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Manitowoc Multiplex Beermaster 175A04, Technician'S Handbook, Page: 94 / 174

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Manitowoc Multiplex Beermaster 175A04 Technician'S Handbook Download Page 94

94

Part Number STH13 9/10

Heat Exchanger 

FUNCTION OF THE HEAT EXCHANGER 

Provides the heat exchange between the glycol circuit 
and the dispensing faucet keeping every beer cold.

FAILURE OF THE HEAT EXCHANGER 

If heat exchanger is not in direct contact with the 
dispensing faucet and the glycol circuit, it could cause 
warm beer after slow or quiet periods. 

STH13_Tech.book  Page 94  Wednesday, September 15, 2010  3:20 PM

Summary of Contents for Multiplex Beermaster 175A04

Page 1: ... information and models are released Visit our website for the latest manual www manitowocfsg com America s Quality Choice in Refrigeration Beermaster Refrigeration Units Part Number STH13 9 10 STH13_Tech book Page 1 Wednesday September 15 2010 3 20 PM ...

Page 2: ...STH13_Tech book Page 2 Wednesday September 15 2010 3 20 PM ...

Page 3: ... this handbook you will see the following types of procedural notices Warning Text in a Warning box alerts you to a potential personal injury situation Be sure to read the Warning statement before proceeding and work carefully Caution Text in a Caution box alerts you to a situation in which you could damage the equipment Be sure to read the Caution statement before proceeding and work carefully Im...

Page 4: ...roceed contact Manitowoc Foodservice Group We will be happy to provide assistance Important Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications We reserve the right to mak...

Page 5: ...Conduit 33 Balancing the System 48 Beermaster Wine Dispensing Kit 54 Aeroquip Connection 58 Condenser and Pre charged Lines Installation 58 Preparing Glycol 66 Additional Glycol Circulating Pump and Motor Kit 68 Beermaster Dispensing Towers 72 High Pressure CO2 Regulator 00211500 73 Dual Secondary Regulator Kit 00211400 75 Beermaster Blenders 78 Beermaster Low CO2 Alarm Kit 79 Component Identifica...

Page 6: ...pment Setup and Close Procedure 116 Troubleshooting Foreword 119 Checklist 121 ETC Error Codes 124 ERC Error Notes 125 Component Check Procedures Head Pressure Control Valve 137 Charging Multiplex Remote Refrigeration Unit 139 Compressor Remote Condenser 140 Agitator Condenser 141 Carbonation System A or B 142 Circulation System A or B 143 ERC Control Board Keypad Display 144 Programming Auto Set ...

Page 7: ...TH13 9 10 7 Charts Conduit Specification Chart 151 Natural Keg Pressures Chart 152 System Calculators 153 Diagrams Circuit Diagrams 159 Wiring Diagrams 162 STH13_Tech book Page 7 Wednesday September 15 2010 3 20 PM ...

Page 8: ...8 Part Number STH13 9 10 STH13_Tech book Page 8 Wednesday September 15 2010 3 20 PM ...

Page 9: ...RX04 175A04 175W04 175R04 175AX04 175WX04 175RX04 300A04 300W04 300R04 300AX04 300WX04 300RX04 450A04 450W04 450R04 450AX04 450WX04 450RX04 04 R404a refrigerant Model Prefix Model Base 300 A 04 A Air cooled AX Air cooled international R Remote RX Remote international W Water cooled WX Water cooled international Condenser Type 300 1 hp 450 2 2 hp STH13_Tech book Page 9 Wednesday September 15 2010 3...

Page 10: ...applications These units must be installed in areas where adequate protection from the elements is provided all other models are ETL listed Model Serial Number Location These numbers are required when requesting information from your local Manitowoc Distributor service representative or Manitowoc Foodservice The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD They are al...

Page 11: ...be returned to activate the warranty on this equipment If a warranty card is not returned the warranty period can begin when the equipment leaves the factory No equipment may be returned without a written Return Materials Authorization RMA Equipment returned without an RMA will be refused at the dock and returned to the sender at the sender s expense Please contact your local distributor for retur...

Page 12: ...ipates or out gasses if allowed to stand in an open container for a period of time If this were to happen the beer would go flat The presence of CO2 gives beer its effervescent quality and distinct flavor There are several factors that affect the level of carbonation and therefore the quality and flavor of the beer that is delivered to the customer Pressure Beer is pressurized in the keg by the br...

Page 13: ...he vehicle for forcing the beer from the keg through the beer lines and into the glass at the dispensing point Many operators mistakenly believe that this is the only function or at least the major function of the applied pressure and therefore the pressure may be decreased or increased at will to facilitate a desired dispensing rate flow rate Because of the effects on the carbonation level of the...

Page 14: ...nt This type of system is commonly known as a long draw or remote system Manufacturers of these systems recommend using a blend of gasses or beer pumps usually a mixture of CO2 and air or CO2 and nitrogen to pressurize the system without over carbonating the beer The refrigerated chamber containing the kegs can be located more than 450 ft 91 4 m away from the serving location using these long draw...

Page 15: ...aming can occur more readily This energy level continues to increase at higher temperatures resulting in a rapid increase in the beer s tendency to foam An increase in temperature in the beer lines or the faucet itself can result in fracturing out gassing when the beer is dispensed This generally occurs when un refrigerated beer lines extend outside of the beer cooler and the ambient temperature s...

Page 16: ...prevent over carbonation In actual practice pure CO2 pressures above approximately 16 5 psi 1 1 bar at sea level should be avoided at normal temperature 36 F 2 2 C to 38 F 3 3 C to avoid an unacceptable level of over carbonation which leads to foaming problems When the pressures above this level are required for good dispensing the operator should switch to a blend of CO2 and nitrogen for pressuri...

Page 17: ...ontained in a flexible insulated housing These systems when properly designed and installed generally offer the best and most consistent draught beer product On the other hand an improperly designed installed or maintained system even a rough or damaged gasket can produce shots of foam continuous foam or continuously warm and therefore foamy beer NOTE A properly designed installed and maintained d...

Page 18: ...lve To maintain the cold temperature in the conduit the refrigeration system uses the Multiplex Beermaster refrigeration unit which chills a glycol bath This glycol which is adjusted to below 30 F 1 11 C is circulated through the conduit up to the dispensing faucet and back where it is re chilled in the bath These chilled glycol lines are touching the beer lines in the conduit maintaining the cold...

Page 19: ...gas is fed to the secondary regulators to beer pumps or the optional blender which may nitrogen with the CO2 to help reduce the chance of providing extra carbonation to the beer The secondary regulators are adjusted to the installer calculated pressure calculated for each keg This pressure is calculated to push the beer through the conduit to the dispensing faucets and flow at a desired 1 75 oz pe...

Page 20: ...ent lines in the conduit The beer lines which are also in the conduit are in contact with the glycol lines which will maintain the temperature of the beer This ensures that the product is dispensed at the beer cooler temperature The refrigeration compressor will cycle ON and OFF as needed to maintain the consistent temperature of glycol Each size of Beermaster Refrigeration Unit is rated for a max...

Page 21: ... second flow rate to reduce the chance of foaming and to dispense a proper glass of beer The proper way to adjust the flow rate of the beer is to reduce the diameter of the tubing using an installer calculated length of 3 16 diameter restrictor tubing The beer then flows through an aluminum or stainless steel heat exchanger that is kept in contact with the very cold glycol lines to maintain the co...

Page 22: ...nal pressure of the keg according to the Brewmaster the altitude at the location as well as the temperature of the beer in the cooler The object is to dispense the beer as fast as possible 2 oz per second with the proper gas pressure CO2 or mixed gas applied to the keg and adjusted so it will not change the carbonation or taste of the beer The installer must determine the proper pressure applied t...

Page 23: ...ng chase Dimensions and Clearances All Models Wall 6 15 2 cm Diameter Chase minimum Air Flow Control Switches 18 45 7 cm minimum J Electrical Junction Box 6 15 2 cm minimum 12 30 5 cm minimum Wall Wall Top View Side View P Wall Electrical Junction Box Incoming Water Line Incoming CO2 Supply Line Incoming Syrup Supply Lines Drain Plug D STH13_Tech book Page 23 Wednesday September 15 2010 3 20 PM ...

Page 24: ...art Number STH13 9 10 Front View W Ceiling Wall 18 45 7 cm minimum I H CO2 Regulator Panel Optional N Drain Plug Wall Conduit to Dispensing Towers STH13_Tech book Page 24 Wednesday September 15 2010 3 20 PM ...

