Lancer 82-0109-01 Service Manual

INSTALLATION AND SERVICE MANUAL

FOR

LANCER MAXI SYRUP PUMP

ART NUMBER DESCRIPTION

82-0109/01 (FAMILY) LANCER MAXI SYRUP PUMP

For use with Disposable Bag-in-Box (BIB) Package

This manual, reactivated and revised by Lancer in June 1997,

supersedes Installation Manual 28-0030, dated 08/07/90.

REV. 06/20/97 P.N. 28-0030/01

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 – 210-524-9567 / 210-310-7245 • EUROPE – 32-2-755-2399 • PACIFIC – 61-8-8268-1978 •

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.

ABLE OF CONTENTS

1. GENERAL DESCRIPTION ..........................................................................................................................1

1.1 GENERAL INFORMATION ................................................................................................................1

1.2 SYRUP INLET FITTINGS ..................................................................................................................1

1.3 GAS INLET FITTING..........................................................................................................................1

2 PRINCIPLES OF OPERATION ...................................................................................................................1

2. INSTALLATION ...........................................................................................................................................2

2.1 RECEIVING AND INSPECTION ........................................................................................................2

2.2 LOCATION OF PUMP ........................................................................................................................2

2.3 CONNECTING LINES TO UNIT ........................................................................................................2

2.4 PREPARING UNIT FOR OPERATION ..............................................................................................3

2.5 SOLD-OUT DEVICE (MAY BE OPTIONAL ON SOME MODELS)....................................................3

3. SERVICE AND MAINTENANCE .................................................................................................................3

3.1 LUBRICATION....................................................................................................................................3

3.2 ADJUSTMENTS.................................................................................................................................4

3.3 PRIMING THE PUMP AT THE CORRECT PRESSURE ...................................................................4

3.4 CLEANING AND SANITIZING ...........................................................................................................4

3.5 REPLENISHING SYRUP SUPPLY ....................................................................................................5

3.6 WINTERIZING PUMP ........................................................................................................................6

4. TROUBLESHOOTING.................................................................................................................................6

4.1 PUMP WILL NOT CYCLE ..................................................................................................................6

4.2 PUMP WILL NOT STOP (WHEN DISPENSING VALVE IS CLOSED)..............................................6

4.3 PUMP WILL NOT PRIME...................................................................................................................7

4.1 PUMP WILL NOT DEVELOP PRESSURE ........................................................................................7

5. ILLUSTRATIONS AND PARTS LISTINGS .................................................................................................8

5.1 SYRUP PUMP ASSEMBLY (PN 82-0109/01) ....................................................................................8

5.2 REVERSING VALVE ASSEMBLY (PN 17-0406/01) ..........................................................................9

5.3 SOLD OUT VALVE (PN 17-0428) ....................................................................................................10

5.4 BRACKETS ......................................................................................................................................11

5.5 SYRUP INLET AND OUTLET FITTINGS.........................................................................................11

5.6 INLET GAS FITTINGS .....................................................................................................................11

1. GENERAL DESCRIPTION

1.1 GENERAL INFORMATION

A. The Lancer Syrup Pump is a pneumatically operated, double acting, diaphragm pump. It is

designed to pump up to 1.5 ounces (45 ml) of syrup per second at up to 75 PSI (5.28 kg/cm2) line pressure. Either CO2 gas or compressed air can be used to drive the pump. One pump is required for each product dispensed.

NOTE

If compressed air is used, the compressed air must be dry and oil free.

B. Dimensions of the pump are 7.3 inches (18.6 cm) width x 4.5 inches (11.5 cm) depth x

6.0 inches (15.24 cm) height.

1.2 SYRUP INLET FITTINGS

A. Syrup inlet fittings are 3/8 inch (0.95 cm) barbed hose connector. Syrup outlet fittings are either

1/4 inch (0.635 cm) or 3/8 inch (0.95 cm) barbed connectors, depending on the tubing used.

