Multiplex 175A04 Service Manual

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Beermaster

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Refrigeration Units

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America’s Quality Choice in Refrigeration

Part Number STH13 9/10

www.manitowocfsg.com

Safety Notices

Warning

Caution

Important

As you work on Manitowoc equipment, be sure to pay close attention to the safety notices in this handbook. Disregarding the notices may lead to serious injury and/or damage to the equipment.

Throughout this handbook, 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 equipment. 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 handbook. These notices supply helpful information which may assist you as you work.

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

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: T ext set off as a Note provides you with simple,

Caution

Important

! Warning

We reserve the right to make product

improvements at any time. S pecifications and

design are subject to change without notice.

but useful, extra information about the procedure you are performing.

Read These Before Proceeding:

Proper installation, care and maintenance are essential for maximum performance and troublefree operation of your Manitowoc equipment. If you encounter problems not covered by this handbook, do not proceed, contact Manitowoc Foodservice Group. We will be happy to provide assistance.

Routine adjustments and maintenance procedures outlined in this handbook 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.

Table of Contents

General Information

Model Numbers . . . . . . . . . . . . . . . . . . . . . . . 9

How to Read a Model Number . . . . . . . . . . . . . 9

Accessories . . . . . . . . . . . . . . . . . . . . . . . . . 10

Special Applications . . . . . . . . . . . . . . . . . . . . 10

Model/Serial Number Location . . . . . . . . . . . . . 10

Warranty Information . . . . . . . . . . . . . . . . . . . 11

Complete System Overview . . . . . . . . . . . . . . . 12

Multiplex Beermaster™ Beer Dispensing System 18

Installation

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Dimensions and Clearances — All Models . . . . . 23

Safe Installation Do’s and Don’ts . . . . . . . . . . . 26

Location Requirements . . . . . . . . . . . . . . . . . . 28

Installer Instructions . . . . . . . . . . . . . . . . . . . . 30

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Balancing the System . . . . . . . . . . . . . . . . . . . 48

Beermaster Wine Dispensing Kit . . . . . . . . . . . 54

Aeroquip Connection . . . . . . . . . . . . . . . . . . . 58

Condenser and Pre-charged Lines Installation . . 58

Preparing Glycol . . . . . . . . . . . . . . . . . . . . . . 66

Additional Glycol Circulating Pump and Motor Kit 68

Beermaster Dispensing Towers . . . . . . . . . . . . 72

High Pressure CO2 Regulator (00211500) . . . . . . 73

Dual Secondary Regulator Kit (00211400) . . . . . 75

Beermaster Blenders . . . . . . . . . . . . . . . . . . . 78

Beermaster Low CO2 Alarm Kit . . . . . . . . . . . . 79

Component Identification

Typical System . . . . . . . . . . . . . . . . . . . . . . . 81

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . 82

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Cap Tube or Expansion Valve . . . . . . . . . . . . . 84

Evaporator Coil . . . . . . . . . . . . . . . . . . . . . . . 85

Glycol Bath . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Agitator . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Circulating Pump/Motor . . . . . . . . . . . . . . . . . 88

Glycol Bath Strainer . . . . . . . . . . . . . . . . . . . . 89

Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Part Number STH13 9/10 5

John Guest Fittings

Restriction Line . . . . . . . . . . . . . . . . . . . . . . .92

Dispensing Faucet . . . . . . . . . . . . . . . . . . . . .93

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . .94

High Pressure Regulator . . . . . . . . . . . . . . . . .95

Secondary Regulator . . . . . . . . . . . . . . . . . . . .96

Tavern Head . . . . . . . . . . . . . . . . . . . . . . . . .97

Keg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .98

Wall Bracket . . . . . . . . . . . . . . . . . . . . . . . . . .99

Blender . . . . . . . . . . . . . . . . . . . . . . . . . . . . .100

Low CO2 Alarm . . . . . . . . . . . . . . . . . . . . . . .101

. . . . . . . . . . . . . . . . . . . . .91

Maintenance

Major Components . . . . . . . . . . . . . . . . . . . . .103

Scheduled Frequency . . . . . . . . . . . . . . . . . . .105

Shipping, Storage and Relocation . . . . . . . . . . .106

Operation

How the Multiplex Works . . . . . . . . . . . . . . . . .107

Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Sequence of Operation . . . . . . . . . . . . . . . . . . .109

Equipment Setup and Close Procedure . . . . . . .116

Troubleshooting

Foreword . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .121

ETC Error Codes . . . . . . . . . . . . . . . . . . . . . . .124

ERC Error Notes . . . . . . . . . . . . . . . . . . . . . . .125

Component Check Procedures

Head Pressure Control Valve . . . . . . . . . . . . . .137

Charging Multiplex Remote Refrigeration Unit . . .139

Compressor & Remote Condenser . . . . . . . . . .140

Agitator Condenser . . . . . . . . . . . . . . . . . . . . .141

Carbonation System A or B . . . . . . . . . . . . . . . .142

Circulation System A or B . . . . . . . . . . . . . . . . .143

ERC Control Board, Keypad & Display . . . . . . . .144

Programming / Auto Set . . . . . . . . . . . . . . . . . .145

ERC Component (Output) Connector Layout . . . .146

ERC Sensor (Input) Connector Layout . . . . . . . .146

Component Specifications

Specifications . . . . . . . . . . . . . . . . . . . . . . . . .147

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . .149

6 Part Number STH13 9/10

Charts

Conduit Specification Chart . . . . . . . . . . . . . . . 151

Natural Keg Pressures Chart . . . . . . . . . . . . . . 152

System Calculators . . . . . . . . . . . . . . . . . . . . 153

Diagrams

Circuit Diagrams . . . . . . . . . . . . . . . . . . . . . . 159

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . 162

Part Number STH13 9/10 7

8 Part Number STH13 9/10

General Information

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

Model Numbers

This manual covers the following models:

(A) Air Cooled (W) Water Cooled

75A04 75W04 75R04 75AX04 75WX04 75RX04 175A04 175W04 175R04

175AX04 175WX04 175RX04

300A04 300W04 300R04

300AX04 300WX04 300RX04

450A04 450W04 450R04

450AX04 450WX04 450RX04

How to Read a Model Number

(R) Remote

cooled

Part Number STH13 9/10 9

Accessories

! Warning

Depending on store type and location, various optional equipment 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 beginning with the letters TO are NOT marine listed.

OUTDOOR APPLICATIONS

TO 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.

Personal Injury Potential

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

Model/Serial Number Location

These numbers are required when requesting information from your local Manitowoc Distributor, service representative, or Manitowoc Foodservice. The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD. They are also listed on the MODEL/SERIAL NUMBER DECAL affixed to the unit.

10 Part Number STH13 9/10

Warranty Information

Consult your local 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 activate the warranty on this equipment. If a warranty card is not returned, the warranty period can begin when the equipment leaves the factory.

No equipment may be returned without a written Return Materials Authorization (RMA). Equipment returned without an RMA will be refused at the dock and returned to the sender at the sender’s expense.

