Beermaster Refrigeration Unit Installation, Use & Care Manual

Beermaster Refrigeration Unit Installation, Use & Care Manual
Beermaster
Refrigeration Unit
Installation, Use & Care Manual
This manual is updated as new information and models are released.
Visit our website for the latest manual. www.manitowocfsg.com
America’s Quality Choice in Refrigeration
Part Number 000003913 7/08
Safety Notices
Read These Before Proceeding:
As you work on Manitowoc equipment, be sure to pay
close attention to the safety notices in this manual.
Disregarding the notices may lead to serious injury and/
or damage to the equipment.
Throughout this manual, you will see the following types
of safety notices:
! Warning
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
! Caution
Proper installation, care and maintenance are
essential for maximum performance and trouble-free
operation of your Manitowoc equipment. Read and
understand this manual. It contains valuable care
and maintenance information. If you encounter
problems not covered by this manual, do not
proceed, contact Manitowoc Foodservice Group.
We will be happy to provide assistance.
Important
! Caution
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
Text in a Caution box alerts you to a situation in
which you could damage the equipment. Be sure to
read the Caution statement before proceeding, and
work carefully.
! Warning
PERSONAL INJURY POTENTIAL
Procedural Notices
As you work on Manitowoc equipment, be sure to read
the procedural notices in this manual. These notices
supply helpful information which may assist you as you
work.
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
NOTE: SAVE THESE INSTRUCTIONS.
Throughout this manual, you will see the following types
of procedural notices:
Important
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will not
cause damage or injury, but it may slow you down as
you work.
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about the procedure you
are performing.
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
Table of Contents (continued)
General Information 1
Read This Manual 1
Unit Inspection 1
Model Numbers 1
How to Read a Model Number 1
Accessories 1
Special Applications 1
Attention: Marine Installations 1
Outdoor Applications 1
Serial Plate Location 2
Warranty Information 2
Installation 1
General 1
Dimensions and Clearances — All Models 1
Remote Condenser 2
Safe Installation Dos and Don’ts 2
Location Requirements 3
Multiplex Chiller Model Selection Chart 3
Clearances 3
Ratings 3
Kitchen Equipment Installer Representative Responsibilities 4
Requirements for Refrigeration Units 4
Installer Instructions 4
Preparation 4
Electrical 5
General 5
Minimum Circuit Ampacity 5
Electrical Requirements 5
Specifications 5
Grounding Instructions 6
Conduit 7
Introduction 7
Floor Chases 7
Overhead Installation 9
Basement Construction 10
Connecting Beer Conduit 11
Conduit Kit 12
Installing the Conduit Kit 14
Part Number 000003913 7/08
i
Table of Contents (continued)
Beer Restrictor Lines 15
Balancing the System 16
Determining Restrictor Line Length and Applied Keg Pressure 16
Starting Up the System 16
Beermaster Wine Dispensing Kit 17
Introduction 17
Installing 17
Positioning of Refrigeration Unit 18
Equipment Placement 18
Electrical Connections 18
Insulating Connections 19
Aeroquip Connection 19
Condenser and Pre-charged Lines Installation 19
Multiplex Remote Condenser Pre-installation Requirements 19
Multiplex Pre-charged Refrigeration Lines Pre-installation Requirements 20
Installing the Multiplex Remote Condenser 20
Connecting the Pre-charged Refrigeration Lines 21
Preparing Glycol 22
Mixing Glycol Solution 22
Additional Glycol Circulating Pump and Motor Kit 23
Installing the Glycol Circulating Pump and Motor Kit 23
Beermaster Dispensing Towers 25
Introduction 25
Dispensing Tower Template for Beermaster Dispensing Tower 25
Beermaster High Pressure CO2 Regulator (00211500) 26
Introduction 26
Kit Contents 26
Installing 26
Beermaster Dual Secondary Regulator Kit (00211400) 26
Introduction 26
Kit Contents 26
Installing 26
Beermaster Blenders 28
N2/CO2 Blender (Single — 00520182, Dual — 00520183) 28
Installation Checklist 29
Operation 1
Typical System 1
How the Multiplex Works 2
Start-up 2
ii
Part Number 000003913 7/08
Table of Contents (continued)
Placing Equipment in Operation 2
Equipment Setup and Close Procedure 3
Equipment Setup Procedure 3
Equipment Close Procedure 3
System Calculators 4
Beer Pump, System Pressure and Choker Calculator 4
Blended Gas Beer System Pressure and Choker Calculator 5
Pure CO2 Beer System Pressure and Choker Calculator 6
Maintenance 1
Major Components 1
Dispensing Stations 1
Beverage Conduits 1
Air Compressor 1
Refrigeration Unit 1
Gas Blender 1
CO2 Gas Supply 1
Scheduled Frequency 1
Shipping, Storage and Relocation 2
Before Calling for Service 1
Checklist 1
Part Number 000003913 7/08
iii
Table of Contents (continued)
iv
Part Number 000003913 7/08
Section 1
General Information
Read This Manual
Manitowoc Food Service developed this manual as a
reference guide for the owner/operator and installer of
this equipment. Please read this manual before
installation or operation of the machine. A qualified
service technician must perform installation and start-up
of this equipment, consult Section 5 within this manual
for service assistance.
If you cannot correct the service problem, call your
Manitowoc Beverage Equipment (MBE) Service Agent
or Distributor. Always have your model and serial
number available when you call.
Your Service Agent ____________________________
Service Agent Telephone Number _________________
How to Read a Model Number
Condenser
Type
Model Base
Model Prefix
300 A 04
300 - 1 hp
450 - 2.2 hp
04 - R404a refrigerant
A - Air-cooled
AX - Air-cooled, international
R - Remote
RX - Remote, international
W - Water-cooled
WX - Water-cooled, international
Your Local MBE Distributor ______________________
Distributor Telephone Number ____________________
Model Number _______________________________
Serial Number ________________________________
Installation Date ______________________________
Unit Inspection
Thoroughly inspect the unit upon delivery. Immediately
report any damage that occurred during transportation to
the delivery carrier. Request a written inspection report
from a claims inspector to document any necessary
claim.
! Warning
Accessories
Depending on store type and location, various optional
equipment (such as CO2 Panel, water filter kit, water
booster kit, etc.) may be added to this system. Install
and connect any optional equipment in the desired
location according to the installation instructions
provided with these kits/equipment.
Special Applications
ATTENTION: MARINE INSTALLATIONS
! Warning
This unit is for use on vessels over 66 ft (20 m) in
length. This unit must not be installed in the engine
space of a gasoline-powered ship.
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
NOTE: This unit must be secured to the vessel during
installation. Models with part numbers beginning with the
letters TS are NOT marine listed.
OUTDOOR APPLICATIONS
Model Numbers
This manual covers the following models:
Refrigeration Unit
75A04, 75W04, 75R04, 75AX04, 75WX04, 75RX04
175A04, 175W04, 175R04, 175AX04, 175WX04, 175RX04
300A04, 300W04, 300R04, 300AX04, 300WX04, 300RX04,
450A04, 450W04, 450R04, 450AX04, 450WX04, 450RX04
Part Number 000003913 7/08
TS Multiplex Beverage Recirculating units are approved
and listed by Underwriters Laboratories (UL). However
they are not UL approved for weather exposure
applications. These units must be installed in areas
where adequate protection from the elements is
provided, all other models are ETL listed.
1-1
General Information
Section 1
Serial Plate Location
Warranty Information
Consult your local MBE Distributor for terms and
conditions of your warranty. Your warranty specifically
excludes all beverage valve brixing, general
adjustments, cleaning, accessories and related
servicing.
Your warranty card must be returned to MBE to activate
the warranty on this equipment. If a warranty card is not
returned, the warranty period can begin when the
equipment leaves the MBE factory.
No equipment may be returned to MBE without a written
Return Materials Authorization (RMA). Equipment
returned without an RMA will be refused at MBE’s dock
and returned to the sender at the sender’s expense.
Please contact your local MBE distributor for return
procedures.
1-2
Part Number 000003913 7/08
Section 2
Installation
General
•
Refrigeration units require stand or 6" (15.2 cm) legs. Refrigeration unit cannot be placed directly on floor.
•
Conduit can be run through floor or ceiling chase.
Dimensions and Clearances — All Models
Wall
12"
(30.5 cm)
minimum
6" (15.2 cm) minimum
18"
(45.7 cm)
minimum
J
Wall
Wall
Electrical
Junction Box
3-7/8" (9.8 cm) Diameter
(4-7/8" [12.4 cm] Diameter
on Model 450)
Control
Switches
Air Flow
6" (15.2 cm)
Diameter Chase minimum
Top View
Electrical
Junction Box
18" (45.7 cm)
minimum
Ceiling
Conduit to
Dispensing Towers
D
W
Wall
I
Incoming CO2
Supply Line
H
Wall
Wall
Incoming Water
Line
CO2 Regulator
Panel (Optional)
Incoming Syrup
Supply Lines
P
N
Drain Plug
Drain Plug
Side View
Model
Front View
W
D
H
I
(with stand)
J
N
P
5 1/2” (14.0 cm)
75
27 3/4”(70.5 cm)
16 1/4” (41.3 cm)
18 3/4” (47.7 cm)
--
--
19 3/4” (50.2 cm)
150
36 1/4” (92.1 cm)
19 1/2”(49.5 cm)
21 1/2” (54.6 cm)
--
11” (28 cm)
5’” (12.7 cm)
9” (22.9 cm)
300
39-3/4" (101 cm)
24-3/4" (62.9 cm)
28-1/4" (72.4 cm)
60-3/4" (154.3 cm)
11" (28 cm)
6" (15.2 cm)
12" (30.5 cm)
450
42-1/4" (107.3 cm)
28-1/4" (71.8 cm)
32-1/4" (81.9 cm)
66-3/4" (169.5 cm)
11" (28 cm)
8-1/2" (21.6 cm)
14" (35.6 cm)
Part Number 000003913 7/08
2-1
Installation
Section 2
REMOTE CONDENSER
OPTIONAL
38.00" (96.52 cm)
34.00" (86.36 cm)
29.50"
30.00" (76.20 cm) (74.93 cm)
27.94"
(70.97 cm)
1.50"
(3.81 cm)
29.16"
(74.06 cm)
6.00"
(15.24 cm)
6.50"
(16.51 cm)
3.50"
(8.89 cm)
OPTIONAL
20.00" (50.80 cm)
16.00" (40.64 cm)
12.00" (30.48 cm)
14.62"
(37.13 cm)
4.00"
(10.16 cm)
Safe Installation Dos and Don’ts
! Warning
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 are tight. This check
must 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.
