Lancer Delta ii 9100 series Manual

INSTALLATION AND SERVICE

MANUAL

FOR

DELTA II REMOTE RECIRCULATING UNIT

LANCER SERIES 9100

This manual is an initial issue.

DATE: 02/23/96

P.N.: 28-0260

FAX ENGINEERING: • 210-310-7096

Please refer to the Lancer web site (www.lancercorp.com) for

information relating to Lancer Installation and Service Manuals,

Instruction Sheets, Technical Bulletins, Service Bulletins, etc.

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

FAX SALES

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

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

TABLE OF CONTENTS

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

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

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

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

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

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

1.4 SELECTING A COUNTER LOCATION .............................................................................................1

1.5 MOUNTING THE DISPENSER..........................................................................................................1

1.6 FILLING UNIT WITH WATER ............................................................................................................1

1.7 CONNECTING TO ELECTRICAL POWER .......................................................................................2

1.8 CONNECTING PYTHON TO REMOTE RECIRCULATING UNIT .....................................................2

1.9 CONNECTING PYTHON TO TOWER...............................................................................................4

1.10 CONNECTING 24 VAC POWER SUPPLY TO TOWER ....................................................................5

1.11 CONNECTING TO WATER SUPPLY.................................................................................................5

1.12 CONNECTING TO CO2SUPPLY ......................................................................................................5

1.13 CONNECTING TO BAG-IN-BOX (BIB) SYRUP SUPPLY .................................................................5

1.14 CONNECTING TO REMOTE BIB SYRUP PUMPS...........................................................................6

1.15 CONNECTING TO REMOTE PRESSURIZED SYRUP SUPPLY......................................................6

1.16 PURGING THE CARBONATION SYSTEM .......................................................................................6

1.17 COMPLETE INSULATION BETWEEN UNIT AND PYTHON ............................................................6

1.18 COMPLETE INSULATION BETWEEN TOWER AND PYTHON .......................................................7

2. SCHEDULED MAINTENANCE ...................................................................................................................7

2.1 DAILY .................................................................................................................................................7

2.2 WEEKLY.............................................................................................................................................7

2.3 MONTHLY ..........................................................................................................................................7

2.4 EVERY SIX MONTHS........................................................................................................................7

2.5 YEARLY..............................................................................................................................................7

3. DISPENSER CLEANING AND SANITIZING ..............................................................................................7

3.1 AMBIENT PROCESS.........................................................................................................................7

3.2 ALTERNATE CLEANING AND SANITIZING AGENTS......................................................................8

4. CONVERTING FROM EXTERNAL PRESSURIZED SYRUP SUPPLY TO BAG-IN-BOX

WITH BUILT-IN SYRUP PUMPS.................................................................................................................8

5. CONVERTING FROM BUILT-IN SYRUP PUMPS TO REMOTE PUMPS OR SYRUP TANKS.................8

5.1 REMOVING EXISTING BUILT-IN SYRUP PUMPS ...........................................................................8

5.2 INSTALLING REMOTE PUMP OR SYRUP TANKS ..........................................................................8

5.3 CONNECTION FOR PLAIN WATER PRODUCT...............................................................................9

6. TROUBLESHOOTING .......................................................................................................................9

6.1 MISCELLANEOUS LEAKAGE ...........................................................................................................9

6.2 INSUFFICIENT WATER FLOW..........................................................................................................9

6.3 INSUFFICIENT SYRUP FLOW..........................................................................................................9

6.4 ERRATIC RATIO ................................................................................................................................9

6.5 NO PRODUCT DISPENSED .............................................................................................................9

6.6 WATER ONLY DISPENSED, NO SYRUP; OR SYRUP ONLY DISPENSED, NO WATER...............9

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

TO CARBONATOR TANK)...............................................................................................................10

6.8 SYRUP ONLY DISPENSED, NO WATER; BUT CO2GAS DISPENSED WITH SYRUP................10

6.9 EXCESSIVE FOAMING ...................................................................................................................10

6.10 WATER CONTINUALLY OVERFLOWS FROM WATER BATH INTO DRIP TRAY .........................10

6.11 COMPRESSOR STARTS AND CONTINUES TO RUN UNTIL FREEZE UP, AND WILL

NOT CUT OFF .................................................................................................................................10

6.12 WARM DRINKS................................................................................................................................11

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

AND NO ICE BANKS .......................................................................................................................11

6.14 COMPRESSOR DOES NOT START (NO HUM), BUT CONDENSER FAN MOTOR RUNS ..........11

6.15 COMPRESSOR DOES NOT START, BUT HUMS...........................................................................11

6.16 COMPRESSOR STARTS, BUT DOES NOT SWITCH OFF START WINDING ..............................12

6.17 COMPRESSOR STARTS AND RUNS A SHORT TIME, BUT SHUTS OFF ON OVERLOAD ........12

6.18 COMPRESSOR RUNS NORMALLY, BUT WATER LINE IS FROZEN............................................12

6.19 COMPRESSOR CYCLES ON AND OFF FREQUENTLY DURING THE INITIAL PULLDOWN

AND/OR NORMAL OPERATIONS...................................................................................................12

6.20 CIRCUIT BREAKER POPPING .......................................................................................................12

6.21 BIB PUMP DOES NOT OPERATE WHEN DISPENSING VALVE IS OPENED ..............................13

6.22 BIB PUMP OPERATES, BUT NO FLOW.........................................................................................13

6.23 BIB PUMP CONTINUES TO OPERATE WHEN BAG IS EMPTY ...................................................13

6.24 BIB PUMP FAILS TO RESTART AFTER BAG REPLACEMENT ....................................................13

6.25 BIB PUMP FAILS TO STOP, WHEN DISPENSING VALVE IS CLOSED ........................................13

6.26 LOW OR NO CARBONATION .........................................................................................................13

7. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS ..........................................................14

7.1 REFRIGERATION DECK ASSEMBLY........................................................................................14-15