Please contact your local distributor for return procedures.

Part Number STH13 9/10 11

Complete System Overview

BEER PROPERTIES General Information

The object of every establishment serving draught beer is to deliver the same high quality of beer to the customer that is delivered to it by the beer distributor. Unfortunately, this objective may be more difficult to achieve than the vendor or proprietor realizes, especially if he is not thoroughly familiar with the relationships that exist between temperature, pressure, and beer delivery systems, all of which have a major effect on the quality of the beer delivered to the customer. A brief discussion of these factors may prove helpful in understanding why a problem exists and what corrective action is required.

Beer is a unique liquid; no two barrels (even of the same brand) are exactly alike. There are large variations between brands. Chemically speaking, beer is a “supersaturated” liquid. Simply stated, beer contains excess carbon dioxide (CO2) which dissipates or “out gasses” if allowed to stand in an open container for a period of time. If this were to happen, the beer would go “flat”. The presence of CO gives beer its effervescent quality and distinct flavor. There are several factors that affect the level of carbonation, and therefore the quality and flavor of the beer that is delivered to the customer.

Pressure

Beer is pressurized in the keg by the brewer to his exact specifications, which ar e op ti mized for the best possible flavor. For example, under pressurized beer will taste flat and over pressurized beer will taste bitter. It therefore follows that the vendor must carefully balance his system to the beer specifications of the brewer in order to dispense the beer with the best possible flavor to his customers. Failure to do so can result in poor tasting or foamy beer. This is why it is strongly recommended that each keg or beer supply be regulated by its own pressure regulator.

The optimum pressure for most domestic beer, dispensed at normal temperatures and at sea level, is 12 to 14 pounds per square inch (psi) keg pressure.

12 Part Number STH13 9/10

Some domestic beers require slightly higher pressure and some imported beers require lower pressure, which explains the need for separate pressure regulators for each brand. This information is readily available from the beer distributor. Areas with higher elevations will require higher keg pressure, specifically one psi for each 2,000 ft (609.6 m) elevation above sea level. This increase in keg pressure is necessary to retain the correct carbonation level in the beer itself, since the carbonation level is a function of the “absolute pressure” and not the difference in pressure between keg and atmospheric (which is the pressure maintained by the pressure regulator on the beer system).

The applied CO forcing the beer from the keg through the beer lines

pressure is also the vehicle for

and into the glass at the dispensing point. Many operators mistakenly believe that this is the only function, or at least the major function, of the applied pressure, and therefore the pressure m ay be decreased or increased at will to facilitate a desired dispensing rate (flow rate). Because of the effects on the carbonation level of the beer, and therefore the quality of the beer itself, the pressure must not be changed to achieve a desired change in the flow rate. The only acceptable method for adjusting the flow rate is by changing the amount of the restriction or “drag” in the system with respect to the flowing beer. The amount of additional restriction may be adjusted by adding or removing lengths of the main beer lines, or adding or removing shorter portions of smaller sized tubing (choker lines) to the beer lines.

Part Number STH13 9/10 13

In some beer systems the walk-in cooler or storage room is located remotely and on different levels from the dispensing points. Under these conditions, even with large size beer lines it is often not feasible to dispense beer at an adequate flow rate with normal keg pressures since the drag, or resistance of the lines, as well as vertical lift that may be required can be sufficient to reduce the flow greatly at these standard pressures. In these cases it is often necessary to pressurize the keg as much as two or three times the normal keg pressure in order to provide an acceptable flow rate at the dispensing point. This type of system is commonly known as a “long draw” or “remote” system. Manufacturers of these systems recommend using a blend of gasses or beer pumps (usually a mixture of CO and nitrogen) to pressurize the system without over

and air or CO2

carbonating the beer. The refrigerated chamber containing the kegs can be located more than 450 ft (91.4 m) away from the serving location using these long draw techniques.

Natural Keg Pressures at Sea Level (Pounds/ Square inch)

Brewing

Company

Anheuser Busch 11 12 13 14

Adolph Coors (requires 1/4"

Ported Shanks)

Miller 12.5 13.5 14.5 15.5

Schlitz/Stroh’s 12 13 14 15

Add 1 psi to adjust for altitude for every 2,000 ft above sea level. An additional 1 psi may be required for “Light” beers.

Cooler Temperature

36°F 38°F 40°F 42°F

14.5 15.5 16.5 17.5

14 Part Number STH13 9/10

TEMPERATURE

26 ft (7.9 m)

T o tal Conduit Length:

50 ft (15.2 m)

Altitude:

1,000 ft (304.8 m)

Walk-in Cooler

38°F

(3.3°C)

8 ft

(2.4 m)

8 ft

(2.4 m)

5 ft

(1.5 m)

4 ft

(1.2 m)

The effects of temperature are manifested in several ways. The temperature itself is very significant. A temperature between 36°F (2.2°C) and 38°F (3.3°C) gives the best dispensing results, and is generally favored by most people as providing the best taste. If the beer is cooled below 36°F (2.2°C), more CO absorbed and a greater tendency to out gas may occur when the beer is released to atmospheric pressure by dispensing, thereby producing more foam. The greater absorption of CO2 also imparts a slightly more bitter taste to the beer, which is objectionable to most beer drinkers.

Above 38°F (3.3°C) the CO a higher energy level and can escape more easily.

contained in the beer is at

Therefore out gassing and foaming can occur more readily. This energy level continues to increase at higher temperatures, resulting in a rapid increase in the beer’s tendency to foam.

An increase in temperature in the beer lines or the faucet itself can result in “fracturing” (out gassing) when the beer is dispensed. This generally occurs when un-refrigerated beer lines extend outside of the beer cooler and the ambient temperature surrounding the lines is at a higher temperature than the cooler itself. This can also occur in the beer “tower” at which the faucets are connected when an insufficient amount of coolant is circulated in the tower. The general result is that the first glass dispensed after a delay of several minutes will experience significant fracturing, resulting

Part Number STH13 9/10 15

in a larger head of foam. To maintain the correct temperature in the tower, care must be taken to ensure that a sufficient amoun t of coolant is delivered to this area.

THE TEMPERATURE/PRESSURE COMBINATION

Since carbonation of the beer is related to both pressure and temperature, it is important to understand this relationship in order to assure that the highest quality beer product is delivered to the customer. Higher than normal temperatures require higher than normal pressures in order to maintain carbonation. Specifically, in order to maintain proper carbonation, the CO when there is an increase in the beer temperature. For

pressure must be increased

example, a typical American beer that would be properly carbonated at 12 psi (0.8 bar) at a temperature of 38°F (3.3°C) would require an increase in pressure to maintain the same level of carbonation at a temperature of 39°F (4.2°C). Conversely, lowering the temperature requires a corresponding decrease in CO

pressure to prevent over-carbonation. In actual

practice pure CO

16.5 psi (1.1 bar) (at sea level) should be avoided at

pressures above approximately

normal temperature (36°F [2.2°C] to 38°F [3.3°C]) to avoid an unacceptable level of over carbonation which leads to foaming problems. When the pressures above this level are required for good dispensing, the operator should switch to a blend of CO for pressurization or beer pumps.

and nitrogen

The beer faucet itself is surrounded by normal ambient room air and will warm slightly over a period of several minutes. Since a small amount of beer is trapped behind the faucet, there is a likelihood that this small amount of beer will also warm slightly. The result will be that this trapped beer will fracture and produce foam on the first beer dispensed after an extended idle time. When all of the slightly warmed beer has been depleted from the faucet and the beer line, subsequent beers drawn immediately following the first should produce about the same amount of foam or head, but less than the first beer.

