Turbo Carbonator Manual

TURbO CARbONATOR
Installation and Service Manual
PN 28-0315/07
1/26/2010
85-1923-00 Carbonator, 115V, VCV, Diagnostic
85-1923-01 Carbonator, 115V, VCV, Diagnostic, Insulated
85-1923-02 Carbonator, 115V, VCV, Diagnostic, Tee
85-1923-07 Carbonator, 115V, VCV, Diagnostic, Polished
85-1924-00 Carbonator, 230V, VCV, Diagnostic
85-1924-01 Carbonator, 230V, VCV, Diagnostic, Insulated
85-1924-06 Carbonator, 230V, VCV, Diagnostic, Reset
SAVE
THESE
INSTRUCTIONS
Before Getting Started
Each carbonator is tested under operating conditions and is thoroughly
inspected before shipment. At the time of shipment, the carrier accepts
responsibility for the carbonator. Upon receiving the carbonator, carefully
inspect the carton for visible damage. If damage exists, have the carrier
note the damage on the freight bill and file a claim with carrier. Responsibility
for damage to the carbonator lies with the carrier.
LANCER CORP
6655 Lancer Blvd.
San Antonio, Texas 78219
To order parts, call
Customer Service: 800-729-1500
Your Service Agent:____________________________
Service Agent Telephone Number:_________________
Carbonator Serial Number:_______________________
Warranty/Technical Support: 800-729-1550
Email: [email protected]
www.lancercorp.com
“Lancer” is the registered trademark of Lancer Corp © 2012 by Lancer Corp, all rights reserved.
Certified
< 0.25 weighted
average percent lead
Table of Contents
1.
2.
3.
4.
5.
6.
7.
INSTALLATION INSTRUCTIONS ...............................................................................................................3
ELECTRICAL REQUIREMENTS ...............................................................................................................4
OPERATING INSTRUCTIONS ....................................................................................................................5
INSPECTIONS.............................................................................................................................................6
CLEANING AND REPLACEMENT..............................................................................................................6
TROUbLESHOOTING .................................................................................................................................9
ILLUSTRATIONS, PARTS LISTINGS, AND WIRING DIAGRAMS...........................................................10
7.1 ChECk vALvE ASSEmBLy .............................................................................................................10
7.2 Wiring diAgrAm (Pn 06-0266/02)...............................................................................................10
7.3 CArBonATor TAnk ......................................................................................................................11
SPECIFICATIONS
DIMENSIONS
Width
depth
height
12 1/4 inches (311 mm)
15 1/4 inches (387 mm)
11 1/2 inches (292 mm)
WEIGHT
Shipping
Empty
operating
33.5 pounds (15.2 kg)
31.1 pounds (14.1 kg)
45.3 pounds (20.5 kg)
ELECTRICAL
Domestic
operating voltage
hertz
Amps
115
60
6.3
Export
operating voltage
hertz
Amps
230
50/60
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
CO2 INLET
1/4 inch s.a.e. male Flare
CARbONATED WATER OUTLET (TWO)
3/8 inch s.a.e. male Flare
TANK OPERATING CAPACITY
bACKFLOW PREVENTER
215 ounces (6.4 L)
max 130° F (54° C)
max 200 PSig (13.8 BAr)
ASSE 1022 Compliant
TIMEOUT FEATURE: The carbonator is designed with a Timeout feature for self-protection. if the carbonator
runs for longer than three minutes without the demand for water being met, the carbonator will shut down.
refer to Troubleshooting section.
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2
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 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 the 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.
WARNING!
AVERTISSEMENT!
Carbon dioxide (CO2) displaces oxygen. Strict attention must be
observed in the prevention of CO2 gas leaks in the entire CO2 and soft
drink system. if a CO2 gas leak is suspected, immediately ventilate the
contaminated area before attempting to repair the leak. CO2 is heavier
than air. it is a colorless, non-combustible gas with a faintly pungent
odor. high percentages of CO2 may displace oxygen in the blood;
prolonged exposure to CO2 may be harmful. Personnel exposed to
high concentrations of CO2 gas will experience tremors which are
followed rapidly by loss of consciousness and suffocation.
