Page 1 Beermaster ™ Refrigeration Units Technician’s Handbook This manual is updated as new information and models are released. Visit our website for the latest manual. www.manitowocfsg.com America’s Quality Choice in Refrigeration Part Number STH13 9/10...
Page 3 Safety Notices 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...
Page 4 ! Caution Proper installation, care and maintenance are essential for maximum performance and trouble- free 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.
Page 5: Table Of Contents
Table of Contents General Information ..... . . 9 Model Numbers ... . . 9 How to Read a Model Number .
Page 6 .....91 John Guest Fittings ..... . .92 Restriction Line .
Page 7 Charts ....151 Conduit Specification Chart ....152 Natural Keg Pressures Chart ....153 System Calculators Diagrams .
Page 8 Part Number STH13 9/10...
Page 9: General Information
General Information Model Numbers This manual covers the following models: (R) Remote (A) Air Cooled (W) Water Cooled 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...
Page 10: Accessories
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.
Page 11: Warranty Information
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.
Page 12: Complete System Overview
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,...
Page 13 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.
Page 14 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...
Page 15 26 ft (7.9 m) Total Conduit Length: 50 ft (15.2 m) 38°F 8 ft (3.3°C) Altitude: (2.4 m) 1,000 ft (304.8 m) 8 ft (2.4 m) 5 ft (1.5 m) Walk-in Cooler 4 ft (1.2 m) TEMPERATURE The effects of temperature are manifested in several ways.
Page 16 in a larger head of foam. To maintain the correct temperature in the tower, care must be taken to ensure that a sufficient amount 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...
Page 17 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...
Page 18: Multiplex Beermaster™ Beer Dispensing System
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.
Page 19 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 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 to help...
Page 20 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.
Page 21 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.
Page 22 BALANCING THE SYSTEM 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.
Page 23: Installation
Installation 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 Wall 12" 6" (15.2 cm) minimum (30.5 cm) minimum 18"...
Page 24 Ceiling Conduit to Dispensing Towers Regulator Panel (Optional) Drain Plug Front View Part Number STH13 9/10...
Page 25 Part Number STH13 9/10...
Page 26: Safe Installation Do's And Don'ts
REMOTE CONDENSER OPTIONAL 27.94" 38.00" (96.52 cm) 1.50" (70.97 cm) 34.00" (86.36 cm) (3.81 cm) 29.50" 30.00" (76.20 cm) (74.93 cm) 29.16" (74.06 cm) OPTIONAL 6.50" 20.00" (50.80 cm) 6.00" (16.51 cm) 16.00" (40.64 cm) (15.24 cm) 12.00" (30.48 cm) 3.50"...
Page 27 • DO use caution when handling metal surface edges of all equipment. • DO handle CO cylinders and gauges with care. Secure cylinders properly against abrasion. • DO store CO cylinder(s) in well ventilated areas. • DO NOT exhaust CO gas (example: syrup pump) into an enclosed area, including all types of walk-in coolers, cellars, and closets.
Page 28: Location Requirements
Location Requirements 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: •...
Page 29 KITCHEN EQUIPMENT INSTALLER REPRESENTATIVE RESPONSIBILITIES Prior to scheduling Multiplex Equipment installer, the following steps listed below must be completed: 1. Electrical power supply meeting the requirements for the unit to be installed. (See the specification in this section or refer to the unit’s serial plate). 2.
Page 30: Installer Instructions
Installer Instructions 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.
Page 31 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.
Page 32 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.
Page 33: Conduit
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) •...
Page 34 Part Number STH13 9/10...
Page 35 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.
Page 36 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.
Page 37 OVERHEAD INSTALLATION Part Number STH13 9/10...
Page 38 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.
Page 39 BASEMENT CONSTRUCTION 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.
Page 40 4. Once the conduit has been routed, ensure an adequate supply of conduit is on hand to make all connections. CONNECTING BEER CONDUIT ! Caution Only an approved cutting tool should be used to cut polyethylene tubing. The cutting tool should contain a razor sharp cutting blade so that the tubing will not be crushed when cutting.