Page 25: ...m 150 36 1 4 92 1 cm 19 1 2 49 5 cm 21 1 2 54 6 cm 11 28 cm 5 12 7 cm 9 22 9 cm 300 39 3 4 101 cm 24 3 4 62 9 cm 28 1 4 72 4 cm 60 3 4 154 3 cm 11 28 cm 6 15 2 cm 12 30 5 cm 450 42 1 4 107 3 cm 28 1 4 71 8 cm 32 1 4 81 9 cm 66 3 4 169 5 cm 11 28 cm 8 1 2 21 6 cm 14 35 6 cm STH13_Tech book Page 25 Wednesday September 15 2010 3 20 PM ...

Page 26: ...lity seal DO inspect pressure on regulators before starting up equipment DO protect eyes when working around refrigerants Warning Read the following warnings before beginning an installation Failure to do so may result in possible death or serious injury OPTIONAL 38 00 96 52 cm 34 00 86 36 cm 30 00 76 20 cm 29 50 74 93 cm 29 16 74 06 cm 6 00 15 24 cm 3 50 8 89 cm 4 00 10 16 cm 14 62 37 13 cm 6 50 ...

Page 27: ... with a chain DO NOT connect the CO2 cylinder s directly to the product container Doing so will result in an explosion causing possible death or injury It is best to connect the CO2 cylinder s to a regulator s DO NOT store CO2 cylinders in temperature above 125 F 51 7 C near furnaces radiator or sources of heat DO NOT release CO2 gas from old cylinder DO NOT touch refrigeration lines inside units ...

Page 28: ... the top rear of unit Optional equipment may require additional power supplies Warning Carbon Dioxide CO2 displaces oxygen Exposure to a high concentration of CO2 gas causes tremors which are followed rapidly by loss of consciousness and suffocation If a CO2 gas leak is suspected particularly in a small area immediately ventilate the area before repairing the leak CO2 lines and pumps must not be i...

Page 29: ... wire 1 Phase 60 Hz dual wall receptacle for optional electrical equipment domestic only NOTE Do not schedule the authorized Multiplex Equipment Installer until all of the above have been completed It will only result in charge backs to you for the unnecessary trips REQUIREMENTS FOR REFRIGERATION UNITS Conduit can be run through floor or ceiling chase 60 F 15 6 C minimum and 105 F 40 5 C maximum o...

Page 30: ...interization process Electrical GENERAL MINIMUM CIRCUIT AMPACITY The minimum circuit ampacity is used to help select the wire size of the electrical supply Minimum circuit ampacity is not the beverage ice machine s running amp load The wire size or gauge is also dependent upon location materials used length of run etc so it must be determined by a qualified electrician See Specifications section W...

Page 31: ...ical codes Warning 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 stripes 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 ...

Page 32: ...ord Unplug from outlet when not in use and before servicing or cleaning Do not operate any appliance with a damaged cord or plug or after the appliance malfunctions or is dropped or damaged in any manner Contact the nearest authorized service facility for examination repair or electrical or mechanical adjustment g For a permanently connected appliance Turn the power switch to the off position when...

Page 33: ...or chase ensure the floor chase contains the following 6 15 cm minimum PVC conduit chase Chase openings should extend 6 15 cm above floor Wide sweep elbows 2 ft 0 6 m radius minimum Chase must be clean and dry no foreign materials STH13_Tech book Page 33 Wednesday September 15 2010 3 20 PM ...

Page 34: ... 9 10 Beermaster Refrigeration Unit Walk in Cooler Dispensing Station Beer Conduit 6 15 2 cm PVC Conduit Chase minimum Wide Sweep Elbows 2 ft 61 cm Radius minimum STH13_Tech book Page 34 Wednesday September 15 2010 3 20 PM ...

Page 35: ...onnection secure a swab to rope use mop heads or a bundle of rags for swab 4 Pull end of fish tape from starting point through chase with rope and swab The swab will clean any construction materials moisture or debris that may exist in floor chase Continue to swab the chase until the swab exits the chase clean and dry 5 After floor chase has been cleaned remove steel fish tape and swab from rope L...

Page 36: ... Place pointed end of the conduit through chase opening While one person pushes the conduit through chase another person should be pulling the conduit through the chase with rope at the opposite end 9 Once the conduit has been routed through the chase pull enough conduit through the openings to ensure an adequate supply at each end of the chase for connections STH13_Tech book Page 36 Wednesday Sep...

Page 37: ...umber STH13 9 10 37 OVERHEAD INSTALLATION Beermaster Refrigeration Unit Walk in Cooler Dispensing Station Ceiling Tiles Conduit Hanger Beer Conduit STH13_Tech book Page 37 Wednesday September 15 2010 3 20 PM ...

Page 38: ...ove ceiling tiles and connect to ceiling and or pipes using the appropriate conduit hangers Be sure the conduit is suspended above ceiling tiles not lying on the tiles Care should be taken when determining appropriate method of handing conduit securely Hangers must not crush or pinch insulation This will reduce cooling efficiency 4 Once the conduit has been routed ensure an adequate supply of cond...

Page 39: ...he conduit up basement wall and secure with appropriate conduit hangers 3 After routing the conduit up the basement wall route conduit overhead on the basement ceiling Connect to the basement ceiling using appropriate conduit hangers Beermaster Refrigeration Unit Walk in Cooler Dispensing Station Conduit Hanger Beer Conduit STH13_Tech book Page 39 Wednesday September 15 2010 3 20 PM ...

Page 40: ...gs causes thin wall tubing to split or crack and leaks will result Caution Only an approved cutting tool should be used to cut polyethylene tubing The cutting tool should contain a razor sharp cutting blade so that the tubing will not be crushed when cutting A razor blade knife or butterfly tubing cutter is sufficient see figures Multiplex packs a butterfly cutter with each Beermaster Glycol Chill...

Page 41: ...Number STH13 9 10 41 Beermaster Refrigeration Unit Walk in Cooler Dispensing Station Main Beer Conduit 6 Minimum Dia Beer Conduit to Walk in Cooler STH13_Tech book Page 41 Wednesday September 15 2010 3 20 PM ...

Page 42: ...s Five 5 Tail pieces Five 5 Beer nuts One 1 60 ft of PVC tape One 1 60 ft of foil One 1 Spanner wrench 10 and 14 line conduit kits Four 4 Return bends 15 Elbows 42 Unions Eight 8 Tail pieces Eight 8 Beer nuts One 1 60 ft of PVC tape One 1 60 ft of foil One 1 Spanner wrench STH13_Tech book Page 42 Wednesday September 15 2010 3 20 PM ...

Page 43: ...der to function properly you must follow these guidelines Up to eight line conduit six beer maximum one glycol circuit two lines Ten and over line conduit two glycol circuits four lines To ensure colder dispensing temperatures glycol should flow directly to the dispensing towers before returning to the remote Glycol Chiller Unit After examining the drawings determine the desired glycol circuit to ...

Page 44: ... washer and 1 2 John Guest union see the following image 2 Identify the appropriate beer lines to be connected to each of the wall bracket fittings cut to length and insert into the proper John Guest 1 2 connector as shown below John Guest Adapter Tail Piece Washer Wall Bracket Fitting To Beer Keg Beer Nut Beer Line to Tower 1 2 John Guest Union STH13_Tech book Page 44 Wednesday September 15 2010 ...

Page 45: ...ower Connections image 2 Attach the opposite end of each 1 2 John Guest union to the 1 2 adapter located at the base of the dispensing tower Tower Connections 3 16 Barb x 1 2 John Guest Adapter 1 2 John Guest Union 1 2 John Guest Union Beer Line Beer Conduit Glycol Line Glycol Manifold Adapter Restrictor Lines Adjustable Clamp See Calculating Restriction for Length Dispenser Tower Dispenser Tower ...

Page 46: ... 1 2 John Guest Union to each Neatly wrap the excess restrictor line securely around the glycol supply lines to ensure good heat exchange Connect the adapter from each restrictor to the 1 2 connector of each of the appropriate beer lines Connecting Main Beer Conduit to Branch Beer Conduit 1 At the required point of connection carefully split open and fold back the insulation on the main beer condu...

Page 47: ... a smooth curve into the branch conduit Attach appropriate beer line s from main beer conduit to beer line s in branch beer conduit with 1 2 John Guest Union s Main Beer Conduit Connections Caution To avoid agitation use only straight unions when splicing beer lines 1 2 John Guest Union 1 2 John Guest Elbow Branch Beer Conduit Main Beer Conduit STH13_Tech book Page 47 Wednesday September 15 2010 3...

Page 48: ... To determine the appropriate Applied Keg pressures and Restrictor Line Lengths see attached work sheets and refer to examples A and B To properly determine the required restrictor line lengths and applied keg pressure to be used for each beer follow the instructions below 1 First determine which brands of beer will be dispensed at which faucet Use the System Calculators to record data see the Cha...

