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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii
569000203
TABLE OF CONTENTS (cont’d)
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. . . . . . . . . . . . . . . . . . . . .

iii 569000203
TABLE OF CONTENTS (cont’d)
Page
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. . . . . . . . . . . . . . .

iv
569000203
TABLE OF CONTENTS (cont’d)
Page
LIST OF TABLES
TABLE 1. DESIGN DATA 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE 2. LOOSE-SHIPPED PARTS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1569000203
SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury.
Follow recommended precautions and safe operating
practices.
DANGER
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identi-
fies the most serious hazards.
Safety signs with signal word DANGER or WARNING
are typically near specific hazards. WARNING
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety mes-
sages in this manual. CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. 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 instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2(Carbon Dioxide) Warning
CO2Displaces Oxygen. Strict Attention must be observed in the prevention of CO2(carbon dioxide)
gas leaks in the entire CO2and soft drink system. If a CO2gas leak is suspected, particularly in a
small area, immediately ventilate the contaminated area before attempting to repair the leak. Person-
nel exposed to high concentration of CO2gas will experience tremors which are followed rapidly by
loss of consciousness and suffocation.
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 temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.
Shipping, Storing, Or Relocating Unit

2569000203
THIS PAGE LEFT BLANK INTENTIONALLY

5690002033
GENERAL INFORMATION
This manual is a guide for installing, operating, and maintaining this equipment. Refer to Table of Contents for
page location of detailed information pertaining to questions that arise during installation, operation, service and
maintenance, or troubleshooting this equipment. This section gives the unit description, theory of operation, and
design data for the Six and Eight-Flavor Vanguard 245 Post-Mix Overcounter Dispensers (hereafter referred to
as Units).
This Unit contains no User serviceable parts and must be installed and serviced by a qualified Service Person.
UNIT DESCRIPTION
The Units are compact and may be installed on a countertop as a self-serve Unit or the Unit may be installed in
a drive-through or may be center-island mounted. The Units are equipped with 3/4 H.P. 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 six-flavor Vanguard 245 Post-Mix Dispenser (P/N 497306660WS) is equipped with a plain water dispensing
spout located between No. 5 and No. 6 dispensing valves (see Figure 2 and 9) that when activated, will
dispense chilled plain water.
The only requirements for operation are installation of the Unit, 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 CO2regulators, 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.
Available is an optional Straw Holder (P/N 560000440) that provides a place to store drink straws and a Cup Lid
Holder (P/N 560000439) that provides a place to store a supply of cup lids. A Plain Water Cooling Coil
(P/N 560000477) is available that may be installed in the Unit that provides pre-cooled plain water that may be
connected to a remote Orange Juice Dispenser. Also available is a CO2“OUT”Light Kit (P/N 1983) and a
Dispenser Leg Kit (P/N 560000126) to raise the Dispenser up off the countertop.
WARRANTY REFERENCE INFORMATION
Warranty Registration Date
(to be filled out by customer)
Unit Part Number:
Serial Number:
Install Date:
Local Authorized
Service Center:
FIGURE 1. VANGUARD 245 DISPENSER (EIGHT-FLAVOR UNIT SHOWN)

