Hoshizaki Lancer S4E Polaris V3 Superchiller Manual

www.lancerbeverage.com
240V / 50Hz
Installation, Operation &
Service Manual
S4E Polaris
V3 Superchiller™

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Table of contents
1. Product Details............................................................................................................4
1.1 Model ...................................................................................................................4
1.2 Product Features..................................................................................................4
1.3 Specifications.......................................................................................................4
1.4 Options ................................................................................................................4
1.5 Ice Bank...............................................................................................................5
2. Superchiller Safety Information .................................................................................5
2.1 Safety Instructions................................................................................................5
2.2 Recognise Safety Alert Symbols ..........................................................................5
2.3 Operating .............................................................................................................5
2.4 Service & Maintenance ........................................................................................5
3. Installation ...................................................................................................................6
3.1 Receiving .............................................................................................................6
3.2 Unpacking ............................................................................................................6
3.3 Selecting a Location.............................................................................................6
3.4 Mounting Superchiller...........................................................................................7
3.5 Connecting Python...............................................................................................7
3.6 Plumbing the Drain...............................................................................................7
3.7 Filling Unit ............................................................................................................7
3.8 Electrical Connection............................................................................................7
3.9 Commissioning.....................................................................................................8
3.10 Purge System ......................................................................................................9
4. Thermostat –Carel Pjeasy –Thermostat Parameters ..............................................9
4.1 Thermostat Settings .............................................................................................9
4.2 Programming Instructions ....................................................................................9
5. Scheduled Maintenance............................................................................................10
5.1 Scheduled Maintenance.....................................................................................10
6. Electrical Circuit Diagram.........................................................................................12
6.1 S4E Polaris V3 –Circuit Diagram.......................................................................12
7. Airflow Diagram.........................................................................................................13
8. Trouble Shooting.......................................................................................................14
8.1 Refrigeration ......................................................................................................14
9. Omni Icebank Control Test.......................................................................................15
11. Refrigeration & Body Assembly Parts List..............................................................16
11.1 13.1 Assembly Diagram .....................................................................................17
12. Certificate of Warranty..............................................................................................18
13. Manufacturer’s Checklist..........................................................................................19

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1. Product Details
1.1 Model
31000231 S4E POLARIS V3 SPC54 4C 240/50
31000232 S4E POLARIS V3 SPK2-11 240/50
31000233 S4E POLARIS V3 SPC54 6C 240/50
31000236 S4E POLARIS V3 SPC54 240/50
31000237 S4E POLARIS V3 SPC54 SP-EVENTS
31002000 S4E POLARIS V3 SPC54 6C EVENTS
31002001 S4E POLARIS V3 SPC54 4C EVENTS
31000234 S4E POLARIS V3 SPC54 6C CCA
31000235 S4E POLARIS V3 SPK2-11 CCA
31000238 S4E POLARIS V3 SPC54 0C CCA
31000239 S4E POLARIS V3 SPC54 4C DOUGH
31000244 S4E POLARIS V3 SPC54 4C CCA
1.2 Product Features
The Lancer S4E Polaris V3 Superchiller is a refrigerated unit designed to maintain a liquid
product temperature through the python and dispenser. When coils are fitted the unit will
chill liquid products stored at ambient temperature. The superchiller has a range of two
pumps with different flow rates and can be used in ice bank or Glycol operation.
1.3 Specifications
Version SPC54 SPK2-11
Voltage 240 Volts 240 Volts
Frequency 50 Hz 50 Hz
Max Current Draw 5.6 Amps 7.0 Amps
Ambient Temperature 2 - 40°C 2 - 40°C
Max Product Pressure 10 BAR(145 PSIG) 10 BAR(145 PSIG)
Dimensions
Width 880 mm 880 mm
Depth 505 mm 505 mm
Height with 150mm legs 880 mm 1005 mm
Weight
Shipping 90 kg 114 kg
Empty 82 kg 109 kg
Operating 157 kg 179 kg
Refrigerant 800 Grams R134a 800 Grams R134a
Tank 72 litres 72 litres
Ice bank Weight 18 kg N/A –glycol use only
Construction Stainless Steel Stainless Steel
1.4 Options
•Legs are standard; Optional casters