Le dioxyde de carbone (CO2) déplace l’oxygène. il faut porter une
attention très stricte à la prévention des fuites de gaz de CO2 dans
l’ensemble du système de CO2 et de boissons gazeuses. Si vous
soupçonnez une fuite de gaz de CO2, ventiler immédiatement l’endroit
contaminé avant de tenter de réparer la fuite. Le CO2 est plus lourd
que l’air. C’est un gaz incolore incombustible ayant une légère odeur
âcre. de forts pourcentages de CO2 peuvent déplacer l'oxygène dans
le sang; une exposition prolongée au CO2 peut être nocive. Le
personnel exposé à de fortes concentrations de CO2 peut ressentir
des tremblements, suivis rapidement de la perte de connaissance et
de la suffocation.
1. Installation Instructions
Select a level, well-ventilated, accessible location convenient to water and electrical supply, which
can support a weight of 100 lbs (45.3 kg).
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28-0315/08
2. Electrical Requirements
IMPORTANT SAFETY INSTRUCTIONS/CONSIGNES DE SÉCURITÉ IMPORTANTES
When using electric appliances, basic precautions should
always be followed, including the following:
WARNING!
AVERTISSEMENT!
a)
b)
c)
d)
read all the instructions before using the appliance.
do not use outdoors.
do not unplug by pulling on the cord.
For a grounded appliance, connect to properly grounded outlet only. See
grounding instructions.
e) Unplug from outlet before servicing or cleaning.
Des précautions de base doivent toujours être suivies lorsque des appareils
ménagers électriques sont utilisés, notamment :
a)
b)
c)
d)
Lire toutes les instructions avant d’utiliser l’appareil.
ne pas utiliser à l’extérieur.
ne jamais tirer sur le cordon pour débrancher l’appareil.
Brancher tout appareil devant être mis à la terre uniquement sur une prise
avec mise à la terre. voir les instructions de mise à la terre.
e) débrancher l’appareil de la prise avant de le réparer ou de le nettoyer.
GROUNDING INSTRUCTIONS/INSTRUCTIONS DE MISE à LA TERRE
For all grounded, cord-connected appliances/Pour tout appareil à cordon avec mise
à la terre:
This appliance must be properly 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. In the event of malfunction or breakdown, grounding
provides a path of least resistance for electric current to reduce the risk of electric
WARNING!
shock. This appliance is equipped with a cord having an equipment-grounding plug.
AVERTISSEMENT! The plug must be plugged into an appropriate outlet that is properly installed and
grounded in accordance with all local codes and ordinances.
This appliance is for use on a nominal 120V (or 230V, as applicable) circuit, and has a
grounding plug that looks like the plug illustrated below.
Cet appareil doit être mis à la terre de la manière appropriée afin d’éviter des chocs
électriques mortels ou des blessures graves à l’opérateur. Le cordon d’alimentation est
fourni avec une fiche à trois broches pour la mise à la terre. Utiliser une autre méthode
approuvée pour mettre l'appareil à la terre lorsqu'une prise de courant de mise à la
terre (trois trous) n’est pas disponible. Advenant une défaillance ou un bris, la mise à la
terre fournit un trajet de moindre résistance pour le courant électrique afin de réduire le
risque de choc électrique. Cet appareil est équipé d’un cordon ayant une fiche de
mise à la terre. La fiche doit être branchée sur une prise appropriée correctement
installée et mise à la terre conformément aux codes aux règlements locaux.
Cet appareil doit être utilisé sur un circuit de 120 V (ou 230V est d"application)
nominal et comporte une fiche qui ressemble à la fiche illustrée ci-dessous.