7.2 CABINET ASSEMBLY.................................................................................................................16-17

7.3 CARBONATOR DECK/PUMP BRACKET ASSEMBLY...............................................................18-19

7.4 CARBONATOR WATER/SYRUP LINES ASSEMBLIES............................................................20-21

7.5 CONTROL HOUSING ......................................................................................................................22

7.6 REGULATOR WATER ASSEMBLY..................................................................................................23

7.7 MERCHANDISER ASSEMBLY ........................................................................................................23

7.8 WIRING DIAGRAM .........................................................................................................................24

SPECIFICATIONS

DIMENSION

Width 16 7/8 inches (42.86 cm)

Depth 24 3/4 inches (62.87 cm)

Height (without legs) 25 1/2 inches (64.77 cm)

WEIGHT

Shipping 170 lbs (77.1 kg)

Empty 156 lbs (70.8 kg)

Operating 220 lbs (99.8 kg)

WATER REQUIREMENTS

Minimum flowing pressure of 25 PSIG (1.76 kg/cm2, 1.72 BAR)

Maximum static pressure of 50 PSIG (3.52 kg/cm2, 3.45 BAR)

WARNING

IF WATER SOURCE EXCEEDS 50 PSIG (3.52 KG/CM2), A RECOMMENDED WATER REGULATOR

ASSEMBLY (PN 18-0253) MUST BE USED TO LIMIT WATER PRESSURE TO 50 PSIG (3.52 KG/CM2).

FAILURE TO USE REGULATOR WILL RESULT IN IMPROPER PERFORMANCE OF DISPENSER.

CARBON DIOXIDE (CO2) REQUIREMENTS

Minimum pressure of 70 PSIG (4.92 kg/cm2, 4.83 BAR)

Maximum pressure of 80 PSIG (5.62 kg/cm2, 5.52 BAR)

ICE BANK WEIGHT

27 to 30 lbs (12.2 to 13.6 kg)

DRINK CAPACITY

200 - 12 oz. drinks under 40°F (4.4°C) at 4 drinks per minute with 75°F (23.9°C) ambient inlet water and

inlet syrup using 1/3 HP, 115 V, 60 Hz refrigeration system.

DISPENSER INSTALLATION HIGHLIGHTS

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

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

2. The carbonator pump motor must be disconnected from the power supply (see Section 1.8A) prior to connection

to water supply for initial build up of ice bank. Failure to do so will result in automatic shut off of carbonator (see

item 6 below) or damage to the pump.

3. If this dispenser is installed in an area that is susceptible to ±10% variation of the nominal line voltage, consider

installing a surge protector or similar protection device.

4. There is a 5 minute delay, which prevents the compressor and condenser fan from starting until the delay has

lapsed. If electrical current is interrupted, there is always a 5 minute delay before the compressor starts.

5. The unit is equipped with a protective timer for the carbonator pump motor, set for 3 minutes. If the carbonator

motor has timed out, it must be manually reset by either momentarily unplugging the unit or switching off the

ON/OFF switch (if present). Once power is restored, the 5 minute compressor delay would be in effect.

6. Supply Water Pressure: Minimum - 25 PSIG (1.76 kg/cm2); Maximum - 50 PSIG (3.5 kg/cm2). If pressure is over

50 PSIG, a water pressure regulator must be used.

7. On units with the built in water regulator, the regulator must be removed if inlet water pressure is less than 25 PSIG.

8. CO2Pressure: Recommend nominal pressure 70 PSIG (4.92 kg/cm2, 4.83 BAR). Pressure may be reduced to a

minimum of 60 PSIG (4.22 kg/cm2, 4.13 BAR) if remote syrup pumps are being used. It may be increased to a

maximum of 80 PSIG (5.62 kg/cm2, 5.52 BAR), only when internal syrup pumps are being used with highly

viscous syrups. Important: Internal syrup pumps may not work at pressures less than 60 PSIG. CO2pressure

over 80 PSIG may result in damage or leakage from the syrup pump system, or may cause excessive foam in the

drink.

9. Bag-in-Box syrup packages must be within 6 feet from unit when internal syrup pumps are being used.

10.Valve Adjustment: Make sure drink temperature is below 40oF (4.4oC) before adjusting brix.

iii

1. INSTALLATION

1.1 RECEIVING

Each unit is tested and thoroughly inspected before shipment. At time of shipment, the carrier

accepts the unit and any claim for damages must be made with the carrier. Upon receiving units

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 plastic band and remove.

B. Remove top portion of carton by lifting up.

C. Remove accessory kit and loose parts from top packaging.

D. Remove top inner carton pad and corners.

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

F. Inspect unit for concealed damage(s) and if evident, notify delivering carrier and file a claim

against same.

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

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

NOTE

IF UNIT IS TO BE TRANSPORTED, IT IS ADVISABLE TO LEAVE UNIT SECURED TO

PLYWOOD SHIPPING BASE.

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

UNIT ON ITS SIDE OR BACK.

1.3 UNPACKING INSTALLATION KITS

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

same.

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

1.4 SELECTING A LOCATION

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

requirements as scheduled on the Specifications page.

B. Condenser air is drawn in the front of the unit and discharged out the top of the unit. A

minimum of 8 inches (20.3 cm) clearance must be maintained over the top of the unit.

WARNING

FAILURE TO MAINTAIN THIS CLEARANCE WILL CAUSE THE COMPRESSOR TO OVERHEAT

AND WILL RESULT IN COMPRESSOR FAILURE.

C. Units with built-in syrup pumps must be located no more than 8 meters (25 ft.) from the

dispensing tower, and no more than 2.4 meters (8 ft.) below the tower. Use external pumps if

these limits are exceeded.

1.5 MOUNTING THE DISPENSER

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

on 4 inch legs.

B. For permanent mounting, use Lancer sealant kit (PN 15-0010) to seal the dispenser to the

counter.