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1.5 Ice Bank
All S4E Polaris V3 Superchiller units are suitable for ice bank operation as an alternative to
glycol / water. Simply fill tank with water, no other changeover is required.
2. Superchiller Safety Information
2.1 Safety Instructions
For your personal safety, and that of others working around you please read, understand,
and follow thoroughly all safety instructions included in this manual and on the superchiller.
•Review all applicable OSH (Occupational Safety & Health) regulations.
•Review all applicable Beverage Dispensing Gas Standards
•Learn how to operate the superchiller and use the controls properly.
•Do not allow untrained personnel to operate the machine.
•Ensure that the superchiller is maintained according to service manual instructions.
•Do not allow any unauthorised modifications to the machine.
2.2 Recognise Safety Alert Symbols
The safety alert symbol precedes Warning and Caution notes throughout this manual. To
prevent personal injury or damage to the machine these alerts must be strictly adhered
too.
Warning
Alerts to a potentially hazardous situation that if not avoided CAN
result in death, serious injury.
Caution
Alerts to a potentially hazardous situation that if not avoided MAY
result in injury or equipment damage.
2.3 Operating
Warning
Superchillers are intended for indoor operation only; do not
operate outside unless suitably protected by a weatherproof
enclosure. This appliance is not suitable for installation in an area
where a water jet could be used.
Caution
This appliance is not intended for use by persons (including
children) with reduced physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they have been given
supervision or instruction concerning use of the appliance by a
person responsible for their safety. Children should be
supervised to ensure that they do not play with the appliance.
2.4 Service & Maintenance
Caution
Installation of superchiller and service work should only be
performed by fully trained & certified Electrical, Plumbing, &
Refrigeration Technicians.

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Warning
ALL WIRING AND PLUMBING MUST CONFORM TO LOCAL AND
NATIONAL CODES.
Warning
SUPERCHILLER MUST BE ISOLATED FROM ELECTRICAL
SUPPLY BEFORE COMMENCING ANY SERVICE OR
MAINTENANCE WORK.
3. Installation
Warning
To avoid personal injury or damage, do not attempt to lift a
superchiller without help. Use of a mechanical lift is
recommended.
3.1 Receiving
Each unit 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(s)
must be made with the carrier. Upon receiving units from the delivering carrier, carefully
inspect shipping crate for visible indication(s) of damage. If damage exists, have carrier
note damage on bill of landing and file a claim with the carrier.
3.2 Unpacking
Caution
The use of gloves is recommended to protect hands from potential
injury from sharp edges. The superchiller must always be handled
in a vertical position.
Carefully unpack the Lancer S4E Polaris V3 Superchiller from the shipping carton, remove
the wooden base.
If appropriate, assemble legs to unit by carefully tilting (tilt should not be more than 45°).
Inspect unit for concealed damage and if evident, notify delivering carrier and file a claim
against the carrier.
3.3 Selecting a Location
Warning
Superchillers are intended for indoor operation only; do not
operate outside unless suitably protected by a weatherproof
enclosure.
This appliance is not suitable for installation in an area
where a water jet could be used.
This appliance is only to be installed in locations where its
use and maintenance is restricted to trained personnel.
Caution
The superchiller is not suitable for use in subfreezing
temperatures.
To prevent damage to the water supply line, turn off and drain unit
when air temperature is below zero.
•The superchiller should be located in a well-ventilated, firm, level location close to
dispenser, water and electrical supplies, with easy access for servicing
•SPC version superchillers are intended for use in the bar area.

