Lancer 9106 User Manual

INSTALLATION AND SERVICE
MANUAL
FOR
DELTA II REMOTE RECIRCULATING UNIT
LANCER SERIES 9100
This manual is an initial issue.
DATE: 02/23/96 P.N.: 28-0260
"Lancer" is the registered trademark of Lancer • Copyright — 1996 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.
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 .............................................................................................................................................iii
1. INSTALLATION ...........................................................................................................................................1
1.1 RECEIVING........................................................................................................................................1
1.2 UNPACKING ......................................................................................................................................1
1.3 UNPACKING INSTALLATION KITS ...................................................................................................1
1.4 SELECTING A COUNTER LOCATION .............................................................................................1
1.5 MOUNTING THE DISPENSER..........................................................................................................1
1.6 FILLING UNIT WITH WATER ............................................................................................................1
1.7 CONNECTING TO ELECTRICAL POWER .......................................................................................2
1.8 CONNECTING PYTHON TO REMOTE RECIRCULATING UNIT .....................................................2
1.9 CONNECTING PYTHON TO TOWER...............................................................................................4
1.10 CONNECTING 24 VAC POWER SUPPLY TO TOWER ....................................................................5
1.11 CONNECTING TO WATER SUPPLY.................................................................................................5
1.12 CONNECTING TO CO2SUPPLY ......................................................................................................5
1.13 CONNECTING TO BAG-IN-BOX (BIB) SYRUP SUPPLY .................................................................5
1.14 CONNECTING TO REMOTE BIB SYRUP PUMPS...........................................................................6
1.15 CONNECTING TO REMOTE PRESSURIZED SYRUP SUPPLY......................................................6
1.16 PURGING THE CARBONATION SYSTEM .......................................................................................6
1.17 COMPLETE INSULATION BETWEEN UNIT AND PYTHON ............................................................6
1.18 COMPLETE INSULATION BETWEEN TOWER AND PYTHON .......................................................7
2. SCHEDULED MAINTENANCE ...................................................................................................................7
2.1 DAILY .................................................................................................................................................7
2.2 WEEKLY .............................................................................................................................................7
2.3 MONTHLY ..........................................................................................................................................7
2.4 EVERY SIX MONTHS........................................................................................................................7
2.5 YEARLY..............................................................................................................................................7
3. DISPENSER CLEANING AND SANITIZING ..............................................................................................7
3.1 AMBIENT PROCESS.........................................................................................................................7
3.2 ALTERNATE CLEANING AND SANITIZING AGENTS......................................................................8
4. CONVERTING FROM EXTERNAL PRESSURIZED SYRUP SUPPLY TO BAG-IN-BOX
WITH BUILT-IN SYRUP PUMPS.................................................................................................................8
5. CONVERTING FROM BUILT-IN SYRUP PUMPS TO REMOTE PUMPS OR SYRUP TANKS.................8
5.1 REMOVING EXISTING BUILT-IN SYRUP PUMPS ...........................................................................8
5.2 INSTALLING REMOTE PUMP OR SYRUP TANKS ..........................................................................8
5.3 CONNECTION FOR PLAIN WATER PRODUCT...............................................................................9
6. TROUBLESHOOTING .......................................................................................................................9
