornelius Inc. 301135000E...

  • Page 7: Safety

    Vanguard 245 Service Manual SAFETY AFETY NSTRUCTIONS 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.

  • Page 8: Authorized Service Personnel

    Vanguard 245 Service Manual UTHORIZED ERVICE ERSONNEL 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. ARBON IOXIDE ARNING WARNING -- CO Displaces Oxygen. Strict Attention must be...

  • Page 9: Shipping And Storage

    Vanguard 245 Service Manual HIPPING TORAGE CAUTION — 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.
  • Page 10 Vanguard 245 Service Manual NOTE - 4 - © 2006, IMI Cornelius Inc. 301135000E...

  • Page 11: General Information

    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.
  • Page 12 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 offers the following features: • Six or eight valves • Built-in carbonator (optional) • Removable refrigeration deck •...

  • Page 13: Specification

    Vanguard 245 Service Manual PECIFICATIONS DESIGN DATA Unit Requiring Connection Unit With Built-In To Remote Carbonator Carbonator Valve 6 or 8 valves 6 or 8 valves Valve Positions No. 3 & No. 4 (6 Valves) Convertible To Water* No. 4, No. 7 & No. 8 (8 Valves)

  • Page 14: Capability

    Vanguard 245 Service Manual CAPABILITY Dispensing rate : 12 OZ. drinks 4 / min. or fewer 1000 * NOTE: Number of drinks dispensed 4° C ( 40° F ) or below @ 24 ° C ( 75° F ) syrup and water inlet temperature and 24° C ( 75° F ) ambient.
  • Page 15 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).
  • Page 16 Vanguard 245 Service Manual NOTE - 10 - © 2006, IMI Cornelius Inc. 301135000E...

  • Page 17: Installation

    Vanguard 245 Service Manual INSTALLATION 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. ELIVERY NSPECTION AND NPACKING 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.

  • Page 18: Identification Of Loose-Shipped Parts

    Vanguard 245 Service Manual DENTIFICATION OF OOSE- HIPPED ARTS 1. Drip tray brackets to be installed on the unit, then drip tray to be installed on the drip tray brackets and secured with screws, thread cutting. Cup rest is then to be installed in the drip tray.

  • Page 19: Installation Procedure

    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. A minimum clearance of 300 mm (12 inches) must be maintained on the back side of the Unit and a minimum of 150 mm (6 inches) clearance to the nearest obstruction must be maintained on both sides of the Unit.
  • Page 20 Vanguard 245 Service Manual 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.

  • Page 21: Installing Water Lever Kits

    Vanguard 245 Service Manual INSTALLING WATER LEVER KITS The water lever kits are loose-shipped only with dispenser’s equipped with UF-1 dispensing valves. The water lever kits may be installed on dispensing valves to dispense plain or carbonated water only. Refer to instructions included with the kits for installation instructions.
  • Page 22 Vanguard 245 Service Manual 622 mm UNIT 127 mm MINIMUM 406 mm 108 mm 102 mm MINIMUM MAXMUM DRIP TRAY AREA VANGUARD 245 COUNTER CUTOUT - 16 - © 2006, IMI Cornelius Inc. 301135000E...

  • Page 23: Connecting Carbonated Water Source (Unit Requiring Connection To Remote Carbonator)

    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.

  • Page 24: Source Line (Unit With Integral Carbonator)

    Vanguard 245 Service Manual 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.

  • Page 25: Fill Water Tank And Start The Refrigeration System

    Vanguard 245 Service Manual FILL WATER TANK AND START THE REFRIGERATION SYSTEM 1. Make sure plug in end of the water tank drain hose is secure. NOTE: Use a low-mineral-content water where a local water problem exists. 2. Remove plug from drop-in refrigeration assembly platform water fill hole. Fill the water tank with clean water until water flows out of the water tank overflow hose.

  • Page 26: Preparation For Operation

    Vanguard 245 Service Manual 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.

  • Page 27: Operator's Instructions

    Vanguard 245 Service Manual OPERATOR’S INSTRUCTIONS WARNING: Disconnect electrical power to the Unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service the internal components or electrical wiring. CAUTION: Do not place or store anything on top of unit.

  • Page 28: Dispensing Valves Keyed Lock-Out Switch

    Vanguard 245 Service Manual 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 keyed lock-out switch in the “OFF” (horizontal) position turns off electrical power to the dispensing valves only but the refrigeration system will continue to operate.

  • Page 29: Checking Drop-In Refrigeration Assembly Condenser Coil For Restrictions

    Vanguard 245 Service Manual CHECKING DROP-IN REFRIGERATION ASSEMBLY CONDENSER COIL FOR RESTRICTIONS CAUTION: Circulating air, required to cool the refrigeration assembly condenser coil, is drawn in through grille on back of the hood and is exhausted out through grille on top of the hood. Restricting air in or out of the Unit will decrease the refrigeration system cooling efficiency.

  • Page 30: Unit With Integral (Built-In) Carbonator

    Vanguard 245 Service Manual 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.