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•SPK2-11 version superchillers are intended for use in a non temp controlled storage
area.
•Ensure sufficient clearance around superchiller to allow good fresh air circulation
through the condenser –allow at least 200mm at rear, sides and top, with the front
unobstructed.
•Installation should only be performed by a qualified and competent technician.
3.4 Mounting Superchiller
•Install on a flat, level surface using adjustable legs or casters (Optional).
Caution
Superchiller operational weight is 157/179kg; ensure that all
supporting structures are certified for this loading by a registered
Mechanical Engineer.
Supporting structure must be securely fixed to floors or walls.
3.5 Connecting Python
Connect Python to Superchiller and Dispenser.
Caution
NOTE: The superchiller is rated to operate with a maximum of 30m
of python connected.
Exceeding manufacturer’s ratings may cause damage to the
superchiller and void warranty.
Python Details
Recirculation Lines ½” Dia Glycol tubing
Beer Lines: Max 6-off 3/8” Dia Beer line tubing
Beer line connections are made on top of the tank onto John Guest 3/8” Superseal
flowbend connection.
3.6 Plumbing the Drain
The 13mm elbow exiting from the RH Pump Panel of the unit should be plumbed to a
suitable drain, installation in accordance with AS/NZS 3500.1 and AS/NZS 3500.2.
3.7 Filling Unit
Glycol - Remove superchiller lid and fill the tank with glycol/water mixture of 30% (refer to
chart in Section 5 for details) until mixture flows out of the overflow.
Water - If the unit is to be used as an ice bank, simply fill with clean water until it flows out
the overflow tube.
3.8 Electrical Connection
•This unit is connected to the supply via a flexible cord fitted with a 3 pin plug.
•Check the name plate on the machine for electrical supply requirements. Use only the
power supply specified on the name plate.
Warning
If the supply cord is damaged, it must be replaced by the
manufacturer, its service agent or similarly qualified persons in
order to avoid a hazard.
Warning
To avoid possible fatal electric shock or serious injury the
superchiller must be electrically grounded.
Electrical Connection Must Be Made In Accordance With The
Appropriate Local Codes And Regulations.
Use of an RCD is recommended.

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3.9 Commissioning
•Connect superchiller power supply lead to an appropriate 3 pin socket outlet and switch
on. Compressor, condenser fans and pump/agi motor should all operate.
•On initial start up, remove the pump plug to allow the tank temperature to reduce
without the unit cutting out on overload. If the unit cuts out during pull down, turn off at
mains socket to reset then continue to pull down as before.
•Once the unit is cycling normally, the pump plug should be replaced, ensure the pump
is running.
•Allow lines to fill. Ensure liquid level does not drop below pump intake during initial
filling of the python.
•As required top up the unit.
•Check all connections for leaks.
•Fully insulate all chilled lines and ensure air tight at all connections.
•Before running unit, sanitise product lines using beer line cleaner.
Glycol Units:
•Check water / glycol mixture with refractometer (refer to chart Section 5.1 for details).
•Check the set point of the controller (reset per Section 4)
•Monitor the indicated temperature on the thermostat and ensure temperature reduces
to the set point.
•Don’t leave water in coils as the water will freeze.
•Polaris chillers are configured to allow either ice bank or glycol operation with no
change to the control system.
•If filled with water the system will operate on the ice bank control and as the water
temperature will never drop below zero the thermostat will display the tank temperature
only.
•If filled with a glycol solution the system will cycle on the thermostat settings as the ice
bank control probe normally needs to be embedded in ice to turn off.
•The operation of the ice bank / level control board (83000278) as used on Polaris
chillers relies on the tank fluid conductivity being within a defined range.
•When used as a glycol chiller the tank temperature is controlled by the thermostat,
however the ice bank control provides HP protection to the refrigeration system and low
fluid level protection.
•Using low conductivity (pure) water and high glycol concentration can result in the fluid
conductivity being outside the parameters that will allow the control to operate correctly.
•Aqueous glycol solutions lower their conductivity as the temperature is reduced and the
higher the glycol concentration the more pronounced the effect.
•Several instances have been reported where the refrigeration will not turn on until the
glycol fluid has reached much higher temperature than suggested by the set point of
the thermostat.
•A basic test for tank fluid conductivity can be done using a Total Dissolved Solids (TDS)
or Conductivity meter.
•A TDS of 100 to 200 is recommended. (100 –300 uS/cm using a conductivity meter)
•If the TDS is below this level add two tablespoons (approx. 40 grams) of carb soda,
allow this to circulate, and dissolve then recheck TDS. If needed add further carb soda
to achieve the desired TDS reading

