Multiplex 464-GP SERVICE MANUAL

Flomatic

Beverage Valves

Technician’s

Handbook

This manual is updated as new information and models

are released. Visit our website for the latest manual.

America’s Quality Choice in Refrigeration

Part Number STH15 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 Ca ution 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, but useful, extra information about the procedure you are performing.

Read These Before Proceeding:

Caution

Important

! Warning

We reserve the right to make product

improvements at any time. S pecifications and

design are subject to change without notice.

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 . . . . . . . . . . . . . . . . . . . . .7

How to Read a Model Number . . . . . . . . .8

Model/Serial Number Location . . . . . . . .8

Accessories . . . . . . . . . . . . . . . . . . . . . . .8

Special Applications . . . . . . . . . . . . . . . .12

Warranty Information . . . . . . . . . . . . . . . .12

Installation

Pre-installation Checklist . . . . . . . . . . . . .13

324, 424 & 464 Valves . . . . . . . . . . . . . . .13

Component Identification

Valve Types . . . . . . . . . . . . . . . . . . . . . . . .19

Levers . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Maintenance

Maintenance Schedule . . . . . . . . . . . . . . .23

Cleaning and Sanitizing the Dispensing

Valves and Product Lines . . . . . . . . . . . .25

Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . .28

Setting the Brix . . . . . . . . . . . . . . . . . . . . .32

Operation

Flow Rate . . . . . . . . . . . . . . . . . . . . . . . . .33

Automatic Fill Valve . . . . . . . . . . . . . . . . .34

Troubleshooting

Checklist . . . . . . . . . . . . . . . . . . . . . . . . . .35

Carbonated Water System . . . . . . . . . . . .37

Circulating System . . . . . . . . . . . . . . . . . .44

Dispensing Valve . . . . . . . . . . . . . . . . . . .45

When the Brix is OFF . . . . . . . . . . . . . . . .50

Component Check Procedures

RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

BUZZING . . . . . . . . . . . . . . . . . . . . . . . . . .53

LEAKS . . . . . . . . . . . . . . . . . . . . . . . . . . . .53

Every 6 months (2 times per year) . . . . . 53

Part Number STH15 9/10 5

Component Specifications

Flow Rates . . . . . . . . . . . . . . . . . . . . . . . . 57

424 Specifications . . . . . . . . . . . . . . . . . . 57

464 Specifications . . . . . . . . . . . . . . . . . . 58

Product Viscosity . . . . . . . . . . . . . . . . . . 58

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General Information

Model Numbers

This manual covers the following models:

424 464-GP

(Back Block) 380-Q (Back Block)

372-Q

Tower

Part Number STH15 9/10 7

How to Read a Model Number

GP - Global Performance HF - High Flow

464 454 424 324 202

Model Suffix

Model Base

464–GP

VALVE MODEL NUMBERS

With all models, mounting and ratio control are the same. All Flomatic valves are identified by a Model Number, Serial Number, a manufacture month and year on the underside of the flow control base. These numbers are a helpful reference before beginning any valve service.

Model/Serial Number Location

This number is required when requesting information from your local distributor. All Flomatic valves are identified by a Model Number, Serial Number, a manufacture month and year on the underside of the flow control base. These numbers are a helpful reference before beginning any valve service

Accessories

Manitowoc Foodservice developed this manual as a reference guide for the service agent and installer of fountain equipment.

Fountain dispensing is the serving of a beverage (soft drink, tea, or juice, etc.) from a dispenser that will chill the product to an acceptable serving temperature for the consumer.

The beverage, delivery system and dispenser can be postmix or premix. The system may be an elaborate system with most of the components in the back of the store and the dispenser in the front. Fountain systems could be a simple system with the complete system under the counter where the dispenser is located.

Our goal is that this manual will remove some of the confusion, and mystery of beverage dispensing equipment while providing a general overview of service to the equipment.

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VALVES

Most Flomatic valves are available in sanitary push lever, push button,automatic fill lever, and portion control models.

Replacement

WHAT IS CARBONATION

Carbonation is the process of mixing carbon dioxide gas into a liquid (water). The resulting liquid is called soda water or carbonated water . The carbon dioxide gas is the bubbles you see when a carbonated beverage (like soda) is dispensed.

Most cola, lemon-lime products, etc. are carbonated. Normally teas, juices, etc. are noncarbonated.

Some beverage technicians refer to noncarbonated water as sweet water.

