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SHURFLO®

PRODUCT INSTALLATION& OPERATING GUIDELINES

PRODUCT INSTALLATION AND OPERATING GUIDELINES WWW.PENTAIRFOODSERVICE.COM

Product Installation andOperating Guidelines

Contents

1 Pumps PageSyrup 1-9Juice 10-15Beer Ace II 16-20Brix Proportioning 21-30Electric Wine Pump 31-32Variable Speed Electric Pump 33-34Electric Wine and Beer Pump Installation 35-44

2 System AccessoriesSold Out Switch 45-46Automatic Selector Valve 47-50BIB Rack Assembly 51-55Fob-Stop 56-59

3 R.O and Water BoostWater Boost Systems 60-61R.O. Silver Series Pumps 62Brushless D.C. Booster Pump 63R.O. Pump Power Supply 64

Illustrations and tabulated information shown in this publication are for guidance only, anddoes not constitute a contractual offer. For applications requiring critical data please contactyour local Pentair officeInformation is believed to be accurate at the time of publication.Pentair reserves the right to alter product specifications without notice.


1

Design: Two chamber double diaphragm.

Power Source: CO2 gas, Nitrogen or clean compressed air.

Materials of Construction: Polypropylene, Celcon, EPDM, Santoprene,Stainless steel.

Body colour: Black.

Temperature Limits: 1.1 to 49C (34 to 120 degrees F).

Weight: 0.5 kg (1.2 lbs).

Size: 171mm (7.3'') H x 145mm (5.9'') W x 97mm (3.8'') D.

Fittings available: Liquid6mm (1/4''), 10mm (3/8'') & 12mm (1/2'')straight and elbows in plastic or st. st. 10mm(3/8'') J. Guest style smooth stem.Gas6mm (1/4'') elbow and “T” with check valve,6mm (1/4'') elbow and straight no check valve.10mm (3/8'') and 8mm (5/16'') J. Guest stylesmooth stem.

Displacement: 101cc per cycle.

Maximum Operating Pressure: 5.8 bar (85 psi).

Minimum Operating Pressure: 1.4 bar (20 psi).

Flow Rate: Approximately 3.30 litres (6 pints) per minutedependant on viscosity.

Advantage(Gas Pump)

Model Number 166-296-XX


2

Heavy Duty Advantage Pump

Advantage(Design)

New Smooth Body is Easier to Keep

Clean and Can Handle Higher

Operating Pressure

Straight Through Flow Path

Pistons are Allowed

to Float Apart if

Reverse Pressure is

Applied to Pump

One Piece Piston Diaphragm

Heavy Duty Actuator

Mechanism Increases Life

Hydraulic Advantage-

Syrup On Inside of Piston

and Air on Outside:

Reduces Pressure Drop

Quick Disconnect Fittings

Reduces Labor and Parts

When Replacing Pumps


3

SHURflo’s Beverage Gas Pump supplies syrup under pressure to a post-mixdispenser, which mixes the syrup with water to an exact ratio (brix).

The pump is used in conjunction with non-pressurised Bag-In-Box (B-I-B) containers and a bag connector (Q.D.) fitting. The pump can beoperated on regulated CO2 nitrogen or compressed filtered air. Thecompressed gas drives the pump and is not in contact with the syrup.Separate syrup and gas chambers prevent contamination, foaming andpurging of the outlet tubing when the B-I-B has emptied.

The pump retains pressure in the outlet line, operating only when syrup isneeded. When the dispenser valve is opened, the pump reacts to the pressuredrop by operating to maintain pressure in the line. When the dispenser is closed,the incoming gas and output syrup pressures equalise and the pump stops. Actual dynamic linepressure is dependent upon system losses as outlined in the section “Pumping Capability”.

The automatic “sold-out” feature within the pump ensures consistent syrup delivery right up to themoment the B-I-B is empty. Vacuum produced by the pump evacuates the syrup within the bag.Once the pre-set vacuum point is achieved and held, incoming gas pressure to the pump is shutoff causing the outlet syrup pressure to drop to zero. When a new B-I-B is installed, thevacuum drops, the pump automatically restarts and pressurises the system. The SHURfloBeverage Gas Pump ensures quality from the first drink to the last.

Application InformationBeverage Gas Pumps are intended for soda syrups concentrates that do not contain solids.

The use of SHURflo Juice Pump (-09) is recommended for concentrates containing soft solids,classed as round, up to 0.025 in [0.6mm] or that are of higher viscosity than soda syrups.

When concentrates contain pulp classed as long/stringy, seed particles or are exceptionally viscous the Particulate Juice Pump (-10) should be used as it can handle soft solids up to 1/4” [6mm] cube.

Installation GuidelinesAs indicated on the pump, the outlet port is to be mounted up.

Pumps are to be mounted at the same level or higher than the B-I-B. The best choice is tohave the pump above the B-I-B.

MAXIMUM INLET tubing length is 10 ft. [3M], with NO MORE than a 5 ft. [1.5M] vertical lift.Use only 3/8” I.D. [10mm] heavy wall (1/8” [3mm]) clear, NSF listed vacuum tubing from theB-I-B to the pump.

Inlet tubing should not have excessive length. Tubing that is allowed to drape down can trapair in the B-I-B creating a potential for pump “sold-out” problems.

Advantage(Gas Pump)

Beverage Gas Pump 166-296-XX


4

If plumbing multiple B-I-B’s to a pump, B-I-B’s should be “Teed” side by side horizontal,rather than on top of the other (vertically).

OUTLET tubing from the pump to the dispenser should be high pressure rated and NSF listed.

Always cut CO2 and outlet tubing at least 2 ft. [6M] longer to provide a “service loop” so the B-I-B rack can be moved for cleaning or service.

Use new (clean), 1/4” I.D. [6mm], flexible, high pressure, braided tubing from the CO2regulator to the pump.

NEVER connect a transfer tank “system” in series with a B-I-B system. Syrup contaminants in oldcomponents may work their way through the air supply causing premature failure of the gas pump.The gas used to drive the pump MUST be clean and contain no contaminants (syrup, oil, rust,water, etc). Air compressors may be used with proper particle filters and moisture separators Airstorage tanks should be drained regularly. Pumps subjected to contaminated air are not covered by warranty.

High concentrations of CO2 can be fatal, as it will displace the air from non-ventilated areas.Pumps operated by CO2 must be in ventilated areas. If placed in a confined area (basement, closet, cooler, box, etc.), exhaust fans capable of changing the room air on a continuous basisshould be used.

All tubing connections must be secured with stainless steel, stepless Oetiker® clamps.

Cable-tie all tubing securely to prevent kinks or sags that inhibit performance or cause damage to the pump fittings.

Start-up Procedure1. Confirm that all tubing connections are properly clamped,fittings are tight, and tubing is not

kinked. Install bag connector the B-I-B.

2. Adjust gas regulator to about 20 psi. [1.4 bar] allowing the pump to stroke slowly.

3. Operate the valve until all air trapped within the tubing has been purged.

4. Once the air has been purged, adjust the CO2 regulator to the pressure necessary to maintain the desired brix. The most efficient gas usage occurs at 40 psi. [2.8 bar]. MAXIMUM static gas pressure to the pump is 85psi. [5.8 bar], minimum 20 psi. [1.4 bar].

Flowrates that result in a stroke-rate of more than two strokes per second will decrease pump life.

To prevent air from entering the system always leave the bag connector attached to the empty B-I-B until a new B-I-B can be installed. Air entered into the system, via air in the bags or vacuum leaks, may cause brix fluctuation, foaming spitting, non-operation of the vacuum sold-out or pump “run-on” with the valve closed. Symptoms of this kind can lead to a misdiagnosis of the pump.

Advantage(Gas Pump)


5

Pump Sanitising/WinterizingSanitization of the SHURflo Beverage Gas Pump is required. The frequency of Sanitization is dependanton the concentrate type and its manufacturer’s requirements. Factors which also affect the frequency ofthis procedure are temperature, concentrate volatility, facility conditions, installation and equipment.

Pumps that are subjected to freezing (below 32ºF [0ºC] must be purged of fluid to prevent damage.

Refer to the equipment manufacturer’s instructions for sanitising and winterzing procedure forcarbonators, dispensers and tubing.

Pumps that have been winterized and/or out of service for a period of time should be sanitised prior tobeing placed back in service.

Never apply pressure to the pump’s liquid inlet. Pressurised tanks may damage internal components ifused to sanitise or purge fluid from the pump (operating or not).