Page 49: ...e and adding 2 psi Example 12 5 psi adjusted keg pressure 2 0 psi 14 5 psi Applied Keg Pressure pressure the secondary regulator will be adjusted at 6 Determine the total line length and tubing diameter from bottom of keg to faucet This must be done for each individual beer line refer to the figures below for proper method of determining line length 7 Once the run length is known calculate the amo...

Page 50: ...t 15 2 m Altitude 1 000 ft 304 8 m Walk in Cooler 38 F 3 3 C 8 ft 2 4 m 8 ft 2 4 m 5 ft 1 5 m 4 ft 1 2 m 26 ft 7 9 m Total Conduit Length 50 ft 15 2 m Altitude 1 000 ft 304 8 m Walk in Cooler 38 F 3 3 C 19 ft 5 8 m 5 ft 1 5 m STH13_Tech book Page 50 Wednesday September 15 2010 3 20 PM ...

Page 51: ...each of the previously calculated restriction factors Example 3 5 psi length of run restriction 2 5 psi lift drop restriction 6 0 psi total line restriction 10 Determine the required psi of restriction that will be required by taking the Applied Keg Pressure and subtracting the Total Line Restriction Example 14 5 psi applied keg pressure 6 0 psi total line restriction 8 5 psi restriction factor If...

Page 52: ...ressure the secondary regulator will be adjusted to can now be determined by taking the Total Line Restriction and adding 8 psi Example 3 5 psi run restriction 12 0 psi lift drop restriction 15 5 psi total line restriction 15 5 psi total line restriction 8 0 psi 23 5 psi adjusted keg pressure STARTING UP THE SYSTEM Before Starting Up the System Each of the steps below should be done 24 hours prior...

Page 53: ...ors It is recommended that when applied keg pressures exceed 20 PSI the secondary regulators be adjusted 2 PSI below the calculated pressure If more pressure is required after tapping keg increase as needed 4 Tap the kegs and proceed to draw beer from each valve one at a time Ensure each brand is properly drawing before proceeding to the next The proper flow rate for beer at each valve is 2 ounces...

Page 54: ... x 3 8 John Guest tube connector appropriate length of 3 8 O D poly to reach location of wine tank 3 8 x 1 4 FF John Guest connector and liquid disconnect 4 Connect nitrogen regulator to nitrogen tank and connect gas line to regulator outlet 5 Connect empty wine tank and turn on nitrogen tank Adjust to 30 PSI and pressurize system to check for leaks 6 Turn OFF nitrogen and depressurize system Dete...

Page 55: ...ACEMENT NOTE All Refrigeration Units must be mounted on either 6 legs or optional stand 1 Move the stand refrigeration unit to the designated area and position it near the wall at a distance of at least 6 15 2 cm for air circulation in air cooled units or at a distance required by local code 2 Level the stand unit by adjusting the leg levelers provide on the legs or stand 3 If the unit is equipped...

Page 56: ...h all safety codes Make sure all refrigeration unit power switches are in the OFF position 5 Route and connect power supply to leads in the electrical junction box at the top rear of the motor compartment NOTE Be sure to connect ground wire s to ground screw located on back panel of junction box Caution Make sure power supply to unit is turned off STH13_Tech book Page 56 Wednesday September 15 201...

Page 57: ... is to be used to fill the openings between the conduit insulation and the inside diameter of the floor chases The purpose is to provide an air tight seal at the floor level to prevent foreign matter from entering the chases Please read the foam manufacturer s instructions carefully We recommend using the adapter with the right angle extension 5 Insert the adapter into the openings approximately 1...

Page 58: ...tely use a torque wrench to tighten the 1 2 coupling to 40 ft lbs and 3 8 fitting to 11 ft lbs 5 Leak check all your connections If you detect any leaks repair and recheck Condenser and Pre charged Lines Installation Before proceeding with installation verify that all requirements for roof mounted remote condenser units if applicable have been satisfied If unit has a remote condenser refer to the ...

Page 59: ...it for servicing 4 If the refrigeration unit is located in a stationary location you must remove excess refrigeration tubing as described below MULTIPLEX PRE CHARGED REFRIGERATION LINES PRE INSTALLATION REQUIREMENTS 1 Both the discharge and liquid remote condensing lines must be kept to a minimum distance for maximum performance All Multiplex systems are capacity rated to 100 ft 30 5 m tubing dist...

Page 60: ...plit capacitor and internal overload protection The electrical wires from the refrigeration unit wire to the condenser The electrical installation must be in accordance with local codes National Electrical Code and regulations 1 Determine a position for installation that will allow access for maintenance and is free from obstruction Verify hot air discharge from other condensers does not interfere...

Page 61: ... lines shipped with the system These lines must be a correct length for the building design Avoiding any kinks neatly route these lines from the remote condenser to the refrigeration unit Excess refrigeration tubing must be handled in one of two ways When coiling the excess tubing make sure the inlet to the coil is at the top of the coil and the exit is the bottom of the coil There can be no more ...

Page 62: ...set NOTE If for any reason the lines are damaged and or leaking or the lines no longer charged refer to How to Re charge the Line Sets If the line set is too long for the application refer to How to Shorten the Line Sets 2 Always make the connections at the condenser first using the end of the pre charged lines with the valve ports 3 Connect the condenser side with the quick connectors discharge a...

Page 63: ... The coil must continue in a downward spiral with no overlaps similar to a cork screw If you have more tubing you must cut out the excess before connecting the ends When cutting the tubing you must first evacuate the refrigerant 3 After shortening the tubing and welding together again you must vacuum the tubing to 250 microns 4 Recharge the tubing with the appropriate refrigerant at 4 ounces per l...

Page 64: ...tion titled Aeroquip Connection in these instructions 4 Be sure to observe proper refrigeration techniques when running the line set A The discharge line must loop down at the compressor end to trap liquid from returning to the compressor unless you are coiling refrigeration tubing behind the unit B The discharge line must loop above discharge connector at the condenser to resist liquid returning ...

Page 65: ...d terminal block are energized from each remote unit Turn OFF switches on each unit before opening quick disconnect switch on condensing unit On the completion of the wiring of the remote condenser make sure the electrician placed the switch lever in the ON position This switch must be ON before turning ON the refrigeration toggle switch on the unit Also the water bath must be filled with water To...

Page 66: ...lution reaches the Fill Here mark located on tank wall NOTE The glycol water solution in the water bath is now mixed to the proper ratio 5 Push the switches marked Compressor and Agitator if equipped to the ON position After compressor cycles OFF check to ensure glycol solution reads 27 F 2 7 C to 29 F 1 6 C Caution Do not turn on the circulating pump s until system installation is complete Cautio...

Page 67: ...before proceeding 6 Turn on the circulator The circulator must run continuously Verify that glycol is returning to the glycol bath through the return bulk head fitting Drain Plug Overflow Tube Glycol Bath Tank Tab Clamp STH13_Tech book Page 67 Wednesday September 15 2010 3 20 PM ...

Page 68: ...Glycol Circulating Pump and Motor Kit Pump and Motor Kit Motor Installation NOTE Only two fasteners required Carriage Bolts Later Units Mounting Studs Early Units 5 16 18 Hex Nut STH13_Tech book Page 68 Wednesday September 15 2010 3 20 PM ...

Page 69: ...mber STH13 9 10 69 Tube Installation End Panel 1 2 O D x 1 2 O D John Guest Elbow 1 2 O D Red Connecting Tube Circulating Pump Discharge Cooling Coil STH13_Tech book Page 69 Wednesday September 15 2010 3 20 PM ...

Page 70: ... side of the glycol pump 6 Slide the 1 2 x 1 2 John Guest Elbow supplied in kit onto the end of the discharge tube at pump motor assembly 7 Locate the circulator pump discharge cooling tube supplied with kit and insert into the water bath area Insert straight end of tube into the John Guest elbow fitting as shown 8 Insert the two 1 2 O D John Guest bulkhead unions supplied in kit into the pre punc...

Page 71: ...f wire harness coming from control box 14 Installation of glycol circuit pump is now complete The Beermaster refrigeration unit can now be turned ON 15 The added glycol circulating pump can now be controlled by a switch located on the switch box For Model 450 the CIRC 4 switch will control added pump NOTE After starting the new circulator pump it may be necessary to top off the glycol bath with th...

Page 72: ... diameter when using screws provided if mounting in wood NOTE If more than one tower is being installed use only the tower intended for each location to mark the mounting screw positions 5 Position gasket over top of 3 7 6 cm access hole and align holes for mounting screws It is recommended that a small bead of silicon caulking be placed on both sides of the gasket at this point 6 Route beer tower...

