Manitowoc Multiplex N2Fusion, Service Manual

Page 1: ...ce Manual This manual is updated as new information and models are released Visit our website for the latest manual www manitowocfsg com Part Number 020007115 06 27 2019 N Fusion Nitrogen Beverage Dispenser ...

Page 2: ...n about the procedure you are performing Read These Before Proceeding Caution Proper installation care and maintenance are essential for maximum performance and trouble free operation of your equipment Visit our website www manitowocfsg com for manual updates translations or contact information for service agents in your area Importan Routine adjustments and maintenance procedures outlined in this...

Page 3: ...a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures nWarning 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 par...

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Page 5: ...p by Step Installation 15 Pre installation Checklist 15 Remote Tower Installation 16 Nitrogen Regulator Tank Assembly 17 Nitrogen Installation Replacement 18 Nitrogen Connections Pressures 18 N2 Quick Disconnect Drain 19 Keg Pump Regulators 19 Keg Connections 21 Door Hinge Reversal 22 Section 3 Operation Product Dispense Operation 23 Prerequisites 23 Operation 23 Taps Nozzles 23 Flow Control Locki...

Page 6: ...on 5 Troubleshooting Dispensing Issues 35 Dispensing Flowchart 36 Pouring 37 Coffee Dispense System 37 Pump Flowchart 38 No Power Flowchart 39 Refrigerator Cabinet Issues 39 Refrigerated Cabinet Flowchart 40 Cabinet Temperature Out of Range 41 High Product Temperature 41 Refrigeration System Diagnostics 42 Refrigeration System Checklists 42 Discharge Pressure High Checklist 42 Discharge Pressure L...

Page 7: ...osing Start Components 47 Compressor Electrical Diagnostics 48 Compressor Drawing Locked Rotor 48 Diagnosing Capacitors 48 Filter Driers 49 System Contamination Clean Up 50 General 50 Determining Severity Of Contamination 50 Cleanup Procedure 51 Replacing Pressure Controls 52 Section 8 Charts Total System Refrigerant Charge 53 Section 9 Diagrams Wiring Diagram 55 Plumbing Diagram 56 Programmable l...

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Page 9: ...erage Dispenser is a self contained dispensing unit that allows the operator to dispense chilled and or nitrogenized drink combinations of coffee It holds product containers or kegs in a refrigerated reach in base enclosure The operator controls the product pour on the unit using mechanical beer style taps Drink size options are manually controlled Purging and cleaning are controlled through and i...

Page 10: ... 30 75 78cm ND21RS02 This dimension represents units using 1 25 3 175cm low profile casters regular casters are 1 25 3 175cm taller nWarning To avoid instability the installation area must be capable of supporting the weight of the equipment Additionally the equipment must be level side to side and front to back CAPACITY WEIGHT Model Max Capacity Volume Weight ND21TS00 3 3 Gallon 11 36L Coffee Keg...

Page 11: ...limate class 4 Location must have proper ventilation DO NOT install in an enclosure enclosed cabinet with no access to ambient air The location must not be near heat generating equipment or in direct sunlight and must be protected from weather Verify floor of install location is within 1 2 1 3 cm of level front to back side to side Keep equipment area clear of combustible material Do not install t...

Page 12: ...ord International units only The following instructions cover the installation of a 220VAC 50 60 Hz international unit An appropriate 3 wire power receptacle must be located within 6 ft 1 8 m of the unit Unpack the unit from its transportation packaging and visually check for any signs of damage NOTE Only use an approved plug for the country in which the unit is being installed Importan The wires ...

Page 13: ...rate 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 Follow applicable lock out tag out procedures before working on equipment H Connect to a properly grounded outlet only See Grounding Instructions SYSTEM PRESSURES Sup...

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Page 15: ... should be noted and reported to the delivering carrier immediately Check the lower portion of the unit to be sure casters are not bent Visually inspect the refrigeration package compressor compartment housing Be sure lines are secure and base is still intact Inspect installation location behind the unit for electrical outlet location and Nitrogen N2 Power unit up by plugging into power source Che...