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3.10 Purge System
•Progressively activate each fount connected to the superchiller systems to achieve an
uninterrupted flow of product.
4. Thermostat –Carel Pjeasy –Thermostat Parameters
4.1 Thermostat Settings
Parameter
Type
Def
Description
St
Set
point
-2.0
Refrigeration will turn off when glycol reaches this temperature.
rd
F
1.0
Temperature differential, glycol temperature will increase from
the cut out point by this value before the refrigeration turns on.
AF
F
-5.0
Antifreeze alarm set point. If the evaporator suction line reaches
this temperature the control will stop the refrigeration system
and will require a manual reset.
Antifreeze alarm can be reset by holding “UP” and “DOWN”
keys for 5 seconds.
In case of probe 2 failure, the antifreeze alarm function is
inhibited and regulation is still performed.
If “AF parameter is set to its minimum value the alarm function is
inhibited.
rt
F
**
Time (in hours) of max/min temperatures logging.
rH
F
**
Highest/ maximum recorded temperature.
rL
F
**
Lowest/ minimum recorded temperature.
AH
F
20.0
High temperature alarm (relative to set point).
AL
F
4.0
Low temperature alarm (relative to set point).
c2
F
3 mins
Minimum time in mins after turning off before the control will give
an output to the refrigeration solenoid (short cycle protection).
r4
F
7.0
Value to increase the set point in ECO mode.
r2
F
5.0
Maximum allowed set point.
r1
F
-5.0
Minimum allowed set point.
Controls programmed during manufacture.
All other non used parameters are hidden to avoid confusion.
4.2 Programming Instructions
4.2.1. Set Point
Push and hold the “SET” key, “st” is displayed then the current set point is
displayed and flashes, release “SET” key to change the set point value.
Push the “UP” or “DOWN” arrow keys to change the set point value.
To accept the new value press the “SET” key or wait 60 seconds without pressing
any keys for the unit to time out.
4.2.2. Other Parameters
Push and hold the “SET” key, until “rd” is displayed.
•Select the required parameter to change using the “UP or “DOWN arrow keys
then press the “SET” key to display its value.

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•Press the “UP” or “DOWN” key to change its value.
•Press the “SET” key to store the new value and move to the next parameter.
To exit from programming mode press the “SET” key for 3 seconds or wait 60
seconds without pressing any keys for the unit to time out.
4.2.3. Eco Mode
In the ECO mode an offset is added to the Set point: “St” + “r4”.
To set the ECO mode press and hold the “UP” key, “on” or “oF” is displayed
showing how ECO mode will be changed, when “on” or “oF” disappears release
key. In ECO mode “Ec” is displayed alternated to probe 1, Glycol temperature
actual value.
4.2.4. Alarm Signals
When an alarm is activated, the display shows the corresponding message that
flashes alternating with the temperature.
Message
Cause
Reset
“E0”
Glycol Probe Failure
Automatic
“E1”
Refrigeration Line Probe
Failure
Automatic
“LO”
Low Temperature Alarm
Automatic
“HI”
High Temperature Alarm
Automatic
“AF”
Antifreeze Alarm
Manual
Antifreeze alarm can be reset by holding “UP”
and “DOWN” keys for 5 seconds.
5. Scheduled Maintenance
Warning
The superchillers must not be cleaned by a water jet.
The following superchiller routine maintenance should be performed at the intervals listed.
5.1 Scheduled Maintenance
5.1.1. Weekly
•As per brewery instructions, ensure weekly sanitisation of the whole beer
system is carried out, including keg couplers, beer lines, chiller coils, pythons,
founts and taps.
5.1.2. Monthly
•Disconnect the machine from the power supply.
•Remove the condenser filter and rinse in warm soapy water.
•Re-install the condenser filter.
•Check the tank level. Fill if necessary.
•Check operation of pump.
•Check for beer leaks.
•If Glycol type, inspect and if contaminated replace with 30% Glycol and 70%
Water mix.
•Check concentration with a refractometer. (see chart below)

