Fountain Technical Handbook 2100 Future Drive, Sellersburg, IN 47172 Tel: 812 246 7000 Fax: 812 246 9922 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218009 Revision D July, 2002 Complete System Overview Fountain Beverage Dispensing Equipment 2100 Future Drive, Sellersburg, IN 47172 Phone: 812 246 7000 Fax: 812 246 9922 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218010 Revision D July 2002 Multiplex Company, Inc. Complete System Overview Table of Contents Ingredients Required to Manufacture Quality Carbonated Water .......................................... Good Quality CO2 ................................................................................................ Clean Water ..................................................................................................... Cold Temperature .............................................................................................. Proper Agitation ................................................................................................. 1 1 1 1 1 Multiplex Post-mix Beverage System ............................................................................ 2 Water Filter System ................................................................................................ 3 Carbonation System ................................................................................................ 4 Carbonator Pump off ........................................................................................ 4 Carbonator Pump on ......................................................................................... 5 Liquid Level Control (Electrode Circuit) ........................................................................ 6 Circulating Carbonated Water Supply System ................................................................. 8 Single Carbonated Water Supply ................................................................................. 9 Dual Carbonated Water Supply .................................................................................. 10 Dual and Split Carbonated Water Supply ...................................................................... 11 Dispensing System ................................................................................................. 12 Maintenance Schedule ............................................................................................ 13 Periodic maintenance for soft drink equipment (listed by major components) ..................... 13 Dispensing stations ......................................................................................... 13 Beverage conduits .......................................................................................... 13 Air compressor .............................................................................................. 13 Refrigeration unit .......................................................................................... 13 Water filters ................................................................................................. 14 Syrup supply ................................................................................................. 14 CO2 gas supply .............................................................................................. 14 Periodic maintenance for soft drink equipment (listed by scheduled frequency) ................... 15 Daily (365 times per year) ................................................................................ 15 Every 4 months (3 times per year) ....................................................................... 15 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Ingredients Required to Manufacture Quality Carbonated Water Good Quality CO2 Multiplex Refrigeration Units are designed to operate properly on 90 psi (6.4 bar) of CO2 pressure. Clean Water Carbonated drinks are made up of over 83% water. Clean water is required for good taste and to protect the equipment. Cold Temperature Multiplex Refrigeration Units use a cold carbonation system, water is carbonated in an ice cold water bath. It is very important to dispense drinks below 39°F (4°C). Proper Agitation Multiplex carbonation systems are designed to give you the exact amount of agitation to give you the proper carbonation. CO2 Water Temperature Agitation 00218010 Revision B (KAK) 31 July, 2000 1 Multiplex Company, Inc. Complete System Overview Multiplex Post-mix Beverage System Multiplex Post-mix beverage systems use filtered water from a filtered water supply system and chill it as it passes through stainless steel cooling coils located in an ice cold water bath. The water bath is maintained at 32°F (0°C) by a mechanical refrigeration system which produces a large ice bank reserve to provide sufficient cooling for peak draw periods. This ice reserve allows a relatively small refrigeration unit to maintain drink temperatures, drawing form the ice reserve during heavy load periods and then re-establishing the ice bank during light draw periods. The chilled water passing through the water bath is mixed with carbon dioxide (CO2) in the carbonated water supply system. This is when and where it becomes carbonated water in the carbonation tank. Syrup is also chilled as it passes through stainless steel cooling coils located in the ice cold water bath. Chilled, the syrup is connected to one of several beverage tubes contained within a beverage conduit. This conduit is then routed to a dispensing station. The circulating carbonated water supply system allows for the circulation of carbonated water through use of a pump to create an outlet and inlet carbonated water supply. Outlet and inlet carbonated water supplies are connected to tubes contained within the same beverage conduit as the syrup. This allows carbonated water to flow from the water bath to the dispensing station and back, maintaining a constant beverage temperature throughout the system. Ice cold carbonated water and syrup are dispensed from valves at the dispensing station. Dispensing valves contain flow controls which allow for flow adjustment to maintain the proper ratio of syrup to carbonated water. Syrup and carbonated water are released when the dispensing valves are opened. This allows mixing to begin as escaping products are allowed to flow through the valve nozzle. They continue to mix as they fall into the customers cup to complete the production of a bottler-quality soft drink. 2 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Water Filter System Incoming water pressure is to be maintained at 55 psig (3.9 bar) to ensure proper flow throughout the system. An in-line water regulator and gauge controls high water pressure and allows for pressure monitoring. Water enters the pre-filter(s) that remove the coarse particles that are contained in the supply water, protecting the fine filter. Water flows from the pre-filter(s) to the taste/odor activated carbon filter, absorbing taste and odor causing chemicals, such as chlorine and sulfur. Finally, water runs through a fine filter, filtering out the finer particles left in the supply water, thus protecting the equipment and helping to insure quality water for carbonation. Pressure gauges located before and after the filtration system allow the monitoring of pressure across the filter system, indicating clogged filters and the need for replacement. To the Carbonation System Taster/Order Activated Carbon Filter 55 psig (3.9 bar) Incoming Water Regulator Fine Filter 00218010 Revision B (KAK) 31 July, 2000 Pre-filter 3 Multiplex Company, Inc. Complete System Overview Carbonation System Carbonator Pump off Carbon dioxide (CO2) regulated to 90 psi (6.3 bar) passes through a single check valve, which prevents water from backing up into the CO2 supply, and fills the carbonator tank with CO2. The incoming filtered water at 55 psig (3.9 bar) feeds the brass carbonator pump, then proceeds through a stainless steel cooling coil located in the 32°F (0°C) water bath. Chilled water is then delivered to the double check valve on top of the carbonator tank. CO2 is prevented from leaving the carbonator tank through the fresh water supply by the double check valve. When the carbonator motor is off, the high CO2 pressure within the carbonator tank prevents replacement water from entering the carbonator tank. Liquid Level Control Water 55 psig (3.9 bar) CO2 90 psig (6.3 bar) 55 psig (3.9 bar) Cooling Coil Check Valves Carbonated Water Pick-up Tube Electrodes Carbonation Tank 4 Motor Ice Water Bath 32°F (0°C) 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Carbonation System (continued) Carbonator Pump on When the carbonated water level in the carbonator tank falls below both the electrodes, the liquid level control will send electricity to the carbonator motor. The motor turns the carbonator pump, which increases the water pressure from 55 psig (3.8 bar) to approximately 140 to 170 psig (10 to 12 bar). This boosted water goes through the cooling coil in the water bath, through the double check valve and overcomes the 90 psig (6.3 bar) CO2 pressure within the carbonator tank. Water flowing through the orifice at the base of the check valve is broken into tiny droplets and sprayed into the carbonator tank, absorbing CO2 to produce cold, quality carbonated water. While the motor and pump is running, the carbonated water level in the tank will rise until it reaches the low and then the high electrode, at which point the liquid level control will shut off the electricity to the motor. Each time a sufficient amount of carbonated water is drawn from the carbonation tank, the cycle will repeat. Liquid Level Control CO2 90 psig (6.3 bar) Water 55 psig (3.9 bar) 140 psig (10 bar) Cooling Coil Check Valves Carbonated Water Pickup Tube Electrodes Carbonation Tank 00218010 Revision B (KAK) 31 July, 2000 Motor Ice Water Bath 32°F (0°C) 5 Multiplex Company, Inc. Complete System Overview Liquid Level Control (Electrode Circuit) Emptying - OFF OFF OFF Power off to the Pump Motor 6 ON ON - Filling ON Power on to the Pump Motor 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Liquid Level Control (Electrode Circuit) (continued) When the carbonator tank is full, carbonated water is touching both the low and high electrodes and the liquid level control will not supply power to the carbonator motor. When carbonated water is drawn out of the tank, it will first fall below the high electrode. This opens the circuit between the G and H terminals of the liquid level control. The continued draw of carbonated water from the tank will cause the level of carbonated water to fall below the low electrode. This opens the circuit between the G and L terminals of the liquid level control. With both circuits open, the liquid level control directs power to the carbonator motor and the pump, turning it on and replenishing the supply of carbonated water in the tank. The carbonated water level will quickly rise to the low electrode and close the circuit between the G and L terminals of the liquid level control. Continuing to pump water into the tank, the level will next rise to the high electrode and close the circuit between the G and H terminals of the liquid level control. This turns the motor off and stops water from being pumped into the tank. The electrodes work with the liquid level control to maintain the level of carbonated water in the tank. Continuity through the carbonated water from both electrodes (low and high) to the tank (ground) turns the carbonator motor off. No continuity from both electrodes to the tank turns the carbonator motor on. 00218010 Revision B (KAK) 31 July, 2000 7 Multiplex Company, Inc. Complete System Overview Circulating Carbonated Water Supply System Cold, carbonated water is pushed from the carbonator tank by 90 psig (6.3 bar) of CO2, up through the pick up tube and out of the carbonator tank. It is then chilled as it flows through the stainless steel cooling coil located in the 32°F (0°C) water bath. Feeding a stainless steel circulating pump, the chilled and carbonated water is then forced up to the dispensing station. Carbonated water from the circulating pump is connected to one of the two carbonated water lines found within the beverage supply conduit. At the opposite end of the beverage conduit, the supply line, along with the remaining return carbonated water line, is connected respectively to the inlet and outlet ends of a turn-around manifold located in the beverage dispensing unit. Returning carbonated water mixes with newly manufactured carbonated water as it is forced out of the tank to replenish the supply in the circulating loop. The circulating, carbonated water ensures that the syrups that are also contained within the beverage conduit are properly cooled and that all finished drinks are drawn at 39°F (3.9°C) or less. To Dispenser Return 90 psig (6.3 bar) Circulating Pump 8 Motor Cooling Coils Water Bath 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Single Carbonated Water Supply Tower 2 Tower 1 Circulating Pump 00218010 Revision B (KAK) 31 July, 2000 9 Multiplex Company, Inc. Complete System Overview Dual Carbonated Water Supply Tower 2 Tower 1 B Carbonated Water Supply A Carbonated Water Supply 10 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Dual and Split Carbonated Water Supply Tower 2 Tower 1 B Carbonated Water Supply A Carbonated Water Supply 00218010 Revision B (KAK) 31 July, 2000 11 Multiplex Company, Inc. Complete System Overview Dispensing System Syrup at the refrigeration unit is pressurized and pushed through cooling coils located in the 32°F (0°C) water bath and then on to the dispensing valves. The push pressure is achieved by one of two methods. One way is by applying direct gas pressure (air or CO2) on the surface of syrup stored in stainless steel syrup tanks (figals) which is then connected to the cooling coil. Another way is to use syrup pumps to draw syrup out of bag-in-box containers and then push the syrup through the cooling coils. Cold syrup flows from the cooling coils and into the beverage conduit where it is then kept cool by circulating carbonated water to the final point of dispensing. Activating a dispensing valve allows syrup and carbonated water to escape through the diffuser/nozzle assembly of the valve. The actual mixing of the beverage occurs as the syrup and carbonated water enter the nozzle. As the beverage falls from the nozzle, it continues to mix until captured in the customers cup, where mixing is completed. To ensure consistent mixing, the dispensing valves are equipped with adjustable flow controls that react to line pressure changes, opening and closing orifices to keep a constant ratio of carbonated water to syrup. Water and Syrup Dispense Conduit Syrup Tanks 60 psi (4.1 bar) Sugar 15 psi (1 bar) Diet 12 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Maintenance Schedule This section provides a list of periodic maintenance tasks and the scheduled frequency required to ensure the proper operation of your Multiplex dispensing equipment. To ensure quality beverages, prevent down-time, and reduce costs, these tasks must be performed as indicated. Periodic maintenance for soft drink equipment (listed by major components) Dispensing stations Daily (365 times per year) w Take temperature of finished drinks. Pour off the first and take the temperature of the second drink. The proper temperature of drinks must be 40°F (4°C) or less. w Remove nozzles and diffusers from each dispensing valve. Clean with soap and warm water (not hot). Rinse with carbonated water and reinstall. w Flush all dispenser drains. Pour hot water down drains at closing. Beverage conduits Every 4 months (3 times per year) w Inspect beverage conduits for damage. Re-insulate and seal any uninsulated areas. w Inspect floor chases and seal any open chase ends. Air compressor Monthly (12 times per year) w Drain condensate water from air compressor tank. Every 4 months (3 times per year) w Inspect air compressor filter and replace if clogged. Air filter must be replaced every 6 months. w Inspect air compressor to verify cut-in at 70 psi (4.8 bar) and cut-out at 90 psi (6.3 bar). Adjust pressure switch if necessary. w Inspect system for air leaks and repair as required. Refrigeration unit Every 4 months (3 times per year) w Clean the refrigeration unit air-cooled condenser using a vacuum cleaner. If equipped with water-cooled condenser, verify the water discharge temperature is at 105°F (41°C). Adjust water modulating valve if necessary. w Inspect water bath to verify water level is at the top of stand pipe. If below, add water and repair water makeup device. If excessive amount of water is flowing over stand pipe, locate leak within bath and repair. w Inspect ice bank within the water bath to verify proper size ice bank and clarity. Look for uniform, 2" to 4" thick ice bank. w Drain, clean, and refill water bath. w Inspect agitator motor and ensure proper operation. w Inspect the circulating motor/pump assembly. Clean strainer and oil motor. w Inspect the carbonating motor/pump assembly. Clean strainer and oil motor. w Inspect entire system for leaks and repair as required. 00218010 Revision B (KAK) 31 July, 2000 13 Multiplex Company, Inc. Complete System Overview Maintenance Schedule (continued) Periodic maintenance for soft drink equipment (listed by major components) (continued) Water filters Every 4 months (3 times per year) w Verify that incoming water pressure is not less than 40 psi (2.8 bar) or greater than 60 psi (4.1 bar). If equipped with a water regulator, verify proper setting of 55 psi (3.8 bar). Adjust if necessary. w If pressure is low, inspect water filter cartridges to ensure they are able to supply adequate water pressure under normal system flow. Replace if unable to provide minimum 20 psi (1.4 bar) under load. Syrup supply Daily (365 times per year) w Clean general area of syrup hookup with soap and warm water. Rinse off all soap. Every 4 months (3 times per year) w Inspect syrup lines for proper flavor identification labels. Replace labels if necessary. w Disconnect syrup containers. Clean connector with soap and warm water. Rinse with plain water and reconnect to syrup containers. CO2 gas supply Every 4 months (3 times per year) w Inspect pressure setting at CO2 high pressure regulator. Verify proper 90 psi (6.3 bar) pressure setting. Adjust if necessary. 14 w Inspect pressure setting at syrup pressure regulators. Verify proper pressure setting. Adjust if necessary. w Inspect system for CO2 leaks, repair as required. 00218010 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Maintenance Schedule (continued) Periodic maintenance for soft drink equipment (listed by scheduled frequency) Daily (365 times per year) w Take temperature of finished drinks. Pour off the first and take the temperature of the second drink. The proper temperature of drinks must be 40°F (4°C) or less. w Remove nozzles and diffusers from each dispensing valve. Clean with soap and warm water (not hot). Rinse with carbonated water and re-install. w Flush all dispenser drains. Pour hot water down drains at closing. w Clean general area of syrup hookup with soap and warm water. Rinse off all soap. Every 4 months (3 times per year) w Using Brix cup and syrup separator, check for proper carbonated water flows (standard flow: 5 oz. in 4 seconds, fast flow: 10 oz. in 4 seconds) and syrup to water ratios at each dispensing station. Adjust as required. w Inspect beverage conduits for damage. Re-insulate and seal any uninsulated areas. Inspect floor chases and seal any open chase ends. w Inspect air compressor filter and replace if clogged. Air filter must be replaced every six months. w Inspect air compressor to verify cut-in at 70 psi (4.8 bar) and cut-out at 90 psi (6.3 bar). Adjust pressure switch if necessary. w Inspect system for air leaks. Repair as required. w Clean the refrigeration unit air-cooled condenser using a vacuum cleaner. If equipped with water-cooled condenser, verify the water discharge temperature is at 105°F (41°C). Adjust water modulating valve if necessary. w Inspect water bath to verify water level is at the top of stand pipe. If below, add water and repair water makeup device. If excessive amount of water is flowing over stand pipe, locate leak within bath and repair. w Inspect ice bank within the water bath to verify proper size ice bank and clarity. Look for uniform, 2" to 4" thick ice bank. w Drain, clean, and refill water bath. w Inspect agitator motor and ensure proper operation. w Inspect the circulating motor/pump assembly. Clean strainer and oil motor. w Inspect the carbonating motor/pump assembly. Clean strainer and oil motor. w Inspect entire system for leaks and repair as required. w Verify that incoming water pressure is not less than 40 psi (2.8 bar) or greater than 60 psi (4.1 bar). If equipped with a water regulator, verify proper setting of 55 psi (3.8 bar). Adjust if necessary. w If pressure is low, inspect water filter cartridges to ensure they are able to supply adequate water pressure under normal system flow. Replace if unable to provide minimum 20 psi (1.4 bar) under load. w Inspect syrup lines for proper flavor identification labels, replace labels if necessary. w Disconnect syrup containers, clean connector with soap and warm water, rinse with plain water and reconnect to syrup containers. w Inspect pressure setting at CO2 high pressure regulators. Verify proper 90 psi pressure setting. Adjust if necessary. w Inspect pressure setting at syrup pressure regulators. Verify proper pressure setting. Adjust if necessary. w Inspect system for CO2 leaks. Repair as required. 00218010 Revision B (KAK) 31 July, 2000 15 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218010 Revision B (KAK) 31 July, 2000 Component Parts Workbook Fountain Beverage Dispensing Equipment 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Table of Contents Water Regulator .................................................................................................... 1 Function of the water regulator .............................................................................. 1 Failure of the water regulator ................................................................................ 1 Water Filter ......................................................................................................... Function of the water filter ................................................................................... Failure of the water filter ..................................................................................... Solids .......................................................................................................... Suspended .................................................................................................... 2 2 2 2 2 Accumulator Tank Pressures ...................................................................................... 3 Water booster tank ............................................................................................. 3 Filtered water accumulator tank ............................................................................. 3 Primary Regulator .................................................................................................. 4 Function of the primary regulator ........................................................................... 4 Failure of the primary regulator ............................................................................. 4 Secondary Regulator (Syrup Regulator) ......................................................................... 5 Function of the secondary regulator ......................................................................... 5 Failure of the secondary regulator ........................................................................... 5 Carbonator Pump and Motor ...................................................................................... 6 Function of the carbonator pump and motor ............................................................... 6 Failure of the carbonator pump and motor ................................................................. 6 Carbonator Pumps .................................................................................................. Determining the strength of a carbonator pump .......................................................... Carbonator pumps chart ....................................................................................... Carbonator pumps metric chart .............................................................................. Procedure for properly adjusting the relief valve setting on a pump .................................. 7 8 8 8 8 Low Water Pressure Safety Circuit .............................................................................. 9 Check Valves ....................................................................................................... 10 Function of the check valves ................................................................................. 10 CO2 Check Valves ........................................................................................... 10 Water Check Valves ........................................................................................ 10 Failure of the check valves ................................................................................... 