Page 16: ...nduit and tower mount screw holes will be drilled 3 Cut and drill holes in the counter using the markings NOTE Drip trays equipped with a drain will need a 7 8 2 22cm hole drilled into the counter using the provided template for routing to a floor drain Mounting Routing Importan Make sure the rubber counter top gasket is in place on the tower before routing conduit and mounting tower To Cabinet TA...

Page 17: ...can be hazardous if not handled properly Make sure you READ and UNDERSTAND the following procedures for nitrogen cylinders BEFORE installation Importan Use only food grade nitrogen 99 5 pure 1 ALWAYS connect the nitrogen cylinder to the primary regulator and NEVER directly to the unit keg or dispensing system Failure to do so could result in an explosion with possible death or injury when the cyli...

Page 18: ...ey B as far out as it will go The regulator is now in the off position 3 Remove regulator from empty cylinder at D 4 Remove dust cap from new cylinder at D Open and close valve A quickly to blow dust from outlet 5 With cylinder valve A in closed position re attach regulator to cylinder at D 6 Open valve A all the way This is important because this cylinder valve seals in two places 7 Screw regulat...

Page 19: ...ly Connection Drain Line Floor Drain N2 Purge Tube 2 Air Gap NOTE Purge tube releases under pressure make sure it is fastened down 4 Ensure drain line is not kinked or otherwise blocked for proper drainage KEG PUMP REGULATORS 5 Once the nitrogen line is hooked up to the unit check the pressures on the two 2 regulators located in the back of the unit Regulator 1 Keg Regulator 2 Nitrogenator 6 Verif...

Page 20: ... Set each regulator by slowly turning the adjustment knob clockwise to increase the pressure Importan If the target pressure is missed and the regulator pressure is too high start over Set the regulator back to zero then relieve all system pressure from the keg and nitrogenator See Step 11 A Set Regulator 1 Nitrogen Tank to Coffee Keg Set to 16 psi 2 psi 110 MPa 110 kPa 1 10 bar Push the yellow lo...

Page 21: ...y seat in the grove below the taper CollarGroove Connecting the Keg DANGER Never stand directly over keg when connecting disconnecting or when keg is pressurized Importan Only use AEB Kegs Available from Manitowoc Foodservice 3 First connect the Black quick connect line to the connection labeled OUT on the coffee keg This supplies coffee to Tap 1 and 2 Importan Hook the OUT line up to the coffee k...

Page 22: ...ded 10 Check for leaks inside the cabinet and at the taps 11 Close cabinet door and unit is ready for use DOOR HINGE REVERSAL Instructions for installations that require the cabinet door to be reversed 1 Use a screwdriver to remove the top metal hinge pin NOTE Lock tight was used during factory installation so extra force may be required 2 Tilt door out from top and slide bottom pin out of the hin...

Page 23: ...performance do not allow both taps to remain fully opened for extended periods of time TAP 1 Surface TAP 2 Importan TAP 2 Contains an o ring diffuser disc and diffuser Tap 1 Regular Coffee Tap 2 Nitrogenized Coffee HOW TO REMOVE NOZZLES A Rotate nozzle counter clockwise by hand no tool should be required for removal NOTE Be aware of the diffuser and o ring in the tap 2 nitro nozzle If they are tak...

Page 24: ...de Importan Make sure new coffee keg has been chilled to the operating temperature range of 45 36 F 7 2 C before use or may cause foaming in the system DANGER Never stand directly over keg when connecting disconnecting or when keg is pressurized 1 DisconnecttheGASIN gray fittingfromthekegbypulling upontheringaroundtheconnectortoreleasefromthepost Pull up on ring around connector to release 2 Leave...

