Hoshizaki Lancer Superchiller Remote R8E V2 Series Manual

lancerbeverage.com
230V / 50Hz
Installation, Operation &
Service Manual
R8E V2
Superchiller Remote

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Table of contents
1.Introduction ................................................................................................................................. 4
2.The Company .............................................................................................................................. 4
3.Our Products ............................................................................................................................... 4
4.Product Details............................................................................................................................ 4
4.1Product Features ................................................................................................................ 4
4.2Specifications...................................................................................................................... 5
4.3Models ................................................................................................................................ 5
4.4Options................................................................................................................................ 5
5.Superchiller Safety Information ................................................................................................ 6
5.1Safety Instructions .............................................................................................................. 6
5.2Recognise Safety Alert Symbols ........................................................................................ 6
5.3Operating ............................................................................................................................ 6
5.4Service & Maintenance....................................................................................................... 7
5.5Carbon Dioxide (CO2) ........................................................................................................ 7
6.Installation ................................................................................................................................... 8
6.1Receiving ............................................................................................................................ 8
6.2Unpacking........................................................................................................................... 8
6.3Selecting a Location ........................................................................................................... 8
6.4Mounting Superchiller......................................................................................................... 9
6.5Connecting Superchiller to Remote Condensing Unit........................................................ 9
6.6Electrical Connection .......................................................................................................... 9
6.7Connecting Python ........................................................................................................... 10
6.8Plumbing the drain and CO2exhaust ............................................................................... 10
6.9Connecting to water supply .............................................................................................. 11
6.10Connecting to CO2 supply................................................................................................ 11
6.11Filling unit with water......................................................................................................... 11
6.12Commissioning ................................................................................................................. 11
6.13Purge System ................................................................................................................... 12
6.14Sanitise System ................................................................................................................ 12
7.Scheduled Maintenance........................................................................................................... 13
8.Postmix Circuit Diagram .......................................................................................................... 15
8.1.Single Carbonator Superchiller (3 pumps) ....................................................................... 15
8.2.Twin Carbonator Superchiller (5 pumps).......................................................................... 16
9.Electrical Circuit Diagram ........................................................................................................ 17
10.Trouble Shooting ...................................................................................................................... 18
11.Hydra Icebank Control Go/No Go Test................................................................................... 20
12.Hydra Carbonator Level Control Test .................................................................................... 21
13.Assembly Diagrams & Parts List ............................................................................................ 22
13.1.Postmix Spare Parts List .................................................................................................. 22
13.2.Postmix Assembly Diagram.............................................................................................. 23
13.3.Refrigeration Spare Parts List........................................................................................... 24
13.4.Refrigeration Assembly Diagram...................................................................................... 25
14.Certificate of Warranty ............................................................................................................. 26
15.Manufacturer’s Checklist ......................................................................................................... 27

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1. Introduction
Thank you for purchasing this quality Lancer product. All Lancer products are constructed using the highest
quality materials and components. They are designed to the highest possible standards, therefore offering
our customers endless hours of optimum performance.
2. The Company
Hoshizaki Lancer is a wholly owned subsidiary of Lancer Corporation, a world leader in the supply of
Beverage Dispensing Equipment based in San Antonio, Texas. Lancer has manufacturing bases and
distribution networks in 97 countries. Lancer is in turn ultimately owned by Hoshizaki Electric Co Ltd of
Nagoya, Japan. Hoshizaki is a global leader in food service equipment.
Hoshizaki Lancer’s head office and manufacturing base is located in Adelaide (SA), with branch offices and
warehousing facilities in Sydney (NSW), Melbourne (VIC), Brisbane (QLD), Perth (WA) and Auckland (New
Zealand).
3. Our Products
Lancer specialises in the design, engineering, manufacture, and marketing of beverage dispensing in two
core categories:
Soft Drink Equipment
Mechanically cooled and ice cooled soft drink dispensers, frozen beverage dispensers, dispensing valves,
carbonators and an extensive line of beverage dispensing parts and accessories.
Beer Equipment
Lancer manufactures and markets beer dispensing and chilling equipment, and related accessories.
Products include founts, chillers, Chillerplates, drip trays, taps, handles, beer line cleaning equipment and an
extensive line of beverage dispensing parts and accessories.
4. Product Details
4.1 Product Features
The Lancer Remote Superchiller is an Australian designed and manufactured unit designed to
refrigerate and distribute post-mix (soft drinks) as well as maintaining the product temperature
through the python and dispenser.

