Lancer 800 CED Service Manual

INSTALLATION AND SERVICE MANUAL

LANCER SERIES 800

COUNTER ELECTRIC DISPENSER

100VAC/50-60HZ SERVICE

REV: 02/26/99 P.N. 28–0421

This Manual is an initial issue.

USA Patent Number: 5,499,744

Manufactured for

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 •

INTENTIONALLY LEFT BLANK

TABLE OF CONTENTS

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

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

DISPENSER INSTALLATION HIGHLIGHTS....................................................................................................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 CONNECTING THE DRAIN...............................................................................................................1

1.7 FILLING UNIT WITH WATER ............................................................................................................2

1.8 CONNECTING TO ELECTRICAL POWER .......................................................................................2

1.9 CONNECTING TO WATER SUPPLY.................................................................................................2

1.10 CONNECTING THE CO

2 SUPPLY ....................................................................................................2

1.11 CONNECTING TO REMOTE BIB SYRUP PUMPS...........................................................................3

1.12 CONNECTING TO REMOTE PRESSURIZED SYRUP SUPPLY......................................................3

1.13 PURGING THE CARBONATION SYSTEM .......................................................................................3

1.14 VOLUMETRIC VALVE ADJUSTMENT...............................................................................................3

1.15 PORTION CONTROL ........................................................................................................................5

2. SCHEDULED MAINTENANCE ...................................................................................................................6

2.1 DISPENSER.......................................................................................................................................6

2.2 VOLUMETRIC VALVE CLEANING AND SANITIZING PROCEDURES ............................................7

3. DISPENSER CLEANING AND SANITIZING ..............................................................................................8

3.1 AMBIENT PROCESS.........................................................................................................................8

3.2 ALTERNATE CLEANING AND SANITIZING AGENTS......................................................................9

4. TROUBLESHOOTING.................................................................................................................................9

4.1 WATER LEAKAGE AROUND NOZZLE .............................................................................................9

4.2 MISCELLANEOUS LEAKAGE ...........................................................................................................9

4.3 WATER LEAKAGE - VALVE...............................................................................................................9

4.4 SYRUP LEAKAGE - VALVE...............................................................................................................9

4.5 INSUFFICIENT WATER FLOW........................................................................................................10

4.6 INSUFFICIENT SYRUP FLOW........................................................................................................10

4.7 DRINK RATIO INCORRECT (WEAK OR STRONG) - VALVE ........................................................10

4.8 VALVE POURS ERRATICALLY .......................................................................................................10

4.9 NO PRODUCT DISPENSED WHEN VALVE ACTIVATED...............................................................11

4.10 WATER ONLY DISPENSED; NO SYRUP; OR SYRUP ONLY DISPENSED; NO WATER .............11

4.11 NO WATER JUST SYRUP...............................................................................................................12

4.12 VALVE WILL NOT SHUT OFF .........................................................................................................13

4.13 SYRUP ONLY DISPENSED. NO WATER, BUT CO

2 GAS DISPENSED WITH SYRUP

(VALVE CYCLES ON AND OFF QUICKLY).....................................................................................13

4.14 EXCESSIVE FOAMING ...................................................................................................................13

4.15 WATER CONTINUALLY OVERFLOWS FROM WATER BATH INTO DRIP TRAY .........................13

4.16 COMPRESSOR STARTS AND CONTINUES TO RUN UNTIL FREEZE UP AND

WILL NOT CUT OFF........................................................................................................................14

4.17 WARM DRINKS................................................................................................................................14

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

DOES NOT RUN AND NO ICE BANK.............................................................................................14

4.19 COMPRESSOR DOES NOT START (NO HUM), BUT CONDENSER FAN MOTOR RUNS..........14

4.20 COMPRESSOR DOES NOT START BUT HUMS ...........................................................................14

4.21 COMPRESSOR STARTS BUT DOES NOT SWITCH OFF START WINDING ...............................15

4.22 COMPRESSOR STARTS AND RUNS A SHORT TIME BUT SHUTS OFF ON OVERLOAD.........15

4.23 COMPRESSOR RUNS NORMALLY, BUT WATER LINE IS FROZEN............................................15

4.24 COMPRESSOR CYCLES ON AND OFF FREQUENTLY DURING THE

INITIAL PULLDOWN AND/OR NORMAL OPERATIONS ................................................................15

4.25 CIRCUIT BREAKER POPPING .......................................................................................................15

4.26 BIB PUMP DOES NOT OPERATE WHEN DISPENSING VALVE IS OPENED ..............................16

4.27 BIB PUMP OPERATED BUT NO FLOW .........................................................................................16

4.28 BIB PUMP CONTINUES TO OPERATE WHEN BAG IS EMPTY ...................................................16

4.29 BIB PUMP FAILS TO RESTART AFTER BAG REPLACEMENT ....................................................16

4.30 BIB PUMP FAILS TO STOP WHEN DISPENSING VALVE IS CLOSED.........................................16

4.31 NO PRODUCT OUT LIGHT.............................................................................................................16

