Lancer 85-4562H, 4500 Service Manual
INSTALLATION AND SERVICE MANUAL
LANCER SERIES 4500
85-4562H, ICE BEVERAGE DISPENSER
44 INCH WIDE, 12 VALVE, 115V/60Hz
SPECIFICATIONS
DIMENSIONS
HEIGHT: 34.00 Inches (864 mm)
WIDTH: 44.00 Inches (1118 mm)
DEPTH: 30.50 Inches (775 mm)
TOTAL ICE CAPACITY: 360 Pounds (163.29 kg)
DISPENSABLE ICE CAPACITY: 300 Pounds (136.08 kg)
COUNTER WEIGHT (WITHOUT ICE): 400 Pounds (181.44 kg)
SHIPPING WEIGHT: 460 Pounds (208.66 kg)
ELECTRICAL
VOLTAGE: 115
AMPS: 6.0
Hz: 60
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.
This manual supersedes Installation and Service Manual 28-0420/01, Dated 05/21/04,
and is being published on the Lancer Web Site only.
DATE: 02/15/06
P.N. 28–0420/02
• FAX ENGINEERING: • 210-310-7096 •
• "Lancer" is the registered trademark of Lancer •
• Copyright — 2006 by Lancer, all rights reserved •
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 •
W
ARNING
THIS UNIT IS EQUIPPED WITH AUTOMATIC AGITATION. IT MAY ACTIVATE UNEXPECTEDLY. DO NOT
PLACE HANDS, OR FOREIGN OBJECTS IN THE ICE STORAGE COMPARTMENT.
WHEN UNIT IS BEING SERVICED, CLEANED, OR SANITIZED, UNPLUG DISPENSER FROM THE
POWER SOURCE.
NOTE
Lancer does not recommend the use of shaved, flake, nugget, or pellet ice in the dispenser. Dispenser will
only operate with cube ice.
TABLE OF CONTENTS
SPECIFICATIONS ...................................................................................................................................COVER
TABLE OF CONTENTS .....................................................................................................................................1
1. INSTALLATION ...........................................................................................................................................1
1.1 RECEIVING........................................................................................................................................1
1.2 UNPACKING ......................................................................................................................................1
1.3 SELECTING COUNTER LOCATION .................................................................................................1
1.4 INSTALLING THE DISPENSER .........................................................................................................2
2. CLEANING AND SANITIZING INSTRUCTIONS ........................................................................................3
2.1 GENERAL INFORMATION ................................................................................................................3
2.2 REQUIRED CLEANING EQUIPMENT...............................................................................................4
2.3 DAILY CLEANING..............................................................................................................................4
2.4 ICE BIN CLEANING – START UP AND MONTHLY ..........................................................................4
2.5 CLEANING AND SANITIZING BEVERAGE COMPONENTS - FIGAL SYSTEMS............................5
2.6 CLEANING AND SANITIZING BEVERAGE COMPONENTS - BAG-IN-BOX SYSTEMS.................6
3. TROUBLESHOOTING.................................................................................................................................6
4. LIGHT EMITTING DIODES .........................................................................................................................7
5. AUTOMATIC AGITATION AND LOW ICE ALARM CONTROL..................................................................8
6. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS............................................................9
6.1 DECALS AND LABELS.................................................................................................................9-10
6.2 FINAL ASSEMBLY, POST-MIX IBD AND ICE DISPENSER .......................................................11-12
6.3 FAUCET PLATE AND ICE CHUTE SUB-ASSEMBLY, POST-MIX, IBD .....................................13-14
6.4 ELECTRICAL BOX AND GEAR MOTOR SUB-ASSEMBLY, POST-MIX, IBD............................15-16
6.5 WIRING DIAGRAM - 115V/60HZ .....................................................................................................17
6.6 AGITATION - CONTROLS, EXPANDED VIEW ...............................................................................18
1. INSTALLATION
1.1 RECEIVING
Each unit is completely tested under operating conditions and thoroughly inspected before
shipment. At the time of shipment the carrier accepts the unit, and any claim for damage must be
made with the carrier. Upon receiving units from the delivering carrier, carefully inspect carton for
visible indication of damage. If damage exists, have carrier note the same on bill of lading and file
claim with carrier.
1.2 UNPACKING
A. Set shipping carton upright on the floor.
B. Cut band and remove.
C. Open top of carton and remove interior packing.
D. Lift carton up and off of the dispenser.
E. Remove wood shipping base from the bottom of the dispenser. (Support dispenser while
removing shipping base to prevent damage to the dispenser.)
