lancer S4E V2 Hi-Carb Superchiller Manual

lancerbeverage.com
S4E V2 Hi-Carb Superchiller
220V / 60Hz
Installation, Operation &
Service Manual

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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............................................................................................................................. 7
6.1 Receiving...................................................................................................................... 7
6.2 Unpacking..................................................................................................................... 8
6.3 Selecting a Location..................................................................................................... 8
6.4 Mounting Superchiller................................................................................................... 8
6.5 Connecting Python....................................................................................................... 8
6.6 Connecting to water supply........................................................................................ 10
6.7 Connecting to CO2 supply......................................................................................... 10
6.8 Filling unit with water.................................................................................................. 10
6.9 Electrical Connection.................................................................................................. 10
6.10 Plumbing the drain and CO2 exhaust........................................................................ 11
6.11 Commissioning........................................................................................................... 11
6.12 Purge System............................................................................................................. 11
7. Scheduled Maintenance .................................................................................................... 11
8. Postmix Circuit Diagram ................................................................................................... 14
9. Electrical Circuit Diagram ................................................................................................. 15
10. Airflow Diagram.................................................................................................................. 16
11. Trouble Shooting................................................................................................................ 17
11.1 Refrigeration............................................................................................................... 17
11.2 Troubleshooting –Postmix......................................................................................... 18
12. Hydra Icebank Control Go/No Go Test............................................................................ 20
13. Hydra Carbonator Level Control Test.............................................................................. 21
14. Assembly Diagrams & Parts List ..................................................................................... 22
14.1. Postmix Parts List....................................................................................................... 22
14.2. Postmix Assembly Diagram....................................................................................... 23
14.3. Refrigeration Parts List............................................................................................... 24
14.4. Refrigeration Assembly Diagram............................................................................... 25
15. Certificate of Warranty....................................................................................................... 26
16. Manufacturer’s Checklist .................................................................................................. 27

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1. Introduction
Thank you for purchasing this qualityLancer product. All Lancer products are constructed using the highest
qualitymaterials 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 byHoshizaki 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) and Auckland (New Zealand).
3. Our Products
Lancer specialises in the design, engineering, manufacture, and marketing ofbeverage dispensing and Heat
Recovery equipment in three 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.
Heat Recovery Equipment
Lancer manufactures a range of Heat Recovery systems designed to provide our customers with free hot
water.
4. Product Details
4.1 Product Features
The Lancer Superchiller is an Australian design and manufactured remote refrigerated 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 220 Volts
Frequency 60 Hz
Max Current Draw 7.5 Amps
Ambient Temperature 2 - 40°C
Heat Rejection 3200 watts
Dimensions
Width 1050 mm
Depth 505 mm
Height 655 mm
Weight
Shipping 110 kg
Empty 103 kg
Operating 175 kg
Refrigerant 800 Grams R134a
Ice bank Weight 30 kg
Water Bank Capacity 72 litres
Construction Stainless Steel
Drink Capacity 275 x355 ml (12oz) drinks below4.4°Cat 4 drinks perminute with
40°C ambient, syrup inlet temperature and 32°C water inlet
temperature.
4.3 Models
S4E22LB V2 Superchiller with carbonation and soda circulation pumps.
S4E22LBS V2 Superchiller with carbonation and soda circulation pumps with Syrup coils.
S4E23LB V2 Superchiller with carbonation, soda and water circulation pumps.
S4E23LBS V2 Superchiller with carbonation, soda and water circulation pumps with Syrup coils.
4.4 Options
Adjustable Legs (79232218). Height with legs approx. 805mm
Casters (79602411). Height with casters 765mm

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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 bya 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 onlybe
performed by fully trained & certified Electrical, Plumbing, &
Refrigeration Technicians.
Warning
Carbonator contains CO2 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 CO2 (Carbon Dioxide) supply. CO2 is a
heavier than air, colourless,non-combustible gas with a faintly
pungent odour.
Personnel exposed to high concentrations of CO2 gas will
experience tremors, which are followed rapidly by loss of
consciousness and suffocation.
Ifa CO2 gas leak is suspected, immediately ventilate the
contaminated area before attempting to repair the leak.
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 S4E Superchiller weight: 103kg)
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) ofdamage. If damage exists, have carrier note damage on bill of landing and file a claim
with the carrier.