4.32 LOW OR NO CARBONATION .........................................................................................................16

5. ILLUSTRATIONS, PARTS LISTINGS AND WIRING DIAGRAMS ...........................................................18

5.1 800 CED - CABINET ASSEMBLY...............................................................................................18-19

5.2 800 CED - REFRIGERATION DECK ASSEMBLY ......................................................................20-21

5.2 800 CED - CARBONATOR/WATER/SYRUP LINE ASSEMBLIES .............................................22-23

5.3 800 CED - CONTROL HOUSING ASSEMBLY...........................................................................24-25

5.5 800 CED- WIRING DIAGRAM ........................................................................................................26

TABLE OF CONTENTS (CONTINUED)

iii

SPECIFICATIONS

DIMENSION

Width 355.6 mm (14 inches) Depth 628.7 mm (24 3/4 inches) Height (without feet) 689.0 mm (27 1/8 inches)

WEIGHT

Shipping 70.3 kg (155 pounds) Empty 66.2 kg (146 pounds) Operating 100.0 kg (220 pounds)

CARBON DIOXIDE (CO

2) REQUIREMENTS

Minimum pressure of 70 PSIG (4.92 kg/cm

, 4.83 BAR)

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

ICE BANK WEIGHT

6.8 to 7.7 kg (15 to 17 pounds)

DRINK CAPACITY

164 - 355 ml (12 ounce) drinks under 4.4

C (40oF) at two (2) drinks per minute with 23.9oC (75oF)

ambient inlet water, and syrup.

DISPENSER INSTALLATION HIGHLIGHTS

Listed below are nine (9) 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 (refer to 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 five (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 five (5) minute delay before the compressor starts.

5. The unit is equipped with a protective timer for the carbonator pump motor, set for three (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 five (5) minute compressor delay would be in effect.

6. Supply Water Pressure: Minimum - 10 PSIG (0.70 kg/cm2); Maximum - 70 PSIG (4.92 kg/cm2).

7. CO2 Pressure: Recommend nominal pressure 70 PSIG (4.92 kg/cm2, 4.83 BAR). Important: Internal syrup pumps may not work at pressures less than 60 PSIG and the carbonator tank might overfill during plain water drink dispensing. CO2 pressure over 80 PSIG may result in damage or leakage from the syrup pump system or may cause excessive foam in the drink.

8. Programmer connection to the Volumetric Valves should only be done with the valve power wire set connected to the non boost-pump position on the connector circuit board behind the water pump motor.

9. Valve Adjustment: Make sure drink temperature is below 4.4°C (40°F) before adjusting brix.

NOTES

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.

1. INSTALLATION

1.1 RECEIVING

Each unit is completely tested under operating conditions and thoroughly inspected before shipment. At the time of shipment, the carrier accepts the unit and any claim for damage must be made with the carrier. Upon receiving units from the delivering carrier, carefully inspect carton for visible indication of damage. If damage exists, have carrier note same on bill of lading and file claim with carrier.

1.2 UNPACKING

A. Cut plastic banding 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 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 the unit secured to the plywood 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 COUNTER LOCATION

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

requirements as scheduled on the SPECIFICATION page.

B. Counter location must be able to support a minimum of 113.6 kg (250 pounds).

CAUTION

FAILURE TO MAINTAIN SPECIFIED CLEARANCE WILL CAUSE THE COMPRESSOR TO OVERHEAT AND WILL RESULT IN COMPRESSOR FAILURE.

C. Condenser air is drawn in the back of the unit and discharged out the top of the unit.

A minimum of 203 mm [eight (8) inches] clearance must be maintained over the top of the unit and a minimum of 152 mm [six (6) inches] clearance must be maintained behind the unit to ensure proper air circulation. Failure to do so will result in compressor failure.

1.5 MOUNTING THE DISPENSER

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

18 mm feet.

B. When the dispenser is to be permanently bolted to the counter top, seal dispenser base to

counter top with a silicone sealant which provides a smooth and easily cleanable bond to the counter.

C. For feet mounting, use the threaded mount feet that are packaged with this manual.

1.6 CONNECTING THE DRAIN

A. Remove cup rest. Lift splash plate up and pull out and down on the bottom to remove. B. Remove the drip tray from the unit and connect the drain tube to the drain fitting located on the

back.

C. Route the drain tube to a suitable drain and replace the unit’s drip tray.

1.7 FILLING UNIT WITH WATER

A. Remove the bonnet from the unit. B. Remove the plastic plug (located on the front of the unit’s compressor deck) from the unit’s fill

hole.

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.

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.

NOTE

Do NOT use distilled water to fill water bath.

D. Replace the plug.

1.8 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 TWO PRONG PLUG WITH SEPARATE GROUND LEAD. FASTEN THE GROUND LEAD TERMINAL TO THE OUTLET PLATE CENTER SCREW OR OTHER VERIFIABLE GROUND.

