Lancer 85-3322 Manuel

INSTALLATION AND SERVICE MANUAL

FOR

MINUTE MAID JUICER

TWO VALVE DISPENSER

Part Number 85-3322 Two Valve, Push Control 115V/60 Hz

Part Number 85-3332 Two Valve, Portion Control 115V/60 Hz

This manual supersedes and replaces 28-0703, dated 05/24/06

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.

DATE: 08/23/06

P.N. 28–0703/01

FAX Engineering: • 210-310-7096

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 •

TABLE OF CONTENTS

TABLE OF CONTENTS ......................................................................................................................................i

ACCESSORIES FOR MINUTE MAID JUICER .................................................................................................ii

SPECIFICATIONS..............................................................................................................................................ii

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

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

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

1.3 SELECTING COUNTER LOCATION .................................................................................................1

1.4 FILLING THE UNIT WITH WATER ....................................................................................................1

1.5 CONNECTING THE WATER SUPPLY ..............................................................................................2

1.6 CONNECTING THE ELECTRICAL POWER .....................................................................................2

1.7 KEY LOCK SWITCH ..........................................................................................................................2

1.8 INSTALLING THE CONCENTRATE PACKAGES..............................................................................2

1.9 PURGING THE WATER SYSTEM OF AIR........................................................................................2

2. OPERATING THE UNIT ..............................................................................................................................3

2.1 PRODUCT LOADING/UNLOADING ..................................................................................................3

2.2 SOLD OUT OPERATIONS.................................................................................................................4

2.3 SETTING RATIOS..............................................................................................................................4

2.4 DISPENSING CONFIGURATIONS ....................................................................................................6

2.5 OPERATION WITH “PUSH AND HOLD” ...........................................................................................6

2.6 OPERATION WITH “PORTION CONTROL”......................................................................................6

2.7 CLEANING AND SANITIZING INSTRUCTIONS ...............................................................................7

3. OPERATING PRINCIPLES .........................................................................................................................8

3.1 WATER SYSTEM ...............................................................................................................................8

3.2 CONCENTRATE DELIVERY SYSTEM..............................................................................................8

3.3 REFRIGERATION SYSTEM ..............................................................................................................8

3.4 ELECTRICAL SYSTEM......................................................................................................................9

3.5 ELECTRONIC SYSTEM ....................................................................................................................9

4. RELOCATING OR SHIPPING UNIT .........................................................................................................10

4.1 REMOVING AN OPERATING UNIT ................................................................................................10

4.2 TRANSPORTING UNIT ...................................................................................................................10

4.3 SHIPPING UNIT...............................................................................................................................10

5. REPAIR AND REPLACEMENT.................................................................................................................10

5.1 LIGHTED FRONT DISPLAY ............................................................................................................10

5.2 DOOR DISASSEMBLY.....................................................................................................................11

5.2.1 DOOR REMOVAL.............................................................................................................................11

5.2.2 DOOR BOARD REPLACEMENT .....................................................................................................11

5.2.3 ELECTRONIC LIGHT BOARD REPLACEMENT.............................................................................11

5.2.4 DOOR LOCK SOLENOID ................................................................................................................11

5.2.5 DOOR SEAL REPLACEMENT.........................................................................................................11

5.2.6 GAS STRUT REPLACEMENT.........................................................................................................12

5.3 CONDENSER FAN MOTOR REPLACEMENT................................................................................12

5.4 AGITATOR MOTOR REPLACEMENT .............................................................................................12

5.5 ICE BANK CONTROLLER...............................................................................................................12

5.6 TOP COVER REMOVAL ..................................................................................................................12

5.7 REFRIGERATION DECK REMOVAL...............................................................................................12

5.8 PRODUCT RECOGNITION/SOLD OUT SENSORS REMOVAL.....................................................13

5.9 PRODUCT CHAMBER CIRCULATION FAN REMOVAL .................................................................13

5.10 WATER CALIBRATIONS VALVE/FLOW WASHER REMOVAL .......................................................13

5.11 NOZZLE REPLACEMENT ...............................................................................................................14

5.12 DOOR SPOUT SEAL REPLACEMENT ...........................................................................................14