  • Page 31: Service

    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 should service the internal components or electrical wiring.

  • Page 32: Periodic Inspection

    Vanguard 245 Service Manual 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.

  • Page 33: Adjusting Dispensing Valves For Water Flow Rate

    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-feet in length. Syrup lines longer than 30-feet in length may require a slightly higher setting of 12-psi maximum.

  • Page 34: Sanitizing Post-Mix Syrup Systems

    Vanguard 245 Service Manual 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.
  • Page 35 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.
  • Page 36 Vanguard 245 Service Manual 13. Syrup Tank Systems Connect sanitizing solution tank, pressurized at 60 to 80-psi, into one of the syrup systems. Bag-in-Box Syrup System Place all bag-in-box syrup containers syrup outlet tubes in container containing sanitizing solution. 14. Sanitize the syrup system and dispensing valve as follows: A.

  • Page 37: Cleaning Drop-In Refrigeration Assembly Condenser Coil

    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.

  • Page 38: Checking Ice Water Bath

    Vanguard 245 Service Manual 1. Disconnect electrical power from the Unit. 2. Remove screw securing the hood, then lift the hood straight up to remove from the Unit. 3. Vacuum or use a soft brush to clean the condenser coil. If available, use low-pressure compressed air.
  • Page 39 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) connector, protruding upthrough hole in drop-in refrigeration assembly deck, from mating ground wire connector on top of the refrigeration assembly deck.

  • Page 40: Carbonator Water Pump Yearly Maintenance Or After Water System Disruptions

    Vanguard 245 Service Manual A. Referring to previous IMPORTANT note, very carefully, lower drop-in refrigeration assembly down into the Unit lower housing. Make sure carbonated water tank ground wire connector is routed up through hole in the refrigeration assembly deck.

  • Page 41: Unit With Integral (Built-In) Carbonator

    Vanguard 245 Service Manual UNIT WITH INTEGRAL (BUILT-IN) CARBONATOR The carbonator water pump water inlet strainer screen and double liquid check valve must be inspected and cleaned at least once a year under normal circumstances and after any water system disruption (plumbing work, earthquake, etc.). This service procedure must be performed by a qualified Service Person.
  • Page 42 Vanguard 245 Service Manual 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.

  • Page 43: Cleaning Co 2 System Co 2 Gas Check Valves

    Vanguard 245 Service Manual LEANING CO YSTEM HECK ALVES 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.
  • Page 44 Vanguard 245 Service Manual NOTE - 38 - © 2006, IMI Cornelius Inc. 301135000E...

  • Page 45: Trouble Shooting

    Vanguard 245 Service Manual TROUBLE SHOOTING IMPORTANT Only a service person should service internal components or electrical wiring. 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.
  • Page 46 Vanguard 245 Service Manual TROUBLESHOOTING UNIT Trouble Probable Cause Remedy Only syrup dispensed. 1. Remote Carbonator Unit 1. Open plain water inlet Plain water inlet supply line supply line shutoff valve. shutoff valve closed. Carbonator not operating. Refer to manual provided with carbonator.
  • Page 47 Vanguard 245 Service Manual TROUBLESHOOTING UNIT Trouble Probable Cause Remedy Adjustment of dispensing 1. Dirty or inoperative 1. 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.
  • Page 48 Vanguard 245 Service Manual TROUBLESHOOTING UNIT Trouble Probable Cause Remedy Dispensed product 1. Recovery rate of refrigeration of 1. Allow ice bank to produces foam as it system exceeded, ice bank recover. leaves dispensing depleted. valve. 2. Primary CO regulator pressure 2.
  • Page 49 Vanguard 245 Service Manual TROUBLESHOOTING UNIT Trouble Probable Cause Remedy No product dispensed. 1. Dispensing valves keyed 1. Place keyed lock-out lock-out switch in “OFF” switch in “ON” position. position. 2. No electrical power to 2. Plug in dispenser power dispenser.

  • Page 50: Troubleshooting Carbonator

    Vanguard 245 Service Manual TROUBLESHOOTING CARBONATOR Trouble Probable Cause Remedy Only carbonated water 1. Syrup supply container 1. Securely connect syrup dispensed. not securely connected supply container into into syrup system. syrup system. 2. No syrup supply. 2. Replenish syrup supply.

  • Page 51: Troubleshooting Refrigeration System

    Vanguard 245 Service Manual TROUBLESHOOTING REFRIGERATION SYSTEM Trouble Probable Cause Remedy Refrigeration 1. Ice bank sufficient. 1. No refrigeration called for. compressor does 2. No water in water 2. Fill water tank with water as not operate. tank. instructed. 3. Control board power 3.
  • Page 52 Vanguard 245 Service Manual TROUBLESHOOTING REFRIGERATION SYSTEM Trouble Probable Cause Remedy Compressor will not stop 1. Ice bank probe location 1. Place probe in proper after sufficient ice bank is incorrect. location. produced. 2. Ice temperature sensor 2. Replace ice temperature inoperative.