2-2
•
DO NOT exhaust CO2 gas (example: syrup pump)
into an enclosed area, including all types of walk-in
coolers, cellars, and closets.
•
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. It is best to connect
the CO2 cylinder(s) to a regulator(s).
•
DO NOT store CO2 cylinders in temperature above
125°F (51.7°C) near furnaces, radiator or sources of
heat.
•
DO NOT release CO2 gas from old cylinder.
•
DO NOT touch refrigeration lines inside units; some
may exceed temperatures of 200°F (93.3°C).
NOTICE: All utility connections and fixtures must be
sized, installed, and maintained in accordance with
Federal, State, and Local codes.
Part Number 000003913 7/08
Section 2
Installation
Location Requirements
MULTIPLEX CHILLER MODEL SELECTION CHART
Model #*
300
450
Line length
up to 300'
up to 450'
Included
glycol
circulation
pump
1
Optional
glycol
circulation
pumps
up to 2 additional
Qty of
flavors**
up to 22
RATINGS
Model
Evaporator Rating
at 20°F (-6.5°C)
Heat Rejection
(Max.)
75
2500 BTUH
490 kcal/hr
4500 BTUH885
kcal/hr
150
5150 BTUH
1,159 kcal/hr
8,638 BTUH
1,949kcal/hr
300
9,700 BTUH
2,340 kcal/hr
13,576 BTUH
3,685 kcal/hr
450
14,900 BTUH
3,310 kcal/hr
20,400 BTUH
4,285 kcal/hr
3
one additional
up to 32
* Chiller condensing options are available, refer to
Condenser and Pre-charged Lines Installation for details.
** Requires maximum number of optional pumps to reach
these levels.
Select a location for the refrigeration unit that meets the
requirements of the building plans, local codes, and
personnel. The unit must be positioned for free airflow
as well as for future service. The following requirements
must be met:
•
CLEARANCES
Control Side (Right)
18" (45.7 cm)
Connection Side (Left)
12" (30.5 cm)
Back Side
6" (15.2 cm)
Ceiling
18" (45.7 cm)
Beverage quality CO2 gas (bulk or bottled supply)
with a minimum 3/8" (.96 cm) line
NOTE: Refer to serial plate on front of refrigeration unit
for voltage and amperage specifications. Make all
electrical connections at the junction box located at the
top rear of unit. Optional equipment may require
additional power supplies.
! Warning
Carbon Dioxide (CO2) displaces oxygen. Exposure
to a high concentration of CO2 gas causes tremors,
which are followed rapidly by loss of consciousness
and suffocation. If a CO2 gas leak is suspected,
particularly in a small area, immediately ventilate the
area before repairing the leak. CO2 lines and pumps
must not be installed in an enclosed space. An
enclosed space can be a cooler or small room or
closet. This may include convenience stores with
glass door self serve coolers. If you suspect CO2
may build up in an area, venting of the BIB pumps
and/or CO2 monitors must be utilized.
Part Number 000003913 7/08
2-3
Installation
KITCHEN EQUIPMENT INSTALLER
REPRESENTATIVE RESPONSIBILITIES
Prior to scheduling Multiplex Equipment installer,
the following steps listed below must be completed:
1. Electrical power supply meeting the requirements for
the unit to be installed. (See the specification in this
section or refer to the unit’s serial plate).
2. CO2 Gas (bulk or bottled supply); minimum 3/8" line.
3. A 120 VAC, 3-wire, 1 Phase, 60 Hz dual wall
receptacle for optional electrical equipment
(domestic only).
NOTE: Do not schedule the authorized Multiplex
Equipment Installer until all of the above have been
completed. It will only result in charge-backs to you for
the unnecessary trips.
REQUIREMENTS FOR REFRIGERATION UNITS
•
Conduit can be run through floor or ceiling chase.
•
60°F (15.6°C) minimum and 105°F (40.5°C)
maximum operating ambient conditions.
•
For indoor installation only.
•
Beer supply can be located on stand or adjacent to
refrigeration unit.
Section 2
Installer Instructions
Important
The remainder of these instructions is to be
completed by an authorized Multiplex Installer.
These equipment instructions are intended to assist
qualified personnel in the unpacking, locating and the
initial operation of the Multiplex Beverage Equipment
Refrigeration Unit.
Important
This publication must be saved for future reference.
Read instructions before attempting installation.
PREPARATION
The Multiplex Beverage Equipment Refrigeration Unit is
pre-assembled in the factory and requires minimum
installation.
For future reference or to be used when ordering parts,
record the Model Number, Serial Number, Part Numbers
of Unit, Condenser (if remote), Towers, etc., and Date of
Installation on the inside of this Manual. Leave manual
on site in a safe place. Do not discard manual.
Ambient Location Requirement
This equipment is rated for indoor use only. It will not
operate in sub-freezing temperature. In a situation when
temperatures drop below freezing, the equipment must
be turned off immediately and properly winterized.
Contact the manufacturer for winterization process.
2-4
Part Number 000003913 7/08
Section 2
Installation
Electrical
GENERAL
! Warning
All wiring must conform to local, state and national
codes.
MINIMUM CIRCUIT AMPACITY
The minimum circuit ampacity is used to help select the
wire size of the electrical supply. (Minimum circuit
ampacity is not the beverage/ice machine’s running amp
load.) The wire size (or gauge) is also dependent upon
location, materials used, length of run, etc., so it must be
determined by a qualified electrician.
ELECTRICAL REQUIREMENTS
Refer to Ice Machine Model/Serial Plate for
voltage/amperage specifications.
SPECIFICATIONS
Minimum
Circuit Breaker Compressor
Amps
Model
Volt/Cycle/
Phase
75
120/601
230/50/1
20.3
9.0
25A
16A
1/3 hp
.46 kw
150
120/601
230/50/1
21.5
10.7
30A
16A
12 hp
.97 kw
300
208-230/60/1
230/50/1
20.6
20.6
30A
25A
1 hp
1.9 kW
450
208-230/60/3
230/400/50/3
25.2
11.6
30A
20A
2.2 hp
2.0 kW
Part Number 000003913 7/08
2-5
Installation
Section 2
GROUNDING INSTRUCTIONS
! Warning
! Warning
The beverage/ice machine must be grounded in
accordance with national and local electrical codes.
This appliance must be grounded. In the event of
malfunction or breakdown, grounding provides a path of
least resistance for electric current to reduce the risk of
electric shock. This appliance is equipped with a cord
having an equipment-grounding conductor and a
grounding plug. The plug must be plugged into an
appropriate outlet that is properly installed and grounded
in accordance with all local codes and ordinances.
! Warning
Improper connection of the equipment-grounding
conductor can result in a risk of electric shock. The
conductor with insulation having an outer surface
that is green with or without yellow stripes is the
equipment grounding conductor. If repair or
replacement of the cord or plug is necessary, do not
connect the equipment-grounding conductor to a
live terminal. Check with a qualified electrician or
serviceman if the grounding instructions are not
completely understood, or if in doubt as to whether
the appliance is properly grounded. Do not modify
the plug provided with the appliance — if it will not fit
the outlet, have a proper outlet installed by a
qualified electrician.
When using electric appliances, basic precautions
must always be followed, including the following:
a. Read all the instructions before using the
appliance.
b. To reduce the risk of injury, close supervision is
necessary when an appliance is used near
children.
c. Do not contact moving parts.
d. Only use attachments recommended or sold by
the manufacturer.
e. Do not use outdoors.
f. For a cord-connected appliance, the following
shall be included:
• Do not unplug by pulling on cord. To unplug,
grasp the plug, not the cord.
• Unplug from outlet when not in use and
before servicing or cleaning.
• Do not operate any appliance with a
damaged cord or plug, or after the appliance
malfunctions or is dropped or damaged in any
manner. Contact the nearest authorized
service facility for examination, repair, or
electrical or mechanical adjustment.
g. For a permanently connected appliance — Turn
the power switch to the off position when the
appliance is not in use and before servicing or
cleaning.
h. For an appliance with a replaceable lamp —
Always unplug before replacing the lamp.
Replace the bulb with the same type.
i. For a grounded appliance — Connect to a
properly grounded outlet only. See Grounding
Instructions.
2-6
Part Number 000003913 7/08
Section 2
Installation
Conduit
INTRODUCTION
CONDUIT SPECIFICATION CHART
The following instructions will provide information for
installing Multiplex Beer Conduit with your Beermaster
System. Areas which will be covered include routing the
conduit for different bar setups, connecting the conduit
at the Beermaster Glycol Chiller, connecting the conduit
at the beer cooler, and connecting the conduit at the
dispensing stations.