5.13 CONTROL BOX REMOVAL .............................................................................................................14

5.14 STEPPER MOTOR REMOVAL/REPLACEMENT............................................................................14

5.15 WRAPPER REMOVAL .....................................................................................................................15

6. TROUBLESHOOTING...............................................................................................................................15

REFRIGERATION SYSTEM ......................................................................................................................15

DISPENSING SYSTEM .............................................................................................................................16

7. ILLUSTRATIONS, PARTS LISTINGS, WIRING AND WATER FLOW DIAGRAMS ................................19

7.1 FRAME/INSULATION, TANK ASSEMBLY .......................................................................................19

7.2 INSULATED TANK ASSEMBLY .......................................................................................................20

7.3 PUMP PLATFORMS/FAN PLATE ASSEMBLY...........................................................................21-22

SPECIFICATIONS

7.4 DOOR STRUTS/TRIM ASSEMBLY .................................................................................................23

7.5 ELECTRICAL COMPONENT, DETAIL .............................................................................................24

7.6 CABINET ASSEMBLY ......................................................................................................................25

7.7 PERIPHERAL COMPONENTS/FINAL ASSEMBLY.........................................................................26

7.8 UNPACKING DETAIL .......................................................................................................................27

7.9 FLOW METER/SOLENOID ASSEMBLY..........................................................................................28

7.10 COMPRESSOR DECK ASSEMBLY ...........................................................................................29-30

7.11 LEFT DOOR ASSEMBLY (TYPICAL) .........................................................................................31-32

7.12 TOP COVER ASSEMBLY, DETAIL ..................................................................................................33

7.13 ASSEMBLED UNIT ..........................................................................................................................34

7.14 WATER FLOW DIAGRAM................................................................................................................35

7.15 WIRING DIAGRAM ..........................................................................................................................36

TABLE OF CONTENTS (CONTINUED)

DIMENSIONS:

WIDTH 10 1/8 inches (257 mm)

DEPTH 25 1/2 inches (648 mm)

HEIGHT 33 inches (838 mm)

WEIGHT:

SHIPPING 125 pounds (56.7 kg)

EMPTY 112 pounds (50.8 kg)

OPERATING 160 pounds (72.6 kg)

ELECTRICAL REQUIREMENTS (running): 115 VAC, 60 Hz 7 Amps

WATER REQUIREMENTS: MINIMUM flowing pressure of 35 PSI, at a flow

rate of six (6) ounces per second (177 ml/sec)

MAXIMUM operating pressure of 90 PSI

WATER CONNECTION: 3/8” (9.525 mm) barbed hose fitting

ACCESSORIES FOR MINUTE MAID JUICER

Part Number Description

82-3789 Drop Down Drip Tray

REFRIGERATION: 1/4 Horsepower (HP) Compressor, using R134-A refrigerant

10.0 pounds (+/- 2.0 pounds) (4.54 kg) ice bank weight

6.5 gallon (24.6 liter) water bath capacity

DRINK CAPACITY:

More than 100 twelve (12) ounce drinks at three (3) per minute under 45oF at 75oF ambient.

More than 20 thirty-three (33) ounce drinks at one (1) per minute under 45oF at 75oF ambient.

More than 50 twelve (12) ounce drinks at two (2) per minute under 45oF at 90oF ambient.

More than 15 thirty-three (33) ounce drinks at one (1) per minute under 45oF at 90oF ambient.

NOTE

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 CO2injection 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.

1. INSTALLATION

1.1 RECEIVING

Each shipment is completely tested under operating conditions and thoroughly inspected before

shipment. At time of shipment, the carrier accepts the Unit and any claim for damage must be made

with the carrier. Upon receiving Unit from the delivering carrier, carefully inspect carton 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. Cut packing band and remove.

B. Lift and remove top portion of carton.

C. Remove inner packing.

D. Remove package containing installation kit.

E. Lift plywood shipping base, and remove lower portion of carton.

F. Slide a corner of unit (on plywood shipping base) over the edge of counter and remove the

shipping screw and washer from unit.

G. Replace shipping screw and washer with a 3/8” x 16 stainless Phillips truss head from

installation kit.

