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INSTALLATION AND SERVICE MANUAL
FOR
TURBO-CARB HIGH CAPACITY CARBONATOR
Part Number 85-1922, 115 Volts, 50/60 Hz
Part Number 85-1922-06, 115 Volts, 50/60 Hz, with Vented Check Valve
DATE: 01/19/01
P.N. 28–0475
This Manual is an initial issue
"Lancer" is the registered trademark of Lancer • Copyright — 2001 by Lancer, all rights reserved.
FAX ENGINEERING: • 210-310-7096
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 •
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.
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T
ABLE OF CONTENTS
TABLE OF CONTENTS ......................................................................................................................................i
SPECIFICATIONS..............................................................................................................................................ii
1. INSTALLATION ...........................................................................................................................................1
1.1 RECEIVING........................................................................................................................................1
1.2 SELECTING LOCATION....................................................................................................................1
1.3 CONNECT WATER LINE TO PUMP..................................................................................................1
1.4 CONNECT CO2 LINE TO TANK ........................................................................................................1
1.5 CONNECT CARBONATED WATER TO DISPENSING SYSTEM .....................................................1
1.6 ELECTRIC POWER SUPPLY ............................................................................................................1
2. START UP ...................................................................................................................................................2
2.1 START UP PROCEDURE ..................................................................................................................2
3. CLEANING AND REPLACEMENT .............................................................................................................2
3.1 CO
2 CHECK VALVE...........................................................................................................................2
3.2 INLET WATER CHECK VALVE..........................................................................................................2
3.3 PUMP STRAINER SCREEN..............................................................................................................3
3.4 REPLACING PROBE .........................................................................................................................3
3.5 REPLACING P.C. BOARD .................................................................................................................3
4. TROUBLESHOOTING.................................................................................................................................4
4.1 MOTOR FAILS TO START (MOTOR HUMS) ....................................................................................4
4.2 MOTOR FAILS TO START (MOTOR DOES NOT HUM)...................................................................4
4.3 MOTOR RUNS CONTINUOUSLY .....................................................................................................4
4.4 WATER IS RELEASED FROM PRESSURE RELIEF VALVE............................................................4
4.5 LOW CARBONATION ........................................................................................................................4
4.6 FOAMY PRODUCT............................................................................................................................4
5. BASIC GO/NO GO CARBONATOR CONTROL TEST ..............................................................................5
6. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS............................................................7
6.1 LARGE CARBONATOR TANK........................................................................................................7-8
6.2 CO
2 CHECK VALVE ASSEMBLY.......................................................................................................8
6.3 CHECK VALVE ASSEMBLY...............................................................................................................8
6.4 PUMP ASSEMBLY .............................................................................................................................9
6.5 WIRING DIAGRAM (PN 06-0266/02).................................................................................................9
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SPECIFICATIONS
DIMENSIONS
Width 12 1/4 inches (311 mm)
Depth 15 1/4 inches (387 mm)
Height 11 1/2 inches (292 mm)
WEIGHT
Shipping 33.5 pounds (15.2 kg)
Empty 31.1 pounds (14.1 kg)
Operating 45.3 pounds (20.5 kg)
ELECTRICAL
Domestic Operating Voltage 115
Hertz 60
Amps 6.2
MOTOR 1/3 Horsepower (HP)
PUMP 125 Gallons Per Hour (GPH)
[473 Liters Per Hour (LPH)]
WATER INLET 3/8 inch S.A.E. Male Flare
CO
2
INLET 1/4 inch S.A.E. Male Flare
CARBONATED WATER OUTLET (TWO) 3/8 inch S.A.E. Male Flare
TANK OPERATING CAPACITY 215 Ounces (6.4 L)
THEORY OF OPERATION
A carbonator is a device designed to dissolve carbon dioxide gas (CO2) in water, producing carbonated
water. CO2 gas is delivered through a regulator to the carbonator tank. Simultaneously, plain water is
pumped into the tank. The CO
2
gas, under pressure, dissolves in the water and the result is
carbonated water. When the level of carbonated water reaches a pre-determined point, the liquid level
sensing device (inside the tank) signals the liquid level control module which, in turn, shuts off the pump
motor. As carbonated water is drawn from the tank, the level of carbonated water will drop. At a
certain point, the liquid level sensing device recognizes that drop in the level and turns on the pump
motor which replenishes the amount of carbonated water that has been taken out of the tank.