CAUTION

FAILURE TO DISCONNECT THE MOTOR POWER SUPPLY WILL DAMAGE THE CARBONATOR MOTOR AND PUMP AND VOID THE WARRANTY.

A. 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 five (5) minute delay has elapsed.

1.9 CONNECTING TO WATER SUPPLY

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

the inlet water regulator using a flare seal washer (PN 05-0017). Use a back-up wrench to prevent damage to the regulator.

D. Leave 300 mm [12 inches] of extra tubing length below the counter for servicing and moving the

dispenser.

E. Turn on water supply and check for leaks.

1.10 CONNECTING THE CO

2 SUPPLY

A. Connect high pressure CO

2 regulator assembly to CO2 cylinder. Use a new CO2 tank washer if

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

B. Place CO

2 cylinder 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 300 mm (12 inches) of extra tubing length below the counter for servicing and moving the

dispenser.

CAUTION

DO NOT TURN ON THE CO

SUPPLY AT THIS TIME.

G. Connect directly to the carbonator CO

2 inlet check valve.

1.11 CONNECTING TO REMOTE BIB SYRUP PUMPS

A. Install 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.

1.12 CONNECTING TO REMOTE PRESSURIZED SYRUP SUPPLY

A. Place the five (5) gallon (Figal) syrup containers and the CO

2 cylinder and regulator 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 Figal syrup containers and attach them to the appropriate

syrup flavor.

D. Attach a CO2 supply line from each of the Figal syrup containers to the low pressure regulator

and pressurize the containers.

1.13 PURGING THE CARBONATION SYSTEM

A. The relief valve for the built-in carbonator is located on the left 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 CO

2 regulator pressure adjusting screw all the way. Open the CO2 cylinder

handle slowly. Turn the CO2 pressure regulator up slowly to 75 PSIG (5.1 bar).

D. Open a dispensing valve 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 CO

2 connections for leaks and repair if necessary.

NOTE

To check for CO2 leaks, close the valve on the CO2 cylinder and observe if the pressure to the system drops with the cylinder valve closed for five (5) minutes. Open the cylinder valve after check has been accomplished.

G. Replace the unit’s bonnet, splash plate and cup rest.

1.14 VOLUMETRIC VALVE ADJUSTMENT

CAUTION:

WHEN USING THE HAND HELD PROGRAMMER, FIRST CONNECT VALVE POWER CONNECTION TO NON-BOOST POSITION ON THE VALVE CONNECTION CIRCUIT BOARD LOCATED BEHIND THE WATER PUMP MOTOR. THIS PRECAUTION PROTECTS ELECTRICAL RELAYS WITHIN THE DISPENSER’S CONTROL SYSTEM FROM POSSIBLE DAMAGE WHILE PROGRAMMING.

A. Valve Specifications

1. Finished Drink Flow Rates

88.7 ml/sec (3.0 ounces per second)

66.6 ml/sec (2.25 ounces per second)

44.4 ml/sec (1.5 ounces per second), as shipped

2. Flowing Pressure Requirements

MINIMUM

MAXIMUM

Water 40 psig (2.8 kg/cm2) 110 psig (7.7 kg/cm2) Syrup (Sugar) 20 psig (1.4 kg/cm

) 70 psig (4.9 kg/cm2)

Syrup (Diet) 10 psig (0.7 kg/cm2) 70 psig (4.9 kg/cm2)

3. Electrical Requirement

24 VAC, 50/60Hz

B. Programmer Operating Procedures

1. Connecting a. Remove the ID panel from the front of the valve.

b. Insert the programmer's 10-pin connector into the ID Panel plug on the front of the

circuit board.

c. When properly connected, the programmer will run a self diagnostic test. The display

will show all "8"s with the decimal points lighted. After three (3) seconds, the display indicates the setting of the dip switches.

d. If the programmer does not run its diagnostic test properly, disconnect it and try

plugging it in again. If the programmer still fails, replace the programmer.

2. Functions

Read Memory:

Press this button to read and display the current settings programmed into the valve memory (i.e., S/W revision, ratio, and carb/non carb settings).

Read Dip Switches:

Press this button to read the dip switch settings (applies only to valves manufactured before July 1997).

NOTE

Dip switches were used on some field test valves (refer to 28-0301, 12/20/95).

Write Memory:

Press this button to write the programmer’s displayed ratio and carbonation settings into the valve’s memory.

Timed 5 Second Water:

Press this button to pour water for five (5) seconds. The programmer will display the ratio, the counts from the flowmeter, the flow rate in oz/sec, and the flow rate in ml/sec.

Timed 5 Second Pour:

Press this button to dispense a five (5) second pour of water and syrup for ratio testing. When complete, the programmer displays the ratio, carbonation settings, and total Flowmeter counts.

Syrup Purge:

Press and release to dispense a six (6) second syrup purge. Continue holding to purge syrup from system.

Ratio + (Plus):

Pressing this button will increase the ratio number on the display.

Hand Held Programmer

Figure 1

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