1.3 GAS INLET FITTING

A. Gas inlet fitting is a 1/4 inch (0.635 cm) barbed hose connector.

2. PRINCIPLES OF OPERATION

2.1 The following describes the Lancer syrup pump theory of operation:

A. When the system demands syrup for dispensing, gas pressure enters the reversing Valve and

is directed to the Gas Chamber on the right, while the Gas Chamber on the left is allowed to exhaust gas. This causes the Diaphragm Assembly to move to the right (see Figure 1).

B. As the Diaphragm Assembly moves to the right, syrup is forced out of right side Chamber

through Check Valve and Syrup Outlet while syrup is sucked into the left side Chamber through the Inlet Check Valve.

C. When the Diaphragm Assembly reaches the end of its stroke, the reversing Valve switches and

directs gas pressure to the left Gas Chamber while the right Gas chamber is allowed to exhaust gas. This causes the Diaphragm Assembly to move to the left (see Figure 2).

D. As the Diaphragm Assembly moves to the left, syrup is forced out of the left side Chamber

through Check Valve and Pump Outlet while syrup is sucked into right side Chamber through Inlet Check Valve. The syrup pump cycle will be repeated as many times as necessary to fulfill syrup needs of Dispenser [approximately five (5) ounces (147.9 ml) of syrup are pumped per cycle].

E. The Syrup Pump will pull syrup from a non-pressurized package. The Pump will normally

self-prime up to ten (10) feet (3.0 m).

Figure 1

Figure 2

2. INSTALLATION

2.1 RECEIVING AND INSPECTION

A. Each Pump is tested and thoroughly inspected before shipment. At the time of shipment, the

carrier accepts the Pump and any claim for damages must be made with the carrier. Upon receiving Dispensers 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.

B. After Pump has been unpacked, remove shipping tape and other packing material. Check for

obvious damage and follow installation instructions. If shipping damage is evident, notify delivering carrier and file claim against the same.

2.2 LOCATION OF PUMP

ARNING

CARBON DIOXIDE (CO2) IS A HEAVIER THAN AIR, COLORLESS, NONCOMBUSTIBLE GAS WITH A FAINTLY PUNGENT ODOR. SINCE HIGH PERCENTAGES OF CO2 MAY DISPLACE OXYGEN IN THE BLOOD, PROLONGED EXPOSURE TO CO2 MAY BE HARMFUL.

A. Syrup Pumps that are operated by CO

2 gas should be installed in well ventilated areas.

B. If a Syrup Pump is installed in a basement, it should be operated on compressed air. CO2 gas

may be used for a basement installation, provided the area has a positive ventilation system (exhaust fans) capable of changing the room air every 20 minutes (minimum) or a vented Pump is used.

C. It is best to locate the Syrup Pump in a place near the syrup supply to keep the line from the

package to the Pump Inlet as short as possible. A maximum recommended Syrup Inlet Line is 12 feet (3.66 m) of 0.375 inch (0.95 cm), or larger, ID tubing must be used.

D. The Syrup Pump must be installed above the syrup package, but no more than 10 feet (3.0 m)

higher than the syrup package.

E. The Syrup Pump should be mounted on a wall or other support using the Bracket provided on

the Pump Body. Mounting should be horizontal with the Syrup Outlet Line as the top as shown in Figure 3. The Pump is identified showing IN and OUT ports and direction of mounting.

F. Used enclosed Screws provided for mounting the Syrup Pump Bracket.

2.3 CONNECTING LINES TO UNIT

A Syrup Inlet Line, a Syrup Outlet Line and a Gas line must be connected to the Syrup Pump for

operation (see Figure 3).

B. Attach 0.375 inch (0.95 cm) ID by 0.630 inch (1.6 cm) OD, approved, vinyl beverage tubing line

to the Inlet Fitting on the Pump and attach a Bag-in-Box (BIB) Quick Disconnect Coupling to the other end of the tubing.