Page 73: ...l cover procedures required for properly installing the Beermaster high pressure CO2 regulator KIT CONTENTS 1 Beermaster High Pressure CO2 Gas Regulator with seal 20 ft of 5 16 I D tubing 6 8 screws 6 tie mounts 6 self locking cable ties 4 tab clamps Installation should only be performed by qualified personnel 3 7 6 cm Cut Out 3 7 6 cm Diameter STH13_Tech book Page 73 Wednesday September 15 2010 3...

Page 74: ...vinyl tubing from the primary regulator s to the secondary regulator in the beer keg cooler or to the optional blender 4 Secure the vinyl tubing in place with tie mounts and cable ties provided in kit see the Securing Vinyl Tubing figure NOTE At start up the primary regulator should be adjusted to 40 PSI 2 8 bar and locked Attaching Regulator Primary High Pressure CO2 Regulator To CO2 Blender or S...

Page 75: ...ll handle two beer kegs Additional dual secondary regulator kits can be placed in series to handle additional beer kegs KIT CONTENTS 1 dual secondary regulator assembly with wall bracket CO2 gas lines Beer lines 12 ft 5 16 I D black vinyl tubing 10 boss coupling washers 8 tab clamps 1 1 1 4 MPT pipe plug 6 ft 3 8 I D clear vinyl line assembly Tie Mount Cable Tie 8 Screw STH13_Tech book Page 75 Wed...

Page 76: ...om the primary high pressure regulator or gas blender and attach to the 5 16 Barb fitting of the secondary regulator Use two tab clamps Secondary Regulator Installation Beer Keg Black Vinyl Tubing from Primary Regulator or Gas Blender Tab Clamps 5 16 Barb x 1 4 MPT VIEW A Plug Black Vinyl Attach to Next Regulator Assembly Lock Bar Tab Clamp Boss Coupling Washer 4 ft Clear Vinyl Beer Line Tavern He...

Page 77: ...connection 5 Additional dual secondary regulator kits can be placed in series from the first regulator panel To plug the last regulator in a series of regulators remove the Barb fitting from the regulator outlet and install the 1 4 MPT plug provided in kit see the Secondary Regulator Installation figure View A NOTE Do not adjust pressure regulators at this point See Conduit Kit section for regulat...

Page 78: ... Do not remove 1 4 female threaded fittings from panel as they contain filters 4 Test all fittings for leaks 5 Use regulators and tubing suitable for 70 150 PSI NOTE Regulators set at 50 PSI are suitable on a 50 PSI blender 6 Secure all cylinders to the wall NOTE Store cylinders in a well ventilated accessible area Outlet for Mixed Gas most beers Outlet for Mixed Gas Guiness Secondary Regulators U...

Page 79: ...ll this tee in the CO2 pressure line between the high pressure regulator and the medium pressure regulator Use two tab clamps per connection refer to the figure below NOTE If beer system is equipped with an blender tee must be installed upstream of the blender 3 Locate the alarm box and transformer supplied with kit Mount the alarm box in a convenient location near the CO2 pressure switch Place sl...

Page 80: ...O2 alarm Low Pressure light should illuminate 6 Turn ON CO2 at the CO2 tank Adjust pressure to 40 psig Slide the switch to Normal Operation position beeper will sound Press switch to Test Reset position light will extinguish and beeper will stop 7 Installation is complete CO2 Supply CO2 Low Pressure Switch Assembly 1 4 x 1 4 x 1 4 Stainless Steel Tee Low CO2 Alarm Box Primary Regulator set at 40 p...

Page 81: ...r STH13 9 10 81 Component Identification Typical System N2 Tank CO2 Tank CO2 Alarm Refrigeration Unit Kegs Cooler Regulators Tower Conduit Tower Blender STH13_Tech book Page 81 Wednesday September 15 2010 3 20 PM ...

Page 82: ...the cooling side of the refrigeration cycle and squeezes or compresses the gas into high pressure on the condensing side of the cycle FAILURE OF THE COMPRESSOR An inoperative or weak compressor would adversely affect the capability of the unit to chill glycol STH13_Tech book Page 82 Wednesday September 15 2010 3 20 PM ...

Page 83: ...hich transfers heat from the refrigerant to the surrounding air FAILURE OF THE CONDENSER A non operational fan motor or restricted condenser will reduce the cooling efficiency of the refrigeration unit Air Cooled Condenser STH13_Tech book Page 83 Wednesday September 15 2010 3 20 PM ...

Page 84: ...e reduction of liquid refrigerant from high pressure to its evaporating pressure The expansion valve is better suited for varying temperature conditions FAILURE OF THE CAP TUBE OR EXPANSION VALVE A defective expansion valve or cap tube will not properly regulate the flow of refrigerant Compressor Condenser Water Bath Receiver STH13_Tech book Page 84 Wednesday September 15 2010 3 20 PM ...

Page 85: ... OF THE EVAPORATOR COIL Coil in the glycol bath in which refrigerant vaporizes and absorbs heat chilling the bath FAILURE OF THE EVAPORATOR COIL This copper tube assembly is extremely reliable STH13_Tech book Page 85 Wednesday September 15 2010 3 20 PM ...

Page 86: ...ficient method of removing heat FAILURE OF THE GLYCOL BATH If not maintained and glycol is allowed to dilute ice may form reducing efficiency NOTE Three parts water to one part glycol 3 1 17 to 22 on a sugar refractometer 10 F on an antifreeze tester STH13_Tech book Page 86 Wednesday September 15 2010 3 20 PM ...

Page 87: ...glycol in the glycol bath to distribute heat load and keep the bath a consistent temperature FAILURE OF THE AGITATOR An inoperative agitator will warm beer during busy times causing foaming at the dispensing faucet STH13_Tech book Page 87 Wednesday September 15 2010 3 20 PM ...

Page 88: ...OF THE CIRCULATING PUMP MOTOR A weak or defective circulating pump or motor will cause warm beer and foaming at the dispensing faucets NOTE Brass Pump No strainers in pumps 70 GPH pumps Strainer Plate 1 2 O D John Guest Bulkhead 1 2 O D Tube Retaining Collet Circular Pump Discharge Cooling Tube 2 ft x 1 2 I D Insulation 1 2 x 1 2 John Guest Elbow 1 2 O D x 8 Plastic Tube Pickup Tube STH13_Tech boo...

Page 89: ...COL BATH STRAINER Keeps debris from continually recirculating throughout the glycol system FAILURE OF THE GLYCOL BATH STRAINER Can restrict the flow of glycol back into the water bath overflowing the strainer STH13_Tech book Page 89 Wednesday September 15 2010 3 20 PM ...

Page 90: ...ntain cold beer and glycol from the refrigeration unit to the dispensing station FAILURE OF THE CONDUIT Temperature will not be maintained and condensation may develop if the conduit is improperly insulated or if the insulation becomes saturated STH13_Tech book Page 90 Wednesday September 15 2010 3 20 PM ...

Page 91: ...ries with the conduit tubing to provide quick and easy connections for the glycol circuit FAILURE OF THE JOHN GUEST FITTINGS These are very reliable fittings when installed properly The tubing must be cut with a razor type blade to ensure tubing will not be crushed when cutting The tubing must be pushed completely into the fitting Collet Collet Cover Wrong Right Tubing Collet Collet Cover Tubing S...

Page 92: ...adjustment to the keg to balance the system giving a proper foam free beer flow from each dispensing faucet FAILURE OF THE RESTRICTION LINE If the length is not correct will cause foaming at the dispensing faucets NOTE If too long can cause slow flow Standard flow rate is 2 oz sec STH13_Tech book Page 92 Wednesday September 15 2010 3 20 PM ...

Page 93: ...T To dispense cold beer with very little agitation and the proper head FAILURE OF THE DISPENSING FAUCET Will dispense inferior beer with excessive foam NOTE If dirty inside or worn or swollen gaskets can cause foaming STH13_Tech book Page 93 Wednesday September 15 2010 3 20 PM ...

Page 94: ...n the glycol circuit and the dispensing faucet keeping every beer cold FAILURE OF THE HEAT EXCHANGER If heat exchanger is not in direct contact with the dispensing faucet and the glycol circuit it could cause warm beer after slow or quiet periods STH13_Tech book Page 94 Wednesday September 15 2010 3 20 PM ...

Page 95: ... the beer from the kegs FAILURE OF THE HIGH PRESSURE REGULATOR Low pressure or a sluggish regulator can cause pressure variations and different flow rates at the dispensing faucet High pressure or a creeping regulator will cause the relief valve to relieve NOTE 55 psi 3 8 bar relief Caution Soda regulators should never be used for beer STH13_Tech book Page 95 Wednesday September 15 2010 3 20 PM ...