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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.
Carefullyunpack the Lancer S4E Superchiller fromthe shipping carton, removethe 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 bya weatherproof
enclosure.
This appliance is not suitable for installation in an area where a
water jet could be used.
Superchillers are not intended to be placed on a kitchen floor.
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 S4E Superchiller should be located in a well-ventilated, firm, level location close to
dispenser, water and electrical supplies, with easyaccess for servicing
Ensure sufficient clearance around Superchiller to allow good fresh air circulation through the
condenser –allowat least 200mm at rear and sides.
Installation should only be performed bya qualified and competent technician.
6.4 Mounting Superchiller
Install on a flat, level surface using adjustable legs orcasters (Optional).
Fix to supporting structure using 4 x ¾” BSW bolts screwed into base supports.
Caution
Superchiller operational weight is 175kg; ensure that all
supporting structures are certified for this loading by a
registered Mechanical Engineer.
Supporting structure must be securelyfixed to floors or walls.
6.5 Connecting Python
ConnectPython to Chillerand Dispenser.
Caution
NOTE: The S4E 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.

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Python Details
Recirculation Lines
Recommended Product Tube Markings Colour Configuration
Water Supply Water Supply Beige
Water Return Water Return White
Soda Supply Soda Supply Maroon
Soda Return Soda Return Black
Product Lines - Syrup Coils (Optional):
Tube Markings Colour Configuration
1----1----1 Blue
2----2----2 Violet
3----3----3 Green
4----4----4 Yellow
5----5----5 Grey
6----6----6 Orange
7----7----7 Brown
8----8----8 Red
Ensure lines are insulated from python to Superchiller connections to prevent condensation.
Note: For additional Soda reserve on short python lengths used in high volume accounts, it may be
necessaryto extend the soda circuitby 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).

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6.6 Connecting to water supply
Using appropriate tubing and fittings connect a 10mm water supply line from Superchiller
carbonator pump inlet tee to a filtered, regulated water supply. (See Postmix circuit diagram
page 13). 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 carbonator relief valve until water flows from CO2 exhaust tube; then close the relief
valve.
Warning
The water inlet has to be supplied through a water tap that is
installed in accordance with plumbing rules and regulations.
Caution
Maximum water supply pressure to be 275 kpa.
Normal operating water temperature should be within 7°C to
35°C.
6.7 Connecting to CO2 supply
Warning
As carbon dioxide (CO2) displaces oxygen; prevention of CO2
leaks is paramount. If a leak is suspected, immediately ventilate
the contaminated area, before attempting repairs.
Connect CO2supply line from regulator to gas inlet on carbonator. (See Postmix circuit diagram
page 13 for details)
Adjust CO2Regulator supplying Carbonator to 550 kpa.
Turn on CO2supply.
6.8 Filling unit with water
Remove Superchiller lid and fill water bath until water flows out overflow tube.
NOTE: Do not use water supplied from newlyinstalled carbon filter as ice bank control operation will
be adversely affected.
6.9 Electrical Connection
This unit is connected to the supply via a 10 amp 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.

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Warning
To avoid possible fatal electric shock or serious injurythe
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.
6.10 Plumbing the drain and CO2 exhaust
The 19mm overflowdrain tube 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.
The 6mm barb labelled as CO2EXHAUST should be plumbed to an outside safe area.
6.11 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.
Compressors, condenser fans and agitator motors should all operate.
When Superchiller ice bank is fully formed (approx. 4 hours) the compressors and condenser
fans will cycle off, but agitator will run continuously (unit has cycled off).
After Superchiller has cycled off, reconnect carbonator and recirculation pumps.
6.12 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.
7. Scheduled Maintenance
Warning
The Chillers must not be cleaned bya water jet.
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 qualityand
system performance at all times please follow cleaning and sanitising procedures for the dispensing
valves/barguns recommended by the valve/bargun manufacturer.

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Checking CO2Supply
Ensure that the contents gauge on the CO2Regulator reads higher than 1400kpa on the dial. Ifit does not,
then the CO2cylinder is empty and must be changed using safe working practices.
Warning
To avoid personal injury and/or propertydamage, always secure
the CO2cylinder 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
CO2cylindercan cause serious personnel injury.
Quarterly
The Superchiller should be connected to a filtered water supply. To ensure optimum drink qualityand
system performance, water filters should be replaced every 3 months.
Half Early
Remove & Clean condenser filters on the Superchiller. Clean condenser with lowpressure
compressed air. When using compressed air always directair from the fan side through condenser.
Remove all dust and foreign particles from refrigeration deck.
Caution
When using compressed air always wear safety glasses.
Check that the water is level with the top of the overflow tube. Add water if necessary.
Open carbonator relief valve to purge CO2 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
flowis less than 5 litres per minute, replacepump.
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 BIBcontainers.
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. Allowsanitiserto 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

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9. Electrical Circuit Diagram