H. Repeat procedure for remaining corners.

I. Slide unit off of plywood shipping base.

NOTE

Save the original carton, inner packing material, and plywood shipping base for future use in the

event unit is to be returned or transported.

J. Inspect Unit for concealed damage and if evident notify delivering carrier and file a claim against

same.

NOTE

If unit is to be transported to a different location for installation, it could be transported easier if

the unit is left firmly mounted to the shipping base.

1.3 SELECTING COUNTER LOCATION

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

requirements listed on the Specification Page.

CAUTION

WITHOUT PROPER VENTILATION, THE UNIT’S COMPRESSOR WILL OVERHEAT, POSSIBLY

TRIP THE OVERLOAD PROTECTOR, AND HAVE SIGNIFICANTLY SHORTER LIFE.

B. Condenser air is drawn in the back of the Unit and exhausted out the top. The Unit requires a

minimum of four (4) inches between the wall, ceiling, and the back of the wrapper for proper

ventilation.

C. Seal unit to countertop by applying a small bead of clear silicone R.T.V. sealant around the

perimeter of the base platform. Use a sealant that is designated for countertop application.

1.4 FILLING THE UNIT WITH WATER

The water bath overflow is located in the back center of the product compartment, behind the pump

platform sheet metal plate.

A. Remove the top cover.

B. Remove the yellow cap.

C. Insert water hose into exposed hole.

D. Open front door.

E. Use a flashlight to see the overflow hole through the two upper rectangular slots in the pump

platform sheet metal plate.

F. Stop the water flow when water drips out from the overflow hole.

G. Shut the front door, and remove water hose.

H. Replace the yellow cap and replace the top cover.

1.5 CONNECTING THE WATER SUPPLY

NOTE

This unit is to be installed with adequate backflow protection to comply with applicable

federal, state and local codes. This is an NSF requirement.

The unit can be installed with the water and electric supply entering the unit through an access plate

in the back of the wrapper, or through a hole in the countertop, directly into the unit.

A. Flush the water supply line thoroughly.

B. Remove drip tray by pulling up slightly, while lifting away from the Unit.

C. Remove splash plate by pulling the bottom up slightly, then out from the Unit.

D. The installation kit contains both a straight connector (for through the countertop) and an elbow

connector (for through the back of the Unit). Use the appropriate connector and securely attach

to the included tubing with clamp.

E. Lubricate the O-rings on the fitting with Lancer Lube and insert into the 1/4 turn shutoff valve

and secure with sliding clip. (On installations going through the back of the wrapper, remove the

cover plate on the back of the Unit and thread the tubing through the lower section of the

machine and out the back of the Unit.)

1.6 CONNECTING THE ELECTRICAL POWER

WARNING

THIS UNIT MUST BE 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 OUTLET IS NOT

AVAILABLE, USE AN APPROVED METHOD TO GROUND THE UNIT.

A. Thread the unit power cord, following the water connection routing, and plug the female end of

the unit power cord into the outlet on the transformer box.

B. Connect the other end to the appropriate grounded outlet. The agitator motor will start running

immediately and will run continuously. The compressor and condenser fan are in parallel.

There is a five minute delay timer in this circuit. After that time has elapsed, the

compressor/condenser fan with start and run continuously until a complete ice bank is built. This

will take about two (2) hours, depending on ambient and water temperature.

1.7 KEY LOCK SWITCH

The key lock switch, located on the lower right hand front of the unit, has three positions. These

positions, taken clockwise, are:

A. OFF. In this position, the refrigeration system remains on but the door latch release solenoids

are deactivated. The merchandising panel is not lighted and the unit will not dispense product.

B. ON. In this position, the refrigeration system remains on, the door latch release solenoids are

deactivated, the front merchandising panel is lit, and the unit dispenses product.

C. FLUSH. In this position, the refrigeration system remains on, the door latch release solenoids

are activated, the front merchandising panel is lighted, but only the water solenoid coils are

activated. Set-up and Diagnostics are performed in this position.