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4.2 Specifications
Voltage 230 Volts
Frequency 50 Hz
Max Current Draw 10 Amps
Ambient Temperature 2 - 40°C
Dimensions
Width 1000 mm
Depth 685 mm
Height 815 mm
Weight 3 pump 5 pump
Shipping 136 kg 158kg
Empty 123 kg 145kg
Operating 305 kg 327kg
Ice bank Weight 75 kg
Water Bath Capacity 180 litres
Construction Stainless Steel
Agitator Motor 25W, 230 VAC 1 Phase
Ice bank Control Electronic
Carbonation Level Control Electronic
Drink Capacity Continuous 473ml (16 oz) drinks below 4.4°C at 4 drinks per minute
with 40°C ambient, syrup inlet temperature and 32°C water inlet
temperature.
4.3 Models
R8E23LA V2 Lancer Superchiller Remote with 3 pumps, single Carbonator.
R8E95LA V2 Lancer Superchiller Remote with 5 pumps, dual Carbonator.
4.4 Options
Adjustable Legs (79232218) – height with legs approx 960mm.
Casters (79602411) – height with casters approx. 921mm.

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5. Superchiller Safety Information
5.1 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.
5.2 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.
5.3 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.

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5.4 Service & Maintenance
Caution
Installation of Superchiller and service work should only be
performed by fully trained & certified Electrical, Plumbing, &
Refrigeration Technicians.
Warning Carbonator contains CO
2
gas and water under pressure. De-
pressurise before performing any work on the system.
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.
5.5 Carbon Dioxide (CO2)
Warning
The Superchiller uses a CO
2
(Carbon Dioxide) supply. CO
2
is a
heavier than air, colourless, non-combustible gas with a faintly
pungent odour.
Personnel exposed to high concentrations of CO
2
gas will
experience tremors, which are followed rapidly by loss of
consciousness and suffocation.
If a CO
2
gas leak is suspected, immediately ventilate the
contaminated area before attempting to repair the leak.

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6. Installation
Warning
To avoid personal injury or damage, do not attempt to lift a
Superchiller without help.
Use of a mechanical lift is recommended.
(NOTE: Empty R8E Superchiller weight: 145kg)
6.1 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.
6.2 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 R8E 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.
6.3 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.
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 R8E Superchiller should be located in a well-ventilated, firm, level location close to
dispenser, water and electrical supplies, with easy access for servicing
Installation should only be performed by a qualified and competent technician.

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6.4 Mounting Superchiller
Install on a flat, level surface using adjustable legs or casters (Optional).
Fix to supporting structure using 4 x ¾” BSW bolts screwed into base supports.
Caution
Superchiller operational weight is 327kg; 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.
6.5 Connecting Superchiller to Remote Condensing Unit
The R8E Superchiller is supplied with a nitrogen holding charge only. It requires a connection to a
remote condensing unit with a minimum capacity of 3.2kW @ -5C SST, 43C ambient temperature.
Note: the serial plaque on the R8E Superchiller must be checked to confirm correct refrigerant type
before connection to the condensing unit.
Suction and liquid line should be sized correctly to provide a minimum return vapour velocity of
7.5m/s (vertical risers) and 3.5m/s horizontal sections.
Suction line pressure drop should comply with industry standard guidelines of 1.1K and must not
exceed 2K.
Note: An oil separator must be used on the remote condensing unit and P traps must be installed
every 3m vertical lift of suction line.
Standard refrigeration practice of deep evacuation (150 micron) before charging the system is
necessary. The electronic icebank control closes 2 x liquid line solenoid valves to start the pump
down cycle on condensing unit before turning off via the low pressure switch on the condensing unit.
6.6 Electrical Connection
This unit requires a 10 amp power supply.
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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6.7 Connecting Python
Connect Python to Chiller and Dispenser.
Caution
NOTE: The R8E Superchiller is rated to operate with a
maximum of 90m of python connected at 32°C.
Exceeding manufacturer’s ratings may cause damage to the
Superchiller and void warranty.
Connect the Python to Chiller and Dispenser.
Refer to Python and Dispenser specifications for connection data.
Superchiller can be supplied with 5 pumps, dual carbonator, or 3 pumps single carbonator; python
should be connected to Chiller as follows:
5 Pump 3 Pump
SODA
RETURN A
WATER
RETURN
SODA
RETURN B SODA RETURN A
WATER
RETURN
SODA
SUPPLY A
WATER
SUPPLY
SODA
SUPPLY B SODA
SUPPLY A
WATER
SUPPLY
Important: Ensure lines from python to Superchiller connections are insulated to prevent
condensation.
Note: For additional Soda reserve on short python lengths used in high volume accounts, it may be
necessary to extend the soda circuit by connecting the 2 spare lines in the python onto the soda
return line (i.e. double pass of soda circuit out and back from dispense point to soda return).
6.8 Plumbing the drain and CO2exhaust
The 19mm overflow drain tube exiting from the base of the tank should be plumbed to a suitable
drain, installation in accordance with AS/NZS 3500.1 and AS/NZS 3500.2.
The 6mm barb labelled as CO2 EXHAUST should be plumbed to an outside safe area.
SODA SUPPLY
SODA RETURN
10mm 'U' BEND
PYTHON