C. For leg mounting, use Lancer leg kit (PN 82-0962).

NOTE

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

1.6 FILLING UNIT WITH WATER

A. Remove the bonnet from the unit.

B. Remove the yellow plastic plug (located on the front of the unit's carbonator deck) from the unit's

fill hole.

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

overflow tube into the drip tray.

CAUTION

THE WATER BATH COMPARTMENT MUST BE FILLED WITH WATER BEFORE PLUGGING IN

THE UNIT. OTHERWISE, THE COMPRESSOR DECK AND CONDENSER FAN MAY NOT

OPERATE PROPERLY.

D. Replace the yellow plug.

1.7 CONNECTING TO ELECTRICAL POWER

WARNING

THIS UNIT MUST BE PROPERLY ELECTRICALLY GROUNDED TO AVOID POSSIBLE FATAL

ELECTRICAL SHOCK OR SERIOUS INJURY TO THE OPERATOR. THE POWER CORD IS

PROVIDED WITH A THREE PRONG GROUNDED PLUG. IF A THREE-HOLE GROUNDED

ELECTRICAL OUTLET IS NOT AVAILABLE, USE AN APPROVED METHOD TO GROUND THE

UNIT.

WARNING

FAILURE TO DISCONNECT THE MOTOR POWER SUPPLY WILL DAMAGE THE

CARBONATOR MOTOR AND PUMP AND VOID THE WARRANTY.

A. If the unit is equipped with a built-in carbonator, disconnect the power supply to the carbonator

motor by disconnecting the four pin connector, located near the top of the electrical control box

on the refrigeration deck.

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

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

available.

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

rating, and plug in the unit. This will turn on the refrigeration system and allow it to start

cooling, while completing the rest of the installation. The agitator motor will start immediately,

but the compressor and fan motor will not start until the 5 minute delay has elapsed.

1.8 CONNECTING PYTHON TO REMOTE RECIRCULATING UNIT (see Figure 1)

A. All remote units have the plain water feature, factory installed. If plain water is not wanted,

remove the barbed fitting and short extension fitting, and cap end of plain water line with cap

from accessory kit.

B. Determine length of python required, allowing additional length as required for servicing. The

length of the python must not exceed 25 feet (8 meters) if built-in syrup pumps are being used.

C. Position one end of python near remote unit. Slit the python insulation back 18 inches (45 cm)

from end and roll insulation back to expose individual tubes. Take care not to cut into tubing

bundle.

D. Slide the tube insulation from the accessory kit over one of the 3/8 inch ID plastic soda lines.

Connect this line to the 3/8 inch barbed 90° elbow located on the inlet to the recirculating pump.

Secure with an Oetiker clamp from the kit.

E. Connect the other 3/8 inch ID plastic soda line to the 3/8 inch barbed fitting on the stainless steel

soda recirculating. Secure with Oetiker clamp from kit.

F. Connect each of the 1/4 inch ID plastic lines from the python to the barbed fittings on each of

the stainless steel lines (and plain water line, if used). Secure with Oetiker clamps. The

individual barbed fittings for the lines can be removed for insertion into the python tubing by

removing the “U” shaped retainer pin and g fitting off of syrup line.

NOTE

Do not insulate connections at this time. Leave all connects exposed for inspection for leaks.

Refer to Section 1.17 to complete insulation.

Connecting Python to Remote Recirculating Unit

Figure 1

1.9 CONNECTING PYTHON TO TOWER (See Figure 2)

A. Route opposite end of python to tower. Determine length required, and cut if necessary. Be

sure to allow additional length as required for servicing.

WARNING

USE A SHARP KNIFE, RAZOR BLADE, OR TUBE CUTTER TO CUT TUBING. TUBING CUT

WITH A SAW WILL RESULT IN PLASTIC SHAVINGS, WHICH WILL PLUG THE FLOW

CONTROLS IN THE DISPENSING VALVE.

B. Slit python insulation back 12 inches (30 cm) from end and roll insulation back to expose

individual tubes. Cut tubing to length as shown in Figure 2.

C. All Delta towers have the plain water feature, factory installed. If plain water is not wanted,

splice a stainless steel, reducing, barbed hose tee (PN 01-0527) in the 3/8 inch soda line. Use

a separate 1/4 inch tube to complete the connection from the barbed tee to the tower manifold.

D. Connect each of the plastic lines from the python to the barbed fittings on each of the stainless

steel syrup, soda, and plain water lines on the tower manifold. Start with connections at the back

of the tower manifold first. Secure with Oetiker clamps.

NOTE

Do not insulate connections at this time. Leave all connects exposed for inspection for leaks.

Refer to Section 1.18 to complete insulation.

Connecting Python to Delta Tower

Figure 2

1.10 CONNECTING 24VAC POWER SUPPLY TO TOWER

NOTE

The remote recirculating unit is designed to supply 24VAC power to the valves on the dispensing

tower. An extension cord of 25 feet (8 meters) is provided for this purpose in the tower. A separate

power supply must be used if the tower is located more than 25 feet (8 meters) from the remote

recirculating unit.

A. Remove cover from electrical control box on remote recirculating unit, and route white and black

wires (bundled) through the opening in side of control box. Replace cover.

B. Connect extension cord to white and black wires.

C. Route extension cord with python to tower.

D. Connect white wire to terminal on key lock switch, and black wire to loose black wire in tower.

E. A separate power cord is provided for the lighted merchandiser.

1.11 CONNECTING TO WATER SUPPLY

WARNING

IF WATER SOURCE EXCEEDS 50 PSIG (3.52 KG/CM2), A WATER REGULATOR KIT MUST BE

USED TO LIMIT WATER PRESSURE TO 50 PSIG (3.52 KG/CM2). FAILURE TO USE

REGULATOR WILL RESULT IN IMPROPER PERFORMANCE OF DISPENSER.