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1
1. INSTALLATION
1.1 RECEIVING
A. 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(s)
must be made with the carrier. Upon receiving units 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. Open the top of the carton. Remove interior packing. Carefully lift the Carbonator out of
carton.
C. Inspect for concealed damage(s) and if detected, notify delivering carrier and file claim.
1.2 SELECTING LOCATION
A. Select a level, well ventilated, accessible location convenient to water and electric supply. The
selected location should be able to withstand a load of 100 pounds (45.5 kg).
1.3 CONNECT WATER LINE TO PUMP
A. Connect Flexible Pressure Tubing, 3/8 inch ID or larger, from water supply to Pump Inlet using
a 3/8 inch SAE Female Swivel Nut (PN 01-0232) and Flare Seal Washer (PN 05-0017).
B. A Shutoff Valve should be installed in water line to Carbonator.
C. Water supply must provide a minimum flow rate of 125 GPH (473 LPH), and have a minimum
pressure of 25 PSIG (1.83 kg/cm
2
) and a maximum of 80 PSIG (5.62 kg/cm2). If water
pressure exceeds 80 PSIG (5.62 kg/cm2), install a Regulator (Lancer models are available) and
adjust to 50 PSIG (3.51 kg/cm
2
).
D. Off tastes and excessive silt, sand, or iron require that a water filter be installed in the water
supplying the Carbonator. The water filter should be checked periodically, as required by local
conditions.
NOTE
Do not connect to a heated (hot) water source or a water source supplying soft water. This will
cause excessive foaming.
1.4 CONNECT CO
2 LINE TO TANK
A. Connect Flexible Pressure Tubing, 1/4 inch ID or larger from CO
2 Regulator to the Tank Inlet
using a 1/4 inch SAE Female Swivel Nut and Flare Seal Washer.
B. CO
2 supply must have a Regulator (Lancer models are available) and Gauge (Lancer models
are available) adjustable from 0 to 150 PSIG (3.5 kg/cm2) minimum.
1.5 CONNECT CARBONATED WATER TO DISPENSING SYSTEM
A. Connect Flexible Pressure Tubing, 3/8 inch ID or larger, from Dispensing System to Outlet on
Tank, using a 3/8 inch SAE Female Swivel Nut and Flare Seal Washer.
B. If only one Carbonated Water Outlet on the Tank is used, the other Outlet must be capped with
a Stainless Steel Cap Nut (PN 01-0212) and Flare Seal Washer (PN 05-0017).
1.6 ELECTRIC POWER SUPPLY
W
ARNING
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.
A. The electric power supply must be a three prong, ground convenience outlet having the same
configuration as the power cord.
B. Outlet must have proper voltage, cycles and ampere ratings. See Carbonator Name Plate for
ratings.
NOTE
Do not plug into electrical outlet unless ratings on name plate agree with local current available.
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2. START UP
2.1 START UP PROCEDURE
A. Turn water supply ON, and start filling Tank.
B. Pull UP on Pressure Relief Valve Yellow Lever to allow air to escape.
C. Hold Pressure Relief Valve OPEN, until Tank is full and water spurts out of Valve.
D. Check for water leaks.
E. Turn on CO
2 supply and set Regulator at 100 PSIG (7.03 kg/cm
2
).
F. Check for CO
2 leaks (see Section 3.1).
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.
G. Plug in power supply.
H. Open a Dispensing Valve. Allow water to flow until Pump Motor turns on.
I. Close Dispensing Valve and allow Pump Motor to cycle off.
J. Repeat steps H and I several times, until carbonated water flows freely from Valve.
K. Check for leaks (see Section 3.2).
L. Check CO
2 Regulator to ensure that CO2
pressure has not changed.
3. CLEANING AND REPLACEMENT
3.1 CO
2
CHECK VALVE
A. UNPLUG Power Cord.
B. Shut water supply OFF to Pump.
C. Turn CO2 supply OFF and set CO2 pressure regulator at 0 PSIG.
D. Disconnect CO2 supply line from CO2 Check Valve.
CAUTION
DO NOT PROBE VALVE WITH ANY OBJECT.