In long draw or remote systems as described above, it is essential to refrigerate the beer lines throughout

16 Part Number STH13 9/10

their entire length at about the same temperature as the beer in the cooler. Most manufacturers of these systems agree that it is not possible to adequately refrigerate these lines using cold air over distances greater than about 15 ft (4.6 m). Therefore, these systems utilize a liquid refrigerant line continuously cycling propylene glycol at a temperature below 30°F (-1.1°C) (or other suitable liquid coolant) in physical contact with beer lines and with the overall assembly contained in a flexible, insulated housing. These systems, when properly designed and installed, generally offer the best and most consistent draught beer product. On the other hand, an improperly designed, installed, or maintained system (even a rough or damaged gasket) can produce “shots” of foam, continuous foam, or continuously warm and therefore, foamy beer.

NOTE: A properly designed, installed, and maintained draught dispensing system should deliver beer at 1.75 to 2.0 ounces per second. The beer should be dispensed at 38°F (3.3°C) or less. The beer should flow in a solid, clear column smoothly (neither falling or pushing) from the faucet to the glass.

Part Number STH13 9/10 17

Multiplex Beermaster™ Beer Dispensing System

The beer keg is kept in a refrigerated cooler at the proper temperature for dispensing. The pressure system supplies pressurized gas to the kegs at a specific pressure for each keg, this pressure is determined by the installer taking into consideration the distance, vertical rise and fall of the conduit (insulated bundle of tubing), along with the natural pressure in the keg. The beer is pushed through the lines in the conduit from the cooler to the dispensing valve. T o maintain the cold temperature in the conduit the refrigeration system uses the Multiplex Beermaster™ refrigeration unit which chills a glycol bath. This glycol, which is adjusted to below 30°F (-1.11°C), is circulated through the conduit up to the dispensing faucet and back where it is re-chilled in the bath. These chilled glycol lines are touching the beer lines in the conduit, maintaining the cold temperature of the beer. The beer is then brought up to the dispensing system where the conduit tubing is restricted down to a smaller diameter tube of a length, calculated by the installer, that’s designed to give a 1.75 ounce per second flow of a perfectly dispensed beer.

18 Part Number STH13 9/10

PRESSURE SYSTEM

The pressure system supplies the pressurized gas to the kegs at a specific pressure for each keg. This consists of a high pressure regulator to reduce the CO

or mixed gas pressure from the high pressure

cylinder to 40 psi (2.8 bar). This gas is fed to the secondary regulators to beer pumps or the optional blender which may nitrogen with the CO reduce the chance of providing extra carbonation to

to help

the beer. The secondary regulators are adjusted to the installer calculated pressure, calculated for each keg. This pressure is calculated to push the beer through the conduit to the dispensing faucets and flow at a desired 1.75 oz per second flow rate.

Part Number STH13 9/10 19

REFRIGERATION SYSTEM

The refrigeration system consists of the Multiplex Beermaster™ refrigeration unit which chills a food grade glycol to below 30°F (-1.11°C). This glycol is circulated through an insulated bundle of tubing (conduit) by a 70 GPH circulating pump and returned to the refrigeration unit for re-chilling. This very cold glycol is continually circulating through independent lines in the conduit. The beer lines (which are also in the conduit) are in contact with the glycol lines which will maintain the temperature of the beer. This ensures that the product is dispensed at the beer cooler temperature. The refrigeration compressor will cycle ON and OFF as needed to maintain the consistent temperature of glycol. Each size of Beermaster™ Refrigeration Unit is rated for a maximum total conduit length to keep the beer dispensing at a consistently cold temperature, maintaining the proper temperature and taste of the beer.

20 Part Number STH13 9/10

DISPENSING SYSTEM

The dispensing system consists of one of the many different styles and sizes of dispensing towers which can have any number of dispensing faucets used to dispense the beer into the glass, mug or pitcher. As the beer comes out of the conduit it must be adjusted to give a maximum 2 oz per second flow rate to reduce the chance of foaming and to dispense a proper glass of beer. The proper way to adjust the flow rate of the beer is to reduce the diameter of the tubing, using an installer calculated length, of 3/16" diameter restrictor tubing. The beer then flows through an aluminum or stainless steel heat exchanger, that is kept in contact with the very cold glycol lines, to maintain the cold temperature all the way to the dispensing faucet and into the glass.

Part Number STH13 9/10 21

BALANCING THE SYSTEM

Keg Temperature/Pressure

Applied Keg Pressure

Tubing Resistance

Tubing Lift/Fall

Length of Restrictor Line

To keep the proper amount of carbon dioxide gas in solution in the beer to maintain the proper taste throughout the life of the keg, the system must have the proper balance of temperature, applied pressure to the keg and rate of flow at the faucet.

The installer must calculate, taking into consideration the static resistance in the conduit (amount of vertical rise and fall) as well as frictional resistance (the length of the conduit itself), the internal pressure of the keg according to the Brewmaster, the altitude at the location as well as the temperature of the beer in the cooler. The object is to dispense the beer as fast as possible (2 oz per second) with the proper gas pressure (CO adjusted so it will not change the carbonation or taste

or mixed gas) applied to the keg and

of the beer. The installer must determine the proper pressure applied to the keg as well as the length of the restrictor attached to the dispensing faucet giving a consistent properly dispensed beer.

22 Part Number STH13 9/10

Installation

Wall

6" (15.2 cm)

Diameter Chase

minimum

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

Side View

Wall

Electrical

Junction Box

Incoming

Water Line

Incoming CO

Supply Line

Incoming Syrup

Supply Lines

Drain Plug

General

• Refrigeration units require a 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

Part Number STH13 9/10 23

Front View

Ceiling

Wall

18" (45.7 cm)

minimum

CO2 Regulator

Panel (Optional)

Drain Plug

Wall

Conduit to

Dispensing

Towers

24 Part Number STH13 9/10

Model W D H

(with stand)

JNP

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)

(12.7 cm)

(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)

(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 STH13 9/10 25

REMOTE CONDENSER

Warning

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)

Safe Installation Do’s 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 ensure a quality seal.

• DO inspect pressure on regulators before starting up equipment.

• DO protect eyes when working around refrigerants.

26 Part Number STH13 9/10

• DO use caution when handling metal surface edges of all equipment.

• DO handle CO Secure cylinders properly against abrasion.

cylinders and gauges with care.