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•Reconnect the machine to the power supply.
5.1.3. Yearly
•Disconnect the machine from the power supply.
•Check interior of the tank, clean product coils and evaporator if necessary to
remove any accumulated deposits.
•Check pump operation
•Inspect agitator blade for deposits and wear.
•Reinsert overflow tube and re-fill tank with water or Glycol/water mix per above.
•Reconnect power supply and start machine.
Relative freeze points and refractometer readings for propylene glycol / water mix
-30
-20
-10
0
10
20
30
0% 10% 20% 30% 40%
glycol / water mix
freeze point °C / refractometer reading
refractometer reading
freeze point

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6. Electrical Circuit Diagram
6.1 S4E Polaris V3 –Circuit Diagram

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7. Airflow Diagram

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8. Trouble Shooting
8.1 Refrigeration
TROUBLE
CAUSE
REMEDY
Compressor will not
start.
Power Failure.
High Pressure temperature
switch activated.
LED on Ice Bank Control board
illuminated.
Ice bank control faulty contacts
not closing.
Low tank level.
Check compressor start
mechanism components.
Thermal overload faulty, open,
circuit compressor seized,
contactor faulty.
Check for blown fuse, supply cord
pulled out or supply outlet turned off.
Turn superchiller “off” at supply
socket then “on” again to reset
controller.
Check Ice bank control using
Procedure in Section 9. Replace
control or probe if defective.
If faulty, replace e.g. capacitors, start
relays.
Replace compressor, check
condenser, check power supply,
evacuate system and if necessary fit
burnout drier to industry standards.
Compressor short
cycling on thermal
overload (frequent
starting and stopping
of the compressor
while control
contacts remain
closed).
Dirty condenser.
Restricted air flow over unit.
Low supply voltage.
Defective thermal overload.
Check wiring connections.
Fan motor bearings tight or
seized.
Clean condenser of all lint and dirt.
Check for air restriction to condenser.
Check with voltmeter.
Replace compressor.
Tighten if loose.
Replace motor(s)
Product too warm
Control defective (permanently
open circuit).
Low refrigerant charge.
Check agitator motor, seized or
fused.
Check Carel control using procedure
in Section 5. If icebank, Section 9.
Replace control or probe if defective.
Leak check, repair leak, charge with
correct amount of refrigerant.
Replace if not working.
Compressor runs
too long or doesn’t
cycle.
Location too hot.
Superchiller overloaded.
Loss of refrigerant.
Condenser clogged.
Fan not operating.
Inefficient compressor
Relocate or improve ventilation.
Use larger model, or reduce python
length.
Leak check and repair.
Clean off dust, line, grease, etc.
Remove obstruction or replace motor.
Replace

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9. Omni Icebank Control Test
This is a test to simulate the building and erosion of the icebank; to determine if the icebank
control is operating correctly. The test assumes that all other components in the refrigeration
system (e.g. high pressure cut-out reset) are in an operational condition.
Warning
230VAC is present on PC Board.
Work should only be performed by fully trained & certified
Electrical, Plumbing & Refrigeration Technicians.
1.
Remove the ice bank probe at the PC Board.
2.
Jumper the three terminals as shown. Use a
spare male connector with wiring if available.
The compressor relay should close and
refrigeration system start.
(Simulates water covering all probes)
3.
With refrigeration system operating
(compressor relay energised) remove the
jumper from the centre terminal. Refrigeration
system should continue to operate.
(Simulates ice growth over green probe. Water
still
contacting red and black probes)
4.
Remove the remaining jumper. The
compressor relay should open and the
refrigeration system should stop.
(Simulates ice growth over the probes)