1.8 INSTALLING THE CONCENTRATE PACKAGES

A. Turn key lock from the “ON” position to the “FLUSH” position.

B. Place the concentrate package on the platform, ensuring that the cap faces front.

C. Insert the “yellow” check valve “o-ring” side into the cap of the concentrate package.

D. Repeat procedures 1.8.B and 1.8.C for the one remaining position.

1.9 PURGING THE WATER SYSTEM OF AIR

A. Turn key lock from the “ON” position to the “FLUSH” position.

B. Place a cup beneath the left most (when facing the machine) dispensing nozzle and press the

PUSH or POUR/CANCEL buttons until a clear stream is observed.

C. Purge the remaining valve the same way, moving progressively to your right.

D. Rotate the key lock switch back to the “ON” position.

E. Dispense a small amount from each valve until product is visible in the stream.

F. The dispenser is ready to operate.

2. OPERATING THE UNIT

2.1 PRODUCT LOADING/UNLOADING

A. Thaw the Minute Pak®in a 40 degree

F cooler for 48-72 hours.

B. Shake the Minute Pak®well (see

Figure 1).

D. Open dispenser door (press the # key)

(see Figure 3). Then lift the door.

E. Install the Minute Pak®into the slot for the appropriate flavor.

F. Insert check valve into the Minute Pak®opening (see Figures 4 and 5).

Figure 4

G. Prime pump using the *key.

H. Dispense enough juice to prime the

pump (see Figure 6), until the dispensed

beverage appears consistent [dispense

approximately two to four (2-4) ounces of

product].

Figure 3

Figure 1

Figure 2

C. Turn unit to “Flush Mode” (key on

right bottom side of dispenser) (see

Figure 2).

Figure 5

Figure 6

2.2 SOLD OUT OPERATIONS

A. When the display shows SOLD OUT or

CHANGE PRODUCT, follow the loading

procedures to change the package.

B. Once the package is changed, touch the *in

the bottom left hand corner of each touch

pad affected until concentrate pours (see

Figure 7).

C. This will reset the sold out feature.

D. Continue with the loading procedures to

prime the pump.

Figure 7

2.3 SETTING RATIOS

A. Enter juice selection programming mode by simultaneously pressing

the * and #buttons.

B. Toggle up or down to select juice type (see Figure 8).

1. Press left hidden button to scroll down.

2. Press right hidden button to scroll.

C. Press pour/cancel (“PUSH” Button) when correct juice is identified.

Figure 8

NOTE:

For Other (non-standard brands),

toggle to “Other Custom” and

simultaneously press the * and #

buttons again.

• Display will default to 5:1.

• The left button will decrease

ratio by .25 ratio units.

• The right button will increase by

.25.

D. Check/Adjust Ratios

1. To check and/or adjust the ratio you measure the amount of water dispensed and then the

finished product dispensed into a graduated cylinder. You adjust the finished product to

equal the volume of water dispensed.

2. Process

a. Turn key switch to flush mode.

b. Purge water line until clear by pressing pour cancel button.

c. Press the * and #buttons on outside edge of door panel at the same time to access the

RATIO MODE (see Figures 9 and 10).

Figure 9

HIDDEN RATIO

CHECK/ADJUST

BUTTONS

POUR / CANCEL

E. To check ratio:

1. Press and release pour cancel

a. Water will pour automatically (use a 500 ml graduated cylinder,

see Figures 11 and 12, to catch dispensed water - note level of

water for use in step G below).

b. 450 ML should pour into cylinder - Each band is 5 ml (if off more

that two bands, then troubleshoot water sub-system).

F. Put cup under nozzle and press pour cancel. Throw first sample away.

G. Empty cylinder and place under nozzle assembly. Press and release

pour cancel.

1. Combined water and juice will dispense – Target is same as water

only level in step 1.

2. If within one band-width, return to operation.

Figure 12

Figure 10

Figure 11

H. If out of spec (finished product volume does not equal water volume), adjust the ratio by

pushing the * and #buttons: For example:

1. If the ratio is 4 bands below, toggle down to -4 using the * and #buttons (see Figure 13).

Press pour cancel and check volume again - Repeat until correct.

2. If the ratio is 3 bands above water level, toggle up to +3. Press pour cancel and check

volume again.

3. When the volume of combined product equals the water level, turn key switch to run position

and return unit to service.

NOTE:

This process should only be performed during startup, pump replacement or changing of

brand.

