Remcor Cornelius VANGUARD 245 Supplement

Installation/Service Manual
VANGUARD 245 POST-MIX DISPENSER
(Mc DONALD’SRAPPLICATIONS)
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of
the Installer to ensure that
the water supply to the
dispensing equipment is
provided with protection
against backflow by an air
gap as defined in
ANSI/ASME A112.1.2-1979;
or an approved vacuum
breaker or other such
method as proved effective
by test.
Water pipe connections
and fixtures directly
connected to a potable
water supply shall be
sized, installed, and
maintained according to
Federal, State, and Local
Codes.
CORNELIUS INC; 1996–2002
Part No. 569000203
September 20, 1996
Revised: July 2, 2002
Revision D
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment.

i569000203
TABLE OF CONTENTS
Page
SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RECOGNIZE SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNDERSTAND SIGNAL WORDS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOLLOW SAFETY INSTRUCTIONS 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 (CARBON DIOXIDE) WARNING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SHIPPING, STORING, OR RELOCATING UNIT 1. . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT DESCRIPTION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY REFERENCE INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THEORY OF OPERATION 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR 5. . . . . . . . . . .
UNIT WITH INTEGRAL (BUILT–IN) CARBONATOR 5. . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNPACKING AND INSPECTION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IDENTIFICATION OF LOOSE-SHIPPED PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . .
SELECTING LOCATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLACING UNIT IN OPERATING POSITION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING OPTIONAL PLAIN WATER COOLING COIL (ITEM 15) 13. . . . . . . .
CONNECTING DRIP TRAY DRAIN HOSE TO A PERMANENT DRAIN 13. . . . . .
CONNECTING SYRUP SOURCE LINES TO THE UNIT 13. . . . . . . . . . . . . . . . . . .
CONNECTING CARBONATED WATER SOURCE LINE TO THE UNIT (UNIT
REQUIRING CONNECTION TO REMOTE CARBONATOR) 13. . . . . . . . . . . . . . .
CONNECTING PLAIN WATER SOURCE LINES TO UNIT 14. . . . . . . . . . . . . . . . .
CONNECTING CO2 SOURCE LINE (UNIT WITH INTEGRAL
CARBONATOR) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SEALING UNIT BASE TO COUNTERTOP 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 REGULATORS ADJUSTMENTS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FILL WATER TANK AND START THE REFRIGERATION SYSTEM 17. . . . . . . . .
PREPARATION FOR OPERATION 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING FRONT ACCESS PANEL, SPLASH GUARDS, DRIP TRAY,
AND CUP REST 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING OPTIONAL CUP LID HOLDER 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLING OPTIONAL STRAW HOLDER 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATOR’S INSTRUCTIONS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OPERATING CONTROLS 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSING VALVE OPERATION 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT POWER SWITCH (50 HZ UNITS EXCLUDED) 21. . . . . . . . . . . . . . . . . . . . . .
DISPENSING VALVES KEYED LOCK-OUT SWITCH 22. . . . . . . . . . . . . . . . . . . . .
DAILY PRE-OPERATION CHECK 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT OPERATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING OF UNIT 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING SYRUP SYSTEMS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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569000203
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Page
CHECKING DROP-IN REFRIGERATION ASSEMBLY CONDENSER COIL
FOR RESTRICTIONS 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING ICE WATER BATH 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBONATOR WATER PUMP YEARLY MAINTENANCE OR AFTER WATER
SYSTEM DISRUPTIONS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR 23. . . . . . . . . . .
UNIT WITH INTEGRAL (BUILT-IN) CARBONATOR 23. . . . . . . . . . . . . . . . . . . . . . .
CLEANING CO2 GAS CHECK VALVES 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE AND MAINTENANCE 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREPARING UNIT FOR SHIPPING OR RELOCATING 25. . . . . . . . . . . . . . . . . . . . .
HOOD AND FRONT ACCESS PANEL REMOVAL 25. . . . . . . . . . . . . . . . . . . . . . . . . .
HOOD REMOVAL 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FRONT ACCESS PANEL REMOVAL 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PERIODIC INSPECTION 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTMENTS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CO2 REGULATORS ADJUSTMENTS 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING DISPENSING VALVES FOR WATER FLOW RATE 26. . . . . . . . . . . .
CHECKING WATER VOLUME (PORTION-CONTROL DISPENSING
VALVES) 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CHECKING DISPENSING VALVES SYRUP CALIBRATION (BRIX) 32. . . . . . . . .
PORTION CONTROL ADJUSTMENT (DOLE AND CC-1 DISPENSING
VALVES) 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING AND SANITIZING 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DAILY CLEANING OF UNIT 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SANITIZING POST-MIX SYRUP SYSTEMS 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING DROP-IN REFRIGERATION ASSEMBLY CONDENSER COIL 37. . . .
CHECKING ICE WATER BATH 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING WATER TANK 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CARBONATOR WATER PUMP YEARLY MAINTENANCE OR AFTER WATER
SYSTEM DISRUPTIONS 39. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR 39. . . . . . . . . . .
UNIT WITH INTEGRAL (BUILT-IN) CARBONATOR 39. . . . . . . . . . . . . . . . . . . . . . .
CLEANING CO2 SYSTEM CO2 GAS CHECK VALVES 42. . . . . . . . . . . . . . . . . . . . .
CONVERTING STILL (NON-CARBONATED) DRINK DISPENSING VALVE TO
DISPENSE A CARBONATED DRINK 42. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNITS REQUIRING CONNECTION TO REMOTE CARBONATOR 42. . . . . . . . . .
TROUBLESHOOTING 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING UNIT 45. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER-TO-SYRUP ‘‘RATIO’’ TOO LOW OR TOO HIGH. 45. . . . . . . . . . . . . . . . . .
ADJUSTMENT OF DISPENSING VALVE SYRUP FLOW REGULATOR DOES
NOT INCREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO’’ 45. . . . . . . . . . . . . .
ADJUSTMENT OF DISPENSING VALVE SYRUP REGULATOR DOES NOT
DECREASE TO DESIRED WATER-TO-SYRUP ‘‘RATIO’’.46. . . . . . . . . . . . . . . . .
DISPENSED PRODUCT CARBONATION TOO LOW. 46. . . . . . . . . . . . . . . . . . . . .

