Multiplex 175A04 Installation 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

Warning

Caution

Important

Caution

Important

Warning

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:

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.

Text in a Caution box alerts you to a situation in which you could damage the equip ment. Be sure to read the Caution statement before proceeding, and work carefully.

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.

Throughout this manual, you will see the following types of procedural notices:

Read These Before Proceeding:

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.

Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.

PERSONAL INJURY POTENTIAL

Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications.

NOTE: SAVE THESE INSTRUCTIONS.

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 th e pr oce dur e yo u are performing.

We reserve the right to make product improvements at any time.

Specifications and design are subject to change without notice.

General Information 1

Installation 1

Table of Contents (continued)

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

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

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 CO

Introduction 26 Kit Contents 26 Installing 26

Beermaster Dual Secondary Regulator Kit (00211400) 26

Introduction 26 Kit Contents 26 Installing 26

Beermaster Blenders 28

/CO2 Blender (Single — 00520182, Dual — 00520183) 28

Installation Checklist 29

Regulator (00211500) 26

Operation 1

Typical System 1 How the Multiplex Works 2 Start-up 2

ii Part Number 000003913 7/08

Maintenance 1

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 CO

Major Components 1

Dispensing Stations 1 Beverage Conduits 1 Air Compressor 1 Refrigeration Unit 1 Gas Blender 1 CO

Scheduled Frequency 1 Shipping, Storage and Relocation 2

Beer System Pressure and Choker Calculator 6

Gas Supply 1

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

Warning

04 - R404a refrigerant

Model Prefix

Model Base

300 A 04

A - Air-cooled AX - Air-cooled, international R - Remote RX - Remote, international W - Water-cooled WX - Water-cooled, international

Condenser

Type

300 - 1 hp 450 - 2.2 hp

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_________________ 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 tr ansportation to the delivery carrier. Request a written inspection report from a claims inspector to document any necessary claim.

PERSONAL INJURY POTENTIAL

Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications.

Model Numbers

This manual covers the following models:

300A04, 300W04, 300R04, 300AX04, 300WX04, 300RX04,

75A04, 75W04, 75R04, 75AX04, 75WX04, 75RX04

175A04, 175W04, 175R04, 175AX04, 175WX04, 175RX04

450A04, 450W04, 450R04, 450AX04, 450WX04, 450RX04

Refrigeration Unit

How to Read a Model Number

Accessories

Depending on store type and location, various optional equipment (such as CO

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

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.

NOTE: This unit must be secured to the vessel during installation. Models with part numbers beginn ing with the letters TS are NOT marine listed.

OUTDOOR APPLICATIONS

TS Multiplex Beverage Recirculating units a re 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.

Part Number 000003913 7/08 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

Wall

6" (15.2 cm)

Diameter Chase minimum

3-7/8" (9.8 cm) Diameter

(4-7/8" [12.4 cm] Diameter

on Model 450)

Air Flow

Control

Switches

18" (45.7 cm) minimum

Electrical

Junction Box

6" (15.2 cm) minimum

12" (30.5 cm) minimum

Wall

Top View

Front ViewSide View

Wall

Electrical

Junction Box

Incoming Water

Line

Incoming CO

Supply Line

Incoming Syrup

Supply Lines

Drain Plug

Ceiling

Wall

18" (45.7 cm)

minimum

CO2 Regulator

Panel (Optional)

Drain Plug

Wall

Conduit to

Dispensing Towers

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

Model W D H

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) 5 1/2” (14.0 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)

(with stand)

JNP

Part Number 000003913 7/08 2-1

Installation Section 2

OPTIONAL

38.00" (96.52 cm)

34.00" (86.36 cm)

30.00" (76.20 cm)

29.50"

(74.93 cm)

29.16"

(74.06 cm)

6.00"

(15.24 cm)

3.50"

(8.89 cm)

4.00"

(10.16 cm)

14.62"

(37.13 cm)

6.50"

(16.51 cm)

OPTIONAL

20.00" (50.80 cm)

16.00" (40.64 cm)

12.00" (30.48 cm)

1.50"

(3.81 cm)

27.94"

(70.97 cm)

Warning

REMOTE CONDENSER

Safe Installation Dos and Don’ts

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 ensur e 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 CO

cylinders and gauges with care.

Secure cylinders properly against abrasion.

• DO store CO

cylinder(s) in well ventilated areas.

• DO NOT exhaust CO

gas (example: syrup pump)

into an enclosed area, including all types of walk-in coolers, cellars, and closets.