Diagram of Pressure Drop-BIB Syrup Container to Valve

Figure 3

50 FEET (15 M) 0.265 INCH I.D. BEVERAGE TUBING

BIB

SYRUP

CONTAINER

FIRST 10 FEET (3 M) OF TUBING 35 PSI (2.5 KG/CM ) PRESSURE FIRST 40 FEET (12 M) OF TUBING 12 PSI (0.85 KG/CM ) PRESSURE

47 PSI (3.3 KG/CM MINIMUM REQUIRED CO OR AIR PRESSURE

VALVE

C. Attach 0.265 inch (0.635 cm) ID braided beverage tubing from the Outlet Fitting on the Pump to

the Dispenser. Where a long run to the Dispenser is encountered, use 0.375 inch (0.95 cm) ID braided beverage tubing.

D. Attach 0.265 inch (0.635 cm) ID braided beverage tubing from the Gas Regulator to the Pump

Inlet Gas Fitting.

E. If Pump is operated by compressed air, the supply line from the air compressor should include

a five (5) micron air filter. If the compressed air contains a substantial amount of water, a drier should be used to remove the water. Excess water in the air supply will wash the lubricant out of the Reversing Air Valve and cause excessive wear of the O-Rings, and thereby shorten the life of the Pump.

2.4 PREPARING UNIT FOR OPERATION

CAUTION

DO NOT OPERATE THE PUMP WITHOUT SYRUP SINCE THIS COULD DAMAGE THE DIAPHRAGM OVER A PERIOD OF TIME. THE GAS LINE TO THE PUMP MUST BE CONTROLLED BY A LOW PRESSURE CO2 REGULATOR CAPABLE OF BEING SET WITH UP TO 75 PSI (5.28 KG/CM2) OUTLET PRESSURE.

A. After all lines and a full BIB Package have been connected to the Pump, turn on the Gas

Pressure and adjust the Regulator Pressure between 35 and 75 PSI (2.5 kg/cm

and

5.28 kg/cm

NOTE

Pumps for sugar free products can be operated at the same pressure as other products since there is no contact between the syrup and gas.

B. Bleed off air in the system by opening Dispensing Valve until flow is steady and full. After air is

removed, no bubbles should be seen in Inlet and Outlet Lines to the Pump. If bubbles appear, check for leak(s) in the Inlet Line.

C. The minimum pressure needed for an installation is 35 pounds (2.5 kg/cm2) for packages

within I0 feet (3 m) of the Dispenser. For packages located more than 10 feet (3 m) from the Dispenser, add 3 pounds (0.21 kg/cm

) for each additional 10 feet (3 m).

CAUTION

GAS PRESSURE TO PUMP MUST NOT EXCEED 75 PSI (5.28 KG/CM2).

NOTE

Examples below are for 0.265 inch ID beverage tubing. The pressure drop for 0.375 inch ID beverage tubing is approximately one-third (1/3) of that for 0.265 inch ID beverage tubing.

D. After removing air and setting Regulator for correct pressure, set the proper syrup/water ratio or

brix for the product.

E. Pump will now operate automatically when drinks are dispensed. If pump continues to cycle

after dispensing is stopped, bleed system to remove air and check for syrup and/or air leaks.

2.5 SOLD-OUT DEVICE (MAY BE OPTIONAL ON SOME MODELS)

A. An optional Sold-Out Device can be used to automatically shut off the Syrup Pump when the

Package(s) is empty. This stops the operation of the Pump and the exhaust of gas until a new syrup package is connected to the Pump.

B. The Lancer Sold-Out device measures syrup vacuum in the Pump Inlet Line. When the Syrup

Package is empty, the Pump increases vacuum causing the device to shut off the gas pressure to stop the Pump. The Lancer Sold-Out automatically resets, after new Syrup Packages are connected.

3. SERVICE AND MAINTENANCE

3.1 LUBRICATION

PUMPS ARE FACTORY LUBRICATED. FIELD LUBRICATION IS NOT

NECESSARY.

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