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DISPENSED PRODUCT COMES OUT OF DISPENSING VALVE CLEAR BUT
FOAMS IN CUP OR GLASS. 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSED PRODUCT PRODUCES FOAM AS IT LEAVES DISPENSING
VALVE. 46. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NO PRODUCT DISPENSED FROM ALL DISPENSING VALVES. 47. . . . . . . . . . .
ONLY CARBONATED WATER DISPENSED. 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ONLY SYRUP DISPENSED. 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TROUBLESHOOTING REFRIGERATION SYSTEM 48. . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR DOES NOT OPERATE. 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR DOES NOT OPERATE. (CONT’D) 49. . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR WILL NOT STOP AFTER SUFFICIENT ICE BANK IS
PRODUCED. 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT FORM
SUFFICIENT ICE BANK. 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN MOTOR NOT OPERATING. 49. . . . . . . . . . . . . . . . . . . . . . . . . .
AGITATOR MOTOR NOT OPERATING. 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 56. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
FIGURE 1. VANGUARD 245 DISPENSER (EIGHT-FLAVOR UNIT SHOWN) 3. .
FIGURE 2. FLOW DIAGRAM (DISPENSER P/N 497306660WS) REQUIRES
REMOTE CARBONATOR 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. FLOW DIAGRAM (SIX-FLAVOR UNIT) REQUIRES REMOTE
CARBONATOR 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 4. FLOW DIAGRAM (EIGHT-FLAVOR) REQUIRES REMOTE
CARBONATOR 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. FLOW DIAGRAM (SIX-FLAVOR UNIT WITH INTEGRAL
CARBONATOR) 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6. FLOW DIAGRAM (EIGHT-FLAVOR UNIT WITH INTEGRAL
CARBONATOR) 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. COUNTERTOP HOLE CUTOUT 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 8. DRIP TRAY INSTALLATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 9. VANGUARD 245 POST-MIX DISPENSER (P/N 497306660WS)
REQUIRES CONNECTION TO REMOTE CARBONATOR 27. . . . . . . . . . . . . . . . . .
FIGURE 10. VANGUARD 245 POST-MIX DISPENSER (REQUIRES
CONNECTION TO REMOTE CARBONATOR) 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 11. VANGUARD 245 DISPENSER (WITH INTEGRAL
CARBONATOR) 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 12. PORTION CONTROL COVER 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 13. WATER STRAINER SCREEN AND DOUBLE LIQUID CHECK
VALVE 40. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 14. DOUBLE LIQUID CHECK VALVE ASS’Y41. . . . . . . . . . . . . . . . . . . . . .
FIGURE 15. CO2 GAS CHECK VALVE ASSEMBLY 42. . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 16. WIRING DIAGRAM (REMOTE OR INTEGRAL CARBONATOR
UNIT) 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 17. WIRING DIAGRAM (DISPENSER P/N 497306660WS) 44. . . . . . . . . .
FIGURE 18. VANGUARD 245 POST-MIX DISPENSER ASSEMBLY 52. . . . . . . . . .
FIGURE 19. VANGUARD 245 REFRIGERATION ASSEMBLY 54. . . . . . . . . . . . . . .

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LIST OF TABLES
TABLE 1. DESIGN DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2. LOOSE-SHIPPED PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .