Lancer Volumetric Post-Mix Valve, LEV 3.0 Parts List
Volumetric Post-Mix Valve
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.
This Manual supersedes Installation and Service Manual, 28-0301/02, dated 03/04/99
DATE: 06/01/04
P.N. 28-0301/03
• FAX ENGINEERING: • 210-310-7096 •
• "Lancer" is the registered trademark of Lancer •
• Copyright — 2004 by Lancer, all rights reserved •
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 •
MAINTENANCE MANUAL
PUSH
Portion Control
Push Button
Standard Lever
Self-Serve Lever
i
CONTENTS
CONTENTS.........................................................................................................................................................i
LISTING OF ILLUSTRATIONS...........................................................................................................................i
DESCRIPTION ...................................................................................................................................................1
SPECIFICATIONS..............................................................................................................................................1
MAINTENANCE TOOLS....................................................................................................................................1
1. PRINCIPLE OF OPERATION......................................................................................................................2
2. VOLUMETRIC VALVE CLEANING AND SANITIZING PROCEDURES ....................................................3
3. VALVE SET-UP............................................................................................................................................4
4. SYRUP RESTRICTOR SETTING................................................................................................................4
5. SYRUP PURGE PLUG................................................................................................................................4
6. PROGRAMMER OPERATING PROCEDURES..........................................................................................5
7. PORTION CONTROL PROGRAMMING PROCEDURES ..........................................................................7
8. COVER AND ID PANEL..............................................................................................................................8
9. VALVE .........................................................................................................................................................9
10. LEVER ARM ................................................................................................................................................9
11. NOZZLE/DIFFUSER ..................................................................................................................................10
12. CIRCUIT BOARD ......................................................................................................................................10
13. FLOWMETER ............................................................................................................................................10
14. FLOW WASHER ASSEMBLY ...................................................................................................................11
15. SYRUP REGULATOR PLUG ....................................................................................................................13
16. WATER SOLENOID ACCESS...................................................................................................................14
17. WATER SOLENOID ASSEMBLY..............................................................................................................14
18. SYRUP BODY ACCESS ...........................................................................................................................15
19. SYRUP SOLENOID ACCESS ...................................................................................................................16
20. SYRUP SOLENOID ASSEMBLY ..............................................................................................................17
21. TROUBLESHOOTING...............................................................................................................................18
VOLUMETRIC VALVE PARTS LIST ...............................................................................................................22
LISTING OF ILLUSTRA
TIONS
1. MAIN COMPONENTS .................................................................................................................................2
2. OPERATION DIAGRAM - VALVE ON ........................................................................................................2
3. OPERATION DIAGRAM - VALVE ON ........................................................................................................2
4. OPERATION DIAGRAM - VALVE OFF.......................................................................................................3
5. NOZZLE/DIFFUSER....................................................................................................................................3
6. VALVE CONTROLS ....................................................................................................................................4
7. SYRUP PURGE PLUG................................................................................................................................5
8, HAND HELD PROGRAMMER, PN 52-1420/01..........................................................................................5
9. PORTION CONTROL, CUP BUTTONS, OVERLAY...................................................................................7
10. PORTION CONTROL, CUP BUTTONS, OVERLAY, WITH WATER ..........................................................7
11. RAISED TAB CONFIGURATION ................................................................................................................8
12. REMOVING THE HOUSING .......................................................................................................................8
13. ID PANEL INSTALLATION..........................................................................................................................9
14. LEVER ARM REPLACEMENT....................................................................................................................9
15. NOZZLE/DIFFUSER ..................................................................................................................................10
16. CIRCUIT BOARD CONNECTIONS...........................................................................................................10
17. CIRCUIT BOARD MOUNTING ..................................................................................................................11
18. FLOW METER ACCESS ...........................................................................................................................12
19. FLOW WASHER/SYRUP PLUG ACCESS ...............................................................................................12
20. WATER SOLENOID ACCESS...................................................................................................................13
21. WATER SOLENOID ASSEMBLY..............................................................................................................14
22. SYRUP BODY ACCESS ...........................................................................................................................15
23. SYRUP SOLENOID ACCESS ...................................................................................................................16
24. SYRUP SOLENOID ASSEMBLY ..............................................................................................................17
25. EXPLODED VIEW, VOLUMETRIC VALVE ASSEMBLY ..........................................................................23
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
DESCRIPTION
The Volumetric Valve dispenses post-mix beverages accurately over a broad range of pressures and syrup
viscosities. Configurations, from a cup lever to a portion control panel interface, allow the Volumetric Valve
to fit many different applications. The Volumetric Valve mounts to a standard LEV
® back block and utilizes
the same cover as the LEV®.