A. Using tubing and fittings from installation kit, connect tubing assembly to water source. DO NOT

CONNECT TO DISPENSER AT THIS TIME.

B. Flush water supply line thoroughly.

C. IF THE WATER SOURCE IS ABOVE 50 PSIG (3.52 KG/CM2), CUT TUBING ASSEMBLY AND

INSTALL WATER REGULATOR KIT (PN 18-0253/01) AS SHOWN IN KIT INSTRUCTION

SHEET.

D. Route tubing through hole in counter and through opening behind splash plate and connect to

carbonator pump, using a flare seal washer (PN 05-0017). Use a back-up wrench to prevent

damage to carbonator pump.

E. Leave 1 foot (30 cm) of extra tubing length below the counter for servicing and moving the

dispenser.

F. Turn on water supply and check for leaks.

G. Using test gauge assembly (PN 22-0138), set regulator at 50 PSIG (3.52 kg/cm2).

1.12 CONNECTING THE CO2SUPPLY

A. Connect high pressure CO2regulator assembly to CO2cylinder. Use a new CO2tank washer

if regulator does not have built-in o-ring seal.

B. Place CO2cylinder in service location under counter, etc., and secure it with a safety chain.

C. Using tubing and fittings from installation kit, connect tubing assembly to tank mount regulator

using flare seal washer (PN 05-0011). Use a back-up wrench to prevent damage to regulator

assembly.

D. Route gas line through hole in counter and through opening behind the dispenser splash plate.

E. Leave 1 foot (30 cm) of extra tubing length below the counter for servicing and moving the

dispenser.

F. Remove the protective plug from the CO2manifold (located on top of mini pumps on left side of

unit) and connect the CO2supply line using a 1/4 inch elbow (supplied in installation kit.)

WARNING

DO NOT TURN ON THE CO2SUPPLY AT THIS TIME

G. If dispenser does not have built in syrup pumps, connect directly to the carbonator CO2inlet

check valve.

1.13 CONNECTING TO BAG-IN-BOX (BIB) SYRUP SUPPLY (Units with Built-in Syrup Pumps)

A. Remove the protective caps from the syrup pump inlets and connect syrup inlet tube

assemblies, furnished in the installation kit, to the syrup pumps. Lubricate o-rings before

installation, using food grade glycerine or equivalent. Be careful not to cut o-rings when

installing in pump.

CAUTION

THE SYRUP INLET TUBE ASSEMBLIES SHIPPED WITH THE INSTALLATION KIT, ARE 8 FEET

(2.4 M) LONG. THESE LINES CAN BE EXTENDED UP TO A MAXIMUM OF 12 FEET (3.7 M). THE

MAXIMUM HEIGHT OF THE PUMPS ABOVE THE LOWEST BIB PACKAGE SHOULD NOT

EXCEED 8 FEET (2.4 M). IF EITHER THE HEIGHT OF PUMPS OR LENGTH OF INLET LINE

LIMITATIONS ARE EXCEEDED, REMOTE SYRUP PUMPS OR PRESSURIZED SYRUP

CONTAINERS SHOULD BE USED.

B. Mark syrup tube assemblies at BIB hose connector end with product ID tape.

C. Route the syrup supply tubes from the unit, through hole in counter, to the BIB syrup supply.

D. Dip hose connectors in a cup of warm, potable water.

E. Attach the BIB hose connectors to the appropriate syrup flavor.

1.14 CONNECTING TO REMOTE BIB SYRUP PUMPS

A. Locate the remote BIB, syrup supply, and pumps in a convenient location.

B. Attach the syrup supply tubes to the dispensers syrup inlet fittings (located behind the splash

plate) using a 1/4 inch Oetiker clamp for each syrup flavor.

C. Route the syrup supply tubes to the remote syrup pumps.

D. Complete installation of the remote syrup pump system following the manufacturer's

instructions.

1.15 CONNECTING TO REMOTE PRESSURIZED SYRUP SUPPLY

A. Locate the five gallon syrup containers and the CO2cylinder and regulator set in a convenient

location.

B. Attach the syrup supply tube assembly to the dispensers syrup inlet fittings (located behind the

splash plate) using a 1/4 inch Oetiker clamp for each syrup flavor.

C. Route the syrup supply tubes to the five gallon syrup containers and attach them to the

appropriate syrup flavor.

D. Attach a CO2supply line from each of the five gallon syrup containers to the low pressure

regulator and pressurize the containers.

1.16 PURGING THE CARBONATION SYSTEM

A. The relief valve for the built-in carbonator is located on the right hand side of the unit's

carbonator deck. Lift the yellow lever on the top of the relief valve until water flows from the

holes in the relief valve. Then, release the relief valve.

B. Reconnect the power supply to the carbonator pump.

C. Back off on the CO2regulator pressure adjusting screw all the way. Open the CO2cylinder

handle slowly. Turn the CO2pressure regulator up slowly to 75 PSIG (5.1 bar).

D. Open a dispensing valve at tower, until water and syrup are flowing steadily from the valve.

E. Repeat procedure “D” for each valve.

F. Check all of the unit's syrup, water and CO2connections for leaks and repair if necessary.

NOTE

To check for CO2leaks, close the valve on the CO2cylinder and observe if the pressure to the

system drops with the cylinder valve closed for five (5) minutes. Open the cylinder valve after

check.

G. Replace the unit's bonnet and splash plate.

1.17 COMPLETE INSULATION BETWEEN REMOTE UNIT AND PYTHON

A. Check all of the unit’s syrup, water, and CO2connections for leaks and repair, if necessary.

B. Close the python insulation, which had been rolled back earlier for connection to remote unit

syrup, soda, and plain water lines. Seal python insulation with plastic tape. There should be no

gaps in the insulation. The insulated soda line to the recirculating pump will protrude

approximately 18 inches from the end of the python insulation.

C. Starting as close to the remote unit as possible, wrap the syrup, soda, and plain water lines with

a single layer of insulated tape until all plastic tubing has been covered.