Page 41 Part Number STH13 9/10...
Page 42 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 •...
Page 43 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.
Page 44 Connecting Main Beer Conduit at Walk-in Cooler 1. At the top of each beer wall bracket fitting, found on the dual secondary regulator, secure a Beer Nut, John Guest adapting tail piece, washer, and 1/2" John Guest union (see the following image). 2.
Page 45 Connecting Beer Conduit to the Tower Glycol lines in 1. Peel the insulation back from the end of the beer conduit to expose all lines. Locate the appropriate glycol circuit lines, cut to length and attach a 1/2" John Guest union to each line (see the “Tower Connections”...
Page 46 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"...
Page 47 3. Locate the appropriate beer line(s) in the main beer conduit to be connected to the branch conduit. Cut desired beer line(s) long so that they can be pulled back and then routed in a smooth curve into the branch conduit. Attach appropriate beer line(s) from main beer conduit to beer line(s) in branch beer conduit with 1/2"...
Page 48: Balancing The System
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.
Page 49 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...
Page 50 EXAMPLE A 26 ft (7.9 m) Total Conduit Length: 50 ft (15.2 m) 38°F 8 ft (3.3°C) Altitude: (2.4 m) 1,000 ft (304.8 m) 8 ft (2.4 m) 5 ft (1.5 m) Walk-in Cooler 4 ft (1.2 m) EXAMPLE B 5 ft (1.5 m) 26 ft (7.9 m)
Page 51 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.
Page 52 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).
Page 53 3. After leak testing all glycol and beer supply lines, wrap the lines firmly with foil (to ensure a good heat exchange) and then insulate all lines; to ensure a minimum of 1" insulation over all areas of exposed beverage line. 4.
Page 54: Beermaster Wine Dispensing Kit
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.
Page 55 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).
Page 56 ELECTRICAL CONNECTIONS ! Caution Make sure power supply to unit is turned off. NOTE: The electrician must refer to the nameplate and wiring schematic on the refrigeration unit for correct electrical requirements. All wiring must comply with all safety codes. Make sure all refrigeration unit power switches are in the OFF position.
Page 57 INSULATING CONNECTIONS 1. Make sure all exposed lines are well insulated on towers to conduit, conduit junctions, refrigeration unit to conduits. 2. To insulate the above, use the leftover conduit sections and tape. 3. Cut the conduit sections to fit snugly over the exposed lines and fittings.
Page 58: Aeroquip Connection
Aeroquip Connection 1. Lubricate male half diaphragm and synthetic rubber seal with refrigerant oil. 2. Thread male coupling to its proper female half by hand to ensure proper mating of threads. 3. Use proper wrenches (on coupling body hex and its union nut) and tighten union nut until coupling bodies “bottom”.
Page 59 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.
Page 60 Discharge Line Condenser Trap To the Condenser 3" (7.6 cm) x 6" (15.2 cm) Discharge Line Trap Every Maximum Trap Area 25 Vertical ft. (7.62 m) Compressor 3 ft (.9 m) (minimum) of Discharge Line Trap at the Compressor 4. The trap(s) must be of minimum height of 3" (7.6 cm) and a width of 6"...
Page 61 3. The General Contractor or Owner must secure two treated lumber 4" x 4" x 36" (or longer). You may then mount the remote condenser to the treated lumber. 4. The General Contractor or Owner must install a 3" pitch pot in the roof. Then seal for weather protection.
Page 62 tubing, you must cut out the excess before connecting the ends. When cutting the tubing, you must first evacuate the refrigerant (line sets have a positive refrigerant holding charge of two to three ounces). After shortening and welding the tubing together again, you must evacuate the tubing to 250 microns.
Page 63 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.
Page 64 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.