Conduit Specifications
Choose
# of Beer
Flavors
Brewmaster
Beer Glycol Glycol Total
2 Conduit
Lines Lines Circuits Lines
Part #
2
MC043346
2
2
1
4
3
MC053346
3
2
1
5
4
MC063346
4
2
1
6
Before pulling beer conduit through a floor chase,
ensure the floor chase contains the following:
5
MC073346
5
2
1
7
•
6" (15 cm) minimum PVC conduit chase
6*
MC083346
6
2
1
8
•
6*
MC103346
6
4
2
10
Chase openings should extend 6" (15 cm) above
floor
8
MC123346
8
4
2
12
•
Wide sweep elbows (2 ft [0.6 m] radius)
•
Chase must be clean and dry — no foreign materials
10
MC143346
10
4
2
14
12
MC163346
12
4
2
16
15
MC193346
15
4
2
19
16
MC203346
16
4
2
20
glycol
line**
MC023346
2
1
2
FLOOR CHASES
* To maximize system performance on 6-flavor applications,
Multiplex recommends using a 10 line conduit with 4 glycol
lines/2 circuits.
** 2-line “glycol only” conduit, used between chiller and keg
cooler.
Walk-in Cooler
Beermaster™
Refrigeration Unit
Dispensing
Station
Beer Conduit
6" (15.2 cm) PVC
Conduit Chase
Part Number 000003913 7/08
Wide Sweep Elbows
2 ft (61 cm) Radius
2-7
Installation
Section 2
Pulling Conduit Through Floor Chase
1. Determine the most convenient way of routing
conduit, starting at the end which offers adequate
room for installation. The conduit installation process
requires the assistance of at least two (2) qualified
personnel.
2. Route the steel fish tape through chase opening.
Push fish tape through entire chase until it appears
at opposite end.
3. Locate an appropriate length of rope and tie to end
of fish tape (end which was routed through chase in
step 2). Approximately 2 ft (0.6 m) from steel fish
tape/rope connection, secure a swab to rope (use
mop heads or a bundle of rags for swab).
4. Pull end of fish tape from starting point through
chase with rope and swab. The swab will clean any
construction materials, moisture, or debris that may
exist in floor chase. Continue to swab the chase until
the swab exits the chase clean and dry.
5. After floor chase has been cleaned, remove steel
fish tape and swab from rope. Locate bundle of beer
conduit and unspool conduit to allow unrestricted
feed during installation process.
7. After rope has been connected, tape end of conduit,
including rope, and form conduit end to a point (see
figure above). Tape will ensure that no contaminants
enter conduit tubes during installation.
8. Place pointed end of the conduit through chase
opening. While one person pushes the conduit
through chase, another person should be pulling the
conduit through the chase with rope at the opposite
end.
9. Once the conduit has been routed through the
chase, pull enough conduit through the openings to
ensure an adequate supply at each end of the chase
for connections.
6. Locate rope through floor chase opening and
connect to proper end of beer conduit.
NOTE: The beer conduit is designed to be pulled
through floor chase in the direction of arrows printed on
conduit.
2-8
Part Number 000003913 7/08
Section 2
Installation
OVERHEAD INSTALLATION
Ceiling Tiles
Conduit Hanger
Beer Conduit
Walk-in Cooler
Dispensing
Station
Beermaster™
Refrigeration Unit
Refer to the figure above for the following:
1. Determine the correct location for routing the beer
conduit. Be sure to avoid heat ducts, hoods, grills, or
any sharp objects that may exist above drop ceiling
tile.
2. Unspool the beer conduit to allow unrestricted feed.
3. Route the conduit above ceiling tiles and connect to
ceiling and/or pipes using the appropriate conduit
hangers. Be sure the conduit is suspended above
ceiling tiles, not lying on the tiles. Care should be
taken when determining appropriate method of
handing conduit securely. Hangers must not crush
or pinch insulation. This will reduce cooling
efficiency.
4. Once the conduit has been routed, ensure an
adequate supply of conduit is provided at each end
to make all connections.
Part Number 000003913 7/08
2-9
Installation
Section 2
BASEMENT CONSTRUCTION
Dispensing
Station
Conduit Hanger
Walk-in Cooler
Beer
Conduit
Beermaster™
Refrigeration Unit
Refer to the figure above for the following:
1. Unspool the beer conduit to allow unrestricted feed
during installation process.
2. Route the conduit up basement wall and secure with
appropriate conduit hangers.
3. After routing the conduit up the basement wall, route
conduit overhead on the basement ceiling. Connect
to the basement ceiling using appropriate conduit
hangers.
4. Once the conduit has been routed, ensure an
adequate supply of conduit is on hand to make all
connections.
2-10
Part Number 000003913 7/08
Section 2
Installation
CONNECTING BEER CONDUIT
Before connecting the beer conduit at the walk-in beer
cooler and beer towers, ensure an adequate length of
conduit is being supplied to make proper connections.
! Caution
Only an approved cutting tool should be used to cut
polyethylene tubing. The cutting tool should contain
a razor sharp cutting blade so that the tubing will not
be crushed when cutting. A razor blade knife or
butterfly tubing cutter is sufficient (see figures).
Multiplex packs a butterfly cutter with each
Beermaster Glycol Chiller.
1. Locate the lines of the beer conduit routed to the
Beermaster Glycol Chiller.
2. Using an approved cutting tool, cut the beer conduit
insulation along the top side while peeling insulation
back at the same time.
NOTE: Glycol circuit is a pair of lines; one blue and one
red. The blue line is the discharge or supply line. The red
line is the return line.
3. Locate the return glycol supply lines of the beer
conduit and connect to the corresponding John
Guest fitting on the Beermaster Glycol Chiller.
4. Locate the discharge glycol supply lines of the beer
conduit and connect to the corresponding John
Guest fitting on the Beermaster Glycol Chiller.
5. Locate the glycol lines in the main conduit. Connect
the glycol lines of the beer unit to walk-in cooler
conduit to the glycol lines of the main beer conduit.
Butterfly Cutter
Razor Knife
6. Locate the beer and glycol supply lines at the
dispensing station. Connect each beer line,
incoming glycol line, and outgoing glycol line to the
appropriate John Guest fitting at the dispensing
station.
NOTE: The 3/8" I.D. poly line used in the beer conduit is
thin wall tubing. Barbed fittings should not be used. The
usage of barbed fittings causes thin wall tubing to split or
crack and leaks will result.
Beer Conduit to
Walk-in Cooler
Main Beer
Conduit
Walk-in Cooler
Beermaster™
Refrigeration Unit
Dispensing
Station
Part Number 000003913 7/08
2-11
Installation
Section 2
CONDUIT KIT
Kit contents
General
Four (4) and Seven (7) line conduit kits
The following instructions will cover installation
procedures required for properly connecting each
component of the Beermaster system. These
instructions also contain the necessary information
required for; calculating restrictor line length, required
regulator operating pressures and start-up procedures. It
is recommended that before proceeding with these
instructions you ensure that each of the following items
have been properly installed. Items listed in suggested
order of installation:
•
Three (3) Return bends
•
Eight (8) Elbows
•
29 Unions
•
Five (5) Tail pieces
•
Five (5) Beer nuts
•
One (1) 60 ft of PVC tape
•
One (1) 60 ft of foil
•
One (1) Spanner wrench
1. Glycol Chiller Unit
2. Dispensing Towers
3. Secondary Regulator Kits
4. Beer Conduit
5. High Pressure CO2 Regulator Kit
6. Blender Kit or Beer Pumps
7. Air Compressor Kit (optional)
8. Low CO2 Alarm Kit
Once the above items have been installed, the following
instructions can be completed.
10 and 14 line conduit kits
•
Four (4) Return bends
•
15 Elbows
•
42 Unions
•
Eight (8) Tail pieces
•
Eight (8) Beer nuts
•
One (1) 60 ft of PVC tape
•
One (1) 60 ft of foil
•
One (1) Spanner wrench
NOTE: Your system may not include each item.
2-12
Part Number 000003913 7/08
Section 2
Installation
Single Faucet
Beer Tower
MC045541
(4 line beer conduit [2 beer, 2 Glycol lines])
To Beer Keg
* Depending on line run
Walk-in Cooler
Single Conduit, Two Beer System
Two Faucet
Beer Tower
MC073341 (2 beer, 2 Glycol lines)
To Beer Keg
Two Faucet
Beer Tower
Walk-in Cooler
(shown with optional pump)
MC073341 (2 beer, 2 Glycol lines)
To Beer Keg
* Depending on line run
Walk-in Cooler
Dual Conduit, Eight Beer System
Four Faucet Beer Tower
MC103310 (4 beer and Glycol lines)
To Beer Keg
MC103310
(8 beer and Glycol lines)
Walk-in Cooler
(shown with optional pump)
* Depending on line run
Single Conduit, Eight Beer System
Part Number 000003913 7/08
2-13
Installation
Section 2
INSTALLING THE CONDUIT KIT
Connections Preview
Review the three previous illustrations to determine
which best illustrates your particular installation.
Consider the following while examining the drawings:
Beer conduits have been designed to achieve the proper
cooling of each encased beer line. In order to function
properly, you must follow these guidelines:
Up to eight line conduit:
• six beer maximum, one glycol circuit (two lines)
Ten and over line conduit:
• two glycol circuits (four lines)
To ensure colder dispensing temperatures, glycol should
flow directly to the dispensing towers before returning to
the remote Glycol Chiller Unit. After examining the
drawings determine the desired glycol circuit to be
achieved and illustrate on paper for referral. Do the
same for the assignment of the beer supply lines.