Page 25: ...imed it is ready to pour drinks 4 Close cabinet door and unit is ready for use NOTE See Error Code on page 44 if priming fails and the LED blinks continuously NITROGENATOR Nitrogen tank is equipped with a pressure relief valve that will automatically purge when pressure exceeds operating limit of the system of 100 psi 689 MPa 689 kPa 6 89 bar When valve relieves there may be a quick pressure relie...

Page 26: ...or other debris in the strainer and clean if needed HOW TO REMOVE STRAINER A First depressurize the system and disconnect the keg See KegChange onpage24 B Put down a towel or small cloth to catch any coffee that may still be in the line or bowl during removal C Grasp the bowl and rotate counterclockwise to loosen and remove the bowl Strainer Gasket Bowl NOTE The strainer is a metal mesh ring that ...

Page 27: ...Warning Never Use Steel Pads Wire Brushes or Scrapers nWarning Do not damage the refrigeration circuit when installing maintaining or servicing the unit nWarning Disconnect power to the unit before performing any service or maintenance functions Importan Never use a high pressure water jet for cleaning or hose down or flood interior or exterior of units with water Do not use power cleaning equipme...

Page 28: ...and gaskets STAINLESS STEEL CARE CLEANING To prevent discoloration or rust on stainless steel several important steps need to be taken First we need to understand the properties of stainless steel Stainless steel contains 70 80 iron which will rust It also contains 12 30 chromium which forms an invisible passive film over the steel s surface which acts as a shield against corrosion As long as the ...

Page 29: ... high pressure water wash for this cleaning procedure as water can damage the electrical components located near or at the condenser coil GENERAL CLEANING Interior Cleaning Notic When cleaning interior and exterior of unit care should be taken to avoid the rear power cord Keep water and or cleaning solutions away from electrical parts Importan Never use a high pressure water jet for cleaning or ho...

Page 30: ... gallon pressure kegs One 1 for cleaning solution Two 2 for sanitizing solution Importan Kegs used for cleaning sanitizing solutions and rinse water should be emptied and cleaned before reuse 3 Towels wipes brushes and buckets Use clean towels for any spilled fluid during cleaning process Small cleaning wipes for cleaning top sides and interior of unit A small brush is useful to clean keg connecti...

Page 31: ...that ships with the unit part number 9290312 Weekly Cleaning Weekly cleaning consists of the following De pressurizing the system Cleaning the In Line Strainer Mixing approved cleaning sanitizing solutions Keg connectors cleaning sanitizing Using the Prime Clean button to perform system cleaning sanitizing Prime Clean Button Cleaning Keg Cleaning Hoses 5 Gallon Bucket Performing Daily Cleaning But...

Page 32: ...on Bucket 3 Following completion of the second sanitizing keg A Close the taps system B Leave only nitrogen in the system until unit is placed back in service nWarning This equipment is intended for indoor use only DO NOT install operateorstorethisequipmentinoutdoorareasor where the unit may be subject to freezing temperatures nWarning DO NOT leave sanitizer in system for extended periods of time ...

Page 33: ...pull out of the frame which may damage both the doors and the hinges In some cases this may require qualified service agents or maintenance personnel to perform repairs Door Adjustment If the door needs lowering at the handle use a 5 16 8mm wrench to loosen the hinge screws and install a spacer outside of the hinge Tighten the screws If the door needs to be higher at the handle use a 5 16 8mm wren...

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Page 35: ...on section checklist See Controls Programming Settings onpage44 andSee KegChange onpage24 Coffee keeps leaking from the clear drain hose The nitrogenator tank relief valve is stuck open Close or replace There is a hissing sound coming from the nitrogen tank Regulator nut Tighten regulator nut See Nitrogen Regulator Tank Assembly on page 17 Check for missing washer inside of regulator nut There is ...