Page 65 ! Caution Relays and terminal block are energized from each remote unit. Turn OFF switches on each unit before opening quick disconnect switch on condensing unit. On the completion of the wiring of the remote condenser make sure the electrician placed the switch lever in the ON position.
Page 66: Preparing Glycol
Preparing Glycol MIXING GLYCOL SOLUTION 1. Inspect the glycol reservoir tank for dirt and/or foreign debris. The tank must be clean before mixing glycol solution. 2. Locate the glycol kit: Model 75 3 Gallons (19 ltr) Glycol Model 150 5 Gallons (19 ltr) Glycol Model 300 15 Gallons (57 ltr) Glycol Model 450...
Page 67 Glycol Bath Tank Overflow Tube Drain Plug Clamp NOTE: Verify that the pump box holding tank is full before proceeding. 6. Turn on the circulator. The circulator must run continuously. Verify that glycol is returning to the glycol bath through the return bulk head fitting. Part Number STH13 9/10...
Page 68: Additional Glycol Circulating Pump And Motor Kit
Additional Glycol Circulating Pump and Motor Kit Pump and Motor Kit Carriage Bolts (Later Units) 5/16" - 18 Hex Nut Mounting Studs (Early Units) Motor Installation NOTE: Only two fasteners required. Part Number STH13 9/10...
Page 69 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 Tube Installation Part Number STH13 9/10...
Page 70 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).
Page 71 11. Locate the 1/2" O.D. x 4" or 8" plastic tube, provided with kit. Insert one end of this tube into the upper bulkhead fitting. Insert opposite end of this tube into hole of strainer plate (see “Pump Connections” figure). 1/2"...
Page 72: Beermaster Dispensing Towers
Beermaster Dispensing Towers 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"...
Page 73: High Pressure Co 2 Regulator (00211500)
DISPENSING TOWER TEMPLATE FOR BEERMASTER DISPENSING TOWER NOTE: This template is 50% of actual size. 3" (7.6 cm) Cut Out 3" (7.6 cm) Diameter High Pressure CO Regulator (00211500) INTRODUCTION The following instructions will cover procedures required for properly installing the Beermaster high pressure CO regulator.
Page 74 INSTALLING 1. Determine the location where the beer system tank(s) will be located. CO tanks must be chained securely in place. 2. Attach the primary regulator to the CO tank. Use seal provided in kit (see the “Attaching Regulator” figure). 3.
Page 75: Dual Secondary Regulator Kit (00211400)
Cable Tie Tie Mount #8 Screw Securing Vinyl Tubing 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.
Page 76 INSTALLING 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 gas line from the primary high pressure regulator (or gas blender) and attach to the 5/16"...
Page 77 3. Cut the black vinyl CO gas line looped between the two regulators. Attach each CO gas line to the 5/16" inlet of the tavern head (not provided). Use one tab clamp per connection. 4. Attach each of the clear vinyl beer lines to the beer outlet of the tavern head.
Page 78: Beermaster Blenders
Beermaster Blenders BLENDER (SINGLE — 00520182, DUAL — 00520183) Installing 1. Decide where the N Blender Kit will be mounted. NOTE: Be sure the panel is on a wall in a well ventilated, accessible indoor area that is out of harm’s way.
Page 79: Beermaster Low Co Alarm Kit
Beermaster Glycol Chiller Compressor Mounting Channel Support Stand Pump Assembly Beermaster Low CO Alarm Kit 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 ALARM KIT 1.
Page 80 4. Neatly route the two conductor cables of the 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.
Page 81: Component Identification
Component Identification Typical System Tower Tower Regulators Cooler Conduit Blender Alarm Tank Kegs Tank Refrigeration Unit Part Number STH13 9/10...
Page 82: Compressor
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.
Page 83: Condenser
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...
Page 84: Cap Tube Or Expansion Valve
Cap Tube or Expansion Valve 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.
Page 85: Evaporator Coil
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...
Page 86: Glycol Bath
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) •...