• DO store CO2 cylinder(s) in well ventilated areas.

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

cylinder. Secure the

• 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 CO regulator(s).

• DO NOT store CO above 125°F (51.7°C) near furnaces, radiator or

cylinder(s) to a

cylinders in temperature

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).

NOTE: All utility connections and fixtures must be sized, installed, and maintained in accordance with Federal, State, and Local codes.

Part Number STH13 9/10 27

Location Requirements

Warning

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 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.

gas (bulk or bottled supply)

Carbon Dioxide (CO2) displaces oxygen. Exposure to a high concentration of CO causes tremors, which are followed rapidly by loss of consciousness and suffocation. If a CO gas leak is suspected, particularly in a small area,

gas

immediately ventilate the area before repairing the leak. CO installed in an enclosed space. An enclosed

lines and pumps must not be

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 CO

28 Part Number STH13 9/10

monitors must be utilized.

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).

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

2. CO

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 floor in a walk-in adjacent to refrigeration unit.

Part Number STH13 9/10 29

Installer Instructions

Warning

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.

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. See Specifications section.

30 Part Number STH13 9/10

GROUNDING INSTRUCTIONS

Warning

The unit 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.

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.

Part Number STH13 9/10 31

Warning

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.

32 Part Number STH13 9/10

Conduit

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 minimum)

• Chase must be clean and dry — no foreign materials

Part Number STH13 9/10 33

Beermaster™

Refrigeration Unit

Walk-in Cooler

Dispensing

Station

Beer Conduit

6" (15.2 cm) PVC

Conduit Chase minimum

Wide Sweep Elbows 2 ft

(61 cm) Radius minimum

34 Part Number STH13 9/10

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.

Part Number STH13 9/10 35

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.

36 Part Number STH13 9/10

OVERHEAD INSTALLATION

Beermaster™

Refrigeration Unit

Walk-in Cooler

Dispensing

Station

Ceiling Tiles

Conduit Hanger

Beer Conduit

Part Number STH13 9/10 37

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.

38 Part Number STH13 9/10

BASEMENT CONSTRUCTION

Beermaster™

Refrigeration Unit

Walk-in Cooler

Dispensing

Station

Conduit Hanger

Beer

Conduit

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.

Part Number STH13 9/10 39

4. Once the conduit has been routed, ensure an

Caution

Butterfly Cutter

Razor Knife

adequate supply of conduit is on hand to make all connections.

CONNECTING BEER CONDUIT

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.

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.

40 Part Number STH13 9/10

Beermaster™

Refrigeration Unit

Walk-in Cooler

Dispensing

Station

Main Beer

Conduit - 6”

Minimum Dia.

Beer Conduit to Walk-in

Cooler

Part Number STH13 9/10 41

CONDUIT KIT Kit Contents Four (4) and Seven (7) line conduit kits

• 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

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

42 Part Number STH13 9/10

INSTALLING THE CONDUIT KIT Connections Preview

Review the three illustrations under “Circuit Diagrams” in the Diagrams section 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.

Part Number STH13 9/10 43

Connecting Main Beer Conduit at Walk-in Cooler

John Guest Adapter Tail

Piece

Washer

Wall

Bracket

Fitting

To Beer Keg

Beer Nut

Beer Line to

Tower

1/2" John

Guest Union

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.

44 Part Number STH13 9/10

Connecting Beer Conduit to the Tower

3/16" Barb

x 1/2"

John

Guest

Adapter

1/2" John

Guest Union

1/2" John

Guest Union

Beer

Line

Beer

Conduit

Glycol

Line

Glycol

Manifold

Adapter

Restrictor

Lines

Adjustable

Clamp

See

“Calculating

Restriction”

for Length

Dispenser Tower Dispenser Tower

Dispenser 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.

Part Number STH13 9/10 45

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 “To wer 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.

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).

46 Part Number STH13 9/10

3. Locate the appropriate beer line(s) in the main

Caution

1/2" John

Guest Union

1/2" John

Guest Elbow

Branch Beer

Conduit

Main Beer

Conduit

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).

To a void agitation use only straight unions when splicing beer lines.

Main Beer Conduit Connections

Part Number STH13 9/10 47

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 (if blended gas is used to push the beer, this is not required).

• 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 and refer to examples A and B.

To prope rly determine the required restrictor line lengths and applied keg pressure to be used for each beer follow the instructions below.

1. First determine which brands of beer will be dispensed at which faucet. Use the “System Calculators” to record data (see the Charts section).

2. Determine keg temperature at cooler.

3. Once the brand and keg temperature are known the Internal Keg Pressure can be found by referring to the “Natural Keg Pressures Chart” in the Charts section.

4. Determine the number of feet above sea level to adjust natural keg pressure for particular location.

5. If required adjust for “Lite” or “Light” beer by adding 1 psi to natural keg pressure. Check with local beer wholesaler for additional information.

48 Part Number STH13 9/10

Example:

- Budweiser on faucet number 1

- Walk-in cooler for kegs at 38°F

- Anheuser Busch (Budweiser) at 38°F=12 psi

- Altitude adjustment at 1,000 ft (1 psi/2,000 ft above sea level)=0.5 psi

- “Lite” beer adjustment = 0 Adjusted keg pressure = 12.0 + .5 + 0 = 12.5 psi

- Determine the required Applied Keg Pressure by taking the adjusted keg pressure and adding 2 psi

Example:

12.5 psi (adjusted keg pressure) + 2.0 psi = 14.5 psi Applied Keg Pressure

(pressure the secondary regulator will be adjusted at)

6. Determine the total line length and tubing diameter from bottom of keg to faucet. This must be done for each individual beer line (refer to the figures below for proper method of determining line length).

7. Once the run length is known calculate the amount of restriction.

Example:

50 ft (length of conduit) x 0.07 (restriction 3/8" ID poly) = 3.5 psi

Part Number STH13 9/10 49

EXAMPLE A

EXAMPLE B

26 ft (7.9 m)

Total Conduit Length:

50 ft (15.2 m)

Altitude:

1,000 ft (304.8 m)

Walk-in Cooler

38°F

(3.3°C)

8 ft

(2.4 m)

8 ft

(2.4 m)

5 ft

(1.5 m)

4 ft

(1.2 m)

26 ft (7.9 m)

T o tal Conduit Length:

50 ft (15.2 m)

Altitude:

1,000 ft (304.8 m)

Walk-in Cooler

38°F

(3.3°C)

19 ft

(5.8 m)

5 ft

(1.5 m)

50 Part Number STH13 9/10

Restriction (pounds per square inch) Restrictor Line: 3/16" ID @ ft=3.0 psi Beer Supply Line: 3/8" ID @ ft=0.07 psi

8. Determine the lift or drop restriction by taking the total vertical lift in feet and subtracting the total vertical drop in feet and multiplying the remainder by 0.5 psi.

Add 1/2 psi for every foot of vertical lift. Subtract 1/2 psi for every foot of vertical drop.

