Lancer 8000 Parts List

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INSTALLATION AND SERVICE MANUAL

FOR

LANCER SERIES 8000

COLD CARBONATED DISPENSER (CCD)

REV: 10/08/04 P.N. 28–0631/05

This Manual supersedes Installation and Service Manual 28-0631/04, dated 03/12/99,

and is being published ONLY on the Lancer Web Site

• FAX ENGINEERING: • 210-310-7096 •

Please refer to the Lancer web site (www.lancercorp.com) for information relating to Lancer Installation and Service Manuals, Instruction Sheets, Technical Bulletins, Service Bulletins, etc.

6655 LANCER BLVD. • SAN ANTONIO, TEXAS 78219 USA • (210) 310-7000

FAX SALES

• NORTH AMERICA – 210-310-7245 • INTERNATIONAL SALES – 210-310-7242 • CUSTOMER SERVICE – 210-310-7242 •

• LATIN AMERICA – 210-310-7245 • EUROPE – 32-2-755-2399 • PACIFIC – 61-8-8268-1978 •

9.750

Series 8000 Performance

Draw Performance

Draws per

Minute 75

4-12s Indefinite 325 2-24s Indefinite 168 2-18s Indefinite 290

Initial Pull Down

105

2:45 3:40 5:40

OPTIONAL ACCESSORIES, SERIES 8000

ART NUMBER DESCRIPTION

82-2203 MARQUEE 06-1784 GRAPHICS, COCA-COLA, SCREENED 06-2104 GRAPHICS, COCA-COLA, THREE CUP 82-2184/01-20 MERCHANDISER KIT ASSEMBLY, USA 82-2184/01 MERCHANDISER KIT ASSEMBLY, INTERNATIONAL

30.625

24.000

6.125

22.500

28.625

TABLE OF CONTENTS

SERIES 8000 PERFORMANCE.........................................................................................................................i

OPTIONAL ACCESSORIES, SERIES 8000 .......................................................................................................i

TABLE OF CONTENTS.....................................................................................................................................ii

SPECIFICATIONS.............................................................................................................................................iii

DISPENSER INSTALLATION HIGHLIGHTS....................................................................................................iii

1. INSTALLATION ...........................................................................................................................................1

1.1 RECEIVING .......................................................................................................................................1

1.2 UNPACKING ......................................................................................................................................1

1.3 UNPACKING INSTALLATION KITS...................................................................................................1

1.4 COUNTER SELECTION....................................................................................................................1

1.5 PROVIDING CLEARANCE................................................................................................................1

1.6 WATER REQUIREMENTS.................................................................................................................1

1.7 CARBON DIOXIDE (CO2

) REQUIREMENTS ....................................................................................2

1.8 ELECTRICAL REQUIREMENTS .......................................................................................................2

1.9 DRAIN REQUIREMENTS..................................................................................................................2

1.10 SEALING THE DISPENSER TO THE COUNTER.............................................................................2

1.11 REQUIRED TOOLS FOR INSTALLATION ........................................................................................2

1.12 MOUNTING THE DISPENSER..........................................................................................................2

1.13 CONNECTING THE DRAIN...............................................................................................................2

1.14 FILLING UNIT WITH WATER ............................................................................................................2

1.15 CONNECTING TO ELECTRICAL POWER .......................................................................................3

1.16 CONNECTING TO WATER SUPPLY.................................................................................................3

1.17 CONNECTING THE CO

2 SUPPLY ....................................................................................................3

1.18 PURGING THE CARBONATION SYSTEM .......................................................................................3

1.19 ADJUSTING WATER FLOW..............................................................................................................4

1.20 ADJUSTING WATER TO SYRUP RATIO (BRIX) ..............................................................................4

2. SCHEDULED MAINTENANCE...................................................................................................................4

2.1 DAILY .................................................................................................................................................4

2.2 WEEKLY.............................................................................................................................................4

2.3 MONTHLY..........................................................................................................................................5

2.4 EVERY SIX (6) MONTHS ..................................................................................................................5

2.5 YEARLY..............................................................................................................................................5

3. DISPENSER CLEANING AND SANITIZING..............................................................................................5

3.1 AMBIENT PROCESS.........................................................................................................................5

3.2 ALTERNATE CLEANING AND SANITIZING AGENTS ......................................................................5

4. TROUBLESHOOTING.................................................................................................................................6

4.1 WATER LEAKAGE AROUND NOZZLE.............................................................................................6

4.2 LEAKAGE BETWEEN UPPER AND LOWER VALVE BODIES.........................................................6

4.3 MISCELLANEOUS LEAKAGE...........................................................................................................6

4.4 INSUFFICIENT WATER FLOW..........................................................................................................6

4.5 INSUFFICIENT SYRUP FLOW..........................................................................................................6

4.6 ERRATIC RATIO................................................................................................................................6

4.7 NO PRODUCT DISPENSED.............................................................................................................6

4.8 WATER ONLY DISPENSED, NO SYRUP; OR SYRUP ONLY DISPENSED, NO WATER ...............7

4.9 NO WATER, JUST SYRUP. (ICE BANK GREW TO WATER INLET LINE TO

CARBONATOR TANK........................................................................................................................7

4.10 VALVE WILL NOT SHUT OFF...........................................................................................................7

4.11 SYRUP ONLY DISPENSED. NO WATER, BUT CO2 GAS DISPENSED WITH SYRUP.................7

4.12 EXCESSIVE FOAMING.....................................................................................................................7

4.13 WATER CONTINUALLY OVERFLOWS FROM WATER BATH INTO DRIP TRAY ...........................8

4.14 COMPRESSOR STARTS AND CONTINUES TO RUN UNTIL FREEZE UP AND

WILL NOT TURN OFF.......................................................................................................................8

4.15 WARM DRINKS..................................................................................................................................8

4.16 COMPRESSOR DOES NOT START (NO HUM), CONDENSER FAN MOTOR DOES NOT RUN

AND NO ICE BANK ...........................................................................................................................8

4.17 COMPRESSOR DOES NOT START (NO HUM) BUT CONDENSER FAN MOTOR

RUNS .................................................................................................................................................8

4.18 COMPRESSOR DOES NOT START BUT HUMS .............................................................................9

4.19 COMPRESSOR STARTS, BUT DOES NOT SWITCH OFF START WINDING (WILL RUN ONLY FOR A FEW SECONDS BEFORE INTERNAL OVERLOAD SWITCHES

COMPRESSOR OFF)........................................................................................................................9

SPECIFICATIONS

DIMENSION

Width 24.000 inches (609.6 mm) Depth 28.625 inches (727.1 mm) Height 30.625 inches (777.9 mm)

ICE BANK WEIGHT

55.0 pounds (24.95 kg)

DISPENSER INSTALLATION HIGHLIGHTS

Listed below are six critical elements which will aid in a successful installation.

1. Fill water bath until water over flows from tank overflow tube.

NOTE

Do NOT use distilled water to fill water bath.

2. The carbonator pump motor must be disconnected from the power supply (refer to this manual Section 1.8A, Page 2) prior to connection to water supply for initial build-up of ice bank. Failure to do so will result in automatic shut off of carbonator (see item 5 below) or damage to the pump.

3. If this dispenser is installed in an area that is susceptible to ±10% variation of the nominal line voltage, consider installing a surge protector or similar protection device.

4. There is a five (5) minute delay which prevents the compressor and condenser fan from starting until the delay has lapsed. If electrical current is interrupted, there is always a five (5) minute delay before the compressor starts.

5. The unit is equipped with a protective timer [set for three (3) minutes] for the carbonator pump motor. If the carbonator motor has timed out, it must be manually reset by either momentarily unplugging the unit or switching the on/off switch OFF (if present). Once power is restored, the five (5) minute compressor delay would be in effect.

6. Valve adjustment: Make sure drink temperature is below 40°F (4.4°C) before adjusting brix.

4.20 COMPRESSOR STARTS AND RUNS A SHORTTIME BUT SHUTS OFF

ON OVERLOAD.................................................................................................................................9

4.21 COMPRESSOR RUNS NORMALLY, BUT WATER LINE IS FROZEN ..............................................9

4.22 CIRCUIT BREAKER POPPING.........................................................................................................9

4.23 LOW OR NO CARBONATION...........................................................................................................9

4.24 CARBONATOR MOTOR DOES NOT RUN .....................................................................................10

4.25 REDUNDANT CONTROL LIGHT COMES ON................................................................................10

5. ILLUSTRATIONS, PARTS LISTINGS, WIRING AND PLUMBING DIAGRAMS ......................................11

5.1 WATER REGULATOR......................................................................................................................11

5.2 MERCHANDISER ASSEMBL Y.........................................................................................................11

5.3 CABINET ASSEMBLY.................................................................................................................12-13

5.4 SHROUDED ASSEMBLY, 8000 CCD.........................................................................................14-15

5.5 CARBONATOR, WATER/SYRUP LINE ASSEMBLY..................................................................16-17

5.6 CARBONATOR DECK/PUMP BRACKETASSEMBLY...............................................................18-19

5.7 REFRIGERATION DECK ASSEMBLY........................................................................................20-21

5.8 CONTROL HOUSING ASSEMBLIES .........................................................................................22-23

5.9 CONTROL HOUSING ASSEMBLIES - 115V/60HZ - REDUNDANT CONTROL ............................24

5.10 CONTROL HOUSING ASSEMBLIES - 115V/60HZ.........................................................................25

5.11 CONTROL HOUSING ASSEMBLIES - 230V/50HZ - 220V/60HZ...................................................26

5.12 WIRING DIAGRAM - 115V/60HZ, PN 06-1604 ...............................................................................27

5.13 WIRING DIAGRAM - 230V/50HZ - 220V/60HZ, PN 06-1652..........................................................28

5.14 WIRING DIAGRAM - 115V/60HZ - REDUNDANT CONTROL, PN 06-1718...................................29

5.15 PLUMBING DIAGRAM - 6 VALVE, PN 06-1716..............................................................................30

5.16 PLUMBING DIAGRAM - 8 VALVE, PN 06-1393..............................................................................31

iii

TABLE OF CONTENTS (CONTINUED)

1. INSTALLATION

1.1 RECEIVING

Each unit is tested and thoroughly inspected before shipment. At time of shipment, the carrier accepts the unit(s) and any claim for damages must be made with the carrier. Upon receiving unit(s) from the delivering carrier, carefully inspect carton(s) for visible indication(s) of damage. If damage exists, have carrier note same on bill of lading and file a claim with the carrier.

1.2 UNPACKING

A. Carefully cut steel band and remove. B. Remove top portion of carton by lifting up. C. Remove accessory kit and loose parts from top packaging. D. Remove top inner carton, pad and corners. E. Using proper lifting techniques, lift unit up by plywood shipping base, and remove lower portion

of carton.

F. Inspect unit for concealed damage. If evident, notify delivering carrier and file a claim against

same.

G. Remove plywood shipping base from unit by locating unit so that one side is off the counter top

or table, allowing access to screws on the bottom of the plywood shipping base.

NOTE

If unit is to be transported, it is advisable to leave unit secured to plywood shipping base.

H. If unit is to be installed with optional legs, assemble legs to unit by tilting unit. DO NOT LAY

UNIT ON ITS SIDE OR BACK.

1.3 UNPACKING INSTALLATION KITS

A. Inspect kits for concealed damage. If evident, notify delivering carrier and file a claim against

same.

B. Each kit contains a listing of the parts and a drawing showing the proper assembly of the parts.

1.4 COUNTER SELECTION

A. Select a location close to a properly grounded electrical outlet and water supply that meet the

requirements outlined below.

B. Counter location must be able to support a minimum of 400 pounds (181.44 kg) per unit.

1.5 PROVIDING CLEARANCE W

ARNING

FAILURE TO MAINTAIN PROPER AIR CLEARANCE WILL CAUSE THE COMPRESSOR TO OVERHEAT AND WILL RESULT IN PREMATURE COMPONENT FAILURE.

Condenser air is drawn in the front of the unit and discharged out the top back of the unit. A minimum of 15 inches (381 mm) clearance must be maintained over the top of the unit.

1.6 WATER REQUIREMENTS

CAUTION

IF WATER SOURCE EXCEEDS 50 PSIG (3.52 KG/CM2), A WATER REGULATOR ASSEMBLY MUST BE USED TO LIMIT WATER PRESSURE TO 50 PSIG (3.52 KG/CM

). FAILURE TO USE

REGULATOR WILL RESULT IN IMPROPER PERFORMANCE OF DISPENSER. This dispenser incorporates a built-in cold carbonator. There are three (3) water inlets to the

dispenser. Two (2) inlets (plain water circuits) supply water to the non-carbonated drinks and one (1) inlet (prechill circuit) supplies the carbonator pump.

A. Plain Water Circuit Requirements

Minimum flowing pressure of 40 PSIG (2.81 kg/cm

, 2.75 BAR).

B. Prechill Water Circuit Requirements

Minimum flowing pressure of 25 PSIG (1.76 kg/cm2, 1.72 BAR). Maximum static pressure of 50 PSIG (3.52 kg/cm

, 3.44 BAR).

1.7 CARBON DIOXIDE (CO2) REQUIREMENTS

Operating pressure: 75 PSIG (5.27 kg/cm2, 5.18 BAR).

1.8 ELECTRICAL REQUIREMENTS W

ARNING

ALL ELECTRICAL CIRCUITS MUST MEET LOCAL BUILDING CODES. EACH DRINK DISPENSER MUST BE SUPPLIED WITH A SEPARATE ELECTRICAL CIRCUIT.

The drink dispenser must have an independent (115 Volt, 60 Hz, 20 Amp; 230 Volt, 50 Hz, 10 Amp; or, 220 Volt, 60 Hz, 10 Amp) grounded circuit, depending on dispenser configuration. The ice dispenser should be connected per the manufacturer’s recommendations.

NOTE

The Ice Dispenser Installation Manual can be found in the ice bin, if so equipped.

1.9 DRAIN REQUIREMENTS

A drain connection should be located within three (3) feet (91.44 cm) of the dispenser.

1.10 SEALING THE DISPENSER TO THE COUNTER

When the dispenser is to be permanently mounted to the counter top, seal dispenser base to counter top with a silicone sealant which provides a smooth, easily cleanable bond to the counter.

1.11 REQUIRED TOOLS FOR INSTALLATION

The following tools will be required for installation:

A. Screw Driver, Flat Head B. Screw Driver, Phillips Head C. Screw Driver, Nut Driver D. Beverage Tubing Cutter E. Oetiker Clamp Crimper

1.12 MOUNTING THE DISPENSER

A. The dispenser is designed to be permanently mounted and sealed to the counter, or installed on

four (4) inch legs.

NOTE

NSF listed units must be sealed to the counter or have four (4) inch legs installed.

B. When the dispenser is to be permanently mounted to the counter top, seal dispenser base to

counter top with a silicone sealant which provides a smooth, easily cleanable bond to the counter.

1.13 CONNECTING THE DRAIN

A. Remove Cup Rest. Lift Splash Plate up and pull out and down on the bottom to remove. B. Remove the Drip Tray from the unit, and connect the drain tube to the drain fitting located on the

back. Secure Drain Tube.

C. Route the Drain Tube to a suitable drain, and replace the unit's Drip Tray.

1.14 FILLING UNIT WITH WATER

A. Remove the Bonnet from the unit. B. Remove the Plastic Plug (located on the front of the unit's Compressor Deck) from the unit's fill

hole.

CAUTION

THE WATER BATH COMPARTMENT MUST BE FILLED WITH WATER BEFORE PLUGGING IN THE UNIT. OTHERWISE, THE COMPRESSOR DECK AND CONDENSER FAN MAY NOT OPERATE PROPERLY.

C. Using a funnel or tube, fill the Water Bath compartment with water until it flows out of the Overflow

Tube into the Drip Tray.

NOTE

Do NOT use distilled water to fill water bath.

D. Replace the Plastic Plug.

1.15 CONNECTING TO ELECTRICAL POWER W

ARNING THIS APPLIANCE MUST BE EARTHED. THIS UNIT MUST BE PROPERLY ELECTRICALLY GROUNDED TO AVOID POSSIBLE FATAL

ELECTRICAL SHOCK OR SERIOUS INJURY TO THE OPERATOR. THE POWER CORD IS PROVIDED WITH A THREE PRONG GROUNDED PLUG. IF A THREE-HOLE GROUNDED ELECTRICAL OUTLET IS NOT AVAILABLE, USE AN APPROVED METHOD TO GROUND THE UNIT.

A. Disconnect the power supply to the Carbonator Motor by separating the four pin connector

located on the Electrical Control Box on the Refrigeration Deck.

CAUTION

FAILURE TO DISCONNECT THE MOTOR POWER SUPPLY WILL DAMAGE THE CARBONATOR MOTOR AND PUMP AND VOID THE WARRANTY.

B. Check the Dispenser serial number plate for unit's correct electrical requirements. Do not plug

into wall electrical outlet unless serial number plate current shown agrees with local current available.

C. Route the power supply cord to a grounded electrical outlet of the proper voltage and amperage

rating, and plug in the unit. This will turn on the refrigeration system and allow it to start cooling while completing the rest of the installation. The Agitator Motor will start immediately, but the Compressor and Fan Motor will not start until the five (5) minute delay has elapsed.

1.16 CONNECTING TO WATER SUPPLY CAUTION

IF WATER SOURCE EXCEEDS 50 PSIG (3.52 KG/CM2), AWATER REGULATOR MUST BE USED TO LIMIT WATER PRESSURE TO 50 PSIG (3.52 KG/CM

). FAILURE TO USE REGULATOR WILL

RESULT IN IMPROPER PERFORMANCE OF DISPENSER. A. Using tubing and fittings from installation kit, connect Tubing Assembly to water source. DO

NOT CONNECT TO DISPENSER AT THIS TIME.

B. Flush water supply line thoroughly. C. IF THE WATER SOURCE IS ABOVE 50 PSIG (3.52 KG/CM

), CUT TUBING ASSEMBLY AND

INSTALL WATER REGULATOR KIT.

D. Route through hole in counter and through opening behind Splash Plate and connect to

Carbonator Pump. E. Turn on water supply and check for leaks. F. Using Test Gauge Assembly (PN 22-0138), set Regulator at 50 PSIG (3.52 kg/cm

1.17 CONNECTING THE CO2 SUPPLY

A. Connect High Pressure CO

2 Regulator Assembly to CO2 Cylinder. Use a new CO2 Tank Washer

if Regulator does not have built-in O-Ring Seal. B. Place CO2 Cylinder in service location under counter, etc., and secure it with a safety chain. C. Route gas line through hole in counter and through opening behind the Dispenser Splash Plate.

CAUTION

DO NOT TURN ON THE CO2 SUPPLYAT THIS TIME D. Connect the CO

2 supply line directly to the Carbonator CO2 Inlet Check Valve.

1.18 PURGING THE CARBONATION SYSTEM

A. The Relief Valve for the built-in Carbonator is located in front of the unit's Compressor Deck on

the right hand side. Lift the yellow lever on the top of the Relief Valve until water flows from the

holes in the Relief Valve. Then release the Relief Valve.

B. Reconnect the power supply to the Carbonator Pump. C. Back off on the CO

2 Regulator Pressure Adjusting Screw all the way. Open the CO2 Cylinder

handle slowly. Turn the CO

2 Pressure Regulator up slowly to 75 PSIG (5.1 bar).

D. Open a Dispensing Valve until water and syrup are flowing steadily from the Valve.

E. Repeat procedure “D” for each valve. F. Check all of the unit's syrup, water, and CO

2 connections for leaks. Repair if necessary.

NOTE

To check for CO2 leaks, close the Valve on the CO2 Cylinder and observe if the pressure to the system drops with the Cylinder Valve closed for five (5) minutes. Open the Cylinder Valve after check.

Adjusting Valve

Figure 1

I. To obtain the proper flow, use a screwdriver to adjust water flow control (see Figure 1). J. Repeat process for each valve.

1.20 ADJUSTING WATER TO SYRUP (RATIO) BRIX

A. Hold the Lancer Brix Cup under the Syrup Separator and activate Valve. Check brix. B. To obtain the proper brix, use screwdriver to adjust Syrup Flow Control (see Figure 1). C. Once proper ratio is obtained, repeat to verify. D. Remove Syrup Separator. E. Install Diffuser and Nozzle. F. Slide down I.D. Panel. G. Repeat process for each Valve.

2. SCHEDULED MAINTENANCE

2.1 DAILY

A. Remove the Nozzle and Diffuser from each Valve and wash them in warm water. B. Remove the Cup Rest and wash in warm soapy water. Rinse in warm water. C. Pour warm soapy water into the Drip Tray and wipe with a clean cloth. Rinse in warm water. D. With a clean cloth and warm soapy water, wipe off all of the unit’s exterior surfaces. Rinse with

warm water.

E. Replace the Cup Rest, Valve Diffusers and Valve Nozzles.

2.2 WEEKLY

A. Check the brix of each Valve, following the brixing instructions given in Section 1.20. B. Remove the unit's Bonnet and check the level of water in the Water Bath. Replenish as

required, and replace the Bonnet.

G. Replace the unit's Bonnet, Splash Plate, and Cup Rest.

1.19 ADJUSTING WATER FLOW

A. The water flow can be adjusted between 1.25

ounces/second (37 ml/sec) and 2.50 ounces/second (74 ml/sec) on all Dispensing Valves using the following procedure.

B. The Refrigeration Unit should have been running for a

least one hour before you attempt to brix the Valves. The drink temperature should be no higher than 40

F (4.4oC) when the brix is set. This is best done after the unit has made an ice bank.

C. Slide up I.D. Panel until Flow Controls are exposed. D. Remove Nozzle by twisting counter clockwise and

pulling down.

E. Remove Diffuser by pulling down. F. Install Lancer (yellow) Syrup Separator (PN 54-0031)

in place of Nozzle.

G. Activate Dispensing Valve to fill Separator Syrup Tube. H. Hold a Lancer Brix Cup under the Syrup Separator and

dispense water and syrup into cup for four (4) seconds. Divide number of ounces (ml) of water in cup by four (4) to determine water flow rate per second.

FLOW CONTROL

WATER

DecreaseIncrease

I.D. PANEL

(Shown in

open position)

COVER SCREW

FLOW CONTROL

SYRUP

DecreaseIncrease

DIFFUSER

NOZZLE

2.3 MONTHLY

A. Unplug the Dispenser from its power source. B. Remove the Bonnet, and clean the dirt from the unit's Condenser using a soft brush. C. Replace the Bonnet and plug in the unit.

2.4 EVERY SIX (6) MONTHS

A. Clean and sanitize the unit using the appropriate procedures outlined in Section 3.

2.5 YEARLY

A. Clean water bathe interior, including evaporator coils and refrigeration components. B. Clean the entire exterior of the unit. C. Sanitize syrup lines.

3. DISPENSER CLEANING AND SANITIZING

3.1 AMBIENT PROCESS CAUTION

BECAUSE OF DIFFICULTY IN RINSING, DETERGENT SOLUTION SHOULD NOT BE INTRODUCED INTO THE CARBONATOR.

A. The ambient process is the most common method for cleaning and sanitizing dispenser

equipment. The detergent should be caustic-based and the sanitizer should be a low pH (7.0)

chloride solution. B. Disconnect syrup containers and remove product from tubing by purging with carbon dioxide. C. Rinse the lines and fittings with clean room temperature water to remove all traces of residual

product. D. Fill lines with a caustic-based (low-sudsing, non-perfumed, and easily rinsed) detergent solution.

The solution should be prepared in accordance with the manufacturer’s recommendations, but

should be at least 2 percent sodium hydroxide. Make sure the lines are completely filled and

allow to stand for at least 10 minutes. E. Flush the detergent solution from the lines with clean water. Continue rinsing until testing with

phenolphthalein shows that the rinse water is free of residual detergent. F. Fill the lines with a low pH (7.0) chlorine solution containing at least 50 PPM (50 mg/L) chlorine.

Make sure that lines are completely filled and allow to stand for 10 minutes. G. Reconnect syrup containers and ready unit for operation. H. Draw drinks to refill lines and flush the chlorine solution from the dispenser. I. Taste the beverage to verify that there is no off taste.

3.2 ALTERNATE CLEANING AND SANITIZING AGENTS

A. The above approach to cleaning and sanitizing is strongly recommended. However, the Division

Quality Assurance Manager may approve other cleaning and sanitizing agents such as

chlorinated alkaline detergents. B. However, while chlorinated alkaline detergents or compounds may be used as the cleaning

agent, they may not be used as combined cleaner/sanitizer.

ARNING

IODOPHORS AND QUATERNARY AMMONIUM COMPOUNDS (QUATS) ARE BROAD CLASSES OF COMPOUNDS. SOME MEMBERS OF EACH GROUP CAN CAUSE SERIOUS PROBLEMS WITH FOAMING, DISTORTION OR DISCOLORATION OF POLYMERIC PARTS, POOR RINSIBILITY, AND OFF TASTE. THE RINSIBILITY AND OFF TASTE PROBLEMS HAVE BEEN ESPECIALLY PREVALENT WITH QUATS. BECAUSE OF THE POTENTIAL PROBLEMS, APPROVAL MUST BE GRANTED BY THE DIVISION QUALITY ASSURANCE MANAGER TO SPECIFIC COMPOUNDS. THIS APPROVAL SHOULD BE BASED UPON TESTING IN THE LABORATORY.

C. Iodophors may be substituted for chlorine as the sanitizing agent. D. Quaternary ammonium compounds may be used as a combined cleaner/sanitizer, but are

generally not recommended. These compounds are not to be utilized at concentrations

exceeding 200 PPM (200 mg/L), or that concentration specified in local regulations, which ever

is lower.

4. TROUBLESHOOTING TROUBLE CAUSE REMEDY

4.1 Water leakage around A. Damaged or improperly A. If damaged, replace. If

Nozzle. installed O-Ring above improperly installed, adjust.

Diffuser.

4.2 Leakage between A. Gap between upper and A. Tighten all six (6) retaining

upper and lower valve lower valve bodies. screws. bodies. B. Worn or damaged Paddle B. Replace Paddle Arm

Arm Assemblies. Assemblies.

4.3 Miscellaneous leakage. A. Gap between parts. A. Tighten appropriate retaining

screws.

B. Damaged or improperly B. Replace or adjust appropriate

installed O-Rings. O-Rings.

4.4 Insufficient water flow. A. Insufficient incoming supply A. Verify incoming supply water

water pressure. pressure is a minimum of 25 PSI.

B. Shutoff on Mounting Block B. Open Shutoff fully.

not fully open.

C. Foreign debris in Water Flow C. Remove Water Flow Control from

Control. upper body and clean out any

foreign material to ensure smooth free spool movement.

D. Foreign debris in Water Pump D. Remove Water Pump Strainer and

Strainer. clean.

4.5 Insufficient syrup flow. A. Insufficient CO

2 pressure to A. Adjust CO2 pressure to 80 PSI

BIB pumps. (minimum 70 PSI) for BIB pumps.

B. Shutoff on Mounting Block B. Open Shutoff fully.

not fully open.

C. Foreign debris in Syrup Flow C. Remove Syrup Flow Control from

Control. upper body and clean out any

foreign material to ensure smooth free spool movement.

4.6 Erratic ratio. A. Incoming water and/or syrup A. Check pressure and adjust.

supply not at minimum flowing pressure.

B. Foreign debris in water B. Remove flow controls from upper

and/or syrup flow controls. body and clean out any foreign

material to ensure smooth free spool movement.

4.7 No product dispensed. A. Water and syrup Shutoffs on A. Open Shutoffs fully.

Mounting Block not fully open.

B. The Key Switch on an Electric B. Turn Key Switch to ON position.

Valve is in the OFF position.

C. Cup Lever Arm or I.D. Panel C. Repair.

Actuator on Electric Valve is not actuating the Switch.

D. Electric current not reaching D. Check electric current supplied to

Electric Valve. Valve. If current is adequate, check

Solenoid Coil and Switch, and replace if necessary.

E. Improper or inadequate E. Remove Valve from Mounting Block

water or syrup supply. and open Shutoffs slightly and

check water and syrup supply. If no supply, check Dispenser for freeze-up or other problems.

F. Circuit Breaker tripped on F. Find cause of short and correct.

24 volt transformer. Then, reset transformer.

4.8 Water only dispensed, A. Water or syrup Shutoff on A. Open Shutoff fully. no syrup; or syrup only Mounting Block not fully open. dispensed, no water. B. Improper or inadequate water B. Remove Valve from Mounting Block

or syrup supply. and open Shutoffs slightly and

check water and syrup supply. If no supply, check Dispenser for freeze-up or other problems. Ensure BIB connection is engaged.

C. BIB supply too far from C. Ensure that BIB supply is within

Dispenser. six (6) feet of the dispenser.

D. CO

2 pressure too low. D. Check the CO2 pressure to the

Pump Manifold to ensure it is between 70 and 80 PSI.

E. Stalled or inoperative BIB E. Check CO2 pressure and/or replace

Pump. Pump.

F. Kinked line. F. Remove kink or replace line.

4.9 No water, just syrup. A. Syrup in water bath. A. Melt ice bank and remove all water. (Ice bank grew to Water Refill. Locate possible syrup leak Inlet Line to Carbonator area and repair. Tank.)

B. Water Cage is out of position. B. Reposition water cage. C. Coolant leak. C. Find leak and recharge unit (if unit

is not frozen).

D. Check water supply. D. Turn on water and shut unit OFF,

then ON to reset Carbonator.

E. Carbonator timed out. E. Turn unit OFF, then ON to reset

Carbonator.

F. Ice Bank Control F. Replace Ice Bank Control.

malfunctioning.

4.10 Valve will not shut off. A. Cup Lever may be sticking or A. Correct or replace Lever.

binding. B. Switch not actuating freely. B. Check Switch for free actuation. C. Solenoid Armature not C. Replace defective Armature or

returning to bottom position. Spring.

4.11 Syrup only dispensed. A. Improper water flow to A. Check for water flow to No water, but CO

2 gas Dispenser. Dispenser (see Item 4.4).

dispensed with syrup. B. Carbonator Pump Motor has B. Reset by turning the unit OFF, and

timed out. and then ON by using the ON/OFF

Switch on top of the unit, or, unplugging unit momentarily.

C. Liquid Level Probe not C. Check connections of Liquid Level

connected properly to PCB. Probe to PCB assembly. D. Faulty PCB Assembly. D. Replace PCB Assembly. E. Faulty Liquid Level Probe. E. Replace Liquid Level Probe. F. Water bath frozen. F. Thaw water bath and repair faulty

component. (See Refrigeration Related Symptoms.)

G. Water line frozen. G. Refer to Item 4.14 listed below.

4.12 Excessive foaming. A. Incoming water or syrup A. Correct prior to dispenser. temperature too high. Consider larger Dispenser or

Pre-cooler.

B. CO2 pressure too high. B. Adjust CO2 pressure downward,

but not less than 70 PSI.

C. Water flow rate too high. C. Readjust and reset ratio. Refer to

Section 1.19, this Manual.

D. Nozzle and Diffuser not D. Remove and reinstall properly.

properly installed.

E. Nozzle and Diffuser not clean. E. Remove and clean. F. Air in BIB lines. F. Bleed air from BIB lines. G. Poor quality ice. G. Check quality of ice used in drink. H. High beverage temperature. H. Check refrigeration system.

TROUBLE CAUSE REMEDY

4.13 Water continually over- A. Loose water connection(s). A. Tighten water connections.

flows from water bath into Drip Tray. B. Flare Seal Washer leaks. B. Replace Flare Seal Washer.

C. Faulty Water Coil. C. Replace Water Coil.

4.14 Compressor starts and A. Ice Bank Control A. Replace Ice Bank Control. continues to run until malfunctioning. freeze up and will not B. Ice Bank Probe positioned B. Check positioning of Ice Bank turn off. improperly. Probe, and reset (if needed).

NOTE:

First check to ensure that the three (3) minute Carbonator Timer has not timed out. Turn unit OFF, and then ON. If the pump shuts off in less than 30 seconds, the Dispenser is not frozen.

4.15 Warm drinks. A. Restricted airflow. A. Check clearances around sides,

top, and inlet of unit. Remove objects blocking airflow through grill.

B. Dispenser connected to hot B. Switch to cold water supply.

water supply.

C. Refrigeration system not C. Refer to Items 5.15 through 5.19.

running. D. Refrigerant leak. D. Repair and recharge. E. Condenser Fan Motor not E. Replace Condenser Fan Motor.

working. F. Dirty Condenser. F. Clean Condenser. G. Dispenser capacity exceeded. G. Add Pre-Cooler, or replace with

larger dispenser.

4.16 Compressor does not A. There is a five (5) minute A. Allow for five (5) minute delay to start (no hum), Con- Compressor and Condenser lapse. denser Fan Motor does Fan delay. not run and no ice bank. B. Ice Bank Probe not B. Fill Water Reservoir until water

completely submerged. flows from Overflow Tube.

C. Circuit Breaker or Fuse C. Reset Breaker or replace Fuse. If

tripped. problem persists:

1. Determine reason and correct.

2. Electrical circuit overloaded; switch to another circuit.

D. Inadequate voltage. D. Measure voltage across common

and run terminal on Compressor. Voltage must not drop below 90% of rated voltage.

E. Ice Bank Control E. Replace Ice Bank Control.

malfunctioning.

F. Incorrect wiring. F. Refer to Wiring Diagram and

correct.

G. Circuit Breaker tripped on G. Find cause of short and correct.

24 volt transformer. Then reset transformer.

4.17 Compressor does not A. Compressor Relay or A. Replace Compressor Relay or start (no hum), but Overload malfunctioning. Overload. Condenser Fan Motor B. Inadequate voltage. B. Measure voltage across common runs. and run Terminal on Compressor.

Voltage must not drop below 90% of rated voltage.

C. Incorrect wiring. C. Refer to Wiring Diagram and

correct.

D. Compressor malfunctioning. D. Replace Compressor.

TROUBLE CAUSE REMEDY

4.18 Compressor does not A. Inadequate voltage. A. Measure voltage across common

start, but hums. and run Terminal on Compressor.

Voltage must not drop below 90% of rated voltage.

B. Incorrect wiring. B. Refer to Wiring Diagram and

correct.

C. Starting Relay malfunctioning. C. Replace Starting Relay. Be sure to

use correct relay. Failure to use correct relay will cause Compressor failure.

D. Compressor malfunctioning. D. Replace Compressor or Deck.

4.19 Compressor starts, but A. Inadequate voltage. A. Measure voltage across common does not switch off start and run Terminal on Compressor. winding (will run for only B. Incorrect wiring. B. Refer to Wiring Diagram and a few seconds before correct. internal overload C. Starting Relay malfunctioning. C. Replace Starting Relay. Be sure to switches Compressor use correct relay. Failure to use off). correct relay will cause Compressor

failure.

4.20 Compressor starts A. Dirty Condenser. A. Clean the Condenser. and runs a short time B. Insufficient or blocked air flow. B. Remove all obstructions and allow but shuts off on for minimum clearances of eight (8) overload. inches (203 mm) over top of unit.

C. Inadequate voltage. C. Measure voltage across common

and run Terminal on Compressor. Voltage must not drop below 90% of rated voltage.

D. Incorrect wiring. D. Refer to Wiring Diagram and

correct.

E. Defective Condenser Fan E. Replace Condenser Fan Motor.

Motor. F. Refrigerant coolant leak. F. Repair and recharge. G. Compressor malfunctioning. G. Replace Compressor.

4.21 Compressor runs A. Low water level in Water Bath. A. Add water to Water Bath until water normally, but water line B. Syrup in Water Bath. runs out of overflow into Drip Tray. is frozen. B. Drain water from Water Bath and

refill with clean water. C. Water Cage is out of position. C. Reposition Water Cage. D. Low coolant charge/slow D. Find and repair leak. Recharge

coolant leak. system.

4.22 Circuit Breaker popping. A. Valve Wire Harness shorted A. Detect short by disconnecting to itself or to Faucet Plate. input faston to keylock and single

pin connector. Restore power. If Breaker doesn't pop, then Valve Wire Harness is shorted; if OK, reconnect.

B. Secondary Wire Harness is B. If Breaker does not pop, locate

bad. short in Secondary Wire Harness

between transformer, PCB and Valve Wire Harness.

C. Transformer failure. C. Detect short by disconnecting both

Transformer fastons and restore power. If Breaker does pop, replace Transformer.

4.23 Low or no carbonation. A. Low or no CO2. A. Check CO2 supply. Adjust CO2

pressure to 70 PSI.

B. Excessive water pressure. B. Water Regulator should be set at

50 PSI.

C. Worn or defective Carbonator C. Replace Carbonator Pump.

Pump.

TROUBLE CAUSE REMEDY

4.24 Carbonator Motor does A. Incorrect Wiring. A. Refer to Wiring Diagram and

not run. correct.

B. Bad Carbonator Capacitor. B. Replace Carbonator Capacitor. C. Blown Fuse on PCB. C. Repair cause of blown Fuse and

replace defective or blown Fuse. D. Relay failure D. Replace Relay/PCB. E. Transformer failure. E. Replace Transformer.

4.25 Redundant Control A. Probe failure. A. Replace Probe. Light comes on. B. PCB/Relay failure. B. Replace PCB/Relay.

C. Probe Springs contacting C. Replace Probe.

each other.

D. Incorrect Probe Wiring. D. Refer to Wiring Diagram and

correct or replace as required.

NOTES

TROUBLE CAUSE REMEDY

NOTES

ITEM PART NO. DESCRIPTION

- 18-0302 Regulator Water Assy 1 07-0438 Clamp, Oetiker 2 08-0311 Hose 3 18-0252 Regulator 4 01-0446 Stem, Hose, 9/16 inch, Brass 5 15-0087 Sealant, Perma-Lok, Pure 6 07-0481/01 Bracket, Regulator 7 04-0504 Screw, 8 - 18 x 0.375 AB 8 01-1429 Nut, 7/8 - 18 UNS

5. ILLUSTRATIONS, PARTS LISTINGS, WIRING AND PLUMBING DIAGRAMS

5.1 WATER REGULATOR

5.2 MERCHANDISER ASSEMBLY

ITEM PART NO. DESCRIPTION

- 82-2184/01-20 Merchandiser Kit Assy, USA

- 82-2184/01 Merchandiser Kit Assy, International

1 51-5544 Plate Assy, Front Merchandiser 2 10-0229 Stand Off 3 04-0069 Screw, 10 - 24 x 0.500, PH,

Machine

4 06-1966 Decal, Merchandiser, USA, 8000

- 06-1965 Decal, Merchandiser, International, 8000

RADEMARKS

5.3 CABINET ASSEMBLY

12 40

5.3 CABINET ASSEMBLY (CONTINUED)

ITEM PART NO. DESCRIPTION

- 82-2089-01 Cabinet Assy, Self-Serve, 8000

- 82-2089-06 Cabinet Assy, MDS, 8000

- 82-2089 Cabinet Assy, 8000 1 30-7039 Wrapper, Tank, 8000 2 12-0097 Key Switch 3 30-7087 Cover, Two (2) Inch Base 4 04-0068 Screw, 10 - 24 X 0.375 FH, Machine 5 42-0101 Tank Assy, Foamed, 8000 6 04-0504 Screw, 8 - 18 X 0.375 AB 7 30-7042 Front Plate, 8000 8 REF Faucet Plate Assy

- 51-5515 Faucet Plate Assy, 6 Valve, 8000

- 51-5579 Faucet Plate Assy, 8 Valve, 8000 9 REF Harness Assy

- 52-2032 Harness Assy, 6 Valve, 8000

- 52-0893 Harness Assy, 8 Valve, 8000 10 13-0005 Bushing 11 11-0015 Socket, Housing 12 05-1508 Drip Tray Top, 8000 13 51-5510 Weld Assy, Drip Tray, 8000 14 04-0407 Screw, 6 - 19 X 0.500, PHD 15 REF Splash Plate

- 30-7080 Splash Plate, for Drip Tray, 8000

- 30-7028 Splash Plate, No Drip Tray, 8000 16 REF Cup Rest

- 23-1209 Cup Rest, 8000

- 23-1219 Cup Rest, Sure-Fill, 8000 17 51-5529 Frame Assy, Base 18 06-0075-01 Nameplate, Serial Number 19 23-1208 Bonnet Assy, 8000 (Graphics Ordered

by Country)

- 23-1092 Bonnet Assy, Self-Serve, 8000

- 23-1235 Bonnet Assy, Front Access, 8000

- 23-1223 Bonnet Assy, MDS 20 03-0062 Clip, Retaining 21 04-0074 Nut, Clip 22 50-0307 Insulation, Back, 8000 23 04-0072 Rivet 24 04-0077 Screw, 4 - 20 X 0.250 AB 25 04-0545 Screw, 8 - 16 X 0.780 Plastite 26 06-0881 Label, Key Switch 27 06-0632 Label CAUTION, Bonnet 28 06-0851 Label, Overflow 29 50-0308 Insulation, Front, 8000 30 08-0004 Drain Tube, 8000 31 03-0302 Clip, Retaining, Drain Tube, 8000 32 50-0306 Insulation, Sides, 8000 33 05-0786 Plug, Bonnet 34 REF Name Plate

- 06-0075-86 Name Plate, 8006 Model

- 06-0075-88 Name Plate, 8008 Model 35 82-2121 Merchandiser Plate Assy, 8000

ITEM P

ART NO. DESCRIPTION

36 10-0229 Stand Off 37 04-0069 Screw 38 30-5314 Shim Plate 39 07-0405 Plug, Key Lock 40 05-1054 Fitting, Insert X IPS, 3/4 inch

NOTE: For the No Drip Tray Configuration, Items

37 - 40 in Figure 5.4 replace Items 12 - 16 and Item 40 in Figure 5.3.

5.4 SHROUDED ASSEMBLY, 8000 CCD

THIS AREA SLIGHTLY ENLARGED TO SHOW MORE DETAIL

ITEM PART NO. DESCRIPTION

1 23-1070 Bonnet, Insert

- 52-1858 Reflector Assy (Includes Items 2 through 9)

2 52-1754/01 PCB Board 3 12-0225 Lampholder, Bi-Pin 4 30-5637 BRKT, Marquee, Reflector, Support 5 30-7313 BRKT, Reflector 6 04-1046 Receiver, Stud 7 04-0336 Rivet, SS, 42BS 8 12-0254 Lamp, Fluorescent 9 04-0613 Screw, 6 - 32 x 0.250

- 82-1964 Marquee Assy (Includes Items 10 through 16)

10 27-0051 Lens, Marquee 11 06-1379 Graphics, Marquee, Thirst On Ice 12 04-1044 Stud, Ball 13 04-1045 Spacer, Nylon, 0.500 x 0.250 14 05-1562 Marquee 15 04-0780 Screw, 6 - 32 x 0.750 16 05-1566 Retainer, Lens, Marquee

- 82-1977 Shroud Assy, 8 Valve (Includes Items 17 through 33)

- 82-1965 Shroud Assy, 6 Valve (Includes Items 17 through 33)

17 04-0406 Screw, 8 - 32 x 0.375 18 30-7145 BRKT, Shroud Slide 19 12-0199 Switch, Water, Push Button 20 10-0501 Bearing, Slide 21 05-1337 Slide, Shroud, 8 Valve

- 05-1561 Slide, Shroud, 6 Valve

22 52-2071 Wire Harness, Switch 23 10-0502 Knob, Slide 24 52-2074 Wire Harness, Soda Only 25 04-0269 Screw, 8 - 16 x 0.375 26 05-1336 Shroud, 8 Valve, Self Serve

- 05-1560 Shroud, 6 Valve, Self Serve

27 04-1032 Screw, 8 - 32 x 0.375 28 06-1681 Decal, Soda Water Only 29 12-0216 Boot, Splash Proof 30 02-0502 Gasket, Bottle Cap Button 31 05-1214/01 Holder, Switch, Ribbed 32 12-0259 Switch, Bottle Cap 33 05-1213 Housing, Bottle Cap, MDS 34 51-5397 BRKT Assy, Left Valve Cover Holder 35 51-5398 BRKT Assy, Right Valve Cover Holder 36 30-6745 BRKT, Valve Cover, 8 Valve

- 30-7301 BRKT, Valve Cover, 6 Valve

37 23-1156 Splash Plate, without Drip Tray 38 REF Frame Assy, Cup Rest

- 51-5491 Frame Assy, Cup Rest, Self-Serve, 8 Valve

- 51-5492 Frame Assy, Cup Rest, Self-Serve, 6 Valve

39 REF Cup Rest, Target

- 23-1075 Cup Rest, Target, 8 Valve

- 51-5492 Cup Rest, Target, 6 Valve

40 04-0148 Screw

NOTE: For the No Drip Tray Configuration, Items

37 - 40 in Figure 5.4 replace Items 12 - 16 and Item 40 in Figure 5.3.