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10. Airflow Diagram

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11. Trouble Shooting
11.1 Refrigeration
TROUBLE
CAUSE
REMEDY
Compressor will not
start.
Power Failure.
High Pressure temperature switch
activated.
LED on Ice Bank Control board
illumined.
Ice bank control faulty contacts not
closing.
Check start mechanism
components.
Thermal overload faulty, open,
circuit compressor seized.
Check for blown fuse, supply cord
pulled out or supply outlet turned off.
Turn chiller “off” at supply socket then
“on” again to reset controller.
Check Ice bank control using
Procedure on page 19. 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 ice bank control
contacts remain
closed).
Dirty condenser.
Restricted air flowover 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
Ice bank control defective
(permanently open circuit).
Low refrigerant charge.
Check agitator motor, seized or
fused.
Check Ice bank control using
procedure on page 19.
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.
Relocate or improve ventilation.
Use larger model, or reduce python
length.
Leak check and repair.
Clean off dust, line, grease, etc.
Remove obstruction orreplace motor.

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11.2 Troubleshooting –Postmix
TROUBLE
CAUSE
REMEDY
Rusty appearance
and/or metallic taste to
water.
Poor water supply - contaminated.
Carbon filter required.
CO2gas or water
escapes from
pressure relief valve.
(Observed
from CO2exhaust)
CO2 pressure too high.
Pump motor will not stop.
Inadequate water supply.
Lines too small or restricted.
Misaligned or damaged motorand
pump facings.
Check CO2 pressure relief valve.
Bleed gas by opening and closing the
relief valve - set to 550 kpa.
Check carbonator control using
procedure on page 20.
Replace control or probe if defective.
If strainer and filter are clear and line
valves are fully open, noisypump
operation indicates insufficient water
supply. Minimum water supply is 70
kpa flowing pressure.
Realign or file flat.
Poor carbonation
(low CO2volume).
Flooded carbonator.
Dirty water supply.
CO2 pressure too low.
Poor quality paper cups.
Dirty or greasy glasses.
Improperly drawn drink.
Check carbonator control using
procedure on page 20.
Replace control or probe if defective.
Check filters.
Check CO2 pressure at regulator.
Should be set between 550 kpa. CO2
inlet check valve stuck, shut or
blocked, repair or replace.
Purchase better quality cups.
Wash all glasses.
Open faucet all the wayand draw
against side of glass or cup.
Pump leaks from shaft
seal.
Worn pump seals.
Replace pump.
Pump will not run.
Power failure or low voltage.
Carb pump hi temp LEDon
icebank control board illuminated
Defective motor.
Locked up pump. Motor has cut out
on overload.
Faulty low pressure switch (if fitted).
Carbonator flooded –filled
completely with water.
Check fuses. Check power supply.
Check for icebank growth into product
coils, defrost and turn off chiller supply
socketand on again to reset
Replace motor.
Replace pump.
Ensure of adequate water supply.
Switch should close above 70 kpa.
Replace if defective.
Check mains water pressure - must be
at least 135 kpa lower than CO2 (install
water pressure regulator if necessary)

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Carbonator empty - faulty
Carbonator probe or control.
Low water supply pressure.
Excessive CO2 Pressure.
Check CO2 regulator.
Check carbonator control using
procedure on page 20. Replace
control or probe if defective.
Check carbonator control
Using procedure on page 20.
Replace control or probe if defective.
A minimum of 70 kpa water supply
pressure is required
Check function & setting of CO2
regulator.
Faucet delivers CO2
gas continuously.
Carbonator pump will notrun due to
power failure or low voltage.
Pump water supply restricted.
Carbonator pump will notrun due to
excessive carbonator CO2
pressure.
Faulty low pressure switch.
Defective Carbonator motor.
Locked up pump. Motor has cut out
on overload.
Carb pump hi temp LED on
icebank control board illuminated
Carbonator empty –faulty control
board or level probe.
Check fuses. Check power supply.
Ensure clean mains water supply tap is
open, or replace filters.
Check Carbonator CO2pressure
regulator for creeping. It should be set
at 550 kpa.
Ensure adequate water supply
(minimum pressure 70 kpa flowing
pressure). Pressure switch is set to
open below 20 kpa and reset at 70
kpa.
Check operation byplugging into
circulation pump socket momentarily.
Replace motor if necessary.
Replace pump.
Check for icebank growth into product
coils, defrost and turn off chiller supply
socketand on again to reset
Check carbonator control using
procedure on page 20.
Replace control or probe if defective.

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12. 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 thatall 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 fullytrained & 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)