6.1 MISCELLANEOUS LEAKAGE ...........................................................................................................9
6.2 INSUFFICIENT WATER FLOW..........................................................................................................9
6.3 INSUFFICIENT SYRUP FLOW..........................................................................................................9
6.4 ERRATIC RATIO ................................................................................................................................9
6.5 NO PRODUCT DISPENSED .............................................................................................................9
6.6 WATER ONLY DISPENSED, NO SYRUP; OR SYRUP ONLY DISPENSED, NO WATER...............9
6.7 NO WATER, JUST SYRUP (ICE BANK GREW TO WATER INLET LINE
TO CARBONATOR TANK) ...............................................................................................................10
6.8 SYRUP ONLY DISPENSED, NO WATER; BUT CO
2
GAS DISPENSED WITH SYRUP................10
6.9 EXCESSIVE FOAMING ...................................................................................................................10
6.10 WATER CONTINUALLY OVERFLOWS FROM WATER BATH INTO DRIP TRAY .........................10
6.11 COMPRESSOR STARTS AND CONTINUES TO RUN UNTIL FREEZE UP, AND WILL
NOT CUT OFF .................................................................................................................................10
6.12 WARM DRINKS................................................................................................................................11
6.13 COMPRESSOR DOES NOT START (NO HUM), CONDENSER FAN MOTOR DOES NOT RUN
AND NO ICE BANKS .......................................................................................................................11
6.14 COMPRESSOR DOES NOT START (NO HUM), BUT CONDENSER FAN MOTOR RUNS ..........11
6.15 COMPRESSOR DOES NOT START, BUT HUMS...........................................................................11
6.16 COMPRESSOR STARTS, BUT DOES NOT SWITCH OFF START WINDING ..............................12
6.17 COMPRESSOR STARTS AND RUNS A SHORT TIME, BUT SHUTS OFF ON OVERLOAD........12
6.18 COMPRESSOR RUNS NORMALLY, BUT WATER LINE IS FROZEN............................................12
6.19 COMPRESSOR CYCLES ON AND OFF FREQUENTLY DURING THE INITIAL PULLDOWN
AND/OR NORMAL OPERATIONS...................................................................................................12
i
ii
6.20 CIRCUIT BREAKER POPPING .......................................................................................................12
6.21 BIB PUMP DOES NOT OPERATE WHEN DISPENSING VALVE IS OPENED ..............................13
6.22 BIB PUMP OPERATES, BUT NO FLOW.........................................................................................13
6.23 BIB PUMP CONTINUES TO OPERATE WHEN BAG IS EMPTY ...................................................13
6.24 BIB PUMP FAILS TO RESTART AFTER BAG REPLACEMENT ....................................................13
6.25 BIB PUMP FAILS TO STOP, WHEN DISPENSING VALVE IS CLOSED ........................................13
6.26 LOW OR NO CARBONATION .........................................................................................................13
7. ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS..........................................................14
7.1 REFRIGERATION DECK ASSEMBLY ........................................................................................14-15
7.2 CABINET ASSEMBLY.................................................................................................................16-17
7.3 CARBONATOR DECK/PUMP BRACKET ASSEMBLY...............................................................18-19
7.4 CARBONATOR WATER/SYRUP LINES ASSEMBLIES............................................................20-21
7.5 CONTROL HOUSING ......................................................................................................................22
7.6 REGULATOR WATER ASSEMBLY..................................................................................................23
7.7 MERCHANDISER ASSEMBLY ........................................................................................................23
7.8 WIRING DIAGRAM .........................................................................................................................24
SPECIFICATIONS
DIMENSION
Width 16 7/8 inches (42.86 cm) Depth 24 3/4 inches (62.87 cm) Height (without legs) 25 1/2 inches (64.77 cm)
WEIGHT
Shipping 170 lbs (77.1 kg) Empty 156 lbs (70.8 kg) Operating 220 lbs (99.8 kg)
WATER REQUIREMENTS
Minimum flowing pressure of 25 PSIG (1.76 kg/cm2, 1.72 BAR) Maximum static pressure of 50 PSIG (3.52 kg/cm2, 3.45 BAR)
WARNING
IF WATER SOURCE EXCEEDS 50 PSIG (3.52 KG/CM2), A RECOMMENDED WATER REGULATOR ASSEMBLY (PN 18-0253) MUST BE USED TO LIMIT WATER PRESSURE TO 50 PSIG (3.52 KG/CM2).
FAILURE TO USE REGULATOR WILL RESULT IN IMPROPER PERFORMANCE OF DISPENSER.