Equal lifts and drops cancel one another.

Example:

13 ft lift - 8 ft drop = 5 ft of lift 5 ft of lift x 0.5 psi = 2.5 psi lift*

*This figure will be negative if the drop exceeds the lift.

9. Determine the total line restriction by adding each of the previously calculated restriction factors.

Example:

3.5 psi (length of run restriction) + 2.5 psi (lift/drop restriction) = 6.0 psi (total line restriction)

10. Determine the required psi of restriction that will be required by taking the Applied Keg Pressure and subtracting the T otal Line Restriction.

Example:

14.5 psi (applied keg pressure) + 6.0 psi (total line restriction) = 8.5 psi (restriction factor)

If this figure is greater than or equal to 6.0 psi proceed to the instructions outlined in step A. below. If this figure is less than 6.0 psi proceed to the instructions outlined in step B. below.

A. To convert the psi of restriction needed to

inches of required 3/16" ID restriction line, use the following equation:

Number psi needed ÷ 0.25 psi = number of inches of restrictor

Part Number STH13 9/10 51

Example:

8.5 psi (restriction factor) ÷ 0.25 psi = 34.0 in (of required restrictor line)

B. This example (refer to the figures above,

Example B) reflects an increased vertical lift factor of 24 ft (19 ft of lift + 5 ft of lift=24 ft). It requires a lift/drop restriction of 12 psi (24 x

0.5/ft lift=12 psi).

Example:

14.5 psi (applied keg pressure) - 15.5 psi (total line restriction) = -1.0 psi (restriction factor)

Since the restriction factor in this example is less than 6.0 psi, a 24" fixed restrictor length will be required.

Volumes (liquid oz per linear ft)

3/16" ID @ ft = 0.18 1/4" ID @ ft = 0.33 5/16" ID @ ft = 0.51 3/8" ID @ ft = 0.73

1/2" ID @ ft = 1.31

The Adjusted Applied Keg Pressure (the pressure the secondary regulator will be adjusted to) can now be determined by taking the To tal Line Restriction and adding 8 psi.

Example:

3.5 psi (run restriction) + 12.0 psi (lift/drop restriction) = 15.5 psi (total line restriction)

15.5 psi (total line restriction) + 8.0 psi = 23.5 psi (adjusted keg pressure)

STARTING UP THE SYSTEM Before Starting Up the System

Each of the steps below should be done 24 hours prior 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.

2. Turn ON the Beermaster Glycol Chiller circulating glycol pump(s).

52 Part Number STH13 9/10

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 al l are as 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.

Pressure Setting and Start-up

1. Adjust the primary CO secure the lock nut.

regulator to 40 PSI and

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.

Part Number STH13 9/10 53

Beermaster Wine Dispensing Kit

To dispense chilled wine through the Beermaster™ system, the following components are required:

• Wine Dispensing Kit (P.N. 00211504)

• Nitrogen Regulator (P.N. 00219381)

• Wine Tank, Stainless Steel with general disconnects

INSTALLING Single Faucet

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 walk-in 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 location of wine tank, 3/8" x 1/4" FF John Guest connector, and liquid disconnect.

4. Connect nitrogen regulator to nitrogen tank and connect gas line to regulator outlet.

5. Connect empty wine tank and turn on nitrogen tank. Adjust to 30 PSI and pressurize system to check for leaks.

6. Turn OFF nitrogen and depressurize system. Determine system pressure resistance and reset regulator for desired flow.

Multiple Faucets from Same Tank

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.

54 Part Number STH13 9/10

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 the unit is to rest on the floor, locate the four 6" (15.2 cm) adjustable legs (optional). Screw and tighten the legs into the bottom of the refrigeration unit. Set the unit in desired location and adjust legs until the unit is level and sturdy. If the unit is to be mounted on a stand, position stand and secure the unit to stand. If the unit is to be installed on a wall mount bracket, install the wall mount bracket and position the unit on the bracket at this time. Fasten the unit to the 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 the 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 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 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.

Part Number STH13 9/10 55

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 positi on .

5. Route and connect power supply to leads in the electrical junction box at the top rear of the motor compartment.

NOTE: Be sure to connect ground wire(s) to ground screw located on back panel of junction box.

56 Part Number STH13 9/10

INSULATING CONNECTIONS

Aerosol

Foam

Chase

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. A 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.

Part Number STH13 9/10 57

Aeroquip Connection

Important

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”.

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.

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.

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.

58 Part Number STH13 9/10

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.

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.

3. The easiest method to create a trap is to bend the tubing (smoothly, no kinks) into the trap form.

Part Number STH13 9/10 59

4. The trap(s) must be of minimum height of 3"

To the

Condenser

Discharge Line Trap Every

25 Vertical ft. (7.62 m)

3 ft (.9 m) (minimum) of Discharge

Line Trap at the Compressor

Compressor

3" (7.6 cm) x 6" (15.2 cm)

Maximum Trap Area

Discharge Line

Condenser Trap

(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.

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.

60 Part Number STH13 9/10

3. The General Contractor or Owner must secure

3" Pitch Pot

Roof

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.

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

Part Number STH13 9/10 61

tubing, you must cut out the excess before

Caution

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.

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”.

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.

62 Part Number STH13 9/10

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.

HOW TO SHORTEN THE LINE SETS

1. Do not connect either end of the tubing to the system before everything is set in place. Standard refrigeration practices must be followed regarding the tubing installation.

2. Excess refrigeration tubing must be handled in one of two ways. With a short amount of excess tubing (about 10 feet), you may coil that amount vertically between the condenser and refrigeration unit. When coiling the excess tubing, make sure the inlet to the coil is at the high side of the coil and the exit is the low side of the coil. There can be no more than one turn to the coil. The coil must continue in a downward spiral with no overlaps, similar to a cork screw. If you have more tubing, you must cut out the excess before connecting the ends. When cutting the tubing, you must first evacuate the refrigerant.

3. After shortening the tubing and welding together again, you must vacuum the tubing to 250 microns.

4. Recharge the tubing with the appropriate refrigerant at 4 ounces per length of tubing.

HOW TO RE-CHARGE THE LINE SETS

NOTE: This procedure to be used only with damaged or evacuated line sets or with unknown refrigerant type.

1. With the remote condenser lines properly hooked and sealed to the condenser, evacuate to 250 microns for 1 hour, using both Schrader ports on the service line set.

2. For units with model numbers beginning with “SS”, charge the condenser and line set as described here. Add 0.72 oz/ft (0.067 kg/m) of remote line set (one way run distance) plus condenser name plate charge.

Part Number STH13 9/10 63

Example: 45 ft of line set 45 x 0.72 oz = 32.4 oz

32.4 oz + condenser charge = Total charge If the line set and the main refrigeration unit are

connected, you must also add that refrigerant charge.

For units with part numbers beginning with “TS”, charge according to the nameplate charge on the refrigeration unit. That is enough refrigerant for up to 100 feet of tubing plus the Multiplex condenser. If you have another brand condenser, please add additional charge for the condenser (example: up to three pounds for a MAC condenser).