Page 36: ...T IS THERE 24VDC AT PLC VERIFY STORE N GAS TANK CONNECTED AND REGULATED AT 90PSI UNIT NOT DISPENSING ONE OR BOTH TAPS IS 120VAC AT POWER SUPPLY INLET CONNECTOR CHECK POWER HARNESS ON IS 24VDC AT POWER SUPPLY OUTLET VERIFY POWERCORD AND OUTLET REPLACE POWER SUPPLY ARE BOTH INLINE FUSES OK REPLACE ONE OR BOTH FUSES YES YES YES YES YES YES YES NO NO NO NO NO NO NO NO VERIFY WIRE INSERTED PROPERLY AT ...

Page 37: ...urned ON and connected to the unit See Nitrogen Installation Replacement on page 18 3 Is Nitrogen supply pressure to unit between 85 90 psi 586 621 MPa 586 621 kPa 5 86 6 21 bar See System Pressures on page 13 4 Is Regulator 1 Nitrogen Tank to Coffee Keg set to 16 psi 2 psi 110 MPa 110 kPa 1 10 bar See System Pressures on page 13 5 Is Regulator 2 Nitrogen Tank to Nitrogenator set to 34 psi 2 psi 2...

Page 38: ...DC AT POWER SUPPLY OUTLET VERIFY POWERCORD AND OUTLET REPLACE POWER SUPPLY ARE BOTH INLINE FUSES OK REPLACE ONE OR BOTH FUSES YES YES NO NO NO VERFIY LDD HAS FLUID AND TUBING CONNECTED VERIFY WIRING BETWEEN PLC AND VERIFY 15VDC AT PLC PIN I 06 VERFIY N GAS TANK CONNECTED AND REGULATOR VALUE 90PSI CHECK KEG CONNECTION TUBING AND ATTEMPT TO PRIME UNIT IS THERE 24VDC AT PLC NO NO VERIFY WIRE INSERTED...

Page 39: ... cold Also check gasket condition Cabinet temperature is too high Thermostat set too high Set thermostat to lower temperature Poor air circulation in cabinet Re arrange product to allow proper air circulation Excessive amount of warm product placed in cabinet Allow adequate time for product to cool down Prolonged door openings or door s ajar Make sure door s are closed when not in use Avoid prolon...

Page 40: ...cles Machine On Off No Yes No Yes Replace Motor Power To Fan Motor Repair Wiring Shaft Turns Replace Fan Blade No Yes No Yes Power Supplied Plug In Reset Breaker No Temperature Set 45º 36º No Reset Temperature Verify Compressor Overload is Closed Start Components Function Condenser Fan Motor Functions Voltage Must Be Within 10 Of Nameplate At Compressor Startup Compressor On No Yes Yes Compressor ...

Page 41: ...thin Spec s refer to Refrigeration diagnostics See Refrigeration System Diagnostics on page 42 Below temperature limit Compare temps on internal gauge Check temperature control HIGH PRODUCT TEMPERATURE Check Duct Cooling Fan Product temperature is greater than 42 F Verify the door was not left open or warm product was added Reboot machine by unplugging waiting 30 seconds then plugging back in Veri...

Page 42: ...t Non OEM components in system SUCTION PRESSURE HIGH CHECKLIST Improper Installation Refer to Installation Visual Inspection Checklist Discharge Pressure Discharge pressure is too high and is affecting suction pressure Improper Refrigerant Charge Overcharged also see Freeze Cycle Discharge Pressure High Checklist Wrong type of refrigerant Non condensible in system Components Defective compressor O...

Page 43: ...d hold the Prime Clean button until the LED turns OFF Priming may be required to put the unit back into dispense mode PRIMING MODE Press once to prime the coffee line The LED around the button will flash ON once then OFF signifying that the Prime function has been activated NOTE The pump will run for up to twenty 20 seconds while priming Once the system is primed it is ready to pour drinks Priming...