5.4 SHROUDED ASSEMBLY, 8000 CCD (CONTINUED)

ITEM PART NO. DESCRIPTION

5.5 CARBONATOR, WATER/SYRUP LINE ASSEMBLY

32 (REF)

FIGAL/REMOTE

CONFIGURATION

32 (REF)

BAG-IN-BOX

CONFIGURATION

32 (REF)

(REF)

32 (REF)

ITEM PART NO. DESCRIPTION

- 82-2092 Carbonator Assy, 230V/50Hz, With Pumps

- 82-2102 Carbonator Assy, 115V/60Hz, Without Pumps

- 82-2110 Carbonator Assy, 230V/50Hz, Without Pumps

- 82-2116 Carbonator Assy, 115V/60Hz, With Pumps

1 REF Tank Assy, Carbonator

- 23-1212 Tank Assy, Carbonator, 60 Cycle

- 23-1215 Tank Assy, Carbonator, 50 Cycle

2 02-0096 Washer 3 52-2043 Probe Assy

- 17-0468 Fitting Assy, CO

2 IN (For Use

With Pumps)

- 17-0469 Fitting Assy, CO2 IN (For Use Without Pumps)

4 01-1311 Fitting Sub-Assy, CO

5 02-0003 O-Ring 6 01-0689 Sleeve 7 01-0674 Ball 8 02-0025 O-Ring 9 01-1334 Body, Check Valve, Gas 10 01-0669 Body, Check Valve, Gas

- 54-0066 Relief Valve Assy

11 02-0023 Seat 12 05-0536 Stem 13 03-0024/01 Spring 14 05-0537 Body, Relief Valve 15 05-0525 Lever 16 81-0196 Pin 17 05-0011 Flare Seal Washer, Small

- 17-0485 Valve Assy, Double Check

- 17-1001 Valve Assy, Check, Carmun

18 01-1466 Fitting, Check Valve 19 01-0673 Body 20 03-0021 Spring 21 01-0670 Body 22 48-1596 Tube Assy, Plain Water Coils, 8000 23 48-1617 Tube Assy, Soda Coils, 8000 24 30-7202 Water Coils Separators, 8000 25 30-7073 Brace, Water Coils, 8000 26 01-1697 Spacer, 10 - 24, TRD 27 04-0222/01 Screw, 10 - 24 X 1.50 RHD, SL,

MS, SS

28 REF Manifold Assy

- 48-1598 Rechill Manifold Assy, 6 Valve

29 48-0492/01 Adapter, CO2 Water Out 30 01-0204 Cap 31 05-0017 Flare Seal Washer, Large 32 REF Syrup Tube Assemblies

- Syrup Tubes - 6 Valve Unit, No Pumps, 1/4 Barb Inlet

- 48-1508 Tube Assy, Syrup #1

- 48-1509 Tube Assy, Syrup #2

- 48-1510 Tube Assy, Syrup #3

- 48-1511 Tube Assy, Syrup #4

- 48-1512 Tube Assy, Syrup #5

- 48-1513 Tube Assy, Syrup #6

- Syrup Tubes - 6 Valve Unit, No Pumps, 3/8 Barb Inlet

- 48-1411 Tube Assy, Syrup #1

- 48-1412 Tube Assy, Syrup #2

- 48-1413 Tube Assy, Syrup #3

- 48-1414 Tube Assy, Syrup #4

- 48-1415 Tube Assy, Syrup #5

- 48-1416 Tube Assy, Syrup #6

- Syrup Tubes - 6 Valve Unit, With Pumps

- 48-1520 Tube Assy, Syrup #1

- 48-1521 Tube Assy, Syrup #2

- 48-1522 Tube Assy, Syrup #3

- 48-1523 Tube Assy, Syrup #4

- 48-1524 Tube Assy, Syrup #5

- 48-1525 Tube Assy, Syrup #6

- Syrup Tubes - 8 Valve Unit, No Pumps, 1/4 Barb Inlet

- 48-1640 Tube Assy, Syrup #1

- 48-1641 Tube Assy, Syrup #2

- 48-1642 Tube Assy, Syrup #3

- 48-1643 Tube Assy, Syrup #4

- 48-1644 Tube Assy, Syrup #5

- 48-1645 Tube Assy, Syrup #6

- 48-1646 Tube Assy, Syrup #7

- 48-1647 Tube Assy, Syrup #8

- Syrup Tubes - 8 Valve Unit, No Pumps, 3/8 Barb Inlet

- 48-1192 Tube Assy, Syrup #1

- 48-1193 Tube Assy, Syrup #2

- 48-1194 Tube Assy, Syrup #3

- 48-1195 Tube Assy, Syrup #4

- 48-1196 Tube Assy, Syrup #5

- 48-1197 Tube Assy, Syrup #6

- 48-1198 Tube Assy, Syrup #7

- 48-1199 Tube Assy, Syrup #8

- Syrup Tubes - 8 Valve Unit, With Pumps

- 48-1175 Tube Assy, Syrup #1

- 48-1176 Tube Assy, Syrup #2

- 48-1177 Tube Assy, Syrup #3

- 48-1178 Tube Assy, Syrup #4

- 48-1179 Tube Assy, Syrup #5

- 48-1180 Tube Assy, Syrup #6

- 48-1181 Tube Assy, Syrup #7

- 48-1182 Tube Assy, Syrup #8

33 08-0029 Tube, Flexible 34 REF Adapter Assy

- 01-1483 Adapter Assy, Elbow

35 07-0409 Clamp, Oetiker 36 02-0005 O-Ring 37 17-1004 Valve Assy , Check

5.5 CARBONATOR, WATER/SYRUP LINE ASSEMBLY (CONTINUED)

ITEM PART NO. DESCRIPTION

5.6 CARBONATOR DECK/PUMP BRACKET ASSEMBLY

FROM

CO SOURCE

CARBONATO

LINE

SYRUP

TO SYRUP

LINE

FILL

HOLE

ICE BANK

-IMPORTANT-

REMOVE ICE BANK PROBE BEFORE

PROBE

REMOVING COMPRESSOR DECK

PRIMARY

ICE BANK

PROBE

REDUNDANT

ICE BANK

PROBE

-IMPORTANT-

REMOVE ICE BANK PROBE BEFORE

REMOVING COMPRESSOR DECK

ITEM PART NO. DESCRIPTION

- 82-2094 Deck Assy, Carbonator, 115V/60Hz, 8000

- 82-2104 Deck Assy, Carbonator, 230V/50Hz, 8000

- 82-2147 Deck Assy, Carbonator, 115V/60Hz, Redundant Control

- 82-2381 Deck Assy, Carbonator, 230V/50Hz, Redundant Control

1 REF Plate, Carbonator Deck

- 51-5524 Carbonator Deck Assy, PEM, 8000

- 51-5552 Carbonator Deck Assy, PEM, Redundant Control

2 REF Insulation, Carbonator Deck

- 50-0305 Insulation, Carbonator Deck, 8000

- 50-0317 Insulation, Carbonator Deck, Redundant Control

3 05-0436 Sleeve, Probe 4 05-0502 Sleeve, CO

2 IN

5 04-1004 Cap Plug, Two (2) Inch Fill Hole 6 REF Pump, BR, 100GPH

- 86-0001 Pump, 100GPH

- 86-0085 Pump, 100GPH, Fluid-O-Tech

7 REF Carbonator Motor

- 91-0063 Carbonator Motor, 115V/60Hz

- 91-0065 Carbonator Motor, 220V/50-60Hz

8 50-0309 Insulation, Carbonator Bracket 9 04-0061 Screw, 8 - 18 X 0.500, PHD 10 07-0017 Clamp with Screw 11 01-0987 Elbow, 90, 3/8 MF X 3/8 MP 12 04-0576 Washer, Lock, Internal Tooth 13 REF Label, Carbonator Motor

- 06-0431 Label, 115V/60Hz, 1/4HP

- 06-0461 Label, 220V/50-60Hz

14 06-1648 Label, Cap Plug 15 23-1211 Assy, Pump Outlet, 8000 16 04-0110 Nut, 8 - 32, ST, BT 17 06-0877 Label, Ground 18 30-7069 Bracket, Carbonator Motor 19 04-1013 Bolt, Carriage, 1/4 - 20 X 0.750 20 04-0032 Nut, Lock, 1/4 - 20, ST, BT 21 04-0033 Washer, Flat, 1/4 X 0.065, TX 22 06-1649 Label, Probe 23 06-1605 Label, Remove Probe 24 06-1683 Label, Redundant Probe

- 82-2093 Pump Bracket Assy, 6 Pump

- 82-2201 Pump Bracket Assy, 8 Pump

25 51-5512 Bracket Assy, Mini-Pump 26 02-0005 O-Ring 27 04-0359 Screw 28 04-0275 Screw, Half Moon 29 07-0441 Clamp, Oetiker 30 54-0093 Manifold Assy 31 54-0092 Manifold Assy 32 54-0091 Manifold Assy 33 05-0604 Plug, CO

2 Manifold

34 13-0005 Strain Relief, Bushing 35 08-0271 Tube, CO2 36 08-0268 Tube, CO2 37 08-0269 Tube, CO

38 49-0221 Tube Assy, 12 Inch 39 49-0271 Tube Assy, 18 Inch 40 48-1556 Tube Assy, Carbonator Pump 41 82-0251 Mini Pump 42 06-1682 Label, Primary Probe

5.6 CARBONATOR DECK/PUMP BRACKET ASSEMBLY (CONTINUED)

ITEM PART NO. DESCRIPTION

5.7 REFRIGERATION DECK ASSEMBLY

LOAD

LINE

33 36

ITEM PART NO. DESCRIPTION

- 82-2091 Deck Assy, Refrigeration, 115V/60Hz, 134A

- 82-2146 Deck Assy, Refrigeration, 115V/60Hz, 134A, Redundant Control

- 82-2146-06 Deck Assy, Refrigeration, 115V/60Hz, 134A, Redundant, MDS

- 82-2130 Deck Assy, Refrigeration, 115V/60Hz, 134A, Export

- 82-2195 Deck Assy, Refrigeration, 220V/60Hz, 134A

- 82-2101 Deck Assy, Refrigeration, 230V/50Hz, 134A

- 82-2382 Deck Assy, Refrigeration, 230V/50Hz, 134A, Redundant Control

- 82-2382-06 Deck Assy, Refrigeration, 230V/50Hz, 134A, Redundant Control, MDS

- 82-2384 Deck Assy, Refrigeration, 220V/60Hz, 134A, Redundant Control

- 82-2384-06 Deck Assy, Refrigeration, 220V/60Hz, 134A, Redundant Control, MDS

1 51-5523 Deck/Pem Assy, Compressor

- 51-5551 Deck/Pem Assy, Compressor, Redundant Control

2 50-0304 Insulation, Compressor Deck 3 04-0063 Washer, Flat 4 89-0014 Cover, Hole 5 REF Evaporator Coil Assy

