Lancer 82-2049E Installation Manual

INSTALLATION AND SERVICE

MANUAL

FOR

LANCER SERIES 2500

DISPENSERS

REV: 10/06/04 P.N. 28–0089/04

This Manual supersedes Installation and Service Manual, 28-0089/03, dated 01/15/99,

and is being published ONLY on the Lancer Web Site

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..............................................................................................................................................ii

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

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

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

1.3 SELECTING A COUNTER LOCATION..............................................................................................1

1.4 CONNECTING THE DRAIN...............................................................................................................1

1.5 FILLING UNIT WITH WATER ............................................................................................................1

1.6 CONNECTING TO ELECTRICAL POWER .......................................................................................2

1.7 CONNECTING TO PLAIN WATER SUPPLY.....................................................................................2

1.8 CONNECTING TO CARBONATED WATER SUPPLY.......................................................................3

1.9 CONNECTING TO SYRUP SUPPLY.................................................................................................3

1.10 ADJUSTING WATER FLOW..............................................................................................................3

1.11 ADJUSTING WATER TO SYRUP (RATIO) BRIX ..............................................................................3

2. SCHEDULED MAINTENANCE

2.1 DAILY .................................................................................................................................................4

2.2 WEEKLY.............................................................................................................................................4

2.3 MONTHLY..........................................................................................................................................4

2.4 EVERY SIX MONTHS........................................................................................................................4

2.5 YEARLY..............................................................................................................................................4

3. DISPENSER CLEANING AND SANITIZING..............................................................................................4

3.1 AMBIENT PROCESS.........................................................................................................................4

3.2 VALVES..............................................................................................................................................4

4. TROUBLESHOOTING.................................................................................................................................5

4.1 WATER LEAKAGE AROUND NOZZLE .............................................................................................5

4.2 LEAKAGE BETWEEN UPPER AND LOWER VALVE BODIES.........................................................5

4.3 MISCELLANEOUS LEAKAGE...........................................................................................................5

4.4 INSUFFICIENT WATER FLOW..........................................................................................................5

4.5 INSUFFICIENT SYRUP FLOW..........................................................................................................5

4.6 ERRATIC RATIO ................................................................................................................................5

4.7 NO PRODUCT DISPENSED.............................................................................................................5

4.8 WATER ONLY DISPENSED; NO SYRUP; OR SYRUP ONLY DISPENSED, NO WATER...............6

4.9 VALVE WILL NOT SHUT OFF...........................................................................................................6

4.10 EXCESSIVE FOAMING.....................................................................................................................6

4.11 COMPRESSOR DOES NOT START (NO HUM), BUT CONDENSER FAN MOTOR RUNS............6

4.12 COMPRESSOR STARTS AND CONTINUES TO RUN UNTIL FREEZE UP AND

WILL NOT CUT OFF..........................................................................................................................6

4.13 COMPRESSOR DOES NOT START BUT HUMS .............................................................................6

4.14 COMPRESSOR STARTS BUT DOES NOT SWITCH OFF START WINDING (WILL RUN FOR ONLY A FEW SECONDS BEFORE INTERNAL OVERLOAD SWITCHES

COMPRESSOR OFF)........................................................................................................................6

4.15 COMPRESSOR STARTS AND RUNS A SHORT TIME BUT SHUTS OFF ON OVERLOAD...........6

4.16 COMPRESSOR AND CONDENSER FAN MOTOR WILL NOT START AFTER

FIVE (5) MINUTE POWER OFF DELAY (LANCER EIBC, EXPORT ONLY).....................................7

4.17 COMPRESSOR AND CONDENSER FAN MOTOR WILL NOT START AFTER

FIVE (5) MINUTE POWER OFF DELAY (LANCER EIBC, USAONLY) ............................................7

4.18 WARM DRINKS ................................................................................................................................7

5. ILLUSTRATIONS, PARTS LISTS, AND WIRING DIAGRAMS ..................................................................8

5.1 2500 REFRIGERATION DECK ASSEMBLY, R-134A, LANCER ELECTRONIC ICE

BANK CONTROL (EIBC), USA ONLY, PN 82-2660 (MANUFACTURED FROM 01/99)................8-9

5.2 2500 REFRIGERATION DECK ASSEMBLY, WITH ELECTRONIC ICE BANK CONTROL (EIBC), R-134A; PN 82-2049E, 230V/50HZ; PN 82-2103E, 115V/60HZ;

PN 82-2098E, 240V/60HZ...........................................................................................................10-11

5.3 2500 CONTROL HOUSING ASSEMBLY, ELECTRONIC ICE BANK CONTROL(EIBC),

INTERNATIONAL ONLY.............................................................................................................12-13

5.4 2500 CABINET ASSEMBLY........................................................................................................14-15