• DO NOT throw or drop a CO

cylinder. Secure the

cylinder(s) in an upright position with a chain.

• DO NOT connect the CO

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 CO

• DO NOT store CO

cylinder(s) to a regulator(s).

cylinders in temperature above

125°F (51.7°C) near furnaces, radiator or sources of heat.

• DO NOT release CO

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.

2-2

Part Number 000003913 7/08

Section 2 Installation

Warning

Location Requirements

MULTIPLEX CHILLER MODEL SELECTION CHART

Model #* 300 450

Line length up to 300' up to 450'

Included

glycol

circulation

pump

Optional

glycol

circulation

pumps

Qty of

flavors**

* 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.

up to 2 additional one additional

1 3

up to 22 up to 32

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)

RATINGS

Model

150

300

450

Evaporator Rating

at 20°F (-6.5°C)

2500 BTUH

490 kcal/hr

5150 BTUH

1,159 kcal/hr

9,700 BTUH

2,340 kcal/hr

14,900 BTUH

3,310 kcal/hr

Heat Rejection

(Max.)

4500 BTUH885

kcal/hr

8,638 BTUH 1,949kcal/hr

13,576 BTUH

3,685 kcal/hr

20,400 BTUH

4,285 kcal/hr

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:

• Beverage quality CO

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.

Carbon Dioxide (CO2) displaces oxygen. Exposure to a high concentration of CO

gas causes tremors,

which are followed rapidly by loss of consciousness and suffocation. If a CO

gas leak is suspected,

particularly in a small area, immediately ventilate the area before repairing the leak. CO

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 CO

may build up in an area, venting o f the BIB pumps and/or CO

Part Number 000003913 7/08 2-3

monitors must be utilized.

Installation Section 2

Important

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. CO

3. A 120 VAC, 3-wire, 1 Phase, 60 Hz dual wall

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)

• For indoor installation only.

• Beer supply can be located on stand or adjacent to

Gas (bulk or bottled supply); minimum 3/8" line.

receptacle for optional electrical equipment (domestic only).

maximum operating ambient conditions.

refrigeration unit.

Installer Instructions

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.

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

Warning

Electrical

GENERAL

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

Model

150

300

450

Volt/Cycle/

Phase

120/601

230/50/1

120/601

230/50/1

208-230/60/1

230/50/1

208-230/60/3 230/400/50/3

Minimum

Circuit

Amps

20.3

9.0

21.5

10.7

20.6

25.2

11.6

Breaker Compressor

25A 16A

30A 16A

30A 25A

30A 20A

1/3 hp .46 kw

12 hp

.97 kw

1 hp

1.9 kW

2.2 hp

2.0 kW

Part Number 000003913 7/08 2-5

Installation Section 2

Warning

GROUNDING INSTRUCTIONS

When using electric appliances, basic precautions

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 inst alled and grounded in accordance with all local codes and ordinances.

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.

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.

2-6

i. For a grounded appliance — Connect to a

properly grounded outlet only. See Grounding Instructions.

Part Number 000003913 7/08

Section 2 Installation

Beermaster™

Refrigeration Unit

Walk-in Cooler

Dispensing

Station

Beer Conduit

6" (15.2 cm) PVC

Conduit Chase

Wide Sweep Elbows

2 ft (61 cm) Radius

Conduit

CONDUIT SPECIFICATION CHART

Choose

# of Beer

Flavors

2 MC043346 2 2 1 4 3 MC053346 3 2 1 5 4 MC063346 4 2 1 6

5 MC073346 5 2 1 7 6* MC083346 6 2 1 8 6* MC103346 6 4 2 10

8 MC123346 8 4 2 12

10 MC143346 10 4 2 14 12 MC163346 12 4 2 16 15 MC193346 15 4 2 19 16 MC203346 16 4 2 20

Brewmaster

2 Conduit

Part #

Conduit Specifications

Beer

Lines

Glycol

Lines

Glycol

Circuits

Total

Lines

INTRODUCTION

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.

FLOOR CHASES

Before pulling beer conduit through a floor chase, ensure the floor chase contains the following:

• 6" (15 cm) minimum PVC conduit chase

• Chase openings should extend 6" (15 cm) above floor

• Wide sweep elbows (2 ft [0.6 m] radius)

• Chase must be clean and dry — no foreign materials

glycol

line**

* 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.

MC023346 2 1 2

Part Number 000003913 7/08 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.

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.

7. After rope has been connected, t ape end of co nduit, 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.

2-8

Part Number 000003913 7/08

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