28-0315/08
4
Improper connection of the equipment-grounding conductor can result in a risk of
electric shock. The conductor with insulation having an outer surface that is green,
with or without yellow strips, is the equipment-grounding conductor. If repair or
replacement of the cord or plug is necessary, do not connect the equipment-grounding
conductor to a live terminal. Check with a qualified electrician or serviceman if the
grounding instructions are not completely understood, or if in doubt whether the
appliance is properly grounded. Do not modify the plug provided with the appliance.
If it will not fit the outlet, have a proper outlet installed by a qualified electrician.
Un branchement inapproprié du conducteur de mise à la terre peut causer un risque
de choc électrique. Le conducteur de mise à la terre est celui dont l’isolant a une
surface extérieure verte (avec ou sans barres jaunes). S'il est nécessaire de réparer
ou de remplacer le cordon ou la fiche, ne pas brancher le conducteur de mise à la
terre sur un terminal sous tension. Faire appel à un électricien ou un réparateur
qualifié si les instructions de mise à la terre ne sont pas complètement comprises ou si
l’appareil ne semble pas être mis à la terre de la manière appropriée. Ne jamais
modifier la fiche fournie avec l’appareil. Si elle ne s’insère pas dans la prise,
demander à un électricien qualifié d’installer une prise appropriée.
2.1 Check the serial number plate for correct electrical requirements of the unit. do not plug into the
electrical outlet unless the current shown in the serial number plate agrees with local current
available.
2.2 A separate electrical circuit must be supplied for each carbonator.
2.3 do not use extension cords or “gang” together with other electrical devices on the same outlet.
3. Operating Instructions
3.1 Connect 3/8” flexible pressure tubing, or larger, from water supply to pump inlet. Do not
connect to a hot water or soft water source. A shutoff valve and screen (minimum 100 mesh),
should be installed in water supply line to carbonator. A water filter may also be necessary in
water supply line to carbonator, depending on local conditions. Water pressure entering the
pump should be at a minimum of 25 PSig (1.72 BAr); recommended water pressure is 50
PSig (3.45 BAr), and should never exceed Co2 pressure. if necessary, install a regulator.
5
28-0315/08
3.2 Connect Co2 pressure supply to Co2 inlet on carbonator tank, with normal operating pressure
at 105 PSig (7.2 BAr). Do not exceed 120 PSIG (8.3 bAR). if excessive foam in drink is
present, reduce Co2 pressure to approximately 90 PSig (6.2 BAr).
3.3 Connect carbonator water outlet to dispensing system. if only one tank outlet is used, cap
remaining with stainless steel cap and flare washer, Pns 01-0212 and 05-0017. To avoid
contamination of potable liquids, do not connect copper tubing or fitting between the discharge
fitting of carbonator tank and dispenser.
3.4 open pressure relief valve by moving yellow lever to vertical position.
3.5 To remove air, turn water supply on and fill tank until water can be seen coming out of pressure
relief valve.
3.6 Close pressure relief valve by moving yellow lever to horizontal position.
3.7 Turn on Co2 supply and adjust to correct pressure.
3.8 if electrical requirements have been met, plug in carbonator.
3.9 Check for Co2 and water leaks.
3.10 open a dispensing valve. Allow carbonator to cycle several times, turning motor oFF and on
to flush system.
User Maintenance Instructions
4. Inspections
4.1 Periodically inspect for Co2 or water leaks. Perform maintenance as necessary.
4.2 inspect and clean pump strainer.
5. Cleaning and Replacement
5.1 CO2 Check Valve
A.
B.
C.
d.
Unplug power cord.
Shut water supply oFF to pump.
Turn Co2 supply oFF and set Co2 pressure regulator at 0 PSig.
disconnect Co2 supply line from Co2 check valve.
do not probe valve with any object.
ne jamais sonder le clapet avec un objet quelconque.
CAUTION!
ATTENTION!
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 Co2 supply line to Co2 check valve.