10 CO2 Check Valves ........................................................................................... 10 Water Check Valves ........................................................................................ 10 Water Bath Feeder ................................................................................................ 11 Function of the water bath feeder .......................................................................... 11 Failure of the water bath feeder ............................................................................ 11 Carbonator Tank ................................................................................................... 12 Function of the carbonator tank ............................................................................ 12 Failure of the carbonator tank ............................................................................... 12 Electrode ........................................................................................................... 13 Function of the electrode .................................................................................... 13 Failure of the electrode ...................................................................................... 13 Electrodes .......................................................................................................... 14 Liquid Level Control .............................................................................................. 15 Function of the liquid level control ......................................................................... 15 Failure of the liquid level control ........................................................................... 15 Cooling Coils ....................................................................................................... 16 Function of the cooling coils ................................................................................. 16 Failure of the cooling coils ................................................................................... 16 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Complete System Overview Table of Contents (continued) Circulating Pump and Motor ..................................................................................... 17 Function of the circulating pump and motor .............................................................. 17 Failure of the circulating pump and motor ................................................................ 17 How to flush a contaminated system ....................................................................... 17 Alternate Suppliers for Carbonator/Circular Motors ......................................................... 18 Conduit .............................................................................................................. 19 Function of conduit ............................................................................................ 19 Failure of conduit .............................................................................................. 19 Refrigeration Compressor ........................................................................................ 20 Function of the refrigeration compressor .................................................................. 20 Failure of the refrigeration compressor .................................................................... 20 Multiplex Refrigeration Components ........................................................................... 21 Normal Operating Pressures of Domestic Refrigeration Units .............................................. 24 Head pressure of domestic refrigeration units ............................................................ 24 Evaporator pressure of domestic refrigeration units ..................................................... 24 Normal Operating Pressures of International Refrigeration Units ......................................... 25 Head pressure of international refrigeration units ....................................................... 25 Evaporator pressure of international refrigeration units ................................................ 25 Condenser .......................................................................................................... 26 Function of the condenser ................................................................................... 26 Failure of the condenser ...................................................................................... 26 Air Cooled Condenser ...................................................................................... 26 Water Cooled Condenser .................................................................................. 26 Equipment Installation Instructions for Multiplex Remote Condenser and Pre-charged Refrigeration Lines ................................................................................................................. 27 Pre-installation requirements ................................................................................ 27 Multiplex Remote Condenser Requirements ........................................................... 27 Multiplex Pre-charged Refrigeration Lines Requirements ........................................... 27 Installing the multiplex remote condenser ................................................................ 27 Connecting the pre-charged refrigeration lines .......................................................... 28 How to re-charge the line sets .............................................................................. 28 Proper Refrigeration Technique for Running the Line Set ........................................... 29 Aeroquip Connection .......................................................................................... 29 Expansion Valve or Cap Tube .................................................................................... 30 Function of the expansion valve or cap tube .............................................................. 30 Failure of the expansion valve or cap tube ................................................................ 30 Evaporator Coil .................................................................................................... 31 Function of the evaporator coil ............................................................................. 31 Failure of the evaporator coil ................................................................................ 31 Water Bath ......................................................................................................... 32 Function of the water bath ................................................................................... 32 Failure of the water bath ..................................................................................... 32 Agitator Motor ..................................................................................................... 33 Function of the agitator motor .............................................................................. 33 Failure of the agitator motor ................................................................................ 33 Ice Bank Control ................................................................................................... 34 Function of the ice bank control ............................................................................ 34 Failure of the ice bank control .............................................................................. 34 Head Pressure Control (used on Remote Condensing units only) .......................................... 35 Function of the head pressure control ..................................................................... 35 Failure of the head pressure control ....................................................................... 35 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Table of Contents (continued) Refrigeration Unit, Line, and Condenser Cross Reference Chart .......................................... 36 Condenser unit ................................................................................................. 36 Refrigeration line sets ........................................................................................ 36 Refrigeration units ............................................................................................. 37 High Pressure Cut-out (limiting switch) ........................................................................ 38 Dispensing Valves .................................................................................................. 39 Function of the dispensing valves ........................................................................... 39 Failure of the dispensing valves ............................................................................. 39 Flow Controls ....................................................................................................... 40 Function of the flow controls ................................................................................ 40 Failure of the flow controls .................................................................................. 40 Keyboards and Timers ............................................................................................ 41 Function of the keyboards and timers ...................................................................... 41 Failure of the keyboards and timers ........................................................................ 41 Multiplex Programmable Portion Control Timers ............................................................. 42 Whats New at Multiplex ......................................................................................... 42 Instructions for Proper Dispensing Valve Calibration (Flow, Ratio, and Volume) using the 4-Size Portion Control .................................................................................................... 43 Flow (to set the water flow rate only) ..................................................................... 43 Ratio (water to syrup mixture) .............................................................................. 43 Volume (setting drink portion sizes) ........................................................................ 43 Special feature ................................................................................................. 44 Test Procedures ................................................................................................... 45 Model MPC64A timer/selection pad ......................................................................... 45 Pin identification .............................................................................................. 45 J-17 calibration button and light ............................................................................ 45 Dual Transformers ................................................................................................. 46 Service Bulletin .................................................................................................... 47 MOVs field testing ............................................................................................ 47 New Model MPC84A Portion Control Board .................................................................... 48 Instructions for Multiplex Model MPC84AT Portion Control Board with Top-off ......................... 49 Run Mode ........................................................................................................ 49 Size Buttons ................................................................................................. 49 STOP-FILL Buttons .......................................................................................... 49 Program Mode .................................................................................................. 49 Entering the Program Mode ............................................................................... 49 Volume Sizing ............................................................................................... 49 Flow Rate Calibration ...................................................................................... 49 One Station Sets All ........................................................................................ 49 Exiting the Program Mode ................................................................................. 49 Top-off program mode ........................................................................................ 49 Entering the Top-off Program Mode ..................................................................... 49 Enabling and/or Disabling the individual station Top-off ............................................ 49 Exiting the Top-off Program Mode ....................................................................... 49 Test mode ....................................................................................................... 49 Sanitation mode ................................................................................................ 49 McDonalds Portion Control Timer .............................................................................. 50 Sitco 4-Selection Portion Control Timers ...................................................................... 51 Adjusting portion control for size of drinks dispensed ................................................... 51 Cancel/pour .................................................................................................... 51 Installation ...................................................................................................... 51 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Water Regulator Function of the water regulator Regulates the incoming water pressure to 55 psi (3.8 bar) preventing flooding of the carbonator tank in locations with high water pressure. Failure of the water regulator An unregulated water supply can overcome the 90 psi (6.2 bar) CO2 pressure in the carbonator tank and prevent the proper absorption of CO2 into the water resulting in poor carbonation. Notes: w Look for fluctuations in pressure (poor city water pressure) w To increase pressure turn clockwise w Dont assume plumber flushed pipes w Regulators can be taken apart and cleaned 00218011 Revision B (KAK) 31 July, 2000 1 Multiplex Company, Inc. Complete System Overview Water Filter Function of the water filter Filters out both solid and suspended impurities found in the water supply. Preventing damage to components, insuring proper absorption of CO2 into the water and a drink free of off taste. Failure of the water filter Solids With use, filter will become restricted to the point of starving water pumps, effecting drink recovery rate. Suspended With use, filters will become saturated, effecting drink taste. Activate Filter by (activate when system is not in use): 1. Put filter on by-pass. 2. Open activation valve (to relieve pressure). 3. Replace cartridge. 4. Slowly take filter off bypass (leaving activation valve open). 5. Activate for proper amount of time. Notes: w Examine water pressure gauge, if pressure drops 40 psi (2.8 bar) or more, when carbonator pumps cycle, put filter on by-pass and replace w Must activate filter to fully coat element and allow for good filtration and filter life (Everpure only) w Filter life is determined by: Filter Activation Water Volume Water Quality (dirt) Water Pressure 2 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Accumulator Tank Pressures Accumulator tanks have a rubber diaphragm in the middle of the steel tank, air is stored on one side of the diaphragm and water is stored on the other side, a plastic liner protects the steel from rust. Multiplex uses accumulator tanks for several purposes: Water booster tank A water booster pump is used to increase the incoming water pressure to 65 psi (4.5 bar) to 85 psi (6.0 bar). We then store that higher pressure water in an accumulator tank. As a result, the pump isnt running every time water is needed. The air in the tank gives the water a nice push out of the tank so that the water pressure slowly drops, allowing the pump to cycle on run for a short period of time and then cycle off. The air charge of this tank should be 60 psi (4.1 bar) to 65 psi (4.5 bar). Filtered water accumulator tank Filtered water is stored in an accumulator tank to be used when the carbonator pumps demand more water than will flow through your restricted water filters, and then slowly refill the tank when the pumps shut off. This enables you to use your filters for a longer period of time. The air charge of this tank should be 15 psi (1.0 bar) to 20 psi (1.4 bar). The air charge in the tank should be filled or checked with no water pressure to the tank, because once you have water pressure applied to the tank the air will compress and equalize with the water pressure and you will get a false reading. It is very important to use air and not CO2 to charge the tank, because CO2 will eventually bleed through the rubber diaphragm, thus reducing the charge in the tank. On the bigger WX103 tank, when used as a water booster tank, it is critical to have the 60 psi (4.1 bar) to 65 psi (4.5 bar) air charge, because if the air pressure drops below 45 psi (3.1 bar), the diaphragm will break. S12196 00218011 Revision B (KAK) 31 July, 2000 3 Multiplex Company, Inc. Complete System Overview Primary Regulator Function of the primary regulator Regulates the CO2 tank pressure to maintain a constant 90 psi (not over, not under) for the production of carbonated water. Failure of the primary regulator Low pressure or a sluggish regulator will cause poor absorption of CO2 into the water resulting in poor carbonation. High pressure or a creeping regulator will cause increased absorption of CO2 into the water resulting in over carbonation. 90 psi (6.2 bar) Notes: 4 w Check with bubble soap around adjustment screw (for leaking diaphragm) w Creeping can be caused by a faulty cartridge or a bad diaphragm w CO2 gas bursting from the relief valve on regulator could be caused by a defective or frozen regulator 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Secondary Regulator (Syrup Regulator) Function of the secondary regulator Regulates the CO2 or air pressure used to push the syrups to the dispensing valves. Failure of the secondary regulator Low pressure or a sluggish regulator will cause an insufficient supply of syrup during dispensing, resulting in drinks that taste over carbonated (fast dispersing foam). High pressure or a creeping regulator will cause increased supply of syrup during dispensing, resulting in drinks that taste flat and under carbonated (slow lingering foam). w Letting syrup tanks to empty or a defective leaking syrup disconnect will cause air in the lines and foaming at the dispensing valve (especially at the slab stores with underground chases). 15 psi (1 bar) Diet 60 psi (4.1 bar) w To clear activate both valves at once until air clears. w When jumping syrup tanks, always put the new thank on the front (syrup feed side) and move the partial tank to the back (gas feed side). Notes: w Check for leaks with bubble soap (always rinse soap from tubing). w Cartridge could cause pressure to decrease, diaphragm could cause increase w Sticking check/relief valve can cause lower pressure to a tank or allow syrup to back up into the regulator (remove front of regulator, check for syrup - can be cleaned with warm water) w To increase pressure, turn clockwise w Syrup tank disconnect not properly seated or defective could cause restriction 00218011 Revision B (KAK) 31 July, 2000 5 Multiplex Company, Inc. Complete System Overview Carbonator Pump and Motor Function of the carbonator pump and motor Increases the pressure of the water, to overcome the CO2 pressure and manufacture/replenish the carbonated water supply within the carbonator tank. Failure of the carbonator pump and motor A weak or defective carbonator pump or motor (key) will cause poor carbonation and limit the capacity of the unit to manufacture carbonated water. To determine the approximate cycle time: 1. Right after the carbonator kicks off, draw the carbonated water into a volume cup until the carbonator starts again. 2. Note how many ounces you have and multiply by 0.28 to determine how many seconds your cycle time should be. Coupling Clamp (100 GPH pump = 3.56 oz/second) Note: A unit with two 100 GPH pumps feed the same carbonator tank, multiply by 0.14 Must have 250 psi (17.2 bar) relief valve setting Notes: w Check water pressure with pumps running (10 psi [0.7 bar] minimum) w To adjust relief valve setting, dead head to gauge (incoming water pressure + 250 relief setting) w 6 Check strainer w Check for frozen coil in water bath (water to carbonator tank coil) w Check for power to the motor w Make sure pump turns freely 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Carbonator Pumps 00218011 Revision B (KAK) 31 July, 2000 7 Multiplex Company, Inc. Complete System Overview Carbonator Pumps (continued) All Multiplex equipment requires carbonator pumps with a 250 psi (17.6 bar) relief setting. w w This relief valve is designed to relieve in emergency situations only (when you have a serious restriction on the outlet of the pump. For example, a freeze up of the cooling coil in the water bath, etc.) A standard carbonator pump has a 170 psi (12 bar) relief valve setting. Multiplex equipment generates quite a bit of back pressure, thus causing the standard 170 psi (12 bar) pump to relieve excessively. This causes wear to the relief valve, prematurely weakening the pump. Determining the strength of a carbonator pump Note: Do not be dispensing drinks during the test. 1. Dispense carbonated water until the carbonator pump cycles on, then stop. 2. Wait for the carbonator to cycle off, then turn off the electrical switch for the carbonator. 3. Dispense exactly 50 fl oz (2 L) of carbonated water only. 4. Turn on the electrical switch for the carbonator and time how many seconds it takes to cycle off. This is the actual cycle time. 5. From the chart on the following page, determine the expected cycle time. For example: 50 ounces x .28, for a 100 GPH pump = 14 seconds 2 liters x 9.52 for a 378.5 LPH pump = 19 seconds 6. If your actual cycle time is much greater than your expected cycle time, your pump has been weakened and the capacity of your equipment has been reduced. Carbonator pumps chart Gallon Per Hour 100 125 200 240 Ounces Per Second 3.56 4.44 7.11 8.53 Multiplier 0.28 0.23 0.14 0.12 Carbonator pumps metric chart Liters Per Hour 60 Hz 50 Hz 378.5 318.2 473 397.6 757 636.3 908.5 763.7 Liters Per Second 60 Hz 50 Hz 0.105 0.088 0.131 0.110 0.210 0.177 0.252 0.212 Multiplier 60 Hz 50 Hz 9.52 11.36 7.63 9.09 4.76 5.65 3.97 4.72 Procedure for properly adjusting the relief valve setting on a pump 1. Remove the large acorn nut on the top side of the pump. 2. Mount a gauge on the outlet flow of the pump (as shown, to totally block the discharge flow). 3. Turn on the pump. While the pump is running, adjust the relief valve screw so that the gauge reads 275 psi (19.3 bar) (250 psi [17.6 bar] relief setting + 25 psi [1.7 bar] safety factor). 4. Reassemble. 