Connecting the Glycol Chiller to the Walk-in Cooler
or Main Beer Conduit
1. Route the glycol conduit(s) from the Beermaster
Glycol Chiller to the point of connection on the main
beverage conduit(s). This connection could be done
in the walk-in cooler or at any desired location along
the length of the main beer conduits.
2. Identify the proper glycol lines within the glycol
conduit(s) at the Beermaster Glycol Chiller, cut to
length and insert into the appropriate John Guest
bulkhead fitting(s) found on the side panel of the
Beermaster Glycol Chiller as shown below.
Connecting Main Beer Conduit at Walk-in Cooler
1. At the top of each beer wall bracket fitting, found on
the dual secondary regulator, secure a Beer Nut,
John Guest adapting tail piece, washer, and 1/2"
John Guest union (see the following image).
2. Identify the appropriate beer lines to be connected
to each of the wall bracket fittings, cut to length and
insert into the proper John Guest 1/2" connector as
shown below.
Beer Line to
Tower
John Guest
Adapter Tail
Piece
Washer
1/2" John
Guest Union
Wall
Bracket
Fitting
Beer Nut
To Beer Keg
Connecting Beer Conduit to the Tower
Glycol lines in
1. Peel the insulation back from the end of the beer
conduit to expose all lines. Locate the appropriate
glycol circuit lines, cut to length and attach a 1/2"
John Guest union to each line (see the “Tower
Connections” image).
2. Attach the opposite end of each 1/2" John Guest
union to the 1/2" adapter located at the base of the
dispensing tower.
John Guest
Bulkhead Fitting
Glycol Lines
3. At the walk-in end of the conduit(s), peel back the
insulation from the beer conduit and identify the
appropriate glycol circuit and lines to be connected
(blue and red). Cut glycol lines and secure to the
appropriate elbow or union connections that are best
suited for connection with the beer conduit.
2-14
Part Number 000003913 7/08
Section 2
Installation
Dispenser Tower
Glycol
Manifold
Dispenser Tower
See
“Calculating
Restriction”
for Length
Dispenser Tower
Adapter
1/2" John
Guest Union
Restrictor
Lines
Beer
Line
Glycol
Line
3/16" Barb
x 1/2" John
Guest
Adapter
1/2" John
Guest Union
Adjustable
Clamp
Beer
Conduit
Tower Connections
NOTE: If conduit contains more than one glycol circuit it
will be necessary to attach U-bends for each of the
additional circuits. Use a 1/2" U-bend quick connect
fitting or the U-bend can be built by attaching two (2) 1/2"
John Guest elbows to one another by means of a 2"
length of 1/2" tubing.
BEER RESTRICTOR LINES
1. Refer to the section on “Balancing the System” in
this manual for determining the required length of
restrictor line. Calculate the required length for each
faucet. Cut each restrictor line to the calculated
length and carefully insert the 3/16" Barb x 1/2" John
Guest adapter and clamp securely with the
adjustable clamps provided (see the “Tower
Connections” figure).
2. Identify the beer line to be connected to each of the
appropriate restrictor line, cut the beer lines to
length and attach a 1/2" John Guest Union to each.
Neatly wrap the excess restrictor line securely
around the glycol supply lines to ensure good heat
exchange. Connect the adapter from each restrictor
to the 1/2" connector of each of the appropriate beer
lines.
Part Number 000003913 7/08
Connecting Main Beer Conduit to Branch Beer
Conduit
1. At the required point of connection carefully split
open and fold back the insulation on the main beer
conduit and identify the correct set of glycol lines
(circuit) to connect to the branch beer conduit. Cut
the glycol line(s) and attach the appropriate 1/2"
elbow or union connections that are best suited to
connecting with the main beer conduit (see the
“Main Beer Conduit Connections” figure).
2. Peel the insulation back from the end of the branch
beer conduit to expose all lines. Locate the glycol
circuit lines, cut to length and insert each line into
the open end of the previously attached 1/2"
connectors at the main beer conduit (see the “Main
Beer Conduit Connections” figure).
3. Locate the appropriate beer line(s) in the main beer
conduit to be connected to the branch conduit. Cut
desired beer line(s) long so that they can be pulled
back and then routed in a smooth curve into the
branch conduit. Attach appropriate beer line(s) from
main beer conduit to beer line(s) in branch beer
conduit with 1/2" John Guest Union(s).
2-15
Installation
Section 2
STARTING UP THE SYSTEM
! Caution
To avoid agitation use only straight unions when
splicing beer lines.
Before Starting Up the System
Each of the steps below should be done 24 hours prior
to the tapping or dispensing of any beer.
1. Place all kegs in a walk-in cooler at 36°F to 38°F
and allow them to temper properly.
1/2" John
Guest Union
Branch Beer
Conduit
1/2" John
Guest Elbow
2. Turn ON the Beermaster Glycol Chiller circulating
glycol pump(s).
3. After leak testing all glycol and beer supply lines,
wrap the lines firmly with foil (to ensure a good heat
exchange) and then insulate all lines; to ensure a
minimum of 1" insulation over all areas of exposed
beverage line.
4. After glycol has circulated through system for
approximately one hour, remove the strainer from
the glycol bath. Flush the strainers clean with fresh
water and reinstall.
Main Beer
Conduit
Main Beer Conduit Connections
Balancing the System
DETERMINING RESTRICTOR LINE LENGTH AND
APPLIED KEG PRESSURE
In order to ensure a proper, foam-free, beer flow from
each faucet, the following instructions and calculations
must be completed. Use the formulas found in this
section to determine the required restrictor line length
and applied keg pressure needed for each beer line. In
order to complete these calculations the following
information will be needed:
•
Brands of beer to be dispensed.
•
Temperature of the Walk-in Cooler (default 38°F
[3.3°C]).
•
Altitude (distance above sea level).
•
Total line length for each beer line.
•
Overall lift or drop for each beer line.
To determine the appropriate Applied Keg pressures
and Restrictor Line Lengths see attached work
sheets.
Pressure Setting and Start-up
1. Adjust the primary CO2 regulator to 40 PSI and
secure the lock nut.
2. If a blender is utilized proceed with adjustments
provided with blender kit.
3. Adjust the secondary regulators. It is recommended
that when applied keg pressures exceed 20 PSI the
secondary regulators be adjusted 2 PSI below the
calculated pressure. If more pressure is required
after tapping keg, increase as needed.
4. Tap the kegs and proceed to draw beer from each
valve one at a time. Ensure each brand is properly
drawing before proceeding to the next. The proper
flow rate for beer at each valve is 2 ounces per
second. Beer should be flowing clear with a full flow
from the dispensing faucet (a considerable amount
of dispensing may be needed).
5. Secure all secondary regulator lock nuts and
complete the information label, identifying the
product and its applied keg pressure for each
appropriate regulator.
6. Instruct operator on proper maintenance and
operating requirements.
1. First determine which brands of beer will be
dispensed at which faucet. Use one work sheet to
record data for each faucet.
2. Determine keg temperature at cooler.
3. Determine the type of push for the beer to determine
which work sheet to use to calculate flow of beer.
4. Follow the instructions for that particular work sheet.
2-16
Part Number 000003913 7/08
Section 2
Installation
Beermaster Wine Dispensing Kit
location of wine tank, 3/8" x 1/4" FF John Guest
connector, and liquid disconnect.
INTRODUCTION
4. Connect nitrogen regulator to nitrogen tank and
connect gas line to regulator outlet.
To dispense chilled wine through the Beermaster™
system, the following components are required:
5. Connect empty wine tank and turn on nitrogen tank.
Adjust to 30 PSI and pressurize system to check for
leaks.
•
Wine Dispensing Kit (P.N. 00211504)
•
Nitrogen Regulator (P.N. 00219381)
•
Wine Tank, Stainless Steel with general disconnects
6. Turn OFF nitrogen and depressurize system.
Determine system pressure resistance and reset
regulator for desired flow.
INSTALLING
Single Faucet
Multiple Faucets from Same Tank
1. Select faucet on beer tower for wine and remove
metal beer faucet. Replace metal beer faucet with
plastic wine faucet.
2. Locate product line connected to this faucet at walkin cooler. If connected to beer wall bracket,
disconnect and remove beer nut, tail piece, and
John Guest tube connector.
3. Assemble 1/2" x 3/8" John Guest tube connector,
appropriate length of 3/8" O.D. poly, to reach
In addition to component required for single faucet
installation, each additional faucet requires:
•
Faucet (P.N. 00211885)
•
Tee (P.N. 00210862)
1. Install faucets at desired locations.
2. Install tees at appropriate places in 1/2" O.D. poly
wine line.
Wine Dispensing Setup
Part Number 000003913 7/08
2-17
Installation
POSITIONING OF REFRIGERATION UNIT
Before proceeding with installation, verify that all
requirements for roof mounted Remote Condenser Units
have been satisfied (if applicable). Refer to the
instructions on installing the Remote Condenser
supplied with the unit.
If unit is to rest on floor, locate four 6" (15.2 cm)
adjustable legs (optional). Screw and tighten legs into
the bottom of the refrigeration unit. Set unit in desired
location and adjust legs until unit is level and sturdy. If
unit is to be mounted on stand, position stand and
secure unit to stand. If unit is to be installed on a wall
mount bracket, install wall mount bracket and position
unit on bracket at this time. Fasten unit to bracket with
bolts provided.
EQUIPMENT PLACEMENT
NOTE: All Refrigeration Units must be mounted on
either 6" legs or optional stand.
1. Move the stand/refrigeration unit to the designated
area and position it near the wall at a distance of at
least 6" (15.2 cm) for air circulation in air-cooled
units, or at a distance required by local code.
2. Level the stand/unit by adjusting the leg levelers
provide on the legs or stand.