Figure 13

2.4 DISPENSING CONFIGURATIONS

The dispenser has two (2) different dispensing configurations, depending on the model. These

configurations are:

A. PUSH and HOLD. The is the basic machine where the touch sensor switch is pushed to start

dispensing and released to terminate the dispense.

B. PORTION CONTROL. This option has a different touch sensor switch and switch control board.

Each valve can be individually programmed to remember four (4) different dispense volumes

and then to dispense those volumes when the individual sections of the touch sensor switch is

activated.

2.5 OPERATION WITH “PUSH and HOLD”

A. Place a vessel on the target located on the Cup Rest.

B. Depress the “Push” area to start the flow of product.

C. Release the pressure on the switch to terminate the flow of product.

2.6 OPERATION WITH “PORTION CONTROL”

A. Place a vessel on the target located on the Cup Rest.

B. Activate the program mode for that valve by simultaneously depressing the “SMALL” and

“EXTRA LARGE” buttons.

C. Place a glass of the proper size (i.e., small, medium, large, or extra large) on the target on the

Cup Rest and depress the corresponding button.

D. Continue holding the button until the proper fill level is obtained.

E. Use the same procedure for setting the fill volume for the other sizes of glasses.

F. Push the “POUR/CANCEL” button to exit the program mode. The program will automatically

store the last fill volume that was dispensed through that button size before you exited the

program mode.

(This section continued on next page)

G. Follow the same procedures to set the fill volume for the remaining valves.

NOTE

Since the volume settings are unique to each valve, each valve can have four different dispense

volumes. Lemonade in valve position 1, for example, could have a different dispense volume

(i.e., “SMALL” , “MEDIUM” , etc.) than Orange Juice in valve position 2.

2.7 CLEANING AND SANITIZING INSTRUCTIONS

For optimum dispenser performance and highest drink quality, please follow the instructions listed

below for cleaning your dispenser. The instructions are also shown on the inside front cover of the

Dispenser.

CAUTION

DO NOT USE ANY POWDERS OR ABRASIVE CLEANING COMPOUNDS THAT WILL DAMAGE

FINISH.

A. Daily

1. Turn the dispenser to FLUSH Mode.

2. Flush each valve until clear water only is dispensed.

3. Remove and wash drip tray and cup rest in warm, soapy water using a mild detergent. Rinse

thoroughly with clean, warm water and reinstall drip tray and cup rest to dispenser.

4. Wipe down any areas where concentrate may have spilled or beverages splashed.

5. If doors were opened to wipe soiled areas, close the doors.

6. Ensure the drain tube into the drip tray is properly seated.

7. Follow the Loading procedures in the ON Mode.

WARNING

REMOVE SANITIZING SOLUTION FROM DISPENSER AS INSTRUCTED. RESIDUAL

SANITIZING SOLUTION LEFT IN SYSTEM COULD CREATE HEALTH HAZARD.

CAUTION

DO NOT SOAK NOZZLES IN CHLORINE SOLUTION OVERNIGHT. THIS WILL CAUSE

NOZZLES TO SWELL AND PLASTIC WILL BEGIN TO DETERIORATE.

B. Every Two Weeks

1. Turn key switch to “FLUSH MODE”, flush each valve of dispenser until clear water flows

from the nozzle.

2. Open door and lift up on the check valve (yellow elbow) to remove it from the Minute Pak®

container.

3. Remove Minute Pak container from dispenser and refrigerate.

4. Remove nozzles (see Figures 14 and 15). Wash thoroughly with warm, soapy water using

a mild detergent (see Figure 16). Rinse thoroughly with clean, warm water and replace.

DO NOT SOAK NOZZLES IN CHLORINE SOLUTION OVERNIGHT. THIS WILL CAUSE

NOZZLES TO SWELL AND PLASTIC WILL BEGIN TO DETERIORATE.

5. Using a funnel, fill each specially marked sanitizing container up to the top with COOL

chlorinated sanitizing solution (Diversol CX, or equivalent), minimum 100 PPM available

chlorine, but not to exceed 200 PPM; place sanitizing container in dispenser.

Figure 14 Figure 15 Figure 16 Figure 17

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