8 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Low Water Pressure Safety Circuit If water pressure is greater than 4 psi (0.3 bar), the pressure switch will be open and not allow electricity to pass, and the relay will be closed and allow electricity to flow to the motor. If the water pressure drops below 4 psi (0.3 bar), the pressure switch will close and allow electricity to flow to the relay, heating the relay, causing it to open, stopping the electricity from flowing to the motor. If the water pressure then goes above 4 psi (0.3 bar), the pressure switch will again open, stopping the electricity from flowing to the relay, the relay will start to cool, after about 3 minutes the relay will close, again sending electricity to the motor. Relay Motor Pressure Switch Line connects to the Pump Inlet Water Supply S12296.pm5 00218011 Revision B (KAK) 31 July, 2000 9 Multiplex Company, Inc. Complete System Overview Check Valves Function of the check valves Prevents the back-flow of a liquid or gas by allowing flow in one direction only. CO2 Check Valves Single check valve for incoming CO2 to prevent water from backing up into the regulator and CO2 tank. Water Check Valves Double check valve and or back-flow preventer to keep CO2 from backing up into the water supply, and to provide a shower of water into the carbonator tank to absorb more CO2. Failure of the check valves CO2 Check Valves Liquid could back up into gas regulators and/or CO2 tank causing damage. Water Check Valves CO2 could back up into the plain water supply or cause back flow preventer to dispel CO2 or water into the water bath. Vented Double Check Valve Double Check Valve Back-flow Preventer (Vent) Notes: 10 w Could restrict water flow if sticking w Check for CO2 escaping from vent hole or w Slowly disconnect line from top of check valve, if anything is escaping, check valve needs to be cleaned or replaced 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Water Bath Feeder Function of the water bath feeder To replenish water in the water bath and skim the surface preventing bacterial buildup. Failure of the water bath feeder Restricted will not allow recovery resulting in low water level and dirt buildup. Uncontrolled flow will effect cooling capacity causing poor ice bank buildup. Restrictor and adjustable Relief Valve Cap Tube and 130 psi (9 bar) Relief Valve Notes: w Water released when the carbonator motor runs w Old machines have float type fillers (when the water drops below the float level it allows more water into the bath) w If water continually runs down the stand pipe, check the rubber seat in the relief valve or float 00218011 Revision B (KAK) 31 July, 2000 11 Multiplex Company, Inc. Complete System Overview Carbonator Tank Function of the carbonator tank To provide a pressure vessel to mix water and CO2 to manufacture/store carbonated water. Failure of the carbonator tank Stainless steel design insures relatively few problems. However, the many connection points require occasional checks for CO2 or water leaks. Pick-up Tube Water Inlet CO2 Inlet Notes: 12 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Electrode Function of the electrode Dual electrodes monitor carbonated water level in the carbonator tank. Electrodes signal the liquid level control and advise it of when to switch on the carbonator pump and motor. Failure of the electrode An open electrode circuit of insulated electrode(s) will cause the carbonator pump and motor to run continuously. Grounded electrodes will not allow the liquid level control to switch on the carbonator pump and motor. Shorted electrodes will cause short cycling of the carbonator pump and motor. Notes: w Could short cycle because of a short to ground or switched electrode wire leads w Check for leaks in cap or gasket w Check wires from liquid level control to electrode (broken, bare or shorted) 00218011 Revision B (KAK) 31 July, 2000 13 Multiplex Company, Inc. Complete System Overview Electrodes Special care must be taken to use the correct length electrodes in each carbonator tank. Below are listed the refrigeration units with correct size for each. Electrode Refrigeration Unit Model 11H Model 2803 Probe Length 7.9" Red 10.8" Black 5.9" Red 8.8" Black Model 2000 Model 1200 Model 72 Model 50 Model 39 Model 38H Model 11 Model 3410 Model 3610 Model 50H Model 44 Model 37 Model 37F Model 37T 00701216 (1" Cap) 7.5" and 5.5" 00210828 (1" Cap) 9.5" and 5.5" Model 44 Model 44K Y0212106 Y0212105 Y0212104 Y0212104 00213554 00213553 6.2" Red 8.9" Black 11.6" White 11.6" White 9.5" Black 5.5" Red 00701214 (1" Cap) 00211977 00211978 00211979 5.5" 6.9" 9.5" Model CPSS Model 44 (Limited Unit Run) 3-Probe Assembly 14 Part Number Y0208031 Y0208032 Y0208029 Y0208030 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Liquid Level Control Function of the liquid level control Switches off and on the carbonator pump and motor when the electrodes indicate a full or empty tank. Continuity across L and H to G cause the liquid level control to switch off the carbonator pump and motor. Open circuits across L and H to G cause the liquid level control to switch on the carbonator pump and motor. Failure of the liquid level control Defective liquid level control will cause the carbonator pump and motor to run continuously or not at all. Note: For proper voltage meter reading, you must test to ground or you will get a ghost reading. Notes: w 90% control fails closed (motor runs all the time) 10% control fails open (motor does not run) w If you start two pumps with one liquid level control, you must use the heavy duty 15 AMP control (P.N. 208162) 00218011 Revision B (KAK) 31 July, 2000 15 Multiplex Company, Inc. Complete System Overview Cooling Coils Function of the cooling coils Located within the 32°F water bath. Coils allow heat to be removed from the syrup, water and carbonated water supply lines. Failure of the cooling coils Improperly located cooling coils found outside the designed retaining basket may freeze-up if touching the ice bank. Notes: w 16 Check coils for freezing (ice touching the coils) 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Circulating Pump and Motor Function of the circulating pump and motor Circulates coils carbonated water from the refrigeration unit up to the dispensing valves and back to be re-chilled. This keeps the syrups, water and carbonated water continually chilled. Failure of the circulating pump and motor A weak or defective circulating pump or motor will cause warm drinks at the dispensing valves. How to flush a contaminated system 1. Take the fittings off the circulating pump. 2. Plug one line. 3. Turn on water. 4. Turn off the water on the CO2. 5. Plug other line. 6. Repeat. Carbonated Water Strainer Coupling Key Notes: w Draw about one gallon of carbonated water if temperature drops, replace pump w Verify motor is turning (check power to the motor) w Verify coupling key is operational w Verify pump turns freely w Check carbonated water strainer (if equiped with machine) w 100 gallon pump = fast flow system 50 gallon pump = standard flow system w When a pump goes out it can cause black specks to contaminate the carbonated water circuit (carbon veins in the pump breaking up) you must flush circuit 00218011 Revision B (KAK) 31 July, 2000 17 Multiplex Company, Inc. Complete System Overview Alternate Suppliers for Carbonator/Circular Motors In 1992, Multiplex Engineering established P.N. 00213596 as the standard motor for all carbonator and circular motor applications. It is a 1/3 hp dual voltage (110-120/220-240 VAC), 50/60 Hz motor. Until recently, this motor was supplied to us only by General Electric. We now have two additional sources, Motors & Armatures (MARS) and Emerson Electric. The MARS motor has been approved and authorized for production while the Emerson motor is undergoing life testing in our laboratory. While all three motors are equivalent, the high and low voltage hookups are different for each motor. Illustrated below are the connections for high and low voltage for each motor. Line (110 VAC) Line (110 VAC) White Brown Line (110 VAC) Brown White 110 VAC Emerson (110 VAC) G.E. (110 VAC) White Mars (110 VAC) Line (220 VAC) Line (220 VAC) Line (220 VAC) White Brown Brown 220 VAC Emerson (220 VAC) 18 G.E. (220 VAC) Mars (220 VAC) 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Conduit Function of conduit Insulated beverage tubing used to move and maintain cold syrup, water, and carbonated water from the refrigeration unit to the dispensing station. Failure of conduit Temperature will not be maintained to the dispensing station if the conduit is improperly insulated or if the insulation becomes saturated. Air tight seal to prevent foreign matter from entering the chase and prevent condensation. Notes: w Must be well insulated 00218011 Revision B (KAK) 31 July, 2000 19 Multiplex Company, Inc. Complete System Overview Refrigeration Compressor Function of the refrigeration compressor Refrigeration pump which draws a low pressure gas on 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 refrigeration compressor An inoperative or weak compressor would adversely effect the capability of the unit to manufacture ice. Start Relay (relay over 1/3 hp looks like square box) Start Relay starts the Compressor and then goes into the run mode. To install, look for a label marked Top or for á . Start capacitor (plastic) Run capacitor (metal) To test, use capacitor tester. Can loose one leg, but it may be fuse and not contactor (use wire diagram). Refrigeration Compressor Contactor 2-Pole Single Phase 3-Pole Three Phase Notes: 20 w Check amp load on compressor w Check water bath feeder, or for leak somewhere in water bath (look at stand pipe) w Check cleanliness of condenser (temperature of water on water cooled units (100°F 105°F) w Check room temperature w Check refrigeration charge 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Multiplex Refrigeration Components Unit 2803A, 2803W, 75A Refrig R-12 2803AX, 2803W R-12 2803A, 2803W R-22 150A R-12 11A R-12 2803A, 2803W, 75A R-12 4205A R-12 4205HA, 150MA, 11MA R-22 11AZ R-12 38R R-12 38H, 38A, 38R, 38W, 39SC, 38HAC 300MA, 44KW, 44W, 300A R-12 R-502 38HAX, 38HWX R-12 11MAX R-22 44A, 44R, 44KA, 44KR R-12 Compressor Multiplex Manufacturer 00755104 EMB-E5187B117VG20 (0.33 hp, 1 Phase, 115 VAC) 00755107 EMB-E5187A117CA20C (0.33 hp, 1 Phase, 220 VAC) 00213997 EMB-E6210E-217RA (0.33 hp, 1 Phase, 220 VAC) 00755099 TEC-AJ6435AAJ311BT-124C4 (0.5 hp, 1 Phase, 115 VAC) 00755090 TEC- 165-B4, AJ7441A-AJ530AT (0.5 hp, 1 Phase, 115 VAC) 00213979 EMB-E6210E217RG20 (0.33 hp, 1 Phase, 115 VAC) 00211108 AJ7441A-AJ530AT165-A4 (0.5 hp, 1 Phase, 115 VAC) 00212830 AK9442E-AK165AT035-B4 (0.5 hp, 1 Phase, 115 VAC) 00755092 AJ7441A-AJ530J165-B4 (0.5 hp, 1 Phase, 240 VAC) 00755021 AJ7465A-AJ201AT206-A4 (0.75 hp, 1 Phase, 115 VAC) 00755095 TEC-AJ7465ABAJ201AT-206-B4 (0.75 hp, 1 Phase, 115 VAC) 00211147 TEC-AK947JAK160ET-032-C4 (0.75 hp, 1 Phase, 230 VAC) 00755080 AJ465BBXAJ201JT-206-B4 (0.75 hp, 1 Phase, 240 VAC) 00214229 TEC-AK9455EBXAK167JT-035-B4 (1 hp, 1 Phase, 230 VAC) 00755097 TEC-AH7480AAH160FT-083-A4 (1.4 hp, 1 Phase, 230 VAC) 00218011 Revision B (KAK) 31 July, 2000 Start Start Relay Capacitor 00755106 00215135 Aspera 145175 MFD TI9660040182 165 VAC 00755109 00215135 Aspera (145-175 MFD TI9660040182 165 VAC) Run Capacitor N/A 00755109 00215135 Aspera (145-175 MFD TI9660040149 165 VAC) 00207166 00207186 Aspera (88-106 MFD TI9660040149 165 VAC) N/A 00755302 Tecumseh 82498-1 N/A N/A 00801241 (378-455 MFD 125 VAC) N/A 00755109 00215135 Aspera (145-175 MFD TI9660040149 165 VAC) N/A 00755022 GE 3 ARR3-AZJ6 00755023 (270-324 MFD 110 VAC) 00755024 15 MFD 370 VAC 00755302 Tecumseh 82498-1 00801241 (378-455 MFD 125 VAC) N/A GE 3AARZ KCR1765 No P.N., (121-146 MFD 250 VAC) N/A 00755022 GE 3 ARR3-AZJ6 00755023 (270-324 MFD 110 VAC) 00755024 (15 MFD 370 VAC) 00755022 GE 3 ARR3-AZJ6 00755023 (270-324 MFD 110 VAC) 00755024 (15 MFD 370 VAC) 00211173 Mars 19003 No P.N. (72-88 MFD 250 VAC) 00755024 (15 MFD 370 VAC) 00801236 GE ARRZKCR1715 00208926 GE ARR3 ASUZ 00801237 (108-130 MFD 330 VAC) N/A 00208927 (216-259 MFD 250 VAC) 00208928 (25 MFD 370 VAC) 00207947 00755077 (135-155 MFD 330 VAC) 00755024 (15 MFD 370 VAC) 21 Multiplex Company, Inc. Complete System Overview Multiplex Refrigeration Components Unit 4210R Refrig R-22 3610A, 3610R, 450A, 3410A, 3410R 44KX, 44KAX, 44KR, 44X, 44A, 44R 50A, 50W R-502 Compressor Multiplex Manufacturer 00213366 TEC-AJ9484EAJ801ET-361-B4 (1 hp, 1 Phase, 230 VAC) 00208929 TEC-AJ9510KAJ201HT 206-H4 (1 hp, 1 Phase, 230 VAC) (continued) Start Relay 00208926 Start Capacitor 00208927 (216-259 MFD 250 VAC) Run Capacitor 00208928 (25 MFD 370 VAC) 00208926 GE ARR3 ASUZ 00208927 (216-259 MFD 250 VAC) 00215942 (25 MFD 370 VAC) R-12 00755098 TEC-AH7480AAH160JT-1680A4 (1 hp, 1 Phase, 230 VAC) 00207947 Tecumseh 820AR13C31 00755077 (135-155 MFD 330 VAC) 00755024 (15 MFD 370 VAC) R-12 00755082 00201073 Tecumseh 82477 00201075 (88-108 MFD 250 VAC) 00201074 (35 MFD 370 VAC) 4KX, 44M, 44MX, 44A, 44R, 44W, 3610MR 37F, 37T, 50H, 50A, 50R, 50W R-22 00212975 TEC-AH7514AAH3334ET-108-A4 (1.5 hp, 1 Phase, 230 VAC) MAN-MT-18JA-1 (1.8 hp, 1 Phase, 230 VAC) 00211173 Mars 19003 00212977 (88-108 MFD 250 VAC) 00212976 (15 MFD 440 VAC) R-12 00202124 N/A N/A N/A 37X, 50HX, 50A, 50R, 50W 50MA R-12 00202842 N/A N/A N/A R-22 00213594 N/A N/A N/A 50MAX R-22 00213595 N/A N/A N/A 50MR, 37M, 37A, 37R, 37W 37MX, 37A, 37R, 37W, 50MRX, 37KX HC900504, HC900-04 R-22 00212979 N/A N/A N/A R-22 00212980 TEC-AH7514AAH334RT-108-A4 (1.5 hp, 3 Phase, 230 VAC) TEC-AH4525AAH303TT-128-A4 (2.0 hp, 2 Phase, 380 VAC) MAN-MT22JC-3 (2.2 hp, 3 Phase, 380 VAC) MAN-MT22JC-4 (2.2 hp, 3 Phase, 380 VAC) MAN-MT28JE-3 (2.8 hp, 3 Phase, 380 VAC) MAN-MT28JE-4 (2.8 hp, 3 Phase, 380 VAC) N/A N/A N/A R-404A 00215805 00215816 Copeland 040-0001-38 00215814 (72-86 MFD 350 VAC) 00215815 (30 MFD 440 VAC) 38MA04M, 38MA04 R-404A 00215805 00215816 Copeland 040-0001-38 00215814 (72-86 MFD 350 VAC) 00215815 (30 MFD 440 VAC) HC900X04, 44KAX04 R-404A 00215799 00215424 Copeland 040-0001-19 00201075 (88-105 MFD 250 VAC) 00214943 (25 MFD 440 VAC) 22 CPLND-R564CIECAA-232 (0.75 hp, 1 Phase, 115 VAC) CPLND-R564CIECAA-232 (0.75 hp, 1 Phase, 115 VAC) CPLND-R597CIE-CAZ-232 (1 hp, 1 Phase, 230 VAC) 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Multiplex Refrigeration Components Unit 44MAX04, 44MAX04E Refrig R-404A 150A04, 11MA04 R-404A 2803AX04, 75A04 R-404A 2803A04, HC180-04, 2803A04B, 75A04 300MA04 R-404A 300MAX04, 44MX, 44MA, 44MR, 44MW 38HA39, 38HA, 38HW, 38HAC 38HA, 38HR, 38HW R-404A R-404A Compressor Multiplex Manufacturer Start Relay 00215799 CPLND-R59700215424 CIE-CAZ-232 Copeland (1 hp, 1 Phase, 040-0001-19 230 VAC) 00215878 TEC-AK9451Z00215943 AK170AT-032-A4 Tecumseh (0.5 hp, 1 Phase, 820ARR3D10 230 VAC) 00215881 TEC-AK174JT00215967 035-B4 Tecumseh (0.33 hp, 1 Phase, 82494-1 115 VAC) 00215880 TEC-AK9427200755302 AK174AT-035-B4 Tecumseh (0.33 hp, 1 Phase, 8294-1 115 VAC) 00215423 CPLND-RS97C1E00215424 CAV-232 Copeland (1 hp, 1 Phase, 040-0001-19 230 VAC) 00215799 CPLND-RS9700215424 CIE-CAZ-232 Copeland (1 hp, 1 Phase, 040-0001-19 230 VAC) R-404A 00755095 R-404A 00755095 38HAX39, 38HAX, 38HW R-404A 00755080 44KA04, 44MA04, 44MA04E R-404A 00215423 450MA04, 450MR04, 450MW04, 50MA04 50MAX04 R-404A 00215457 R-404A 00215922 3610R404C R-404A 00215423 00218011 Revision B (KAK) 31 July, 2000 TEC-AG201AT206-B4 (0.75 hp, 1 Phase, 240 VAC) TEC-AG201AT206-B4 (0.75 hp, 1 Phase, 240 VAC) TEC-AJ201JT206-B4 (0.75 hp, 1 Phase, 240 VAC) CPLND-RS97CIECAV-232 (1 hp, 1 Phase, 230 VAC) MAN-MTE22-JC3L (2.2 hp, 3 Phase, 203 VAC) MAN-MTE22-JC4 (2.2 hp, 3 Phase, 230 VAC) CPLND-RS97CIECAV-232 (1 hp, 1 Phase, 230 VAC) (continued) Start Capacitor 00201075 (88-105 MFD 250 VAC) Run Capacitor 00214943 (25 MFD 440 VAC) 00215941 (72-88 MFD 250 VAC) 00215942 (25 MFD 370 VAC) 00215969 (72-88 MFD 250 VAC) N/A 00215968 (161-193 MFD 165 VAC) N/A 00201075 (88-108 MFD 250 VAC) 00214943 (25 MFD 440 VAC) 00201075 (88-108 MFD 250 VAC) 00215798 (30 MFD 370 VAC) 00755022 GE 3ARR3-A2J6 00755023 (270-324 MFD 110 VAC) 00755024 (15 MFD 370 VAC) 00755022 GE 3ARR3-A2J6 00755023 (270-324 MFD 110 VAC) 00755024 (15 MFD 370 VAC) 00801236 GE 3ARR2 KCR1715 00215424 Copeland 040-0001-19 00801237 N/A (108-130 MFD 330 VAC) 00201075 (88-108 MFD 250 VAC) 00214943 (25 MFD 440 VAC) N/A N/A N/A N/A N/A N/A 00215424 Copeland 040-0001-19 00201075 (88-108 MFD 250 VAC) 00214943 (25 MFD 440 VAC) 23 Multiplex Company, Inc. Complete System Overview Normal Operating Pressures of Domestic Refrigeration Units Head pressure of domestic refrigeration units R-12 psig R-502 psig R-22 psig R-134A psig R-404A psig 100-140 200-260 180-240 110-160 210-280 120-170 230-300 210-280 130-180 240-320 75°F Condenser Ambient 10-100% Ice on Evaporator 90°F Condenser Ambient 10-100% Ice on Evaporator Evaporator pressure of domestic refrigeration units 75°F Evaporator, or 80°F Water 10-100% Ice on Evaporator 1. R-12 psig R-502 psig R-22 psig R-134A psig R-404A psig 75 140 130 75 150 9-20 30-50 24-44 6-18 33-55 On system with expansion valve (pressure limiting) evaporator gets no higher than: 50 psig on R-12 53 psig on R-502 85 psig on R-22 2. Water system head pressure should be manually set (adjustable water control valve) to maintain 105°F water condenser out temperature. 3. Remote Condenser system head pressure will be controlled by Low Ambient Control. 75 psig on R-12, R-134A 150 psig on R-502, R-22, R-404A 24 S03995.pm5 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Normal Operating Pressures of International Refrigeration Units Head pressure of international refrigeration units R-12 bar R-502 bar R-22 bar R-134A bar R-404A bar 24°C Condenser Ambient 10-100% Ice on Evaporator 6.9-9.7 13.8-17.9 12.4-16.5 7.6-11.0 14.5-19.3 32°C Condenser Ambient 10-100% Ice on Evaporator 8.3-11.7 15.9-20.6 14.5-19.3 8.9-12.4 16.5-22.1 Evaporator pressure of international refrigeration units 24°C Evaporator, or 27°C Water 10-100% Ice on Evaporator 1. R-12 bar R-502 bar R-22 bar R-134A bar R-404A bar 5.2 9.7 9.0 5.2 10.3 0.6-1.4 2.1-3.4 1.7-3.0 0.4-1.2 2.3-3.8 On system with expansion valve (pressure limiting) evaporator gets no higher than 3.4 bars on R-12 3.7 bars on R-502 5.9 bars on R-22 2. Water system head pressure should be manually set (adjustable water control valve) to maintain 41°C water condenser out temperature. 3. Remote Condenser system head pressure will be controlled by Low Ambient Control 5.2 bars on R-12, R-134A 10.3 bars on R-502, R-22, R-404A S04095 00218011 Revision B (KAK) 31 July, 2000 25 Multiplex Company, Inc. Complete System Overview Condenser Function of the condenser A heat exchanger which transfers heat from the refrigerant to the surrounding air or water. Failure of the condenser Air Cooled Condenser A non operational fan/motor or restricted condenser will reduce the cooling efficiency of the refrigeration unit. Water Cooled Condenser A restricted water supply to the condenser will reduce the efficiency of the refrigeration unit, a water modulating valve that is stuck open will additionally waste water. Air Cooled Condenser Remote Cooled Condenser (use refrigeration oil) Water Cooled Condenser Notes: 26 w Water cooled condensers should have water exiting condenser 100°F to 105°F regulator adjusts water flow to refrigerant pressure (higher pressure, more flow) w Clean condenser monthly 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Equipment Installation Instructions for Multiplex Remote Condenser and Pre-charged Refrigeration Lines Pre-installation requirements 3. Multiplex Remote Condenser Requirements 1. Installation and maintenance are to be performed only by qualified personnel who are 4. familiar with local codes and regulations, and are experienced with this type of equipment. 2. Equipment of this type is intended for instal- 5. lation by qualified refrigeration mechanics. As a condition of the warranty, the check test and start-up procedure must be performed by qualified personnel. Because of possible shipping damage, both the Condensing Unit and Refrigeration Unit(s) must be checked for refrigerant leaks. The easiest method to create a trap, is to bend the tubing (smoothly, no kinks) into the trap form (refer to figure 3). This trap(s) should be of minimum height of 3" (7.6 cm) and a width of 6" (15.2 cm) to minimize oil accumulation. It is critical that the Multiplex Remote Condensing line size specifications for the specific model, be maintained. The specifications are normally 1/2" discharge and 3/8" ID liquid lines. Installing the multiplex remote condenser The Multiplex Remote Condensing Units have Check to insure that the Remote Condensing Unit, the Refrigeration Unit, and the Charged either a 230 Volt, 50/60 Hz, 1 PH Fan Motor or Refrigerant Lines are marked with the same a 120 Volt, 50/60 Hz, 1 PH Fan Motor that includes a permanent split capacitor and refrigerant. internal inherent overload protection. Motors Multiplex Pre-charged Refrigeration Lines are factory wired to an external disconnect Requirements switch located on the end of the unit. 1. Both the Discharge and Liquid Remote ConRefrigeration unit has an electrical nipple densing lines should be kept to a minimum extending out of the back left side with the distance for maximum performance. All Mulelectrical wires from the refrigeration contactor tiplex systems are capacity rated to 100 ft extending through. The electrician must install (30.5 m) distance between the Compressor and an electrical box at this location. Connect the Condenser. Systems with distances greater conduit to this box and the Remote Condenser. than this will experience some efficiency loss The electrical installation should be in in proportion to the distance. This should be accordance with local codes, National Electrical a minor capacity loss, less than one drink per Code and regulations. Proper fuse protections minute up to 300 ft (90 m). should be provided for the Fan Motor. 2. Any vertical rise greater than 25 ft (7.62 m) must have a manufactured or installed trap 1. Determine a position for installation that will allow access for maintenance and is free from (bend), in at least the Discharge Remote Conobstruction. denser Refrigeration Line. A trap is necessary for every additional 25 ft (7.62 m) vertical rise. 2. Install the four (4) legs to the sides of the conWhen excessive vertical rise exists, this trap denser using the mounting bolts provided. allows oil to reach the Condenser and return 3. Secure two (2) treated 4" x 4" to the roof or to the Compressor. mounting surface. Mount to the Remote Condenser (refer to figure 1). Remote Condenser 4. Install a 3" Pitch Pot in the roof (refer to figure 2). Seal for weather protection. 3. 5. Locate the Pre-charged Refrigeration Lines shipped with the system. These lines should be a correct length for the building design. Neatly avoiding any kinks, route these lines from the Remote Condenser to the Refrigeration Unit. Caution: Excess refrigeration line should be coiled and placed in a horizontal (flat) position. When stored in a vertical position, the loops act as an oil trap and will effectively reduce the performance of our equipment as well as increase the risk of compressor failure. Wolmanized 4 x 4 (not included) Figure 1 EI216524 00218011 Revision B (KAK) 31 July, 2000 27 Multiplex Company, Inc. Complete System Overview Equipment Installation Instructions for Multiplex Remote Condenser and Pre-charged Refrigeration Lines (continued) Connecting the pre-charged refrigeration lines How to re-charge the line sets Note: Before connecting the Pre-charged Refrigeration Lines, the Refrigeration Unit must be properly located, leveled, and the water bath filled 1" (2.5 cm) below the drain pipe. 1. Attach low side Gauge Set to service port on each line set to verify positive pressure within the line set. If there is positive pressure, assume line set is fully charged. Note: If for any reason the lines are damaged and/ or leaking or lines are no longer charged, refer to How To Re-charge 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 one time quick connects (discharge and liquid) up to Condenser. Refer to the section titled Aeroquip Connection in these instructions. 4. Check that the sight glass clears during pull down to verify the Line Set charge. 5. If the sight glass does not clear, attach the gauges. Adjust the charge if necessary. Remote Condenser Note: This procedure to be used only with damaged or evacuated Line Sets or with unknown refrigerant type. 1. Repair any damages to the Line Sets before proceeding. 2. With the Remote Condenser lines properly hooked and sealed to the Condenser, evacuate to 30 in mercury (76.2 cm mercury) for 1 hour, using one or both Schrader ports on the service Line Set. 3. Charge the Condenser and Line Set accordingly. Add 0.72 oz/ft (0.067 kg/m) of Remote Line Set (one way run distance) plus 6 oz (170 g) of refrigerant for any size Condenser. Example: 50 ft of Line Set 50 x 0.72 = 36 oz 36 oz + 6.0 oz = 42.0 oz (Total) 4. Connect Line Sets to the proper discharge and liquid mating connectors on the Refrigeration Unit using one (1) time quick connects. Refer to the section titled Aeroquip Connection in these instructions. Service Ports Electrical Supply to the Remote Condenser 3" Pitch Pot Coiled Excess Refrigeration Line Handy Box Pre-charged Refrigerant Lines Roof Figure 2 28 EI216524 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Equipment Installation Instructions for Multiplex Remote Condenser and Pre-charged Refrigeration Lines (continued) 5. Be sure to observe proper refrigeration technique when running the Line Set. Proper Refrigeration Technique for Running the Line Set a. The discharge line should loop down at the Compressor end to trap liquid from returning (refer to figure 3). b. c. The Discharge Line should loop above discharge connector at the Condenser to resist liquid returning to the Compressor. Any excess line should be coiled horizontally with line from the Compressor at top and line to the Condenser at bottom to keep from trapping oil and returning liquid. Discharge line should be trapped (P Trap) every 20-25 ft (6.1-7.6 m) of vertical rise, to allow oil to stair-step up to the Condenser and eventually return to the Compressor. Aeroquip Connection 1. Lubricate male half diaphragm and synthetic rubber seal with refrigerant oil. 2. Thread male coupling to its proper female half by hand to insure proper mating of threads. 3. Use proper wrenches (on coupling body hex and its union nut) and tighten union nut until coupling bodies bottom. Note: You must use body wrench to keep body from turning while tightening nut with the second wrench. If body turns excessively, piercing seal will be damaged. 4. Use proper wrenches to tighten an additional 1 /4 turn (90°). This final 1/4 turn is necessary to insure the formation of a leak proof joint. Alternately use a torque wrench to tighten 1/2" Coupling to 40 ft lbs and 3/8" fitting to 11 ft lbs. Note: When the connections are made, the seal in the couplings are broken and if removed for any reason, the refrigerant charge will be depleted. Caution: Relays and 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. Discharge Line Condenser Trap To the Condenser Coil any extra Condensing Lines in a horizontal plane with output below input. 