Page 96: ...ded CO2 and air or blended gas used to push the beer FAILURE OF THE SECONDARY REGULATOR Any fluctuations in pressure will cause beer to be dispensed with excessive foam NOTE 55 psi 3 8 bar relief Caution Soda regulators should never be used for beer STH13_Tech book Page 96 Wednesday September 15 2010 3 20 PM ...

Page 97: ...AVERN HEAD Attaches to the keg and provides the pressure inlet and beer outlet from the keg FAILURE OF THE TAVERN HEAD If defective or worn will leak and or not allow beer to leave the keg properly STH13_Tech book Page 97 Wednesday September 15 2010 3 20 PM ...

Page 98: ... STH13 9 10 Keg FUNCTION OF THE KEG Container that holds the pressurized beer FAILURE OF THE KEG Must be properly chilled and not agitated before dispensing STH13_Tech book Page 98 Wednesday September 15 2010 3 20 PM ...

Page 99: ...KET A wall mounted connection point for the tubing coming from the flexible tavern head connecting to the fixed beer line in the conduit FAILURE OF THE WALL BRACKET This metal fitting is extremely reliable STH13_Tech book Page 99 Wednesday September 15 2010 3 20 PM ...

Page 100: ...HE BLENDER If not blended properly could cause over or under carbonation in the beer NOTE Air and CO2 adjusted to 40 psi 2 8 bar Desired Air CO2 mixture should have 23 to 26 CO2 The graph on the right can be used as a guide to determine if setting falls in the recommended range 26 23 GPM Air 40 41 42 43 44 45 46 47 48 49 50 GPM CO2 20 19 18 17 16 15 14 13 12 11 10 STH13_Tech book Page 100 Wednesda...

Page 101: ...ure you will not have pressure to push the beer With blended gas if only air is supplied to the blender the beer in the kegs could loose carbonation Primary Regulator Set at 40 psig Low CO2 Alarm Box 1 4 x 1 4 x 1 4 Stainless Steel Tee CO2 Low Pressure Switch Assembly 120 VAC Outlet Transformer CO2 Supply STH13_Tech book Page 101 Wednesday September 15 2010 3 20 PM ...

Page 102: ...102 Part Number STH13 9 10 This Page Intentionally Left Blank STH13_Tech book Page 102 Wednesday September 15 2010 3 20 PM ...

Page 103: ...e Re insulate and seal any un insulated areas REFRIGERATION UNIT Every 4 Months 3 Times per Year Clean the refrigeration unit air cooled condenser using a vacuum cleaner Inspect glycol bath verify level of glycol solution is to fill mark If below mark add food grade glycol solution to bring level back up to mark Clean out all glycol pump strainers Check the temperature difference between the disch...

Page 104: ... GAS SUPPLY Every 4 Months 3 Times per Year Inspect pressure setting at CO2 high pressure regulator Verify proper 40 PSI 2 8 bar pressure setting Adjust if necessary Inspect all secondary beer regulators Verify proper pressure settings Adjust if necessary Inspect system for CO2 leaks Repair as required Inspect Beer Pumps STH13_Tech book Page 104 Wednesday September 15 2010 3 20 PM ...

Page 105: ...everage conduits for damage Re insulate and seal any un insulated areas Inspect Beer Pumps Inspect secondary air pressure regulator setting to blender verify proper 40 PSI 2 8 bar pressure setting Adjust if necessary Inspect system for air leaks repair as required Inspect gas blender and verify CO2 and air flow meters are set at the proper flow rate Adjust if necessary Inspect pressure setting at ...

Page 106: ...systems must be sanitized After sanitizing all liquids sanitizing solution and water must be purged from the unit A freezing environment causes residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components STH13_Tech book Page 106 Wednesday September 15 2010 3 20 PM ...

Page 107: ... changes Start up PLACING EQUIPMENT IN OPERATION Before placing equipment in operation verify that all requirements for roof mounted Remote Condenser Units if applicable have been satisfied Refer to the instructions on installing the Remote Condenser UNITS WITH ROCKER SWITCHES ETC CONTROLS 1 Fill the refrigeration unit bath tank with 3 1 water glycol mix to within 1 2 1 27 cm of the top of the ove...

Page 108: ...the water glycol bath 3 The water glycol bath will reach its operating temperature within 2 to 4 hours 4 If optional CO2 N2 Control Panel has been installed refer to the installation instructions for operation and testing the circuits for leaks 5 All circuits must be checked for leaks and possible cross circuits before turning ON NOTE All pumps on a beer unit are factory programmed as circulating ...

Page 109: ...l operation the LCD displays the glycol bath temperature and an icon indicating the cooling mode The LCD will also display various codes for programming and for indicating faults Programming is factory set and locked into the ETC The following fault codes are defined with associated remedial action Fault Code Definition Solution SF flashing alternately with OP sensor Open temperature sensor or sen...

Page 110: ... lower terminals of upper left terminal strip 3 Ensure jumper on P5 is in Keypad Unlocked position Both pins covered 4 Ensure jumpers on P4 are in Cooling Mode Cut in at Setpoint position Only one pin on both jumps covered 5 Re attach cover loosely It will be removed again after programming Programming The following to be performed when power is applied to control 1 Press and hold the MENU button ...

Page 111: ...s have part numbers that end with E and only applies to these units Prerequisites The glycol bath must cover the evaporator and low level probe Initial Power up Delay The control has a 30 second delay when power is connected or disconnected and reconnected The display will show Pd power delay and the seconds left in the countdown cycle Normal Circuit Operation Pressing the COMP AGIT button will st...

Page 112: ...sor and condenser fan on again This cycle will repeat as required depending on load Power Interruption During a power interruption the control will resume from the point of interruption when power is reapplied and the time delay expires Any switches components that were energized when power was interrupted will be energized when power is reapplied Error Codes E3 Water Glycol mix too low add mix E4...

Page 113: ...DE 1 0001 will display indicating Mode 1 Wait 3 seconds C000 will display Press and hold CIRC A switch Display will indicate water glycol bath probe conductivity CL0 Water Glycol mix too low CL1 Water Glycol mix high enough Press and hold PGM switch for 3 seconds to exit program mode PROGRAM MODE 2 Add circulation pumps C D Press PGM button for 3 seconds Display shows 0001 Press PGM button Display...

Page 114: ... shows 0001 Press PGM button twice in less than 3 seconds to enter program mode 3 Display shows 0003 Wait 3 seconds display shows 1273 1 thermistor controlled temperature 27 27 F factory default temperature setpoint 3 program mode 3 Decrease setpoint Press CIRC B button Increase setpoint Press CIRC A button Differential is 2 F above the set point EXAMPLE At 27 F set point the compressor is off but...

Page 115: ...conds Display shows 004 All error codes will be displayed during run mode Press COMP AGIT button once Display shows 4 error codes will not be displayed during run mode NOTE Disconnecting and reconnecting main power will reset the control board to the factory setting 004 Error codes will be displayed in the run mode Multiplex Beermaster System Operation and Layout N2 Tank CO2 Tank CO2 Alarm Refrige...

Page 116: ...erify that all pressure gauges are set at correct operating pressures 3 Check the kegs to make sure a sufficient number of kegs are connected in series to satisfy business volume 4 Clean beer inlet and outlet quick disconnects at the same time tanks are replaced Rinse disconnects in clean potable water EQUIPMENT CLOSE PROCEDURE 1 Clean the underside of the dispensing tower around the nozzle area w...

Page 117: ...Y DISABLE ERRORS PRESS PGM SWITCH THREE TIMES 3 IN LESS THAN 3 SECONDS DISPLAY 0004 WAIT THREE 3 SECONDS DISPLAY 004 PROGRAM MODE 3 PROGRAM TEMPERATURE CONTROL OF WATER BATH BEER PRESS PGM SWITCH TWICE 2 IN LESS THAN 3 SECONDS DISPLAY 0003 WAIT THREE 3 SECONDS DISPLAY 003 PROGRAM MODE 2 PROGRAM ONE 1 OR TWO 2 MORE CIRCULATING PUMPS PRESS PGM SWITCH ONCE 1 IN LESS THAN 3 SECONDS DISPLAY 0002 WAIT T...

Page 118: ... B SWITCH TO SHOW SUCTION TEMP P000 PRESSURE PRESS CARB A SWITCH TO SHOW WATER SUPPLY PRESSURE PRESS CARB B SWITCH TO SHOW CO2 PRESSURE PRESS COMP AGIT SWITCH ONCE DISPLAY 1XX3 WHERE XX SET POINT TEMPERATURE DEFAULT 1273 DIFFERENTIAL FIXED AT 2 ABOVE SET POINT PRESS CIRC A SWITCH TO LOWER SET POINT TEMPERATURE PRESS CIRC B SWITCH TO RAISE SET POINT TEMPERATURE NOTE SET POINT COMPRESSOR OFF DIFFERE...