3. If unit is equipped with optional stand, lift the
Refrigeration Unit onto the stand. Position the unit in
the center of the stand. Be sure to orientate the drain
2-18
Section 2
of the refrigeration unit with the drain access hole of
the stand. Secure with 5/8"-11 x 1" bolts supplied in
kit, use two (2) bolts diagonally. Schedule the
electrician to connect the electrical service if you
have not already done so (refer to Electrical
Requirements for requirements listed in these
instructions).
4. Mount any optional equipment at this time. Follow
the installation instructions for each kit required.
ELECTRICAL CONNECTIONS
! Caution
Make sure power supply to unit is turned off.
NOTE: The electrician must refer to the nameplate and
wiring schematic on the refrigeration unit for correct
electrical requirements. All wiring must comply with all
safety codes. Make sure all refrigeration unit power
switches are in the OFF position.
1. Remove junction box cover.
2. Route and connect power supply to leads in the
electrical junction box at the top rear of the motor
compartment.
NOTE: Be sure to connect ground wire(s) to ground
screw located on back panel of junction box.
3. Replace junction box cover.
Part Number 000003913 7/08
Section 2
Installation
INSULATING CONNECTIONS
1. Make sure all exposed lines are well insulated on
towers to conduit, conduit junctions, refrigeration
unit to conduits.
2. To insulate the above, use the leftover conduit
sections and tape.
3. Cut the conduit sections to fit snugly over the
exposed lines and fittings. A little extra time spent
doing a thorough job initially will eliminate a call back
in several days to make corrections.
NOTE: Do not inject foam material directly on the
connections where the tubing connects to the barb
fittings or directly on poly tubing.
4. Use proper wrenches to tighten an additional 1/4
turn (90°). This final 1/4 turn is necessary to ensure
the formation of a leak proof joint. Alternately, use a
torque wrench to tighten the 1/2" coupling to
40 ft-lbs and 3/8" fitting to 11 ft-lbs.
5. Leak check all your connections. If you detect any
leaks, repair and recheck.
Condenser and Pre-charged Lines
Installation
Before proceeding with installation, verify that all
requirements for roof mounted remote condenser units
(if applicable) have been satisfied. If unit has a remote
condenser, refer to the instructions on installing the
remote condenser supplied with the condensing unit and
refer to the section on installation of remote refrigeration
line sets.
Aerosol Foam
Chase
4. The can of foam is to be used to fill the openings
between the conduit insulation and the inside
diameter of the floor chases. The purpose is to
provide an air tight seal at the floor level to prevent
foreign matter from entering the chases. Please
read the foam manufacturer’s instructions carefully.
We recommend using the adapter with the right
angle extension.
5. Insert the adapter into the openings approximately
1" to 2" (2.5 to 5.1 cm) while depressing the adapter.
6. Move the extension around throughout the area
where the foam is to be placed. Do not over fill, allow
room for expansion. If the chase opening is too deep
insert a section of the leftover conduit insulation in
the opening prior to using the foam insulation.
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 ensure proper mating of threads.
3. Use proper wrenches (on coupling body hex and its
union nut) and tighten union nut until coupling
bodies “bottom”.
Part Number 000003913 7/08
NOTE: You must use a wrench on the body to keep the
body from turning while tightening the nut with the
second wrench. If the body turns excessively, the
piercing seal will be damaged.
Important
If you are installing a remote unit, there is a
refrigeration king valve located behind the
compressor. This valve must be back seated prior to
starting the compressor. Failure to do so will short
cycle and may damage the compressor.
MULTIPLEX REMOTE CONDENSER
PRE-INSTALLATION REQUIREMENTS
1. Installation and maintenance are to be performed
only by qualified refrigeration personnel. These
technicians must have EPA certification (USA), are
familiar with local codes and regulations, and are
experienced with this type of remote refrigeration
equipment.
2. As a condition of the warranty, the check, test and
start-up procedure must be performed by qualified
personnel. Because of possible shipping damage,
check both the condensing unit and refrigeration
unit(s) for refrigerant leaks.
3. If the refrigeration unit is located on a roll out
platform, you must coil up to one round between the
back of the stand and the wall. This allows pull out of
the refrigeration unit for servicing.
4. If the refrigeration unit is located in a stationary
location, you must remove excess refrigeration
tubing as described below.
2-19
Installation
Section 2
MULTIPLEX PRE-CHARGED REFRIGERATION
LINES PRE-INSTALLATION REQUIREMENTS
1. Both the discharge and liquid remote condensing
lines must be kept to a minimum distance for
maximum performance. All Multiplex systems are
capacity rated to 100 ft (30.5 m) tubing distance
between the compressor and condenser.
2. Any vertical rise 25 ft (7.62 m) or greater must have
a manufactured or installed trap (bend), in the
discharge refrigeration line from the compressor to
the remote condenser. A trap is necessary for every
additional 25 ft (7.62 m) vertical rise. When
excessive vertical rise exists, this trap allows oil to
reach the condenser and return to the compressor.
1. Determine a position for installation that will allow
access for maintenance and is free from obstruction.
Verify hot air discharge from other condensers does
not interfere with the inlet of this condenser.
2. Install the four legs to the sides of the condenser
using the mounting bolts provided.
3. The General Contractor or Owner must secure two
treated lumber 4" x 4" x 36" (or longer). You may
then mount the remote condenser to the treated
lumber.
4. The General Contractor or Owner must install a 3"
pitch pot in the roof. Then seal for weather
protection.
3. The easiest method to create a trap is to bend the
tubing (smoothly, no kinks) into the trap form.
Discharge Line
Condenser Trap
3" Pitch Pot
To the
Condenser
3" (7.6 cm) x 6" (15.2 cm)
Maximum Trap Area
Discharge Line Trap Every
25 Vertical ft. (7.62 m)
Roof
Compressor
3 ft (.9 m) (minimum) of Discharge
Line Trap at the Compressor
4. The trap(s) must be of minimum height of 3"
(7.6 cm) and a width of 6" (15.2 cm) to minimize oil
accumulation. The traps can also be bent out of the
refrigeration tubing. Carefully bend the tubing down
12", and then sweep the tubing back up.
5. It is critical that the Multiplex remote condensing line
size specifications for the specific model be
maintained. The specifications are 1/2" discharge
and 3/8" liquid lines.
INSTALLING THE MULTIPLEX REMOTE
CONDENSER
The Multiplex remote condensing units have a 208-230
Volt, 50/60 HZ, 1 PH fan motor that includes a
permanent split capacitor and internal overload
protection. The electrical wires from the refrigeration unit
wire to the condenser. The electrical installation must be
in accordance with local codes, National Electrical Code
and regulations.
2-20
5. Locate the pre-charged refrigeration lines shipped
with the system. These lines must be a correct
length for the building design. Avoiding any kinks,
neatly route these lines from the remote condenser
to the refrigeration unit. Excess refrigeration tubing
must be handled in one of two ways. When coiling
the excess tubing, make sure the inlet to the coil is
at the top of the coil and the exit is the bottom of the
coil. There can be no more than one turn to the coil.
If you have more tubing, you must cut out the
excess before connecting the ends. When cutting
the tubing, you must first evacuate the refrigerant
(line sets have a positive refrigerant holding charge
of two to three ounces). After shortening and
welding the tubing together again, you must
evacuate the tubing to 250 microns. Then recharge
the tubing with 4 ounces of appropriate refrigerant.
Part Number 000003913 7/08
Section 2
Installation
! Caution
Excess refrigeration tubing must be properly cared
for before being connected to either the remote
condenser or the refrigeration unit.
CONNECTING THE PRE-CHARGED
REFRIGERATION LINES
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
installed drain pipe.
1. Attach low side gauge set to service port on each
line set to verify positive pressure within the line set.
NOTE: If for any reason the lines are damaged and/or
leaking or the lines no longer charged, refer to “How To
Re-charge the Line Sets”. If the line set is too long for
the application, refer to “How to Shorten the Line Sets” in
Section 3.
2. Always make the connections at the condenser first,
using the end of the pre-charged lines with the valve
ports.
3. Connect the condenser side with the quick
connectors (discharge and liquid) up to condenser.
Refer to the section titled “Aeroquip Connection” in
these instructions.
4. Connect the refrigeration unit side with the quick
connects (discharge and liquid). Make sure to
provide a discharge trap at back of refrigeration unit,
or bend discharge line down 12" and then up
smoothly (no kinks) to provide a trap.
5. If a low refrigerant charge is detected, recover and
recharge the system adding the unit name plate
charge.
6. Repair any damages to the line sets before
proceeding.
Part Number 000003913 7/08
2-21
Installation
Section 2
Preparing Glycol
MIXING GLYCOL SOLUTION
1. Inspect the glycol reservoir tank for dirt and/or
foreign debris. The tank must be clean before mixing
glycol solution.
2. Locate the glycol kit:
! Caution
Glycol water ratio should be maintained at a 3 to 1
ratio (17-22 Refractometer). Additional water will be
required after starting pumps and solution fills
circulation system.
Model 75 . . . . . . . . . . . . . . 4 Gallons (19 ltr) Glycol
Model 150 . . . . . . . . . . . . . 5 Gallons (19 ltr) Glycol
Model 300 . . . . . . . . . . . . 15 Gallons (57 ltr) Glycol
Glycol Bath
Tank
Overflow
Tube
Model 450 . . . . . . . . . . . . 20 Gallons (75 ltr) Glycol
3. Pour the glycol into the reservoir tank.
! Caution
Do not turn on the circulating pump(s) until system
installation is complete.
4. Add water until level of glycol/water solution reaches
the “Fill Here” mark located on tank wall.