Advantage(Gas Pump)


6

Does not operate/Gas applied/Dispenser Valve open3 B-I-B empty or inlet tubing pinched off activating vacuum “sold-out”3 Gas regulator over-pressurized3 Outlet tube kinked or restricted3 Operated without fluid for excessive period (Dry run)3 Transfer tube and gas lines contaminated (syrup, rust, oil, etc.) [ensure clean gas supply,

change out all contaminated pumps]3 Internal damage of control cover

Operates but will not prime/Dispenser Valve open[consult Start-up Procedure for proper priming]3 Pump valves have no moisture/dry [add water to the inlet port with pump stroking slowly]3 Vacuum leaks at Q.D., barb fitting clamps, or inlet fitting o-ring3 Debris in valve seats or warped/swollen valves.

Does not achieve sold-out with empty B-I-B3 Vacuum leaks at Q.D., barb fitting clamps, or inlet fitting o-ring3 Excessive amount of air in B-I-B from improper packaging3 Air trapped in outlet tubing and/or fluid chambers

Air in Inlet and/or Outlet tubing3 Vacuum leaks at Q.D. o-ring or barb fitting clamps3 Vacuum leaks at inlet fitting; o-ring pinched or missing3 Large amounts of air noticed only in the outlet tubing when pump operates [diaphragm/

piston assemblies required]

Strokes with dispenser valve closed3 Air trapped in outlet tubing and/or fluid chambers [open outlet and purge air, check for

vacuum leaks, or air in B-I-B]3 Debris in outlet valves or warped/swollen valves

Fluid from exhaust or visible within gas inlet tubing3 Carbonator check valve3 Ensure clean gas supply3 Diaphragm/piston assemblies ruptured [change out all contaminated pumps]

Gas blowing from exhaust continuously3 Control cover subjected to contaminated gas supply or damaged [ensure clean gas supply,

change out all contaminated pumps]

Advantage(Gas Pump)

Troubleshooting


7

Calculating Maximum Pumping Distance

Advantage

1 Obtain the maximum horizontal tubing length from tables (=A).

2 Take 3% of the maximum horizontal tubing length in meters (=B). B = A * 0.03

3 Multiply the result above by the vertical distance (=V). C = B * V

4 Subtract this product (C) from the max. horizontal tubing length (A) to obtain the maximum pumping distance (=Lmax). Lmax = A-C


8

Advantage(Example)

10mm. (3/8'') I. D. TUBING

GAS IN

10mm. (3/8'') I. D. VACUUM TUBING

BIBHEAVYSODA

SYRUP

TOTAL TUBINGLENGTH

113m. (370ft.)

6.7m. (22ft.)VERTICAL

FAST FLOW VALVE15ml/sec (1/2 oz/sec)

1 A = 152m (from tables)

2 B = 152 * 0.03 = 4.56m

3 V = 6.7m; C = 4.56 * 6.7m = 30.5m; C = 30.5m

4 Lmax = 152 - 30.5m = 121.5m

The maximum tubing length is 121.5m, while the example only requires 113m.


9

Maximum Horizontal Tubing Length vs. Viscosity Table

Advantage

Flow Rate 6mm I.D. 10mm I.D. 13mm I.D.(1/4'') (3/8'') (1/2'')

Oz./sec ml./sec Feet Meter Feet Meter Feet Meter

0.5 15 500+ 152+ 500+ 152+ 500+ 152+0.75 22.5 500 152 500+ 152+ 500+ 152+1.0 30 453 138 500+ 152+ 500+ 152+1.5 45 212 65 500+ 152+ 500+ 152+2.0 60 102 31 500 152 500+ 152+2.5 75 64 19 398 121 500 152 3.0 90 32 9 297 90 500 1523.5 105 – – 212 65 500 152

0.5 15 500 152 500+ 152+ 500+ 152+0.75 22.5 133 40 500 152 500+ 152+1.0 30 79 24 388 118 500 1521.5 45 32 9 193 59 500 1522.0 60 10 3 127 39 366 112

0.5 15 129 39 500 152 500+ 152+0.75 22.5 75 23 345 105 500+ 152+1.0 30 53 16 239 73 500 1521.5 45 26 8 127 39 425 129

DietSoda Syrup(5 cps ± 3)

StandardSoda Syrup(20 cps ± 3)

HeavySoda Syrup(35 cps ± 3)

Distances shown are intended as a guideline only.


10

Juice Gas Pump

Model Number 94-360-12

Design: Twin Chamber Double Diaphragm.

Materials of Construction: Polypropylene, EDPM, Santoprene, 316 Stainlesssteel, FDA Sanctioned, NSF listed.

Power Source Dry CO2, Nitrogen, or filtered compressed air.

Operating Pressure 4.7 bar [70 psi.] MAX./1.4 bar [20 psi.] MIN.

Displacement 74cc per cycle.

Maximum Stroke Rate One cycle p/sec intermittent duty.

Sold Out Automatic – No reset requiredActivated at 20 in/Hg. [508 mm/Hg.].

Temperature Limits 1.1º – 49ºC [34º – 120ºF].

Weight 0.5 kg.

CO2/Air Fitting Standard plastic 6 mm [1/4”] 90ºOptional “T” or 90º plasticAll with internal check valve.

Liquid Fittings (STD.) 13 mm [1/2”] Barb, Plastic, 90º (black Polypropylene).

Available Fittings 6 mm [1/4”], 10 mm [3/8”], and 13 mm [1/2”] barb, Plastic or Stainless Steel; Straight or 90º configurations.


11

Juice Gas Pump94-360-12

Model 94-360-12 (Particulate Juice pump) is designed to transfer concentrates that contain, pulp classedas long/string, seed particles, or soft solids up to 6mm cube. It is also recommended for concentrates thatare extremely viscous. The pumps valve cartridges minimize the collection of particulates and promotesthorough flushing during sanitization.Both models of the Juice pump are compatible with concentrates that are acidic (low pH value), and areidentified by black inlet and outlet fittings.Juice concentrates are generally supplied in flexible plastic bags, packaged inside cardboard boxes (Bag-In-Box). Juice concentrates generally require more frequent sanitization. The manufacturer of the concentrate should specify the interval for sanitising; however, other factors such as system configuration,and/or temperature may affect concentrate life.The Juice pump pressurizes the concentrate to match the pressure of the gas supply. The pump can beoperated on regulated CO2, nitrogen, or clean compressed air. The compressed gas is used to operate the pump and does not come in contact with the concentrate. The pump operates when concentrate isneeded, which is termed as its “automatic demand” feature. When the post-mix dispenser valve is opened,the pump reacts to the drop in pressure by operating to maintain pressure in the line. When the dispensingvalve is closed, the input gas and output concentrate pressures equalize and the pump stops. As the B-I-Bempties, the pump draws a vacuum above 508 mm/Hg. [20 in/Hg.]. When a new B-I-B is connected thevacuum drops, the pump automatically resumes pumping.

Pumping CapabilityDue to diversity of both the installations and equipment used within beverage systems, it is difficult to calculate/predict total pumping distance. The ability to deliver fluid is limited by the dynamics of the fluidand pump displacement at pressure. Consider all the following factors when estimating pressure dropwithin a beverage system.• Fluid viscosity (Centipose/cP.) @ temperature. • Inside diameter of the inlet/outlet tubing, fittings,

etc.• Horizontal distance of the outlet tubing. • Total syrup flow rate of valve(s) supplied by a given

pump.• The pressure drop per foot within vertical tubing runs is significant. To estimate the losses use the

appropriate distance given by Max. Horz. Dist. Chart. Take 1% of that distance (3% if metres). Multiplythe vertical distance by that number. Subtract the product from the original Max. Horz. distance. Theresult is the total tubing run (includes vertical) that should be attempted for that flow rate, tubing I.D.,and viscosity.

Example: The facility requires a total tubing run of 196 ft.[60m]; included in that run is a 4.26m [14ft.]vertical.The product is 100% Grape juice dispensed by one fast flow valve (14.8 cc/sec [.5 oz/sec.]).The distance chart indicates 76m [248 ft.] (50-100 cP @ .5 oz/sec) with 10mm I.D.[3/8”] tubing.

1% of 248 is 2.48, which is then multiplied by 14 ft, equaling approximately 35 ft. Subtracted that productfrom the 248 ft. (248-35 = 213. 213 ft. is the total tubing run that can be achieved including the 14 ft vertical.To calculate the vertical losses for distances measured in metres, take 3% of the distance given [76m] = 2.28.Multiply by the vertical metres (2.28 x 4.26 = 9.7). Subtract that product (76-9.7 = 66.3). 66.3 metres is thetotal tubing run that can be achieved including the 4.26m vertical.NOTE: Had the example above resulted in a value that was equal to, or less than the necessary total tubing

run, consider a larger I.D. tubing or installation of a pump(s) in series using a vacuum regulator.