WATER CHARACTERISTICS

Water makes up over 80% of the typical finished beverage. The quality of this primary ingredient is of utmost importance. You should use regular cold tap water, not water that has been through a water sof tener, conditioner, etc. Any of f taste or color should be treated by proper water filtration.

Part Number STH15 9/10 9

WATER FILTERS

It is recommended that proper water filters treat the water supply for the beverages. There are two basic filters commonly in use.

1. Pre-filter, or sand filter . This filter re moves any foreign matter from the water down to 25 microns in size.

2. Carbon or activated charcoal filter is also used. This filter will reduce chlorine and other chemicals, offtaste and odor . Some of the higher quality filters may reduce organic compounds (bacteria) in the water.

Do not use a filter containing any typ e of phosphate on the beverage system. Phosphate as used for scale reduction will cause the beverage to loose its carbonation and become “flat” quickly .

WATER PRESSURES

Dynamic (flowing) water pressures to most carbonators should be a minimum of 40 PSI. Water pressure to dispensers for noncarbonated beverages should be a minimum of 60 pounds. These pressures are minimum operating pressures, not static pressure.

SYRUP BASICS

Your concentrated syrup containers should be stored in a cool dry location that is easily accessible. Any extremes in temperature can wreak havoc with the quality of the product. For best results, the syrup should be maintained in an environment between 40 and 90 degrees.

PREMIX

Premix fountain dispensing consists of a container (figal) of beverage ready for dispensing, beverage delivery system, carbon dioxide (CO

2) propellant,

beverage cooling system, and dispenser. We shall discuss each component of this type of system within the context of this manual.

The major advantage of a premix system over most other types is its flexibility . This flexibility is the ability to go anywhere. Many premix systems will operate without electric power or separate water supply.

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POSTMIX

Postmix fountain dispensing consists of either a tank (called a Figal) or a box (called a Bag-in-Box) of beverage syrup. The postmix system will also include the carbonator, fresh water supply, carbon dioxide (CO

2) supply, syrup delivery system, beverage cooling

system, and dispenser. We shall discuss each component of this type of system within the context of this manual.

The major advantage of the postmix system over most other systems is the very low cost of delivering a high quality, fresh beverage to the consumer utilizing less floor and storage space for the quantity of beverages served.

PIPING

The fountain system is connected together by a series of tubing or hoses. This tubing is called beverage tube or hose and is commonly available in 1/4”, 3/8”, and 1/ 2” inside diameters. Beverage hose is a flexible, highpressure hose. This hose is capable of withstanding system pressures in excess of 100 PSI. The beverage hose may be an individual line or assembled with many lines of hose bundled together.

The beverage tubing or hose is attached to the various components of the system with barbed stems, nuts, tees, etc. The tubing is held onto the fittings with small tube clamps called stepless (Oetiker®) clamps. When attaching the tubing and fitting to a “flared” fitting, the use of a flare washer is required.

Several different type of tubing are available for the beverage industry. If there is any possibility of the tubing laying in a damp environment, the use of nonpermeable tubing should be used. Tubing is also available as a single tube or bundled together. Single tube is available as non-permeable plastic or stainless steel. Bundled tube is available as plastic only.

Part Number STH15 9/10 11

Special Applications

Warning

OUTDOOR APPLICATIONS

Flomatic Valves 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 misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications.

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.

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.

12 Part Number STH15 9/10

Installation

Important

Pre-installation Checklist

When installing any system, first make sure the following has been done:

Relieve the system pressure before removing or repairing the mounting block.

Determine which mounting block you need.

324, 424 & 464 Valves

These valves are available in manual, electric, portion control and automatic fill models. All of these Flomatic valves share the same mounting and flow control characteristics. The 324 valves are also compatible with the 300-Q mounting block.

Flomatic created a kit (5007842) to replace both the 372-Q or 380-Q Flomatic mounting blocks. All Flomatic mounting blocks are identical in appearance, except for the part numbers shown on the front recess of the block. The 380-Q has inlet ports sized at 0.380 in. The 372-Q inlet ports are sized at 0.372 in. Select the appropriate mounting option and install the mounting block. Wet the inlet O-rings with water to ease installation; do not use Vaseline®. Align the four bolt holes and mount

Be sure to relieve the system pressure before removing or repairing the mounting block.

Remove the valve cover and align the valve stems with the mounting block. Independent positive shut-offs and the locking system prevent removal while the system is pressurized. The valve cannot be removed unless the shut-off valves are closed (arrows pointed across service line).