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6.9 Connecting to water supply
Using appropriate tubing and fittings connect a 10mm water supply line from Superchiller
carbonator pump inlet to a filtered, regulated water supply. (See Postmix circuit diagram page
13-15). Installation in accordance with AS/NZS 3500.1 and AS/NZS 3500.2.
Turn on water supply, check for leaks, adjust water regulator to 172-275kpa.
Open the bypass ball valve on the carbonator relief and bypass assembly until water flows from
CO
2
exhaust tube; then close the bypass ball valve. For dual carbonators, repeat this operation
for each carbonator.
Caution
Maximum water supply pressure to be 275 kpa.
Normal operating water temperature should be within 7°C to
32°C.
6.10 Connecting to CO2 supply
Warning
As carbon dioxide (CO
2
) displaces oxygen; prevention of CO
2
leaks is paramount. If a leak is suspected, immediately ventilate
the contaminated area, before attempting repairs.
Connect CO
2
supply line from regulator to gas inlet on carbonator. (See Postmix circuit diagram
page 13 – 15 for details)
Adjust CO
2
Regulator supplying Carbonator to 550 kpa.
Turn on CO
2
supply.
6.11 Filling unit with water
Remove Superchiller lid and fill water bath until water flows out overflow tube.
NOTE: Do not use water supplied from newly installed carbon filter as ice bank control operation will
be adversely affected.
6.12 Commissioning
Unplug carbonator and recirculation pumps power supply leads from electrical box located
under lid.
Connect Superchiller power supply lead to an appropriate 3 pin socket outlet and switch on.
When Superchiller ice bank is fully formed (approx. 4 hours) the remote compressor and
condenser fan will cycle off, but superchiller agitator will run continuously.
After Superchiller has cycled off, reconnect carbonator and recirculation pumps.

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6.13 Purge System
Progressively activate each dispensing valve or Bargun connected to the Superchiller systems until
an uninterrupted flow of soda, water (where applicable), and syrup pours from each dispenser.
6.14 Sanitise System
Prepare sanitising solution:
Prepare sanitising solution in accordance with the manufacturer’s written recommendations and
safety guidelines.
Sanitising BIB System
Remove all disconnects from BIB containers.
Immerse all disconnects in warm water and clean using a nylon bristle brush. Rinse with clean
water.
Prepare sanitising solution according to manufacturer’s instructions.
Attach sanitising fittings to BIB disconnects, if sanitising fittings are not available cut fittings from
empty BIB bags.
Immerse all sanitising fittings with attached BIB disconnects in bucket of sanitising solution.
Operate all dispensing valves until the sanitising solution flows from the valve. Allow sanitiser
to remain in lines for fifteen (15) minutes.
Immerse all sanitising fittings with attached BIB disconnects in bucket of clean water. Operate
all dispensing valves until all sanitiser has been flushed from the system.
Remove sanitising fittings from BIB disconnects and re-connect disconnects to appropriate
BIB's. Operate dispensing valves until syrup flows freely.