NOTE: The glycol/water solution in the water bath is now
mixed to the proper ratio.
5. Push the switches marked “Compressor” and
“Agitator” if equipped to the ON position. After
compressor cycles OFF, check to ensure glycol
solution reads 27°F (-2.7°C) to 29°F (-1.6°C).
2-22
Tab
Clamp
Drain Plug
NOTE: Verify that the pump box holding tank is full
before proceeding.
6. Turn on the circulator. The circulator must run
continuously. Verify that glycol is returning to the
glycol bath through the return bulk head fitting.
Part Number 000003913 7/08
Section 2
Installation
Additional Glycol Circulating Pump and
Motor Kit
INSTALLING THE GLYCOL CIRCULATING PUMP
AND MOTOR KIT
1. Remove the lid from the Beermaster refrigeration
unit.
2. Install the glycol circulating motor with pump to the
motor shelf located in the Beermaster Glycol Unit
motor compartment (see “Motor Installation” figure).
NOTE: Motor must be installed with the glycol pump
facing away from the glycol bath.
3. Locate the pickup tube and discharge tube
assemblies. Slide one piece of insulation over each
of the tube assemblies (see “Tube Installation”
figure).
Pump and Motor Kit
Carriage Bolts
(Later Units)
5/16" - 18 Hex Nut
Mounting Studs
(Early Units)
Motor Installation
NOTE: Only two fasteners required.
End Panel
1/2" O.D. x 1/2" O.D.
John Guest Elbow
4. Attach the pickup tube to the inlet side of the glycol
pump making sure the opposite end from the pump
is submerged in glycol bath.
5. Attach the discharge tube to the outlet side of the
glycol pump.
6. Slide the 1/2" x 1/2" John Guest Elbow, supplied in
kit, onto the end of the discharge tube at pump
motor assembly.
7. Locate the circulator pump discharge cooling tube,
supplied with kit, and insert into the water bath area.
Insert straight end of tube into the John Guest elbow
fitting as shown.
8. Insert the two 1/2" O.D. John Guest bulkhead
unions, supplied in kit, into the pre-punched holes
located in the end of the refrigeration unit.
9. Locate the two 1/2" O.D. tube retaining collets,
provided in kit, and insert into each of the John
Guest bulkhead unions.
10. Insert the free end (bent end) of the circulator pump
coil tube into the lower John Guest bulkhead union.
1/2" O.D. Red
Connecting Tube
NOTE: Do Not discard the condensation cover over the
reservoir tank. It is necessary to prevent excessive
condensation from diluting the water-glycol mixture.
Circulating Pump
Discharge Cooling Coil
11. Locate the 1/2" O.D. x 4" or 8" plastic tube, provided
with kit. Insert one end of this tube into the upper
bulkhead fitting. Insert opposite end of this tube into
hole of strainer plate (see “Pump Connections”
figure).
Tube Installation
Part Number 000003913 7/08
2-23
Installation
Section 2
Strainer Plate
1/2" x 1/2" John
Guest Elbow
1/2" O.D. John
Guest Bulkhead
1/2" O.D. x 8"
Plastic Tube
2 ft x 1/2" I.D.
Insulation
1/2" O.D. Tube
Retaining Collet
Circulator Pump
Discharge Cooling
Tube
Pickup Tube
Pump Connections
12. Locate the 8 ft piece of cork tape, provided with kit,
and insulate the glycol pump and all exposed
connections to prevent condensation.
13. Remove and discard safety plug from connector of
wire harness coming from control box. Attach
connector of glycol pump motor to connector of wire
harness coming from control box.
14. Installation of glycol circuit pump is now complete.
The Beermaster refrigeration unit can now be turned
ON.
15. The added glycol circulating pump can now be
controlled by a switch located on the switch box.
-
For Model 450, the CIRC #4 switch will control
added pump.
NOTE: After starting the new circulator pump, it may be
necessary to top off the glycol bath with the proper
propylene glycol/water mixture to maintain marked level
in tank.
2-24
Part Number 000003913 7/08
Section 2
Installation
Beermaster Dispensing Towers
NOTE: If more than one tower is being installed, use
only the tower intended for each location to mark the
mounting screw positions.
INTRODUCTION
The following instructions will cover installation
procedures required for properly installing Beermaster
Dispensing Towers. Kit includes one (1) Template, (1)
Beermaster Dispensing Tower, (4) Mounting Screws (for
Wooden Counter Top), (1) Gasket, (2) 3/8" MF x 1/2"
John Guest Adapters, (1) 3/16" Barb x 1/2" John Guest
Adapter, and (1) Adjustable Clamp.
1. Determine desired location of beer tower.
2. Using the template provided, locate and mark the
center of the tower column.
3. Cut a 3" (7.6 cm) hole and place the tower over the
hole to locate and mark the mounting screw
positions.
5. Position gasket over top of 3" (7.6 cm) access hole
and align holes for mounting screws. It is
recommended that a small bead of silicon caulking
be placed on both sides of the gasket at this point.
6. Route beer tower beverage lines through 3" (7.6 cm)
hole and secure dispensing tower base to counter
with mounting hardware.
7. Ensure lines are neatly sealed and wrapped until the
necessary beer and glycol connections can be
made, as outlined in the Conduit Kit Installation Kit
section.
! Caution
4. Drill appropriate holes for mounting (1/8" diameter
when using screws provided, if mounting in wood).
The 6 ft beer restrictor lines for beer tower should
not be trimmed until completely reviewing the
instructions for conduit kits.
DISPENSING TOWER TEMPLATE FOR BEERMASTER DISPENSING TOWER
3"
(7.6 cm)
Cut Out
3" (7.6 cm)
Diameter
Part Number 000003913 7/08
2-25
Installation
Section 2
Beermaster High Pressure CO2 Regulator
(00211500)
Cable Tie
Tie Mount
INTRODUCTION
#8 Screw
The following instructions will cover procedures required
for properly installing the Beermaster high pressure CO2
regulator.
KIT CONTENTS
•
(1) Beermaster High Pressure CO2 Gas Regulator
with seal
•
20 ft of 5/16" I.D. tubing
•
(6) # 8 screws
•
(6) tie mounts
•
(6) self locking cable ties
•
(4) tab clamps
Securing Vinyl Tubing
Beermaster Dual Secondary Regulator Kit
(00211400)
INTRODUCTION
Installation should only be performed by qualified
personnel.
INSTALLING
1. Determine the location where the beer system CO2
tank(s) will be located. CO2 tanks must be chained
securely in place.
2. Attach the primary regulator to the CO2 tank. Use
seal provided in kit (see the “Attaching Regulator”
figure).
3. Neatly route the 5/16" I.D. vinyl tubing from the
primary regulator(s) to the secondary regulator in
the beer keg cooler or to the optional blender.
4. Secure the vinyl tubing in place with tie mounts and
cable ties provided in kit (see the “Securing Vinyl
Tubing” figure).
NOTE: At start-up the primary regulator should be
adjusted to 40 PSI (2.8 bar) and locked.
The following instructions cover the installation of a
Multiplex secondary regulator panel kit. Each dual
secondary regulator kit will handle two beer kegs.
Additional dual secondary regulator kits can be placed in
series to handle additional beer kegs.
KIT CONTENTS
•
(1) dual secondary regulator assembly with wall
bracket
•
CO2 gas lines
•
Beer lines
•
12 ft - 5/16" I.D. black vinyl tubing
•
(10) boss coupling washers
•
(8) tab clamps
•
(1) 1-1/4" MPT pipe plug
•
6 ft - 3/8" I.D. clear vinyl line assembly
INSTALLING
Refer to the “Secondary Regulator Installation” figure for
the following procedures:
Primary High
Pressure CO2
Regulator
Seal
1. Mount the dual secondary regulator panel in a
convenient location above the area where beer kegs
will be stored.
2. Route the CO2 gas line from the primary high
pressure regulator (or gas blender) and attach to the
5/16" Barb fitting of the secondary regulator. Use
two tab clamps.
To CO2 Blender or
Secondary Regulator
Assembly
Attaching Regulator
2-26
Part Number 000003913 7/08
Section 2
Installation
Lock Bar
Tab
Clamps
Black Vinyl (Attach
to Next Regulator
Assembly)
Black Vinyl
Tubing from
Primary
Regulator or
Gas Blender
4 ft Clear Vinyl
Beer Line
Boss Coupling
Washer
Plug
Tab Clamp
Tavern Head
VIEW
A
5/16" Barb x 1/4" MPT
Beer Keg
Secondary Regulator Installation
3. Cut the black vinyl CO2 gas line looped between the
two regulators. Attach each CO2 gas line to the
5/16" inlet of the tavern head (not provided). Use
one tab clamp per connection.
4. Attach each of the clear vinyl beer lines to the beer
outlet of the tavern head. Use one boss coupling
washer, 3/8" nipple and hex nut (provided in kit) at
each connection.
5. Additional dual secondary regulator kits can be
placed in series from the first regulator panel. To
plug the last regulator in a series of regulators,
remove the Barb fitting from the regulator outlet and
install the 1/4" MPT plug, provided in kit (see the
“Secondary Regulator Installation” figure, View A).
NOTE: Do not adjust pressure regulators at this point.
See “Conduit Kit” section for regulator adjustments.
Part Number 000003913 7/08
2-27
Installation
Section 2
Beermaster Blenders
N2/CO2 BLENDER (SINGLE — 00520182, DUAL — 00520183)
Installing
1. Decide where the N2/CO2 Blender Kit will be
mounted.
NOTE: Be sure the panel is on a wall in a well ventilated,
accessible indoor area that is out of harm’s way.