12


Maximum Horizontal Distance by Viscosity (cP)The following tables are to be used as a guideline only.

• Values in Bold create an inlet vacuum of 16” Hg. or higher at flow rates shown. Inlet tubing used was 3/8” I.D. [10mm]with a total length of 5 ft, with 3 ft. of vertical lift. Conditions of this kind should use 1/2” [13mm] I.D. vacuum tubingwith minimal vertical lift. Fittings such as Liquibox Q.C.D.™ III connector and bag fitment are less restrictive and utilizea larger barb fitting/tubing which can minimise inlet vacuum.

• Product viscosity and solids content may vary, depending upon the manufacture and type of concentrate.

• The tables above are the results of test conducted with 70psi. [4.8 bar] (to the pump), with a minimum of 20 psi [1.4 bar] at the dispenser valve (to maintain brix). Ambient temperature was 70ºF [20ºC].

FLOW RATE 1/4” [6mm] I.D. TUBING 3/8” [10mm] I.D. TUBING.OZ/SEC CC/SEC FEET METRE FEET METRE

.25 7.4 272 83 500 152.5 14.8 150 42 450 137

.75 22.2 101 31 303 921.0 29.6 50 15 153 47

1.25 37.0 – – 110 341.5 44.4 – – 62 19


.25 7.4 296 90 394 120.5 14.8 248 76 347 106

.75 22.2 205 63 298 911.0 29.6 150 47 251 77

1.25 37.0 78 24 206 631.5 44.4 54 16 153 47

1.75 51.8 – – 112 342.0 59.2 – – 59 18


.25 7.4 122 37 246 75.5 14.8 104 32 198 60

.75 22.2 77 23 153 471.0 29.6 56 17 105 32

1.25 37.0 29 9 50 151.5 44.4 13 4 27 8


.25 7.4 56 17 123 37.5 14.8 32 9.7 100 30

.75 22.2 17 5.2 78 241.0 29.6 7 2 52 16

1.25 37.0 – – 27 8


.25 7.4 49 15 96 29.5 14.8 27 8 58 18

.75 22.2 13 4 32 101.0 29.6 – – 18 6

20-50 (cP)50% Apple 5:1

100% Apple 4:1Fruit Punch 5:1Lemonade 5:1

Pink Lemonade 5:1Lemon lime Soda 5:1

Typ. Heavy Soda Bev. 5:1

50-100 (cP)50% Grape 5:1

100% Grape 5:1Grapefruit 5:1Cranberry 5:1Pineapple 5:1

100-500 (cP)50% O. J. 5:1

100% O. J. 4:1100% O. J. 3.5:1

Margarita 4:1Tomato 1.5:1

500-1000 (cP)O. J. (Natural) 3:1

Tomato 2:1Bloody Mary 2:1

Canadian Caesar 2:1

1000-3500 (cP)O. J. (Natural) 5:1

Caesar 2:1


13


Installation Guidelines• The outlet port/fitting of the pump is mounted vertical, up.

• The pump should be mounted above the B-I-B or at least at the same level. Pumps placed lower thanthe B-I-B’s will increase the ability to entrap air in the B-I-B.

• Use 10 or 13mm I.D. [3/8” or 1/2”] heavy wall (3mm [1/8”]) clear, NSF listed vacuum tubing from theB-I-B to the pump inlet.a) With low viscosity (thin) products (40 cP or less); the maximum length of inlet tubing is 1.5m [5 ft.]

with NO MORE than a .7m [3 ft.] vertical lift.

b) High viscosity (thick) products (over 500 cP); may require 13mm I.D. [1/2”] tubing with minimal vertical lift. In some instances no vertical lift can be achieved, the pump may need to be placedwithin one foot from the B-I-B, and slightly above the centre of the B-I-B.

NOTE: High inlet vacuum and/or restrictions can evacuate air suspended in some concentrates causinglow brix or premature operation of the vacuum shut-off.

• Use high pressure, NSF listed, braided tubing from the pump outlet to the dispenser equipment. Use10mm I.D. [3/8”] or 13mm I.D. [1/2”] tubing as necessary.

• Tie-wrap all tubing securely to prevent kinks or sags that inhibit performance or cause damage to thepump fittings.

• Use new 1/4” [6mm], high pressure braided tubing from the secondary CO2/air regulator to the pump.

NOTE: NEVER connect a transfer tank “system” in series with a B-I-B system. Concentrate/contaminantsin old components may work their way through the air supply causing premature failure of the gaspump. The gas used to drive the pump MUST be clean and contain no contaminants (syrup, oil, rust, water, etc.). Air compressors may be used with proper particle filters and moistureseparators. Air storage tanks should be drained weekly. Pumps subjected to contaminated air are not covered by warranty.

CAUTION: Pumps driven with CO2 are to be operated in well-ventilated areas. If used in a confined area(basement, closet, cooler box, etc.), exhaust fans capable of changing the room air on a continuous basis should be used.

Start-up Procedure1. Confirm that all tubing connections are properly clamped, fittings are locked, and tubing is not kinked.

2. Connect the bag connector onto the B-I-B fitment. Open the dispenser valve (syrup side).

3. Adjust gas regulator to about 1.4 bar [20 psi.] allowing the pump to stroke slowly. Once the pump isprimed the regulator can be adjusted up. With high viscosity (thick) products (over 500cP), the pumpshould be primed with a minimum of gas pressure. This prevents the shut-off feature frominterrupting pump operation due to high inlet vacuum during priming.

4. Continue to operate the dispenser valve until all the air trapped within the tubing has been purged.

5. Once the air has been purged, adjust the CO2 regulator to the pressure necessary to maintain thedesired brix. The most efficient gas usage occurs at 2.8 bar [40 psi.]. Maximum gas pressure to thepump is 4.8 bar [70 psi.]; minimum 1.4 bar [20 psi.].

NOTE: To prevent air from entering the system always leave the bag connector connected to the empty B-I-B until a new B-I-B can be installed. Air entered into the system, via air in the bags or vacuumleaks, may cause brix fluctuation, foaming, spitting, non-operation of the vacuum shut-off, or thepump to run while the dispenser is closed. Symptoms of this kind can lead to a misdiagnosis of thepump as the problem.


14


Pump SanitisingThe SHURflo Juice pump is only one component in a beverage dispensing system. Therefore, frequent sanitization of the pump and ALL equipment in the system is required. Sanitization is dependent on theconcentrate type and its’ manufacturers requirements. Factors which also affect the frequency of thisprocedure are, temperature, facility conditions, installation, and equipment. Consult other equipment manufacturer’s instructions for their sanitising requirements. Perform the following procedure to assurecompliance with NSF listed sanitising requirements for the SHURflo Juice pump (only).

Materials Required• Common household bleach (Sodium Hypochlorite; 5.25%) or equivalent.• Common household non-sudsing liquid detergent, suitable for use in a automatic dish washing machine.• An adapter is needed to hold the bag connector on the syrup inlet (suction) line open. A fitting cut

from an empty B-I-B will serve as an adaptor.• A 2m [6 ft.] length of 6mm [1/4”] tubing with a SHURflo output fitting. (To serve as the bypass hose).• Two 20 litre buckets.

Sanitising Procedure1. Turn off CO2 pressure to the pump. Open the dispenser valve to drop the line (outlet) pressure.

a) Remove the liquid outlet fitting from the pump. Install the bypass tube fitting in the outlet port ofthe pump and screw into place.

b) Immerse the bag connector and inlet suction tubing in 7.5 litres of warm water (120-180ºF [48-82ºC]).

2. Turn on CO2 to the pump (approx. 1.4 bar [20 psi.]), and pump the 7.5 litres of warm water through the pump to flush out concentrate residue. Turn off CO2 pressure to the pump.

