Lancer 85-1924 Operators Manual
INSTALLATION AND SERVICE MANUAL
FOR
TURBO-CARB HIGH CAPACITY CARBONATOR
Part Number 85-1923, 115 Volts, 50/60 Hz
Part Number 85-1924, 230 Volts, 50/60 Hz
Part Number 85-1926, 115 Volts, 50/60 Hz, with Insulated Tank
Part Number 85-1965, 100 Volts, 50/60 Hz
This Manual supersedes Installation and Service Manual 28-0022/04, dated 11/22/99,
and is being published only on the Lancer Web Site.
SPECIFICA
TIONS
DIMENSIONS
Width 12 1/4 inches (31.11 cm)
Depth 15 1/4 inches (38.74 cm)
Height 11 1/2 inches (29.21 cm)
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
Export Operating Voltage 230
100 (Japan Only)
Hertz 50/60
Amps 3.5/3.0
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)
DATE: 09/26/01
P.N.: 28-0022/05
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
"Lancer" is the registered trademark of Lancer • Copyright — 2001 by Lancer, all rights reserved.
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.
T
ABLE OF CONTENTS
SPECIFICATIONS
TABLE OF CONTENTS ......................................................................................................................................i
THEORY OF OPERATION..................................................................................................................................i
1. INSTALLATION ...........................................................................................................................................1
1.1 RECEIVING........................................................................................................................................1
1.2 SELECTING LOCATION ....................................................................................................................1
1.3 CONNECT WATER LINE TO PUMP..................................................................................................1
1.4 CONNECT CO
2 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 INLET WATER CHECK VALVE..........................................................................................................2
3.2 CO2 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............................................................6
6.1 LARGE CARBONATOR TANK........................................................................................................6-7
6.2 CO2 CHECK VALVE ASSEMBLY.......................................................................................................7
6.3 CHECK VALVE ASSEMBLY...............................................................................................................7
6.4 PUMP ASSEMBLY .............................................................................................................................8
6.5 WIRING DIAGRAM (PN 06-0266/02) ................................................................................................8
THEORY OF OPERATION
A carbonator is a device designed to dissolve carbon dioxide gas (CO
2) in water, producing carbonated water.
CO
2 gas is delivered through a regulator to the carbonator tank. Simultaneously, plain water is pumped into
the tank. The CO2
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.
i
1. INSTALLATION
1.1 RECEIVING
A. 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
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 ofcarton.
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.
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 and Flare Seal Washer.
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/cm
2
), install a Regulator and adjust to 50 PSIG (3.51 kg/cm2).
D. Off tastes and/or excessive silt, sand, or iron require that a water filter be installed in the water
line 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 CO2 Regulator to the Tank Inlet
using a 1/4 inch SAE Female Swivel Nut and Flare Seal Washer.
B. CO2 supply must have a Regulator and Gauge 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 and Flare Seal Washer.
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.
1
2
2. START UP
2.1 START UP PROCEDURE
A. Turn water supply ON, and start filling Tank.
B. Pull UP on Pressure Relief Valve Ring 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.
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.
E. Plug in power supply.
F. Turn on CO2 supply and set Regulator at 100 PSIG (7.03 kg/cm
2
).
G. Check for CO2 leaks (see Section 3.1).
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.
L. Check CO
2 Regulator to ensure that CO2 pressure has not changed.
3. CLEANING AND REPLACEMENT
3.1 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 CHECK 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.
F. Turn CO2 pressure OFF. 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 Stainless Steel Line to water inlet Check Valve.
J. Follow start up procedure (see Section 2.1) to put Carbonator back into operation.
3.2 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 CHECK 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.
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