D. Deal the insulated soda line from the python to the recirculating pump. The soda line insulation

should be butted firmly against the recirculating pump and python insulation and sealed at both

junctions with plastic tape.

1.18 COMPLETE INSULATION BETWEEN TOWER AND PYTHON

A. Check all of the unit’s syrup, water, and CO2connections for leaks and repair, if necessary.

B. Close the python insulation, which had been rolled back earlier for connection to tower manifold.

Seal python and tower manifold insulation with plastic tape. There should be no gaps in the

insulation.

C. The python insulation should be butted firmly against the tower manifold insulation and sealed

in place with plastic tape.

CAUTION

THE PYTHON INSULATION MUST BE AIR TIGHT TO PREVENT THE FORMATION OF

CONDENSATION. ALL AREAS MUST BE SEALED WITH PLASTIC TAPE AND THEN COVERED

WITH INSULATION TAPE. FAILURE TO SEAL BOTH ENDS OF THE PYTHON WILL RESULT IN

POOR PERFORMANCE FROM THE DISPENSER.

2. SCHEDULED MAINTENANCE

2.1 DAILY

A. With a clean cloth and warm soapy water, wipe off all of the units exterior surfaces.

2.2 WEEKLY

A. Remove the unit's bonnet and check the level of water in the water bath. Replenish as required,

and replace the bonnet.

2.3 MONTHLY

A. Unplug the dispenser from its power source.

B. Remove the bonnet. Clean the dirt from the unit's condenser, using a soft brush.

C. Replace the bonnet, and plug in the unit.

2.4 EVERY SIX (6) MONTHS

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

2.5 YEARLY

A. Clean water bath interior, including evaporator coils and refrigeration components.

B. Clean the entire exterior of the unit.

C. Sanitize syrup lines.

NOTE

Because of difficulty in rinsing, detergent solution should not be introduced into the carbonator.

3. DISPENSER CLEANING AND SANITIZING

3.1 AMBIENT PROCESS

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

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

chlorine solution.

B. Disconnect syrup containers. Remove product from tubing by purging with carbon dioxide.

C. Rinse the lines and fittings with clean, potable room temperature water to remove all traces of

residual product.

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

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

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

allow to stand for at least 10 minutes.

E. Flush the detergent solution from the lines with clean water. Continue rinsing until testing with

phenolpthalein shows that the rinse water is free of residual detergent.

F. Fill the lines with a low pH (7.0) chlorine solution containing at least 50 PPM (50 mg/L) available

chlorine. Make sure that lines are completely filled and allow to stand for 10 minutes.

G. Reconnect syrup containers and ready Unit for operation.

H. Draw drinks to refill lines and flush the chlorine solution from the dispenser.

I. Taste the beverage to verify that there is no off taste.

3.2 ALTERNATE CLEANING AND SANITIZING AGENTS

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

Quality Assurance Manager may approve the following cleaning and sanitizing agents.

B. Chlorinated alkaline detergents. These compounds may be used as the cleaning agent, but

may not be used as combined cleaner/sanitizer.

WARNING

IODOPHORS AND QUATERNARY AMMONIUM COMPOUNDS (QUATS) ARE BROAD

CLASSES OF COMPOUNDS. SOME MEMBERS OF EACH GROUP CAN CAUSE SERIOUS

PROBLEMS WITH FOAMING, DISTORTION OR DISCOLORATION OF POLYMERIC PARTS,

POOR RINSIBILITY, AND OFF TASTE. THE RINSIBILITY AND OFF TASTE PROBLEMS HAVE

BEEN ESPECIALLY PREVALENT WITH QUATS. BECAUSE OF THE POTENTIAL PROBLEMS,

APPROVAL MUST BE GRANTED BY THE DIVISION QUALITY ASSURANCE MANAGER TO

SPECIFIC COMPOUNDS. THIS APPROVAL SHOULD BE BASED UPON TESTING IN THE

LABORATORY.

C. Iodophors may be substituted for chlorine as the sanitizing agent.

D. Quaternary ammonium compounds may be used as a combined cleaner-sanitizer, but are

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

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

is lower.

4. CONVERTING FROM EXTERNAL PRESSURIZED SYRUP SUPPLY TO BIB WITH BUILT-IN SYRUP

PUMPS

This conversion can be done. Contact Lancer Corporation for parts and instructions.

5. CONVERTING FROM BUILT-IN SYRUP PUMPS TO REMOTE PUMPS OR SYRUP TANKS

5.1 REMOVING EXISTING BUILT-IN SYRUP PUMPS

A. Disconnect the unit from the power supply and remove the bonnet.

B. Shut off the water supply to each Valve at the tower.

C. Prepare three to four (3 to 4) gallons of warm, potable water in a suitable open container.

D. Disconnect the syrup supply lines from the BIB syrup supply, assemble a BIB adapter to the end

of each line, and place the line in the container of warm water.

E. Open each dispensing valve until the water flowing from the valve shows no discoloration due

to syrup.

F. Remove the syrup supply lines from the warm water and open each dispensing valve to purge

the water from the system.

G. Turn off the CO2supply to the unit. Disconnect the CO2supply line from CO2inlet fitting on the

built-in pump package.

H Disconnect the syrup inlet lines from the built-in syrup pumps, and remove them from the unit.

I. Disconnect the pump's syrup outlet lines from the unit's syrup inlet fittings.

J. Remove 1/8 inch barbed carbonator CO2check valve, if one is present.

K. Remove the four (4) sheet metal screws that secure the pump assembly to the carbonator deck,

and remove the pump assembly from the unit.

L. Remove braided inlet tubes and elbow. It will be necessary to cut the securing Oetiker clamps.

5.2 INSTALLING REMOTE PUMP OR SYRUP TANKS

A. Install new 1/4 inch male flare CO2carbonator check valve.

B. Connect the CO2supply line to the carbonator check valve.

C. Connect the syrup outlet line from each remote pump to the appropriate syrup inlet fitting on the

unit, using a 1/4 inch Oetiker clamp.