569000203 4
Table 1. Design Data
Unit Part Numbers:
Units Requiring Connection to Remote Carbonator:
Six-Flavor Unit (115 VAC, 60 Hz) 417306660XX
Eight-Flavor Unit (115 VAC, 60 Hz) 417308660XX
Six-Flavor Unit (208-230 VAC, 60 Hz) 477306660XX
Eight-Flavor Unit (208-230 VAC, 60 Hz) 477308660XX
Six-Flavor Unit (220 VAC, 50 Hz) 497306660XX
Six-Flavor Unit W/Plain Water Spout (220 VAC, 50 Hz) 497306660WS
Eight-Flavor Unit (220 VAC, 50Hz) 497308660XX
Units with Integral (Buit–in) Carbonator:
Six-Flavor Unit (230 VAC, 50 Hz) 497316660XX
Eight-Flavor Unit (230 VAC, 50 Hz) 497318660XX
Overall Dimensions:
Width 24–1/2 inches (622 MM)
Height 31 inches (787 MM)
Depth 29–3/8 inches (746 MM)
Weights:
Units Requiring Connection to Remote Carbonator:
Shipping (one carton) approximate 240 pounds (109 Kg)
Dry Weight (approximate) 236 pounds (107 Kg)
Ice Bank Weight (approximate) 50 pounds (27 Kg)
Drop-In Refrigeration Assembly 100 pounds (45 Kg)
Units with Integral (Buit–in) Carbonator:
Shipping (one carton) approximate 255 pounds (116 Kg)
Dry Weight (approximate) 230 pounds (104 Kg)
Ice Bank Weight (approximate) 50 pounds (27 Kg)
Drop-In Refrigeration Assembly 130 pounds (59 Kg)
Water Bath Capacity (no ice bank) approximately
Units Requiring Connection to Remote Carbonator 21.25 gallons (80 LITERS)
Units with Integral (Buit–in) Carbonator: 20.5 gallons gallons (78 LITERS)
Dispensing Rate:
12-oz. (355 ml) drinks 4/min. or fewer *1000
NOTE: *Number of drinks dispensed 40°F (4.4°C) or below @ 75°F (24°C) syrup and water inlet tem-
perature and 75°F (24°C) ambient.
Refrigeration Requirements:
Refrigerant Type and Amount See Unit
Nameplate
Ambient Operating Temperature 40°F (4.4°C) to 105°F (40.5°C)
Electrical Requirements:
Operating Voltage see Unit nameplate
Current Draw see Unit nameplate
Electric Dispensing Valves 24VAC
*Operating Voltage Range
115 VAC, 60 Hz Unit 103–127 VAC
208–230 VAC, 60 HZ Unit 198–253 VAC
230 VAC, 50 Hz Unit 207–253 VAC

5690002035
THEORY OF OPERATION
UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR
(see applicable Figure 2, 3, or 4)
NOTE: The Unit was set up at the factory to dispense a still (noncarbonated) drink from No. 3
dispensing valve (six-flavor Unit) or No. 4 dispensing valve (eight-flavor Unit) and carbonated drinks
from remaining dispensing valves. The still (non-carbonated) drink dispensing valves may be
converted to also dispense a carbonated drinks. Refer to TABLE OF CONTENTS for converting still
(non-carbonated) drink dispensing valves to dispense carbonated drinks.
A CO2cylinder delivers carbon dioxide (CO2) gas through adjustable CO2regulators 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 CO2gas pressure also entering the water tank. When dispensing valve is
opened, CO2gas 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 CO2gas 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. A still (non-carbonated) drink is dispensed from the No. 3 dispensing valve
(six-flavor Unit) or No. 4 dispensing valve (eight-flavor) Unit in the same manner as the carbonated drink except
plain water is substituted for carbonated water.
The six-flavor Vanguard 245 Post-Mix Dispenser (P/N 497306660WS) is equipped with a plain water dispensing
spout located between No. 5 and No. 6 dispensing valves (see Figure 2 and9). A filtered plain water supply line
is connected to the plain water solenoid valve on top of the refrigeration deck. Pressing the plain water dispense
switch on side of the drip tray support opens the electrically operated plain water solenoid valve which permits
chilled plain water to be dispensed.
UNIT WITH INTEGRAL (BUILT–IN) CARBONATOR
(see applicable Figure 5 or 6 )
NOTE: The Unit was set up at the factory to dispense still (noncarbonated drinks) from No. 4 and No. 5
dispensing valves and carbonated drinks from the remaining dispensing valves. If the factory installed
option to convert No.4 or 5 or both No.4 and 5 to dispense a carbonated drink instead of a still
(non-carbonated) drink was installed on your Unit, refer to TABLE OF CONTENTS for the conversion
instructions.
A CO2 cylinder delivers carbon dioxide (CO2) gas through adjustable CO2 regulators to the applicable syrup
tanks or bag-in-box syrup pumps and also the integral (built-in) carbonator. Plain water enters the integral
carbonator carbonated water tank and is carbonated by CO2 gas pressure also entering the water tank. When
dispensing valve is opened, CO2 gas pressure exerted upon the applicable syrup tank contents or bag-in-box
syrup pump pushes syrup from the syrup supply, through the Unit syrup cooling coil, and on to the dispensing
valve. Carbonated water is pushed from the integral carbonator carbonated water tank by CO2 gas head
pressure and is pushed through the carbonated water manifold to the dispensing valve. Syrup and carbonated
water meet simultaneously at the dispensing valve resulting in a carbonated drink being dispensed. A still
(non-carbonated) drink is dispensed from No. 4 and No. 5 dispensing valves in the same manner as the
carbonated drink except plain water is substituted for carbonated water.