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7. Scheduled Maintenance
The following Superchiller routine maintenance should be performed at the intervals listed.
Daily
Cleaning/Sanitising
The Superchiller supplies soda water to the dispensing valves/barguns. To ensure optimum drink quality and
system performance at all times please follow cleaning and sanitising procedures for the dispensing
valves/barguns recommended by the valve/bargun manufacturer.
Checking CO
2
Supply
Ensure that the contents gauge on the CO
2
Regulator reads higher than 1400kpa on the dial. If it does not,
then the CO
2
cylinder is empty and must be changed using safe working practices.
Warning
To avoid personal injury and/or property damage, always secure
the CO
2
cylinder with a safety chain to prevent it from falling over;
and use appropriate protective equipment (as defined in Clause
3.3.2 of AS 5034) to handle cylinders.
Should the valve become accidentally damaged or broken off, a
CO
2
cylinder can cause serious personnel injury.
Quarterly
The Superchiller should be connected to a filtered water supply. To ensure optimum drink quality and
system performance, supply water filters should be replaced every 3 months.
Half Yearly
Check that the water is level with the top of the overflow tube. Add water if necessary.
Open carbonator relief valve to purge CO
2
and check leakage, close relief valve after checking.
Yearly
Water bath and recirculation pump inspection.
Isolate Superchiller from power supply by switching off at socket.
Thaw the bank of ice formed in the tank. Empty the water from the tank with a suction pump or
drainage pipe.
Inspect coils and agitator in water bath for algae or slime accumulation. Clean as necessary using a
soft brush, rinse with clean water.
Check recirculation pump strainers for accumulation, replace if necessary.
Fill tank with clean water until water flows out the overflow tube.
Switch on power supply and check ball position in flow indicator section of strainer. If ball indicates
flow is less than 5 litres per minute, replace pump.
Commission and purge system as per clause 6.11 and 6.12.

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Sanitisation of Beverage System
To maintain optimum quality of dispensed product each Superchiller and its associated beverage system
components must be thoroughly cleaned and sanitised annually.
Prepare sanitising solution
Prepare sanitising solution in accordance with the manufacturer’s written recommendations and safety
guidelines.
Sanitising BIB System
Remove all disconnects from BIB containers.
Immerse all disconnects in warm water and clean using a nylon bristle brush. Rinse with clean water.
Prepare sanitising solution according to manufacturer’s instructions.
Attach sanitising fittings to BIB disconnects, if sanitising fittings are not available cut fittings from
empty BIB bags.
Immerse all sanitising fittings with attached BIB disconnects in bucket of sanitising solution. Operate
all dispensing valves until the sanitising solution flows from the valve. Allow sanitiser to remain in
lines for fifteen (15) minutes.
Immerse all sanitising fittings with attached BIB disconnects in bucket of clean water. Operate all
dispensing valves until all sanitiser has been flushed from the system.
Remove sanitising fittings from BIB disconnects and re-connect disconnects to appropriate BIB's.
Operate dispensing valves until syrup flows freely.

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8. Postmix Circuit Diagram
8.1. Single Carbonator Superchiller (3 pumps)

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8.2. Twin Carbonator Superchiller (5 pumps)
SODA RELIEF
VALVE
SODA RELIEF
VALVE

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9. Electrical Circuit Diagram