5.5 2500 WIRING DIAGRAM AND HOUSING CONNECTIONS, LANCER ELECTRONIC

ICE BANK CONTROL USA ONLY...................................................................................................16

5.6 2500 WIRING DIAGRAM, ELECTRONIC ICE BANK CONTROL (EIBC)

INTERNATIONAL ONLY ..................................................................................................................17

5.7 2500 INSTALLATION KITS AND OPTIONALACCESSORIES........................................................18

SPECIFICATIONS

DIMENSIONS

Width 26 inches (660 mm) Depth 27 1/8 inches (690 mm) Height (without legs) 31 1/4 inches (790 mm)

WEIGHT

Shipping 257 pounds (117 kg) Empty 209 pounds (95 kg) Operating 376 pounds (171 kg)

ICE BANK WEIGHT 50 pounds (23 kg) Nominal WATER BATH CAPACITY 21 gallons (79 Liters) COMPRESSOR 3/4 HP Tecumseh, 115V/60Hz AGITATOR MOTOR 25 WATT, 115V CONDENSER MOTOR 35 WATT, 115V ICE BANK CONTROL Lancer Electronic Ice Bank Control (EIBC) TRANSFORMER Basler, 115V (Primary)/24V (Secondary) OPTIONAL 230V/50Hz and 240V/60 Hz systems available DRINK CAPACITY

538 - 12 ounce drinks under 40

F (4.4oC) at four (4) drinks per minute with 75oF (23.9oC) ambient inlet

water and syrup.

21 7/8 " 560 mm

31 1/4 "

790 mm

11 1/8 "

280 mm

3 1/2 "

90 mm

26 "

660 mm

27 1/8 "

690 mm

iii

NOTES

1. INSTALLATION

1.1 RECEIVING

Each unit is completely tested under operating conditions and thoroughly inspected before shipment. At time of shipment, the carrier accept s 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 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 band and remove. B. Remove top portion of carton by lifting up. C. Remove top inner carton pad and corners. D. Lift Unit up by plywood shipping base and remove lower portion of carton. E. Inspect unit for concealed damage and if evident, notify delivering carrier and file a claim against

same.

F. 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.

G. 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.

H. Remove accessory kit of loose parts from drip tray.

1.3 SELECTING A COUNTER LOCATION

The dispenser is designed to sit on a flat, supported surface capable of supporting a minimum weight of 400 pounds (182 kg). It may be either counter or leg mounted. Atemplate is furnished to cut and/or drill the necessary holes for mounting. 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.

NOTE

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

WARNING

FAILURE T O MAINTAIN THE PROPER AIR CLEARANCE WILL CAUSE THE COMPRESSOR TO OVERHEAT AND WILL RESULT IN PREMATURE COMPRESSOR FAILURE.

Locate dispenser to allow approximately 15 inches (380 mm) of unobstructed space above and six (6) inches (160 mm) behind the unit for proper air circulation. Air is drawn in through the back grill and exhausted out of the top grill.

1.4 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

bottom. Secure drain tube with clamp provided in accessory kit.

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

1.5 FILLING UNIT WITH WATER

A. Remove the bonnet from the unit. B. Remove the yellow plastic plug from the 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. Use bottled water where a water problem exists.

D. Replace the yellow plug.

1.6 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.

DO NOT USE EXTENSION CORDS WITH THIS UNIT. DO NOT “GANG” TOGETHER WITH OTHER ELECTRICAL DEVICES ON THE SAME OUTLET.

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

into electrical outlet unless unit electrical configuration, located on serial plate, agrees with local available power supply.

B. 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. Approximately three (3) hours are required to form a full ice bank.

NOTE

Units equipped with an electronic ice bank control contain a five (5) minute delay. Compressor and fan motor will not begin running until five (5) minutes after the unit is energized.

1.7 CONNECTING TO PLAIN WATER SUPPLY

See Figure 1. If unit has no plain water circuits, proceed to Section 1.8.

A. Valves 4, 5, and 6 through 8 (on 8 valve units) and valves 3, 4, and 5 (on 6 valve units) have

optional plain water or carbonated water capabilities. Using Figure 1, determine which valves are to be plumbed with plain water.

B. Using proper beverage tubing and fittings, connect to water source [must be 35 PSI (2.4 bar) or

more]. C. Flush water supply line thoroughly. D. Route tubing through cutout in counter or through access hole in back of unit. E. Leave 12 inches (300 mm) of extra tubing length below the counter for servicing and moving

the dispenser. F. Connect to desired plain water inlet behind splash plate and secure with Oetiker Clamp. G. Turn on water supply and check for leaks. H. Actuate each valve until all air is expelled.