3. Prepare 3.8 litres of detergent solution in a clean container. Mix at the ratio of 30cc of detergent per3.8 litres of warm water.a) Place the bag container in the detergent solutionb) Pump approximately 2.8 litres of detergent solution through the pump.c) Turn off CO2 pressure to the pump. Allow the detergent solution to remain in the pump for a

contact time of two minutes.d) Turn the pump upside down and operate the pump until the remaining detergent solution is

pumped out. Turn off CO2 pressure.4. Repeat steps; 1b) and 2 (i.e.: flush with 7.5 litres of warm water).5. Prepare 3.8 litres of santising solution (Hypochlorite) in a clean container. Mix at the ratio 7.5cc of

bleach per each 3.8 litres of water to obtain a mixture of 100 ppm.a) Place the bag connector in sanitising solution.b) Pump approximately 3.8 litres of sanitising solution through the pump.c) Turn off CO2 pressure to the pump. Allow the sanitising solution to remain in the pump for a

contact time of two minutes.d) Turn the pump upside down and operate the pump until the remaining sanitising solution is

pumped out. Turn off CO2 pressure.6. PRODUCT PURGE: Connect bag connector to the concentrate B-I-B. Operate the pump until a steady

stream of concentrate flows through the bypass tubing. Pump approximately 300cc of concentratethrough the pump. Turn off CO2 pressure.


15


WinterizingIf the pump is subjected to temperatures of 32ºF [0ºC] or lower, the system must be drained of all liquid to prevent damage due to freezing. It is suggested that when taking the pump out of service, the pump andlines etc. must be sanitised and purged of all fluid. Operating the pump at low pressure, simply allow air toenter through the bag connector after the sanitising procedure has been performed. Opening the outletvalve will help in purging the lines of sanitising solution.

CAUTION: Purge with a maximum of 1.4 bar [20 psi.], for approximately 3-5 seconds. The product outletfitting at the pump may also need to be removed and purged of any remaining solution. Refer tothe equipment manufacturer’s recommendation on purging lines and dispenser equipment. If there is any chance the solution may drain back to the pump leave the fitting out of the port.


16

The Beer Ace II has been designed to accept

pressurised beer and lagers, directly from the keg.

The pump will operate from a gas supply up

to 85 psi (5.8 bar), enabling greater dispense

distances and lifts to be achieved, while not

affecting the carbonation levels of the

product as intended by the brewer. The

pump will operate on either a supply of

CO2 or Mixed Gas or from a clean dry

source of compressed air.

The Beer Ace II is a gas driven

demand pump, automatically operated

when a tap is opened at the bar. The

pump has been designed to supply up

to three taps up to 150 metres (500 feet)

from a keg with a flow rate of between 3.8 –

11.4 l/min. Actual flow rates will be determined by

the length of run, line size, vertical lift, keg top pressure

and the number of taps being used on the bar.

Beer Ace II166-257-XX

Liquid out

Liquid in

Gas in

Gas out

Typical layout


17

The pump should be mounted with the liquid outlet port at the top.

The distance from the keg to the liquid inlet of the pump must not exceed 3m (10ft).

Brewery approved high pressure tubing should always be used for the gas supply to the pump. Alter the gas pressure to control the operating speed of the pump.

Pumps operated by CO2 must be kept in a well ventilated area.Where this is not possible (e.g. in an enclosed cellar) the gasexhaust should be vented to atmosphere.

The pump gas regulator should be set between 1.5 bar(22 psi) and 5.8 bar (85 psi).

The pump pressure should be a minimum of 0.5 bar (7 psi) higher than keg pressure.

Installing Fob DetectorsIn normal operation (before the keg becomes empty) the Beer AceII is designed to stop pumping when the serving tap is closed. Forautomatic shut-off with an empty keg, a fob shut-off device suchas the SHURflo Fob-Stop should be fitted. The SHURflo Fob-Stop must be plumbed between the kegand the pump. If other types of Fob detectors are used, they must be plumbed into the liquid outletline not more than 0.5m from the pump.

Beer Ace II (Installation Guidelines)

Pressure Setting

Beer Ace IIPerformanceIn the event of gas

breakout (Fobbing) over

long line runs, increase

the pump pressure.

Increase line restriction

at the tap if dispense

speed is too fast.

This data is based on a keg balance pressure of 1 to 1.4 bar (15 to 20 psi). At 3.4 barmaximum flow to each tap was set at 3.22 LPM.

With 3 taps open 150 metre line run, 10mm i.d line3.50

X

3.00

2.50

2.00

1.50

1.00

0.50

0.00

Tap 1 Flow litres/min Tap 2 Flow litres/min Tap 3 Flow litres/min

1.38 2.07 2.76 3.45 4.14

Pump operating pressure

Flow

rate

(Litr

es/m

inut

e)

4.83 5.52 5.86 Bar20 30 40 50 60 70 80 90 psi

XX

XX

XX XX XX XX XX XX

XX


18

Right-ward Stroke

Left-ward Stroke

Beer Ace II (Operation)

Gas in

Control CoverBody

Beer Out

Beer in

Gas in

Control CoverBody

Beer Out

Beer in

Gas (CO2)Beer under pressureBeer under vacuum


19

SpecificationDesign: Two chamber double diaphragm.

Power Source: CO2 gas, Nitrogen or clean compressed air.

Materials of Construction: Polypropylene, Celcon, EPDM, Santoprene,Stainless steel.

Body colour: Black.

Temperature Limits: 1.1 to 49C (34 to 120 degrees F).

Weight: 0.5 kg (1.2 lbs).

Size: 171mm (7.3 inches) H x 145mm (5.9 inches)W x 97mm (3.8 inches).

Fittings available: Liquid6mm (1/4’’), 10mm (3/8’’) & 12mm (1/2’’)straight and elbows in plastic or st. 10mm (3/8’’) J. Guest style smooth stem.Gas6mm (1/4’’) elbow and “T” with check valve,6mm (1/4’’) elbow and straight no checkvalve. 10mm (3/8’’) and 8mm (5/16’’) J.Guest style smooth stem.

Displacement: 101cc per cycle.

Maximum Operating Pressure: 5.8 bar (85 psi).

Minimum Operating Pressure: 1.4 bar (20 psi).

Inlet Pressure: Must be a minimum of 0.5 bar (7 psi) lower than pump drive pressure.

Flow Rate: 11 litres per minute dependant on liquidinlet pressure and line size.

Beer Ace II(Gas/Air Operated Pump)

Model Number 166-257-XX


20

With 3 taps open 150 metre line run, 10mm i.d line

Beer Ace II(Flow rates)

Gas pump Gas pump Tap 1 Tap 2 Tap 3Pressure Pressure Flow Flow Flow

(Bar) (PSI) litres/min litres/min litres/min

1.38 20 2.571.38 20 2.27 2.231.38 20 2.20 2.12 1.97

2.07 30 3.262.07 30 2.84 2.692.07 30 2.54 2.42 2.20

2.76 40 3.792.76 40 3.48 3.332.76 40 3.03 2.91 2.73

3.45 50 4.163.45 50 3.71 3.713.45 50 3.22 3.22 3.22

4.14 60 4.164.14 60 3.79 3.794.14 60 3.22 3.22 3.22

4.83 70 4.164.83 70 3.79 3.794.83 70 3.22 3.22 3.22

5.52 80 4.165.52 80 3.79 3.795.52 80 3.22 3.22 3.22

5.86 90 4.165.86 90 3.67 3.675.86 90 3.20 3.20 3.20

Note: Maximum pump operating pressure is 5.8 Bar/85 PSI Keg pressure 1.5 Bar Media – WaterBeer Ace Model 166-257-XX NOTE: AT 3.4 BAR AND ABOVE MAX FLOW TO EACH TAP WAS SET AT 3.22 LPM.


21

Brix Pump94-260-XX

Design: Positive Displacement; Fix Ratio (non-adjustable)

Power Source: Potable Water

Materials of Construction: Acetal Copolymer, EPDM, Santoprene, Silicone,316 Stainless Steel FDA sanctioned, NSF listed

Temperature Limits: 2-45ºC (34 - 120ºF)

Dimensions: 19.3 x 13.2 x 14.47 cm (7.6” X 5.2” x 5.7”)

Weight: 1 kgs (2.2 lbs.)

Displacement: 190cc/stroke (concentrate & water)

Flow Rate: (1 valve) 60-90cc per sec./ varies with system design and concentrate

Operating Pressure: 3.4 bar (50 PSI.) MAX./ 1.7 bar (25 PSI.) MIN.

Accuracy: ± 3% of available ratio

Sold Out: (available) Automatic B-I-B Vacuum Shut-off @ 18-22 in. Hg. (48-61 kPa)

Suction Lift (Wet): 25 in. Hg. (85 kPa) (minimum)

Standard Fitting: 10mm (3/8”) Barb, Plastic 90º configuration

Available Fittings: 6mm (1/4”), 10mm (3/8”), and 13mm (1/2”) barb,Plastic or Stainless Steel, Straight and/or 90º configurations

Available Ratios: 3.00: 1 (*30) (Red dot)4.00: 1 (*40) (Blue dot)5.00: 1 (*50) (Yellow dot)6.00: 1 (*60)

Other ratios available, contact the factory for specific applications.