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10. Trouble Shooting
TROUBLE CAUSE REMEDY
Product too warm Ice bank control defective
(permanently open circuit).
Low refrigerant charge.
Check agitator motor, seized or
fused.
Check Ice bank control using
procedure on page 24.
Replace control or probe if defective.
Leak check, repair leak, charge with
correct amount of refrigerant.
Replace if not working.
Rusty appearance
and/or metallic taste to
water.
Poor water supply - contaminated. Carbon filter required.
CO
2
gas or wate
r
escapes from
pressure relief valve.
(Observed
from CO
2
exhaust)
CO
2
pressure too high.
Pump motor will not stop.
Inadequate water supply.
Lines too small or restricted.
Check CO
2
pressure relief valve. Bleed
gas by opening and closing the relief
valve - set CO
2
to 550 kpa.
Check carbonator control using
procedure on page 25.
Replace control or probe if defective.
If strainer and filter are clear and line
valves are fully open, noisy pump
operation indicates insufficient water
supply. Minimum water supply is 172
kpa flowing pressure.
Poor carbonation
(low CO
2
volume).
Flooded carbonator.
Dirty water supply.
CO
2 pressure too low.
Poor quality paper cups.
Dirty or greasy glasses.
Improperly drawn drink.
Check carbonator control using
procedure on page 25.
Replace control or probe if defective.
Check filters.
Check CO
2 pressure at regulator.
Should be set between 550 kpa. CO
2
inlet check valve stuck, shut or
blocked, repair or replace.
Purchase better quality cups.
Wash all glasses.
Open faucet all the way and draw
against side of glass or cup.
Pump leaks from shaft
seal.
Worn pump seals.
Misaligned or damaged motor and
pump facings.
Replace pump.
Realign or file flat.
Pump will not run. Power failure or low voltage.
Carb pump hi temp LED on
icebank control board illuminated.
Check fuses. Check power supply.
Check for icebank growth into product
coils, defrost and turn off chiller at
supply socket and turn on again to
reset.

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Faulty low pressure switch (if fitted).
Defective motor.
Locked up pump. Motor has cut out
on overload.
Carbonator flooded – filled
completely with water.
Carbonator empty - faulty
Carbonator probe or control.
Low water supply pressure.
Excessive CO
2 Pressure.
Ensure of adequate water supply.
Switch should close above 172 kpa.
Replace if defective.
Replace motor.
Replace pump.
Check mains water pressure - must be
at least 135 kpa lower than CO 2 (install
water pressure regulator if necessary)
Check CO
2 regulator.
Check carbonator control using
procedure on page 25. Replace
control or probe if defective.
Check carbonator control
Using procedure on page 25.
Replace control or probe if defective.
A minimum of 172 kpa water supply
pressure is required
Check function & setting of CO
2
regulator.
Faucet delivers CO2
gas continuously.
Carbonator pump will not run due to
power failure or low voltage.
Pump water supply restricted.
Carbonator pump will not run due to
excessive carbonator CO
2
pressure.
Faulty low pressure switch.
Defective Carbonator motor.
Locked up pump. Motor has cut out
on overload.
Carbonator empty – faulty control
board or level probe.
Carb pump hi temp LED on
icebank control board illuminated.
Check fuses. Check power supply.
Ensure clean mains water supply tap is
open, or replace filters.
Check Carbonator CO
2
pressure
regulator for creeping. It should be set
at 550 kpa.
Ensure adequate water supply
(minimum pressure 172 kpa flowing
pressure). Pressure switch is set to
open below 35 kpa and reset at 172
kpa.
Check operation by plugging into
circulation pump socket momentarily.
Replace motor if necessary.
Replace pump.
Check carbonator control using
procedure on page 25.
Replace control or probe if defective.
Check for icebank growth into product
coils, defrost and turn off chiller at
supply socket and turn on again to
reset.

R8E V2 Superchiller Remote 230V / 50Hz
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Hoshizaki Lancer reserve the right to change specifications without notice. Part No: 68000009
Images are for illustration purposes only as product may vary. No 027 – 7 March 2013
11. Hydra Icebank Control Go/No Go 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 terminals N, A, ON 1, ON 2 terminals.
Work should only be performed by fully trained & certified
Electrical, Plumbing & Refrigeration Technicians.
1. Remove the ice bank probe connections from
terminals J5, J6, J7.
2. Connect alligator jumper to terminals J5, J6, J7. Ice
bank control relay should close and refrigeration
system start.
(Simulates water covering all probes)
3. With refrigeration system operating (ice bank control
relay energised) remove alligator jumper from
terminal J6. Refrigeration system should continue to
operate.
(Simulates ice growth over green probe. Water still
contacting red and black probes)
4. With refrigeration system operating, remove alligator
lead from terminal J5.
Refrigeration system should stop.
(Simulates ice growth over black probe only)