CARBON DIOXIDE (CO2) REQUIREMENTS
Minimum pressure of 70 PSIG (4.92 kg/cm
2
, 4.83 BAR)
Maximum pressure of 80 PSIG (5.62 kg/cm2, 5.52 BAR)
ICE BANK WEIGHT
27 to 30 lbs (12.2 to 13.6 kg)
DRINK CAPACITY
200 - 12 oz. drinks under 40°F (4.4°C) at 4 drinks per minute with 75°F (23.9°C) ambient inlet water and inlet syrup using 1/3 HP, 115 V, 60 Hz refrigeration system.
DISPENSER INSTALLATION HIGHLIGHTS
Listed below are ten critical elements which will aid in a successful installation.
1. Fill water bath until water over flows from tank overflow tube.
2. The carbonator pump motor must be disconnected from the power supply (see Section 1.8A) prior to connection to water supply for initial build up of ice bank. Failure to do so will result in automatic shut off of carbonator (see item 6 below) or damage to the pump.
3. If this dispenser is installed in an area that is susceptible to ±10% variation of the nominal line voltage, consider installing a surge protector or similar protection device.
4. There is a 5 minute delay, which prevents the compressor and condenser fan from starting until the delay has lapsed. If electrical current is interrupted, there is always a 5 minute delay before the compressor starts.
5. The unit is equipped with a protective timer for the carbonator pump motor, set for 3 minutes. If the carbonator motor has timed out, it must be manually reset by either momentarily unplugging the unit or switching off the ON/OFF switch (if present). Once power is restored, the 5 minute compressor delay would be in effect.
6. Supply Water Pressure: Minimum - 25 PSIG (1.76 kg/cm
2
); Maximum - 50 PSIG (3.5 kg/cm2). If pressure is over
50 PSIG, a water pressure regulator must be used.
7. On units with the built in water regulator, the regulator must be removed if inlet water pressure is less than 25 PSIG.
8. CO
2
Pressure: Recommend nominal pressure 70 PSIG (4.92 kg/cm2, 4.83 BAR). Pressure may be reduced to a
minimum of 60 PSIG (4.22 kg/cm
2
, 4.13 BAR) if remote syrup pumps are being used. It may be increased to a
maximum of 80 PSIG (5.62 kg/cm
2
, 5.52 BAR), only when internal syrup pumps are being used with highly
viscous syrups. Important: Internal syrup pumps may not work at pressures less than 60 PSIG. CO
2
pressure
over 80 PSIG may result in damage or leakage from the syrup pump system, or may cause excessive foam in the drink.
9. Bag-in-Box syrup packages must be within 6 feet from unit when internal syrup pumps are being used.
10.Valve Adjustment: Make sure drink temperature is below 40
o
F (4.4oC) before adjusting brix.
iii
1
1. INSTALLATION
1.1 RECEIVING
Each unit is tested and thoroughly inspected before shipment. At time of shipment, the carrier accepts 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(s) 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 plastic band and remove. B. Remove top portion of carton by lifting up. C. Remove accessory kit and loose parts from top packaging. D. Remove top inner carton pad and corners. E. Lift unit up by plywood shipping base, and remove lower portion of carton. F. Inspect unit for concealed damage(s) and if evident, notify delivering carrier and file a claim
against same.
G. 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.
H. 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.
1.3 UNPACKING INSTALLATION KITS
A. Inspect kits for concealed damage and if evident, notify delivering carrier and file a claim against
same.
B. Each kit contains a list of the parts and a drawing showing the proper assembly of the parts.
1.4 SELECTING A LOCATION
A. Select a location close to a properly grounded electrical outlet and water supply that meet the
requirements as scheduled on the Specifications page.
B. Condenser air is drawn in the front of the unit and discharged out the top of the unit. A
minimum of 8 inches (20.3 cm) clearance must be maintained over the top of the unit.
WARNING
FAILURE TO MAINTAIN THIS CLEARANCE WILL CAUSE THE COMPRESSOR TO OVERHEAT AND WILL RESULT IN COMPRESSOR FAILURE.
C. Units with built-in syrup pumps must be located no more than 8 meters (25 ft.) from the
dispensing tower, and no more than 2.4 meters (8 ft.) below the tower. Use external pumps if these limits are exceeded.