Page 87: Agitator
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...
Page 88: Circulating Pump/Motor
Circulating Pump/Motor 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.
Page 89: Glycol Bath Strainer
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...
Page 90: Conduit
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 and condensation may develop if the conduit is improperly insulated or if the insulation becomes saturated.
Page 91: John Guest Fittings
John Guest Fittings 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.
Page 92: Restriction Line
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.
Page 93: Dispensing Faucet
Dispensing Faucet FUNCTION OF THE DISPENSING FAUCET To dispense 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.
Page 94: Heat Exchanger
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.
Page 95: High Pressure Regulator
High Pressure Regulator FUNCTION OF THE HIGH PRESSURE REGULATOR Regulates the CO tank pressure to maintain a 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 cause pressure variations and different flow rates at the dispensing faucet.
Page 96: Secondary Regulator
Secondary Regulator FUNCTION OF THE SECONDARY REGULATOR Regulates the CO or blended CO and air or blended 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 ! Caution Soda regulators should never be used for beer.
Page 97: Tavern Head
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...
Page 98: Keg
FUNCTION OF THE KEG Container that holds the pressurized beer. FAILURE OF THE KEG Must be properly chilled and not agitated before dispensing. Part Number STH13 9/10...
Page 99: Wall Bracket
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...
Page 100: Blender
Blender 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.
Page 101: Low Co 2 Alarm
Low CO Alarm FUNCTION OF THE LOW CO ALARM Sounds an alarm when the CO tank is empty. FAILURE OF THE LOW CO ALARM When you lose CO pressure you will not have pressure to push the beer. With blended gas, if only air is supplied to the blender the beer in the kegs could loose carbonation.
Page 102 This Page Intentionally Left Blank Part Number STH13 9/10...
Page 103: Maintenance
Maintenance Major Components DISPENSING STATIONS Daily (365 Times per Year) • Take temperature of beer. Pour off the first glass and take the temperature of the second glass of beer. The proper temperature of the dispensed beer is 36°F (2.2°C) to 40°F (4.4°C). •...
Page 104 GAS BLENDER Every 4 Months (3 Times per Year) • Inspect gas blender and verify CO and air flow meters are set at the proper flow rate. Adjust if necessary. GAS SUPPLY Every 4 Months (3 Times per Year) • Inspect pressure setting at CO high pressure regulator.
Page 105: Scheduled Frequency
Scheduled Frequency Daily (365 Times per Year) • Take temperature of beer. Pour off the first glass and take the temperature of the second glass of beer. The proper temperature of the dispensed beer is 36°F (2.2°C) to 40°F (4.4°C). •...
Page 106: Shipping, Storage And Relocation
Shipping, Storage and Relocation ! Caution Before shipping, storing, or relocating this unit, beer systems must be sanitized. After sanitizing, all liquids (sanitizing solution and water) must be purged from the unit. A freezing environment causes residual sanitizing solution or water remaining inside the unit to freeze, resulting in damage to internal components.
Page 107: Operation
Operation How the Multiplex Works The refrigeration units are remote refrigeration units that derive their peak capacity from the water/glycol bath. A tower is used to dispense the beer at the desired location. Conduit (an insulated bundle of tubing) connects the refrigeration unit and kegs of beer to the tower.
Page 108 6. Turn on the rocker switches for the circulating pumps. 7. Add glycol/water mix as needed to maintain correct bath level. Units with Touch Pad (ERC Controls) NOTE: These units have part numbers that end with “E” and only applies to these units. 1.
Page 109: Sequence Of Operation
Sequence of Operation ELECTRONIC TEMPERATURE CONTROL (ETC) The Electronic Temperature Control (ETC) has been factory preset and tested. The ETC will turn the refrigeration compressor on and off to maintain the glycol bath temperature between 27°F (-2.7°C) and 29°F (-1.6°C). This is considered the best temperature range for most beer cooling applications.