3. Connect line sets to the proper discharge and liquid mating connectors on the refrigeration unit using quick connects. Refer to the section titled “Aeroquip Connection” in these instructions.

4. Be sure to observe proper refrigeration techniques when running the line set.

A. The discharge line must loop down at the

compressor end to trap liquid from returning to the compressor, unless you are coiling refrigeration tubing behind the unit.

B. The discharge line must loop above

discharge connector at the condenser to resist liquid returning to the compressor. Any excess tubing must be removed from the line set before the line set is connected to any equipment.

C. The discharge line must have one P trap

every 25 ft (7.6 m) of vertical rise to allow oil to stair-step up to the condenser and eventually return to the compressor.

NOTE: When the connections are made, the seal in the couplings are broken, and if removed for any reason, the refrigerant charge will be lost.

64 Part Number STH13 9/10

Caution

Relays and terminal block are energized from

Caution

To the

Condenser

Discharge Line Trap Every

25 Vertical ft. (7.62 m)

3 ft (.9 m) (minimum) of Discharge

Line Trap at the Compressor

Compressor

3" (7.6 cm) x 6" (15.2 cm)

Maximum Trap Area

Discharge Line

Condenser Trap

each remote unit. Turn OFF switches on each unit before opening quick disconnect switch on condensing unit. On the completion of the wiring of the remote condenser make sure the electrician placed the switch lever in the ON position. This switch must be ON before turning ON the refrigeration toggle switch on the unit. Also, the water bath must be filled with water.

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

Part Number STH13 9/10 65

Preparing Glycol

Caution

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: Model 75 3 Gallons (19 ltr) Glycol Model 150 5 Gallons (19 ltr) Glycol Model 300 15 Gallons (57 ltr) Glycol Model 450 20 Gallons (75 ltr) Glycol

3. Pour the glycol into the reservoir tank.

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).

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.

66 Part Number STH13 9/10

NOTE: Verify that the pump box holding tank is full

Drain Plug

Overflow

Tube

Glycol Bath

Tank

Tab

Clamp

before proceeding.

6. Turn on the circulator. The circulator must run continuously. Verify that glycol is retu rning to the glycol bath through the return bulk head fitting.

Part Number STH13 9/10 67

Additional Glycol Circulating Pump and

Carriage Bolts

(Later Units)

Mounting Studs

(Early Units)

5/16" - 18 Hex Nut

Motor Kit

Pump and Motor Kit

Motor Installation

NOTE: Only two fasteners required.

68 Part Number STH13 9/10

Tube Installation

End Panel

1/2" O.D. x 1/2" O.D.

John Guest Elbow

1/2" O.D. Red

Connecting Tube

Circulating Pump

Discharge Cooling Coil

Part Number STH13 9/10 69

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).

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.

NOTE: Do Not discard the condensation cover over the reservoir tank. It is necessary to prevent excessive condensation from diluting the water-glycol mixture.

70 Part Number STH13 9/10

11. Locate the 1/2" O.D. x 4" or 8" plastic tube,

1/2" O.D. John

Guest Bulkhead

1/2" O.D. x 8"

Plastic Tube

1/2" O.D. Tube

Retaining Collet

Circulator Pump

Discharge Cooling

Tube

Pickup Tube

2 ft x 1/2" I.D.

Insulation

1/2" x 1/2" John

Guest Elbow

Strainer Plate

12. Locate the 8 ft piece of cork tape, provided with

13. Remove and discard safety plug from connector

14. Installation of glycol circuit pump is now complete.

15. The added glycol circulating pump can now be

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.

Part Number STH13 9/10 71

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).

Pump Connections

kit, and insulate the glycol pump and all exposed connections to prevent condensation.

of wire harness coming from control box. Attach connector of glycol pump motor to connector of wire harness coming from control box.

The Beermaster refrigeration unit can now be turned ON.

controlled by a switch located on the switch box.

- For Model 450, the CIRC #4 switch will control added pump.

Beermaster Dispensing Towers

Caution

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 o v er the hole to locate and mark the mounting screw positions.

4. Drill appropriate holes for mounting (1/8" diameter when using screws provided, if mounting in wood).

NOTE: If more than one tower is being installed, use only the tower intended for each location to mark the mounting screw positions.

5. Position gasket over top of 3" (7.6 cm) access hole and align holes for mounting screws. It is recommended that a small bead of silicon caulking be placed on both sides of the gasket at this point.

6. Route beer tower 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.

The 6 ft beer restrictor lines for beer tower should not be trimmed until completely reviewing the instructions for conduit kits.

72 Part Number STH13 9/10

DISPENSING TOWER TEMPLATE FOR

(7.6 cm)

Cut Out

3" (7.6 cm)

Diameter

BEERMASTER DISPENSING TOWER

NOTE: This template is 50% of actual size.

High Pressure CO2 Regulator (00211500)

INTRODUCTION

The following instructions will cover procedures required for properly installing the Beermaster high pressure CO

KIT CONTENTS

• (1) Beermaster High Pressure CO

with seal

• 20 ft of 5/16" I.D. tubing

• (6) # 8 screws

• (6) tie mounts

• (6) self locking cable ties

• (4) tab clamps Installation should only be performed by qualified

personnel.

regulator.

Gas Regulator

Part Number STH13 9/10 73

INSTALLING

Primary High

Pressure CO

Regulator

To CO

Blender or

Secondary Regulator

Assembly

Seal

1. Determine the location where the beer system CO

tank(s) will be located. CO2 tanks must be

chained securely in place.

2. Attach the primary regulator to the CO seal provided in kit (see the “Attaching Regulator”

tank. Use

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.

Attaching Regulator

74 Part Number STH13 9/10

Securing Vinyl Tubing

Tie Mount

Cable Tie

#8 Screw

Dual Secondary Regulator Kit (00211400)

INTRODUCTION

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

•CO

• 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

gas lines

Part Number STH13 9/10 75

INSTALLING

Beer Keg

Black Vinyl Tubing

from Primary

Regulator or Gas

Blender

Tab

Clamps

5/16" Barb x

1/4" MPT

VIEW

Plug

Black Vinyl

(Attach to Next

Regulator

Assembly)

Lock Bar

Tab Clamp

Boss Coupling

Washer

4 ft Clear Vinyl

Beer Line

Tavern

Head

Refer to the “Secondary Regulator Installation” figure for the following procedures:

1. Mount the dual secondary regulator panel in a convenient location above the area where beer kegs will be stored.

2. Route the CO pressure regulator (or gas blender) and attach to

gas line from the primary high

the 5/16" Barb fitting of the secondary regulator. Use two tab clamps.