- 82-2090 Evaporator Coil Assy, 8000

- 82-2148 Evaporator Coil Assy, Redundant Control

6 52-2053 Probe Assy, EIBC

- 52-2088 Probe Assy, Redundant EIBC

7 04-0470 Screw, 6 - 19 X 0.438 8 07-0268 Handle, 2000X Compressor Deck 9 04-0260 Screw, 10 - 16 X 0.625, OHD, PH, AB,

SS, ZP

10 REF Control Housing Assy

- 52-2055 Control Housing Assy, with ON/OFF Switch, 115V/60Hz

- 52-2090 Control Housing Assy, 115V/60Hz, Redundant Control

- 52-2090-06 Control Housing Assy, 115V/60Hz, Redundant, MDS

- 52-2068 Control Housing Assy, 115V/60Hz, Without Kill Switch

- 52-2059 Control Housing Assy, 230V/50Hz

- 52-2104 Control Housing Assy, 220V/60Hz

11 30-7079 Cover, Control Housing

- 30-7166 Cover, Control Housing, Redundant Control

12 02-0032 Washer 13 04-0504 Screw, 8 - 18 X 0.375 14 51-5519 Holder Assy, Probe 15 51-5548 Bracket, Holder Assy 16 52-2048 Lead Assy, Ground 17 REF Transformer

- 25-0047 Transformer, 75VA, 24V, 115V/50-60Hz,

Reset Breaker

- 25-0048 Transformer, 75VA, 24V, 220V/50-60Hz,

Reset Breaker

18 REF Motor Assy

- 52-2034 Motor Assy, Agitator, 25W, 115V/60Hz, 8

Inch Vented

- 52-2060 Motor Assy, Agitator , 230V/50Hz, 18.3

Watts, 8 Inch

19 30-5113/01 Bracket, Agitator 20 05-0424/01 Propeller, 2.625 Diameter, 35

Pitch

21 05-0502 Propeller, 2.250 Diameter, 37

Pitch 22 02-0040 Seal, Extrusion 23 04-0032 Nut, NYLOK, 1/4 - 20

24 04-0033 Washer, Flat (0.281 ID) 25 REF Compressor

- 83-0104 Compressor, 3/4 HP, 134A, 115V/60Hz

- 83-0105 Compressor, 3/4 HP, 134A,. 230V/50Hz

- 83-0106 Compressor, 3/4 HP, 134A, 220V/60Hz 26 02-0114 Grommet, Compressor 27 04-0537 Washer, Flat (0.467 ID) 28 03-0150 Retainer, Clip 29 13-0006 Cover, Terminal 30 03-0301 Bale Strap 31 47-0344 Tube, Process 32 47-2047 Tube, Compressor (HI Side) 33 47-2065 Tube, Suction Line 34 51-5400 Accumulator, Vertical 35 50-0105 Boot 36 50-0310 Insulation, Tube, 35 Inch 37 50-0311 Insulation, Tube, 15 Inch 38 23-1210 Condenser 39 50-0312 Insulation, Baffle, Right 40 50-0313 Insulation, Baffle, Left 41 50-0314 Insulation, Baffle, Top 42 50-0315 Insulation, Baffle, Control Box 43 30-7184 Bracket, Baffle, Right 44 30-7185 Bracket, Baffle, Left 45 30-7186 Plate, Retainer 46 04-0518 Rivet, 0.1250 X 0.328 47 51-5577 Bracket/Shroud Assy, Fan 48 REF Motor, Fan

- 91-0017 Motor, Fan, 35W, 115V/60Hz

- 91-0019 Motor, Fan, 35W, 230V/60Hz 49 07-0553 Fan Blade, 11 Inch, 4 Petal, 28 Degree 50 04-0060 Nut, Flat 51 02-0413 Silencer 52 23-0999 Dryer Cap Assy 53 04-0110 Nut, 8 - 32 54 04-0576 Washer, Internal Tooth 55 06-0877 Label, Ground 56 06-1719 Label, Connector Locations, Redundant

Control

- 06-1609 Label, Connector Locations, Electric Box 57 51-5520 Bracket Assy, Slider 58 51-5547 Bracket Assy, Slider,

Redundant Control 59 13-0089 Relief, Strain 90 Degree 60 30-7173 Bracket, Transformer 61 26-0377 Capacitor, Carbonator Motor (230V/50Hz

ONLY) 62 06-0080-01 Label, Name Plate 63 04-0059 Screw, 8 - 36 X 0.375, PHD 64 01-1713 Fitting, Reducer, EL, 1/2 X 5/16 65 REF Overload

- 12-0227 Overload, Thermal, 3/4 HP, Compressor,

115V/60Hz

- 12-0045 Overload, Thermal, 3/4 HP Compressor,

230V/60Hz 66 95-0177 Refrigerant, R134A 67 30-7071 Bracket, Filter, Left 68 30-7172 Bracket, Filter, Right 69 23-1218 Air Filter Assy, 8000

- 23-1222 Air Filter Assy, MDS 70 52-1213 Harness Assy, Transformer, Second

5.7 REFRIGERATION DECK ASSEMBLY (CONTINUED)

ITEM PART NO. DESCRIPTION

5.8 CONTROL HOUSING ASSEMBLIES

IBC

RLY2

BR1

RLY1

TIMED

TIME

NOTE: See Sections 5.9, 5.10, and 5.11 for a continuation of this illustration.

DETAIL A

SEE

DETAIL A

ITEM

PART NO. DESCRIPTION

- 52-2059 Control Housing, Without ON/OFF, 230V/50Hz

- 52-2055 Control Housing, With ON/OFF, 115/V60Hz

- 52-2068 Control Housing, Without ON/OFF, 115V/60Hz

- 52-2090 Control Housing, Redundant Control, 115V/60Hz

- 52-2090-06 Control Housing, MDS, 115V/60Hz

- 52-2104 Control Housing, 220V/60Hz

1 52-2037 Harness Assy, Recirc A/C Outlet 2 52-2038 Lead Assy, Hot, Power Supply 3 52-2039 Lead Assy, Common Inlet 4 52-2040 Lead Assy, Ground Inlet 5 52-2041 Lead Assy, Hot, PCB, Transformer 6 52-2042 Lead Assy, Common, PCB 7 52-2044 Lead Assy, Carbonator, Terminal PCB 8 52-2045 Lead Assy, Compressor, Terminal

PCB

9 52-2046 Lead Assy, Compressor, PCB Relay 10 52-2047 Lead Assy, Common Relay 11 04-1024 Retainer, Nylon 12 52-2050 Harness Assy, Carbonator Probe 13 52-2051 Cable Assy, Compressor Relay 14 52-2052 Harness Assy, EIBC Probe 15 04-0504 Screw, 8 - 18 X 0.375 16 30-7166 Cover, Control Box, RC

- 30-7079 Cover, Control Box

17 11-0369 Plug, Male, Schurter 18 12-0190 Block, Terminal 19 52-0908 Harness Assy, Carbonator 20 04-0072 Rivet, 0.125 Diameter X 0.312 21 13-0059 Bushing, 2850, Convert 22 51-5555 Control Box Hinge Assy, RC

- 51-5528 Control Box Hinge Assy

23 13-0088 Relief, Strain, 14/3 SJT 24 52-1423 PC Board Assy, Series II 25 04-1015 Stud, Wing Head 26 04-1016 Receptacle, Clip-On 27 04-1017 Spring, SS, Ejector 28 04-0477 Screw, 8-32 X .375, PHD 29 13-0047 Stand-Off, 0.250 30 11-0186 Jumper, Terminal, 40 Circuit 31 12-0233 Capacitor, Start, 115V/60Hz

- 12-0246 Capacitor, Start, 220V/60Hz

- 12-0235 Capacitor, Start, 230V/50Hz

32 12-0231 Capacitor, Run, 115V/60Hz

- 03-0303 Clip, Capacitor, Retaining (For 220V and 230V 50/60Hz Only)

33 12-0232 Relay, Compressor, 115V/60v

- 12-0247 Relay, Compressor, 220V/60Hz

- 30-7034 Bracket, 220V Compressor, Relay (For 220V Use Only)

- 12-0236 Relay, Compressor, 230V/50Hz

34 30-7100 Bracket, Run, Cap, 115V/60Hz 35 30-7101 Bracket, Start, Cap, 115V/60Hz 36 52-2054 Lead Wire Assy, 14 AWG 37 04-1018 Screw, 10 - 32 X 0.500, FH 38 04-1019 Nut, Locknut with Star Washer 39 04-1023 Washer, Black Nylon Wear 40 12-0242 Indicator Light, Neon Red 41 12-0243 Switch, SPST, ON/OFF

- 12-0089 Switch, KILL, SPDT

42 52-2084 Harness Assy, Probe Connector 43 51-5560 Bracket Assy, Transformer 44 25-0101 Transformer, 115V, 12 VA. 45 52-2080 Lead Assy, Power to Kill

- 52-2049 Lead Assy, Power, IN/KILL

46 52-2086 Lead Assy, RPCB to Light 47 52-2087 Lead Assy, Hot RPCB to Light 48 52-2081 Harness Assy, Transformer to PCB 49 52-2085 Lead Assy, Compressor,

PCB - RPCB

50 52-1737 PCB Assy, EIBC 51 04-0110 Nut, 8 - 32 52 04-0576 Washer, Lock, Internal Tooth 53 51-5546 Extension Assy, Switch

5.8 CONTROL HOUSING ASSEMBLIES (CONTINUED)

ITEM PART NO. DESCRIPTION

NOTE: The parts listing above (for Section 5.8) also applies to the illustrations in

Sections 5.9, 5.10, and 5.11 which follow.