J. Follow start up procedure to put carbonator back into operation.
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6
5.2 backflow Preventer
if the first check on the backflow preventer fails, carbonated water will
leak from the vent on the valve. Do not disassemble the backflow
preventer. replace by ordering part number 17-0611. do not disable
the backflow preventer.
CAUTION!
ATTENTION!
A.
B.
C.
d.
E.
F.
g.
h.
i.
Si le premier contrôle du disconnecteur hydraulique échoue, de l’eau
carbonée fuira par l’évent du clapet. Ne jamais désassembler le
disconnecteur hydraulique. Commander un nouveau disconnecteur
hydraulique, nº de pièce 17-0611. ne jamais mettre le disconnecteur
hydraulique hors fonction.
Unplug power cord.
Shut water supply oFF to pump.
Set Co2 pressure at 100 to 125 PSig (6.9 to 8.6 BAr).
disconnect stainless steel water line from water inlet check valve. do not loosen check
valve assembly.
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 i below.
Turn Co2 pressure oFF. release pressure in tank, using relief valve.
replace the backflow preventer.
reconnect stainless steel line to water inlet check valve.
Follow start up procedure to put carbonator back into operation.
5.3 Pump Strainer Screen
A.
B.
C.
d.
E.
F.
g.
h.
Unplug power cord.
Shut water supply oFF to pump.
Unscrew brass plug on pump, and remove strainer from pump.
inspect and clean, or replace, strainer screen.
reinstall strainer, and tighten brass plug.
Turn water supply on.
Check for leaks. if a leak is detected, carefully tighten brass plug.
Plug power cord into electrical outlet.
5.4 Probe
A.
B.
C.
d.
E.
F.
Unplug power cord.
Shut water and Co2 gas supplies oFF.
relieve pressure in tank using relief valve.
remove cover and unplug probe leads from PC board.
Unscrew probe from top of tank.
Screw new probe into top of tank. Be sure to install white plastic washer as a water tight
seal will not be obtained without the washer.
g. Connect probe leads to PC board as follows:
green
g
Black
Lo
White
hi
7
28-0315/08
h. Slide probe strain relief into slot and replace cover.
i. Follow start-up procedure for putting carbonator back into operation.
5.5 PC board
A.
B.
C.
d.
E.
F.
Unplug power cord.
remove cover from PC board enclosure.
Unplug probe, power cord and motor cord leads from PC board.
remove PC board assembly.
install new PC board and secure with screws.
Connect push on leads to PC board as follows:
Probe
Power Cord
Motor Cord
green
g
Black
1
Black
3
Black
Lo
White
2
White
4
White
hi
g. replace cover.
h. Plug in power cord.
i. Test diagnostic switch connector.
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8
6. Troubleshooting
PC board Self-Diagnostics
Follow instruction label on enclosure cover to help determine if probe, motor or board is faulty.
Trouble
motor does not start.
(motor hums.)
Cause
Remedy
1. Pump binding.
1. rotate pump slightly to
free binding. if this fails,
replace pump.
2. open winding infield.
2. replace motor.
1. overload by pump
binding.
1. Let motor cool and free
pump binding.
2. Fuse or circuit breaker.
2. replace fuse or reset
circuit breaker.
3. Faulty motor.
3. replace motor.
4. Faulty PC board.
4. replace PC board.
5. Faulty probe.
5. replace probe.
6. Timeout feature has
activated. This happens
when the carbonator runs
longer than three minutes
without the demand for
water being met.
6. reset power to the
carbonator.
1. restriction in inlet water
check valve.
1. disassemble inlet water
check valve and clean.
2. restriction in pump.
2. Clean strainer or replace
pump.
3. Faulty board or probe.
3. replace board or probe.
Pressure relief valve
releases water.
1. Faulty relief valve.
1. replace relief valve.
Low Carbonation.
1. Low Co2 pressure.
1. increase Co2 pressure
or replace Co2 tank.
motor does not start.
(motor does not hum.)
motor runs continuously.
2. Leaking Co2 supply line. 2. Locate leak and repair.
Foamy product.
1. over carbonation.