E. Cover end of Check Valve with soap suds. If Check Valve is defective, gas bubbles will appear.
If a leak is detected, continue with the following steps.
F. Release pressure in Tank, using Relief Valve.
G. Disassemble Check Valve Body and components. Inspect Spring and O-Rings. Replace as
required.
H. Reassemble and reinstall Check Valve.
I. Reconnect CO
2 supply line to CO2 Check Valve.
J. Follow start up procedure (see Section 2.1) to put Carbonator back into operation.
3.2 INLET WATER CHECK VALVE
CAUTION
A LEAKING INLET WATER CHECK VALVE WILL ALLOW CARBONATED WATER TO FLOW BACK
THROUGH THE PUMP (WHEN IT IS SHUT OFF), AND CONTAMINATE THE WATER SUPPLY.
A. UNPLUG Power Cord.
B. Shut water supply OFF to Pump.
C. Set CO
2 pressure at 100 to 125 PSIG (7.0 to 8.8 kg/cm
2
).
D. Disconnect Stainless Steel Water Line from Water Inlet Check Valve. Do not loosen Check
Valve Assembly.
CAUTION
DO NOT PROBE VALVE WITH ANY OBJECT.
E. Cover end of Check Valve with soap suds. If Check Valve is defective, gas bubbles will appear.
If a leak is detected, continue with the following steps. If no leak is detected, proceed to Step J
below.
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F. Turn CO2 pressure OFF. Release pressure in Tank, using Relief Valve.
G. If equipped with the 17-0341 Check Valve, continue with Step H. If equipped with the 17-0556
Vented Check Valve, replace the valve and continue at Step J.
H. Disassemble Check Valve Body and components. Inspect Spring and O-Rings. Replace as
required.
I. Reassemble and reinstall Check Valve.
J. Reconnect Stainless Steel Line to water inlet Check Valve.
K. Follow start up procedure (see Section 2.1) to put Carbonator back into operation.
3.3 PUMP STRAINER SCREEN
A. UNPLUG Power Cord.
B. Shut water supply OFF to Pump.
C. Unscrew Brass Plug on Pump, and remove Strainer from Pump.
D. Inspect and clean, or replace, Strainer Screen.
E. Reinstall Strainer, and tighten Brass Plug.
F. Turn water supply ON.
G. Check for leaks. If a leak is detected, carefully tighten Brass Plug.
W
ARNING
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.
H. Plug Power Cord into electrical outlet.
3.4 REPLACING PROBE
A. UNPLUG Power Cord.
B. Shut water and CO
2 gas supplies OFF.
C. Remove Cover from PC Board enclosure by removing screws.
D. Unplug Probe Leads from PC Board.
E. Pull lever on Pressure Relief Valve to relieve CO
2 pressure on Tank.
F. Unscrew Probe from top of Tank.
G. Screw new Probe into top of Tank. Be sure to install White Plastic Washer (PN 02-0096) as a
water tight seal seal will not be obtained without the washer.
H. Connect Probe Leads to PC Board as follows:
Green G
Black LO
White HI
I. Slide Probe Strain Relief into slot, replace cover and secure cover with screws.
J. Follow start-up procedure (see Section 2.1) for putting Carbonator back into operation.
3.5 REPLACING PC BOARD
A. UNPLUG Power Cord.
B. Carefully remove Cover from PC Board enclosure by removing two (2) screws, and disconnect
Switch Assembly from PC Board.
C. Unplug Probe Leads, Power Cord Leads, and Motor Cord Leads from PC Board.
D. Unscrew and remove PC Board Assembly.
E. Install new PC Board and secure with screws.
F. Connect push on Leads to PC Board as follows.
1. Probe
2. Power Cord 3. Motor Cord
Green G Black 1 Black 3
Black LO White 2 White 4
White HI
G. Reconnect Switch Assembly to PC Board and install cover. Secure cover with two (2) screws.
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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.
H. Plug Power Cord IN.
4. TROUBLESHOOTING
TROUBLE
CAUSE REMEDY
4.1 Motor fails to start A. Pump binding. A. Loosen Pump CIamp and rotate
(Motor hums). Pump slightly to free binding, If this
fails, replace Pump.
B. Open Winding infield. B. Replace Motor.
4.2 Motor fails to start A. Cutout due to overloading A. Let Motor cool and follow Pump
(Motor does not hum). by Pump binding. binding remedy.