2. Mount the panel on the wall.
4. Test all fittings for leaks.
5. Use regulators and tubing suitable for 70 – 150 PSI.
NOTE: Regulators set at 50 PSI are suitable on a 50 PSI
blender.
6. Secure all cylinders to the wall.
3. Hook-up panel using thread sealant on threads and
a back-up wrench on panel fittings.
NOTE: Store cylinders in a well ventilated, accessible
area.
NOTE: Do not use fittings with check valve on inlets. Do
not remove 1/4" female threaded fittings from panel, as
they contain filters.
Outlet for Mixed Gas
(most beers)
Secondary
Regulators
Use reinforced
tubing suitable
for 70-150 PSI
Primary N2
Regulator
N2 Tank
2-28
Outlet for Mixed Gas
(Guiness)
Use reinforced
tubing suitable
for 70-150 PSI
Secondary
Regulators
Primary CO2
Regulator
CO2 Tank
Part Number 000003913 7/08
Section 2
Installation
Installation Checklist
Check all fittings and conduit attachments for
leaks. Check all insulated connections to make
sure that they are sealed.
Observe the pump operations for leaks.
Check the glycol bath for full ice bank.
The stabilized water bath operating temperature
must be maintained at 33°F (.6°C) to 35°F
(1.7°C).
Close glycol bath feeder valve completely.
Part Number 000003913 7/08
2-29
Installation
Section 2
THIS PAGE INTENTIONALLY LEFT BLANK
2-30
Part Number 000003913 7/08
Section 3
Operation
Typical System
Tower
Tower
Regulators
Cooler
Conduit
Blender
CO2
Alarm
N2 Tank
Kegs
CO2 Tank
Refrigeration Unit
These refrigeration units are remote refrigeration units
that derive their peak capacity from the water/glycol
bath. These systems are controlled to cycle ON and
OFF depending on the temperature of the glycol bath.
The sensing bulb that controls the bath temperature is
located on an adjustable bracket in the glycol bath.
Part Number 000003913 7/08
3-1
Operation
Section 3
How the Multiplex Works
The refrigeration units are remote refrigeration units that
derive their peak capacity from the water/glycol bath. A
tower is used to dispense the beer at the desired
location. Conduit (an insulated bundle of tubing)
connects the refrigeration unit and kegs of beer to the
tower. The conduit has the beer and glycol lines
wrapped together and the glycol is circulated to keep the
beer in the conduit lines cold. The refrigeration system is
controlled by a sensing bulb located on an adjustable
bracket in the glycol bath. Depending on the setpoint of
the temperature control, the refrigeration system cycles
ON and OFF as the temperature of the glycol bath
changes.
Start-up
PLACING EQUIPMENT IN OPERATION
Before placing equipment in operation, verify that all
requirements for roof mounted Remote Condenser Units
(if applicable) have been satisfied. Refer to the
instructions on installing the Remote Condenser.
1. Fill the refrigeration unit bath tank with (3:1) water/
glycol mix to within 1/2" (1.27 cm) of the top of the
overflow tube.
2. Turn on the rocker switch labeled “Refrigeration” to
begin cooling the glycol and energize the agitator
motor in the glycol bath.
3. The water/glycol bath will reach it’s operating
temperature within 2 to 4 hours.
4. If optional CO2/N2 Control Panel has been installed,
refer to the installation instructions for operation and
testing the circuits for leaks.
5. All circuits must be checked for leaks and possible
cross circuits before turning ON.
6. Turn on the rocker switches for the circulating
pumps.
7. Add glycol/water mix as needed to maintaincorrect
bath level.
3-2
Part Number 000003913 7/08
Section 3
Operation
Tower
Tower
Regulators
Cooler
Conduit
Blender
CO2
Alarm
N2 Tank
Kegs
CO2 Tank
Refrigeration Unit
Multiplex Beermaster System Operation and Layout
Equipment Setup and Close Procedure
EQUIPMENT SETUP PROCEDURE
1. Ensure that all valve nozzles are attached to the
valves.
2. Observe pressure of CO2 high pressure tank of
500 PSI (34 bar) or more, or bulk CO2 tank of
150 PSI or more. Primary regulator set at 90 PSI
(6 bar) and the secondary regulator set at 35-40 PSI
(2.4-2.6 bar) depending on the type of beer.
5. Clean beer inlet and outlet quick disconnects at the
same time tanks are replaced. Rinse disconnects in
clean potable water.
EQUIPMENT CLOSE PROCEDURE
1. Clean the underside of the dispensing tower around
the nozzle area with a clean damp towel.
2. Pour at least 60 oz (1.8 liters) of warm water down
the drain openings.
3. Observe the control panel to verify that all pressure
gauges are set at correct operating pressures.
4. Check the kegs to make sure a sufficient number of
kegs are connected in series to satisfy business
volume.
Part Number 000003913 7/08
3-3
Operation
Section 3
System Calculators
BEER PUMP, SYSTEM PRESSURE AND CHOKER CALCULATOR
Section A:
Product you are dispensing
Natural Keg Pressure for this product at this temperature (see chart below)
Add 1 # If your altitude is above 2,000 feet (per 2000 feet or portion thereof)
Section B:
Line run length
PLUS Rise from bottom of keg to outlet
of faucet
MINUS Fall from bottom of keg to outlet
of faucet
PLUS choker
Plus resistance if using Kyees tower
If using Kyees Chill Pak
If using bent tube assembly in tower
Product
Anheuser-Busch
Coors
Miller
Schlitz / Stroh’s
3-4
°
Cooler
Temperature
A=
B=
Total push gas pressure to keg C=
Add A + B
Feet
Feet
X 0.07 # per foot
X 0.5 # per foot
D=
E=
Feet
X 0.5 # per foot
F=
Trunk Line
Length
Up to 100 feet
100 to 125 feet
125 to 150 feet
150 to 175 feet
175 to 200 feet
3/16” Choker
Tube Length
13 feet
12 feet
11 feet
10.5 feet
10 feet
Over 200 feet contact factory
ADD
+ 4.8
ADD
+4.0
ADD
+3.0
# Resistance
(G)
39 lbs.
36 lbs.
33 lbs.
31.5 lbs.
30 lbs.
G=
H=
I=
J=
Total initial resistance K=
Add D +E – F + G +H + I + J
Set the Beer Pump pressure regulator at (K)
A = Natural Keg Pressure at Sea Level (PSI)
Cooler Temperature
32°
34°
26°
9
10
11
13
14
15
10.5
11.5
12.5
10
11
12
38°
12
16
13.5
13
40°
13
17
14.5
14
Part Number 000003913 7/08
Section 3
Operation
BLENDED GAS BEER SYSTEM PRESSURE AND CHOKER CALCULATOR
Line run length
PLUS Rise from bottom of keg to outlet of
faucet
MINUS Fall from bottom of keg to outlet
of faucet
PLUS minimum 24" choker
If using Kyees tower
If using Kyees Chill Pak
If using bent tube assembly in tower
Feet
Feet
X 0.07 # per foot
X 0.5 # per foot
+
Feet
X 0.5 # per foot
–
+ 6.0
ADD
+ 4.8
ADD
+ 4.0
ADD
+ 3.0
Total initial resistance
=
If total initial resistance is 20 # or greater *, you have the Applied Keg Pressure and length of choker tube. If initial resistance is
less than 20 #, add additional choker as below.
Minimum Pressure *
Minus Total initial resistance as calculated above
–
Equals initial additional resistance to add
=
Times 4
X4
Equals initial number of inches choker tube to add
=
Round up the number of initial inches choker tube to add to the
next 1" segment
Plus minimum choker length
+ 24”
Total amount of choker hose to use in the run with 20 # Applied =
Keg Pressure
* If your altitude is above 2,000 feet, add 1 # per 2000 feet or portion thereof to the minimum pressure stated above.
Part Number 000003913 7/08
3-5
Operation
Section 3
PURE CO2 BEER SYSTEM PRESSURE AND CHOKER CALCULATOR
Section A:
Product you are dispensing
Natural Keg Pressure for this product at this temperature (see chart below)
Add 1 # If your altitude is above 2,000 feet (per 2000 feet or portion thereof)
Total Gas Push Pressure
USE THIS AS YOUR KEG PRESSURE
Add A + B
Section B:
Line run length
Feet
X 0.07 # per foot
PLUS Rise from bottom of keg to outlet of
Feet
X 0.5 # per foot
faucet
MINUS Fall from bottom of keg to outlet
Feet
X 0.5 # per foot
of faucet
PLUS minimum 24" choker
Feet
X 3.0 # per foot
Plus resistance if using Kyees tower
ADD
+ 4.8
If using Kyees Chill Pak
ADD
+4.0
If using bent tube assembly in tower
ADD
+3.0
Total initial resistance
Add D + E - F + G + H + I + J
Ideal Resistance (C)
Minus Total initial resistance as calculated above (K)
Equals initial additional resistance to add
Take value of (N) Times 4
Round up (O) to the next foot (i.e. 15 inches, round up to two feet)
Add the original 2 feet choker
Add P + Q
This is the total amount of choker to use
Cooler
Anheuser Busch
Adolph Coors
Miller
Schlitz / Stroh’s
3-6
°
Cooler
Temperature
Natural Keg Pressure at Sea Level (PSI)
Temperature
32°
34°
36°
9
10
11
13
14
15
10.5
11.5
12.5
10
11
12
38°
12
16
13.5
13
A=
B=
C=
D=
E=
F=
G=
H=
I=
J=
K=
L=
M=
N=
O=
P=
Q=
R=
2 Feet
Feet
40°
13
17
14.5
14
Part Number 000003913 7/08
Section 4
Maintenance
Major Components
GAS BLENDER
DISPENSING STATIONS
Every 4 Months (3 Times per Year)
Daily (365 Times per Year)
•
•
•
Take temperature of beer. Pour off the first glass and
take the temperature of the second glass of beer.