Page 119: ...olumn The first is a Qualifier which is designed to quickly qualify or eliminate the Symptoms listed to the right and below the qualifying statement For example under Section 2 Glycol Chiller System you ll find Too little restriction for the same problem A recovery problem Since the recovery problem symptoms simulate a low pressure problem Each asking you to determine if beer had been drawn before...

Page 120: ...ered a service and repair manual in that Multiplex models vary in design It has been written to encompass all model Beermaster Glycol Chillers Some differences from model to model will become obvious and it will be required of the reader to apply this guide to each unit STH13_Tech book Page 120 Wednesday September 15 2010 3 20 PM ...

Page 121: ...warranty Warning Only trained and certified electrical and plumbing technicians must service this unit All wiring and plumbing must conform to national and local codes Warning The unit should be unplugged when servicing except when electrical tests are required Use extreme care during electrical circuit tests Live circuits may be exposed STH13_Tech book Page 121 Wednesday September 15 2010 3 20 PM...

Page 122: ...restriction add the extra restriction to the 3 16 end of the beer line If you have no records make up a new beer line with the proper restriction and replace the existing line Beer draws too fast If the beer draws clear but too fast and the pressure is properly set there may not be enough restriction in the system Beer draws clear but foams in the glass Follow the second corrective step above The ...

Page 123: ...the lines may be frozen Turn OFF coolant compressor then adjust coolant temperature to be between 27 F 2 7 C and 29 F 1 6 C First beer out always seems foamy or streaky Ensure that coolant line is in direct contact with the beer line right up to the back of the shank If not place aluminum foil between beer line and coolant line then insulate This will transfer the cold to the beer line Beer in coo...

Page 124: ...no Air CO2 blender Beer has off taste bitter or skunky Change air intake filters Check for moisture in air tank Clean system Check air intake supply Check air filter and trap Ensure proper rotation of kegs in series Check cleaning schedule for beer lines Fault Code Definition Solution SF flashing alternately with OP sensor Open temperature sensor or sensor wiring Check sensor wiring Turn wiring po...

Page 125: ...Low Glycol Supply Pressure Lower than 5 PSI for 5 Seconds E2 Low CO2 Pressure Lower than 10 PSI for 5 Seconds E3 Low Glycol Level Glycol Bath Must Cover Top of Evaporator E4 High Glycol Bath Temperature Glycol Bath Temperature Greater Than 45 F E5 High Glycol Supply Pressure Glycol Pressure Greater than 75 PSI E6 High Refrigeration Temperature Discharge Line Temperature Greater than 190 F E7 High ...

Page 126: ...E 15 PSI TO CORRECT NORMALLY CAUSED BY WATER LEVEL IN WATER BATH BELOW PROBE CONDUCTORS GO INTO PROGRAM MODE 1 PRESSURE READOUT P000 GO INTO PROGRAM MODE 1 PRESSURE READOUT P000 PRESS CARB A BUTTON TO VERIFY WATER PRESSURE PXXX DISPLAY PRESSURE 15 PSI PRESS CARB B BUTTON TO VERIFY CO2 PRESSURE PXXX PSI DISPLAY PRESSURE 20PSI VERIFY WATER LEVEL ABOVE PROBE TIPS ADD WATER TO WATER BATH ABOVE LEVEL O...

Page 127: ...ANSDUCER 020001992 TROUBLESHOOT WATER SUPPLY SYSTEM TO FIX LOW WATER PRESSURE CONDITION REPLACE CO2 PRESS TRANSDUCER 020001992 TROUBLESHOOT CO2 SUPPLY SYSTEM TO FIX LOW PRESSURE CONDITION DISPLAY CONDUCTIVI TY CL_1 CL_0 REMOVE LEVEL PROBE CONN FROM ERC SHORT ERC LEVEL PROBE PINS VERIFY CO2 SUPPLY PRESSURE TO UNIT 20PSI OR NOT WITH ANOTHER GAUGE IN THE SUPPLY SYSTEM PULL CARB A OR B CONNECTOR OFF E...

Page 128: ...ATH TEMP FXXX F GO INTO PROGRAMMING MODE 1 P000 PRESS CARB A BUTTON TO SHOW INCOMING WATER PRESSURE PXXX PSI GO INTO PROGRAMMING MODE 1 F000 PRESS CIRC A BUTTON TO SHOW LIQUID LINE TEMP FXXX F WATER BATH TEMP DISLAY NO YES WATER PRESS 75 PSI NO 45 F NO YES LIQUID LINE TEMP 200 F VERIFY TEMP WITH SECOND THERMOMETERIF STILL 45 FREPLACE ERC BOARD VERIFY PRESSURE WITH SECOND PRESS GAUGE VERIFY TEMPERA...

Page 129: ...ED GO TO COMPRESSOR REFRIGERATION SYSTEM TROUBLESHOOTING REPLACE WATER PRESSURE TRANSDUCER 020001992 GO TO COMPRESSOR TROUBLESHOOTING TO FIX REFRIGERATION SYSTEM REPLACE DISCHARGE LIQUID LINE TEMPERATURE THERMISTOR 020001991 VERIFY TEMP WITH SECOND THERMOMETERIF STILL 200 F REPLACE ERC CONTROL BOARD 020001985 VERIFY PRESS WITH SECOND GAUGE IF CORRECTREPLACE ERC BOARD 020001985 REPLACE WATER BATH T...

Page 130: ... B MOTOR PUMP NO YES VERIFY VISUALLY THAT ICE IS OVER ICE BANK PROBE PIN 2 MIDDLE PIN FIRST CHECK FOR LEAK IN CARB SYSTEM YES NO PIN 2 COVERED IN ICE LEAK IN SYSTEM VERIFY ICE BANK PROBE INSTALLED CORRECTLYPLASTIC STEP ON PROBE AWAY FROM EVAP FIX LEAK UN PLUG CARB B CONNECTOR FROM ERC 1 TO VERIFY CONDUCTIVITY OK THEN CHECK FOR PUMP OUTPUT 32 OZ IN LESS THAN 20 SEC STH13_Tech book Page 130 Wednesda...

Page 131: ...D OR B BUTTON OFF THEN ON TO RESET COMPRESSOR ON TOO LONGGOTO COMPRESSOR REFRIGERATION TROUBLESHOOTING E7 ERROR GOES AWAY IF E8 AND OR E9 CONTINUE TO OCCUR REPLACE ERC CONTROL BOARD 020001985 REPLACE ERC CONTROL BOARD IF PROBLEM CONTINUES 020001985 REPLACE ICE BANK PROBE 020002091 REPLACE PUMP STH13_Tech book Page 131 Wednesday September 15 2010 3 20 PM ...

Page 132: ... TO FAN REMOTE CONDENSERCHECK MOTORS VERIFY KEYPAD DISPLAY GOOD SEE KEYPAD DISPLAY TROUBLE SHOOTING PAGE 7 VERIFY KEYPAD DISPLAY GOOD SEE KEYPAD DISPLAY TROUBLE SHOOTING PAGE 7 IF COMPRESSOR COMES ON AND STILL NO COOLING USE REFRIGERATION TROUBLESHOOTING COMPRESSOR WILL STILL NOT GO OFF COMPRESSOR WILL STILL NOT COME ON AGITATOR WILL STILL NOT COME ON AGITATOR WILL STILL NOT GO OFF CHECK LIQUID LI...

Page 133: ...SEDSHORT CONN 12 REPLACE ICE BANK PROBE 020002091 IF NO VOLTAGE REPLACE ERC CONTROL BOARD 020001985 REPLACE ERC CONTROL BD 020001985 VERIFY VOLTAGE AT COMP OUTPUT TERMINALS ON ERC REPLACE ERC CONTROL BD 020001985 CHECK CONNECTO RS AND WIRING TO CONTACTOR COIL VERIFY WIRING CONNECTORS TO AGITATOR MOTOR REPLACE CONTACTOR VERIFY VOLTAGE AT CONTACTOR COIL REPLACE AGITATOR MOTOR VERIFY PROPER VOLTAGE A...