3" (7.6 cm) x 6" (15.2 cm) Maximum Trap Area Discharge Line Trap every 25 vertical ft. (7.62 m) Compressor 3 ft (minimum) of Discharge Line Trap at the Compressor Figure 3 EI216524 00218011 Revision B (KAK) 31 July, 2000 29 Multiplex Company, Inc. Complete System Overview Expansion Valve or Cap Tube Function of the expansion valve or cap tube The expansion valve or cap tube, controls the refrigerant flow. Both controls allow the reduction of liquid refrigerant from high pressure to its evaporating pressure. The expansion valve is better suited for varying temperature conditions. Failure of the expansion valve or cap tube A defective expansion valve or cap tube will not properly regulate the flow of refrigerant. Notes: w 30 O.E.M. part adjusted for our super heat 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Evaporator Coil Function of the evaporator coil Coil in the water bath in which the refrigerant vaporizes and absorbs heat creating an ice bank. Failure of the evaporator coil This copper tube assembly is extremely reliable, however, concern should be given when cleaning around the evaporator to insure no sharp instruments, chemicals/cleaners are used that might damage the evaporator. Notes: 00218011 Revision B (KAK) 31 July, 2000 31 Multiplex Company, Inc. Complete System Overview Water Bath Function of the water bath Water and ice reservoir, housing the carbonator tank and cooling coils. Provides an efficient method of removing heat. Failure of the water bath Not maintained, dirty water in the bath may cause poor ice bank formation, poor heat exchange and electrolysis. Notes: w 32 Restrictions in the flow of water, in the water bath, from the agitator motor could cause an uneven ice bank (or blockage in the flow of water). 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Agitator Motor Function of the agitator motor Agitates the water within the bath to distribute heat load and keep the ice bank uniform. Failure of the agitator motor An inoperative agitator will warm drinks and an irregular ice bank formation. Notes: w Make sure agitator motor has a heat sink (it will extend the life of your motor) w Make sure propeller is secured to the agitator motor w An inoperative agitator motor will cause foaming at peak times 00218011 Revision B (KAK) 31 July, 2000 33 Multiplex Company, Inc. Complete System Overview Ice Bank Control Function of the ice bank control Pressure switch that turns on and off the refrigeration compressor when the control bulb indicates the need. Failure of the ice bank control Defective ice bank control stuck in the open position will not allow the refrigeration compressor to operate. Defective ice bank control stuck in the closed position will not allow the refrigeration compressor to cut-off. Removing the cover mounting plate will alter the switch calibration. Notes: 34 w Check circuit breaker w Check head pressure control (on remote condenser units) w If the bulb is engulfed in ice, the compressor should not be running w Check contactor coil for welded points w Do not change bulb location w If you have two controls the primary control bulb is positioned closer and lower on the evaporator coil w A warning light will indicate when the secondary control has taken over 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Head Pressure Control (used on Remote Condensing units only) Function of the head pressure control As the evaporator discharge pressure drops when the outside temperature drops, gas will by-pass the roof condenser and be metered into the receiver maintaining an adequate head pressure. Failure of the head pressure control A valve incapable of by-pass will effect the refrigeration unit when the outside temperature drops below 60°F with little or no ice production. A valve stuck in by-pass will cause high head pressure and effect the ice production capabilities of the unit. R-12 R-502 Condenser Notes: Water Bath Compressor Receiver 00218011 Revision B (KAK) 31 July, 2000 35 Multiplex Company, Inc. Complete System Overview Refrigeration Unit, Line, and Condenser Cross Reference Chart Condenser unit Part Number Size Refrigerant Charge Voltage Frequency 00905222 0.75 ton R-12 23 oz 120 VAC 60 Hz 00905224 0.75 ton R-12 23 oz 220 VAC 50 Hz 00212551 1.5 ton R-12 20 oz 208/230 VAC 50/60 Hz 00213365 1.5 ton R-22 12 oz 208/230 VAC 50/60 Hz 00214150 1.5 ton R-502 6 oz 208/230 VAC 50/60 Hz 00904685 2.0 ton R-12 6 oz 203/230 VAC 50/60 Hz 00904812 2.0 ton R-22 6 oz 208/230 VAC 50/60 Hz 00904811 2.0 ton R-502 6 oz 208/230 VAC 50/60 Hz 00215500 1.5 ton R-404A 6 oz 208/230 VAC 50/60 Hz 00904813 2.0 ton R-134A 6 oz 208/230 VAC 00904814 2.0 ton R-404A 12 oz 208/230 VAC Refrigeration line sets 36 Part Number Refrigerant Charge (ounces) Charge (pounds) 00204017 R-12 0.72 oz/ft 0.045 lb/ft 00213062 R-22 0.72 oz/ft 0.045 lb/ft 00209602 R-502 0.72 oz/ft 0.045 lb/ft 00215425 R-404A 0.72 oz/ft 0.045 lb/ft S90232 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Refrigeration Unit, Line, and Condenser Cross Reference Chart (continued) Refrigeration units Part Number Model Refrigerant Charge 00903731 37KR R-12 172 oz 00903741 37KRX R-12 172 oz 00903758 371RX R-12 172 oz 00903771 37TR R-12 172 oz 00903781 37TRX R-12 172 oz 00903791 00903794 37KR-22 37KRX-22 R-22 R-22 151 oz 151 oz 00903797 37KRX-22 V R-22 151 oz 00904711 371R R-12 172 oz 00904726 37MR-P R-22 151 oz 00904736 37MRX-P R-22 151 oz 00903804 38HR R-12 98 oz 00903940 39SC R-12 98 oz 00904401 44R R-12 128 oz 00904403 44RX R-12 98 oz 00904420 44KR R-12 128 oz 00904423 44KRX R-12 98 oz 00904431 00904434 44MR-G 44MRX-G R-22 R-22 116 oz 116 oz 00904441 44KR-22 R-22 116 oz 00904444 44KRX-22 R-22 116 oz 00904464 44KRX-22 V R-22 116 oz 00904471 44MRXG R-134A 116 oz 00904473 44KRX R-134A 116 oz 00904481 44MR04 R-404A 125 oz 00904491 44KR04 R-404A 125 oz 00905013 50HR R-12 150 oz 00905016 50HRX R-12 150 oz 00905031 00905034 50MR 50MRX R-22 R-22 140 oz 140 oz 00905041 50MR04 R-404A 144 oz 00905044 50MRX04 R-404A 145 oz 00905046 50MR04 R-404A 144 oz 00934101 R3410R R-502 240 oz 00936111 D3610R R-502 240 oz 00936113 D3610R R-404A 240 oz 00936115 3610R04C R-404A 240 oz 00936116 3610R404C R-404A 240 oz 00942100 D4210HR R-22 192 oz 00948102 D4810R R-404A 240 oz To maintain the high quality of your Multiplex equipment we recommend you to contact your Multiplex Regional Technical Manager for the Authorized Multiplex Service Agent nearest you at (636) 256-9797. S90232 00218011 Revision B (KAK) 31 July, 2000 37 Multiplex Company, Inc. Complete System Overview High Pressure Cut-out (limiting switch) Function of the high pressure cut-out Pressure operated control which opens electrical circuit if high-side pressure becomes too high. Failure of the high pressure cut-out Defective high pressure cutout stuck in the open position will not allow the refrigeration compressor to operate. Defective high pressure cutout stuck in the closed position will not protect the refrigeration system from a high pressure situation. Notes: CO 250 CI 200 R-12 CO 400 CI 350 R-502 38 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Dispensing Valves Function of the dispensing valves To dispense cold syrup and carbonated water, consistently at a proper ratio and speed. Failure of the dispensing valves Inferior finished product, poor tasting drinks. Dole FFV with Syrup Separator Dole SEV SF-1 Notes: w Check for operation of solenoids, swollen seats, restricted valve ports and power to the dispensing valve w Flow Rate: 5 oz/4 sec (standard flow) 10 oz/4 sec (fast flow) w Set the flow rate, then adjust the ratio 00218011 Revision B (KAK) 31 July, 2000 39 Multiplex Company, Inc. Complete System Overview Flow Controls Function of the flow controls To regulate the flow of syrup or water and compensate for the drop or rise in pressures that occur when more than one dispensing valve is operated from the same supply. Failure of the flow controls Defective or dirty flow controls will not retain a proper and constant Brix. Notes: 40 w If flow control sticks, replace w You must not interchange spools and sleeves from different sets 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Keyboards and Timers Function of the keyboards and timers Activates the solenoids on the dispensing valve for a specific adjustable amount of time. Generally allowing for three different time ranges. Failure of the keyboards and timers Defective keyboards will cause the continual activation of the timer or no activation at all. Defective timers will cause continual dispensing of the product, no dispensing of product or will not adjust to the desired portion size. Notes: 00218011 Revision B (KAK) 31 July, 2000 41 Multiplex Company, Inc. Complete System Overview Multiplex Programmable Portion Control Timers Whats New at Multiplex We have received some requests to publish descriptions explaining the differences between the various models of Multiplex programmable portion control timers. The following is not intended to be a step by step procedure, but is only a general overview of the unique features of each timer. You may now order new push-button replacement labels for the 4-Size timers that are used on the Model CPss150MD200 and Model 116 tower. The Model 66 was the first programmable portion control timer. It requires a 9 volt battery to retain its memory during power outages. Its 3-Size timer utilizes a separate rocker switch for calibration. To set the drink sizes: w Turn the calibration rocker switch to the on position. w Push the respective size pad for each keypad position at each valve. w Repeat this process for each valve. w Once complete, turn off the rocker switch to store the programmed sizes into memory. The Model 64 is similar to the Model 66, except that the 9 volt battery is no longer required, since memory is stored on a memory chip. Its 4-Size timer still requires the rocker switch for calibration. There are major improvements with the Model 64A Revision B. The 4-Size timer uses a calibration button, integrated into the keypad, rather than a rocker switch. A 4 second pour feature permits easy flow rate adjustments and volume settings for all valves simultaneously from valve number 1, in an emergency. To adjust the flow rate: To replace, peal back worn push-button label carefully with a knife edge as shown above. Peel the covering from the back of label. Attach new label and apply light pressure to adhere the new label to the timer. Please see below for correct label to order for your timers. w Push the CAL pad three (3) times in less than three (3) seconds to enter calibrate mode. Calibration light will go on. w Push the STOP/FILL pad once on any valve to achieve a 4 second pour for that valve. w Once the valve water flow adjustments are complete, push the CAL pad once to exit calibrate mode. Calibration light will go out. P.N. 00214953 To be used with timer cover (P.N. 0021693). w To adjust the Brix (water to syrup ration) for each valve, push the CAL pad three (3) times again. w Push the respective size for each valve until you achieve the desired drink level in your cup. w Exiting calibrate mode (pushing CAL pad once) will lock the programmed sizes to memory. The Model 64A Revision C is similar to the Model 64A Revision B except that the volume settings can be completely accomplished from any valve. To adjust all valves to the same times: P.N. 00214954 To be used with timer cover with soda button (P.N. 00216094). w Push CAL pad three (3) times and push the STOP/FILL pad on any valve (except valve number 1) two (2) times. w Program each size for that valve. w Exit calibration mode by pushing CAL pad once. This will lock the programmed sizes for all valves into memory. Note: It is extremely important that all valves be adjusted to exactly the same water flow rate. If any valve is adjusted to a different flow rate (no matter how slight), it will have to be readjusted separately. 42 P.N. 00214955 To be used with timer cover with water button (P.N. 00210695). 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Instructions for Proper Dispensing Valve Calibration (Flow, Ratio, and Volume) using the 4-Size Portion Control Flow (to set the water flow rate only) Ratio (water to syrup mixture) Check that the Primary CO2 tank high pressure regulator or bulk CO2 regulator is adjusted properly. The Medium pressure regulator for sugar-based syrup must be adjusted to 60 psi (4 bar). The Low pressure regulator for sugar-free syrup must be adjusted to 14-16 psi (0.9-1.1 bar). 1. Remove valve nozzle by turning the nozzle and pulling down. 2. Place syrup separator on valve to be adjusted. Actuate the valve manually (pad, lever) until both syrup and water flow out of the syrup/ water separator. 3. Position the proper ratio cup under the syrup separator. Manually actuate the valve pad or lever valve (pad, lever). Dispense until at least 3 /4 of the ratio cup is filled. Both products should fill to the same level. 4. To adjust the syrup flow (if levels are not equal), turn the syrup flow control adjusting screw clockwise to increase and counterclockwise to decrease the flow of syrup. 1. Turn off the syrup at the dispensing valve by turning the syrup shut-off (located on the valve mounting block). If there is no syrup shut-off, use a syrup separator. 2. Check the water shut-off (if applicable). It should be in the full open position. Note: The syrup and water shut-off (if equipped) are not to be used as an alternate for flow controls. They are to be used only for shutting on or off the syrup and/or the water supply. 3. 4. 5. Place a volume cup with 10 oz. (295.7 mL) measurement line, under valve to be adjusted. If using syrup separator, place volume cup un- 6. der water side of separator only. Use 4-Size portion control timer to obtain an accurate 4 second pour as follows: a. Press CAL pad three (3) times in less than 3 seconds to enter calibrate mode. Calibrate lamp will light. (Omit this step if already in calibrate mode). b. Press STOP-FILL pad of valve to adjusted once to cause 4 second pour into volume cup. Note: Fast-fill valves will dispense 10 oz in 4 seconds and standard-fill valves will dispense 5 oz in 4 seconds. Diet and other products with high foaming tendencies would be adjusted to 7.6 oz and 3.8 oz respectively. 5. 6. 7. 8. 9. Note: Do not adjust the water flow during this procedure. To adjust the water flow rate (if necessary), turn the adjusting screw clockwise to increase and counterclockwise to decrease the flow of water. After syrup is adjusted, remove the syrup separator and replace the valve nozzle. Repeat this procedure (steps 1 through 5 above) for the remaining valves. Volume (setting drink portion sizes) 1. To enter portion control calibrate mode, press CAL pad three (3) times in less than 3 seconds. Calibrate lamp will light. 2. Use volume cup with finished drink marking lines, or use correct size sample cup with desired volume of ice. 3. Press and hold respective SIZE pad until product gets close to proper finished drink mark, or until close to top of sample cup. 4. Release SIZE pad before reaching final mark or before foam exceeds final mark. Press SIZE pad again momentarily, as many times as is necessary (letting foam settle), to get to the correct finished drink mark. 5. Repeat steps 2 through 4 above for all sizes and all stations (products) needing calibration. Be sure to use the correct volume cup finished drink marking line, or correct sample cup size and ice amount, for each size pad. Repeat 4 second dispense (STOP-FILL pad) and water flow adjustment, until volume is correct. Note: If you fill above the final mark or need to Open syrup shut-off or remove syrup separa- "start over" for any reason, you must exit the calitor (if applicable). brate mode and then re-enter the calibrate mode Repeat this procedure (steps 1 through 7 to resume. above) for each valve. 6. Exit calibrate mode by pressing CAL pad once. Calibrate light will go out. All changes will be Press CAL button once to exit calibrate mode. permanently saved. Calibrate lamp will go off. 00218011 Revision B (KAK) 31 July, 2000 43 Multiplex Company, Inc. Complete System Overview Instructions for Proper Dispensing Valve Calibration (Flow, Ratio, and Volume) using the 4-Size Portion Control (continued) Special feature For use by serviceman only, or to temporarily program all stations (products) in an emergency. 1. 2. 44 When you first enter calibration mode (by pressing CAL pad three [3] times in less than 3 seconds), any station (product) STOP-FILL pad can be pressed two (2) times in less than 2 seconds. The calibrate lamp will flash continuously. 3. Immediately exit calibration mode by pressing the CAL pad once, to save changes. Calibration light will go out. Note: All valve flow rates and ratios must be adjusted exactly the same before attempting this "one valve adjusts all" routine. 4. Individual stations/sizes can be re-calibrated when necessary. The size pads of this station can now be calibrated as in steps 2 through 4 of Volume instructions. The times will replicate across all stations (products). All stations and all sizes will now have exactly the same pour times. 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Test Procedures Model MPC64A timer/selection pad MPC 64A Timers can be placed in the test mode as follows: 1. Flip power switch off. 2. While depressing CAL button on selection pad, flip power switch back on. 3. Release CAL button when red LED comes on. Faucets will energize for 2 seconds, each in sequence, starting with faucet #1 (far left). Timer is now in the Test Mode. To stop faucets, use one of two procedures: a. b. Turn power switch off. This will save the programmed times. Use this procedure for testing or sanitizing. Push CAL button. All programmed times for all stations will go to factory default times. Default times are: Size #1: 1 - 1.5 seconds Size #2: 4 - 4.5 seconds Size #3: 6 - 6.5 seconds Size #4: 8 - 8.5 seconds Pin identification J-7 = Valve 1 J-8 = Valve 2 J-9 = Valve 3 J-10 = Valve 4 J-11 = Valve 5 J-12 = Valve 6 Check for 24 Volts at each solenoid cable connector, J-7 through J-12, with cables removed. With cables on, check for 24 VAC across solenoids at dispensing valve while dispensing respective valve. J-15 Power to Valves 1, 2, 3. J-20 Power to Valves 4, 5, 6 and microprocessor. Loss of power at J-20 results on loss of power to microprocessor; no valves will work. J-16 Station and Sizes: #1 Stop/Fill #2 Large #3 Medium #4 Small #5 Valve 6 (or nothing, on a 5 valve tower) #6 Valve 5 #7 Valve 4 #8 Valve 3 #9 Valve 2 #10 Valve 1 #11 Blank #12 Extra Large Use a jumper wire to make these connections to determine if timer is functioning properly. 1. Jump pin 1 to pin 5, 6, 7, 8, 9, 10. Appropriate valve should energize as long as pins are jumped. 2. Jump pin 12 to pin 5, 6, 7, 8, 9, 10. Valves should pour EXTRA LARGE. 3. Jump pin 2 to pin 5, 6, 7, 8, 9, 10. Valves should pour LARGE. 4. Jump pin 3 to pin 5, 6, 7, 8, 9, 10. Valves should pour MEDIUM. 5. Jump pin 4 to pin 5, 6, 7, 8, 9, 10. Valves should pour SMALL. J-17 calibration button and light If microprocessor does not go into calibration, remove connector at J-17. With jumper wire, jump 1st and 2nd pins on left 3 times in less than 3 seconds. Replace connector. Calibration light should be on (microprocessor will be in the calibration mode). White & white = calibration button. Red & black = calibration light. If CAL light does not come on, LED is burned out replace keyboard. Loss of power at J-15 results on loss of power to valves 1, 2, 3. 00218011 Revision B (KAK) 31 July, 2000 45 Multiplex Company, Inc. Complete System Overview Dual Transformers Note: Dual Transformers must be wired in phase.* To determine whether transformers are wired in phase: With power on, take voltage reading at HOT wire of each transformer. Reading should be 0 VOLTS*. If you read voltage, transformers are out of phase. The positions of the wires on one transformer must be switched. * Black to White = 24 VAC +/- 10% Black to Black = 0 VAC 46 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Service Bulletin MOVs field testing Metal Oxide Varistors installed on the water and carbonated water buttons, on McDonalds style dispensing towers, are designed to completely absorb electrical spikes keeping them out of the microprocessor circuit eliminating complaints of: w Not holding calibration w Valves flowing by themselves w Two valves coming on at the same time, etc. Multiplex has designed a field test procedure that will expose a faulty MOV. This procedure will also work on the older style capacitors. The field test procedure: Depress separately both the water and soda water button rapidly 5-6 times. While doing this, watch all other valves. If you notice any dripping or any other valve trying to energize, the MOVs need to be replaced. Note: Factory installed MOVs have heat shrink tubes on each terminal leg. Always check to make sure that heat shrink has not slipped down and is insulating the MOV leg inside the terminal connector. Notes: 00218011 Revision B (KAK) 31 July, 2000 47 Multiplex Company, Inc. Complete System Overview New Model MPC84A Portion Control Board A new portion control board, the Model MPC84A, has been developed to improve the performance and maintain the functions and feature of the previous Model MPC64A. In addition, this Porction Control board has passed the very demanding EMC (radio frequency emissions and interference) testing for European CE approval, at the UL labs. The Model MPC64A has been phased out as of June 1996. Only the Model MPC84A will be used on new production and for service. The new bard is the same size, has the same mounting locations, and uses the same connectors as the previous board. This article is to explain the features (which can be used to your advantage) and minor differences. The major difference is the same size board. The Model MPC84A can control up to eight stations (dispensing valves) with up to four sizes per station. The Model MPC64A could control up to six stations. The illustration in Figure 1 depicts the connectors on the Model MPC64A. The illustration in Figure 2 depicts the connectors on the Model MPC84A. The power connectors J15 and J20 (24 VAC) are the same. The keyboard connectors, J16 for touchpad and J17 for calibration touchpad, are the same. The Model MPC84A adds one more two pin keyboard connector, the J1. For an eight station tower, this connector, along with a separate two wire cable to the proper keyboard, provides the two extra stations. The five pin valve connectors, the J7 to J12 on the Model MPC64A, are changed to a two pin connectors, the J7 to the J14 on the MPC84A. These valve connectors are not polarized (does not matter how you connect the two pins) except when the valve has a water or a soda harness. The calibrating functions of the new portion control board are the same as the old board. Figure 1 Figure 2 48 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Instructions for Multiplex Model MPC84AT Portion Control Board with Top-off Run Mode Top-off program mode Size Buttons Press any size button (1, 2, 3, etc.) on any station to dispense product for that station for the pre-programmed time for that respective size. For example, at Station 1 press the Small size button. Station 1 should dispense the correct amount of product for a Small size. Entering the Top-off Program Mode To enter the Top-off Program Mode, press the CAL button five (5) times in less than 3 seconds. The CAL light will flash each time it is pressed and flash five (5) times after 3 seconds. The light will remain on. STOP-FILL Buttons If no dispense is in progress, press any STOPFILL button to manually dispense from the station. Press the STOP-FILL button to manually stop and cancel any in-progress dispensing at that station. Program Mode Enabling and/or Disabling the individual station Top-off Enabling the individual station Top-off allows every size dispensed on this station to pour all the volume programmed in two (2) pours with a 3 second delay between pours. Disabling the individual station Top-off allows every size dispensed on this station to pour all the volume programmed. Entering the Program Mode 1. To enter the Program Mode, press the CAL button three (3) times in less than 3 seconds. The CAL light will flash each time it is pressed. After 3 2. seconds, the light will remain on constantly (if pressed the proper number of times in the proper time frame). Volume Sizing Note: Use a Calibration cup (or an appropriate size cup with the right amount of ice). 1. Press the respective size button for that cup (small, medium, large, etc.) at that station. 2. Fill the cup with product to the correct level. Note: This same size button may be started and stopped as many times as desired to acquire the correct level while letting the drink settle. All times for same station and size are additive in the program session. 3. Repeat volume sizing procedure for all sizes and stations. Flow Rate Calibration Press any STOP-FILL button one (1) time. That respective valve will flow for exactly 4 seconds allowing for checking or adjusting the valve flow rate. Press the STOP-FILL button on the station desired to change the top-off mode. The CAL light will immediately flash five (5) times to indicate the top-off mode has been toggled. If the respective station was disabled for top-off, then it will toggle to enable for top-off. If the respective station was enabled for top-off, then it will toggle to disable for top-off. Exiting the Top-off Program Mode To exit the Top-off Program Mode, press the CAL button one (1) time turning off the CAL light. All station top-off mode changes made during this session will permanently be stored. Test mode 1. With the power off, press the CAL button and turn power on simultaneously. 