  • Page 53: Component Service

    Vanguard 245 Service Manual COMPONENT SERVICE The following are procedures for replacing the major components of the Vanguard. ARBONATOR EPLACEMENT 1. Shut off water and CO at their sources. 2. Remove the hood by removing screws on the top and lifting up.

  • Page 54: Pump Motor Replacement

    Vanguard 245 Service Manual OTOR EPLACEMENT 1. Shut off water and CO at their sources. 2. 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.

  • Page 55: Agitator Motor Replacement

    Vanguard 245 Service Manual GITATOR OTOR EPLACEMENT 1. Disconnect power to the unit. 2. Shut off water and CO 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.

  • Page 56: Controller Board Replacement

    Vanguard 245 Service Manual ONTROLLER OARD EPLACEMENT 1. Shut off water and CO 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 •...
  • Page 57 Vanguard 245 Service Manual ONDENSER OTOR EPLACEMENT 1. Shut off water and CO at their sources. 2. Remove the hood by removing screws on the top and lifting up. Mounting 3. Disconnect power to the unit. screws of cover 4. Remove cover by removing two mounting screws.

  • Page 58: Illustrated Parts List

    Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER REMOTE FIGURE 1. VANGUARD 245 POST-MIX DISPENSER (REMOTE) ASSEMBLY - 52 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 59 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER REMOTE Item Item Part No. Names Part No. Names 560002628 Tank Assy. 560001329 Hood Assy. 4083 Harn Wire (Not Shown) 560003651 Chassis Rfg 120V 60HZ 560003652 Chassis Rfg 240V 60HZ...
  • Page 60 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER (COLD CARBONATED) FIGURE 2. VANGUARD 245 POST-MIX DISPENSER (COLD CARB) ASSEMBLY - 54 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 61 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER (COLD CARBONATED) Item Item Part No. Names Part No. Names 560002628 Tank Assy. 560003654 Chassis Rfg 230V 60HZ 560003655 Chassis Rfg 220V 50HZ 560007415C Tank Carb Assy. 317015000 O-Ring...
  • Page 62 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER REMOTE FIGURE 3. VANGUARD 245 REFRIGERATION (REMOTE) ASSEMBLY - 56 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 63 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER REMOTE Item Item Part No. Names Part No. Names 200498003 Nut Hex No. 8-32 186154000 Screw SE 8-36 PAPH 12 560002107 Panel Back 560003858 Spacer Evap. 320389000 Bushing Snap...
  • Page 64 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER (COLD CARBONATED) FIGURE 4. VANGUARD 245 REFRIGERATION (COLD CARB) ASSEMBLY - 58 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 65 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER (COLD CARBONATED) Item Item Part No. Names Part No. Names Pump and Mot. Assy. 230 V 60HZ 3600 Blade Agit. Pump and Mot. Assy. 230 V 50HZ 186610000 Pin Sprg 200498003 Nut Hex No.
  • Page 66 Vanguard 245 Service Manual ILLUSTRATED PARTS LIST VANGUARD 245 POST-MIX DISPENSER (COLD CARBONATED) FIGURE 5. PUMP AND MOTOR (COLD CARB) ASSEMBLY Item Item Part No. Names Part No. Names Pump and Motor 230V 60HZ 313438000 Switch Toggle Pump and Motor 230V 50HZ 3175 Harn Wire Carb.

  • Page 67: Reference Material

    Vanguard 245 Service Manual REFERENCE MATERIAL IRING IAGRAM - 61 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 68 Vanguard 245 Service Manual REFERENCE MATERIAL IAGRAM Six-Flavor Unit Requiring Remote Carbonator DISPENSING VALVE(6) DUAL CARB WATER COOLING COILS(5) CARB DRINK CO2 WATER 1 SYRUP 1 SYRUP COOLING CARB DRINK COILS(6) CO2 WATER 2 SYRUP 2 STILL PLAIN WATER (NON-CARB)
  • Page 69 Vanguard 245 Service Manual REFERENCE MATERIAL IAGRAM Eight-Flavor Unit Requiring Remote Carbonator DISPENSING VALVE(8) DUAL CARB WATER COOLING COILS(4) CARB DRINK CO2 WATER 1 SYRUP 1 SYRUP COOLING STILL COILS(8) CO2 / PLAIN WATER 2-3 (NON-CARB) OR CARB DRINK SYRUP 2...
  • Page 70 Vanguard 245 Service Manual REFERENCE MATERIAL IAGRAM Six-Flavor Unit with Integral Carbonator - 64 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 71 Vanguard 245 Service Manual REFERENCE MATERIAL IAGRAM Eight-Flavor Unit with Integral Carbonator - 65 - © 2006, IMI Cornelius Inc. 301135000E...
  • Page 72 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 apply for equipment series no. from 89E0630VDXXX. IMI CORNELIUS ( TIANJIN ) CO., LTD...

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