Page 134: ...VERIF Y PRG MODE 2 IS SET TO 002 FOR BOTH CARB PUMPS VERIFY NO E1 ERRORGOTO PROGRAM MODE 1 CONDUCTIVITY C000 VERIFY NO E1 ERROR PRESS CARB A AND OR CARB B BUTTON VERIFY CARB A AND OR B CONDUCTIVITY PROBES YES NO POWER ERC OFF THEN ON VERIFY NO COUNTDOWN PdXX ON DISPLAY TURN POWER OFF THEN ON TO RESET ERC VERIFY KEYPAD DISPLAY WORKS CIRC LED GOES ON AND OFF CX__ X A OR B VERIFY VOLTAGE AT CIRC OUTP...

Page 135: ...1985 REPLACE KEYPAD DISPLAY IF BAD 020001986 ORIF WIRES MOTOR OK REPLACE ERC BOARD 020001985 CHECK ALL WIRES AND CONNECTORS FOR OPEN ON CARB TANK WIRING HARNESSCHECK CARB MOTOR REPLACE ERC CONTROL BOARD 020001985 IF DISPLAY FLASHES ERRATIC NUMBERS SYMBOLS REPLACE KEYPAD DISPLAY020001986 REPLACE ERC CONTROL BOARD GENERAL NOTE FOR DISPLAY PROBLEMS IF COUNTDOWN OCCURS ON POWER UP PdXX THEN DISPLAY IS...

Page 136: ...136 Part Number STH13 9 10 This Page Intentionally Left Blank STH13_Tech book Page 136 Wednesday September 15 2010 3 20 PM ...

Page 137: ...ad pressure by building up liquid in the condenser and bypassing discharge gas directly to the receiver DIAGNOSING 1 Determine if the coil is clean Air passes through the condenser from the bottom up Verify the coil is clean by looking from the bottom up Do not look down through the fan 2 Determine the air temperature entering the remote condenser 3 Determine if the head pressure is high or low in...

Page 138: ... drops the fan begins to cycle on and off At first everything appears normal But as it continues raining or getting colder the fan cycle control can only turn the fan off All the refrigerant must continue to flow through the condenser coil being cooled by the rain or low outside temperature This causes excessive sub cooling of the refrigerant As a result the liquid line temperature and pressure ar...

Page 139: ...ale zero scale 3 Open high side valve wheel of gauge manifold DO NOT ATTEMPT TO CHARGE SYSTEM ON LOW SIDE CHARGE IN A LIQUID STATE ONLY WITH REFRIGERATION SYSTEM OFF 4 Allow sufficient time for all refrigerant to transfer from cylinder to refrigeration unit If necessary put cylinder into bucket of hot water to increase the internal pressure of the cylinder 5 System total charge is the net result o...

Page 140: ...H VERIFY HPCO SWITCH CLOSEDSHORT CONN 12 REPLACE ICE BANK PROBE 020002091 REPLACE ERC CONTROL BD 020001985 VERIFY VOLTAGE AT COMP OUTPUT TERMINALS ON ERC REPLACE ERC CONTROL BD 020001985 CHECK CONNECTO RS AND WIRING TO CONTACTOR COIL REPLACE CONTACTOR VERIFY VOLTAGE AT CONTACTOR COIL VERIFY PROPER VOLTAGE AT COMPRESSOR REPLACE COMPRESSOR FAN REMOTE CONDENSER REFRIGERATION SYSTEM OUTPUT TERMINALS A...

Page 141: ...KEYPAD DISPLAY GOOD SEE KEYPAD DISPLAY TROUBLE SHOOTING PAGE 7 AGITATOR WILL STILL NOT COME ON AGITATOR WILL STILL NOT GO OFF REPLACE ERC CONTROL BOARD02 0001985 VERIFY VOLTAGE ON ERC AGITATOR TERMINALS IF NO VOLTAGE REPLACE ERC CONTROL BOARD 020001985 VERIFY WIRING CONNECTORS TO AGITATOR MOTOR REPLACE AGITATOR MOTOR STH13_Tech book Page 141 Wednesday September 15 2010 3 20 PM ...

Page 142: ... CARB A AND OR CARB B BUTTON VERIFY CARB A AND OR B CONDUCTIVITY PROBES NO CX__ X A OR B CX00 CARB MOTOR SHOULD BE ON CX11 CARB MOTOR SHOULD BE OFF YES END VOLTAGE AT ERC AGIT OUTPUT TERMINALS VOLTAGE AT ERC AGIT OUTPUT TERMINALS NO NO END YES YES REPLACE ERC CONTROL BOARD 020001985 CHECK ALL WIRES AND CONNECTORS FOR OPEN ON CARB TANK WIRING HARNESSCHECK CARB MOTOR REPLACE ERC CONTROL BOARD 020001...

Page 143: ...ON VERIFY NO E1 ERROR VERIFY KEYPAD DISPLAY WORKS CIRC LED GOES ON AND OFF VERIFY VOLTAGE AT CIRC OUTPUT TERMINALS ON ERC CHECK ALL WIRES AND CONNECTORS TO CIRC MOTOR CHECK CIRC MOTOR REPLACE KEYPAD DISPLAY IF BAD 020001986 ORIF WIRES MOTOR OK REPLACE ERC BOARD 020001985 STH13_Tech book Page 143 Wednesday September 15 2010 3 20 PM ...

Page 144: ...THEN ON VERIFY NO COUNTDOWN PdXX ON DISPLAY TURN POWER OFF THEN ON TO RESET ERC KEYPAD BUTTONS NOW WORK REPLACE ERC CONTROL BOARD DISPLAY SHOWS POWER UP COUNTDOWN PdXX REPLACE KEYPAD DISPLAY 020001986 REPLACE ERC CONTROL BOARD 020001985 IF DISPLAY FLASHES ERRATIC NUMBERS SYMBOLS REPLACE KEYPAD DISPLAY020001986 GENERAL NOTE FOR DISPLAY PROBLEMS IF COUNTDOWN OCCURS ON POWER UP PdXX THEN DISPLAY IS P...

Page 145: ...UCTIVITY C001 PRESS CARB A B BUTTON DISPLAY READS CAOO TROUBLE SHOOT CARB TANK WIRING HARNESS AND CONNECTORS LOOK FOR OPEN CONNECTION AND REPAIR REPLACE REPEAT FOR CARB B SYSTEM SETTINGS IF NECESSARY IF CA11 REPLACE ERC CONTROL 020001985 IF EITHER OR BOTH 0 DIGITS IS A 1 RE PROGRAM TO 0 VIA PROGRAM MODE 2 INSTRUCTIONS VERIFY CARB A B SYSTEMS WORK NOW SEE CARB SYSTEM TROUBLESHOOTING IF NECESSARY ON...

Page 146: ...TH PLUG THIS PIN 12 11 10 9 8 7 6 5 4 3 2 1 CO2 TS TD TW TB TA WL ICE CA A CA B HPCO WATER HIGH PROBE HPCO SWITCH LOW PROBE COM HIGH PROBE GND 5V DC LOW PROBE OUTPUT COM HIGH PROBE GND 5V DC LOW PROBE OUTPUT SUCTION TEMP LEVEL PROBE GND DISCHARGE TEMP CIRC B TEMP CIRC A TEMP WATER BATH TEMP STH13_Tech book Page 146 Wednesday September 15 2010 3 20 PM ...

Page 147: ...densing options are available refer to Condenser and Pre charged Lines Installation for details Requires maximum number of optional pumps to reach these levels Control Side Right 18 45 7 cm Connection Side Left 12 30 5 cm Back Side 6 15 2 cm Ceiling 18 45 7 cm Model Evaporator Rating at 20 F 6 5 C Heat Rejection Max 75 2500 BTUH 490 kcal hr 4500 BTUH 885 kcal hr 150 5150 BTUH 1 159 kcal hr 8 638 B...

Page 148: ...auses tremors which are followed rapidly by loss of consciousness and suffocation If a CO2 gas leak is suspected particularly in a small area immediately ventilate the area before repairing the leak CO2 lines and pumps must not be installed in an enclosed space An enclosed space can be a cooler or small room or closet This may include convenience stores with glass door self serve coolers If you su...

Page 149: ...a qualified electrician ELECTRICAL REQUIREMENTS Refer to Ice Machine Model Serial Plate for voltage amperage specifications SPECIFICATIONS Warning All wiring must conform to local state and national codes Model Volt Cycle Phase Minimum Circuit Amps Breaker Compressor 75 120 601 230 50 1 20 3 9 0 25A 16A 1 3 hp 46 kW 150 120 601 230 50 1 21 5 10 7 30A 16A 12 hp 97 kW 300 208 230 60 1 230 50 1 20 6 ...

Page 150: ...150 Part Number STH13 9 10 This Page Intentionally Left Blank STH13_Tech book Page 150 Wednesday September 15 2010 3 20 PM ...