The proper temperature of the dispensed beer is
36°F (2.2°C) to 40°F (4.4°C).
Flush all dispenser drains, pour hot water down
drains at closing.
CO2 GAS SUPPLY
Every 4 Months [3 Times per Year])
•
Inspect pressure setting at CO2 high pressure
regulator. Verify proper 40 PSI (2.8 bar) pressure
setting. Adjust if necessary.
•
Inspect all secondary beer regulators. Verify proper
pressure settings. Adjust if necessary.
•
Inspect system for CO2 leaks. Repair as required.
BEVERAGE CONDUITS
Every 4 Months (3 Times per Year)
•
Inspect floor chases and seal any open chase ends.
•
Inspect beverage conduits for damage. Re-insulate
and seal any un-insulated areas.
Inspect gas blender and verify CO2 and air flow
meters are set at the proper flow rate. Adjust if
necessary.
Scheduled Frequency
AIR COMPRESSOR
Daily (365 times per year)
Monthly (12 Times per Year)
•
Take temperature of beer. Pour off the first glass and
take the temperature of the second glass of beer.
The proper temperature of the dispensed beer is
36°F (2.2°C) to 40°F (4.4°C).
•
Flush all dispenser drains, pour hot water down
drains at closing.
•
Drain condensate water from air compressor tank
and filters.
Every 4 Months (3 Times per Year)
•
Inspect air compressor filter and replace if clogged.
Air filter must be replaced every six months.
•
Inspect air compressor to verify proper cut-in at
70 PSI (4.8 bar) and cut-out at 90 PSI (6.2 bar).
Adjust pressure switch if necessary.
•
Inspect secondary air pressure regulator setting to
blender, verify proper 40 PSI (2.8 bar) pressure
setting. Adjust if necessary.
•
Monthly (12 times per year)
•
Every 4 months (3 times per year)
•
Inspect floor chases and seal any open chase ends.
•
Inspect beverage conduits for damage. Re-insulate
and seal any un-insulated areas.
•
Inspect air compressor filter and replace if clogged.
Air filter must be replaced every six (6) months.
•
Inspect air compressor to verify proper cut-in at
70 PSI (4.8 bar) and cut-out at 90 PSI (6.2 bar).
Adjust pressure switch if necessary.
•
Inspect secondary air pressure regulator setting to
blender, verify proper 40 PSI (2.8 bar) pressure
setting. Adjust if necessary.
•
Inspect system for air leaks, repair as required.
•
Inspect gas blender and verify CO2 and air flow
meters are set at the proper flow rate. Adjust if
necessary.
Inspect system for air leaks, repair as required.
REFRIGERATION UNIT
Every 4 Months (3 Times per Year)
•
Clean the refrigeration unit air cooled condenser
using a vacuum cleaner.
•
Inspect glycol bath, verify level of glycol solution is to
fill mark. If below mark, add food grade glycol
solution to bring level back up to mark.
•
Clean out all glycol pump strainers.
•
Check the temperature difference between the
discharge and return glycol lines at the glycol bath. It
should be within 3°. Verify proper pump efficiency
and temperature control displays between 27°F
(-2.7°C) and 29°F (-1.6°C).
•
Inspect agitator motor and ensure proper operation.
Part Number 000003913 7/08
Drain condensate water from air compressor tank
and filters.
4-1
Maintenance
•
Inspect pressure setting at CO2 high pressure
regulator. Verify proper 40 PSI (2.8 bar) pressure
setting. Adjust if necessary.
•
Inspect all secondary beer regulators. Verify proper
pressure settings. Adjust if necessary.
•
Inspect system for CO2 leaks. Repair as required.
4-2
Section 4
Shipping, Storage and Relocation
! Caution
Before shipping, storing, or relocating this unit, beer
systems must be sanitized. After sanitizing, all
liquids (sanitizing solution and water) must be
purged from the unit. A freezing environment causes
residual sanitizing solution or water remaining inside
the unit to freeze, resulting in damage to internal
components.
Part Number 000003913 7/08
Section 5
Before Calling for Service
Checklist
If a problem arises during operation of your refrigeration
unit, follow the checklist below before calling service.
Routine adjustments and maintenance procedures are
not covered by the warranty.
! Warning
The unit should be unplugged when servicing,
except when electrical tests are required.
Use extreme care during electrical circuit tests. Live
circuits may be exposed.
! Warning
Only trained and certified electrical and plumbing
technicians must service this unit. All wiring and
plumbing must conform to national and local codes.
Problem
Section 1: Restriction
Possible Cause
To Correct
Too little restriction
Too much or too little restriction in a draught beer system will cause drawing problems. If draught beer system does not have
enough restriction it may cause the following problems:
When drawing one beer, the beer
Since the recovery problem symptoms
A recovery problem simply means that
flows very fast.
simulate a low pressure problem, check to
the beer is leaving the beer line faster
make sure that the CO2 pressure in the keg is
than the keg can fill the line. When this
flowing and set properly.
occurs it creates a vacuum in the keg
which acts as if there was a low pressure If a pitcher is drawn, the beer starts
Refer to your records to recheck your
on the beer in the keg. This causes the
clear then starts to show intermittent restriction calculation for the system. If you
CO2 to come out of the beer line causing streaks of foam followed by all foam. find your line does not have enough
foaming problems. (The following
restriction, add the extra restriction to the
symptoms occur most frequently during
3/16" end of the beer line. If you have no
the high volume time of day.)
records, make up a new beer line with the
proper restriction and replace the existing
line.
Beer draws too fast. If the beer draws
Beer draws clear but foams in the
Follow the second corrective step above.
clear but too fast and the pressure is
glass.
properly set, there may not be enough
The beer draws too fast to satisfy the If the beer still flows too fast, continue to add
restriction in the system.
retailer and his help.
more 3/16" restrictor line to the system to
meet the retailer’s needs.
Too much restriction
If a draught beer system is over restricted it may cause the following problems:
Beer draws too slow
Beer draws too slowly with little or no First, ensure that the keg is properly tapped.
head.
Second, ensure that the CO2 is set at the
proper pressure and is flowing to the keg.
Check the beer faucet to ensure that there is
no burr by the vent hole on the inside of the
faucet.
Systematically remove 6" of the 3/16"
The beer appears to flutter or swirl
out of the faucet causing the CO2 to restrictor line until the beer flows with a full
break out of the beer and thus
faucet and at a rate of flow desired by the
creating excess foam.
retailer.
Part Number 000003913 7/08
5-1
Before Calling for Service
Section 5
Problem
Possible Cause
To Correct
Section 2: Beermaster Glycol Chiller System
When troubleshooting a closed remote system, one should consider the following areas:
Temperature
Beer draws warm and is all foam.
Check coolant circulation by:
• Inspecting the coolant circulation pump to
ensure it is on and running.
• Inspecting the coolant return line in
reservoir to ensure it is circulating. Replace
pump if necessary.
Check coolant temperature by:
• Adjusting the range from 27°F (-2.7°C) to
29°F (-1.6°C).
• Fill reservoir to proper level with 3:1 glycol
mix.
No beer flows through system.
Check tap check ball and free if stuck. Check
Coolant temperature. If it is less than 27°F
(-2.7°C), the beer in the lines may be frozen.
Turn OFF coolant compressor, then adjust
coolant temperature to be between 27°F
(-2.7°C) and 29°F (-1.6°C).
First beer out always seems
Ensure that coolant line is in direct contact
foamy or streaky.
with the beer line right up to the back of the
shank. If not, place aluminum foil between
beer line and coolant line, then insulate. This
will transfer the cold to the beer line.
Beer in cooler is above 40°F
Temperature of cooler ideally should be less
(4.4°C).
than 38°F (3.3°C). Contact an authorized
refrigeration service agency to set cooler.
Glycol is dirty or too weak.
Clean reservoir and add new glycol solution
(add new glycol to weak solution). Should
give Brix on sugar refractor.
Glycol solution is too warm.
Check outlet and inspect agitator for proper
operation.
Pressure
Beer runs with streaks.
System may be under restricted. Add
additional restriction to system by adding
additional 3/16" I.D. vinyl tubing to the faucet
end of the system.
Beer draws great during slow time of See above. Check regulator for proper
day but turns to all foam during peak operation. Check primary regulator to see if it
sale periods.
allows enough CO2 for secondary regulators.
Check walk-in cooler temperature is 38°F
(3.3°C) or less.
Off-taste
Beer is flat.
Adjust air blender by increasing CO2 in blend
and decreasing air in blend. Or there is no
Air/ CO2 blender.
Beer has off-taste (bitter or
Change air intake filters. Check for moisture
“skunky”).
in air tank. Clean system. Check air intake
supply. Check air filter and trap. Ensure
proper rotation of kegs in series. Check
cleaning schedule for beer lines.
5-2
Part Number 000003913 7/08
Section 5
Before Calling for Service
THIS PAGE INTENTIONALLY LEFT BLANK
Part Number 000003913 7/08
5-3
Before Calling for Service
Section 5
THIS PAGE INTENTIONALLY LEFT BLANK
5-4
Part Number 000003913 7/08
© 2008 Manitowoc
Continuing product improvements
may necessitate change of
specifications without notice.
Part Number 000003913 7/08
Manitowoc Foodservice
2100 Future Drive
Sellersburg, IN 47172, USA
Ph: 812-246-7000 Fax: 812-246-7024
Visit us online at: www.manitowocfsg.com
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