22

Brix Pump 94-260-XX

DescriptionThe SHURflo BRIX proportioning pump is driven by pressurized water,allowing the water and product to be delivered at an exact ratio. The pumpoperates whenever there is a differential in pressure between the inlet andoutlet water sides of the pump. The design incorporates large “duck bill”style valves that easily allow concentrates with pulp or particulates to flowthrough. When your customers demand a quality drink, you are assuredthat SHURflo technology will deliver accurate repeatable brix without theneed for expensive metering devices.

Model OptionsThe BRIX pump is offered in two basic configurations, with or without a vacuum shut-off. The last twonumbers of the model indicate the use (-02), or deletion (-01) of the shut-off. The type of concentrate container being used determines if the shut-off should be applied.

When a Bag-in-Box (B-I-B) container is used, a vacuum shut-off is needed. The pump will automaticallystop operation, when the concentrate bag is completely evacuated, by closing of the inlet water. When anew B-I-B is installed, the pump will automatically resume operation without the need to prime thesystem. BRIX pumps without a vacuum shut-off option should be used with rigid sided containers such astanks or jugs. Containers of this type must be vented.

The BRIX pump is available in exact ratios which properly proportion various concentrate types. Pump ratiosare indicated on the part number label. The ratio of a pump is preset and is not adjustable in any way.

Dispenser ConfigurationThe dispenser valve is an important component in the BRIX pump system and contributes heavily to the final performance. A BRIX pump is designed to deliver to one dispense valve at a time. If other valvesare on line, a lock-out device must be used to prevent simultaneous operation. Depending on the systemdesign and the concentrate, finished drink flow rates are generally 45-90cc per second.


23

Brix Pump 94-260-XX

Post MixDispense valves which have separate water and concentrates lines will typically exhibit good performance.Mixing the drink at the nozzle reduces back-pressure, allowing longer outlet tubing lengths. Pumpoperation is controlled by opening or closing the water outlet line of the pump. The concentrate line mustnot be closed off while the water outlet line is open and the pump is cycling, or damage to the pump mayoccur. When multiple concentrates are plumbed to a post-mix dispenser, each pump’s water outlet musthave an individual line, valved to open when that flavour is selected.

“Bar Guns” (generally) are restrictive; therefore, it is recommended that special “Juice Guns” be used.Concentrate passages of standard bar guns are small and may become plugged with pulp or solids. Concentrates with pulps or solids may require sanitising more frequently.


24

Brix Pump 94-260-XX

Teed OutletsBy “teeing” the water and concentrate outlet lines together a standard beverage (non-post mix) valve can be used. A single line to the valve allows the concentrate and water to mix before being dispensed.Teed systems are commonly used in “batch mix” applications such as visual units, bubblers and frozencarbonated beverage units. Concentrates that do not blend properly in the line can be improved byinstalling a static mixing chamber in line prior to the dispense valve.

The single line run length should be minimal to reduce back-pressure. Back-pressure within the teedoutlet line should not exceed 2.0 bar (32 psi.). Pre-mix valves with minimal full-flow back-pressure arecommonly used with this type of configuration. Teed systems should have a one way check valve plumbedafter the concentrate outlet and before teening into the water outlet line to prevent possible water flowback. Whenever the concentrate is in contact with water the possibility of spoilage is increased andsanitising of the system may need to be more frequent.


25

Brix Pump 94-260-XX

MountingDepending on constraints within a facility, the type of system and concentrate characteristics, placement ofthe pump is critical for each particular system installation.

The BRIX pump should be placed as close to the concentrate supply as possible, and mounted with thefittings vertical (up). Preferred mounting is slightly above or at least the same level as the container. If apump must be mounted considerably higher, the amount of vertical lift is dependent upon concentrate viscosity (see Inlet Conditions). If a pump is mounted below the concentrate, be aware that air whichenters into the system can return to the B-I-B, causing loss of the correct ratio. Choose a location thatallows for easy sanitisation and winterising of the BRIX pump once mounted.

The inlet water source should be plumped with 13mm (1/2”) inside diameter (I.D.) tubing and have a shut-off valve. The water source pressure should be regulated to a maximum of 3.4 bar (50 psi). A SHURflo Water Pressure Reducing Valve can be used in place of a regulator.

A double check valve with vent may be required by local city ordinances to prevent the possibility of backflow entering the city water system. National Sanitising Foundation (NSF) listed high pressure braid tubing10 or 13mm (3/8” or 1/2”) I.D. should be used from the regulator to the water inlet of the pump, and fromthe water outlet fitting to the dispense equipment.

Inlet ConditionsThere are several types and sizes of Quick Connect/Disconnect (Q.C.D.) fittings/bags. The type of Q.C.D.used is determined by the company packing the concentrate. Concentrates which are highly viscous and/or contain solids, may be packaged with a connection that uses a less restrictive Q.C.D. and 13mm(1/2”) I.D. tubing.

The length of tubing and vertical lift that a BRIX pump can accommodate at the concentrate inlet is dependent on the particular characteristics of the product. Also, colder concentrate temperatures adversely affect the system inlet side due to the increase in viscosity. A brix system should not create over7 inches of vacuum (in/Hg) (24 kPa) at the inlet fitting while the dispenser is open. An Inlet vacuum that istoo high can evacuate the air suspended within some concentrates (“degassing”), causing inconsistency of brix or premature operation of the vacuum shut-off (if used). If high inlet vacuum conditions are encountered, use larger tubing I.D. When a concentrate is highly viscous and/or contains large amounts of particulates it is advised that the inlet line be as short as possible and have a minimum amount of vertical lift.

Concentrate inlet lines must be NSF listed, clear heavy wall (3mm (1/8”) thick) vacuum tubing in either 13 or 10mm (1/2” or 3/8”) I.D. Allow enough tubing to prevent kinks and include some “extra” tubing incase service in needed at a later date. Always install stainless inserted Oetiker® clamps to all connectionsto prevent vacuum leaks.

The following table gives general recommendations for concentrate INLET TUBING. Actual line I.D. andlength may vary.

Continued on next page


26

Brix Pump 94-260-XX

In a facility where the concentrate cannot be located near the BRIX pump, it can be pumped from a remotelocation using a SHURflo beverage or juice gas pump. The BRIX pump must not have positive pressure atthe concentrate inlet line. The SHURflo Vacuum Regulator (P/N 186-054-00) must be installed prior to theconcentrate inlet fitting of the pump, allowing concentrate to enter the pump under vacuum.

When an uninterrupted flow of concentrate is desired, the SHURflo Automatic Selector Valve (P/N 165-011@ 12 in/Hg.(41 kPa) can be plumbed into the inlet line to allow two or more B-I-B’s to be connected.

Outlet Lines to the DispenserThe total line run of concentrate tubing from the BRIX pump to the dispenser (including cold plate if used)should be kept to a minimum. Concentrate outlet tubing should have minimal back-pressure during pumpoperation. Back-pressure is dependent on the line length & I.D., vertical lift, viscosity, temperature and dispenser valve flow.

The installation of a SHURflo Sanitising Valve is recommended with all drink concentrates. When the valve is moved to the “Sanitise” position it allows santizing solution to be directed from the concentratechambers back into the water side of the pump. Plumb the concentrate outlet line from the pump to thebottom port of the valve. Connect the concentrate line to the dispenser at the port marked “Dispense”.Install a “T” into the inlet water line and plumb to the “Sanitise” port.

Always use NSF listed, high pressure braid tubing (10 or 13mm (3/8” or 1/2”) I.D.) for pressurized lines and secure all connections with stainless steel inserted Oetiker® clamps. Tie-wrap all tubing securely toprevent kinks and relieve stress on pump fittings. Although it is recommended that line lengths are kept to a minimum, it is a good idea to allow some “extra” tubing in case service is required at a later date.

Start-up Procedure1. Confirm that all tubing connections are properly clamped and fittings are tight.

2. Install the Q.C.D. to B-I-B connector or insert inlet tubing into product container.

3. Open the water source valve slowly allowing the pump to cycle; maintain water pressure below themaximum of 3.4 bar (50 psi).

4. Place a container under the dispenser to collect purged drink solution and hold the valve open. The concentrate will be drawn (ratio to water) to the pump with every stroke. Concentrate progresswill be evident with each stroke. Allow the pump to cycle until the air within the system has beenpurged through the dispenser.

5. If the finished drink flow rate is not as desired, adjust the regulator (3.4 bar max. (50 psi.). If using afixed-pressure reducer, adjust the water shut-off valve to obtain the desired finish drink flow rate.