1.3 SELECTING COUNTER LOCATION (SEE FIGURE 1)
W
ARNING
THIS APPLIANCE MUST BE EARTHED. THIS DISPENSER MUST BE ELECTRICALLY
GROUNDED TO AVOID DANGER TO THE OPERATOR. THE POWER CORD PROVIDED HAS
A THREE PRONG GROUNDED PLUG. IF A THREE HOLE GROUNDED ELECTRICAL OUTLET
IS NOT AVAILABLE, USE AN APPROVED METHOD OF INSURING A PROPER GROUND TO
THE DISPENSER.
A. Select a location close to a properly grounded electrical outlet, convenient to an open type drain,
and access for soda, water, and syrup lines.
1. If at all possible, location should be away from direct sunlight or other heat sources.
2. Connecting lines may be run through access in back of the unit or extend down through a
counter cut out.
3. The counter must support the weight of the dispenser, ice, and possibly an ice maker. Total
weight may exceed 800 lbs (363.6 kg).
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B. Unit may be installed directly on the countertop or on legs supplied with the unit. If installed
directly on the counter, the unit must be sealed to the counter top with a silicone sealant which
provides a smooth and easily cleanable bond to the counter. If an ice maker is to be
mounted on top of dispenser, do not install dispenser on legs.
NOTE
NSF listed units must be sealed to the counter or have four (4) inch legs installed.
Water pipe connections and fixtures directly connected to a potable water supply must all be
sized, installed, and maintained according to Federal, State, and Local laws.
The water supply must be protected by means of an air gap, a backflow prevention device
(located upstream of the CO2 injection system) or another approved method to comply with
NSF standards. A backflow prevention device must comply with ASSE and local standards.
It is the responsibility of the installer to ensure compliance.
C. Location must insure sufficient clearance on sides, top and back of unit is provided for
ventilation and air circulation (see Figure 1).
D. Additionally, if an ice maker is not top mounted on the unit, sufficient clearance should be
provided [a minimum of 16 inches (406 mm) is recommended] to allow filling the unit with ice
from a five (5) gallon (19 liter) container (see Figure 1).
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Figure 1
1.4 INSTALLING THE DISPENSER
A. Remove Cup Rest, Drip Tray, Splash Plate, and Top Cover.
B. Remove Cover Plate at rear of unit if not a through the counter installation.
C. Connect soda and water supply lines to 3/8 inch barb fittings at the front of the unit. Check for
leaks. (If dispenser is to operate with all soda valves, connect water line into one of the soda
supply lines.)
D. Connect syrup supply lines to the 3/8 inch barb inlet fittings at the front of the unit. Check for
leaks.
E. Uncoil drain hose from Cold Plate drain and extend to an open type drain.
F. Install Drip Tray and extend hose to open type drain.
G. Both drain lines must be insulated with a closed cell insulation. Insulation must cover the entire
length of the drain hose, including fittings. The drain should be installed in such a manner that
water does not collect in sags or other low points, as condensation will form.
NOTE:
Please refer to specific icemaker
model for proper air intake/exhaust
ventilation with Lancer units.
MINIMUM OF 6" (152 mm)
CLEARANCE ABOVE ICE MAKER
AIR
IN
SUFFICIENT CLEARANCE FOR
FILLING MANUALLY WITH ICE,
WHEN ICE MAKER NOT USED
34" (864 mm)
30 1/2" (775 mm)
WIDTH OF THE 85-4562H DISPENSER IS 44" (1118 mm)
9 3/4" (248 mm)
DISPENSE HEIGHT
30 1/2" (775 mm)
AIR
IN
WALL CLEARANCE
MINIMUM of 6" (152 mm)
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H. Install Cup Rest and Splash Plate.
I. Connect Power Cord to grounded electrical outlet.
J. Test Motor operation by pushing Ice Chute.
K. Clean and sanitize dispenser (see Section 2).
L. Fill unit approximately half full with ice. Push Chute and check for ice delivery.
M. Finish filling unit with ice.
N. Install Top Cover.
NOTE
Lancer does not recommend the use of shaved, flake, nugget, or pellet ice in the dispenser.
Dispenser will only operate with cube ice.
O. Set brix ratio for beverage dispensing valves according to manufacturer’s instructions.
IMPORT
ANT NOTICE
WHEN INSTALLING AN ICEMAKER ON AN IBD UNIT, A BIN THERMOSTAT OR OTHER MEANS
OF CONTROLLING THE ICE LEVEL MUST BE INSTALLED. FAILURE TO DO SO COULD
RESULT IN DAMAGE TO THE DISPENSING MECHANISM AND VOID THE WARRANTY.
