lancer DROPIN 1522 Bargun Manual

www.lancerbeverage.com
Installation, Operation &
Service Manual
Dropin 1522 Bargun
With Flexicarb 230V / 50Hz

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
Images are for illustration purposes only as product may vary. No 030b-12 August 2013
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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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Table of contents
1. Introduction........................................................................................................................... 4
2. The Company........................................................................................................................ 4
3. Our Products ........................................................................................................................ 4
4. Product Details ..................................................................................................................... 5
4.1 Product Features .......................................................................................................... 5
4.2 Specifications................................................................................................................ 5
4.3 Models .......................................................................................................................... 6
4.4 Options.......................................................................................................................... 6
5. Safety Information................................................................................................................ 7
5.1 Safety Instructions ........................................................................................................ 7
5.2 Recognise Safety Alert Symbols.................................................................................. 7
5.3 Operating ...................................................................................................................... 7
5.4 Service & Maintenance ................................................................................................ 7
5.5 Carbon Dioxide (CO2).................................................................................................. 8
6. Installation............................................................................................................................. 8
6.1 Receiving ...................................................................................................................... 8
6.2 Unpacking..................................................................................................................... 8
6.3 Selecting a Location ..................................................................................................... 8
6.4 Assembling the FlexiCarb. ........................................................................................... 9
6.5 Installation................................................................................................................... 10
6.6 Connecting Water and Syrups ................................................................................... 12
6.7 Connecting to CO2 supply ......................................................................................... 13
6.8 Plumbing the CO2 exhaust vent ................................................................................ 13
6.9 Electrical Connection.................................................................................................. 13
7. Commissioning .................................................................................................................. 14
8. Scheduled Maintenance .................................................................................................... 14
8.1. Daily ............................................................................................................................ 14
8.2. Quarterly ..................................................................................................................... 14
9. Electrical Circuit Diagram ................................................................................................. 15
10. Assembly Diagrams & Parts List ..................................................................................... 16
10.1. Parts List..................................................................................................................... 16
10.2. Parts List..................................................................................................................... 18
10.3. Flexicarb Backflow Assy............................................................................................. 19
10.4. Flexicarb Pump Assy.................................................................................................. 20
10.5. Flexicarb Carbonator Assy ......................................................................................... 21
10.6. Flexicarb Junction Box ............................................................................................... 23
11. Certificate of Warranty....................................................................................................... 24
12. Manufacturer’s Checklist .................................................................................................. 25

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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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 Australian 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
equipment 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
Hoshizaki 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.

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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4. Product Details
4.1 Product Features
The Hoshizaki Lancer Dropin Bargun series is an Australian designed and manufactured ice cooled
post mix dispensing system with integrated mounts for up to 2 bar guns plus a single carbonator
designed for smaller installations and limited access areas. It is specifically designed to replace
mechanically cooled dispensing equipment in hotels, pubs and other hospitality venues. The bin,
pump, water lines and carbonator tank are fully insulated to maintain drink quality. The unique
design allows the use of standard bar guns and easy drop-through installation. The Hoshizaki
Lancer FlexiCarb is AS5034 compliant.
4.2 Specifications

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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Dimensions
Width 609 mm
Depth 454 mm
Height 710 mm (484 mm Drop In Only)
Cut-out 570mm x 390 mm
Weight
Shipping 64.5 kg
Empty 49.6 kg
Operating 76.6 kg
Ice Capacity 27 kg
Product Coils 6 Syrup + Soda + Water
Voltage 230 Volts
Frequency 50 Hz
Max Current Draw 0.5 Amps
Ambient Temperature 2 - 40°C
Max Water Inlet Pressure 380 kPa
CO2 Gas Pressure 520 kPa – with chilled water inlet (recommended)
Carbonator Capacity 1 litre nominal
Construction Wetted materials: stainless steel, PE, nylon, Santoprene, EPDM.
Drink Capacity 55 ml (1.8 oz) /second continuous soda flow @ 520 kPa CO2
pressure.
NOTE: Hoshizaki Lancer reserves the right to continuous improvement. Always check the
specification plaque that is attached to your device for the latest product information.
4.3 Models
DropIn 1522 BG1 single bar gun dispenser.
DropIn 1522 BG2 dual bar gun dispenser.
4.4 Options
High capacity Turbo Carbonator