569000203 6
CO2WATER 1
SYRUP 1
CO2WATER 2
SYRUP 2
CO2/PLAIN WATER
SYRUP 4
CO2WATER 4-5
SYRUP 5
SYRUP 6
DUAL CARB WATER
COOLING COILS (5)
SYRUP COOLING
COIL (6)
PLAIN WATER
COOLING COIL STILL
(NON-CARB)
OR CARBDRINK
DISPENSING
VALVE (6)
1
2
3
4
5
6
SYRUP 3
CO2WATER 6
CARB DRINK
CARB DRINK
CARB DRINK
CARB DRINK
CARB DRINK
PLAIN WATER
PLAIN WATER
COOLING COIL
SOLENOID
VALVE
WATER SPOUT
FIGURE 2. FLOW DIAGRAM (DISPENSER P/N 497306660WS) REQUIRES REMOTE CARBONATOR

5690002037
CO2WATER 1
SYRUP 1
CO2WATER 2
SYRUP 2
CO2/PLAIN WATER
SYRUP 4
CO2WATER 4-5
SYRUP 5
SYRUP 6
DUAL CARB WATER
COOLING COILS (5)
SYRUP COOLING
COIL (6)
PLAIN WATER
COOLING COIL STILL
(NON-CARB)
OR CARBDRINK
DISPENSING
VALVE (6)
1
2
3
4
5
6
SYRUP 3
CO2WATER 6
CARB DRINK
CARB DRINK
CARB DRINK
CARB DRINK
CARB DRINK
FIGURE 3. FLOW DIAGRAM (SIX-FLAVOR UNIT) REQUIRES REMOTE CARBONATOR

569000203 8
CO2WATER 1
SYRUP 1
CO2/PLAIN WATER 2-3
SYRUP 2
PLAIN WATER
SYRUP 3
SYRUP 4
CO2/PLAIN WATER 5-6
SYRUP 5
SYRUP 6
CO2WATER 7-8
SYRUP 7
SYRUP 8
DUAL CARB WATER
COOLING COILS (4)
SYRUP COOLING
COIL (8)
PLAIN WATER
COOLING COIL STILL
(NON-CARB)
DRINK
DISPENSING
VALVE (8)
DISPENSER
1
2
3
4
5
6
7
8
STILL
(NON-CARB)
OR CARB DRINK
CARB DRINK
STILL
(NON-CARB)
OR CARB DRINK
STILL
(NON-CARB)
OR CARB DRINK
STILL
(NON-CARB)
OR CARB DRINK
CARB DRINK
CARB DRINK
FIGURE 4. FLOW DIAGRAM (EIGHT-FLAVOR) REQUIRES REMOTE CARBONATOR