NOTE

Each 1/4 inch braided syrup tube will be looped from the inlet line to the remote pumps. Take

caution not to bend, crimp, or kink the 1/4 inch tube at the loop. It may be necessary to use a

tie wrap.

D. Make all necessary connections on remote pump system or syrup tank.

E. Turn on water (25 to 50 PSIG) and CO2(70 to 80 PSIG) supply.

F. Open each valve until syrup flow is established. Check all connections for leaks.

G. Replace the bonnet, and reconnect the unit to the power supply.

H. Open the water supply to each valve.

5.3 CONNECTION FOR PLAIN WATER PRODUCT

A. If plain water product is required, a separate plain water line has been pre-installed for easy

connection to the second valve from the left side of the dispenser.

B. Remove the comb insulation (foam rubber pad) from the top of the inlet tubes.

C. Using a backup wrench, remove the cap from the plain water line. Save for reuse later.

D. Push soda line out of the way and cap with fitting (removed from the plain water line). Ensure

that the flare seal washer is in place. Tighten, using a backup wrench.

E. Align the plain water extension with plain water line. Ensure that the flare seal washer is in place

and lightly tighten by hand. Once the connection is engaged, tighten using a backup wrench.

6. TROUBLESHOOTING

TROUBLE CAUSE REMEDY

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

screws.

B. Damaged or improperly B. Replace or adjust appropriate

installed o-rings. o-rings.

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

water pressure. pressure is a minimum of 25 PSI.

B. Foreign debris in water pump. B. Remove water pump strainer

and strainer. Clean.

6.3 Insufficient syrup flow. A. Insufficient CO2pressure to A. Adjust CO2pressure to 80 PSI

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

6.4 Erratic ratio. A. Incoming water and/or syrup A. Check pressure and adjust, as

supply not at minimum necessary.

flowing pressure.

6.5 No product dispensed. A. Electric current not reaching A. Check electric current supplied to

electric valve. valve. If current is adequate, check

solenoid coil, and switch. Replace,

if necessary.

B. Improper or inadequate water B. Remove valve from mounting block

or syrup supply. and open shutoffs slightly and

check water and syrup supply. If no

supply, check dispenser for

freeze-up or other problems.

C. Transformer failure. C. Reset transformer circuit breaker. If

breaker pops again, refer to Item

6.23.

6.6 Water only dispensed, A. BIB supply too far from A. Check that BIB supply is within six

no syrup; or syrup only dispenser. (6) feet of the dispenser.

dispensed, no water. B. CO2pressure too low. B. Check the CO2pressure to the

pump manifold to ensure it is

between 70-80 PSI.

C. Stalled or inoperative BIB E. Check CO2pressure and/or replace

pump. pump.

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

TROUBLE CAUSE REMEDY

6.7 No water just syrup. A. Low level. A. Add water until it flows from over

(Ice bank grew to flow tube.

water inlet line to B. Unit not level. B. Level unit and add water.

carbonator tank.) C. Syrup in water bath. C. Melt ice bank and remove

All water. Refill. Locate possible syrup leak area.

and repair.

D. Water cage is out of position. D. Reposition water cage.

E. PCB relay sticking. E. Check continuity of compressor

relay. Compressor should time-out

in 5 minutes.

F. Refrigerant leak. F. Find leak and recharge unit (if unit

is not frozen).

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

then ON to reset carbonator.

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

carbonator.

I. PCB malfunctioning. I. Replace PCB.

6.8 Syrup only dispensed, A. Improper water flow to A. Check for water flow to dispenser

no water; but CO2gas dispenser. (see Item 6.4).

dispensed with syrup. B. Carbonator pump motor B. Reset by turning the unit OFF

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

switch on top of the unit, or unplug-

ging unit momentarily.

C. Liquid level probe not C. Check connections of liquid level

connected properly to PCB. probe to PCB assembly.

D. Faulty PCB assembly. D. Replace PCB assembly.

E. Faulty liquid level probe. E. Replace liquid level probe.

F. Water bath frozen. F. Thaw water bath and repair faulty

component. (See refrigeration

related symptoms.)

G. Water line frozen. G. Refer to Item 6.14.

6.9 Excessive foaming. A. Incoming water or syrup A. Correct prior to dispenser.

temperature too high. Consider larger dispenser, or

pre-cooler.

B. CO2pressure too high. B. Adjust CO2pressure downward,

but not less than 70 PSI.

C. Air in BIB lines. F. Bleed air from BIB lines.

D. Poor quality ice. G. Check quality of ice used in drink.

E. High beverage temperature. H. Check refrigeration system.

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

flows from water bath B. Flare seal washer leaks. B. Replace flare seal washer.

into drip tray. C. Faulty water coil. C. Replace water coil.

6.11 Compressor starts and A. PCB malfunctioning or A. Disconnect ice band probe from

continues to run until faulty ice bank probe. PCB.

freeze up and will not 1. If compressor continues to run,

cut off. replace PCB.

2. If compressor stops, replace

ice bank probe.

B. Ice bank probe positioned B. Check positioning of ice bank

improperly. probe, and replace if needed.

C. Ice bank probe shorted to C. Replace ice bank probe.

ground.

NOTE:

First, check to ensure that the 3 minute carbonator timer has not timed out. Turn unit OFF and then ON.

If the pump shuts off in less than 30 seconds, the dispenser is not frozen.

TROUBLE CAUSE REMEDY

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

top, and inlet of unit. Remove

objects blocking airflow through

grill.

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

water supply.

C. Refrigeration system not C. Refer to Items 6.16 through 6.20.

running.

D. Refrigerant leak. D. Repair and recharge.

E. Condenser fan motor not E. Replace condenser fan motor.

working.