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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5. 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.
Review all applicable OSH (Occupational Safety & Health) regulations.
Review all applicable Beverage Dispensing Gas Standards
Install the unit securely and leak check connections.
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 Do not remove, defeat or modify the CO2 relief valve.
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.
5.4 Service & Maintenance
Caution
Installation of all dispensers and service work should only be
performed by fully trained & certified Electrical, Plumbing, & Gas
Technicians.

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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
THE DROP IN MUST BE ISOLATED FROM ELECTRICAL
SUPPLY BEFORE COMMENCING ANY SERVICE OR
MAINTENANCE WORK.
5.5 Carbon Dioxide (CO2)
Warning
The Drop In 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.
If a CO2 gas leak is suspected, immediately ventilate the
contaminated area before attempting to repair the leak.
6. Installation
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
Carefully unpack the Drop In and remove the Flexicarb, drain hose assembly and other contents
from the ice well. Inspect unit for concealed damage and if evident, notify delivering carrier and file a
claim against the carrier.
6.3 Selecting a Location
Warning
Drop Ins with FlexiCarbs are intended for indoor operation only;
do not operate outside unless suitably protected by a
weatherproof enclosure.

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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Caution
The Drop In 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 0oC.
Warning Installation should only be performed by a qualified and
competent technician.
1. The counter must be strong enough to support 80kg with a 570mm x 390mm cut out in it.
2. A 3-pin, Earthed 230V / 10 Amp GPO; potable water supply, regulated CO2 supply and
drainage must be accessible.
3. For best performance the unit should be mounted away from potential heat sources such
as heaters, under-counter refrigeration, dish washers, etc.
6.4 Assembling the FlexiCarb.
The preferred method of mounting the FlexiCarb to the Drop In is provided as an integral
solution. Mounting holes and hardware are provided on the underside of the Drop-In.
1. Ensure there is sufficient clearance (> 710mm) under the counter for the Flexicarb to be
mounted to the drop in.
2. Set the Drop In upside down on the floor or counter to access the underside.
3. Mount the Flexicarb as shown with the screws and washers provided.
4. Locate the Tee fitting on the DropIn and connect the pump inlet as shown. Trim the tube
to suit the installation but make sure to leave excess (>75mm) insulation to insure
adequate coverage of the tube connection and prevent condensation.
5. Locate the Soda Inlet to the Drop In and connect carbonator outlet to it. Repeat Step 4
above trimming the tube but keeping a generous excess of insulation to work over the
connection when finished.
Refer to Label for correct connections
4. Tee to Pump
3. Screw + Washer x 4
5. Carb to
SODA IN

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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If for any reason it is not practical to mount the Flexicarb to the Drop In then:
1. Install the Drop In FIRST. See section 6.5 below.
2. Choose a location as near as possible to the Drop In for the best drink quality.
3. The Flexicarb MUST be mounted in the vertical position for the level sensing device to work
properly.
4. Use any of the mounting holes provided to secure the carbonator in place. We suggest using
6mm diameter or larger screws.
5. Insulate all lines to and from the Drop In.
6.5 Installation
1. Prepare the counter as previously discussed.
2. Apply a sealing compound liberally to the underside of the top flange on the Drop In.
NOTE: IT IS A REGULATORY REQUIREMENT TO SEAL THE FLANGE TO THE TOP OF
THE COUNTER.
3. Set the Drop In in place. The Bargun mounting holes must be facing the operator’s side.
4. Insert Screws into the Bargun Kwick Mount plate as shown.
5. Insert the manifold retainer and inlet fittings as shown.
2. Apply sealant to
underside of flange
Kwick Mount
Plate +
Screws
Inlet Fittings
Retainer
Manifold