5690002039
CO2INLET
PLAIN WATER
INLET
WATER
PUMP
DUAL CHECK
VALVE
CARBONATOR
CARB WATER
MANIFOLD
PLAIN WATER
INLET
SYRUP INLET
11 2
3 4 5
6
CARB DRINK CARB DRINK CARB DRINK CARB DRINK
STILL DRINK
STILL DRINK
FIGURE 5. FLOW DIAGRAM (SIX-FLAVOR UNIT WITH INTEGRAL CARBONATOR)

569000203 10
CO2INLET
PLAIN WATER
INLET
WATER
PUMP
DUAL CHECK
VALVE
CARBONATOR
CARB WATER
MANIFOLD
PLAIN WATER
INLET
SYRUP INLET
11 2 3 4 5 6 7 8
CARB DRINK CARB DRINK CARB DRINK CARB DRINK CARB DRINK CARB DRINK
STILL DRINK
STILL DRINK
FIGURE 6. FLOW DIAGRAM (EIGHT-FLAVOR UNIT WITH INTEGRAL CARBONATOR)

11 569000203
INSTALLATION
This section covers unpacking and inspection, selecting location, installing the Unit, and preparing the Unit for
operation.
UNPACKING AND INSPECTION
(see applicable Figure 9,10, or 11)
NOTE: The Unit was thoroughly inspected before leaving the factory and the carrier has accepted and
signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days
from date of delivery) and immediately reported to the delivering carrier. Request a written inspection
report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier,
not with Cornelius Inc.
1. Unpack Unit and remove shipping tape and other packing material.
2. Remove four shipping nuts that secure the drop-in refrigeration assembly in the lower cabinet.
3. Unpack LOOSE-SHIPPED PARTS. Make sure all items are present and in good condition.
Table 2. Loose-Shipped Parts
Item
No. Part No. Name Qty
1 560000428
560000429
Cup Rest (Eight-Flavor Unit)
Cup Rest (Six-Flavor Unit)
1
1
2 4772 Drip Tray 1
3 560000417 Drip Tray Holder 1
4 4778 Drip Tray Holder Bracket 2
5 331309000 Screw, Sheet Metal Phillips Hd; No. 8 by 1/2-in. Long 4
6 4123 Rear Access Cover 1
7 560000439 Cup Lid Holder (optional) 1
8 560000426 Splash Guard (Right Side) 1
9 560000427 Splash Guard (Left Side) 1
10 317784000 Screw, Thread Cutting Phillips Hd; No. 8-18 by 1/2-in. Long 2
11 151707000 Screw, Thread Rolling Slotted Hd; No. 8-32 by 1/2-in Long 1
12 310445000 Drip Tray Drain Hose 1
13 140135000 Clamp, Drip Tray Drain Hose 1
14 560000440 Straw Holder (optional) 1
15 560000477 Plain Water Cooling Coil (optional) 1
16 560000291 Air Filter (optional) 1
IDENTIFICATION OF LOOSE-SHIPPED PARTS
(see applicable Figure 9, 10, or 11)
1. DRIP TRAY HOLDER BRACKETS (item 4) to be installed on the Unit and secured with SCREWS (item
5), then DRIP TRAY HOLDER (item 3) to be installed on the drip tray holder brackets and secured with
SCREWS (item 10). DRIP TRAY (item 2) is to be installed in the drip tray holder, then the CUP REST
(item 1) is to be installed in the drip tray.