B. Blown Fuse, or Circuit B. Replace Fuse or reset Circuit
Breaker tripped. Breaker.
C. Defective Motor. C. Replace Motor.
D. Defective PC Board. D. Replace PC Board.
E. Defective Probe. E. Replace Probe.
4.3 Motor runs continuously. A. Water supply shut off. A. Reestablish water supply.
B. Water supply pressure less B. Connect Pressure Gage to Pump
than 25 PSIG (1.86 kg/cm2). Tee and increase Pump By-Pass
pressure to 200 PSIG
(14.1 kg/cm2).
C. Restriction in Water C. Locate restriction and establish
Supply Line. proper flow.
D. Restriction in Inlet Water D. Disassemble Inlet Water Check
Check Valve. Valve and clean.
E. Restriction in Pump. E. Remove and clean Pump Strainer.
If Pump is still restricted, replace
Pump.
F. Defective PC Board. F. Replace PC Board.
G. Defective Probe. G. Replace Probe.
4.4 Water is released from A. Defective seal in Pressure A. Replace Pressure Relief Valve.
Pressure Relief Valve. Relief Valve.
B. Defective Spring in Pressure B. Replace Pressure Relief Valve.
Relief Valve.
4.5 Low Carbonation. A. Low CO
2 pressure. A. Increase CO2 pressure or
replace CO2 tank.
B. Leaking CO2 Supply Line. B. Locate leak and repair.
4.6 Foamy Product. A. Over carbonation. A. Reduce CO2 pressure.
B. Dirty Product Valve. B. Disassemble and clean
Product Valve.
C. Product temperature C. Product temperature must be
too high. below 42oF (5.5oC). Check
cooling system.
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5. BASIC GO/NO GO CARBONATOR CONTROL TEST
Part Number 06-1236/01, found on the cover of the Carbonator Assembly, provides a basic
trouble-shooting procedure to determine if the liquid level control is operating properly. The test which is
self-explanatory (see illustration) will help isolate problems to the probe, motor or PC Board.
5
NOTE: IN CASE OF CARBONATION PROBLEMS, VERIFY
TEST SWITCH
CARBONATOR OPERATION BY DRAWING DRINKS. IF
PROBLEMS PERSIST, FOLLOW THE STEPS LISTED BELOW.
STEP I--OBSERVE GREEN LIGHT
OFF--------------CHECK POWER SUPPLY
ON---------------GO TO STEP 2
STEP 2--PUSH TEST SWITCH (WITH TANK EMPTY)
MOTOR STARTS--------REPLACE PROBE
MOTOR DOES NOT START AND ORANGE LIGHT ON -REPLACE MOTOR
ORANGE LIGHT OFF--------REPLACE BOARD
STEP 3--IF MOTOR DOES NOT TURN OFF----
REPLACE BOARD AND PROBE
ORANGE
GREEN
WARNING
®
06-1236/01
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6
NOTES
Page 10
HYBRID1
TIMER
RLY ON
HI
LO
+12V
C6
ER
ON
OFF
C7
JP1
U2
RSIP1
CE
C3
HOT
Q2
L1
6. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS
6.1 LARGE CARBONATOR TANK
7
8A
15
17
40
16
18
19
20
6
5
4
3
2
7
9
8
10
21
12
11
13
14
39
17
22
24
42
13
41
10A
1
13
14A
36
38
37
44
13
36
13
43
25
23
26
27
28
WARNING
100 GPH
M
A
D
E
I
N
I
A
T
Y
L
30
29
35
34
33
31
32
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8
ITEM PART NO. DESCRIPTION
1 07-0199/01 Base Plate
2 23-0369 Tank Assy
-- 06-0039 Label, Warning
-- 06-1134 Label, CO
2