Page 151: ...5 MC073346 5 2 1 7 6 6 MC083346 6 2 1 8 6 6 MC103346 6 4 2 10 6 8 MC123346 8 4 2 12 6 10 MC143346 10 4 2 14 6 12 MC163346 12 4 2 16 6 15 MC193346 15 4 2 19 8 16 MC203346 16 4 2 20 8 glycol line MC023346 2 1 2 4 To maximize system performance on 6 flavor applications Multiplex recommends using a 10 line conduit with 4 glycol lines 2 circuits 2 line glycol only conduit used between chiller and keg c...

Page 152: ...ery 2000 ft above sea level An additional 1 psi may be required for Light beers Brewing Company Cooler Temperature 36 F 38 F 40 F 42 F Anheuser Busch 11 12 13 14 Adolph Coors requires 1 4 Ported Shanks 14 5 15 5 16 5 17 5 Miller 12 5 13 5 14 5 15 5 Schlitz Stroh s 12 13 14 15 STH13_Tech book Page 152 Wednesday September 15 2010 3 20 PM ...

Page 153: ...f faucet Feet X 0 5 per foot E MINUS Fall from bottom of keg to outlet of faucet Feet X 0 5 per foot F PLUS choker Trunk Line Length Up to 100 feet 100 to 125 feet 125 to 150 feet 150 to 175 feet 175 to 200 feet 3 16 Choker Tube Length 13 feet 12 feet 11 feet 10 5 feet 10 feet Resistance G 39 lbs 36 lbs 33 lbs 31 5 lbs 30 lbs G Over 200 feet contact factory Plus resistance if using Kyees tower ADD...

Page 154: ... Pressure at Sea Level PSI Product Cooler Temperature 32 34 26 38 40 Anheuser Busch 9 10 11 12 13 Coors 13 14 15 16 17 Miller 10 5 11 5 12 5 13 5 14 5 Schlitz Stroh s 10 11 12 13 14 STH13_Tech book Page 154 Wednesday September 15 2010 3 20 PM ...

Page 155: ...f using bent tube assembly in tower ADD 3 0 Total initial resistance If total initial resistance is 20 or greater you have the Applied Keg Pressure and length of choker tube If initial resistance is less than 20 add additional choker as below Minimum Pressure Minus Total initial resistance as calculated above Equals initial additional resistance to add Times 4 X 4 Equals initial number of inches c...

Page 156: ...foot E MINUS Fall from bottom of keg to outlet of faucet Feet X 0 5 per foot F PLUS minimum 24 choker Feet X 3 0 per foot G Plus resistance if using Kyees tower ADD 4 8 H If using Kyees Chill Pak ADD 4 0 I If using bent tube assembly in tower ADD 3 0 J Total initial resistance Add D E F G H I J K Ideal Resistance C L Minus Total initial resistance as calculated above K M Equals initial additional ...

Page 157: ...sure at Sea Level PSI Product Cooler Temperature 32 34 26 38 40 Anheuser Busch 9 10 11 12 13 Adolph Coors 13 14 15 16 17 Miller 10 5 11 5 12 5 13 5 14 5 Schlitz Stroh s 10 11 12 13 14 STH13_Tech book Page 157 Wednesday September 15 2010 3 20 PM ...

Page 158: ...158 Part Number STH13 9 10 This Page Intentionally Left Blank STH13_Tech book Page 158 Wednesday September 15 2010 3 20 PM ...

Page 159: ...s Circuit Diagrams Single Conduit Two Beer System Walk in Cooler To Beer Keg Single Faucet Beer Tower MC045541 4 line beer conduit 2 beer 2 Glycol lines Depending on line run STH13_Tech book Page 159 Wednesday September 15 2010 3 20 PM ...

Page 160: ...n with optional pump Two Faucet Beer Tower MC073341 2 beer 2 Glycol lines MC073341 2 beer 2 Glycol lines Walk in Cooler To Beer Keg Walk in Cooler To Beer Keg Two Faucet Beer Tower Depending on line run STH13_Tech book Page 160 Wednesday September 15 2010 3 20 PM ...

Page 161: ... Eight Beer System Four Faucet Beer Tower MC103310 4 beer and Glycol lines shown with optional pump Walk in Cooler To Beer Keg MC103310 8 beer and Glycol lines Depending on line run STH13_Tech book Page 161 Wednesday September 15 2010 3 20 PM ...

Page 162: ...L1 Line 1 L2 Neutral M Motor MS Contactor PS Pressure Switch IBC Ice Bank Control Optional Circulator Motor Agitator Motor IBC L1 M M1 SW4 SW1 SW2 MS Start Relay L2 PS MS M5 Fan MS Compressor Start Cap Run Cap STH13_Tech book Page 162 Wednesday September 15 2010 3 20 PM ...

Page 163: ...Part Number STH13 9 10 163 MODEL 75 WITH ELECTRONIC TEMP CONTROLS STH13_Tech book Page 163 Wednesday September 15 2010 3 20 PM ...

Page 164: ...t Legend L1 Line 1 L2 Neutral M Motor MS Contactor PS Pressure Switch IBC Ice Bank Control Optional Circulator Motor Agitator Motor Compressor IBC L1 L2 M M2 M1 SW4 SW1 SW2 O L Fan Start STH13_Tech book Page 164 Wednesday September 15 2010 3 20 PM ...

Page 165: ...Part Number STH13 9 10 165 MODEL 150 WITH ELECTRONIC TEMP CONTROLS STH13_Tech book Page 165 Wednesday September 15 2010 3 20 PM ...

Page 166: ...ine 1 L2 Neutral M Motor MS Contactor PS Pressure Switch IBC Ice Bank Control Agitator Motor Compressor IBC L1 L2 M2 M1 SW1 O L Fan Start 120 Volt 60 Hz 1 Phase Domestic 230 Volt 50 Hz 1 Phase Export STH13_Tech book Page 166 Wednesday September 15 2010 3 20 PM ...

Page 167: ...Part Number STH13 9 10 167 MODEL 350 WITH ERC 50 HZ 50HZ 50HZ STH13_Tech book Page 167 Wednesday September 15 2010 3 20 PM ...

Page 168: ...osition Power Supply Block Remote Cond Black Black Contactor Air Option Fan Motor Refrigeration Agitator Switch Terminal Strip Circ Motor A Circ Motor A Switch HPCO Optional Fan Motor Sensor Agt Motor Contactor Coil RMT Only Liquid Line Solenoid Temp Controller Circ Motor B Circ Motor C Circ Motor D Circ Motor B Switch Circ Motor C Switch Circ Motor D Switch BIN Common Sensor STH13_Tech book Page ...

Page 169: ...he OFF Position Remote Cond Black Black Contactor Air Option Fan Motor Refrigeration Agitator Switch Terminal Strip Circ Motor A Circ Motor A Switch HPCO Optional Fan Motor Sensor Agt Motor Contactor Coil RMT Only Liquid Line Solenoid Temp Controller Circ Motor B Circ Motor C Circ Motor D Circ Motor B Switch Circ Motor C Switch Circ Motor D Switch BIN Common Sensor STH13_Tech book Page 169 Wednesd...

Page 170: ... Terminal Strip Remote Cond Air Option Fan Motor Fan Motor Black Black Contactor Contactor Coil RMT Only Liquid Line Solenoid AGT Motor P N 020001985 Jumper Carb A Carb A Circ A Circ B Agitator Carb A Carb A Circ A Circ B P N 020001986 HPCO CO 2 Pressure Water Pressure Suction Temp Discharge Temp Waterbath Temp Circ B Temp Circ A Temp Level Probe Ice Probe Carb A Probe Carb B Probe P N 0705 101 Ea...

Page 171: ...n Remote Cond Air Option Fan Motor Fan Motor Black Black Contactor Contactor Coil RMT Only Liquid Line Solenoid AGT Motor P N 020001985 Carb A Carb A Circ A Circ B Agitator Carb A Carb A Circ A Circ B P N 020001986 HPCO CO 2 Pressure Water Pressure Suction Temp Discharge Temp Waterbath Temp Circ B Temp Circ A Temp Level Probe Ice Probe Carb A Probe Carb B Probe P N 0705 101 Earth R C L N L STH13_T...

Page 172: ...172 Part Number STH13 9 10 This Page Intentionally Left Blank STH13_Tech book Page 172 Wednesday September 15 2010 3 20 PM ...

Page 173: ...STH13_Tech book Page 173 Wednesday September 15 2010 3 20 PM ...

Page 174: ...vice 2100 Future Drive Sellersburg IN 47172 USA Ph 812 246 7000 Fax 812 246 7024 Visit us online at www manitowocfsg com 2010 Manitowoc Part Number STH13 9 10 STH13_Tech book Page 174 Wednesday September 15 2010 3 20 PM ...

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