Page 110 PROGRAMMING A REPLACEMENT ELECTRONIC TEMPERATURE CONTROL These instructions apply to programming a Johnson A419 Electronic Temperature control for cooling mode application in a Multiplex Beermaster system. Replacement controls are not pre-programmed at the factory; thus, the following programming steps are required.
Page 111 7. Press the MENU button to display the current value. (5) 8. Press the Down ↓ button to change the display to 2. 9. Press the MENU button to save the new value. 10. Press and hold the MENU button until display changes to flashing SP.
Page 112 energize the circulating pumps and turn on their respective LEDs constantly. The display will show the water/glycol bath temperature. The compressor and condenser fan will continue to run until set temperature is reached. Once reached the compressor and condenser fan will turn off and the LED will change from flashing to constantly on to display that there is power.
Page 113 There are 4 programming modes: 1. View conductivity 2. Add additional (third or fourth) circulation pumps 3. Set water/glycol temperature 4. Temporarily cancel display of error codes SER Switch • LED is energized when LON communication network is connected. • LED is de-energized when LON communication network is disconnected.
Page 114 • Program CIRC C — Press CARB A button — Display shows -102 = Carb A button energizes/ de-energizes pump C • Program CIRC D — Press CARB B button — Display shows -012 = Carb B button energizes/ de-energizes pump D Press and hold PGM switch for 3 seconds to save settings and exit program mode.
Page 115 PROGRAM MODE 4 Temporarily cancel display of error codes. Cancelling the error codes allows circulating glycol temperatures to be displayed until the error can be corrected. • Press PGM button for 3 seconds — Display shows 0001. • Press PGM button three times — Display shows 0004 program mode 4.
Page 116: Equipment Setup And Close Procedure
Equipment Setup and Close Procedure EQUIPMENT SETUP PROCEDURE 1. Observe pressure of CO high pressure tank of 500 PSI (34 bar) or more, or bulk CO tank of 150 PSI or more. Primary regulator set at 90 PSI (6 bar) and the secondary regulator set at 35-40 PSI (2.4-2.6 bar) depending on the type of beer.
Page 117 MULTIPLEX ELECTRONIC REFRIGERATION CONTROL (ERC) PROGRAMMING Part Number STH13 9/10...
Page 118 Part Number STH13 9/10...
Page 119: Troubleshooting
Troubleshooting Foreword This Troubleshooting Guide has been developed to assist you in determining what the probable cause for any particular problem you may experience with your Multiplex Beermaster Beverage System could be. It then advises of the proper corrective action to be taken to remedy that problem.
Page 120 This guide is intended to assist you in locating the cause of a problem. It is not, however, to be considered a service and repair manual in that Multiplex models vary in design. It has been written to encompass all model Beermaster Glycol Chillers.
Page 121: Checklist
Checklist If a problem arises during operation of your refrigeration unit, follow the checklist below. Routine adjustments and maintenance procedures are not covered by the warranty. Warning Only trained and certified electrical and plumbing technicians must service this unit. All wiring and plumbing must conform to national and local codes.
Page 122 Problem Possible Cause To Correct Section 1: Restriction Too little restriction Too much or too little restriction in a draught beer system will cause drawing problems. If draught beer system does not have enough restriction it may cause the following problems: A recovery problem When drawing one Since the recovery...
Page 123 Problem Possible Cause To Correct Section 2: Beermaster Glycol Chiller System When troubleshooting a closed remote system, one should consider the following areas: Temperature Beer draws warm Check coolant circulation and is all foam. • Inspecting the coolant circulation pump to ensure it is on and running.
Page 124: Etc Error Codes
Problem Possible Cause To Correct Pressure Beer runs with System may be under streaks. restricted. Add additional restriction to system by adding additional 3/16" I.D. vinyl tubing to the faucet end of the system. Beer draws great See above. Check during slow time of regulator for proper day but turns to all...