9
1. reduce Co2 pressure.
28-0315/08
basic Go/No Go Carbonator Control Test
Part number 06-1236/01 (shown below) is found on the cover of the carbonator assembly. it provides
a basic troubleshooting procedure to determine if the liquid level control is operating properly. The
procedure will help isolate problems to the probe, motor or PC Board.
7. Ilustrations, Parts Listings, and Wiring Diagrams
7.1 Check Valve Assembly
1
2
ITEM
1
2
3
4
3
PART NO.
DESCRIPTION
17-0342
01-0669
02-0005
01-0689
Co2 Check valve Assy
Body
o-ring
Sleeve
4
6
5
ITEM
5
6
7
7
PART NO.
DESCRIPTION
01-0674
03-0021
02-0003
Ball
Spring
o-ring
7.3 Wiring Diagram (PN 06-0266/02)
GREEN
BLACK
WHITE
J4
J3
PC BOARD
PROBE
LOW VOLTAGE
HI
LO
L1
MOTOR
115 VAC
G
WHITE
BLACK
GREEN
28-0315/08
L2
115 V or 220 V
WHITE
BLACK
GREEN
10
7.3
Carbonator Tank
2
1
3
4
6
Tee (PN 01-2623) not shown.
7
33
35
13
5
34
9
10
9
8
2
32
31
12
30
29
28
27
11
14
26
25
15
24
9
16
17
Item
1
2
3
4
5
7
8
9
10
11
12
13
14
15
16
17
18
Part No.
18
Description
19
22
20
Item
19
20
21
22
23
05-0528-01
04-0470
12-0241
06-1289
06-1236/01
04-0836/01
04-0049
04-0297
06-0266/02
05-0017
87-0026
48-2386
17-0611
Cover, Carb LLC
Screw, 6-19X0.500, PHD
Boot, U-1403-APEM
Label, Test Switch, Carb
Label, Troubleshoot
Washer, Lock, Internal Tooth
Nut, Hex, 8-32, SS
Nut, Hex, 8-32, KEPS, SS
Label, Wiring Diagram
Washer, Seal, Flare, Nylon, 3/8
Tank Assy, Carb, 3/8, Flare
Tubing Assy, Water, 3/8
Check Valve, Vented, BR,
ABCO
17-0611-01 Check Valve, SS
01-0111
Adapter, BR, 3/8 x 3/8
86-0085
Pump Assy, Water,
Replaceable
07-0017/01 Clamp with Screw, ZP
04-0032/01 Nut, Nylock, 1/4-20, SS
24
25
26
27
28
29
30
31
32
33
34
35
11
18
23
21
Part No.
Description
06-0075-01
07-0199/01
04-1361
04-0247
52-0588
52-1898
04-0033/01
04-0520/01
91-0008
91-0011/01
52-0585
13-0028
13-0008
13-0026
05-0529-01
64-5000
64-2962
64-2962-01
54-0066
06-2590
52-0590/01
Nameplate, Vinyl, PN/SN/ ELEC
Plate, Base Probe, Carb
Screw, 8-32 x 0.75, PH, SS
Isolator, 1/4-20 Single Stud
Power Cord Assy
Cord Assy, Carb, 220V
Washer, Flat, 4 x 0.065 x 0.281 ID
Screw, 1/4-20 x 0.500, HHD, SS
Motor, Carb, 1/3HP, 115V/60A
Motor, Carb, 1/3HP, 220V/50Hz
Cord Assy, Motor
Relief, Strain, 7/8 DIA
Bushing Relief, HEYCO, 1200
Strain Relief, Small
Enclosure, Carb, Control, Self
PCB Assy
PCB Assy, 220V
PCB Assy, 220V w/Reset
Relief Valve Assy, Plastic
Label, “Reset Button”
Probe Assy
28-0315/08
LANCER
To order parts, call
Customer Service: 800-729-1500
Warranty: 800-729-1550
Email: [email protected]
www.lancercorp.com