SPECIFICATIONS
FINISHED DRINK FLOW RATES:
• 3.0 ounces per sec (88.7 ml/sec), Standard
• 2.25 ounces per sec (66.5 ml/sec)
• 1.50 ounces per sec (44.4 ml/sec)
PRESSURE REQUIREMENTS:
Flowing pressure (at the valve)
Minimum Maximum
Water 40 psig 110 psig
(2.8 Kg/cm2) (7.7 Kg/cm2)
Syrup (Sugar) 20 psig 70 psig
(1.4 Kg/cm2) (4.9 Kg/cm2)
Syrup (Diet) 10 psig 70 psig
(0.7 Kg/cm2) (4.9 Kg/cm2)
ELECTRICAL REQUIREMENT:
24 VAC, 50/60 Hz
MOUNTING
Mounts on the same hole pattern with the same mounting screws as the following valves:
Lancer LEV
® Cornelius SF-1 Dole SEV McCann Turbo Flo Jr. Dole FFV
MAINTENANCE TOOLS
When troubleshooting and accessing the Volumetric Valve, the following tools will be needed:
Standard
• #2 Phillips Head Screw Driver
• Flat End Screw Driver
• Dow Corning® 111 Valve Lubricant & Sealant
• Volumetric Valve Hand Held Programmer (Lancer PN 52-1420/02; CCPN 532179)
Optional
• 3/16 inch Hex Socket Driver
• Ohmmeter
1
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
1. PRINCIPLE OF OPERATION
1.1 HOW THE SYSTEM WORKS
2
Main Components
Figure 1
A. Three systems in the Volumetric Valve work together to maintain an accurate syrup to water
ratio:
• The circuit board with its computer.
• The water measuring system.
• The syrup injecting system.
B. Set the ratio by using the hand held programmer (Lancer PN 52-1420/02; CCPN 532179).
C. When a customer activates the valve, the water starts flowing to the nozzle. The flow washer
ensures that the water does not flow too fast.
D. The paddle wheel in the flowmeter begins to spin, sending signals to the circuit board (see
Figure 2).
Operation Diagram - Valve ON
Figure 2
Operation Diagram - Valve ON
Figure 3
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
Components:
Circuit Board
Water Syrup
Measuring
System
Water
Solenoid
Flowmeter
Flow Washer
Nozzle
W1
W1
Piston
S1
S1
Syrup Chamber
S2
S2
Injecting
System
Syrup Solenoids
S1
S1
S2
S2
E. The computer on the circuit board
monitors the signals and determines
when to precisely inject syrup into the
water stream. The circuit board
energizes one syrup solenoid and then
the other. This alternating action injects a
metered amount of syrup into the water.
This happens seven to eight (7-8) times
a second (see Figures 2 and 3).
F. The circuit board indicates which
solenoid is activated with the LEDs
mounted on the front of the board. The
green LED corresponds to the water
solenoid and the red LEDs correspond to
the syrup solenoids.
3
Operation Diagram - Valve OFF
Figure 4
2. VOLUMETRIC VALVE CLEANING AND SANITIZING PROCEDURES
2.1 DAILY NOZZLE/DIFFUSER CLEANING (SEE FIGURE 5)
Use the following procedures to clean the nozzle, and the diffuser assembly, each day:
A. Remove nozzle by twisting it counter-clockwise and
pulling it down.
B. Pull the diffuser assembly down to remove it from the
valve.
C. Wash the nozzle and diffuser with warm water.
D. If needed, apply 111 lubricant to the o-ring on the
diffuser assembly. Then, carefully press it into the
diffuser mounting area on the underside of the valve.
E. Install the nozzle by inserting it into the bottom plate
and twisting it clockwise to lock it in place.
2.2 MONTHLY NOZZLE/DIFFUSER SANITIZING
Use the following procedures to sanitize the nozzle, and
the diffuser assembly, once a month.
A. Cleaning Solution
Prepare a caustic-based (low sudsing, non-perfumed,
and easily rinsed) detergent solution and clean,
potable water at a temperature of 90° to 110°F. The
cleaning solution should be 2% sodium hydroxide.
B. Sanitizing Solution
Nozzle / Diffuser
Figure 5
potable water at a temperature of 90° to 110°F. Any sanitizing solution may be used as long as it is
prepared in accordance with the manufacturer’s written recommendations and safety guidelines, and
provides 50 PPM available chlorine.
C. Cleaning Procedure
CAUTION
BE CAREFUL NOT TO GET SANITIZING SOLUTION ON THE CIRCUIT BOARD.