Page 125: Erc Error Notes
ERC Error Notes • Error codes will interrupt the temperature display and stay active until the error is corrected. • If multiple errors are present, the errors will rotate and display every 5 seconds. • Resetting errors — After correcting the problem, the respective switch for the error must be cycled OFF and then ON to reset.
Page 126 ERROR CODES E1, E2, & E3 FLOWCHART Part Number STH13 9/10...
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Page 128 ERROR CODES E4, E5, & E6 FLOWCHART Part Number STH13 9/10...
Page 129 Part Number STH13 9/10...
Page 130 ERROR CODES E7, E8, & E9 FLOWCHART Part Number STH13 9/10...
Page 131 Part Number STH13 9/10...
Page 132 COMPONENT TROUBLESHOOTING Part Number STH13 9/10...
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Page 137: Component Check Procedures
Component Check Procedures Head Pressure Control Valve Multiplex remote systems require head pressure control valves with special settings. Replace defective head pressure control valves only with “original” Multiplex replacement parts. OPERATION The R404A head pressure control valve is non adjustable. At ambient temperatures of approximately 70°F (21°C) or above, refrigerant flows through the valve from the condenser to the receiver inlet.
Page 138 When the temperature drops below 70°F (21°C), the head pressure control valve fails to bypass and the ice machine malfunctions. Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle. Probable Corrective Condition Cause Measure Discharge Pressure - High...
Page 139: Charging Multiplex Remote Refrigeration Unit
Charging Multiplex Remote Refrigeration Unit NOTE: System would have been opened for repairs. Once completed, a vacuum of 500 microns would have been maintained for 1/2 hour. The proper procedure for charging the system includes the reintroduction of all refrigerant that had been recovered before making the repair.
Page 140: Compressor & Remote Condenser
Compressor & Remote Condenser FAN / REMOTE CONDENSER COMPRESSOR REFRIGERATION SYSTEM OUTPUT TERMINALS ARE COMMON TO COMPRESSOR COMPRESSOR COMPRESSOR OUTPUT TERMINALS WILL NOT GO WILL NOT COME ON ERC CHECK CONNECTORS AND WIRING TO FAN / REMOTE VERIFY KEYPAD/DISPLAY GOOD, CONDENSERCHECK SEE KEYPAD / DISPLAY TROUBLE MOTORS...
Page 141: Agitator Condenser
Agitator Condenser AGITATOR AGITATOR AGITATOR WILL NOT GO WILL NOT OFF WITH COME ON WITH KEYPAD KEYPAD BUTTON / LED BUTTON / LED VERIFY KEYPAD/DISPLAY GOOD, SEE KEYPAD / DISPLAY TROUBLE SHOOTING PAGE 7 AGITATOR AGITATOR WILL WILL STILL NOT STILL NOT GO OFF COME ON...
Page 142: Carbonation System A Or B
Carbonation System A or B CARBONATOR SYSTEM A OR B CARB MOTOR CARB MOTOR DOES NOT DOES NOT TURNON TURNOFF VERIFY NO “E1” ERRORGOTO FIRSTVERIF PROGRAM MODE 1 CONDUCTIVITY Y PRG “C000” MODE 2 IS SET TO “- 002”FOR BOTH CARB PRESS CARB A AND/OR CARB B PUMPS BUTTON, VERIFY CARB A AND/OR B...
Page 143: Circulation System A Or B
Circulation System A or B CIRCULATING SYSTEM A OR B CIRC MOTOR CIRC MOTOR DOES NOT DOES NOT TURNON TURNON VERIFY NO “E1” ERROR VERIFY KEYPAD / DISPLAY WORKS, CIRC LED GOES ON AND OFF VERIFY VOLTAGE AT CIRC OUTPUT TERMINALS ON CHECK ALL WIRES CONNECTORS TO...