27

Brix Pump 94-260-XX

Pump SanitisingThe BRIX pump does not require any maintenance. However, depending on the concentrate type and its’manufacturers requirements, the pump and ALL equipment in the system will need periodic sanitization. Thefrequency of this procedure is dependent on the water condition, temperature and concentrate type. Someconcentrates may contain exceptionally “stringy” pulp that may become lodged within the Q.C.D. fitting and/or dispenser valve inhibiting performance. If concentrates of this kind are used, the system mayneed more frequent sanitising to flush out build-up. With a “Teed” system it is recommended that the intervals between sanitization be more frequently than post-mix systems. The reason for this is that when a concentrate is mixed with water it may increase the possibility of product spoilage.NOTE: The following procedure must be followed to assure compliance of NSF listed sanitising requirements

for the SHURflo BRIX pump (only). This procedure will not flush and sanitise the concentrate outletline between the 3-way valve and dispenser. To properly sanitise the concentrate line, repeat the procedure in the “Dispense” mode and perform a product purge of the system. Consult other equipment manufacturer’s instructions for their sanitising requirements.

Materials Required1. Non-sudsing liquid detergent (such as common household automatic dishwasher liquid detergent)2. Household bleach (Sodium Hypochlorite solution; 5.25%) or equivalent3. Clean 20 litre bucket4. Measuring cup5. An adapter is needed to hold the Q.C.D. fitting on the concentrate suction line open. A connector cut

from an empty bag will work.

Sanitising Procedure1. Fill the bucket with 15 litres of warm water 48-82ºC (120-180ºF.).2. Measure 120cc of liquid detergent and add to the water.3. Measure 60cc of bleach and add to the water, then stir.NOTE: 15cc of bleach per 4 litres of water yields a solution of approximately 200 ppm Sodium Hypocholrite

needed to satisfy NSF sanitising requirements.4. Disconnect to concentrate line from the B-I-B and install the adapter on the quick disconnect so the

line is open to the sanitising solution. Place concentrate inlet line into the bucket so that the Q.C.D. willstay at the bottom.

5. Position the SHURflo Sanitising Valve in the “Sanitise” mode. Open the dispenser valve allowing ALLthe solution to be pulled through the Q.C.D. fitting into the BRIX pump out the water outlet line throughto the dispenser.

6. When the bucket is empty (approx 15 min.), return the valve back to the “Dispense” mode.CAUTION: Failure to return the valve to the “Dispense” mode before starting the concentrate purge, will

recontaminate the system. If this occurs, the sanitising procedure steps MUST be performed againto the BRIX pump.

7. PRODUCT PURGE Reconnect Q.C.D. of the inlet line to the concentrate supply. Open the dispenserallowing the pump to operate until all sanitising solution is purged from the system, assuring that no off-taste will be detected.


28

Brix Pump 94-260-XX

TroubleshootingWhen the BRIX pump system is properly installed and maintained it can continually deliver quality drinkswith trouble-free operation. However, various conditions may occur within the facility that affect the systems performance. Listed below are various situations that may affect a correctly installed system:

i. Pump will not cycle:Verify there is adequate water pressure (2-3.4 bar [30-50 psi]) at water inlet fitting.

Verify that the dispenser valve operation (switch/solenoid), passages and lines are unrestricted. Flushand sanitise pump and outlet lines from pump fittings to the dispenser if restricted.

Check to see if the pump has gone into “vacuum shut-off” (B-I-B only), although B-I-B container isfull. Check for plugged or non opening Q.C.D fitting, or kinked or restricted inlet tubing. Flush andsanitise pump and outlet lines from pump fittings to the dispenser if restricted.

ii. No concentrate (pump cycles) improper Brix:Start by checking the items in part i. above.

Verify that the Q.C.D. passage is opening completely when installed on the B-I-B connector. If concentrate is supplied from a tank, verify that the vent is open.

Inspect for vacuum leaks on the concentrate inlet side. Carefully look for air bubbles at Q.C.D. or oneither fittings while the pump is cycling.

Determine if there was air packaged with the concentrate when the bags where filled. Stand the boxup on end and pull the connector up, allowing air to rise up to the bag connector. Install a Q.C.D. andengage it on the bag connector opening the passage. Slowly press the Q.C.D. back down expelling theair until concentrate appears, release the Q.C.D. closing the connector. This is referred to as“burping” the bag.

Pump stroke should be even (time) in both directions of travel. If not even, remove concentrate valves(inlet/outlet) and inspect for debris or improper closing that interferes with their operation.

iii. Pump cycles intermittently/will not shut-off/drips: If the pump continues to cycle after B-I-B has emptied, verify that there are no vacuum leaks.Determine if the concentrate bag has an excessive amount of air. The pump will continue to ratio theair until “shut-off” vacuum (14-18 in/Hg.[48-61 kPa.]) is obtained. To verify that the vacuum shut-offis operating, allow the pump to operate. Pinch the inlet line off. This will create high vacuum causingthe pump to stop operation.

If concentrate drips from the (post-mix) dispenser, the problem may be concentrate particulatestrapped under the piston seals allowing pressurized water to enter the concentrate chamber.Perform the sanitising and flush procedure to the pump which may flush the debris from under theseal. If the problem continues exchanges the BRIX pump.

NOTE: If the concentrate B-I-B has been moved above the pump, head pressure from the B-I-B may besubstantial enough to cause the dispenser to drip.


29

Brix Pump 94-260-XX

Valve InspectionSome concentrates after prolonged periods of contact without regular sanitising, may cause the valves to become stiff or clogged with pulp and/or particulates. If a situation of this type is suspected, valve cartridges can be removed for inspection.

1. Turn off water supply valve and relieve pressure. Remove each assembly by loosening the screw holdingthe cartridge. Turn the cartridge and then pull it out of the housing (Pliers may be required). Note inletand outlet arrows molded on the pump housing for proper orientation of the respective valves.

2. Disassemble each cartridge individually. Do not confuse inlet and outlet components. Inspect the“Duck Bill” valves for tight seal in closed position. Valves should have quick action when pressedopen between the fingers, and materials should not be hard or stiff.

NOTE: Valve kit (#94-402-02) is available for in field replacement. Complete instruction are included witheach kit.

3. Re-assemble each cartridge so that the valve support is not holding the valve open. Lubricate theserrated surface of the valves and o-rings with an NSF listed food grade lubricate. Re-insert theappropriate valves into the housing, turn back into position and tighten the screw. Be aware that the valves may turn, allowing the support to hold the valve open, when reinstalling in the housing.

4. Sanitise and recheck for even (time) stroke in both directions of piston travel.

Winterizing ProcedureIf a BRIX pump is subjected to temperatures below freezing, with either concentrate or water within thepump chambers, severe damage to the pump body may occur. It is advised that the following proceduresbe performed whenever the pump could be subjected to freezing temperatures.

1. Sanitise the system as outlined including the concentrate line to the dispenser. However, DO NOTperform Step: 7 “Product Purge” on the system.

2. Turn off the city water source valve and relieve pressure. Remove all the fittings (Inlet/Outlet) fromthe pump body and allow the solution to drain completely from the tubing.

Continued on next page


30

Brix Pump 94-260-XX

3. Plumb a clean source of regulated compressed gas or filtered air to the water inlet connection of thepump. Remove the pump from its mounting by loosening the two screws in the bracket slots. Turnthe pump upside down (Inlet/Outlet ports pointing down) over a bucket.

4. Apply gas at low pressures (35-1.0 bar [5-15 psi.]) to the water inlet port of the pump allowing it tocycle slowly until all the water trapped within the chambers is expelled. Turn the air off, remove the air line, and reinstall the pump to it mounting.

5. Open the dispenser valves(s) and expel all the solution from both the water and concentrate lines with the compressed air. (Refer to the equipment manufacturer’s recommendations for purgingdispenses and lines). Reconnect all line fitting properly. Leave the inlet water source valve off and DO NOT reinstall Q.C.D. to concentrate container until the system is to be restarted.

NOTE: When the system is to be placed back into service, it MUST have the Sanitising Procedure performed before finished drinks can be dispensed.


31

The SHURflo® 8000 series pumps are ideal for a wide range of dispense applications.