2. Release the CAL button. The Portion Control board will sequence each station for 4 seconds starting with the leftmost. 3. Check that each LED on the Portion Control board comes on sequentially and all valve solenoids fire. Note: If the LED light does not come on for any station(s), the Portion Control board is bad. If the LED light comes on but the valve does not fire, check wiring and valve solenoids. One Station Sets All After entering the Calibrate Mode, press any Sanitation mode STOP-FILL button two (2) times in less than 1 second. The CAL light will flash constantly. Now 1. With the power off, press the CAL button and turn the power on simultaneously. all volumes on that station programmed in this session will copy to all other stations. 2. Release the CAL button. Each station will come on for 4 seconds sequentially. This allows Exiting the Program Mode automatic pouring of the sanitation fluid from To exit the Program Mode, press the CAL button each station constantly until each line drains. one (1) time turning off the CAL light. All volume changes made during this session will permanently Note: If the drain can support more than one (1) valve pouring at a time, press the STOP-FILL butbe stored. ton on the station number for the number of valves flowing simultaneously. Example: At station number 3, press the STOPFILL button. Three (3) valves will flow simultaneously. EI216162 00218011 Revision B (KAK) 31 July, 2000 49 Multiplex Company, Inc. Complete System Overview McDonalds Portion Control Timer A common problem associated with the McDonalds style portion control timer is when one size becomes non-adjustable. This may not be more than the trimming potentiometers being adjusted out of the usable range. To bring them back into range, all that must be done is to turn the screw counterclockwise 20 complete turns, and then clockwise: Number of Complete Turns Fast Fill Standard Fill Medium 3 5 Large 4 7 Super-Size 5 9 This procedure should eliminate the replacement of many good portion control timers. Volume Adjusting Screws 24 VAC Power Manual Fill Switch Large Selection Switch Medium Selection Switch Regular Selection Switch If you have any questions or comments, please contact Multiplex Technical Service at (314) 256-7777. 50 00218011 Revision B (KAK) 31 July, 2000 Multiplex Company, Inc. Component Parts Workbook Sitco 4-Selection Portion Control Timers Adjusting portion control for size of drinks dispensed Small Medium Large X-Large 1. Simultaneously press and hold S (SMALL) and X (EXTRA LARGE) push button switches on Coded Autoset Portion Control Module until LED light in center of module starts blinking, then release switches. Blinking LED indicates 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 Soda/Water Stop/Flow button in until cup fills to desired portion then release button. Wait for foam to settle then actuate button again to top off. Repeat the Cancel/pour above procedure for remaining sizes. 1. Push and release to cancel or stop valve dispensing. After programming all drink sizes, press and release CANCEL/POUR switch to return the 2. Push and hold for continuous pour. Coded Autoset Portion Control to the operaThe portion control has a full memory retention tional mode. Blinking LED light will go out. when programming and in case of power failure. Note: If top-off is not desired or required, the following steps must be followed: 3. a. Follow step 1 above. b. 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. Note: After actuating the last selected size button, momentarily actuate one of the other size buttons. This will signal the microprocessor that all selected sizes are completed. Failure to do this will signal an incomplete response back to the microprocessor and the last selected size will revert back to its previous program. If, at a future date, it is decided to change portion size of the drinks or omit or add the top off feature, the individual sizes can be adjusted by the above procedure. It is not necessary to reprogram every size. Installation 1. Remove the front cover from the valve. 2. Remove the rear cover by loosening the screw at the front top portion of the rear cover and then lift up on the rear cover. 3. Disconnect the valve 24 volt AC electrical connection (white plug) from the dispensing valve connector. 4. Remove the entire valve wiring harness from the dispensing valve (valve lever and micro switch can be removed, if desired). 5. Attach the portion control wiring as shown in Figures 1 or 2. 6. Connect the 24 VAC connector from the portion control to the connector on the dispenser. 7. Place the rear cover on the valve and tighten the screw at the front of the rear cover. 8. Place the coded auto set portion control front cover on the front of the rear cover. Snap the front cover into the rear cover at the bottom of the front cover. Part No. Description 00210693 4-Selection Portion Control for Wilshire Valves 00210694 4-Selection Portion Control with Soda for Wilshire Valves 00210695 4-Selection Portion Control with Water for Wilshire Valves 00210697 4-Selection Portion Control for Lancer Valves 00218011 Revision B (KAK) 31 July, 2000 51 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218011 Revision B (KAK) 31 July, 2000 Fountain Troubleshooting Guide Fountain Beverage Dispensing Equipment 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Table of Contents Caution ................................................................................................................... 1 Foreword ................................................................................................................. 2 Problem Cross Reference Guide ..................................................................................... 3 Troubleshooting Guide ................................................................................................ 4 Section 1: CO2 Gas System ......................................................................................... 4 Loss of CO2 ........................................................................................................ 4 Flat drinks (lack of carbonation in carbonated water) .................................................... 5 Section 2: Carbonated Water System ............................................................................ 7 Flat drinks ........................................................................................................ 7 No carbonated water at any of the dispensing valves ..................................................... 9 Carbonator pump and motor will not cycle off (possibly noisy pump) ............................. 11 Section 3: Circulating System ................................................................................... 14 Warm drinks .................................................................................................... 14 Section 4: Compressed Air System ............................................................................. 16 No syrup ........................................................................................................ 16 Section 5: Dispensing Valve and Tower ........................................................................ 19 No syrup or insufficient syrup in finished drink .......................................................... 19 No carbonated water or insufficient carbonated water in finished drink ............................ 20 No water or insufficient water in finished drinks ........................................................ 21 Section 6: Electrical System .................................................................................... 24 Section 7: Refrigeration System ................................................................................ 25 Warm drinks (carbonated water temperature over 40°F [5°C]) ....................................... 25 No carbonated water at any of the dispensing valves ................................................... 27 Section 8: Syrup System ......................................................................................... 28 Section 9: Water Booster System ............................................................................... 30 Low or no water pressure at noncarbonated beverages ................................................. 30 Section 10: Water Filter System ................................................................................ 32 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Caution: To Avoid Serious Injury Important: Read the following warnings before beginning an installation. Failure to do so may result in possible death or serious injury. DO Adhere to all National and Local Plumbing and Electrical Safety Codes. DO Turn off incoming electrical service switches when servicing, installing, or repairing equipment. DO Check that all flare fittings on the carbonation tank(s) are tight. This check should be performed with a wrench to ensure a quality seal. DO Inspect pressure on Regulators before starting up equipment. DO Protect eyes when working around refrigerants. DO Use caution when handling metal surface edges of all equipment. DO Handle CO2 cylinders and gauges with care. Secure cylinders properly against abrasion. DO Store CO2 cylinder(s) in well ventilated areas. DO NOT Throw or drop a CO2 cylinder. Secure the cylinder(s) in an upright position 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. 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, some may exceed temperatures of 200°F (93.3°C). Notice: Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed and maintained in accordance with Federal, State, and Local codes. 00218012 Revision B (KAK) 7 August, 2000 1 Multiplex Company, Inc. Fountain Troubleshooting Guide Foreword This Troubleshooting Guide has been developed to assist you in determining what the Probable Cause for any particular Problem you may experience with your Multiplex Beverage System could be. It then advises of the proper Corrective Action to be taken to remedy that Problem. Because of the ever present danger from electrical shock, and the existence of high pressure water and gas on the system, it is strongly recommended that only qualified service personnel perform actual repairs. To use this guide you should first recognize the Problem. Once this has been accomplished, you should refer to the Problem Cross Reference Guide, which will direct you to the troubleshooting section or sections which may be responsible for that particular Problem. Under each of the sections, Section 1: CO2 Gas System, Section 2: Carbonated Water System, Section 3: Circulating System, Section 4: Compressed Air System, Section 5: Dispensing valve and tower, Section 6: Electrical System, Section 7: Refrigeration System, Section 8: Syrup System, Section 9: Water Booster System, and Section 10: Water Filter System, youll first find the Problem listed in bold type starting on the left margin. It will be followed by three headings also in bold type and each with its own column. The first is a Qualifier which is designed to quickly qualify or eliminate the Probable Causes listed to the right and below the qualifying statement. Example: Under Section 7: Refrigeration System, youll find three Qualifiers for the same problem, Warm drinks. Carbonated Water Temperature over 40°F (5°C). Each asking you to determine the status of the Refrigeration Compressor and Ice Bank before proceeding to the second column Probable Causes. Not all problems have Qualifiers, but for those that do, first examine each one listed below the Problem before continuing through Probable Causes. The third heading, Corrective Action found on the right margin, will direct you in determining if the Probable Cause is actually responsible for the problem and what should be done to remedy the problem. On occasion, youll find Note and Caution statements which have been included to make special references to items which frequently are misunderstood or ignored. This guide is intended to assist you in locating the cause of a problem. It is not, however, to be considered a service and repair manual in that Multiplex models vary in design. It has been written to encompass all model Refrigeration Units. Some differences from model to model will become obvious and it will be required of the reader to apply this guide to each unit. Of main concern, is on Dual Carbonating and Circulating Systems you must consider there are two separate Carbonating and Circulating Systems. 2 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide X X X X R X X R Water Filter Water Booster Syrup Refrigeration Electrical X X R Dispenser X X X Compress Air Circulating No carbonated water Carbon particles in drink Flat drinks No or insufficient non-carbonated water Warm drinks No or insufficient syrup Peculiar taste carbonated water Peculiar taste non--carbonated water Peculiar taste syrup Carb and booster pump noisy Air compressor operates excessively Loss of CO2 gas Drinks too sweet Too much syrup Too much carbonated water Too much non-carbonated water Foaming Booster pump/motor wont cycle off Booster pump/motor wont cycle on Excessive Carbonation Low pressure CO2 alarm wont cycle on Low pressure CO2 alarm wont cycle off Water found in primary regulator Booster pump/motor wont cycle off Booster pump/motor wont cycle on Product dripping from nozzle Valves will not activate Valves will not shut off Unit totally inoperative Carbonated CO2 Problem Cross Reference Guide X X X X R X X X R X X X X R R X R R R X R X X X X R R R X R R X X X X X X X X X X X X X - Specific problem listed in section R - Problem refer to from section with X 00218012 Revision B (KAK) 7 August, 2000 3 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 1: CO2 Gas System On units not equipped with Air Pump, check all Probable Causes listed below. Qualifier If leak occurs while Change-over valve is positioned on Air, follow the Probable Causes (for units equipped with Air Pump). If leak occurs only while Change-over valve is positioned on CO2, refer to Troubleshooting Section 8: Syrup System. 4 Probable Cause Loss of CO2 Corrective Action CO2 Tank leaking. Use a soap solution around CO2 Tank valve Stem to locate leaks. If leaks are present, bubbles will appear. If valve Stem leaks at Tank, replace CO2 Tank. CO2 Washer damaged or missing. Use a soap solution around Primary Regulator Coupling Nut and CO2 Tank Stem. If bubbles appear, remove Regulator and replace CO2 Washer found inside Nut. Secure Regulator to Tank and check for leaks. Primary Regulator Diaphragm leaking. Use a soap solution around Primary Regulator Adjustment Screw in Bonnet. If bubbles appear, diaphragm is leading. Replace Primary Regulator. Ruptured Line Assembly or leaks at connections. Use a soap solution around all connections. If bubbles appear, tighten loose connections carefully. A to B Change-over Valve leaking. Use a soap solution around A and B CO2 Tank Change-over Valve, tighten if bubbles appear at Connections to stop leaks. CO2 Low Pressure Switch leaking. Use a soap solution around Low Pressure CO2 Switch. If bubbles appear at pipe, tighten Connection. If bubbles appear at Terminal end of Switch - replace Switch. CO2 Check valve leaking. Use a soap solution around Check valve. If bubbles appear, tighten Connection to stop leaks. Back Flow Preventer stuck open. Use a soap solution around Back Flow Preventer. Tighten if bubbles appear at connection. If bubbles appear at Vent Hole on underside of Back Flow Preventer, clean out or replace Back Flow Preventer valve and corresponding Water Check valve. Carbonator Tank Relief valve leaking. Use a soap solution around Relief valve. If bubbles appear, replace Relief valve. Gas leak at the syrup system. Refer to Troubleshooting Section 8: Syrup System under No syrup or insufficient syrup in finished drink. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 1: CO2 Gas System (continued) Qualifier Probable Cause Corrective Action Flat drinks (lack of carbonation in carbonated water) Primary Regulator (less than 500 psi [34.5 bar]). CO2 Supply exhausted (CO2 Tank is functionally empty if pressure reads less than 500 psi [34.5 bar]). Verify CO2 Tank pressure is a minimum of 500 psi (34.5 bar) on the Primary Pressure Regulator Gauge marked 0-2000 psi. Replace tank if necessary. Primary Regulator out of adjustment or inoperative. Verify CO2 Primary Regulators are set at 90 psi (6.3 kg/cm2). Adjust if necessary. If Regulator will not stay in adjustment, replace Regulator. A and B CO2 Tank Changeover Valve incorrectly positioned. If A and B CO2 Tank Change-over Valve is positioned on an empty Tank or halfway between A and B operating positions, CO2 is not supplied to Carbonators. Insure valve handler is in the operating position. Malfunction of the Refrigeration System. Refer to Troubleshooting Section 7: Refrigeration System under Warm drinks. Water Filter restricted. Refer to Troubleshooting Section 10: Water Filter System under Peculiar taste. Malfunction of the Carbonated Water System. Refer to Troubleshooting Section 2: Carbonated Water System under Flat drinks. Excessive carbonation (foaming). Primary Regulators set too high. Verify CO2 Primary Regulators are set at 90 psi (6.3 kg/cm2). Adjust if necessary. If Regulator will not stay in adjustment, replace regulator. Replace. Low Pressure CO2 Warning light or buzzer does not come on. Warning lamp or buzzer burned out. Transformer inoperative. When CO 2 Tank is empty and CO2 warning lamp(s) or buzzer fail, verify voltage across Transformer. If no voltage, replace Transformer. Pressure Switch defective. If CO2 Warning lamps or buzzer and transformer are operative. Pressure Switch is defective and must be replaced. CO 2 Supply adequate (greater than 500 psi [34.5 bar]). 00218012 Revision B (KAK) 7 August, 2000 5 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 1: CO2 Gas System (continued) Qualifier Probable Cause Corrective Action Flat drinks (lack of carbonation in carbonated water) (continued) Low Pressure CO2 Warning light or buzzer does not go off. Water found in CO 2 Regulator and lines. 6 Leaks on system. If leaks exist on CO2 System, not enough pressure is maintained to allow Pressure Switch to cut off CO2 Warning light or buzzer. Use a soap solution to located possible leaks. Tighten connections carefully. Primary Regulator out of adjustment. Check CO2 supply. The Primary Regulators must be set at 90 psi (6.3 kg/cm2). Adjust if necessary. If regulator will not stay in adjustment, replace regulator. Pressure Switch inoperative. Carefully disconnect one wire from the CO2 Pressure Switch, if CO2 Warning Lamps go out, the CO2 Pressure Switch is defective and should be replaced. Carefully disconnect one wire from the CO2 Pressure Switch, if CO2 Warning Lamps go out, the CO2 Pressure Switch is defective and should be replaced. CO2 Check Valve defective. Turn CO2 off at CO2 Tank valve. Remove top Cover from Remote Refrigeration Unit. Locate CO2 Check valve on top of Carbonator Tank. Remove CO2 line on Inlet side of Check Valve. If CO2 is present, escaping from Carbonator Tank, clean out or replace Check valve. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System Qualifier Probable Cause Corrective Action Flat drinks Malfunctioning of Refrigeration System. Beverages at dispensing tower are above 40°F (5°C). Malfunctioning of Circulating System. Beverages at dispensing tower are below 40°F (5°C). Refer to Troubleshooting Section 7: Refrigeration System under Warm drinks. Refer to Troubleshooting Section 3: Circulating System under Warm drinks. CO2 supply exhausted. Verify CO2 Tank pressure is a minimum of 500 psi (35 kg/cm 2) on Primary Pressure Regulator Gauge marked 0-2000 psi. Switch to full tank if necessary. Insure CO2 Shut-off Valves to Carbonators are both in the on position. Refer to Troubleshooting Section 1: CO2 Gas System under Flat drinks. Primary CO2 Regulator out of adjustment or inoperative. Verify CO2 Primary Regulators are set at 90 psi (6.3 kg/cm2). Adjust if necessary if Regulator will not stay in adjustment replace Regulator. Water Regulator incorrectly adjusted or inoperative. Verify Filtered Water Pressure Gauge registers 55 psi (3.9 kg/cm2), if higher than 55 psi, flooding of Carbonator will occur. To adjust, loosen Locknut, turn Adjustment Screw clockwise to increase, counterclockwise to decrease. If regulator will not respond to adjustments, replace regulator. Improper water treatment. Verify By-pass handle is in the filter operating position. Insure Filter Cartridge is still effective, if necessary replace Cartridge. Refer to Troubleshooting Section 10: Water Filter System. Carbonator Pump worn (Brass pump). Dispense Carbonated Water while listening for carbonator pump and motor to cycle on at Refrigeration Unit. Pumps should operated between 6 to 12 seconds before cycling off. If operating time exceeds 30 seconds carbonator pump is worn, replace Pump. Pressure Relief Valve is leaking. Remove top cover from Remote Refrigeration Unit. Dispense Carbonated Water until carbonator Pumps and Motor cycle on. Observe Pressure Relief Valves on carbonator Tank. If water is observed escaping from either, replace leaking Relief valve. Note: Do not confuse the Water Bath Make-up valve for the carbonator Tank Relief valves. 00218012 Revision B (KAK) 7 August, 2000 7 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System (continued) Qualifier Probable Cause Corrective Action Flat drinks (continued) Beverages at Dispensing Tower are below 40°F (5°C). (continued) 8 Back Flow Preventer. Remove top cover from Remote Refrigeration Unit. Use a soap solution around Back Flow Preventer. If bubbles appear at Vent Hole or underside of Back Flow Preventer, clean or replace Back Flow Preventer and corresponding Water Check valve carbonator Tank. Double Check valve (water) stuck open. With top cover from Remote Refrigeration Unit removed and carbonator Pump Switch and Water turned off, loosen water supply line at inlet side of Double Check valve Assembly. If CO2 gas escapes from Check valve, it must be cleaned or replaced. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System (continued) Qualifier Probable Cause Corrective Action No carbonated water at any of the dispensing valves No CO 2 gas or water present at dispensing valves. CO2 gas is present at dispensing valves but no water. Malfunction of Refrigeration System. Refer to Troubleshooting Section 7: Refrigeration System under No carbonated water at any of the dispensing valves (freeze up). Malfunction of Circulating System. Refer to Troubleshooting Section 3: Circulating System under No carbonated water at any of the dispensing valves. No power to carbonator. Verify toggle switch for Carbonator is in the on position and Main Power Supply is on. Water supply restricted to carbonator pump. Verify water to unit by observing Filtered Water Pressure Gauge. It should register 55 psi (3.9 kg/cm2). To adjust, loosen Locknut, turn Adjustment Screw clockwise to increase, counterclockwise to decrease. If regulator will not respond to adjustments, replace regulator. Examine Water Shut-off Valve(s) to Carbonator and insure they are in the on position. Water Filter restricted. Place Filter By-pass Valve into the Filter Bypass position. Replace Cartridge Filter. Reposition valve handle to operating position. Water Inlet clogged. strainer Remove Filter Screen from Inlet Strainer in carbonator Pump (Brass), flush with water to clean and reassemble. Liquid Level Control defective. Push Toggle Switch for carbonator and circulator to the off position. Shut off Main Power Supply unit. Remove electrical Access Panel from unit. Locate liquid level control. Using a pair of insulated needle nose pliers, carefully remove the white wire from the terminal marked H and the black wire from the terminal marked L on the Liquid Level Control Board. Position safely to side. Turn on Main Power Supply. Push carbonator Switch to the on position. If carbonator pump and motor do not cycle on immediately, that Liquid Level Control is defective. Replace. Electrode Assembly defective. If Liquid Level Control is operating, test the Electrode Assembly, refer to Probable Cause Liquid Level Control Defective. Verify wire leads are dry and that they are not touching. If not, replace Electrode. 00218012 Revision B (KAK) 7 August, 2000 9 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System (continued) Qualifier Probable Cause Corrective Action No carbonated water at any of the dispensing valves (continued) CO2 gas is present at Dispensing Valves but no water. (continued) 10 Carbonator Pump worn (Brass pump). Dispense Carbonated Water while listening for carbonator pump and motor to cycle on at Refrigeration Unit. Pumps should operate between 6 to 12 seconds before cycling off. If operating time exceeds 30 seconds, carbonator Pumps is worn, replace Pump. Motor defective. If Motor will not operate, verify voltage across Motor Terminals with voltmeter. If voltage reads 110 to 120 VAC, the Motor or Pump is defective. Loosen the Coupling Clamp with a flatblade screwdriver and disengage Pump from Motor. If Motor still will not operate with Pump disengaged, Motor is defective. Replace. Carbonator Pump frozen. Loosen the Coupling Clamp with a flat-blade screwdriver and disengage Pump from Motor. By hand, turn the Coupling Key in back of Pump. If pump shaft will not spin freely, Pump is defective and must be replaced. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System (continued) Qualifier Probable Cause Corrective Action Carbonator pump and motor will not cycle off (possibly noisy pump) Little or no carbonated Primary CO2 Regulator ad- Verify CO2 Primary Regulators are set at 90 psi water at dispensing justed at extremely high (6.3 kg/cm2). Adjust if necessary. If regulator will not star in adjustment, replace regulator. valve. pressure. Water supply to Carbonator Pump shut-off or restricted. Verify water to unit by observing Filtered Water Pressure Gauge. It should register 55 psi (3.9 kg/cm2). Examine Water Shut-off Valves to carbonator and insure they are in the on position. Examine Pump Strainer for restriction. Clean if necessary. Water Filter restricted. Place Filter By-pass valve into the Filter Bypass position. If carbonator pump and motor immediately cycle off, Filter Cartridge is restricted. Replace Cartridge. Back Flow Preventer or Double Check Valve. Examine Filter Water Pressure Gauge. If it registers 90 psi (6.3 kg/cm2) CO2 gas is passing from the carbonator tank and through the Back Flow Preventer or Double Check Valve, preventing water from entering pump. Clean or replace Back Flow Preventer/Double Check Valve. Carbonator Pump worn. Remove top cover from Remote Refrigeration Unit. Locate Toggle Relief Valve on Carbonator Tank and lift lever to allow CO2 gas to escape from Tank for 30 seconds. If during this time Carbonator Pump cycles off, pump is worn and should be replaced. Coupling Key defective. Loosen the Coupling Clamp with a flat-blade screwdriver and disengage Pump from Motor. Examine Coupling Key in Pump. If defective, replace. 00218012 Revision B (KAK) 7 August, 2000 11 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System (continued) Qualifier Probable Cause Corrective Action Carbonator pump and motor will not cycle off (possibly noisy pump) (continued) Carbonated Water at Liquid Level Control defec- Shut off main power supply to unit and push dispensing valve. tive. Toggle Switch for Carbonator and Circulator to the off position. Remove Electrical Access Panel from Refrigeration Unit and locate Liquid Level Control. Strip a 1 1/2" (3.8 cm) piece of solid strand wire of insulation to use as a jumper. Turn main power supply unit on to unit. With a pair of insulated pliers, jump across Terminals marked G, H and L on Liquid Level Control. Simultaneously, while pushing corresponding Toggle Switch to carbonator to the on position. If carbonator pump and motor continue to operate after Liquid Level Control Jumper Wire is in place, Liquid Level Control is defective, replace. Electrode defective. Examine wire leads to insure no breaks in connections. Remove and clean Electrode with find sand paper and reinstall. Note: Reversing Electrode Wire Leads on either electrode or Liquid Level Control will cause erratic operation of carbonator Motor. Refer to Wiring Diagram. Peculiar taste in carbonated water only. Water filter contaminated. Refer to Troubleshooting Section 10: Water Filter System under Peculiar taste. Back Flow Preventer Valve leaking or Double Check Valve leaking. Push Toggle Switch for carbonator to the off position. Turn Water Shut-off Valve to carbonator to the off position. Remove tope cover from Remote Refrigeration Unit. Carefully disconnect water line on the outlet side of the carbonator pump. If water or CO2 is observed continually escaping from line, Back Flow Preventer/Double Check Valve is leaking. Disassemble, clean, and replace if necessary. Caution: Carbonated water must never be allowed to flow through materials other than plastic or stainless steel. (Copper, zinc or galvanized material is non-acceptable.) Carbonated water flowing through materials other than plastic or stainless. 12 Trace carbonated water flow through system. Insure no foreign materials are present. Replace non-acceptable material if found. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 2: Carbonated Water System (continued) Qualifier Probable Cause Corrective Action Carbonator pump and motor will not cycle off (possibly noisy pump) (continued) Carbon particles in fur- Malfunction of Water Fil- Refer to Troubleshooting Section 10: Water nished drink. ter. Filter System under Carbon particles in finished drinks. Carbonator Motor cycles on and off in short cycles. Defective Carbonator Pump. Remove top cover from Refrigeration Unit. Loosen Coupling Clamp with a flat-blade screwdriver and disengage pump from motor. Turn the Coupling Key by hand, in back of pump. If pump shaft does not turn freely and/or Carbon is found in pump, carbon veins are defective. Replace pump. Defective Circulating Pump. Refer to Troubleshooting Section 3: Circulating System under Carbon particles in finished drinks. Electrode Assembly incorrectly wired or defective. Examine wiring diagram found on Refrigeration Unit. Verify Electrode wiring leads are on proper terminals of both Electrode and Liquid Level Control. If problem still occurs, replace electrode. 00218012 Revision B (KAK) 7 August, 2000 13 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 3: Circulating System Qualifier Probable Cause Corrective Action Warm drinks Drinks warm throughout the day, warm all the time. Malfunction of Refrigeration System. Refer to Troubleshooting Section 7: Refrigeration System under Warm drinks (carbonated water temperature over 40°F [5°C]). Drinks warm during periods of low demand, much colder during periods of high demand. No power to Circulating Motor. Verify Switch to Circulating Motor is in the on position and Main Power Supply is on. Carbon Particles in finished drink. Motor defective. Using a flat-blade screwdriver, loosen the Coupling Clamp and disengage Pump from Motor. If Motor will not operate, verify voltage across Motor Terminal with voltmeter. If voltage reads from 110 to 120 VAC, the Motor is defective and should be replaced. Circulating Pump defective (stainless steel). Dispense approximately 1 gallon of carbonated water at dispensing valves. If temperature of carbonated water drops, Circulating pump is not operating. Examine Coupling Key found between Pump and Motor Shaft. If coupling key is defective, replace. If key is operational, Circulating pump is defective, replace. Malfunction of Water Filter. Refer to Troubleshooting Section 10: Water Filter System under Carbon particles in finished drinks. Malfunction of Carbonated Water System. Refer to Troubleshooting Section 2: Carbonated Water System under Carbon particles in finished drinks. Circulating Pump defective (Stainless Steel). Remove top cover from Refrigeration Unit. Loosen Coupling Clamp with a flat-blade screwdriver and disengage Pump from Motor. Turn Pump shaft with screwdriver. If Pump does not turn freely and/or carbon is found in Pump, carbon veins in pump are defective. Replace Circulating Pump. No CO 2 gas or water present at dispensing valve. 14 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 3: Circulating System (continued) Qualifier Probable Cause Corrective Action Warm drinks (continued) CO2 gas is present at dispensing valves but no carbonated water. Malfunction of Refrigeration System. Refer to Troubleshooting Section 7: Refrigeration System under No carbonated water at dispensing valve (freeze up). Particles obstructing flow through Circulating Circuit (In-line Strainer). Remove top cover from Remote Refrigeration. Push toggle switch to carbonator and circulator to the off position. Lift lever on Toggle Relief valve at top of carbonator Tank until pressure is completely released. Remove In-line Strainer Screen. Flush with clean water and reassemble. Malfunction of Carbonating System. If CO2 gas is present at the Dispensing Valves and there is no water, the problem is in the Carbonated Water System. Refer to Troubleshooting Section 2: Carbonated Water System. 00218012 Revision B (KAK) 7 August, 2000 15 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 4: Compressed Air System Until repairs can be made on Compressed Air System, place Air/CO2 Change-over Valve in the CO2 Operating position. Qualifier Probable Cause Corrective Action No syrup Air Compressor will not cycle on and Air Pressure Gauge registers 0 psi. Air Compressor cycles on and off and Air Pressure Gauge readings range between 70 psi (4.9 kg/cm2) to 90 psi (6.3 kg/cm2). 16 No power to Air Compressor. Verify Toggle Switch to Air Compressor is in the on position and main power supply is on. Pressure Switch defective. Remove Pressure Switch Cover and use a voltmeter across Switch to determine whether open or closed. If in open position, replace switch. Motor defective. Verify voltage across Motor with a voltmeter, if Motor/Pump assembly will not operate, it is defective and should be replaced. Pump frozen. Same as above for Motor defective. Air/CO2 Change-over Valve placed in incorrect position. Place Air/CO2 Change-over Valve to the Air or CO2 operating position. Malfunction of Syrup System. Refer to Troubleshooting Section 8: Syrup System, under No syrup. Malfunction of Refrigeration System. Refer to Troubleshooting Section 7: Refrigeration System, under No carbonated water at dispensing valves (freeze up). Note: If lever is positioned between Air and CO2 the gas supply is shut off to syrup system. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 4: Compressed Air System (continued) Qualifier Probable Cause Corrective Action No syrup (continued) Air Compressor operates excessively. Leak at Shake Machine, Orange Juice Dispenser or other optional equipment. Turn air supply to Shake Machine to off position. If Air Compressor cuts out and maintains pressure, leak is at Shake Machine or Orange Juice Dispenser. Refer to manufacturers manual for Troubleshooting. Leak at Compressed Air System. Use a soap solution around all connections starting from the Air Motor/Pump assembly to the Low and Medium Pressure Syrup Regulators. If bubbles appear, tighten loose connections carefully. Automatic Drain or Petcock leaking. Place drain line for bottom of Automatic Drain or Petcock in cup of water. If air bubbles appear, Automatic Drain or Petcock is leaking. Clean and/or replace as necessary. Air leak in syrup system. Refer to Troubleshooting Section 8: Syrup System under No syrup, air leak at syrup system. Restricted Germicidal Filter on Air Compressor. Replace Germicidal Filter. Note: This Filter is not designed to be cleaned, but must be replaced when exhausted. Water in Air Accumulator Tank. Verify Automatic Drain is operating. If inoperative or defective, replace. If unit is not equipped with Automatic Drain use Petcock to remove water from tank. Motor/Pump Assembly inoperative. If Motor/Pump assembly operate without building up to 90 psi (6.3 kg/cm2) as needed to cycle off. Pump Assembly is defective and must be replaced. Pressure Switch improperly adjusted or defective. Observe Air Pressure Gauge to insure proper cycle on at 70 psi (4.9 kg/cm2) and cycle off at 90 psi (6.3 kg/cm2) settings. Refer to instructions found under Switch cover for adjusting. If Switch will not respond to adjustment, replace switch. Check valve defective. While Air Compressor is in the off cycle, use a soap solution around Head Gasket on Motor/ Pump Assembly. If bubbles appear, replace Check valve located on the Air Accumulator Tank. 00218012 Revision B (KAK) 7 August, 2000 17 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 4: Compressed Air System (continued) Qualifier Probable Cause Corrective Action No syrup (continued) Peculiar taste in finished product. 18 Contaminated Germicidal Filter on Air Compressor. Replace Germicidal Filter. Water in Air Accumulator Tank. Drain trapped water from tank by removing Drain Line from top of Automatic Drain. Disassemble and clean Automatic Drain. If unit is not equipped with automatic drain, use petcock to remove water from tank. Water Filter contaminated. Refer to Troubleshooting Section 10: Water Filter System under Peculiar taste. Note: This filter is not designed to be cleaned, but must be replaced when exhausted. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 5: Dispensing Valve and Tower Qualifier All corresponding valves dispensing no syrup. Probable Cause Malfunction of syrup system. Corrective Action Refer to Troubleshooting Section 8: Syrup System under No syrup or insufficient syrup in finished drink. No syrup at only one dispensing valve. Syrup Shut-off Valve closed or partially closed. Remove top cover from Dispensing valve or Tower. Locate Syrup Shut-off Valve on right hand side of Dispensing valve. Verify shut-off is turned fully open. Mounting Block restricted. Remove Dispensing valve from Mounting Block. Place cup over Syrup outlet on Mounting Block and carefully open Syrup Shut-off Valve. If little or no syrup is present, Mounting Block is restricted. Remove and clean mounting block. Replace if necessary. No syrup or insufficient syrup in finished drink No carbonated water at half or all dispensing valves. Flow Control our of adjustment or inoperative. Readjust Flow Control to proper Brix. If no response, clean Syrup Flow Control. Replace if necessary. Valve Port restricted. Clean Syrup valve Port Assembly. Seat swollen. Replace Syrup Seat. Solenoid Coil defective. Replace Syrup Solenoid Coil. Malfunction of Carbonated Water System. Refer to Troubleshooting Section 2: Carbonated Water System under No carbonated water at any of the dispensing valves. 00218012 Revision B (KAK) 7 August, 2000 19 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 5: Dispensing Valve and Tower (continued) Qualifier Probable Cause Corrective Action No carbonated water or insufficient carbonated water in finished drink No Carbonated Water only at one dispensing valve. 20 Carbonated water Shut-off Valve closed or partially closed. Remove top cover from Dispensing valve or Tower. Locate Carbonated Water Shut-off Valve on left hand side of Dispensing valve. Verify Shut-off Valve is turned fully open. Mounting Block restricted. Remove Dispensing valve from Mounting Block. Place cup over Carbonated Water outlet on Mounting Block and carefully open Carbonated Water Shut-off Valve. If little or no Carbonated Water is present, Mounting Block is restricted. Remove and clean mounting block. Replace if necessary. Flow Control our of adjustment or inoperative. Readjust Flow Control to proper Brix (5 oz in 4 seconds Standard valve, 10 oz in 4 seconds Fast Flow valve). If no response, clean Carbonated Water Flow Control. Replace if necessary. Valve Port restricted. Clean Carbonated Water valve Port Assembly. Seat swollen. Replace Carbonated Water Seat. Solenoid Coil defective. Replace Carbonated Water Solenoid Coil. Carbonated Water Switch defective (black). Replaced Carbonated Water Switch. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 5: Dispensing Valve and Tower (continued) Qualifier Probable Cause Corrective Action No water or insufficient water in finished drinks All valves dispensing noncarbonated drinks no water. Water Shut-off Valve closed or partially closed. Problem occurs at only one dispensing valve. Refer to Troubleshooting Section 9: Water Booster System under Low or No Water Pressure at Noncarbonated Beverages. Refer to this section on No carbonated water at only one dispensing valve in the dispensing valve. Too much Syrup, Carbonated Water or Water in finished drink. Problem occurs at only one dispensing valve. Syrup, carbonated water, or noncarbonated water flow control out of adjustment or inoperative. Readjust appropriate Flow Control. If Flow Control does not respond to adjustment, clean Flow Control. Replace if necessary. Carbonated Water Flow rates: (5 oz in 4 seconds Standard valve, 10 oz in 4 seconds Fast Flow valve). Too much syrup in finished drink. All valves dispensing same flavortoo much syrup. Malfunction of syrup system. Refer to Troubleshooting Section 8: Syrup System under Drinks too sweet. Too much water in finished drink. All valves dispensing noncarbonated drink too much water. Malfunction of water Booster system. Refer to Troubleshooting Section 9: Water Booster System under Qualifier: Pump and motor cycles on and off excessively. Syrup or Carbonated Water or Water dripping from Nozzle. Valve port scarred. Disassemble appropriate Syrup or Water Assembly. Examine valve Port for scars or nicks. Replace if necessary. Armature Spring or Retaining Ring broken. Disassemble appropriate Syrup or Water Assembly. Examine Armature, Spring and Retainer Ring. If damaged, replace. Seat scarred or obstructed. Disassemble appropriate Syrup or Water Assembly. Examine Seat, if scarred, replace. If foreign material is found in Assembly, remove, reassemble. Transformer inoperative. Verify wire leads from Transformer have solid connections. Switch low voltage lead from Transformer supplying power to left and right hand side of Tower. If Valves operate and the other three do not, Transformer is defective. Replace. Dispensing towers on and off Toggle defective. If after switching Leads, the three valves still do not operate, the on and off Toggle Switch is defective. Valves will not activate when Selection Panel pressed. Problem occurs at two (2) or three (3) consecutive Valves on one (1) tower. 00218012 Revision B (KAK) 7 August, 2000 21 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 5: Dispensing Valve and Tower (continued) Qualifier Probable Cause Corrective Action No water or insufficient water in finished drinks (continued) Problem occurs at all valves on one (1) dispensing tower. No power to transformer or transformer defective. Verify power with a voltmeter at wall outlet. Verify power across low voltage leads on transformer. If 24 volts are present on and off Toggle Switch is defective. Replace. Problem occurs at only one (1) dispensing valve. Dispensing towers on and off is Switch defective. Verify Main Power Supply and power at Transformer Leads replace on and off Switch if operative. Poor connection on valve Wire Harness. Trace wiring on defective valve and reconnect any loose wires. Clean and reconnect any corroded connections. Portion Control Timer inoperative. Replace the problem valve Portion Control Timer with a known Operative Timer. If valve then operates, Portion Control Timer was defective. Replace. Selection Switch inoperative. Replace defective Portion Control Timer with operative Timer. If Valves still will not activate, Selection Panel is defective. Replace Selection Switch. Poor connection at Contact Clips on Selection Panel (with Portion Control Timer). Examine Contact Clips on Selection Panel and insure proper contact between Portion Control Timer and Contact Clips. Moisture on Portion Control Timer or Contact Clips. Remove top cover from Dispensing Tower. Remove all moisture from Portion Control Timer and Contacts. Portion Control Timer Adjustment Screw turned beyond control limit. Turn Portion Control Adjustment Screws on defective valve counterclockwise 10 complete turns. If valve shuts off when selection is pressed, readjust for proper portions. Valve will not shut off. Note: Several revolutions may be necessary to bring control back into range. 22 Portion Control Timer defective. Verify above probables are not the problem. Push on/off Switch for Dispensing Tower to the off position. If valve ceases to dispense when pushed to on position, Portion Control Timer is defective. Replace. Selection Panel defective. Push on/off Switch for dispensing tower to the off position. If valve ceases and then continues to dispense when switch is pushed in on position, Selection Panel is defective. Replace. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 5: Dispensing Valve and Tower (continued) Qualifier Probable Cause Corrective Action No water or insufficient water in finished drinks (continued) Foaming of finished products. Nozzles, Syrup Tube Diffusers dirty. Remove and clean Nozzle Assemblies and reassemble. Warm drinks. Refer to Troubleshooting Section 7: Refrigeration System under Warm drinks. Incorrect pressure on syrup. Verify pressure supplied to sugar base products is at 60 psi (4.2 kg/cm2). Adjust Medium Pressure Regulator if necessary. Verify pressure supplied to diet product is at 15 psi (1.1 kg/cm2). Adjust Low Pressure Regulator if necessary. Note: Insure the Low Pressure Supply Line has not mistakenly been switched for a Medium Pressure Supply Line on the diet tank. Unit totally inoperative; all electrical switches in the on position. Change-over Valve Medium or Low Pressure is in the wrong position. Verify valve Medium to Low Pressure is in the Low Pressure position for diet products. Air or CO2 gas in syrup line. Replace empty Syrup Tank. Dispense Syrup from valve until consistent flow is achieved and product stabilizes. If evidence of air is still entering line, replace Liquid Disconnect which is allowing air to be drawn into syrup supply. Flake ice. Only cube ice should be used for carbonated beverages. Improper adjustment of valve. Insure carbonated water flow is properly set (5 oz. in 4 seconds standard valve, 10 oz in 4 seconds Fast Flow valve). Insure Brix is properly set. Adjust as necessary. Power failure, all power to system is off, or Fuse/ Circuit Breaker is open. Check Circuit Breaker. Reset. Examine Time Delay, replace if necessary. 00218012 Revision B (KAK) 7 August, 2000 23 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 6: Electrical System Qualifier Fuse/Circuit Breaker is open. Probable Cause Short Circuit or overload within unit. Corrective Action Push Toggle Switches labeled carbonator and circulator to the off position. Push the Toggle Switches for Booster Pump, Air Compressor, Agitator and Refrigeration to the off position. Replace fuse(s) and reset circuit breaker. Push the Toggle Switches on in the following sequence as labeled below, to locate short or overload within unit, waiting momentarily between steps. *Agitator *Refrigeration *Carbonator A and/or B *Circulator A and/or B (after carbonator Motor Cycles off) *Booster Pump *Air Compressor. Push the Agitator Toggle Switch in the on position. If the fuse/circuit breaker opens, the trouble is in the Agitator Motor Circuit. This Circuit must be checked for shorts and/or overload. If the fuse/circuit breaker does not open after running about 1 minute, the problem is not in the Agitator Motor Circuit. Push the Refrigeration Toggle Switch in the on position. If the fuses/circuit breaker opens, the trouble is in the Refrigeration Circuit. Refer to wiring diagram for possible faulty components. Push the carbonator Toggle Switch A to the on position. Draw Carbonated Water from the Dispensing valve until Pump cycles. If the fuse/circuit breaker opens, the trouble is in the carbonator Circuit. Refer to wiring diagram for possible faulty components. Push the carbonator Toggle Switch B to the on position. Follow procedure above for carbonator A. Push the Circulator Toggle Switch A to the on position. If fuse/circuit breaker opens, the trouble is in the Circulator Circuit. Refer to wiring diagram for possible faulty components. Push the Circulator Toggle Switch B to the on position. Follow procedure above for Circulator A. Push the Booster Pump Toggle Switch to the on position (allow unit to cycle). If fuse/circuit breaker opens, the trouble is in the Booster Pump Circuit. Refer to wiring diagram for possible faulty components. Push the Air Compressor Toggle Switch to the on position. (Allow unit to cycle). If fuse/ circuit breaker opens, the trouble is in the Air Compressor Circuit. Refer to wiring diagram for possible faulty components. Important Note: Worn out Circuit Breakers or low voltage are frequently responsible for shorts and overloads. Contact service agent to examine possible defective Circuit Breakers or low voltage. 24 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 7: Refrigeration System Until repairs can be made on unit with no Ice Bank, push Refrigeration and Agitator Switch to the off position and ice down Bath using ice from Ice Maker. Qualifier Probable Cause Corrective Action Warm drinks (carbonated water temperature over 40°F [5°C]) Compressor operates but no ice present at water bath. Water Bath Feeder Valve inoperative (not enough water in bath). Remove tope cover from Remote Refrigeration Unit. Verify if water level is considerably below Stand Pipe. If so, Water Make-Up valve is inoperative. Remove, disassemble and clean out valve. Replace, refill Bath and allow carbonator to cycle while inspecting valve to insure proper operation. Replace if necessary. Water leak inside bath. Remove top cover from Remote Refrigeration Unit. Inspect Water Bath at Stand Pipe. If considerable water is observed running over and out the drain, there is a water leak inside Bath. The leak causes the Ice Bank to melt as fast as its formed. Drain Bath to located the leak, repair and refill bath. Fan or Motor inoperative (air cooled units). Examine Fan and Motor on Air Cooled Units at Condenser. If either are found to be inoperative while compressor is running, replace inoperative fan or motor. Caution: Inoperative Fan and Motor can cause short cycling of compressor. Compressor operates but no ice present at water bath. Condenser restricted. For Air Cooled Units, clean the Condenser removing all dust and lint. On Water Cooled Units: Using a thermometer verify temperature at water discharge line. If operating outside of the 95°F (35°C) to 105°F (41°C) range, adjust Water Modulating valve, replace. Caution: Restricted Condenser can cause short cycling of compressor. Excessively warm room. Verify the Refrigeration Unit is operating in a well ventilated area and that there are no obstructions blocking Condenser. If so, remove obstructions if inoperative. Lack of Refrigerant Charge. Examine Sight Glass. If bubbles appear while compressor is operating system is low on charge. Refer to Serial Plate for proper refrigeration charge. Defective Expansion valve. If no bubbles appear in Sight Glass then examine suction line, frost on the suction line is a sign of defective Expansion valve. Replace if inoperative. 