DURING THE AUTOMATIC AGITATION CYCLE AND/OR WHILE DISPENSING ICE, THERE
MUST BE ADEQUATE ROOM BETWEEN THE TOP OF THE ICE LEVEL AND THE BOTTOM OF
THE ICEMAKER SO THAT THE ICE CAN MOVE WITHOUT OBSTRUCTION.
CONTACT YOUR ICEMAKER SUPPLIER FOR INFORMATION ON PROPER BIN THERMOSTAT.
2. CLEANING AND SANITIZING INSTRUCTIONS
2.1 GENERAL INFORMATION
A. Lancer equipment (new or reconditioned) is shipped from the factory cleaned and sanitized in
accordance with NSF guidelines. This equipment must be cleaned and sanitized after
installation is complete, and the operator of the equipment must provide continuous
maintenance as required by this manual and/or state and local health department guidelines to
ensure proper operation and sanitation requirements are maintained.
NOTE
The cleaning and sanitizing procedures provided herein pertain to the Lancer equipment
identified by this manual. If other equipment is being cleaned, follow the guidelines established
for that equipment.
B. Cleaning and sanitizing should be accomplished only by trained personnel. Sanitary gloves are
to be used during cleaning and sanitizing operations. Applicable safety precautions must be
observed. Instruction warnings on the product being used must be followed.
C. Water lines are not to be disconnected during the cleaning and sanitizing of syrup lines to avoid
contamination.
D. Do NOT use strong bleaches or detergents. They tend to discolor and/or corrode various
materials.
E. Do NOT use metal scrapers, sharp objects, steel wool, scouring pads, abrasives, solvents, etc.,
on the dispenser.
F. Do NOT use hot water above 140°F (60°C). This may damage certain materials.
2.2 REQUIRED CLEANING EQUIPMENT
A. Cleansers (for example, Ivory Liquid, Calgon, etc.) mixed with clean, potable water at a
temperature of 90° to 110°F (32°C - 43°C) should be used to clean equipment. The mixture
ratio, using Ivory Liquid, is one (1) ounce (27.57 ml) of cleanser to two (2) gallons (7.57 liters)
of water. A minimum of five (5) gallons (19 liters) of cleaning mixture should be prepared. Any
equivalent cleanser may be used as long as it provides a caustic based, non-perfumed, easily
rinsed mixture containing at least two (2) percent sodium hydroxide (NaOH). Rinsing must be
thorough and use clean, potable water which is also at a temperature of 90° to 110°F (32°C to
43°C).
NOTE
Extended lengths of product lines may require that an additional volume of cleaning solution be
prepared.
4
B. Sanitizing solutions should be prepared in accordance with the manufacturer’s written
recommendations and safety guidelines. The solution must provide 200 parts per million (PPM)
available chlorine. A minimum of five (5) gallons (19 liters) of sanitizing solution should be
prepared. Any sanitizing solution may be used as long as it is prepared in accordance with the
manufacturer’s written recommendations and safety guidelines, and provides 200 parts per
million (PPM) available chlorine. Sanitizing solution is to be purged from line(s) and equipment
by flushing with product only until there is no after taste. Do not rinse with water.
NOTE
Please note that a fresh water rinse cannot follow sanitization of equipment. Purge only with
the end use product until there is no after taste in the product. This is an NSF requirement.
Extended lengths of product lines may require that an additional volume of sanitizing solution
be prepared.
C. Other:
(1) Clean cloth towels.
(2) Bucket.
(3) Small brush (PN 22-0017) - included with installation kit.
(4) Extra nozzle.
(5) Sanitary gloves.
2.3 DAILY CLEANING
Using a mild detergent solution, clean Top Cover and all exterior stainless steel surfaces. Clean
exterior of dispensing valves and ice chute. Remove Cup Rest, clean Drip Tray and Cup Rest, and
replace Cup Rest. Wipe clean all splash areas using a damp cloth soaked in cleaning solution.
Clean beverage valves as specified by the valve manufacturer.
2.4 ICE BIN CLEANING - START UP AND MONTHLY
A. Disconnect Dispenser from power source.
B. Remove Top Cover.
C. Remove Agitator Pin from Agitator Shaft. Slide Agitator Shaft rearward out of Motor Shaft and
pull out of rear Bearing to remove.
D. Remove Dispensing Wheel from Motor Shaft by sliding rearward.
E. Remove Dispensing Wheel Shroud.
F. Remove Splash Plate Assembly by lifting it up and out from the dispenser face.
G. Using cleaning solution, described in Section 2.2, and a clean cloth or soft brush, clean all
removable parts, sides of Ice Bin, Ice Chute, and surface of aluminum casting.