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6. Mount the plate to the dropin with the screws provided.
7. Mount the Bar Gun holster and attach the gun to the plate with the wing nuts and thumbscrews
provided.
8. Connect the dropin to the bargun with insulated tubing jumpers with clamps as shown below.
Follow the connection label on the face of the drop in. The Insolex should be approximately
50mm longer than the jumper to assure good coverage after connection. A table on the
following page has recommended lengths.
9. Attach the drain tube to the bottom of the Drop In and connect it to a suitable drain. Wrap the
drain nipple to prevent condensation.

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Recommended Jumper Lengths
PART NUMBER DESCRIPTION
79221203 CLAMP STEPLESS S/S 118
JUMPER 2 TUBE LDP 6MM U/V BLACK X 320MM
JUMPER 3 TUBE LDP 6MM U/V BLACK X 320MM
JUMPER 4 TUBE LDP 6MM U/V BLACK X 320MM
JUMPER 5 TUBE LDP 6MM U/V BLACK X 270MM
JUMPER 6 TUBE LDP 6MM U/V BLACK X 270MM
JUMPER 7 TUBE LDP 6MM U/V BLACK X 380MM
JUMPER 8 TUBE LDP 6MM U/V BLACK X 270MM
JUMPER 9 TUBE LDP 6MM U/V BLACK X 400MM
INSOLEX J2 INSOLEX 10MM ID X 9MM W X 370MM
INSOLEX J3 INSOLEX 10MM ID X 9MM W X 370MM
INSOLEX J4 INSOLEX 10MM ID X 9MM W X 370MM
INSOLEX J5 INSOLEX 10MM ID X 9MM W X 320MM
INSOLEX J6 INSOLEX 10MM ID X 9MM W X 320MM
INSOLEX J7 INSOLEX 10MM ID X 9MM W X 420MM
INSOLEX J8 INSOLEX 10MM ID X 9MM W X 320MM
INSOLEX J9 INSOLEX 10MM ID X 9MM W X 450MM
6.6 Connecting Water and Syrups
1. Using appropriate tubing and fittings connect a 10mm water supply line from the Drop In
WATER IN to a filtered, regulated water supply. Installation in accordance with AS/NZS 3500.1
and AS/NZS 3500.2.
2. Turn on water supply, check for leaks and adjust water regulator to 380 kPa.
3. Open the carbonator relief valve until water flows from CO2 exhaust tube; then close the relief
valve.
4. Connect the syrups to the Drop In according to the connection diagram on the front of the Drop
In.
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 380 kpa.

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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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.
1. Connect CO2supply line from regulator to the 6mm gas inlet on carbonator.
2. Turn on CO2 Supply
3. Adjust CO2Regulator supplying Carbonator to 520 kPa for chilled inlet water.
4. Check for leaks with a mild soap solution and repair as required before continuing.
6.8 Plumbing the CO2 exhaust vent
A 6mm plastc barb is provided to vent any escaped CO2 to a naturally ventilated area in accordance
with AS 5034 gas standards.
6.9 Electrical Connection
1. This unit is connected to the supply via a 10 amp flexible cord fitted with a 3 pin plug.
2. 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 FlexiCarb
must be electrically grounded.
Electrical Connection Must Be Made In Accordance With The
Appropriate Local Codes And Regulations.
Use of an RCD is recommended.
Vent barb

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7. Commissioning
1. Purge all dispensing lines of air by cycling through the flavours on each bar gun and check for leaks.
Repair as required before proceeding.
2. Dispense soda from a valve or Bargun until the pump starts on the FlexiCarb. Close the valve and
allow the FlexiCarb to cycle off to check if the FlexiCarb is operating properly.
3. Fill ice well at least 2/3 full and allow to set 10-15 minutes prior to setting the dispenser flow rates and
brix ratios.
Caution Do not use sub-cooled ice
8. Scheduled Maintenance
Warning The Drop In exterior must not be cleaned by a water jet.
8.1. Daily
Cleaning/Sanitising
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 CO2Supply
Ensure that the contents gauge on the CO2Regulator reads higher than 1400kpa on the dial. If it
does not, then the CO2cylinder is empty and must be changed using safe working practices.
Warning
To avoid personal injury and/or property damage, 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 CO2cylinder can cause serious personnel injury.
8.2. Quarterly
The Drop In should be connected to a filtered water supply. To ensure optimum drink quality and
system performance, water filters should be replaced every 3 months.