F. Dirty condenser. F. Clean condenser.

G. Dispenser capacity exceeded. G. Add pre-cooler, or replace with

larger dispenser.

6.13 Compressor does not A. There is a 5 minute com- A. Allow for 5 minute delay to lapse.

start (no hum), con- pressor and condenser fan

denser fan motor does delay.

not run and no ice bank. B. Ice bank probe not completely B. Fill water reservoir until water flows

submerged. from overflow tube.

C. Circuit breaker or fuse tripped. C. Reset breaker or replace fuse. If

problem persists:

1. Determine reason and correct.

2. Electrical circuit overloaded;

switch to another circuit.

D. Inadequate voltage. D. Measure voltage across common

and run terminal on compressor.

Voltage must not drop below 90%

of rated voltage.

E. PCB malfunctioning. E. Replace PCB assembly.

F. Incorrect wiring. F. Refer to wiring diagram and correct.

G. Faulty ice bank probe. G. Replace ice bank probe.

H. Transformer failure. H. Reset transformer circuit breaker. If

breaker pops again, refer to Item

6.25.

I. Ice bank probe not connected I. Connect ice bank probe to PCB.

properly to PCB.

6.14 Compressor does not A. Compressor relay or overload A. Replace compressor relay or

start (no hum), but malfunctioning. overload.

condenser fan motor B. Inadequate voltage. B. Measure voltage across common

runs. and run terminal on compressor.

Voltage must not drop below 90%

of rated voltage.

C. Incorrect wiring. C. Refer to wiring diagram and correct.

D. Compressor malfunctioning. D. Replace compressor.

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

start, but hums. and run terminal on compressor.

Voltage must not drop below 90%

of rated voltage.

B. Incorrect wiring. B. Refer to wiring diagram and correct.

C. Starting relay malfunctioning. C. Replace starting relay. Be sure to

use correct relay. Failure to use

correct relay will cause compressor

failure.

D. Compressor malfunctioning. D. Replace compressor or deck.

TROUBLE CAUSE REMEDY

6.16 Compressor starts, but A. Inadequate voltage. A. Measure voltage across common

does not switch off start and run terminal on compressor.

winding (will run for only B. Incorrect wiring. B. Refer to wiring diagram and correct.

a few seconds before C. Starting relay malfunctioning. C. Replace starting relay. Be sure to

internal overload use correct relay. Failure to use

switches compressor off). correct relay will cause compressor

failure.

6.17 Compressor starts and A. Dirty condenser. A. Clean the condenser.

runs a short time, but B. Insufficient or blocked air flow. B. Remove all obstructions and allow

shuts off on overload. for minimum clearances of 8 inches

(20.3 cm) over top.

C. Inadequate voltage. C. Measure voltage across common

and run terminal on compressor.

Voltage must not drop below 90%

of rated voltage.

D. Incorrect wiring. D. Refer to wiring diagram and correct.

E. Defective condenser fan E. Replace condenser fan motor.

motor.

F. Refrigerant leak. F. Repair and recharge.

G. Compressor malfunctioning. G. Replace compressor.

6.18 Compressor runs A. Low water level in water bath. A. Add water to water bath until water

normally, but water line runs out of overflow into drip tray.

is frozen. B. Syrup in water bath. B. Drain water from water bath and

refill with clean water.

C. Water cage is out of position. C. Reposition water cage.

D. Low refrigerant charge/slow D. Find and repair leak. Recharge

refrigerant leak. system.

6.19 Compressor cycles on A. PCB malfunctioning. A. Replace PCB assembly.

and off frequently B. Defective probe. B. Replace probe.

during the initial pull-

down and/or normal

operations.

6.20 Circuit breaker popping. A. Valve wire harness shorted A. Detect short by disconnecting

to itself or to faucet plate. input faston to keylock and single

pin connector. Restore power, if

breaker doesn't pop. Then valve

wire harness is shorted; if OK,

reconnect.

B. PCB is bad. B. Detect short by disconnecting J1

connector (24 VAC input) from

PCB. Restore power, if breaker

doesn't pop. Then replace PCB. If

breaker does pop, then PCB is

OK. Reconnect J1 connector.

C. Secondary wire harness is C. If it does not pop, locate short in

bad. secondary harness between

transformer, PCB and valve wire

harness.

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

transformer fastons and restore

power. If breaker does pop, replace

transformer.

TROUBLE CAUSE REMEDY

6.21 BIB pump does not A. Out of CO2, CO2not turned A. Replace CO2supply, turn on CO2

operate when dispensing on, or low CO2pressure. supply, or adjust CO2pressure to

valve is opened. 70-80 PSI.

B. Out of syrup. B. Replace syrup supply.

C. BIB connector not tight. C. Fasten connector tightly.

D. Kinks in syrup or gas lines. D. Straighten or replace lines.

6.22 BIB pump operates, A. Leak in syrup inlet or outlet A. Replace line.

but no flow. line.

B. Defective BIB pump check B. Replace BIB pump.

valve.

6.23 BIB pump continues to A. Leak in suction line. A. Replace line.

operate when bag is

empty. B. Leaking o-ring on pump inlet B. Replace o-ring.

fitting.

6.24 BIB pump fails to restart A. BIB connector not on tight. A. Tighten BIB connector.

after bag replacement. B. BIB connector is stopped up. B. Clean out or replace BIB connector.

C. Kinks in syrup line. C. Straighten or replace line.

6.25 BIB pump fails to stop, A. Leak in discharge line or A. Repair or replace discharge line.

when dispensing valve fittings.

is closed. B. Empty BIB. B. Replace BIB.

C. Air leak on inlet line or bag C. Repair or replace.

connector.

6.26 Low or no carbonation. A. Low or no CO2. A. Check CO2supply. Adjust CO2

pressure to 70 PSI.

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

50 PSI.

C. Worn or defective carbonator C. Replace carbonator pump.

pump.