Pressure
-- 06-2014/01 Label, Warning, CO
2 Check
Valve
3 17-0342 CO2 Check Valve Assy
4 04-0044 Protector Cap
5 02-0096 Washer
6 52-0590/01 Probe
7 54-0066 Relief Valve Assy
8 17-0083 Fitting Assy
8A 01-2013 Fitting Assy, 3/8” Female Flare
9 04-0045 Protector Cap
10 17-0341 Check Valve Assy
10A 17-0556 Check Valve Assy, Vented
11 04-0049 Nut
12 04-0297 Keps Nut
13 05-0017 Flare Seal
14 48-0507 Tube Assy
14A 48-1891 Tube Assy
15 13-0026 Strain Relief
16 12-0241 Boot, Splashproof
17 04-0470 Screw
18 06-0266/02 Label, Wiring Diagram
19 05-0528-01 Cover
6.1 LARGE CARBONATOR TANK (CONTINUED)
20 06-1236/01 Label, Troubleshoot
21 52-1739 Switch Sub Assy
22 52-1677 PC Board Assy
23 13-0028 Strain Relief
24 52-0588 Power Cord Assy
25 05-0529-01 Enclosure
26 52-0585 Motor Cord Assy
27 13-0008 Strain Relief
28 91-0008 Motor, 115 VAC
29 04-0033 Washer
30 04-0520 Hex Bolt, 1/4 - 20 x 1/2 Inch
31 07-0017 Clamp
32 04-0032 Nut, 1/4 - 20 Nylock
33 86-0085 Pump
34 01-0111 Adapter
35 04-0247 Isolator Foot
36 04-0034 Lock Nut
37 11-0004 Connector
38 06-0075-01 Name Plate
39 04-0836 Lock Washer, Internal Tooth, 1/4
Inch
40 06-1289 Label, Test Switch
41 06-2251 Label, ASSE 1022
42 01-1877 Adapter, 1/8 MNPT x 1/8 Barb, SS
43 01-0394 Tee, Brass, 2 5/8 - 18 MT x 3/8 MT
44 01-0213 Nut, Cap, 5/8 - 18
ITEM P
ART NO. DESCRIPTION
1
6.2 CO
2 CHECK VALVE ASSEMBLY
ITEM
PART NO. DESCRIPTION
1 17-0342 CO2 Check Valve Assy
2 01-0669 Body
3 02-0025 O-Ring
4 01-0689 Sleeve
5 01-0674 Ball
6 03-0021 Spring
7 02-0003 O-Ring
ITEM PART NO. DESCRIPTION
6.3 CHECK VALVE ASSEMBLY
1
ITEM PART NO. DESCRIPTION
1 17-0341 Check Valve Assy
2 01-0673 Body
3 02-0025 O-Ring
4 01-0689 Sleeve
5 01-0674 Ball
6 03-0021 Spring
7 02-0003 O-Ring
8 01-0670 Body
ITEM PART NO. DESCRIPTION
4
2
3
2 3
5
6
4
5
6
7
7
8
3
4
5
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6.4 PUMP ASSEMBLY
6.5 WIRING DIAGRAM (PN 06-0266/02)
9
ITEM PART NO. DESCRIPTION
1 86-0085 Pump Assy
2 10-0175 Housing
- 10-0176 Housing, Stainless Steel
- 10-0395 Housing, Replaceable Bypass
3 54-0152 Bypass Seat Sub Assy
4 02-0115 O-Ring
ITEM PART NO. DESCRIPTION
5 17-0438 Bypass Valve Assy
- 17-0439 Bypass Valve Assy,
Stainless Steel
- 10-0396 Bypass Valve Assy,
Replaceable Bypass
6 81-0103 Bypass Valve Filter
7 03-0132 Spring Relief Valve
8 02-0192 Gasket, Acorn Nut
9 01-1771 Acorn Nut, Relief Valve
- 01-1198/01 Acorn Nut, Relief Valve,
Stainless Steel
10 10-0394 Relief Valve, Adjustment Screw
- 10-0183 Relief Valve, Adjustment Screw,
Stainless Steel
- 10-0397 Relief Valve, Adjustment Screw,
Replaceable Bypass
11 02-0181 O-Ring, Adjustment Screw
12 82-0415 Strainer
13 02-0185 O-Ring, Strainer Nut
14 01-1196/01 Cap Nut, Strainer
2
1
12
13
14
PROBE
LOW VOLTAGE
HI LO
PC BOARD
G
3
4
5
6
7
8
9
10
11
GREEN
BLACK
WHITE
J4
J3
L2
L1
MOTOR
115 VAC
WHITE
BLACK
GREEN
115 V or 220 V
WHITE
BLACK
GREEN
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