SHURflo’s expertise is in designing pumps for specific customer requirements.

constant flow to 1 or 2 taps

glass or carafe filling

quiet operation

can run dry

optional timer for added security

suitable for dispense from ‘BIB’ or standard container

Wine Pump8000 Series

Typical DimensionsA B C

Maximum 22.35 cm 12.7 cm 10.8 cm

A1 – with timer (25.35 cm) – as above

Typical Dispense System – Wine


32

8000 SeriesTechnical Specifications

Model Number 8008-902-355 – 230V wine pumpModel Number SUK0209 with 3 minute timer*

Typical Application Wine Dispense; Water Boost

Type of System Vacuum (Bag-in-Box); or Open (kegs, tanks, opencontainers; mains water)

Motor Permanent magnet (thermally protected)

Voltage 230 VAC nominal

Duty Cycle Intermittent

Self Priming 1.6 metres max.

Inlet Pressure 2.2 bar max.

Flow 5 litres/minute at 2.2 bar

Bypass Activates at 3.2 bar; fully open at 4.2 bar

Pressure Switch Factory set; adjustable 2.8-4.2 bar

Ports SHURfit Quick Connect – for use with J Guestcompatible fittings

Standard Fittings** 2 quick fit plastic fittings; fitting outlets are10mm straight, ref. 84-084-01

Approvals N.S.F. listed* The timer automatically switches off the pump after 3 minutes (approx) of continuous pumping

** For optional fittings and more complete information please refer to the SHURflo Beverage ProductGuide, or consult your nearest distributor


33

Pump (SUK 0172)Each pump can be individually adjusted to match the desired dispense requirements of an individualtap, regardless of the line run and lift, and without requiring an increase in gas pressure to the keg.This ensures that the product is dispensed at the correct carbonation level, as intended by the brewer.For non-carbonated products such as wine, the pumps will self prime from a suitable container. The pump should be used in conjunction with the Pump Control Unit. Each control unit is capableof regulating the performance of two pumps.The pump operates on 24Vdc supplied directly from the 220-240Vac Pump Control unit.

APPROVALS: NSF

Variable Speed Electric PumpDesigned to dispense Keg beers, lagers and wines.

Control unit (SF 08-103)Attention has been given to both performance and safety.

Each wall mounted Pump Control Unit is designed to independently control 2 pumps.

Safety: Pump Control Unit Imput:220-240 Vac, Output 24Vdc, ensures safer pump operation, indamp cellar environments.Illuminated power On/Off switch enables the control unit to be easily isolated from the mains electricity supply. The unit is fused for additional safety.

Features: Keg Empty/Power off control, with warning light and reset switch: automatically stopsthe pump when the Keg is empty.

Variable Speed Controller allows the flow rate of each pump to be individually adjusted for optimumperformance up to 6 litres/minute.

Typical layout

DISPENSE HEAD

ELECTRICPUMP

ELECTRICPUMP

PUMP CONTROL UNIT

ASV

WINE WINE LAGERBEER

COOLER

PUMP 1 PUMP 2


34

Pump dimensions

Performance at maximum output

Dual pump control unitWall mounted Box180mm (width) x 180mm (height) x 115mm (depth)

Specifications subject to change without notice.All data based on tests with water.Illustrations and tabulated information shown in this data sheet are for guidance only, and does not constitutea contractual offer.

PRESSURE FLOW RPM CURRENT VOLTAGE(PSI) (LIT/MIN) MIN/MAX (AMPS) (VOLTS)

OPEN 6.1 2310/2320 1.6 24 VDC

10 5.8 2280/2285 2.0 24 VDC

20 5.5 2240/2250 2.4 24 VDC

30 5.3 2200/2220 2.7 24 VDC

40 5.1 2170/2195 3.0 24 VDC

50 4.9 2135/2170 3.3 24 VDC

60 4.7 2105/2150 3.6 24 VDC

70 4.5 2075/2115 3.9 24 VDC

80 4.4 2040/2090 4.2 24 VDC

90 4.2 2010/2060 4.4 24 VDC

100 4.0 1965/2005 4.7 24 VDC1.9

0

20(1.4)

40(2.8)

60(4.1)

80(5.5)

100(6.9)

FLOW – LITRES PER MINUTE

PRES

SURE

P.S.I

. (BAR

)

3.8 5.7 7.6

Shurfit quickconnect


35

Electric Wine and BeerPumpsINSTALLATION GUIDELINES

SHURflo offers various pump models for different applications. The information outlined in this manual is general, and not specific to all 8000 series pumps. Be certain the pumps’ materials will be compatible with the fluid being pumped. 8000 series pumps are intended for intermittent or continuous duty when the properoperating criteria is met. Product Data Sheets outlining specific thermal limits, loads, flow curves, and othertechnical information for a particular model are available.CAUTION: “Intermittent” is defined as; operated and/or frequently started within a period of time that would

cause the motor to reach its maximum thermal limits. Once the maximum thermal limit isobtained, the motor must be allowed to return to ambient temperature before resuming operation.

CAUTION: DO NOT operate the pump at pressures which cause the motor to exceed the amperes rating indicated on the name plate. Various pump models are equipped with thermal breakers to interruptoperation due to excessive heat. Once the temperature of the motor is within proper limits it willautomatically reset, and the pump will start operation without warning.

CAUTION: To prevent electrical shock, disconnect power before initiating any work. In the case of pump failure, the motor housing and/or the pumped fluid may carry high voltage to components normally considered safe.

Pressure Switch Operation (If Equipped)The pressure switch reacts to outlet pressure, and interrupts power at the preset shut-off pressure indicated on the pump label. When outlet pressure drops below a predetermined limit (*typically 15-20 psi.[1-1.4 bar] less than the shut-off pressure), the switch will close and the pump operates until the shut-off(high) pressure is achieved. The shut-off pressure is set to factory calibrated standards.CAUTION: Improper adjustment of the pressure switch setting, may cause severe overload or premature

failure. Failures due to improper adjustment of the pressure switch setting will not be covered under the limited warranty.

If the plumbing is restrictive or the flow rate is very low, the pump may repressurize the outlet faster than thefluid is being released, causing rapid cycling (*ON/OFF within 2 sec.). If the pump is subjected to rapid cyclingduring normal operation, or for infrequent periods, damage may occur. Applications which exhibit rapid cyclingshould have restrictions in the outlet minimized. If not feasible consider SHURflo Accumulator or a SHURflo“bypass” model pump.

Bypass Operation (If Equipped)A bypass pump may be used in any application that would normally induce frequent start/stop of themotor, and thereby create a potential for overheating. Models equipped with an internal bypass aredesigned to pump at high pressure while at low flow rates. Bypass models equipped with a switch mayoperate for several seconds even though the discharge side has been closed off. Models equipped with a bypass without a pressure switch will continue to run until power is turned off.

Mounting The 8000 series pumps are self priming. Horizontal and vertical prime vary depending on the fluid viscosity and pump configuration.

The pump should be located in an area that is dry and provides adequate ventilation. If mountedwithin an enclosure, provisions to cool the motor may be necessary. Heat sinks which attach to themotor are available from SHURflo if increased heat dissipation is necessary.


36

Electric Wine and BeerPumps

CAUTION: DO NOT locate the motor near low temperature plastics or combustible material. The surface temperature of the motor may exceed *250ºF [120ºC].

Secure the rubber feet with #8 hardware. DO NOT compress the feet, doing so will reduce their abilityto isolate vibration/noise.

PlumbingUse high pressure tubing compatible with the fluid to connect the inlet/outlet ports. Tubing should beeither 10 or 13 mm I.D., and at least 46 cm length is suggested to minimize stress on the fitting/portsand reduce noise. Allow for the shortest possible tubing route and avoid sharp bends that may kinkover time.

Installation of a 50 mesh strainer is recommended to prevent foreign debris from entering the system.

NOTE: Restrictions on the inlet may cause vacuum levels to reach the fluid vapor pressure, causing cavitation, degrassing, vapor lock and loss in performance. Inlet pressure must not exceed 30 psi[2.1 bar] maximum.

If a check valve is installed in the plumbing it must have a cracking pressure of no more than 2 psi[.14 bar].

3/8” Female NPT models: In some cases, the ports may require a suitable thread sealer appliedsparingly. DO NOT over-tighten, max. torque 3.7 ft\Lb (45 in\Lb) [5 Nm].

1/2” Male threaded models: Are intended to be used with SHURflo Swivel Barb Fittings which sealwith an internal taper when hand tightened. Standard 1/2” NPT fittings may be used when tighteningto a max. torque of 3.7 ft\Lb (45 in\Lb) [5 Nm].

CAUTION: Sealers and Teflon tape may act as lubricant causing cracked housings or stripped threads dueto over tightening. Care should be used when applying sealers, it may enter the pump inhibitingvalve action, causing no prime or no shut-off. Failures due to foreign debris is not covered underwarranty.