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10. Refrigeration & Body Assembly Parts List
Ref. Parts No. Description
1a 78000116 SPC54 PUMP WITH AGI
1b 78000049 SPK2-11 HARD WIRED ASSY
2 79186786 SUPERSEAL FLOW BEND CONN 3/8
3 85000123 LID S4E POLARIS V3
4 85000125 HATCH INSPECTION S4E POLARIS V3
5 63000220 COIL S4E POLARIS V3
6 61000765 ELECT BOX LID S4E POLARIS V3
7 80000125 CONDENSER ASSY S4E V3
8 64000399 BASE ASSY S4E POLARIS V3
9 83000220 LEAD POWER SUPPLY S4E
10 83000358 CONTROL LEVEL I/B OMNI
11 83000184 PJEASY OEM CONTROL KIT
12 80000124 CONDENSOR FAN ASSY
12a 80000123 EBM FAN MOTOR
13 83000282 COMPRESSOR CONTROL BOX
14 64000100 ICE PROBE ASSY S4E POLARIS
15 95000642 LOUVRE KMD-0101AA
16 87000102 RECEIVER DRIER
17 79001043 CAP CAMLOCK 3348 GP
18 62000300 EVAPORATOR ASSY
19 87000129 TX VALVE HONEYWELL
20 80000073 COMPRESSOR (WITH CONTROL BOX)
21 79232218 LEG
22 61000762 PANEL FRONT S4E POLARIS
23 61000760 PANEL REAR S4E POLARIS
24 61000761 PANEL GRILL S4E POLARIS
25 95000641 CONDENSER FILTER
26 83000209 PROBE NTC STRAP ON
27 83000369 PROBE NTC RUGGEDIZED
28 83000091 PROBE NTC (BULB END)

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10.1 Assembly Diagram

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11. Certificate of Warranty
It is the policy of Hoshizaki to provide to its current customers, warranty for all equipment supplied and
installation work performed within a specified period.
Parts and Equipment
Lancer provides a warranty period of twelve (12) months from the date of original invoice for all
manufactured parts. Repair or replace of defective parts will be at the sole discretion of Lancer.
Changeover parts will be invoiced to the customer at the customers normal purchase cost and upon return
of the warranty item and validation of the claim, the invoice will be credited.
Installations
Lancer provides a warranty period of twelve (12) months from the date of final invoice for workmanship after
the completion of any installation work, provided the parts and labour are completed by Lancer or its
subcontractor.
Labour
Lancer will not normally cover any labour costs associated with a warranty claim. Subject to the approval of
the Divisional Sales Manager, Lancer may choose to reimburse the customer for some or all labour costs
associated with a warranty claim. Any claim for labour costs must be authorized by Lancer prior to the work
being undertaken.
Exclusions
Lancer will not accept any liability or cost associated with any consequential losses (such as loss of syrup or
beer), loss of profit or damage to property as a result of faulty product.
Warranty shall not apply:
a) If in the opinion of Lancer, the equipment has been used in a situation the equipment has not been
designed for;
b) If in the opinion of Lancer, the equipment has been subject to abuse, negligence or accident;
c) If connected to improper, inadequate or faulty power, water or drainage service or operated using
incorrect, insufficient or contaminated lubricants, coolants, refrigerants or additives;
d) Where the product is installed, maintained or operated otherwise than in accordance with the
instructions supplied by Lancer;
e) Where the product has been damaged by foreign objects;
f) Where the product has been serviced, repaired, altered or moved otherwise than by Lancer or its
nominees or using other than Lancer approved replacement parts.

S4E Polaris V3 Superchiller™240V / 50Hz
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Hoshizaki Lancer reserve the right to change specifications without notice. Part No: 68000206
Images are for illustration purposes only as product may vary. No 046-3 –7 August 2019
12. Manufacturer’s Checklist
Checked by ................................................................................. Date
.............................................................
Gas Charge .......................................................... Icebank Probe fitted ........................................................
Electrically tested by ................................................. Refrigeration tested by .................................................
TAG No. ............................................................
High temperature probe located on liquid line between coil and receiver / dryer
Compressor wiring connections label affixed, wiring checked and label signed
Refrigeration system final check. Ensure evaporator fully frosts.
Check all tube work for rubbing e.g. discharge line, liquid line, TX capillary.
Condenser not touching divider panel or grille.
Agitator blades tight and not touching coils cradle.
Overflow pipe correct height and positioned straight.
All motors and pumps secured and mounted correctly.
Check icebank and temp probe position and tightness.
Coils in cradle correctly and spaced.
Superchiller sticker correctly positioned and straight.
Attention sticker fitted and correctly positioned.
Clean exterior of unit including power cords.
Warning sticker applied
Check air filters are fitted
Check body for sharp edges.
Check lid for cleanliness and rough edges. Fit and secure.
Copy checklist & file, put manual/checklist in plastic bag & place in the tank area.
Customer asset No.
W/O ....................................................................
Affix label here