12569000203
2. REAR ACCESS COVER (item 6) is used to cover the rear access hole on back of the Unit 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. SCREW, THREAD ROLLING (item 11) is used to secure hood on the Unit.
4. SPLASH GUARDS (items 8 and 9) are to be installed on the Unit and secured with front access panel
retaining screws.
5. DRIP TRAY DRAIN HOSE (item 12) is to be connected to the drip tray and secured with CLAMP, DRIP
TRAY DRAIN HOSE (item 13).
6. CUP LID HOLDER (optional) item 7 to be installed on the Unit as shown in applicable Figure 10 or 10.
7. STRAW HOLDER (optional) item 14 to be installed on the Unit as shown in applicable Figure 10 or 10.
8. PLAIN WATER COOLING COIL (optional) item 15 to be installed on the Unit. The plain water cooling coil
provides pre-cooled plain water to be connected to a remote Orange Juice Dispenser.
SELECTING LOCATION
DANGER: To avoid possible fatal electrical shock or serious injury to the operator, it is
required that a GFCI (ground fault circuit interrupt) be installed in the electrical circuit for
the domestic Units. It is required that an ELCB (earth leakage circuit breaker) be installed in
the electrical circuit for the export Units
This Unit may be installed on a countertop as a self-serve Unit or the Unit may be installed in a drive-through or
may be center-island installed. Locate the Unit so the following requirements are satisfied.
1. Near a properly grounded electrical outlet with proper electrical requirements. The electrical circuit should
be fused at 20-amps (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.
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 12-inches (305 MM)
must be maintained on the back side of the Unit and a minimum of 6-inches (152.4 MM) 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
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.
PLACING UNIT IN OPERATING POSITION
The water tank drain hose, DRIP TRAY DRAIN HOSE (item 12) , 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, 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.

13 569000203
1. Remove Unit front access panel by removing four screws securing the panel, then remove the panel.
2. Install the DRIP TRAY HOLDER BRACKETS (item 4) on front of the Unit (see applicable Figure 9, 10, or
11) and secure with SCREWS (item 5) installed in the brackets.
3. Install the DRIP TRAY HOLDER (item 3) on the drip tray brackets. Secure drip tray holder to the drip tray
holder brackets with two SCREWS (item 10) as shown in applicable Figure 9, 10, or 11.
4. Place the Unit in operating position on the countertop.
5. Out Unit base back access hole - Route water tank drain hose, DRIP TRAY DRAIN HOSE (item 12) , 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 - Referring to Figure 7, cut hole in countertop as indicated, then place
Unit in position on the countertop. Cutting hole in the countertop allows routing the DRIP TRAY DRAIN
HOSE (item 12), 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 drain hose, DRIP TRAY DRAIN HOSE (item 12) and the water tank overflow hose
down through hole in the countertop. Install REAR ACCESS COVER (item 6) over Unit back access hole.
INSTALLING OPTIONAL PLAIN WATER COOLING COIL (ITEM 15)
The purpose of the optional PLAIN WATER COOLING COIL (item 15) is to provide pre-cooled plain water to be
connected to a remote Orange Juice Dispenser. If applicable to install the plain water cooling coil (see
applicable Figure 9 or 10), it will be necessary to remove the drop-in refrigeration assembly from the Unit lower
housing to install the plain water cooling coil in between two cooling coils already existing in the housing.
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 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 (item 12) to nipple on the drip tray. Secure connection with CLAMP (item 13).
2. Route lower end of drip tray drain hose to and attach to the drain allowing a 3-inch air gap between the
drain and end of the drain hose.
CONNECTING SYRUP SOURCE LINES TO THE UNIT
(see applicable Figure 2, 3, 4, 5, or 6 and applicable Figure 9, 10, or 11)
NOTE: The Unit stainless-steel syrup inlet tubes located on the front of the Unit are labeled to identify
the dispensing valves they serve. For example, the syrup inlet stainless-steel tube labeled “S1”
provides syrup to be dispensed from the No. 1 dispensing valve (No. 1 dispensing valve is the valve on
the left side facing front side of the Unit).
1. Route the syrup source lines (numbered for identification) from the syrup source location up to the Unit
stainless-steel syrup inlet tubes on front of the Unit.
2. Connect the numbered syrup source lines to the corresponding labeled Unit stainless-steel syrup inlet
tubes.
CONNECTING CARBONATED WATER SOURCE LINE TO THE UNIT (UNIT REQUIRING
CONNECTION TO REMOTE CARBONATOR)
(see applicable Figure 2, 3, or 4, and applicable Figure 9 or 10)