1. Disconnect power, so the valve will not be inadvertently activated while cleaning.
2. Remove nozzle by twisting it counter-clockwise and pulling it down.
3. Pull the diffuser assembly down to remove it from the valve.
4. Wash the nozzle and diffuser with the cleaning solution.
5. Immerse the nozzle and diffuser in a bath of the sanitizing solution for 15 minutes.
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
Prepare a chlorine solution (less than pH 7.0)
containing 50 PPM available chlorine with clean,
W1
W1
Diffuser Assembly
54-0176/02
(24245)
Nozzle
05-2053
(24246)
NOTE: Part Number in ( ) is a Coca-Cola PN
S1
S1
S2
S2
6. While the parts are in the sanitizing
solution, visually inspect around the
nozzle mounting area on the valve
for syrup residue. Using a cloth or
nozzle brush and warm water,
clean this area.
7. Wipe off the dispensing lever and
any other areas that may have
been splashed by syrup.
8. Wearing sanitary gloves, remove,
drain, and air dry the nozzle and
diffuser.
9. Wearing sanitary gloves, carefully
press the diffuser into the mounting
area on the underside of the valve.
10. Wearing sanitary gloves, install the
nozzle by inserting it into the
bottom plate and twisting it
clockwise to lock it in place.
4
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
Valve Controls
Figure 6
11. Connect power and replace cover. Valve is ready for operation.
12. Draw drinks to flush residual sanitizing solution. Taste the beverage to verify that there is
no off taste. If an off taste is found, additional flushing may be required.
2.3 VALVE AND SYSTEM SANITIZING
A. The complete valve and dispenser system must be sanitized during initial installation. Follow
the manufacturer’s instructions when scheduling and conducting dispenser sanitizing. The
valve must be sanitized once every two weeks. The valve may remain on the dispensing tower
during the sanitizing process.
B. For syrup side line priming, and cleaning and sanitization procedures, refer to the Syrup Purge
Plug (Lancer PN 52-1912) in the Valve Set-Up Section.
3. VALVE SET-UP
3.1 The following steps provide an overview of the valve set-up procedures:
A. Mount valve on back block (see Section 9).
B. Verify that power supply is 24 VAC, 50/60 Hz, then connect to valve.
C. Connect water (soda) and syrup supplies. Flowing pressures must meet valve specifications
(see Specifications, Page i).
D. Set ratio and select carbonation. See Section 6 for hand held programmer procedures.
E. Set the syrup restrictor for either diet or sugar syrup (see Section 4).
F. Purge syrup lines using the hand held programmer (see Section 6).
G. Install valve cover, and if necessary, connect ID panel (see Section 8).
H. Activate valve to test dispensing.
4. SYRUP RESTRICTOR SETTING
4.1 SUGAR SYRUP AND DIET SYRUP FROM FIGALS
Restrictor out and down. Syrup restrictor is not in use.
4.2 DIET SYRUP FROM BAG-IN-BOX
Restrictor in and up. Syrup restrictor is in use.
5. SYRUP PURGE PLUG
5.1 The Syrup Purge Plug (PN 52-1912), places the valve in continuous syrup side operation.
5.2 The targeted uses for the purge plug consist of priming the syrup line on an initial Volumetric Valve
install, and for cleaning and sanitization of the syrup side of the dispensing unit.
Plug (Programmer,
Portion Control,
Pushbutton, Syrup
Purge Plug)
Syrup Restrictor
5.3 Operation of the syrup purge plug is as follows:
CAUTION
THE VALVE CONSUMES 12VA IN A CONTINUOUS SYRUP SIDE OPERATION. WITH A
STANDARD 75VA TRANSFORMER, UP TO SIX (6) VOLUMETRIC VALVES CAN BE OPERATED
IN SYRUP PURGE MODE SIMULTANEOUSLY.
A. Turn off electrical power to all valves.
B. Install syrup purge plugs into the valve or valves to be primed or sanitized. The syrup purge
5
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
plug installs in the ten-pin connector of the Volumetric
Valve circuit board.
C. Turn on electrical power to the valves. At this time, the
syrup side of the valves will begin continuous operation.
D. When through with the priming or sanitization operation,
syrup purge operation can be stopped either of two
ways:
1. Method 1: Turn off electrical power to all valves,
remove syrup purge plugs from the valves. Turn on
electrical power to all valves. Tap valve lever or
push button to ensure proper operation of all valves.
Syrup Purge Plug
Figure 7
2. Method 2: Remove syrup purge plug from the valves while they are in purge operation. In
this case, the valve may continue in the purge mode for up to six (6) seconds after removal
of the plug (this is normal). Tap valve lever or push button to ensure proper operation of all
valves.
5.4 With a standard 75 VA transformer, up to six (6) Volumetric Valves can be operated in syrup purge
mode simultaneously.