1.5 MOUNTING THE DISPENSER
A. The dispenser is designed to be permanently mounted and sealed to the counter, or installed
on 4 inch legs.
B. For permanent mounting, use Lancer sealant kit (PN 15-0010) to seal the dispenser to the
counter.
C. For leg mounting, use Lancer leg kit (PN 82-0962).
NOTE
NSF listed units must be sealed to the counter, or have 4 inch legs installed.
1.6 FILLING UNIT WITH WATER
A. Remove the bonnet from the unit. B. Remove the yellow plastic plug (located on the front of the unit's carbonator deck) from the unit's
fill hole.
C. Using a funnel or tube, fill the water bath compartment with water until it flows out of the
2
overflow tube into the drip tray.
CAUTION
THE WATER BATH COMPARTMENT MUST BE FILLED WITH WATER BEFORE PLUGGING IN THE UNIT. OTHERWISE, THE COMPRESSOR DECK AND CONDENSER FAN MAY NOT OPERATE PROPERLY.
D. Replace the yellow plug.
1.7 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.
WARNING
FAILURE TO DISCONNECT THE MOTOR POWER SUPPLY WILL DAMAGE THE CARBONATOR MOTOR AND PUMP AND VOID THE WARRANTY.
A. If the unit is equipped with a built-in carbonator, disconnect the power supply to the carbonator
motor by disconnecting the four pin connector, located near the top of the electrical control box on the refrigeration deck.
B. Check the dispenser serial number plate for unit's correct electrical requirements. Do not plug
into wall electrical outlet unless serial number plate current shown agrees with local current available.
C. 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. The agitator motor will start immediately, but the compressor and fan motor will not start until the 5 minute delay has elapsed.
1.8 CONNECTING PYTHON TO REMOTE RECIRCULATING UNIT (see Figure 1)
A. All remote units have the plain water feature, factory installed. If plain water is not wanted,
remove the barbed fitting and short extension fitting, and cap end of plain water line with cap from accessory kit.
B. Determine length of python required, allowing additional length as required for servicing. The
length of the python must not exceed 25 feet (8 meters) if built-in syrup pumps are being used.
C. Position one end of python near remote unit. Slit the python insulation back 18 inches (45 cm)
from end and roll insulation back to expose individual tubes. Take care not to cut into tubing bundle.
D. Slide the tube insulation from the accessory kit over one of the 3/8 inch ID plastic soda lines.
Connect this line to the 3/8 inch barbed 90° elbow located on the inlet to the recirculating pump. Secure with an Oetiker clamp from the kit.
E. Connect the other 3/8 inch ID plastic soda line to the 3/8 inch barbed fitting on the stainless steel
soda recirculating. Secure with Oetiker clamp from kit.
F. Connect each of the 1/4 inch ID plastic lines from the python to the barbed fittings on each of
the stainless steel lines (and plain water line, if used). Secure with Oetiker clamps. The individual barbed fittings for the lines can be removed for insertion into the python tubing by removing the “U” shaped retainer pin and g fitting off of syrup line.
NOTE
Do not insulate connections at this time. Leave all connects exposed for inspection for leaks. Refer to Section 1.17 to complete insulation.
3
Connecting Python to Remote Recirculating Unit
Figure 1
4
1.9 CONNECTING PYTHON TO TOWER (See Figure 2)
A. Route opposite end of python to tower. Determine length required, and cut if necessary. Be
sure to allow additional length as required for servicing.
W
ARNING
USE A SHARP KNIFE, RAZOR BLADE, OR TUBE CUTTER TO CUT TUBING. TUBING CUT WITH A SAW WILL RESULT IN PLASTIC SHAVINGS, WHICH WILL PLUG THE FLOW CONTROLS IN THE DISPENSING VALVE.
B. Slit python insulation back 12 inches (30 cm) from end and roll insulation back to expose
individual tubes. Cut tubing to length as shown in Figure 2.
C. All Delta towers have the plain water feature, factory installed. If plain water is not wanted,
splice a stainless steel, reducing, barbed hose tee (PN 01-0527) in the 3/8 inch soda line. Use a separate 1/4 inch tube to complete the connection from the barbed tee to the tower manifold.