Secondary Regulator Installation

76 Part Number STH13 9/10

3. Cut the black vinyl CO2 gas line looped between

Primary High

Pressure CO

Regulator

To CO

Blender

or Secondary

Regulator Assembly

Seal

the two regulators. Attach each CO the 5/16" inlet of the tavern head (not provided).

gas line to

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 STH13 9/10 77

Beermaster Blenders

Outlet for Mixed Gas

(most beers)

Outlet for Mixed Gas

(Guiness)

Secondary

Regulators

Use

reinforced

tubing

suitable for

70-150 PSI

Primary CO

Regulator

Primary N2

Regulator

Use

reinforced

tubing suitable for 70-150 PSI

Secondary

Regulators

Tank

N2/CO2 BLENDER (SINGLE — 00520182, DUAL —

00520183) Installing

1. Decide where the N 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.

3. Hook-up panel using thread sealant on threads and a back-up wrench on panel fittings.

NOTE: Do not use fittings with check valve on inlets. Do not remove 1/4" female threaded fittings from panel, as they contain filters.

4. Test all fitting s for leaks.

5. Use regulators and tubing suitable for 70 – 150 PSI.

NOTE: Regulators set at 50 PSI are suitable on a 50 PSI blender.

6. Secure all cylinders to the wall.

NOTE: Store cylinders in a well ventilated, accessible area.

/CO2 Blender Kit will be

78 Part Number STH13 9/10

Beermaster Low CO2 Alarm Kit

Beermaster

Glycol Chiller

Pump Assembly

Air

Compressor

Mounting

Channel

Support

Stand

The following instructions cover the installation procedures for installing the Beermaster Low CO Alarm Kit. Installation should be performed by qualified personnel.

INSTALLING THE LOW CO

1. Turn OFF CO pressure from line.

at the CO2 tank and bleed all

ALARM KIT

2. Locate the 1/4" x 1/4" x 1/4" stainless steel tee supplied with the alarm kit. Install this tee in the

pressure line between the high pressure

regulator and the medium pressure regulator. Use two tab clamps per connection (refer to the figure below).

NOTE: If beer system is equipped with an blender, tee must be installed upstream of the blender.

3. Locate the alarm box and transformer supplied with kit. Mount the alarm box in a convenient location near the CO slide switch on face of alarm box to “Beeper off”

pressure switch. Place

position.

Part Number STH13 9/10 79

4. Neatly route the two conductor cables of the

CO2 Supply

Low

Pressure Switch

Assembly

1/4" x 1/4" x 1/4"

Stainless Steel Tee

Low CO

Alarm Box

Primary Regulator

set at 40 psig

120 VAC

Outlet

Transformer

alarm box to the low pressure switch and attach to the terminal of the pressure switch (refer to the figure below).

NOTE: Gray cable connector may be shortened.

5. Plug alarm box transformer into 120 VAC, 60 Hz outlet. The CO illuminate.

6. Turn ON CO 40 psig. Slide the switch to “Normal Operation”

alarm “Low Pressure” light should

at the CO2 tank. Adjust pressure to

position; beeper will sound. Press switch to “Test/Reset” position; light will extinguish and beeper will stop.

7. Installation is complete.

80 Part Number STH13 9/10

Component Identification

Tan k

CO2 Tan k

CO2

Alarm

Refrigeration

Unit

Kegs

Cooler

Regulators

Tower

Conduit

Tower

Blender

Typical System

Part Number STH13 9/10 81

Compressor

FUNCTION OF THE COMPRESSOR

Refrigeration pump which draws a low pressure gas on the cooling side of the refrigeration cycle and squeezes or compresses the gas into high pressure on the condensing side of the cycle.

FAILURE OF THE COMPRESSOR

An inoperative or weak compressor would adversely affect the capability of the unit to chill glycol.

82 Part Number STH13 9/10

Condenser

FUNCTION OF THE CONDENSER

A heat exchanger which transfers heat from the refrigerant to the surrounding air.

FAILURE OF THE CONDENSER

A non-operational fan/motor or restricted condenser will reduce the cooling efficiency of the refrigeration unit.

Air Cooled Condenser

Part Number STH13 9/10 83

Cap Tube or Expansion Valve

Compressor

Condenser

Water Bath

Receiver

FUNCTION OF THE CAP TUBE OR EXPANSION VALVE

The cap tube or the expansion valve controls the refrigerant flow. Both controls allow the reduction of liquid refrigerant from high pressure to its evaporating pressure. The expansion valve is better suited for varying temperature conditions.

FAILURE OF THE CAP TUBE OR EXPANSION VALVE

A defective expansion valve or cap tube will not properly regulate the flow of refrigerant.

84 Part Number STH13 9/10

Evaporator Coil

FUNCTION OF THE EVAPORATOR COIL

Coil in the glycol bath in which refrigerant vaporizes and absorbs heat, chilling the bath.

FAILURE OF THE EVAPORATOR COIL

This copper tube assembly is extremely reliable.

Part Number STH13 9/10 85

Glycol Bath

FUNCTION OF THE GLYCOL BATH

Water and glycol reservoir, providing an efficient method of removing heat.

FAILURE OF THE GLYCOL BATH

If not maintained and glycol is allowed to dilute, ice may form, reducing efficiency.

NOTE:

• Three parts water to one part glycol (3:1)

• 17° to 22° on a sugar refractometer

• -10°F on an antifreeze tester

86 Part Number STH13 9/10

Agitator

FUNCTION OF THE AGITATOR

Agitates the glycol in the glycol bath to distribute heat load and keep the bath a consistent temperature.

FAILURE OF THE AGITATOR

An inoperative agitator will warm beer during busy times, causing foaming at the dispensing faucet.

Part Number STH13 9/10 87

Circulating Pump/Motor

Strainer Plate

1/2" O.D. John

Guest Bulkhead

1/2" O.D. Tube

Retaining Collet

Circular Pump

Discharge Cooling

Tube

2 ft x 1/2" I.D.

Insulation

1/2" x 1/2" John

Guest Elbow

1/2" O.D. x 8"

Plastic Tube

Pickup Tube

FUNCTION OF THE CIRCULATING PUMP/MOTOR

Circulates glycol from the glycol bath through the conduit, up to the dispensing faucet and back to the bath, maintaining the temperature of the beer.

FAILURE OF THE CIRCULATING PUMP/MOTOR

A weak or defective circulating pump or motor will cause warm beer and foaming at the dispensing faucets.

NOTE:

• Brass Pump

• No strainers in pumps

• 70 GPH pumps

88 Part Number STH13 9/10

Glycol Bath Strainer

FUNCTION OF THE GLYCOL BATH STRAINER

Keeps debris from continually recirculating throughout the glycol system.

FAILURE OF THE GLYCOL BATH STRAINER

Can restrict the flow of glycol back into the water bath, overflowing the strainer.

Part Number STH13 9/10 89

Conduit

FUNCTION OF THE CONDUIT

Insulated beverage tubing used to move and maintain cold beer and glycol from the refrigeration unit to the dispensing station.

FAILURE OF THE CONDUIT

Temperature will not be maintained an d condensation may develop if the conduit is improperly insulated or if the insulation becomes saturated.