H. Repeat Step G for all exterior surfaces of the dispenser.
I. Using hot water, thoroughly rinse away the cleaning solution.
J. Wearing sanitary gloves, soak a clean cloth towel in sanitizing solution, described in Section 2.2,
and wash all surfaces of removable parts, sides of Ice Bin, Ice Chute, and surface of aluminum
casting.
K. Repeat Step J for all metal and plastic surfaces (but not labels) of the dispenser exterior.
L. Wearing sanitary gloves, reassemble all removable parts.
M. Fill Unit with ice and replace Top Cover.
NOTE
Lancer does not recommend the use of shaved, flake, nugget, or pellet ice in dispensers not properly
equipped to do so.
N. Reconnect Dispenser to power source.
2.5 CLEANING AND SANITIZING BEVERAGE COMPONENTS - FIGAL SYSTEMS
NOTE
Extended lengths of product lines may require more time for flushing and rinsing lines than
stated below.
A. Disconnect syrup lines from syrup containers (for example, quick disconnects, figal containers,
etc.).
B. Connect hose half of syrup line to a syrup tank filled with clean, potable, room temperature
water. Connect CO2 supply hose to tank and pressurize.
C. Activate valve until water is dispensed. Flush and rinse line and fittings for a minimum of
60 seconds to remove all traces of residual product.
W
ARNING
TO AVOID POSSIBLE PERSONAL INJURY OR PROPERTY DAMAGE, DO NOT ATTEMPT TO
REMOVE SYRUP TANK COVER UNTIL CO
2 PRESSURE HAS BEEN RELEASED FROM TANK.
D. Disconnect CO2 supply hose from the water filled syrup tank.
E. Following the instructions as described in Section 2.2 above, mix appropriate amount of
cleaning solution. Fill a tank with this solution. Connect hose half of syrup line to the tank.
Connect CO2 supply hose to tank and pressurize.
F. Activate valve and draw cleaning solution through lines for a minimum of 60 seconds. This will
ensure line is flushed and filled with cleaning solution. Allow line to stand for at least
30 minutes.
G. Disconnect CO
2 supply hose from the tank.
H. Connect hose half of syrup line to a tank filled with clean, potable, water at a temperature of 90°
to 110°F (32°C to 43°C). Connect CO
2 supply hose to tank and pressurize.
I. Activate valve to flush and rinse line and fittings for a minimum of 60 seconds to remove all
traces of cleaning solution. Continue rinsing until testing with phenolpthalein shows that the
rinse water is free of residual detergent.
J. Disconnect CO2 supply hose from the tank.
K. Following the instructions as described in Section 2.2 above, mix appropriate amount of
sanitizing solution. Fill a tank with this solution. Connect hose half of syrup line to the tank.
Connect CO2 supply hose to tank and pressurize.
L. Activate valve and draw sanitizing solution through line for a minimum of 60 seconds. This will
ensure line is flushed and filled with sanitizing solution. Allow line to stand for at least 30 minutes.
M. Disconnect CO
2 supply hose from the tank.
N. Reconnect syrup lines to syrup containers (for example, quick disconnects, figal containers, etc.)
and ready unit for operation.
O. Draw drinks to refill lines and flush the sanitizing solution from the dispenser.
NOTE
Please note that a fresh water rinse cannot follow sanitization of equipment. Purge only with the
end use product until there is no after taste in the product.
P. Test dispenser in normal manner for proper operation. Taste dispensed product to ensure there
is no off-taste. If off-taste is found, additional flushing of syrup system may be required.
Q. Repeat cleaning, rinsing, and sanitizing procedures for each valve and each circuit.
2.6 CLEANING AND SANITIZING BEVERAGE COMPONENTS - BAG-IN-BOX SYSTEMS
NOTE
Extended lengths of product lines may require more time for flushing and rinsing lines than
stated below.
A. Disconnect syrup quick disconnect coupling from syrup packages and connect coupling to a bag
valve removed from an empty Bag-in-Box (BIB) package.
B. Place syrup inlet line in a clean container filled with clean, potable, room temperature water.
C. Activate valve until water is dispensed. Flush and rinse line and fittings for a minimum of
60 seconds to remove all traces of residual product.
D. Following the instructions as described in Section 2.2 above, mix appropriate amount of
cleaning solution in a clean container. Place syrup inlet line in container filled with cleaning
solution.
E. Activate valve and draw cleaning solution through lines for a minimum of 60 seconds. This will
ensure line is flushed and filled with cleaning solution. Allow line to stand for at least 30 minutes.
F. Place syrup inlet line in a clean container filled with clean, potable, water at a temperature of 90
°
to 110°F (32°C to 43°C).
G. Activate valve to flush and rinse line and fittings for a minimum of 60 seconds to remove all traces
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