Page 44: ...E Error mode can be caused by the following A Keg Needs Primed or Failed to Prime B Keg is Empty Clearing Error Code To exit error state Close both taps if open Press and hold the Prime Clean button until the LED around the button turns OFF This clears the error state and exits into keg change mode NOTE Primingisrequiredafterabortingcleaningorclearingan error See PrimingtheSystem onpage43 Onceaner...

Page 45: ...6 27 2019 45 Component Identification EXTERNAL Front TAP 1 Nozzle Drain Cabinet Door TAP 2 Nozzle with Diffuser Back Tower N Quick Connect PLC Compressor Power Supply Sensor Control Board Section 7 Component Check Procedures ...

Page 46: ...H PRESSURE CUTOUT HPCO CONTROL Function Protects the compressor by interrupting the control signal to the control board Excessive high side pressure operates the HPCO The HPCO control is normally closed and opens on a rise in discharge pressure Location Above the ice compressor Specification Refrigerant Type Cut Out Cut In R404A 2413 kPa 24 13 bar 69 350 psig 10 1723 kPa 17 23 bar 69 250 psig 10 R...

Page 47: ...r a mechanically seized compressor To determine which you have 1 Install high and low side gauges 2 Try to start the compressor 3 Watch the pressures closely A If the pressures do not move the compressor is seized Replace the compressor B If the pressures move the compressor is turning slowly and is not seized Check the capacitors and relay COMPRESSOR DRAWING HIGH AMPS The continuous amperage draw...

Page 48: ...act If continuity is present the compressor windings are grounded and the compressor should be replaced COMPRESSOR DRAWING LOCKED ROTOR To determine if the compressor is seized check the amp draw while the compressor is trying to start The two likely causes of this are a defective starting component and a mechanically seized compressor To determine which you have Install high and low side gauges T...

Page 49: ... filter drier will cause the refrigeration system to be improperly charged with refrigerant Driers are covered as a warranty part The drier must be replaced any time the system is opened for repairs Refer to the parts manual for the recommended OEM field replacement drier Check Procedure The drier should not alter the temperature of the refrigerant Compare the temperature of the copper pipe either...

Page 50: ...levels of contamination or if a test kit is not available inspect the compressor oil 1 Remove the refrigerant charge from the machine 2 Remove the compressor from the system 3 Check the odor and appearance of the oil 4 Inspect open suction and discharge lines at the compressor for burnout deposits 5 If no signs of contamination are present perform an acid oil test Check the chart to determine the ...

Page 51: ...t charge 2 Remove the compressor and inspect the refrigeration lines If burnout deposits are found 3 Wipe away any burnout deposits from suction and discharge lines at compressor 4 Sweep through the open system with dry nitrogen 5 Install a new compressor and new start components 6 Install a suction line filter drier with acid and moisture removal capability Place the filter drier as close to the ...

Page 52: ... complete nWarning Do not unsolder a defective component Cut it out of the system Do not remove the pinch off tool until the new component is securely in place 3 Cut the tubing of the defective component with a small tubing cutter 4 Solder the replacement component in place Allow the solder joint to cool 5 Remove the pinch off tool 6 Re round the tubing Position the flattened tubing in the proper ...

Page 53: ...rigerant R 290 propane is flammable in concentrations of air between approximately 2 1 and 9 5 byvolume LELlowerexplosionlimitandUELupper explosion limit An ignition source at a temperature higher than 470 C is needed for a combustion to occur Refer to nameplate to identify the type of refrigerant in your equipment Importan Due to continuous improvements this information is for reference only Plea...

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Page 55: ...P8 2 2 MOLEX_39 01 2020 1 1 AMP_2 520183 2 FS61 Diode Diode Diode 1 2 S12 2 2 MOLEX_39 01 2021 1 2 S13 2 2 MOLEX_39 01 2021 1 1 T1 1 1 T2 1 1 FS62 1 1 FS63 1 1 FS64 1 1 FS65 SP7 1 1 FS66 1 1 FS67 1 1 FT24 1 1 FT25 1 1 AMP_3 521142 2 FT26 1 1 AMP_3 521142 2 FT27 1 3 S9 2 3 3 3 AMP_640250 3 1 6 S5 2 6 3 6 4 6 5 6 6 6 1 4 P13 2 4 3 4 4 4 MOLEX_22 01 2047 1 5 P11 2 5 3 5 4 5 5 5 MOLEX_22 01 2057 1 6 P...