45 44 43

14 49

52 54

51 53

14 25

19 14

11 58

7. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS

7.1 REFRIGERATION DECK ASSEMBLY

ITEM PART NO. DESCRIPTION
– 82-0942/01 Deck Assy Refrig, R-12, 220V 50Hz,
Export
– 82-1010/01 Deck Assy Refrig, R-12, 220V 60Hz,
Export
– 82-0959/01 Deck Assy Refrig, R-12, 115V 60Hz,
Export
– 82-1286/01 Deck Assy Refrig, R-12, 115V 60Hz,
Domestic
– 82-1248/01 Deck Assy Refrig, R-134a, 220V 50Hz,
Export
– 82-1372/01 Deck Assy Refrig, R-134a 115V 60Hz,
Domestic
– 82-1428/01 Deck Assy Refrig. R-134a 115V60HZ,
Export
1 51-5107/01 Sub Assy, Compressor Deck
2 50-0200/01 Insulation, Compressor Deck
3 04-0063 Washer, Flat
489-0014 Cover, Hole
5 REF Evaporator Coil Assy
– 82-1268 Evaporator Coil, R134a, Export
– 82-1373 Evaporator Coil, R134a, Domestic
– 82-1157 Evaporator Coil, R12, Domestic
– 82-0884 Evaporator Coil, R12, Export
6 54-0137 Probe Assy, IBC
7 04-0470 Screw, 6 - 19 x 0.438
8 51-0068 Handle
9 04-0574 Washer, Lock, 5/16
10 REF Control Housing Assy
– 52-0900/01 Control Housing Assy, with "ON-OFF"
Switch
– 52-0903/01 Control Housing Assy, without "ON-
OFF" Switch
11 REF Cover, Control Housing
– 30-5108/01 Cover, Control Housing, with "ON-
OFF" Switch
–30-5118 Cover, Control Housing, without "ON-
OFF" Switch
12 06-0576/03 Label, Wiring Diagram
13 02-0032 Washer, Rubber, 1.0 inch
14 04-0504 Screw, 8 - 18 x 0.375
15 06-0080-01 Label, Nameplate
16 52-1209 Lead Assy, Ground
17 02-0041 Seal
18 REF Capacitor, Carbonator
– 26-0374 Capacitor, Carbonator, 115V 60 Hz
– 26-0377 Capacitor, Carbonator, 220V 50 Hz
and 60 Hz
19 REF Transformer
–25-0047 Transformer, 115V 60Hz
– 25-0048 Transformer, 220V 50Hz and 60Hz
20 REF Motor, Assy
– 52-1262 Motor, Assy, 220V 50Hz and 60Hz
– 52-1261 Motor, Assy, 115V 60Hz
21 30-5113/01 Bracket, Agitator
22 05-0495 Propeller, 2.062 Dia.
23 05-0502 Propeller, 2.250 Dia.
24 02-0040 Seal, Extrusion
25 04-0032 Nut, Nylok, 1/4 - 20
26 04-0033 Washer, Flat (.281 ID)
27 REF Compressor
– 83-0005 Compressor, R-12, 220V 50Hz, Export
– 83-0010 Compressor, R-12, 220V 60Hz, Export
– 83-0002 Compressor, R-12, 115V 60Hz,
Domestic & Export
– 83-0033 Compressor, R-134a, 115V 60Hz,
Domestic
– 83-0034 Compressor, R-134a, 220V 50Hz,
Export
28 02-0114 Grommet
29 04-0537 Washer, Flat (.467 ID)
30 03-0150 Retainer, Clip
31 REF Relay
–12-0005 Relay, R-12 & R-134a, 115V 60Hz
–12-0031 Relay, R-12 & R-134a, 220V 50Hz &
60Hz
32 REF Overload
– 12-0004 Overload, R-12 & R-134a, 115V 60Hz
–12-0032 Overload, R-12 & R-134a, 220V 50Hz
& 60Hz
33 13-0006 Cover Terminal
34 03-0040 Bale Strap
35 47-0344 Tube, Process
36 REF Tube, Compressor 
– 47-0718 Tube, Compressor (Hi Side)
– 47-0347-01 Tube, Compressor R-12, 220V 60Hz
(Hi Side)
37 47-0724 Tube, Return
38 51-0061 Accumulator
39 50-0211 Boot
40 50-0205 Insulation, Tube
41 50-0159 Insulation, Tube
42 23-0985 Condenser
43 50-0201 Baffle, Condenser
44 30-5112 Plate, Retainer
45 04-0518 Rivet, .1250 x 0.328
46 30-5867 Shield, Air,Left
47 30-5865 Shroud, Fan Top
48 50-0249 Barrier, long
49 30-5866 Shroud, Fan, Bottom
50 REF Motor, Fan
–91-0007 Motor, Fan, 115V 60Hz
– 91-0009 Motor, Fan, 220V 50Hz & 60 Hz
51 07-0354 Fan Blade
52 04-0060 Nut
53 02-0413 Silencer
54 30-5864 Bracket, Fan Motor
55 REF Dryer Cap Assy 
–23-0982 Dryer Cap Assy R-134a, 115V 60Hz
– 23-0932 Dryer Cap Assy R-134a, 220V 50Hz
– 23-0765 Dryer Cap Assy R-12
56 47-0698 Tube, Condenser Out
57 REF Freon
– 95-0177 Freon, R-134a
– 95-0077 Freon, R-12
58 52-1213 Harness Assy, XFM12
59 04-0110 Nut, 8 - 32, ST
60 04-0576 Washer, Int., Tooth
61 06-0877 Label, Ground
62 REF Bracket Assy Guide
– 51-5147 Bracket Assy Guide, R-134a, 115V
60Hz
– 51-0791 Bracket Assy Guide, R-12
15
7.1 REFRIGERATION DECK ASSEMBLY (CONTINUED)
ITEM PART NO. DESCRIPTION