6. PROGRAMMER OPERATING PROCEDURES
6.1 CONNECTING
A. Remove the ID panel from the front of the valve.
B. Insert the programmer's 10-pin connector into the ID Panel plug on the front of the circuit board.
Hand Held Programmer,
Lancer PN 52-1420/02
CCPN 532179
Figure 8
C. When properly connected, the programmer will run a self
diagnostic test. The display will show all "8"s with the
decimal points lighted. After three (3) seconds, the display
indicates the setting of the dip switches.
D. If the programmer does not run its diagnostic test properly,
disconnect it and try plugging it in again. If the programmer
still fails, replace the programmer.
6.2 FUNCTIONS
Read Memory:
Press this button to read and display the current settings
programmed into the valve memory (i.e., S/W revision,
ratio, and carb/non carb settings).
Read Dip Switches:
Press this button to read the dip switch settings.
NOTE
Dip switches were used on some field test valves (see
28-0301, 12/20/95).
SYRUP PURGE
52-1912
Write Memory:
Press this button to write the programmer’s displayed ratio and carbonation settings into the
valve’s memory.
Timed 5 Second Water:
Press this button to pour water for five (5) seconds. The programmer will display the ratio, the
counts from the flowmeter, the flow rate in oz/sec, and the flow rate in ml/sec.
Timed 5 Second Pour:
Press this button to dispense a five (5) second pour of water and syrup for ratio testing. When
complete, the programmer displays the ratio, carbonation settings, and total Flowmeter
counts.
Syrup Purge:
Press and release to dispense a six (6) second syrup purge. Continue holding to purge syrup
from system.
Ratio + (Plus):
Pressing this button will increase the ratio number on the display.
Ratio - (Minus):
Pressing this button will decrease the ratio number on the display.
Carb Toggle:
Pressing this button will toggle the carbonation setting from carbonated “C” to plain water “n”
(non-carbonated).
Pour/Stop:
Press this button to manually pour a mixed drink. This button will also stop a timed pour.
6.3 SETTING THE RATIO/CARBONATION
A. Connect the programmer to the Valve.
B. Press the “Read Mem” button.
C. Press the “Ratio +” or the “Ratio -” key until the desired ratio is displayed.
D. Verify drink type. Press “Carb Toggle”to select “C” for carbonated or “n” for non-carbonated.
E. Press the “Enter” button to program the valve with the setting on the display
F. Verify Ratio by pressing “Read Mem”.
G. Disconnect the programmer.
6
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
7. PORTION CONTROL PROGRAMMING PROCEDURES
The following procedures describe the operation and programming of portion control ID panels for the
Volumetric Valve.
7.1 OPERATION
A. Cup buttons are Small, Medium, Large, Extra-Large.
B. Press and release the desired cup size. Valve will fill cup as programmed (See below).
C. Pour/Cancel Button
1. Push and release to cancel or stop valve dispensing.
2. Push and hold for continuous pour.
D. Water Button
1. Push and hold for continuous water pour.
2. Valve will dispense carbonated or non-carbonated water, depending on its location on the
dispenser.
7.2 TEACH AND LEARN PORTION CONTROL PROGRAMMING
In this mode, the valve “learns” the steps to fill each cup size, including the top off delay time. When
activated, the valve dispenses the appropriate drink volume. Then, if a top off has been entered, it
will pause for the programmed length of time. Finally, the valve will dispense the correct top off
amount.
A. Initial Install Procedure
1. Simultaneously, press and hold the small cup button and the extra-large cup button
switches on the portion control until the LED light in center of module starts blinking, then
release switches. The blinking LED indicates that the set mode is active.
2. Put desired amount of ice in cup, place cup under valve and push selected size button
(small, medium, large, or extra-large). Hold button in until cup fills to desired portion, then
release button.
3. Top off: If a top off is not needed, go to Step 4. Wait for foam to settle, then actuate button
again to top off.
NOTE
Only one (1) top off is allowed.
4. Repeat steps 2 and 3 for other drink sizes. Go to Step 5 to exit program mode.
5. Press and release pour/stop button to return the portion control to the operational mode.
Blinking LED light will go out.
6. Repeat steps 1 through 5 for remaining valves.
7
MAINTENANCE MANUAL
Volumetric Post-Mix Valve
Portion Control, Cup Buttons, Overlay
Figure 9
Portion Control, Cup Buttons, Overlay, with Water
Figure 10
7.3 TO CHANGE DISPENSE SIZE
Use procedures in the Initial Install Procedure discussed above; it is not necessary to reprogram
every size.
Small
Cup Button
Medium
Cup Button
Large
Cup Button
Extra-Large
Cup Button
Small
Cup Button
Medium
Cup Button
Large
Cup Button
Extra-Large
Cup Button
water
Water
Pour/Stop
Cup Button
Button
Pour/Stop
Cup Button
Loading...