Plumbing Diagram, Carbonated/Plain Water

Figure 1

8 VALVE

87654321

INLET VALVE 4 INLET VALVE 5

INLET VALVE 6, 7, & 8

INLET VALVE 1, 2, & 3

6 VALVE

6 45 123

INLET VALVE 3 & 4

INLET VALVE 1, 2, & 6

INLET VALVE 5

1.8 CONNECTING TO CARBONATED WATER SUPPLY

See Figure 1.

A. Install carbonator per manufacturer’s instructions. B. Using proper beverage tubing and fittings, connect to carbonator tank outlets. C. Route tubing through cutout in counter or through access hole in back of unit. D. Leave 12 inches (300 mm) of extra tubing length below the counter for servicing and moving

the dispenser. E. Connect to soda inlets behind splash plate and secure with Oetiker Clamps. F. Fill with water and pressurize carbonation system per manufacturer’s instructions. G. Actuate each valve until a smooth flow of carbonated water is obtained. H. Check for leaks.

1.9 CONNECTING TO SYRUP SUPPLY

A. Using proper beverage tubing and fittings, connect to syrup inlets and secure with Oetiker

Clamps. B. Mark syrup tube assemblies with product ID tape. C. Route tubing through cutout in counter or through access hole in back of unit. D. Leave 12 inches (300 mm) of extra tubing length below the counter for servicing and moving

the dispenser. E. Connect to appropriate five (5) gallon syrup containers or bag-in-box system. F. Pressurize system. G. Actuate each valve until product is observed. H. Check for leaks.

)

Typical Valve Adjustment

Figure 2

1.10 ADJUSTING WATER FLOW

A. The water flow can be adjusted to either1.25 oz/sec

(37 ml/sec) or 2.50 oz/sec (74 ml/sec) on all dispensing valves using the following procedure.

B. The refrigeration unit should have been running for at

least one hour before you attempt to brix the valves. The drink temperature should be no higher than 40

(4.4oC) when the brix is set. This is best done after the

unit has made an ice bank. C. Slide up ID panel until flow controls are exposed. D. Remove nozzle by twisting counter clockwise and

pulling down. E. Remove diffuser by pulling down. F. Install Lancer (yellow) syrup separator (PN 54-0031) in

place of nozzle. G. Activate dispensing valve to fill separator syrup tube. H. Hold a Lancer brix cup under the syrup separator and

dispense water and syrup into cup for four (4) seconds.

Divide number of ounces (ml) of water in cup by four (4)

to determine water flow rate per second. I. To obtain the proper flow, use a screwdriver to adjust water flow control (see Figure 2). J. Repeat process for each valve.

1.11 ADJUSTING WATER TO SYRUP (RATIO) BRIX

A. Hold the Lancer brix cup under the syrup separator and activate valve. Check brix. B. To obtain the proper brix, use screwdriver to adjust syrup flow control (see Figure 2). C. Remove the syrup separator. D. Install diffuser and nozzle. E. Slide down ID panel. F. Repeat process for each valve.

FLOW CONTROL

WATER

DecreaseIncrease

I.D. PANEL

(Shown in

open position)

COVER SCREW

FLOW CONTROL

SYRUP

DecreaseIncrease

NOZZLE (WITH DIFFUSER INSIDE

2. SCHEDULED MAINTENANCE

2.1 DAILY

A. Remove the nozzle and diffuser from each valve and rinse well in warm water. Do NOT use

soap or detergent. This will cause foaming and off taste in finished product.

B. Remove the cup rest and wash in warm soapy water. C. Pour warm soapy water into the drip tray and wipe with a clean cloth. D. With a clean cloth and warm water, wipe off all of the unit's exterior surfaces. DO NOT USE

ABRASIVE SOAPS OR STRONG DETERGENTS.

E. Replace the cup rest, valve diffusers, and valve nozzles.

2.2 WEEKLY

A. Taste each product for off tastes and/or brix changes. B. Remove the 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 power source. B. Remove the bonnet and clean the dirt from the condenser using a soft brush. C. Replace the bonnet and plug in the unit.

2.4 EVERY SIX MONTHS

A. Clean and sanitize the unit using the appropriate procedures outlined in Section 3 of this

manual.

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.

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)

chloride solution. B. Disconnect syrup containers and remove product from tubing by purging with carbon dioxide. C. Rinse the lines and fittings with clean, 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 solu-

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

but should be at least two (2) percent sodium hydroxide. Make sure the lines are completely

filled and allow to stand for at least ten (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 parts per million (PPM)

(50 mg/L) available chlorine. Make sure that lines are completely filled and allow to stand for

ten (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 VALVES

A. Valves may be cleaned and sanitized in the same manner

1. Remove cover and disconnect power so not to activate the valve while cleaning. Remove nozzle and diffuser. Wash these parts in cleaning solution, then immerse them in a bath of sanitizing solution for 15 minutes.

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