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9. Electrical Circuit Diagram
FlexiCarb

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10. Assembly Diagrams & Parts Lists
10.1. Parts List
Ref Part No Description
1 18000041 DROP IN 15 X 22 8 COIL GENERIC
2 23000028 FLEXICARB 1L
3 15000121 KWICK MOUNT KIT FLOW REG WBAR
4 79000402 SCREW 3/16 BSW X ½ PH PHP S/S
5 79000440 WASHER FLAT 10D X 5/16 ID S/S
6 79000422 SCREW S/S 1/4BSW X 1/2” PAN PHILLIPS HEAD
7 81000072 TUBE LDP 10MM U/V BLACK X 35MM LG
8 79120854 CLAMP STEPLESS S/S 157 10MM
9 79000342 SPLICE REDUCING 10/6MM S/S
79000042 TEE S/S 10/10/6 BARB
10 81000010 INSOLEX 12MM ID X 13MM W X 75MM LG
11 81000080 TUBE LDP 6MM U/V BLACK
12 81000009 INSOLEX 10MM ID X 9MM W
13 79221203 CLAMP STEPLESS S/S 118
14 15000111 INPUT FITTING STRAIGHT WUNDERBAR
15000138 ORING INLET / INTERCON WUNDERBAR

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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10.2. Parts list
Ref Description
1 PANEL MOUNTING FLEXICARB 1L
2 FLEXICARB 1 LITRE – PUMP ASSY
3 FLEXICARB 1 LITRE – CARBONATOR ASSY
4 FLEXICARB 1 LITRE – JBOX NON-ILL

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10.3. Flexicarb Backflow Assy
Ref HL Part No Description
1 79000683 BFV WATTS 9DB (AUS COMPLIANT)
2 79117818 TAIL S/S 10MM BARB 3/8 NUT
3 79158134 SEAL NYLON 3/8 FLARE
4 79000206 NUT SWIVEL 3/8 FL CHROME
5 66000031 DIRECTOR BR 1/8NPT X 6MM BARB
6 79121506 TEE NYLON 6/6/6MM BARB T14
7 81000161 TUBE LDP 6MM U/V BLACK
8 79221203 CLAMP STEPLESS S/S 118
9 81000018 INSOLEX 32 ID X 13 W
10 81000072 TUBE LDP 10MM U/V BLACK
11 79120854 CLAMP STEPLESS S/S 157 10MM
12 79000107 CAP BLANKING PLASTIC ½
13 81000010 INSOLEX 12 ID X 13W

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Hoshizaki Lancer reserve the right to change specifications without notice. Part No 68000014
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10.4. Flexicarb Pump Assy
Ref HL Part No Description
1 24000039 PUMP TRIPLEX MODEL R3811503B
23000100 PUMP KIT FLEXICARB
2 79000338 FITTING S/S 3/8 FLARE X 3/8 NPT
3 81000502-1 INSULATION KIT FLEXICARB – PUMP WRAPPER
4 81000502-2 INSULATION KIT FLEXICARB – PUMP BOTTOM
5 79158134 SEAL NYLON 3/8 FLARE
6 79000334 ELBOW SWIVEL 10MM X 3/8 FL FEM
7 81000072 TUBE LDP 10MM U/V BLACK
9 79120854 CLAMP STEPLESS S/S 157 10MM
10 81000010 INSOLEX 12 ID X 13W