Page 56: ...56 Part Number 020007115 06 27 2019 Diagrams Section 9 PLUMBING DIAGRAM NITROGEN COFFEE NITRO COFFEE ...

Page 57: ... Sytem Power ON Pour State T tboot PS NORMAL KE Keg Change T tboot PS NORMAL KE T tboot Not Pouring Not Pouring IDLE Pump OFF SVs OPEN Keg Empty Pump OFF SVs CLOSED NI FULL DEC KE Pouring Still Pouring Nitro Pouring Both TS CLOSED TN OPEN TS TN OPEN TS OPEN TN CLOSED Keg Change NI Filling Pump ON SVs OPEN NI EMPTY INC NI FULL ANY TS TN CLOSED KE PS NORMAL ...

Page 58: ...D TN OPEN TS TN OPEN TS TN CLOSED Keg Change NI Filling Pump ON SVs OPEN NI EMPTY INC NI FULL ANY TS OPEN TN CLOSED KE PS NORMAL Pouring Nitrogenized Coffee Pouring Nitro Pour Pump OFF SVs OPEN Keg Empty Pump OFF SVs CLOSED NI FULL DEC KE Not Pouring Pouring Still Pouring Both TS OPEN TN CLOSED TS TN OPEN TS TN CLOSED Keg Change NI Filling Pump ON SVs OPEN NI EMPTY INC NI FULL ANY TS CLOSED TN OPE...

Page 59: ...LL ANY TS TN OPEN KE PS NORMAL Cleaning Mode Cleaning Mode Flood NI LED ON Pump ON SVs CLOSED Soak LED ON Pump OFF SVs OPEN Flush Taps LED ON Pump ON SVs OPEN T tfni T tft T ts Run to Empty LED ON Pump ON SVs OPEN Keg Empty LED OFF Pump OFF SVs CLOSED KE ANY Switch Hold tcp KE PS NORMAL ERROR LED FAST BLINK Pump OFF SVs CLOSED KE T tfni KE T tft KE T ts T tfni T tft T ts Switch Hold tap Keg Change...

Page 60: ...t Keg New Keg Connected LED OFF Pump OFF SVs CLOSED Connect Keg Pump Prime LED OFF Pump ON SVs CLOSED KE Switch Press tpd tpl T tp tpl KE KE T tp KE LED Flash LED ON Pump ON SVs CLOSED T tpl Keg Change Switch Hold tep Pump Monitor Pump Monitor ANY Pump Motor ON Pour State T tprm Pump Motor ON Pump Motor Timeout LED FAST BLINK Pump OFF SVs CLOSED T tprm Pump Motor ON Keg Change Switch Hold tep Pump...

Page 61: ...eaning Mode NI Tank Flood time tft 60s Cleaning Mode Dispense Taps Flush time ts 60s Cleaning Mode Solution Soak time tpni 120s Cleaning Mode NI Tank Purge time tcp 3s Cleaning Mode Entry Switch Press Hold time tap 3s Cleaning Mode Abort Switch Press Hold time tep 3s Error Clear Switch Press Hold time tpl 1s Keg Change Pump Prime LED flash time tp 20s Keg Change Pump Prime time maximum tpd 7s Keg ...

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Page 64: ...vement may necessitate change of specifications without notice Part Number 020007115 06 27 2019 Every new piece of Manitowoc Foodservice equipment comes with KitchenCare and you choose the level of service that meets your operational needs from one restaurant to multiple locations StarCare Warranty lifetime service certified OEM parts global parts inventory performance audited ExtraCare CareCode 2...