Part Number STH15 9/10 13

The mounting hole pattern typically has key slots to

Valve should seat securely

Shut-off closed

secure the product supply lines. If no key slots are present, use the “S” clip option.

Engage the valve and depress the latch pin. Do not force or you could bend the pin. If you have difficulty, remount the valve and try again. Be sure the valve base is completely seated against the block. Open the shut-off valves by turning 1/4 turn (arrows pointed toward service line) to engage system pressure.

INSTALL ADD-A-LEVER FOR “SODA ONLY”

The Flomatic Add-a-Lever is a two-piece assembly which mounts on the pivot pin. Remove the cover, partially withdraw the pivot pin to allow mounting, reinsert the pin then replace the cover.

CONVERT TO PORTION CONTROL

Flomatic portion control electronics are contained in the cover and can be factory or field installed. When installing in the field, the 5031015 Conversion Kit for the 464-GP makes it easy to add portion control.

The portion control module is designed to simplify installation. The board can be programmed with the first pour.

The “Stop/Fill” button serves as a top-off button and cancels any of the timed portions if you need to abort the pour.

14 Part Number STH15 9/10

Hidden Program Switch

464 Portion Controls

STOP

Hidden Program

Switch

424 Portion Controls

FILL

Each cup size must be programmed separately. Cup sizes are preprogrammed at the factory:

1 second = small 2 second = medium 3 second = large 4 second = x-large.

Set the flow rate first, brix the valve, and then set the cup sizes to match your desired flow rate. Once the valve is brixed, replace the valve cover and set the times (cup sizes) from the front switch pad.

The switch pad has a hidden “program” switch that must be held down to keep the module in program mode. Setting the times or programming is a two-handed operation; push and hold the program switch with one finger while dispensing the cup size you wish to program with another. Once the drink is full, simply release the cup size button to end the pour cycle and then let go of the program switch. Repeat the process for each cup size.

Part Number STH15 9/10 15

The module will remember one top-off cycle

Pivot Pin

Cover

automatically if the foam height requires it to complete the pour. To program a top-off cycle, begin programming as described above. Once the foam crests the top of the cup, PAUSE by removing your finger from the cup size button. Do not release the program button. Pause long enough for the foam to settle, and then continue the pour with your finger on the same cup size button until the cup is full. The module will remember the sequence “pour - pause pour” as it was executed.

If you program the top-off feature, be sure to train the operators so they do not pull a drink before the cycle is complete. The portion control module will finish the pour whether a cup is there or not.

TO CONVERT PUSH BUTTON TO SANITARY LEVER OPERATION

Flomatic Valve W ith Pallet Actu ators

1. Remove the valve cover from the valve.

2. Slide pivot pin far enough to one side to remove the actuator spacer bushing from between the two actuator assemblies.

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3. Slide the pivot pin back into place. Make sure both

Actuator Spacer

Bushing

Actuator Assembly

Actuator Spacer

Bushing

Actuator Assembly

Sanitary Lever

actuator assemblies are mounted correctly on the pivot pin. The “fingers” of the solenoid armature must be located on the back side of the actuators. When the armature pulls into the solenoid, these “fingers” will pull the actuators and open the pallets.

4. Slide sanitary lever from the bottom up into the flow control base. The notch on the sanitary lever will be on the top of the lever facing toward the back of the valve. Hook the notch near the top of the lever over the pivot pin.

5. Snap the electric retainer cap onto the sanitary lever. Make sure it is tight. The retainer cap has a top “arm” extension that is the back portion of the retainer.

6. Remove the screw from the convertible switch housing cover.

Part Number STH15 9/10 17

7. The switch cover snaps together with a top and

Convertible

switch

housing

screw

Switch

bottom half. Unsnap the top cover. Downward pressure on the bottom half of the assembly while unsnapping the sides of the switch assembly makes the job easier. If you accidentally pull the entire switch assembly off the solenoid, you must put it back one piece at a time. Gently lift the micro switch from the two pins in the front of the convertible switch housing base.

8. Being careful not to break any wires, flip the micro switch on its back. Install the switch on the two pins at the rear of the lower switch base. Make sure the button on the switch lines up with the retainer cap arm.

9. Snap the switch housing cover onto the base and re-install the screw. Tighten the screw snug.

10. Install a push lever cover or place a flavor label over the entire front of the valve cover.

18 Part Number STH15 9/10

+ 42 hidden pages