Page 144: Erc Control Board, Keypad & Display
ERC Control Board, Keypad & Display ERC CONTROL BOARD AND KEYPAD / DISPLAY KEYPAD / ERC POWER DISPLAY NOT LED NOT ON WORKING KEYPAD VERIFY PROPER BUTTON(S) DO VOLTAGE ON NOT RESPOND, ERC TERMINALS RESPECTIVE L1 AND L2 LEDS DO NOT COME ON TURN POWER POWER ERC...
Page 145: Programming / Auto Set
Programming / Auto Set CARB A AND/OR CARB B MOTOR COMPRESSOR DOES NOT REACT ONLY A OR B (OR NONE) STAYS ON CONSTANTLY WHEN TO ICE BANK PROBE (SODA & CIRCULATING WATER RESPECTIVE BUTTON ACTIVATED TEMPERATURE DISPLAYED ON CHILLER UNITS) OR BEER UNIT INSTEAD OF STOPPING WHEN CARB KEYPAD, UNIT HAS TWO CIRC DOES NOT REACT TO WATER...
Page 146: Erc Component (Output) Connector Layout
ERC Component (Output) Connector Layout AGITATIOR CARB A CARB B CIRC A CIRC EARTH PLUG THIS PIN ERC Sensor (Input) Connector Layout CA A CA B HPCO WATER HIGH PROBE HPCO SWITCH LOW PROBE HIGH PROBE +5V DC LOW PROBE OUTPUT HIGH PROBE +5V DC...
Page 147: Component Specifications
Component Specifications Specifications MULTIPLEX BEEMASTER SELECTION CHART Model #* Line length up to 75' up to 150' up to 300' up to 450' Included glycol circulation pump Optional up to 1 up to 2 glycol additional additional additional circulation pumps Qty of up to 22 up to 32...
Page 148 NOTE: Refer to serial plate on front of refrigeration unit for voltage and amperage specifications. Make all electrical connections at the junction box located at the top rear of unit. Optional equipment may require additional power supplies. Warning Carbon Dioxide displaces oxygen.
Page 149: Electrical
Electrical Warning All wiring must conform to local, state and national codes. MINIMUM CIRCUIT AMPACITY The minimum circuit ampacity is used to help select the wire size of the electrical supply. (Minimum circuit ampacity is not the beverage/ice machine’s running amp load.) The wire size (or gauge) is also dependent upon location, materials used, length of run, etc., so it must be determined by a qualified electrician.
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Page 151: Conduit Specification Chart
Charts Conduit Specification Chart Conduit Specifications Choose # of Beer Brewmaster Beer Glycol Glycol Total Flavors 2 Conduit Chase Lines Lines Circuits Lines Part # Size MC043346 MC053346 MC063346 MC073346 MC083346 MC103346 MC123346 MC143346 MC163346 MC193346 MC203346 glycol MC023346 line** * To maximize system performance on 6-flavor applications, Multiplex recommends using a 10 line conduit with 4 glycol lines/2 circuits.
Page 152: Natural Keg Pressures Chart
Natural Keg Pressures Chart Natural Keg Pressures at Sea Level (lb/in Cooler Temperature Brewing Company 36°F 38°F 40°F 42°F Anheuser Busch Adolph Coors 14.5 15.5 16.5 17.5 (requires 1/4" Ported Shanks) Miller 12.5 13.5 14.5 15.5 Schlitz/Stroh's Add 1 psi to adjust for altitude for every 2000 ft above sea level. An additional 1 psi may be required for “Light”...
Page 153: System Calculators
System Calculators BEER PUMP, SYSTEM PRESSURE AND CHOKER CALCULATOR Part Number STH13 9/10...
Page 154 A = Natural Keg Pressure at Sea Level (PSI) Cooler Temperature Product 32° 34° 26° 38° 40° Anheuser- Busch Coors Miller 10.5 11.5 12.5 13.5 14.5 Schlitz / Stroh’s Part Number STH13 9/10...
Page 155 BLENDED GAS BEER SYSTEM PRESSURE AND CHOKER CALCULATOR Part Number STH13 9/10...
