Lancer 85-2000-06 Service Manual

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INSTALLATION AND SERVICE MANUAL

FOR

TURBO-CARB HIGH CAPACITY CARBONATOR

Part Number 85-2000, 115 Volts, 60 Hz Part Number 85-2000-06, 115 Volts, 60 Hz

This Manual supersedes 28-0432, dated 05/05/00

FAX ENGINEERING: • 210-310-7096

SPECIFICATIONS

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

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

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: 08/08/00 P.N. 28–0432/01

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 •

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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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 CO2 CHECK VALVE...........................................................................................................................2

3.2 INLET WATER CHECK VALVE..........................................................................................................2

3.3 PUMP STRAINER SCREEN..............................................................................................................3

3.4 REPLACING LIQUID LEVEL CONTROL (LLC).................................................................................3

4. TROUBLESHOOTING.................................................................................................................................3

4.1 MOTOR FAILS TO START (MOTOR HUMS) ....................................................................................3

4.2 MOTOR FAILS TO START (MOTOR DOES NOT HUM)...................................................................3

4.3 MOTOR RUNS CONTINUOUSLY .....................................................................................................3

4.4 WATER IS RELEASED FROM PRESSURE RELIEF VALVE............................................................4

4.5 LOW CARBONATION ........................................................................................................................4

4.6 FOAMY PRODUCT............................................................................................................................4

5. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS............................................................4

5.1 CO2 CHECK VALVE ASSEMBLY.......................................................................................................4

5.2 CHECK VALVE ASSEMBLY...............................................................................................................4

5.3 LARGE CARBONATOR TANK........................................................................................................4-5

5.4 PUMP ASSEMBLY .............................................................................................................................6

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. 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 damages are 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

) and a maximum of 80 PSIG (5.62 kg/cm2). If water pressure

exceeds 80 PSIG (5.62 kg/cm

), install a Regulator (Lancer models are available) and adjust to

50 PSIG (3.51 kg/cm

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/cm

) 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

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

F. Check for CO

2 leaks (see Section 3.1).

ARNING

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

CHECK VALVE

A. UNPLUG Power Cord. B. Shut water supply OFF to Pump. C. Turn CO

supply OFF and set CO2 pressure regulator at 0 PSIG.

D. Disconnect CO

2 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

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. F. Turn CO

2 pressure OFF. Release pressure in Tank, using Relief Valve.

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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.

3.3 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.

ARNING

H. Plug Power Cord into electrical outlet.

3.4 REPLACING LIQUID LEVEL CONTROL (LLC)

A. UNPLUG Power Cord. B. Shut water and CO

2 gas supplies OFF.

C. Pull lever on Pressure Relief Valve to relieve CO2 pressure on Tank. D. Remove three (3) screws securing existing LCC to top of Tank and remove LLC. E. Install new LLC into top of Tank and secure with three (3) screws removed in previous step.

Ensure O-Ring (PN 02-0464) is properly installed to ensure a water tight seal is obtained.

F. Follow start-up procedure (see Section 2.1) for putting Carbonator back into operation.

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 LLC. D. Replace LLC.

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 LLC. F. Replace LLC.

(Troubleshooting continued next page)

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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 CO

2 pressure.

B. Dirty Product Valve. B. Disassemble and clean

Product Valve.

C. Product temperature C. Product temperature must be

too high. below 42

F (5.5oC). Check

cooling system.

TROUBLE

CAUSE REMEDY

ITEM

PART NO.

DESCRIPTION

1 07-0199/01 Base 2 82-2495 Uniprobe Assy (Liquid Level

Control) 3 11-0004 Connector 4 06-1134 Label, CO

2 Pressure

5 04-0247 Foot, Isolator 6 04-0034 Nut, Lock 7 04-0033 Washer 8 04-0520 Bolt, Hex, 1/4 - 20 x 1/2 9 04-0032 Nut, NYLOCK, 1/4 - 20 10 91-0008 Motor, 115 VAC 11 07-0017 Clamp 12 86-0085 Pump, Assy, REPL Bypass 13 01-0111 Adaptor 14A 48-1449 Tube Assy (For 85-2000)

R 14B 48-0507 Tube Assy (For 85-2000-06)

15 04-0045 Cap, Protector 16 04-0044 Cap, Protector 17 05-0017 Seal, Flare

5.3 LARGE CARBONATOR TANK

18 06-0003/02 Name Plate 19 06-0039 Label, WARNING 20 23-1176 Tank, Carbonator Assy 21 52-2159 Power Cord, Assy, 100” 22 52-2153 Power Cord, Carbonator,

Uniprobe

23 17-0342 Check Valve Assy, CO

24A 17-0083 Fitting Assy (For 85-2000) 24B 01-2013 Fitting Assy (For 85-2000-06) 25 54-0066 Relief Valve Assy 26A 17-0341 Check Valve Assy

(For 85-2000)

R 26B 17-0556 Vented Backflow Preventer

(For 85-2000-06)

R 27 01-1877 1/4 Barb R 28 06-2251 Label, Check Valve R 29 06-2014/01 Label, WARNING CO

R in margin indicates change or revision

ITEM

PART NO. DESCRIPTION

5. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS

5.1 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

5.2 CHECK VALVE ASSEMBLY

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

2 3

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5.3 LARGE CARBONATOR TANK (CONTINUED)

24A

24B

26A

26B

14A

14B

PN. 06-1835

LIGHT

ASSY 82-2495

PUMP MOTOR CONNECTION.

2. IF LIGHT BLINKS CHECK

CHECK POWER SUPPLY.

WARNING

100 GPH

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5.4 PUMP ASSEMBLY

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 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