5.9 CONTROL HOUSING ASSEMBLIES - 115V/60HZ - REDUNDANT CONTROL

NOTE: The parts listing for Section 5.8 also applies to this illustration.

GREEN W/ YELLOW

TO TRANSFORMER

B/W

KILL

SWITCH

USA

ONLY

1 3

8W7 56

15 14

B W

TB1 B

OUT

TERM4 TERM3

4 3

PCB,IBC

B3G R

TERM2

TERM1

1012 11 9

TERM2

OUT

J13J2

REDUNDANT

PCB,IBC

COMPRESSOR

B G

OUT

TERM1

1 2

COMPRESSOR

RELAY

START

CAPACITOR

(BLACK)

REDUNDANT CONTROL LIGHT

COMPRESSOR

RUN

CAPACITOR

(SILVER)

WBB

NOTE:

USE POSITION NUMBER TO LOCATE ATTACHMENT POINT. PHYSICAL LOCATION ON RELAY MAY VARY.

GREEN W/ YELLOW

3 1

1 4

TO COMPRESSOR

8000 CCD

115V/60HZ - REDUNDANT CONTROL

SYMBOL

SCHEMATIC SHOWN FOR WIRING CLARITY

DESCRIPTION CONTROL BOX

CHAMFER PIN 1

5.10 CONTROL HOUSING ASSEMBLIES - 115V/60HZ

NOTE: The parts listing for Section 5.8 also applies to this illustration.

GREEN W/ YELLOW

TO TRANSFORMER

KILL

SWITCH

USA

ONLY

TB1

TERM4

65 43B21

1516

1314 1112 910

PCB,IBC

OUT

TERM3

TERM2

OUT

TERM1

COMPRESSOR

CAPACITOR

(BLACK)

COMPRESSOR

CAPACITOR

B B

COMPRESSOR

RELAY

BBWW

1 4

RUN

(SILVER)

NOTE:

USE POSITION

NUMBER TO LOCATE ATTACHMENT POINT. PHYSICAL LOCATION ON RELAY MAY VARY.

GREEN W/ YELLOW

TO COMPRESSOR

8000 CCD

115V/60HZ

SYMBOL

SCHEMATIC SHOWN FOR WIRING CLARITY

DESCRIPTION CONTROL BOX

CHAMFER PIN 1

5.11 CONTROL HOUSING ASSEMBLIES - 230V/50HZ - 220V/60HZ

NOTE: The parts listing for Section 5.8 also applies to this illustration.

BRG

TERM4

PCB,IBC

OUT

TERM3

TO TRANSFORMER

TB1

65 43B21

1516

1314 1112 910

TERM2

OUT

TERM1

S COMPRESSOR

RELAY

COMPRESSOR

START

CAPACITOR

R B

BBWW

1 4

TO COMPRESSOR

8000 CCD

230V/50HZ - 220V/60HZ

SYMBOL

SCHEMATIC SHOWN FOR WIRING CLARITY

DESCRIPTION CONTROL BOX

CHAMFER PIN 1

5.12 WIRING DIAGRAM - 115V/60HZ, PN 06-1604

IMPORTANT

1. WHEN STARTING UNIT OR IF CURRENT IS INTERRUPTED, THERE IS A 5 MINUTE DELAY BEFORE THE COMPRESSOR/FAN STARTS.

ELECTRIC ICE BANK

KILL

LINE 24 V

RIBBED

AGITATOR

BLK

MOTOR

PROBE

PLAIN

BLK

KEY

SWITCH

V A L V E S

POWER

CORD

WGB

SWITCH

USA

ONLY

RGB

BRG

TB1

TERM4

65 43B21

1516

1314 1112 910

PCB,IBC

OUT

IN OUT

TERM3

TERM1TERM2

GBW

CARBONATOR

PROBE

COMPRESSOR

START

CAPACITOR

(BLACK)

COMPRESSOR

RUN

CAPACITOR

(SILVER)

B B

RELAY

CARBONATOR

MOTOR

CAPACITOR

BBWW

1 4

RIBBED

BLK

RIBBED

BLK

8000 CED

COMPRESSOR

SYMBOL

OVERLOAD

B C

DESCRIPTION CHASSIS GROUND CONTROL BOX

CHAMFER PIN 1 COMPRESSOR

BGW

OPTIONAL

MERCHANDISER

FAN

MOTOR

115V/60HZ

WIRING DIAGRAM PN 06-1604

BBWW

CARBONATOR

MOTOR

LABEL,

5.13 WIRING DIAGRAM - 230V//50HZ - 220V/60HZ, PN 06-1652

IMPORTANT

1. WHEN STARTING UNIT OR IF CURRENT IS INTERRUPTED, THERE IS A 5 MINUTE DELAY BEFORE THE COMPRESSOR/FAN STARTS.

ELECTRIC ICE BANK

LINE 24 V

RIBBED

BLK

PROBE

PLAIN

BLK

KEY

SWITCH

V A L V E S

RGB

BRG

PCB,IBC

OUT

TB1

TERM3

TERM4

65 43B21

1516

1314 1112 910

GBW

OUT

TERM1TERM2

RIBBED

BLK

CARBONATOR

COMPRESSOR

PROBE

RELAY

COMPRESSOR

START

CAPACITOR

CARBONATOR

MOTOR

CAPACITOR

POWER

CORD

8000 CED

WGB

AGITATOR

MOTOR

COMPRESSOR

SYMBOL

OVERLOAD

DESCRIPTION CHASSIS GROUND CONTROL BOX

CHAMFER PIN 1 COMPRESSOR

BGW

OPTIONAL

MERCHANDISER

BBWW

1 4

BBWW

CARBONATOR

RIBBED

BLK

FAN

MOTOR

WIRING DIAGRAM

230V/50HZ, 220V/60HZ

PN 06-1652

MOTOR

LABEL,

5.14 WIRING DIAGRAM - 115V/60HZ - REDUNDANT CONTROL, PN 06-1718

IMPORTANT

1. WHEN STARTING UNIT OR IF CURRENT IS INTERRUPTED, THERE IS A 5 MINUTE DELAY BEFORE THE COMPRESSOR/FAN STARTS.

CARBONATOR

GBW

PROBE

BRG

PCB,IBC OUT

IN OUT

TERM3

TERM4

1314 1112 910

R N

REDUNDANT

ELECTRIC

ICE BANK

PROBE

J1 J2

REDUNDANT

PCB,IBC

TERM2

RIBBED

TERM1TERM2

RIBBED

BLK

COMPRESSOR

START

CAPACITOR

(BLACK)

OUT

TERM1

COMPRESSOR

REDUNDANT

CONTROL

RUN

CAPACITOR

(SILVER)

COMPRESSOR

RELAY

CARBONATOR

MOTOR

CAPACITOR

BBWW

1 4

LIGHT

V A L V E S

SWITCH

KEY

POWER

CORD

WGB

PRIMARY ELECTRIC ICE BANK

PROBE

RGB

LINE

24 V

TB1

KILL

RIBBED

BLK

AGITATOR

MOTOR

B/W

G R N

SWITCH

USA

ONLY

65 43B21

1516

PLAIN

BLK

8000 CED

OVERLOAD

COMPRESSOR

SYMBOL

DESCRIPTION CHASSIS GROUND CONTROL BOX

CHAMFER PIN 1 COMPRESSOR

BGW

OPTIONAL

MERCHANDISER

FAN

MOTOR

115V/60HZ - REDUNDANT CONTROL

WIRING DIAGRAM PN 06-1718

BBWW

CARBONATOR

MOTOR

LABEL,

5.15 PLUMBING DIAGRAM - 6 VALVE, PN06-1716

COILS

PLAIN WATER

COILS

PRE-CHILL

CARB.

WATER PUMP

HIGH PRESSURE

V6 V5 V4 V3 V2 V1

8000 CCD

PN 06-1716

PLUMBING DIAGRAM

50 PSIG (MAX.)WATER

CO 75 PSIG

PRESSURE SETTINGS

TO CARBONATOR

PLAIN WATER INLET

S1 PW1 PW2 S2 S3 S4 S5 S6

5.16 PLUMBING DIAGRAM - 8 VALVE, PN 06-1393

S7 S6

COILS

PLAIN WATER

COILS

PRE-CHILL

CARB.

S5 S8

V7 V6 V5 V4 V3 V2

8000 CCD

PN 06-1393

PLUMBING DIAGRAM

V8 V1

S4 S3

HIGH PRESSURE

50 PSIG (MAX.)WATER

CO 75 PSIG

PRESSURE SETTINGS

WATER PUMP

PW2 S2

TO CARBONATOR

PLAIN WATER INLET

PW1 S1

NOTES

Please refer to the Lancer web site (www.lancercorp.com) for information relating to Lancer Installation and Service Manuals, Instruction Sheets, Technical Bulletins, Service Bulletins, etc.

Lancer 8000 Parts List

Specifications and Main Features

Frequently Asked Questions

User Manual