14569000203
1. Route the carbonated water source line from the carbonated water source location up to the Unit.
2. Connect the carbonated water source line to the desired labeled stainless-steel water inlet tubes on front of
the Unit.
CONNECTING PLAIN WATER SOURCE LINES TO UNIT
NOTE: Cornelius Inc; recommends that a water shutoff valve and a water filter be installed in the
plain water source to be connected to the Unit. The plain water source water pressure must not be less
than 35-psi or more than 45-psi. If water pressure exceeds 45-psi, a water pressure regulator must be
used to regulate the water pressure.
The plain water source to the equipment shall be installed with adequate back flow protection to
comply with applicable Federal, State, and local codes.
NOTE: No. 1 dispensing valve is the valve on the left side facing front side of the Unit.
UNIT REQUIRING CONNECTION TO REMOTE CARBONATOR
(see applicable Figure 2, 3, or 4)
Proceed as follows to connect plain water source line to No. 3 (six-flavor Unit) or No. 4 (eight-flavor Unit) dispensing
valve on Unit requiring connection to a remote carbonator.
1. Route plain water source line from plain water source up to the Unit.
2. Connect plain water source line to barbed stainless-steel plain water inlet tube labeled “WTR 3”(six-flavor
Unit) or “WTR 4”(eight-flavor Unit) on front of the Unit.
UNIT WITH INTEGRAL (BUILT-IN) CARBONATOR
(see applicable Figure 5 or 6)
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 barbed stainless–steel plain water inlet tubes for No. 3 and 4 (six–flavor Unit)
dispensing valves or No. 4 and 5 (eight–flavor Unit) dispensing valves.
CONNECTING PLAIN WATER SOURCE LINE TO DESIRED DISPENSING VALVES
(see applicable Figure 2, 3, 4, 5, or 6 and applicable Figure 9, 10, or 11)
1. Route plain water source line from plain water source up to the Unit.
2. Connect the plain water source line to the desired labeled stainless-steel water inlet tube(s) on front of the
Unit.

15 569000203
CONNECTING PLAIN WATER SOURCE LINE TO CHILLED PLAIN WATER DISPENSING SYSTEM
(UNIT P/N 497306660WS)
(see Figures 2, and 9).
1. Route plain water source line from plain water source up to the Unit.
2. Route plain water line up under Dispenser, up behind Dispenser front access panel, and on to the plain
water solenoid valve on top of the refrigeration deck.
3. Connect plain water line to inlet of the plain water solenoid valve.
CONNECTING CO2SOURCE LINE (UNIT WITH INTEGRAL CARBONATOR)
(see Figures 5 or 6 and 11)
Proceed as follows to connect CO2source line to Unit with integral (built-in) carbonator.
1. Route CO2source line, connected to an adjustable CO2regulator, up to the Unit.
2. Connect CO2source line to CO2check valve on end of the Unit CO2inlet tube labeled “CO2”.
SEALING UNIT BASE TO COUNTERTOP
NOTE: An alternate arrangement to avoid sealing the Unit to the countertop as described below, would
be to install the optional Leg Kit (P/N 560000126) to raise the Dispenser up off the countertop.
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 sealed with permagum or an equivalent sealant
material. Proceed as follows to seal the Unit base to the countertop.
1. Tilt the Unit up to expose the bottom of it’s base.
2. 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.
3. Lower the Unit into operating position on the countertop to complete seal from the Unit base to the
countertop.
4. Apply additional sealant around bottom of the Unit base. The seal must have a minimum radius of 1/2-inch
(12.7 MM) to prevent crevices and to ensure a complete seal.
5. Seal all access holes to the Unit base with permagum or an equivalent sealant material.
CO2REGULATORS ADJUSTMENTS
WARNING: CO2displaces oxygen. Strict attention must be observed in the prevention of
CO2(carbon dioxide) gas leaks in the entire CO2and soft drink system. If a CO2gas 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 CO2gas will experience
tremors which are followed rapidly by loss of consciousness and suffocation.