90 Part Number STH13 9/10

John Guest Fittings

Collet

Collet Cover

Wrong

Right

Tubing

Collet

Collet Cover

Tubing

FUNCTION OF THE JOHN GUEST FITTINGS

Provide a “same inside diameter” connection for the beer lines, causing a minimal or no amount of agitation to the beer, reducing foaming. Also are used for the glycol lines in series with the conduit tubing to provide quick and easy connections for the glycol circuit.

FAILURE OF THE JOHN GUEST FITTINGS

These are very reliable fittings when installed properly. The tubing must be cut with a razor type blade to ensure tubing will not be crushed when cutting. The tubing must be pushed completely into the fitting.

Part Number STH13 9/10 91

Restriction Line

FUNCTION OF THE RESTRICTION LINE

Reduces the flow of beer from the faucet. Used with the pressure adjustment to the keg to balance the system, giving a proper foam-free beer flow from each dispensing faucet.

FAILURE OF THE RESTRICTION LINE

If the length is not correct will cause foaming at the dispensing faucets.

NOTE: If too long can cause slow flow. Standard flow rate is 2 oz/sec.

92 Part Number STH13 9/10

Dispensing Faucet

FUNCTION OF THE DISPENSING FAUCET

To dispe nse cold beer with very little agitation and the proper head.

FAILURE OF THE DISPENSING FAUCET

Will dispense inferior beer with excessive foam.

NOTE: If dirty inside or worn or swollen gaskets can cause foaming.

Part Number STH13 9/10 93

Heat Exchanger

FUNCTION OF THE HEAT EXCHANGER

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

FAILURE OF THE HEAT EXCHANGER

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

94 Part Number STH13 9/10

High Pressure Regulator

Caution

FUNCTION OF THE HIGH PRESSURE REGULATOR

Regulates the CO constant 40 psi (2.8 bar) to the secondary regulators, to push the beer from the kegs.

FAILURE OF THE HIGH PRESSURE REGULATOR

Low pressure or a sluggish regulator can ca use pressure variations and different flow rates at the dispensing faucet. High pressure or a creeping regulator will cause the relief valve to relieve.

tank pressure to maintain a

NOTE: 55 psi (3.8 bar) relief

Soda regulators should never be used for beer.

Part Number STH13 9/10 95

Secondary Regulator

Caution

FUNCTION OF THE SECONDARY REGULATOR

Regulates the CO gas used to push the beer.

FAILURE OF THE SECONDARY REGULATOR

Any fluctuations in pressure will cause beer to be dispensed with excessive foam.

NOTE: 55 psi (3.8 bar) relief

or blended CO2 and air or blended

Soda regulators should never be used for beer.

96 Part Number STH13 9/10

Tavern Head

FUNCTION OF THE TAVERN HEAD

Attaches to the keg and provides the pressure inlet and beer outlet from the keg.

FAILURE OF THE TAVERN HEAD

If defective or worn will leak and/or not allow beer to leave the keg properly.

Part Number STH13 9/10 97

Keg

FUNCTION OF THE KEG

Container that holds the pressurized beer.

FAILURE OF THE KEG

Must be properly chilled and not agitated before dispensing.

98 Part Number STH13 9/10

Wall Bracket

FUNCTION OF THE WALL BRACKET

A wall mounted connection point for the tubing coming from the flexible tavern head, connecting to the fixed beer line in the conduit.

FAILURE OF THE WALL BRACKET

This metal fitting is extremely reliable.

Part Number STH13 9/10 99

Blender

26%

23%

GPM Air

40 41 42 43 44 45 46 47 48 49 50

GPM

20 19 18 17 16 15 14 13 12 11 10

FUNCTION OF THE BLENDER

Metering device that blends air or nitrogen with CO supply pressure to the beer, reducing the chance of changing the amount of carbonation in the beer.

FAILURE OF THE BLENDER

If not blended properly could cause over or under carbonation in the beer.

NOTE:

• Air and CO

• Desired Air/CO . The graph on the right can be used as a

guide to determine if setting falls in the recommended range.

100 Part Number STH13 9/10

adjusted to 40 psi (2.8 bar).

mixture should have 23% to 26%

Multiplex 175A04 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Model Numbers

How to Read a Model Number

Accessories

Special Applications

ATTENTION: MARINE INSTALLATIONS

OUTDOOR APPLICATIONS

Model/Serial Number Location

Warranty Information

Complete System Overview

Pressure

Natural Keg Pressures at Sea Level (Pounds/ Square inch)

TEMPERATURE

THE TEMPERATURE/PRESSURE COMBINATION

Multiplex Beermaster™ Beer Dispensing System

PRESSURE SYSTEM

REFRIGERATION SYSTEM

DISPENSING SYSTEM

BALANCING THE SYSTEM

Installation

General

Dimensions and Clearances — All Models

REMOTE CONDENSER

Safe Installation Do’s and Don’ts

Location Requirements

KITCHEN EQUIPMENT INSTALLER REPRESENTATIVE RESPONSIBILITIES

REQUIREMENTS FOR REFRIGERATION UNITS

Installer Instructions

AMBIENT LOCATION REQUIREMENT

Electrical

GENERAL

MINIMUM CIRCUIT AMPACITY

GROUNDING INSTRUCTIONS

Conduit

FLOOR CHASES

Pulling Conduit Through Floor Chase

OVERHEAD INSTALLATION

BASEMENT CONSTRUCTION

CONNECTING BEER CONDUIT

Connecting Main Beer Conduit at Walk-in Cooler

Connecting Beer Conduit to the Tower

BEER RESTRICTOR LINES

Connecting Main Beer Conduit to Branch Beer Conduit

Balancing the System

DETERMINING RESTRICTOR LINE LENGTH AND APPLIED KEG PRESSURE

Pressure Setting and Start-up

Beermaster Wine Dispensing Kit

Multiple Faucets from Same Tank

POSITIONING OF REFRIGERATION UNIT

EQUIPMENT PLACEMENT

ELECTRICAL CONNECTIONS

INSULATING CONNECTIONS

Aeroquip Connection

Condenser and Pre-charged Lines Installation

MULTIPLEX REMOTE CONDENSER PRE-INSTALLATION REQUIREMENTS

MULTIPLEX PRE-CHARGED REFRIGERATION LINES PRE-INSTALLATION REQUIREMENTS

INSTALLING THE MULTIPLEX REMOTE CONDENSER

CONNECTING THE PRE-CHARGED REFRIGERATION LINES

HOW TO SHORTEN THE LINE SETS

HOW TO RE-CHARGE THE LINE SETS

Preparing Glycol

MIXING GLYCOL SOLUTION

INSTALLING THE GLYCOL CIRCULATING PUMP AND MOTOR KIT

Beermaster Dispensing Towers

INTRODUCTION

High Pressure CO2 Regulator (00211500)

INTRODUCTION

KIT CONTENTS

INSTALLING

Dual Secondary Regulator Kit (00211400)

INTRODUCTION

KIT CONTENTS

INSTALLING

Beermaster Blenders

Beermaster Low CO2 Alarm Kit

Component Identification