00218012 Revision B (KAK) 7 August, 2000 25 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 7: Refrigeration System (continued) Qualifier Probable Cause Corrective Action Warm drinks (carbonated water temperature over 40°F [5°C]) (continued) Compressor operates with Ice present at water bath. Defective Agitator Motor Assembly. Remove top cover from Remote Refrigeration Unit. Examine the Agitator Motor Assembly, insure propeller is secured to Agitator and that the Agitator Switch is in the on position, allowing the water in Bath to be agitated across the cooling coils. If Motor or Propeller is inoperative, replace. Malfunctioning of Circulating System. If ice is present on Evaporator Coil and Agitator Motor Assembly is operating the Refrigeration System is functioning. However, the Circulating System may not be functioning. Refer to Troubleshooting Section 3: Circulating System. Caution: Always make certain that proper line voltage is present. Compressor wont operate and no ice at water bath. 26 Defective Switch. Check to insure Refrigeration Switch is in the on position. Fuse/Circuit open. Breaker Locate Circuit Breaker box and identify proper breaker for Remote Refrigeration Unit. Insure it is in the on position by switching off and then on again. If breaker will not reset, refer to Troubleshooting Section 6: Electrical System. Time Delay Fuse burned out. Inspect Time Delay Fuses at the wall quick shutoff panel. One of the fuses may be burned out causing half the unit to shut down. If this is suspected replace all of the fuses. Defective High Pressure Control. Examine High Pressure Control to insure wire leads are securely attached to terminals. If trouble is suspected with control, replace. Defective Ice Bank Control. Remove Electrical Access Panel and using a voltmeter across the Ice Bank Control, verify control is in the closed position. If control is found to be in the open position, that Control should be replaced. Defective Contactor. Remove Electrical Access Panel. Use a voltmeter across Contactor Coil. If current exists across Coil, and Contactor remains open, Contactor is defective. Replace. Defective Relay or Defective Capacitor or Defective Overload. Examine Relay/Capacitor/Overload to insure wire leads are securely attached to terminals. Replace any faulty components. Defective compressor. If after checking each of the above items, you still experience problems, test compressor for possible defects or grounding. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 7: Refrigeration System (continued) Qualifier Probable Cause Corrective Action No carbonated water at any of the dispensing valves CO2 gas is present at dispensing valves but no Carbonated Water. Malfunctioning of Carbonating System. In a freeze up situation, push Refrigeration and Agitator Toggle Switches to the off position. Drain water from Bath. Pour lukewarm (never hot) water over the Product Coils until thawed. Ice down Water Bath using ice from Ice Maker until further repairs can be made. No CO 2 Gas or water present at dispensing valve. On units equipped with the Red Refrigeration Warning Light. If CO2 gas is present at the Dispensing Valves and there is no water, the problem is in the Carbonated Water System. Refer to Troubleshooting Section 2: Carbonated Water System. Defective Agitator. Examine the Agitator Motor Assembly. Insure Propeller is operating and secured to Agitator and that the Agitator Toggle Switch is in the on position. If Motor is inoperative, replace. Defective Ice Bank Control. Remove Electrical Access Panel. Use a voltmeter across the Ice Bank Control. Verify Control is in the open position. If Control is stuck in the closed position, the unit will freeze up. Replace Control if necessary. If unit builds and Ice Bank to the point of extending into stainless steel coils, the Ice Bank Control must be replaced. Defective Contactor. Use a voltmeter across Contactor Coil. If no current is present across Coil, but Contactor remains closed, Contactor is defective. Replace defective Contactor. Defective Primary Ice Bank Control. When the Refrigeration Warning Light illuminates, the Primary Ice Bank Control is defective and should be replaced. The Secondary Control operates the Compressor until the Primary Control is replaced. Refrigeration Warning Light cycles on and off with Compressor. 00218012 Revision B (KAK) 7 August, 2000 Note: When the Refrigeration Compressor cycles on, Warning Light will turn off. When the Compressor cycles off the light will illuminate. 27 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 8: Syrup System Qualifier No syrup of insufficient syrup in finished drink. Probable Cause Syrup Tank is empty. Corrective Action Replace Syrup tank and purge air out of Dispensing Valves affected, until steady syrup supply is dispensed. Kinked Syrup lines. Examine all exposed Syrup Lines and relieve any sharp bends or kinks. Note: Observe all independent lines from Syrup Tank to Filters for kinks or bends. Correct as needed. 28 Low Pressure Regulator inoperative. Low Pressure Regulator controls the pressure to diet beverages. Verify pressure is set at 15 psi (1.1 kg/cm2). To increase, adjust clockwise, to decrease, adjust counterclockwise. If regulator does not respond, repair or replace regulator. Medium Pressure Regulator inoperative. Medium Regulator controls the pressure applied to the sugar based beverages. Verify pressure is set at 60 psi (4.2 kg/cm2). To increase, adjust clockwise. To decrease, adjust counterclockwise. If regulator does not respond, repair or replace regulator. Check Relief valve restricted. Disengage Gas Quick Disconnect on suspected restricted flavor at Syrup Tank. Depress Poppet valve on bottom side of Gas Disconnect. If a low or poor pressure supply is apparent, replace Check Relief valve. Gas/Syrup Tank Plug Valves inoperative. Replace Syrup Tank. If this solves the problem, tag defective tank so bottler can make necessary repairs. (It is extremely rare to have inoperative Tank Plug Valves.) Quick Disconnects (Gas or Syrup) not fully engaged on Syrup Tank. Disengage Quick Disconnects on one Tank at a time. Rinse and clean with warm water. Lubricate the O-ring on the Syrup Tank Plug with water. Reattach the Quick Disconnects to the appropriate Syrup Tank Plug. Gas Quick Disconnects are gray or have two key slots. Syrup Quick Disconnects are black or have three key slots. Quick Disconnect Valves or Tank Jumper inoperative. Gas Quick Disconnects: Open the Relief valve on the top of the syrup tank lid. If the Gas Quick Disconnect is opening properly, pressure should continue to bleed from the Gas Relief valve. If not, replace Gas Quick Disconnect. Syrup Quick Disconnects: Open the Dispensing valve (Syrup Side only) for appropriate flavor. Dispensing syrup for at least 10 seconds. If CO2/Air pockets appear in syrup, replace Syrup Quick Disconnect. If syrup flow is inadequate or fluctuates during 10 seconds of flow, replace Syrup Quick Disconnects. 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 8: Syrup System (continued) Qualifier No syrup of insufficient Syrup in finished drink. (continued) Drinks too sweet. Peculiar taste. Probable Cause Gas leak at Syrup System. Corrective Action Use a soap solution around all connections, starting from the Low and Medium Pressure Regulators to the base of the Syrup Tank Plugs, observe Quick Disconnects, Tank Cap and Gasket, Tank Plugs and Syrup Tank O-rings for leaks. Repair and replace if necessary. Syrup Filter restricted. Disengage Syrup Quick Disconnect from the appropriate Syrup Tank. Relieve pressure at the corresponding Dispensing valve. Remove the Screw clamp and the Filter Screen. Wash the Filter Screen with warm water and reassemble. Frozen Syrup Coil. Refer to Troubleshooting Section 7: Refrigeration System under No carbonated water at any of the dispensing valves (Freeze up). Dispensing valve inoperative. Refer to Troubleshooting Section 5: Dispensing Valve and Tower under No syrup or insufficient syrup. Low Pressure Regulator inoperative. Verify Low Pressure Regulator set at 15 psi (1.1 kg/cm2). Adjust Regulator if necessary. If Regulator will not respond, repair or replace Regulator. Medium Pressure Regulator inoperative. Verify Medium Pressure Regulator set at 60 psi (4.2 kg/cm2). Adjust Regulator if necessary. If Regulator will not respond, repair or replace Regulator. Dispensing valve inoperative. Refer to Troubleshooting Section 5: Dispensing Valve and Tower under Too much syrup in finished drink. Contaminated Syrup. Replace tank and sanitize the system. 00218012 Revision B (KAK) 7 August, 2000 29 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 9: Water Booster System Qualifier Probable Cause Corrective Action Low or no water pressure at noncarbonated beverages Water Booster will not No power to Water Booster Verify Toggle Switch for Booster Pump is in cycle on. Both the Pump. the on position and main power supply is pressurized filter water on. and filtered water pressure register 55 psi Pressure Switch defective. Remove Pressure Switch Cover and use a volt(3.8 bar). meter across terminals to determine whether open or closed. If in the open position, replace Switch. Motor defective. If Motor will not operate, verify voltage across Motor Terminals with a voltmeter. If voltage reads from 110 to 120 VAC, the Motor is defective and should be replaced. Pump frozen. Loosen the Coupling Clamp with a flat-blade screwdriver and disengage pump from Motor. Turn the Coupling key by hand, in back of pump. If pump shaft will not spin freely, Pump is defective and must be replaced. Water Booster cycles on and off and pressurized Filtered Water Gauged readings range between 65 psi (4.6 kg/cm2) to 85 psi (6.0 kg/cm2). Water supply shut-off after Booster System. Examine Shut-off Valve to Plain Water to Unit and Water to Coffee Machine and insure both are in the on position. Frozen Water Coil. Refer to Troubleshooting Section 7: Refrigeration System under No carbonated water at any of the dispensing valves (freeze up). Pump and Motor will not cycle off. Water supply to Booster Pump shut off. Examine the Shut-off Valve to Booster Pump and insure valve is in the on position. Restricted Water Filter. Observe Filter Water Pressure Gauge. If pressure drops total of 40 psi (2.8 bar) or more when pump cycles on. Replace filter. Leak on Booster System Pump Strainer obstructed. Locate water leaks on system and repair. Remove Pump Strainer at Brass Booster Pump, flush screen with water to clean. Reassemble and position in place. Replace screen if necessary. Pump Coupling Key defective. Using a flat-blade screwdriver, loosen Coupling Clamp and disengage Pump from Motor. Examine Coupling Key, if rounded off on either end, replace. Pump defective. Examine Pressurized Filter Water Pressure Gauge. If Pump and Motor continue to operate but fail to build up to 85 psi (6.0 kg/cm2) in order to cut off, pump is defective. Replace Pump. Pressure Switch improperly adjusted or defective. Observe Pressurized Filtered Water Pressure Gauge to insure proper cycle on at 65 psi (4.6 kg/cm 2 ) and cycle off at 85 psi (6.0 kg/cm2). Refer to instructions found under Switch Cover for adjusting. If Switch does not respond to adjustment, replace switch. 30 00218012 Revision B (KAK) 7 August, 2000 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 9: Water Booster System (continued) Qualifier Probable Cause Corrective Action Low or no water pressure at noncarbonated beverages (continued) Pump and Motor cycles on and off excessively. Leak on Booster System. Locate water leaks on system and repair. Check valve defective. Observe Filtered Water Pressure Gauge. If pressure rises and drops with Pressurized Filtered Water Gauge, the Water Inlet Check valve on Pump is defective. Replace Check valve. Pressure Switch improperly adjusted or defective. Observe Pressurized Filtered Water Pressure Gauge to insure proper cycle on at 65 psi (4.6 kg/cm 2 ) and cycle off at 85 psi (6.0 kg/cm2). Refer to instructions found under Switch Cover for adjusting. If Switch will not respond to adjustment, replace switch. Accumulator Tank pressure set improperly. Push Toggle Switch and Water Shut-off Valve to Booster Pump to the off position. Activate Plain Water button until water flow ceases. Using a tire gauge verify a 60 psi (4.2 kg/cm2) charge on Tank. Recharge if necessary. Note: When charging Accumulator Tank, only AIR should be used. Peculiar taste in Noncarbonated beverages. Accumulator Tank bladder ruptured. Repeat procedures above. If water is found inside Air Chamber when verifying pressure charge, bladder is ruptured. Replace Accumulator Tank. Motor overheating. Using a flat-blade screwdriver, loosen Coupling Clamp and disengage Pump from Motor. Turn Coupling Key by hand, in back of Pump. If Coupling Key is difficult to turn, it may cause defective Motor to overheat. Replace Motor if necessary. Water Filter contaminated. Replace Filter. Refer to Troubleshooting Section 10: Water Filter under Peculiar taste. Accumulator Tank bladder ruptured. Replace Accumulator Tank. Refer to Pump and Motor Cycle on and off excessively Accumulator Tank bladder ruptured. Malfunction of Carbonated Water System. Refer to Troubleshooting Section 2: Carbonated Water System under Peculiar taste, Probable Cause: Back Flow Preventer leaking. 00218012 Revision B (KAK) 7 August, 2000 31 Multiplex Company, Inc. Fountain Troubleshooting Guide Troubleshooting Guide WARNING: Inspection, testing, and repair of electrical equipment should be performed only by qualified service personnel. The unit should be unplugged when servicing, except when electrical tests are required. DANGER: Use extreme care during electrical circuit tests. Live circuits may be exposed. Section 10: Water Filter System Until repairs can be made on the Water Filter, place valve handle into filter By-pass position. Qualifier Probable Cause Carbon particles in finished drink. Water By-pass valve is not in the filtering position. Verify By-pass valve handle is in the Filter operating position. If particles continue to appear, filter must be serviced. Defective or damaged seal on Filter Cartridge. Verify O-rings are not twisted or nicked. Verify Cartridge is solid and free of cracks. Replace if necessary. Filter Cartridge installed without Inlet Seal. Remove Cartridge from Canister. Clean Canister Lid and Shell assembly. Replace with new Filter Cartridge, making sure to remove Water Inlet Seal. Defective Pump. carbonator Refer to Troubleshooting Section 2: Carbonated Water System. Defective Pump. Circulating Refer to Troubleshooting Section 3: Circulating System. Carbonator and Water Booster Pump extremely noisy. Peculiar taste. 32 Corrective Action Restricted Water Filter. Observe Filter Water Pressure Gauge. If pressure drops at total of 40 psi (2.8 bar) or more when pump cycles on, replace filter. Filter Cartridge installed without removing Water Inlet Seal. Removed Cartridge from Canister. Clean Canister Lid and Shell Assembly. Install new Filter Cartridge, making sure to remove Cartridge Inlet Seal. Water supply to Filer restricted. Verify water supply is turned on to unit. Refer to Troubleshooting Section 2: Carbonated Water System and Section 9: Water Booster System for additional solutions. Water Filter contaminated. Place Filter valve into Filter By-pass position. Replace Filter and reposition valve handle to filter operating position. 00218012 Revision B (KAK) 7 August, 2000 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218012 Revision B (KAK) 7 August, 2000 Illustrated Fittings and Hardware Catalog Fountain Beverage Dispensing Equipment 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Table of Contents Terms and Conditions Affecting Customer Purchase Orders, Shipments of Materials, and Ordering Parts .................................................................................................................. How to order ..................................................................................................... Terms ............................................................................................................. Method of shipment ............................................................................................ Purchaser pick-up ............................................................................................... Service parts ................................................................................................. How to cancel an order ........................................................................................ Damaged and lost shipments .................................................................................. Return of merchandise ......................................................................................... Replacement parts purchased for out-of-warranty equipment .......................................... Replacement procedure ....................................................................................... 1 1 1 1 1 1 1 1 1 1 1 Adaptors ............................................................................................................. 2 Barbed Connections ................................................................................................ 3 Cable Ties ........................................................................................................... 6 Calibrating and Cleaning .......................................................................................... 6 Check Valves ........................................................................................................ 7 Clamps ............................................................................................................... 9 Disconnects ......................................................................................................... 10 Syrup Filter ......................................................................................................... 10 Flare Connections ................................................................................................. 11 Gauges .............................................................................................................. 12 Pipe Connections .................................................................................................. 12 Compression Fittings .............................................................................................. 13 Pressure Reliefs .................................................................................................... 14 Pump Accessories .................................................................................................. 14 Regulators .......................................................................................................... 15 Strainers ............................................................................................................ 15 Insulation ........................................................................................................... 15 Tools ................................................................................................................. 16 Tubing ............................................................................................................... 18 Valves ............................................................................................................... 19 John Guest Fittings ................................................................................................ 21 How to use john guest fittings ............................................................................... 25 For stainless steel .............................................................................................. 25 Abbreviations ALM FF MCD N/A OJ S/S W WO = = = = = = = = Aluminum Female Flare McDonalds Not Available Orange Juice Stainless Steel With Without 00218013 Revision C (KAK) 7 August, 2000 BRS FPT MF NPB PLS STL BRZ GEN = = = = = = = = Brass Female Pipe Thread Male Flare Nickel PlatedBrass Plastic Steel Bronze General MPT NPT = = PSI = THD VAR = = Male Pipe Thread National Pipe Thread Pressure Square Inch Thread Variable Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Terms and Conditions Affecting Customer Purchase Orders, Shipments of Materials, and Ordering Parts How to order Damaged and lost shipments For prompt service and shipment, contact your nearest Multiplex Company Stocking Distributor. A listing of the stocking distributors can be obtained by contacting Multiplex Company, Inc. (636) 256-7777. To ensure prompt processing of your orders, list each item separately, taking care to specify quantity, the Multiplex part number and description of each item ordered. Faster service can be obtained in the future by listing your system below. The responsibility of Multiplex Co., Inc. ceases upon acceptance of the products being shipped in good condition by the carrier. Any damage or loss sustained in shipment should be reported to the delivering carrier immediately. The carrier is responsible for all shipments. If you receive a damaged shipment, ask the carriers agent for a claim form and have the carrier prepare an inspection report, a copy of Multiplexs invoice, the freight bill, and a letter estimating the cost of repair or replacement must be submitted to the carrier before they can process your claim. Compare the number of cartons received against the number of cartons listed on our packing list or Bill of Lading. If they do not agree, be sure to note the shortage on the delivery receipt before accepting delivery and signing the delivery of the specified number of cartons. UPS shipments are insured individually and UPS will replace all merchandise that is lost. Notify us immediately if you wish to trace merchandise lost in transit. Model Number ____________________________ Serial Number ____________________________ Date of Installation ________________________ Local Authorized Stocking Distributor _______________________ Terms Terms of NET 30 days will be extended to those customers of known and acceptable financial standing. All other orders must be accompanied by check or will be shipped C.O.D. Please send all credit information directly to our controller. Taxes imposed by any present or future federal, state, or local laws, if paid by us, will be charged to purchaser. Sales or use taxes shall be in addition to prices quoted unless an appropriate Tax Exemption Certificate is furnished. Prices and terms, designs, materials, specifications, weights and dimensions for equipment or parts are subject to change without notice. Method of shipment All merchandise is priced F.O.B. factory. All shipments are carefully packed and labeled to prevent damage or loss. Crates, boxes and cartons used are of approved weight and strength. Orders not routed by the purchaser will be shipped at our discretion via the best method possible without any liability on our part for such selection. Purchaser pick-up Return of merchandise No merchandise is to be returned without our approval. The purchaser must prepay the freight for all returned goods. After receiving our approval, all merchandise must be returned to our factory at 250 Old Ballwin Road, St. Louis, Missouri 63021. Multiplex is not responsible for merchandise returned to any location other than our factory. The merchandise authorized to be returned must be in new, unused condition and in its original carton with all original packaging. A credit will be allowed amounting to the original selling price or current selling price, whichever is lower, less a 15% restocking charge, with a minimum charge of $25.00 for each return to cover cost of receiving, inspection, testing, repackaging, and processing all documents. Replacement parts purchased for out-of-warranty equipment Service parts Orders must be received at least 24 hours prior to personal pick-up. These parts will be repaired or replaced on an even exchange basis (no labor allowance) during the 90 day period following shipment from our factory. How to cancel an order Replacement procedure Multiplex will not accept the cancellation of any order for special or proprietary equipment or parts unless we receive payment of reasonable charges based on expenses already incurred and commitments made by Multiplex. Prior approval must be received from Multiplex before a unit, motor compressor and/or components may be returned for replacement or repair. Any unit or component returned, freight collect, will be refused and returned to sender. Multiplex will not accept any used equipment for credit. The minimum invoice charge is $25.00 per order. 