D. Connect each of the plastic lines from the python to the barbed fittings on each of the stainless
steel syrup, soda, and plain water lines on the tower manifold. Start with connections at the back of the tower manifold first. Secure with Oetiker clamps.
NOTE
Do not insulate connections at this time. Leave all connects exposed for inspection for leaks. Refer to Section 1.18 to complete insulation.
Connecting Python to Delta Tower
Figure 2
5
1.10 CONNECTING 24VAC POWER SUPPLY TO TOWER
NOTE
The remote recirculating unit is designed to supply 24VAC power to the valves on the dispensing tower. An extension cord of 25 feet (8 meters) is provided for this purpose in the tower. A separate power supply must be used if the tower is located more than 25 feet (8 meters) from the remote recirculating unit.
A. Remove cover from electrical control box on remote recirculating unit, and route white and black
wires (bundled) through the opening in side of control box. Replace cover. B. Connect extension cord to white and black wires. C. Route extension cord with python to tower. D. Connect white wire to terminal on key lock switch, and black wire to loose black wire in tower. E. A separate power cord is provided for the lighted merchandiser.
1.11 CONNECTING TO WATER SUPPLY
W
ARNING
IF WATER SOURCE EXCEEDS 50 PSIG (3.52 KG/CM2), A WATER REGULATOR KIT MUST BE USED TO LIMIT WATER PRESSURE TO 50 PSIG (3.52 KG/CM
2
). FAILURE TO USE
REGULATOR WILL RESULT IN IMPROPER PERFORMANCE OF DISPENSER.
A. Using tubing and fittings from installation kit, connect tubing assembly to water source. DO NOT
CONNECT TO DISPENSER AT THIS TIME.
B. Flush water supply line thoroughly. C. IF THE WATER SOURCE IS ABOVE 50 PSIG (3.52 KG/CM2), CUT TUBING ASSEMBLY AND
INSTALL WATER REGULATOR KIT (PN 18-0253/01) AS SHOWN IN KIT INSTRUCTION
SHEET.
D. Route tubing through hole in counter and through opening behind splash plate and connect to
carbonator pump, using a flare seal washer (PN 05-0017). Use a back-up wrench to prevent
damage to carbonator pump. E. Leave 1 foot (30 cm) of extra tubing length below the counter for servicing and moving the
dispenser. F. Turn on water supply and check for leaks.
G. Using test gauge assembly (PN 22-0138), set regulator at 50 PSIG (3.52 kg/cm
2
).
1.12 CONNECTING THE CO
2
SUPPLY
A. Connect high pressure CO
2
regulator assembly to CO2cylinder. Use a new CO2tank washer
if regulator does not have built-in o-ring seal. B. Place CO
2
cylinder in service location under counter, etc., and secure it with a safety chain.
C. Using tubing and fittings from installation kit, connect tubing assembly to tank mount regulator
using flare seal washer (PN 05-0011). Use a back-up wrench to prevent damage to regulator
assembly. D. Route gas line through hole in counter and through opening behind the dispenser splash plate. E. Leave 1 foot (30 cm) of extra tubing length below the counter for servicing and moving the
dispenser. F. Remove the protective plug from the CO
2
manifold (located on top of mini pumps on left side of
unit) and connect the CO
2
supply line using a 1/4 inch elbow (supplied in installation kit.)
W
ARNING
DO NOT TURN ON THE CO2SUPPLY AT THIS TIME
G. If dispenser does not have built in syrup pumps, connect directly to the carbonator CO
2
inlet
check valve.
1.13 CONNECTING TO BAG-IN-BOX (BIB) SYRUP SUPPLY (Units with Built-in Syrup Pumps)
A. Remove the protective caps from the syrup pump inlets and connect syrup inlet tube
assemblies, furnished in the installation kit, to the syrup pumps. Lubricate o-rings before
installation, using food grade glycerine or equivalent. Be careful not to cut o-rings when
installing in pump.
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