Page 156 PURE CO BEER SYSTEM PRESSURE AND CHOKER CALCULATOR Part Number STH13 9/10...
Page 157 Natural Keg Pressure at Sea Level (PSI) Cooler Temperature Product 32° 34° 26° 38° 40° Anheuser- Busch Adolph Coors Miller 10.5 11.5 12.5 13.5 14.5 Schlitz / Stroh’s Part Number STH13 9/10...
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Page 159: Circuit Diagrams
Diagrams Circuit Diagrams Single Conduit, Two Beer System Part Number STH13 9/10...
Page 160 Dual Conduit, Eight Beer System Part Number STH13 9/10...
Page 161 Single Conduit, Eight Beer System Part Number STH13 9/10...
Page 162: Wiring Diagrams
Wiring Diagrams MODEL 75 Optional Circulator Motor Agitator Motor Start Relay Compressor Start Component Legend Line 1 Neutral Motor Contactor Pressure Switch Ice Bank Control Part Number STH13 9/10...
Page 163 MODEL 75 WITH ELECTRONIC TEMP CONTROLS Part Number STH13 9/10...
Page 164 MODEL 150 Optional Circulator Motor Compressor Start Agitator Motor Component Legend Line 1 Neutral Motor Contactor Pressure Switch Ice Bank Control Part Number STH13 9/10...
Page 165 MODEL 150 WITH ELECTRONIC TEMP CONTROLS Part Number STH13 9/10...
Page 166 MODEL 350 Agitator Motor Compressor Start 120 Volt, 60 Hz, 1 Phase Domestic 230 Volt, 50 Hz, 1 Phase Export Component Legend Line 1 Neutral Motor Contactor Pressure Switch Ice Bank Control Part Number STH13 9/10...
Page 167 MODEL 350 (WITH ERC 50 HZ) 50HZ 50HZ Part Number STH13 9/10...
Page 168 MODEL 450 (50 HZ) Models 450MAX04 TO945023-353 50HZ 50HZ 450MRX04 TO945024-353 450MWX04 TO945025-353 Caution: Disconnect power before working on electrical circuitry. See Serial Plate for Voltage Shown in the OFF Position Power Supply Block Remote Cond Air Option Contactor Motor Motor (Black) (Black)
Page 169 MODEL 450 (60 HZ) Models 450MA04 TO945013-363 60HZ 60HZ 450MR04 TO945014-363 450MW04 TO945015-363 Caution: Disconnect power before working on electrical circuitry. See Serial Plate for Voltage Shown in the OFF Position Air Option Contactor Remote Cond Motor Motor (Black) (Black) Sensor Temp Controller Common...
Page 170 MODEL 450 (WITH ERC 50 HZ) Models 450MAX04 TO945023-353 50HZ 50HZ 450MRX04 TO945024-353 450MWX04 TO945025-353 Caution: Disconnect power before working on electrical circuitry. See Serial Plate for Voltage Shown in the OFF Position Power Supply Block Terminal Strip Jumper Contactor Option Remote Cond...
Page 171 MODEL 450 (WITH ERC 60 HZ) Models 450MA04 TO945013E-363 60HZ 60HZ 450MR04 TO945014E-363 450MW04 TO945015E-363 Caution: Disconnect power before working on electrical circuitry. See Serial Plate for Voltage Shown in the OFF Position Air Option Contactor Remote Cond Motor Motor (Black) (Black) RMT Only...
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Page 174 Manitowoc Foodservice 2100 Future Drive Sellersburg, IN 47172, USA Ph: 812-246-7000 Fax: 812-246-7024 Visit us online at: www.manitowocfsg.com © 2010 Manitowoc Part Number STH13 9/10...

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Manitowoc Multiplex Beermaster 75A04 Technician's Handbook

General Information

Installation

Component Identification

Maintenance

Operation

Troubleshooting

Component Check Procedures

Component Specifications

Charts

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