00218013 Revision C (KAK) 7 August, 2000 1 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Adaptors Item Part No. Nitrogen Adaptor (for use with Primary Regulator) 00204859 1 Size 1 Male Pipe Thread x 00852505 1 Male Flare (Straight) 00852504 1 00852509 1 00852503 00852502 00852528 3 00852532 1 2 00858514 1 2 00852553 1 8 /4" MPT Size 2 /4" MF Brass /4" MF Brass /8" MF Brass /8" MPT 1 /4" MPT 1 /4" MPT 3 3 /8" MPT 1 /4" MF Brass /8" MPT 3/8" MPT 3 /8" MF 1/2" MF Brass Brass / " MF Brass / " MPT 3 8 / " MPT 1 2 / " MPT 3 8 / " MPT 3 8 / " MPT 1 4 /4" MPT 3 /8" MPT 1 /8" MPT 3 /8" MPT 1 / " MF Brass / " MF Stainless Steel / " MF Stainless Steel / " MF Brass /8" MF Brass /4" MF Brass /8" MF Brass /2" MF Brass /8" MF Brass /2" MF 3/8" MF Brass Stainless Steel 00852523 3 8 00857600 1 4 Male Flare (Elbow - 90) 00857604 1 00857603 3 00855902 3 00857608 3 00857609 1 /2" MPT 3 00855925 00855926 1 /2" MPT 3/8" MPT 1 1 3 Description Brass Male Pipe Thread x Tees Size 3 /2" Nitro 1 00858432 1 8 00858412 1 / " MPT 1 4 /4" MPT 1 00858476 1 /4" MPT 00858408 1 00858435 1 00858425 3 / " MF 1 4 /4" MF 1 3 /8" MF 3 /4" MPT 1 /8" MPT 1 /8" MPT 3 /4" MF 1 /4" MF 3 /8" MF 3 / " MF Brass /4" MF Brass /8" MF Brass /4" MF Brass /4" MF Brass /8" MF Brass 2 1 3 2 Female Pipe Thread x 00858505 1 8 Male Flare (Straight) 00858501 1 4 00852512 1 4 00858502 3 8 Plugs - Barbed 2 / " FPT 1 4 / " FPT 1 4 / " FPT 3 8 / " FPT 3 8 00861518 1 4 00861308 3 8 00861315 1 / " MF Brass / " MF Brass / " MF Brass / " MF Brass /" Stainless Steel /" Stainless Steel /2" Stainless Steel 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Barbed Connections Item Part No. Splicers - Barbed 00217220 Elbows (Barbed 90) U-Bend (Barbed 180) Size 2 /16" 1 3 /4" /" Stainless Steel Stainless Steel /" Stainless Steel /" Stainless Steel /" Stainless Steel /" Stainless Steel /" Stainless Steel /8" Stainless Steel /2" Stainless Steel /2" Stainless Steel /" Stainless Steel /2" Stainless Steel 1 /4" /" 1 3 8 00861317 1 4 /" 1 2 00861304 3 8 /" 3 8 00854994 3 8 /" 1 2 00861306 1 2 /" 1 2 00861400 1 4 /" 1 4 00861404 3 /8" 3 00854998 3 /8" 1 00854996 1 /2" 1 00858464 3 8 /" 3 8 00858469 1 /2" 1 Barbed 00207650 1 1 00206294 2 1 00206290 3 00206280 00206279 4 5 1 00207753 6 1 4 00208412 7 1 4 00208413 8 1 4 U-Bend Manifold 00205897 1 3 8 (1/2 Supply Circuit) 00206296 2 1 00206292 3 1 00206281 4 1 00206278 5 1 00207871 6 00208414 00208415 7 8 1 00861500 1 4 00861502 3 8 00205440 1 2 00861506 1 4 00861504 3 8 00205898 3 00205681 1 00205903 1 Tees - Barbed 00218013 Revision C (KAK) 7 August, 2000 Description Stainless Steel 1 4 No. Ports Size 3 /2" 00861300 00861302 U-Bend Manifold (3/8 Supply Circuit) Size 1 /4" Port Stainless Steel /4" Port Stainless Steel 1 /4" Port Stainless Steel /4" Port 1/4" Port Stainless Steel Stainless Steel / " Port Stainless Steel / " Port Stainless Steel / " Port Stainless Steel / " Port Stainless Steel /4" Port Stainless Steel /4" Port Stainless Steel /4" Port Stainless Steel /4" Port Stainless Steel 1 /4" Port Stainless Steel /4" Port 1/4" Port Stainless Steel Stainless Steel /" 1 4 /" 3 8 /" 1 4 /" 3 8 /" 1 2 /" 1 4 /" 3 8 /8" 3 /2" 1 /2" 1 /" Stainless Steel /" /" 1 2 Stainless Steel /" /" 3 8 Stainless Steel /" /" 1 4 Stainless Steel /" /8" 1 Stainless Steel /2" /2" 1 Stainless Steel /2" 3 /4" Stainless Steel /8" Stainless Steel 3 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Barbed Connections Item Cross-Barbed Stem Barbed (for use with Swivel Nut) Swivel Nut (for use with Barbed Stem) (continued) Part No. 1 00861202 00212364 00854900 1 4 00854908 1 00854910 3 00854993 1 00855000 1 4 00855004 3 00855017 1 00855007 1 00855013 3 8 Stem with Swivel Nut (Straight) Size 1 00861200 1 3 1 2 /8" /" /" 1 4 /4" 3 /8" 3 /2" 1 /" 1 4 /8" 3 /2" 1 /4" 1 /" 3 8 Barb Stem 00854950 3 8 00854910 3 8 00205780 1 Stem with Swivel Nut 00854903 1 (Elbows - 90) 00854930 1 00854943 3 00854927 00208215 00211660 1 4 Size 2 /4" /" Size 3 /4" 1 3 /8" /" 3 1 2 1 2 Description /4" Stainless Steel /8" /" Stainless Steel Stainless Steel / " FF Nut Item Stainless Steel (for use with 00855000 & P.N. 00855007) /8" FF Nut Item Stainless Steel /8" FF Nut Item Stainless Steel (for use with 00855004 & P.N. 00855013) /2" FF Nut Item Stainless Steel (for use with P.N. 00855017) / " Barb Nickel Plated Brass (for use with P.N. 00854900) /8" Barb Nickel Plated Brass (for use with P.N. 00854900) /2" Barb Nickel Plated Brass (for use with P.N. 00854993) /4" Barb Stainless Steel (for use with P.N. 00854900) / " Barb Stainless Steel (for use with P.N. 00854910) Swivel Nut / " FF Stainless Steel /" Stainless Steel /8" FF Stainless Steel /4" FF Stainless Steel /8" FF Stainless Steel /4" FF Stainless Steel 1 4 /" 3 8 /2" 3 /4" 1 /4" 3 /8" 1 3 /8" 3 /8" FF Stainless Steel /2" 1/2" 3 /8" FF 1/2" FF Stainless Steel Stainless Steel 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Barbed Connections Item (continued) Part No. Stem-Barbed x Male Flare (Straight) Size 1 Size 2 Barbed Male Flare 00861600 00861601 1 /4" /" 1 1 4 3 8 00861602 3 8 /" 1 4 00861603 3 8 /" 3 8 Tee Adaptors (Swivel Tees) Barbed 00862800 1 00862801 1 00862803 3 Male Flare x Barbed Tees 00862700 1 4 Dispensing Valve Adaptors (Straight) (for use with Cornelius and Dole) 00854972 1/4" Barb Dispensing Valve Adaptors (Elbow) (for use with Cornelius and Dole) 00854971 Dispensing Valve Adaptors (Adapter) (for use with Cornelius and Dole) 00213681 Wye 00218344 1 4 00218345 3 8 00218346 1 2 00218013 Revision C (KAK) 7 August, 2000 Stainless Steel Stainless Steel / " MF Stainless Steel / " MF Stainless Steel Flare 1 /4" 3 /8" 3 /" 1 4 Barbed /4" FF 1 /8" FF 1 /4" Stainless Steel /4" /8" FF 3 Stainless Steel /8" Stainless Steel / " MF 1 4 /" Stainless Steel / " O O-ring Stainless Steel /8" O Stainless Steel /2" Barb Brass 3 8 /4" 3 /4" Garden Hose 1 3 Description /4" MF / " MF /4" 1 Size 3 /" 1 4 /" 3 8 /" 1 4 /" 3 8 /" 1 2 / " Barb Stainless Steel / " Barb /" 1 2 Stainless Steel / " Barb Stainless Steel 5 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Cable Ties Item Cable Ties Part No. Size 1 00855700 3 3/4" Size 2 Size 3 Nylon 00855701 00855703 7 1/2" 14" Nylon Nylon 00210718 Description Mount, Cable Tie Calibrating and Cleaning Item Backflush Nozzle Brix Cup Syrup Separators Part No. Size 1 Size 2 00206133 6 Description Bar Master Hose 00557496 Dole - SEV 00554531 Flowmatic 00204340 O.J. Multiplex (for Lever Activated) 00201306 3.0 to 1.0 Orange Juice 00208971 3.5 to 6.0 to 1.0 Variable 00687805 4.75 and 5.25 to 1.0 McDonalds 00687802 4.75 and 5.0 to 1.0 General 00687801 5.00 and 5.5 to 1.0 General 00206134 Bar Master Hose 00205840 Cornelius 00557452 Dole - SEV 00557499 Dole -" FFV 00554603 00202160 Flowmatic Orange Juice Lever Activated 00206629 Orange Juice Portion Control 00212610 Volume Cup Size 3 Lancer 00206809 Orange Juice 3/1 McDonalds 00210316 Soda McDonalds 00205163 Soda General 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Check Valves Item Part No. Size 1 Swing 00701325 1 /2" FPT Single (Male Pipe Thread x Male Flare) 00701312 1 8 00204864 1 8 (Male Pipe Thread x Male Pipe 00201702 1 4 Thread) 00701322 3 8 00209527 3 8 00701314 1 8 00701313 1 8 00701330 1 8 00209179 1 00208126 1 00862204 1 8 00701304 1 00862202 1 4 Out / " MPT 1 4 / " MPT 3 8 Single (Male Pipe Thread x Male Flare) In / " MPT 3 8 Brass / " MPT / " MPT 3 8 Brass / " MPT Brass (for O.J.) In Orifice / " MF 0.14 Stainless Steel / " MF 0.09 Stainless Steel / " MF 0.125 Stainless Steel /4" MF 0.125 Stainless Steel (with atomizer) /4" MF 0.09 Stainless Steel (with atomizer) / " MPT 1 4 / " MPT 1 4 / " MPT 1 4 /8" MPT 1 /8" MPT 1 Out In 1 4 / " MF Brass /4" MPT Brass 1 Out In-Line (Female Pipe x Female Pipe) Stainless Steel Out In-Line (Male Flare x Female Flare) Stainless Steel 0.125 / " MPT /4" MF / " MF In / " FF 1 4 Out 00203901 1 4 00204817 1 2 00218013 Revision C (KAK) 7 August, 2000 Brass / " MF 1 4 / " MPT Description Orifice 0.187 Out In-Line Size 3 In / " MF / " MPT Double (Male Pipe Thread x Male Flare) Size 2 /2" FPT 1 Brass In / " FPT 1 4 / " FPT / " FPT 1 2 Brass / " FPT Brass 7 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Check Valves Item (continued) Part No. Male Pipe Thread x Barb 00206974 Relief/Check Assembly 8 Size 2 Out In /8" MPT 1 Vent to Atmosphere (Backflow Preventer) Size 1 /4" Barb 1 Out 00204852 3 8 / " MF 00701324 3 8 00701333 1 4 00205561 Stainless Steel / " MF Stainless Steel / " MF Stainless Steel / " MF Stainless Steel /4" MPT Brass / " MPT Brass 1 4 3 8 / " FF 3 8 / " MPT 3 8 1 00201102 Stainless Steel / " MF / " FF 00686978 /4" MPT / " MF 1 4 Brass In 3 8 1 8 Description / " MPT 3 8 / " MF 00210890 Size 3 3 1 4 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Clamps Item Part No. Size 1 Size 2 Size 3 Range/Inch Each Package 00859116 00859118 .218-.625 .500-.906 (N/A) Stainless Steel Stainless Steel 00859112 .812-1.50 (N/A) Stainless Steel Adjustable Tab - One Ear Description Range/Inch Chudnow Oetiker Each 00855108 00855114 .275-.342 .350-.413 0.348 0.505 8.7 10.5 Stainless Steel Stainless Steel 00208720 .378-.444 0.425 00855110 .398-.464 00855115 .385-.484 00855109 .425-.523 00855116 11.3 Stainless Steel 11.8 Stainless Steel 0.470 12.3 Stainless Steel 0.505 13.3 Stainless Steel .445-.543 0.525 13.8 Stainless Steel 00855127 .443-.551 0.545 14 Stainless Steel 00855119 .519-.618 0.590 15.7 Stainless Steel 00855112 .570-.669 0.635 17 Stainless Steel 00855128 .653-.779 0.745 19.8 Stainless Steel 00855133 .700-.826 210 21 Stainless Steel 00855117 00855122 .822-.948 1.55-1.67 0.925 4043 24.1 42.5 Stainless Steel Steel 00218013 Revision C (KAK) 7 August, 2000 9 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Disconnects Item Part No. Size 1 00207506 Gas 1 4 Size 2 00207505 Liquid 1 4 00565206 Gas 1 4 00565207 Liquid 1 4 00206670 Gas 1 4 00206639 Liquid 1 4 00565208 Gas 1 00565209 Liquid 1 00210789 00210790 Size 3 Description / " Barb Coke / " Barb Coke / " MF Coke / " MF Coke / " Barb General / " Barb General /4" MF General /4" MF General Jumper Assembly, 15" Coca-Cola Jumper Assembly, 15" General Syrup Filter Item 10 Part No. Size 1 00203161 3 00858115 1 4 Size 2 /8" MF 3 / " MF 3 8 Size 3 Description /8" MF Plastic / " MF Adapter (to connect to 1 /4" line, order 2) 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Flare Connections Item Part No. Unions Size 1 00857904 1 00857907 00857908 Reducing 00858115 3 Elbows 00861704 Tees (Male Flare) 00858405 1 Tees (Swivel) 00858477 1 00205783 3 00858410 3 3 3 2 1 Gaskets Nuts Caps Size 2 /4" MF 1 1 /4" MF / " MF 3 3 8 3 8 /8" FF 1 Size 3 Description /4" MF Stainless Steel /8" MF / " MF Stainless Steel Stainless Steel /4" MF Stainless Steel /8" MF 3 /4" MF 1 /4" MF 1 /8" MF 3 /8" FF 3 3 /4" MF 1 /4" FF 1 /8" FF 3 /8" MF 3 /8" MF Brass /4" MF Stainless Steel /4" MF Stainless Steel /8" MF Stainless Steel /8" MF Stainless Steel 2 1 00852900 00852902 1 3 8 /4" /" Plastic Plastic 00851803 1 2 /" Plastic 00856502 00856501 1 /4" /" Brass Brass 00856516 3 8 00856500 1 2 3 8 /" 00856508 1 2 00856528 3 8 /" Brass Brass Long Brass /" Nickel Plated Brass /4" FF Brass /8" FF Brass /2" FF 1/4" FF Brass Stainless Steel / " FF Stainless Steel 00854402 1 00854412 3 00213166 00854409 1 00854411 3 8 00218013 Revision C (KAK) 7 August, 2000 Long /" 11 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Gauges Item Part No. Bottom Mount Back Mount Size 1 Size 2 Range-psi Pipe Size 00683123 00683116 0-30 0-30 00683124 0-100 1 8 00683072 0-100 1 4 00206401 0-120 1 8 00211907 0-150 1 4 00683111 0-160 1 4 Size 3 Description /8" MPT / " MPT 1 1 4 / " MPT / " MPT / " MPT / " MPT with follower / " MPT 00683107 0-2000 1 00205644 0-60 1 /4" MPT 00683108 0-100 1 00684844 0-160 1 /8" MPT /8" MPT /4" MPT Pipe Connections Item Bushings Nipples Reducing Tees 12 Part No. Size 1 00853929 1 00853909 00853953 00853947 1 00853905 3 8 00853906 1 2 00700717 1 8 00700706 1 4 00700720 3 8 00700705 1 00858507 1 00700716 1 00858107 1 00700723 3 00858406 1 4 00858401 3 8 00858467 1 Size 2 /8" FPT 1 1 /4" FPT /4" FPT 3/8" FPT 1 Size 3 Description /4" MPT Brass 3 /8" MPT Brass /2" MPT 1/2" MPT Brass Brass / " MPT Brass / " MPT Brass / " FPT 3 4 / " FPT 3 4 / " MPT 15 16 / " LG Brass / " MPT 1 3/8" LG Brass / " MPT 1 3/8" LG Brass /2" MPT 1 1/2" LG Brass /8" MPT 1 /4" FPT Brass /8" MPT 1 /4" MPT Brass /4" MPT 3 /8" MPT Brass /8" MPT 1 /2" MPT Brass / " FPT 1 4 / " FPT 3 8 /2" FPT 1 / " FPT 1 4 / " FPT 3 8 / " FPT Brass / " FPT /2" FPT 1 Brass /2" FPT Brass 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Compression Fittings Item Part No. Size 1 Size 2 Size 3 Description Compression Nut with 00205754 3 /4" OD Brass Captive Sleeve 00206092 00206093 1 /2" OD 3/8" OD Brass Brass 00213421 1 4 / " OD Brass 00206079 3 00206078 3 00204749 1 00205683 1 00209511 00210481 00204765 1 00204748 3 8 00205076 3 8 00209405 1 4 00209406 1 4 00206083 3 4 00209410 1 00209970 1 00204751 1 00204782 3 00209408 00209404 00209407 1 Adapter, Straight Adaptor, Elbow Tubing /4" OD 3 /4" OD 1 /2" OD 1 /2" OD 3 1 /2" OD /2" OD 3/8" OD 1 Brass /2" MPT Brass /2" MPT Brass /8" MPT Brass 1 /4" MPT Brass /4" MPT 3/8" MPT Brass Brass / " MPT Brass / " MPT Brass / " MPT Brass / " MPT Brass / " MPT Brass /2" MPT Brass /8" MPT Brass /4" MPT Brass /8" MPT Brass / " OD 1 4 / " OD 1 8 / " OD 1 2 / " OD 1 4 / " OD 1 2 /2" OD 1 /2" OD 3 /2" OD 1 /8" OD 3 1 /4" OD 3 /8" MPT Brass /4" OD 1/4" OD 1 /4" MPT 1/4" MPT Brass Brass /2" ID Poly /8" ID Poly PE051254 3 RM151315 1 RM151314 3 RM151129 1 00218013 Revision C (KAK) 7 August, 2000 /4" MPT /4" OD 1 /2" OD 3 /8" OD 1 /4" OD 5 /4" ID Poly /32" ID Nylon 13 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Pressure Reliefs Item Toggle Relief Valve Water Feeder Part No. Size 1 Size 2 Size 3 00701332 100 1 /8" MPT Orange Brass 00200250 00565307 100 130 1 /4" MPT 1/8" MPT Orange Gray Brass Stainless Steel 00701338 130 1 8 / " MPT Blue Brass 00701336 130 1 4 / " MPT Blue Brass 00701334 150 1 8 / " MPT Yellow Stainless Steel 00701311 180 1 8 / " MPT Red Stainless Steel 105 1 4 00205241 00217305 00204920 Air Pump Reliefs / " MPT Description Brass / " FTP Must use John GuestTee P.N. 00211796 105 Brass, Complete Add-on Kit 1 4 00682451 ITT Brass 00204028 GAST Brass Pump Accessories Item Part No. Size 1 Size 2 Size 3 Description Clamp 00705000 Stainless Steel Coupling Key 00702907 Bronze Strainer Screen 00702925 Stainless Steel 14 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Regulators Item Primary CO2 Regulator Part No. Size 2 Size 3 Description Primary CO2 Regulator 00683128 Primary CO2 Regulator 00217392 Guard, Primary CO2 Regulator Secondary Air/CO2 Regulator (less Gauges) Size 1 00204814 Range-psi Pipe Size Application /4" NPT Diet General Line (Low) / " NPT Sugar General Line (Med) /4" NPT Sugar/OJ McDonalds Units and OJ (Med) Pipe Size Application /8" NPT Steamer Less Gauges 3" Port /4" FPT OJ Less Gauges 3" Port / " NPT N/A Less Gauges 3" Port /2" NPT Water No Gauge Port /4" NPT 55 psi No Gauge Port Size 2 Size 3 Description 00683118 0-30 00683058 0-100 1 4 00204553 0-100 1 Water Range-psi 1 00205642 0-30 1 00209162 0-100 1 00686903 10-50 1 4 00683117 10-70 1 00683129 25-75 3 Strainers Item Part No. 00205829 Size 1 / " FPT 3 8 00207633 3 8 00206982 3 8 / " FPT Plastic / " Barb Plastic /8" MF Plastic / " Barb 3 8 3 /8" FF 3 Size 2 Insulation Item Part No. Size 1 00211684 2" x 30' Size 3 Description Aluminum 00689700 RM051120 2" x 30' 2" x 1' Cloth Cork 00689701 2" x 30' Foam 00212342 3" x 100 P.V.C. 00203958 Can Foam Aerosol RM060030 400" Vinyl 00218013 Revision C (KAK) 7 August, 2000 15 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Tools Item Air Chuck (to be used with Adaptor) Part No. Size 1 Size 2 /4" FPT Ball Foot 00859018 1 00852504 1 /4" MPT /4" MF 1 Size 3 Description Adaptor Brush, Nozzle 00681901 Carbonation Tester 00251906 Condenser Fin Comb 00681904 Crimper, Tab Clamp 00681815 Tubing Cutter 00211237 Large 6" Cutter 00681824 Small Butterfly Cutter 16 Flowmatic 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Tools (continued) Item Part No. Size 1 Size 2 Size 3 Description Potenteometer 00681825 Refractometer 00251903 0-32 Thermometer 00251905 Digital Wrenches, Nozzle 00206191 Dole Soda Plastic 00681809 Flowmatic Soda Plastic 00681823 Tap Rite Beer Stainless Steel 00218013 Revision C (KAK) 7 August, 2000 17 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Tubing Item Part No. Size 1 Size 2 Size 3 Description Tubing ID OD Clamp Description /32" 1/4" RM151206 RM157111 0.156 0.265 0.313 0.465 00855108 00855109 Nylon Braid Nylon Braid /" RM152121 0.265 0.469 00855127 Red Braid /" RM152115 0.375 0.640 00855112 Red Braid /" RM157110 0.380 0.588 00855119 EVA Braid /" RM157113 0.515 0.815 00855133 EVA Braid Tubing ID OD Clamp Description /4" RM151129 0.150 0.250 00856502 Nut White Nylon /8" RM151314 0.251 0.375 00204745 00204767 White Nylon /" RM151312 0.231 0.375 00856528 Nut White Nylon /2" RM151315 0.376 0.500 00204744 00204747 White Nylon Tubing ID OD Clamp Description /" PE500650 0.375 0.563 00855119 Poly /" PE051254 0.500 0.686 00855128 Poly Tubing ID OD Clamp Description /8" RM912111 0.625 0.875 00859112 Black 1" RM912113 1.000 1.250 00859112 Black Tubing ID OD Clamp Description 1 /8" 00207002 0.125 0.219 00207003 Clear, Thick Wall / " RM151213 0.188 0.438 00855109 Clear, Thick Wall /16" RM151222 0.313 0.438 00855127 Clear, Thin Wall 1 4 /" RM151214 0.250 0.500 00855127 Clear, Thick Wall /16" RM151215 0.313 0.563 00855119 Clear, Thick Wall /8" RM151216 0.375 0.625 00855112 Clear, Thick Wall /" RM151224 0.500 0.750 00855133 Clear, Thick Wall Braided 5 1 4 3 8 3 8 1 2 Nylon 1 3 3 8 1 Polyethylene 3 8 1 2 Rubber (Drain) 5 Vinyl 3 16 3 5 3 1 2 18 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Valves Item Needle Part No. Size 1 00670023 1 00670021 00670024 1 Petcock 00670014 1 8 Three-Way Ball 00204743 1 00205572 1 00204742 1 4 Shut-off Ball /8" MPT /4" MPT 1/4" MF Size 2 Size 3 Brass /4" MF 1/4 SW Brass Stainless Steel (Elbow) 1 / " MPT Brass /4" FPT Brass /2" FPT Brass / " FPT / " FPT 1 4 Ball Type 00210723 00204789 00209558 00218013 Revision C (KAK) 7 August, 2000 Brass Replacement Lever / " FPT 3 8 / " FPT 3 8 Ball Type 00210725 00670025 Description /4" MPT 1 Brass Replacement Lever / " MF 3 8 /2" FPT 1 / " MF Brass 1 8 /2" FPT 1 Ball Type Brass 19 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog Valves (continued) Item Part No. Size 1 Size 2 Switch Over 00670026 Assembly Less Fittings 00671613 1 /4" MF 1 00670010 1 /4" INVFLX 1 00862201 (use on old valve) 1 /4" INVFLX 1 / " MPT 1 4 Fittings 00862203 (use on 00671613 and 00670010) 20 Size 3 /4" FPT 1 8 Description Aluminum 1 /4" MPT 1 /4" MF Brass /4" MPT 1 /4" INVFLX Brass /4" MF Brass / " MF Brass 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog John Guest Fittings Item Union Elbows (Elbow) Part No. Size 1 Size 2 Size 3 Description 00111006 1 /4" OD 1 /4" OD Tube 00111007 00209741 5 /16" OD 3/8" OD 5 /16" OD 3/8" OD Tube Tube To be used when connecting thin wall poly tubing to thin wall poly tubing. Reducing Elbow 00111016 3 8 / " OD 1 4 00213885 3 8 / " OD 5 16" / " OD Tube / OD Tube 00214918 5 16 / " OD 1 2 / " OD Tube To be used when connecting thin wall poly tubing to thin wall poly tubing. PlasticTubing to Stainless 00208800 3 8 Steel Tubing 00208799 3 8 / " OD 5 16 / " Stainless Steel / " OD 3 8 /" Stainless Steel To be used when connecting thin wall poly tubing to Stainless Steeltubing. Plug in Elbow /8" OD 00214099 3 00211678 1 2 / " OD /8" OD Stem 1/2 OD Stem 3 To be used when connecting thin wall poly tubing to another John Guest Fitting. Union Connectors K0000681 00209190 1 /4" OD / " OD 1 3 8 3 8 /4" OD / " OD 00111022 3 16 / " OD 3 8 00210126 1 2 / " OD 1 2" / " OD / OD To be used when connecting thin wall poly tubing to thin wall poly tubing. 00218013 Revision C (KAK) 7 August, 2000 21 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog John Guest Fittings Item Reducing Union (continued) Part No. Size 1 00111013 3 00209397 00210126 Size 2 /8" OD 5 1 /2" OD / " OD 3 1 2 1 2 Size 3 Description /16" OD /8" OD / " OD To be used when connecting thin wall poly tubing to thin wall polytubing. PlasticUnion to 00208796 3 8 Stainless SteelTubing 00209334 3 8 / " OD 5 16 / " OD 3 8 / " OD Stainless Steel / " OD Stainless Steel To be used when connecting thin wall poly tubing to Stainless Steeltubing. Union Tee 00111010 1 00208791 3 00210862 1 /4" OD 1 /8" OD 3 /4" OD 1 /8" OD 3 /2" OD 1 /4" OD /2" OD 1 /8" OD /2" OD To be used when teeing thin wall poly tubing only. 2-Way Divider 00111008 3 00209346 3 /8" OD 2 5/16" OD /8" OD 2 3/8" OD To be used when dividing thin wall poly tubing only. Male Connector Adaptor 00208801 1 8 00111002 1 00111009 1 00209317 1 00112023 5 00209328 1 00209946 / " MPT 5 32 /8" MPT 1 /8" MPT 5 /8" MPT 3 /16" MF 3 /4" MPT 3 /8" MF 3 3 / " OD /4" OD /16" OD /8" OD /8" OD /8" OD /8" OD To be used when connecting thin wall poly tubing to a female pipe thread fitting. 22 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog John Guest Fittings Item (continued) Part No. Size 1 U-bends 00216816 Stem Adaptor 00111001 1 00111003 1 00111005 1 00111011 1 Size 2 1 /2" OD 1 /4" MPT 1 /8" MPT 1 /8" MPT 5 /4" MPT 1 Size 3 /2" OD Description 1" Centers /4" OD /4" OD /16" OD /4" OD To be used when connecting a John Guest Fitting to a female pipe thread fitting. Collet Covers 00208804 5 00208803 00209398 3 /32" OD /8" OD / " OD 1 2 Used to hold collet and tube in place. Collets 00210798 5 /32" OD Tube Retaining 00210799 00210800 3 /16" OD 1/4" OD Tube Retaining Tube Retaining 00210801 5 16 / " OD Tube Retaining 00210802 3 8 / " OD Tube Retaining 00210803 1 2 / " OD Tube Retaining /4" ID Tube Secures tube fitting. Tube Support 00210255 1 Tubing stiffener used to prevent tubing deflection at fitting which would cause leak. 00218013 Revision C (KAK) 7 August, 2000 23 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog John Guest Fittings Item Tubing Cartridge (continued) Part No. 00209416 Size 1 Size 2 Size 3 /16" OD Description Tubing 5 Secures Stainless Steeltube to fitting. Tube to Hose Stem Adapter 00210750 Plastic 3 8 / " Barb 1 2 00209947 Plastic 3 00210749 Plastic 1 2 00210752 Plastic 00210638 Plastic 1 /8" Barb 3 / " Barb /4" Barb 3 / " Barb 1 2 / " OD Stem 00217015 Stainless Steel /8" OD Stem 00112042 Stainless Steel 3 8 / " OD Stem 00217013 Stainless Steel /8" OD Stem 1/2" OD Stem 00112041 Stainless Steel 00217014 Stainless Steel Used to connect a John Guest Fitting to thick wall poly tubing or braided tubing. Plug 00209383 3 /8" OD Stem 00111023 3 /16" OD Stem Used to plug a John Guest Fitting. Flow Bend Tube Clip 00209333 / " OD 3 8 1 1/4" R Tube Flow Bend Used to reinforce tubing and make sharp bend without crimping. O-ring 00210792 5 00210793 3 /32" 00210794 1 00210795 00210796 5 00210797 1 2 /16" /4" /16" 3/8" /" Correspond to John Guest Fitting size. 24 00218013 Revision C (KAK) 7 August, 2000 Multiplex Company, Inc. Illustrated Fittings and Hardware Catalog John Guest Fittings (continued) How to use john guest fittings Before inserting tubing into John Guest Fitting, be sure end of tubing is cleanly cut at a 90° angle. Right Wrong 2. Insert tubing into John Guest Fitting. Push tubing firmly through fitting until it rests against a tube stop in the fittings main body housing. The tubing is now automatically locked into John Guest Fitting. 3. To release tubing from John guest Fitting, push in collet located on John Guest Fitting (if necessary, remove collet cover). Wrong Right Tubing Collet Collet Cover Tubing Collet Collet Cover For stainless steel Metal tubing must be cut square and have a smooth burr-free end. 1. Turn the LOCKING CAP to show approximately 1/8" (3 mm) of thread at X. 2. Push fitting onto the STAINLESS STEELensuring that it is fully up against the tube stop. 3. Tighten the LOCKING CAP half a turn. If the fitting is not secure, tighten a little further. 4. Make sure fitting is secure. 5. Push Plastictubing into other and of fitting insuring that it is fully up against the tube stop. To release the fitting from the Stainless Steeltube, simply unscrew the LOCKING CAP three quarters of a turn, depressing the collet head as with a conventional John Guest Fitting. Note: If a fitting leaks as the SUPER SEAL end, simply tighten the LOCKING CAP until leaking stops. By doing this you increase the compression sealing of the O-rings on the steel tail. 00218013 Revision C (KAK) 7 August, 2000 25 250 Old Ballwin Road w St. Louis, Missouri 63021-4800 Tel: 636.256.7777 w Fax: 636.527.4313 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218013 Revision B (GSW/KAZ) 05/03/99 2100 Future Drive, Sellersburg, IN 47172 Tel: 812 246 7000 Fax:: 812 246 9922 [email protected] w www.multiplex-beverage.com In accordance with our policy of continuous product development and improvement, this information is subject to change at any time without notice. 00218009 Revision D July 2002
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