Snap-lock models: The slide fittings are open when the slide is moved out toward the switch. Fittingsshould be inserted flush against housing port before the slide is moved to the locked position.Fittings of Nylon or Polypropylene are available in various sizes.

ElectricalCAUTION: Electrical wiring should be performed by a qualified electrician, in accordance with all electrical

codes.

Improper duty cycle and/or rapid start & stop conditions may cause the internal thermal breaker (if equipped) to trip, or can result in premature motor failure due to excessive heat.

The pump should be on a dedicated (individual) circuit, controlled with a double pole switch (UL/C-UL certified) rated at or above the fuse ampere indicated by the pump motor label. Dependingon distance of the power source from the pump and ampere load on the circuit, wire may need to beheavier than indicated by the chart.

CAUTION: All 115 VAC and 230 VAC pump motors and systems, MUST be ground per local and stateelectrical codes.

For the pump to meet UL/C-UL requirements the circuit MUST be protected with a slow-blow fuse(UL/C-UL certified) or equivalent circuit breaker as indicated on the motor label. Use an approvedwire of the size specified or heavier.


37


CAUTION: Circuit protection is dependent on the individual application requirements. Failure to provideproper overload/thermal devices may result in a motor failure.

*The information outlined by this manual is general, and not specific to all 8000 series pumps. Contact thefactory for a Product Data Sheet outlining technical information for a particular model.

12DC 800X-X4X-XXX 15.0

8005-X5X-XXX 2.524DC 8005-X9X-XXX RED (positive +) #14 AWG [2.5 Mm2]

800X-X5X-XXX 10.0 BLACK (negative -) (or heavier)

36DC 800X-X8X-XXX 5.08005-X5X-XXX 1.5

800X-X1X-XXX 1.25 BLACK (common/hot)115AC 800X-X2X-XXX WHITE (neutral)

800X-X3X-XXX 1.0 GREEN (ground) #18 AWG800X-X6X-XX C-UL/TEW 1015

(or heavier)800X-X0X-XXX 0.8 BROWN (common/hot) [1 Mm]

230AC 809X-X0X-XX BLUE (neutral)† 800X-X9X-XXX 0.5 GRN/YELL (ground) 809X-X1X-XX

Voltage Model Fuse (amp) Wire Leads Wire size

† VDE requires a fuse (slow blow) or equivalent circuit breaker.


38


Troubleshooting Pump will not start:3 Fuse or breaker3 For correct voltage (±10%) and electrical connections3 Pressure switch operation and correct voltage at switch or motor wires (as equipped)3 Rectifier or motor for open or grounded circuit3 For locked drive assembly

Will not prime: (No discharge/motor runs)3 Out of product3 Strainer for debris3 Inlet tubing/plumbing; severe vacuum leak3 Inlet/Outlet tube severely restricted (kinked)3 Debris in pump inlet/outlet valves3 Proper voltage with the pump operating (±10%)3 Pump housing for cracks

Leaks from pump head or switch:3 For loose screws at switch or pump head3 Switch diaphragm ruptured or pinched3 For punctured diaphragm if fluid is present at bottom drain holes

Pump will not shut-off: (Pressure switch equip.)3 Output line closed and no leaks3 For air trapped in outlet line or pump head3 For correct voltage to pump (±10%)3 Inlet/Outlet valves for debris or swelling3 For loose drive assembly or pump head screws3 Pressure switch operation/adjustment incorrect

Noisy/Rough operation:3 Mounting feet that are compressed to tight3 For loose pump head or drive screws3 Does the mounting surface multiply noise (flexible)3 Is the pump plumbed with rigid pipe causing noise to transmit


39


Service KitsKits are readily available to repair standard 8000 series pumps. Repair kits include simple illustratedinstructions allowing easy installation. To insure that the correct kit is received the model number and allname plate data must be included with the order. Contact a SHURflo distributor or SHURflo directly toorder the necessary repair kit.


40

Electric Wine and BeerPumpsREPLACEMENT COMPONENTS

Procedures outlined are applicable to all SHURflo 8000 pump configurations. Illustrations may not show a particular model’s configuration in regards to pumphead ports, check valve, or electrical connections, pleasetake note of differences prior to and during disassembly. If unsure of the acceptability of a kit with a particularpump model, please contact SHURflo for assistance. Use of the kit on models other than those recommendedby SHURflo is the sole responsibility of the installer.NOTE: For operating criteria, thermal limits, flow curve, chemical compatibility, and related technical

information consult the pump’s Product Data Sheet, or call SHURflo for assistance.CAUTION: To prevent electrical shock, disconnect power before initiating any work. In the case of pump

failure, the motor housing and/or pumped fluid may carry high voltage to components normallyconsidered safe.

CAUTION: Various pump models are equipped with integral thermal breakers to interrupt operation due toexcessive heat. Once the temperature of the motor is within proper limits it will automatically reset,and the pump will start operation without warning.

Pressure Switch/BypassNever exceed the pressure setting (pressure switch/bypass) indicated on the motor label. Improper pressure settings may cause severe overload and motor failure. Always check pressure setting after making repairs.Pumps equipped with a pressure switch (w/o bypass) may exhibit rapid cycling (ON/OFF within 2 sec.)when the flow rate is too restrictive for the pumps’ output. If the pump is subjected to rapid cycling duringnormal operation damage may occur. Applications that exhibit rapid cycling should consider one or moreof the following: minimize outlet restrictions, properly size pump, output to the flow rate, pump withbypass, or install a SHURflo accumulator in the output side of the system.

Pumphead DisassemblyCAUTION: Relieve outlet pressure and drain inlet/outlet tubing of fluid.NOTE: For replacement or repairs to either the pressure switch or check valve when not making upper

housing or other internal component repairs, refer to Pressure Switch Replacement Procedures.

1. With electrical power turned off, disconnect lead wires from the pressure switch (if equipped). Make certain to note the position of wire terminals to the switch contacts. Pumps have two versions of strainreliefs depending on model and date of manufacture.

A. To remove insert: Working from the back side (motor side) carefully pry the inserts to compress thewires then push the insert out.

B. To release the integral clip design (View A-A): Carefully pry on both clips.

2. If only replacing complete assemblies for either the pumphead or motor remove the three machinescrews as indicated in view A-A. For all other internal repairs remove all six screws.

3. Mark or take notice of the orientation of the lower housing/drive assembly in relation to the motor.Various pump models have small slots, which are normally at the bottom of the pump so liquid candrain in the event of a leak.


41


4. Use care separating the upper housing and valve plate so bypass spring location can be verified (if equipped). Spring orientation and type can be crucial to operation. Locate the valve plate o-ringwhich may be retained in its groove or stuck to the inside of the upper housing.

5. Remove lower housing/drive assembly from “D” shaft of motor. If the assembly does not pull off, use two flat screwdrivers between the drive bearing and motor to pry assembly off.

6. Inspect all assemblies for signs of wear, damage, ruptures, corrosion, foreign matter, and fluid incompatibility. If the motor bearings or internal components have been inundated with fluid the motor assembly should be replaced.

7. For specific assembly repair instructions refer to following sections.


42


Pressure Switch, Upper Housing, or Check Valve replacement proceduresCAUTION: Relieve outlet pressure and drain inlet/outlet tubing of fluid. It is recommended that the pump be

flushed in a responsible manner prior to disassembly.NOTE: The hex head set screw for pressure adjustment should not be removed or turned unless preforming

pressure switch adjustment. Never pry apart the pressure switch housings, internal clips holding thehousing will break.

NOTE: Various pump models may not be equipped with the check valve/spring or Teflon support. If unsure of aparticular models configuration, please contact SHURflo.

1. With electrical power turned off, disconnect lead wires from the pressure switch (if equipped). Make certain to note the position of wire terminals to the switch contacts.

2. Remove three screws holding the switch assembly or bypass cover plate to the upper housing. Take noteof the different screw lengths and position used with the switch.

3. Remove the switch diaphragm and check valve components. If the check valve components are stuck inthe housing, press out from the back side of housing.

4. Clean and inspect check valve and seating surface of the housing for debris or other problems that mayinhibit proper sealing.

5. Reinstall check valve components and insert as shown.6. Install switch diaphragm concave (cupped) side

down flush with the housing.7. Align (new) pressure switch or bypass plate (Teflon

support if equipped) over the two protrusions andscrew holes.

8. Install the three screws and hand-tighten onlyuntil snug. Maximum torque 10-13 in/Lb [11-14.6Nm] for Polypropylene housing, 15-23 in/Lb [17-26 Nm] for Nylon.

9. Reconnect motor and power connectors to theproper switch terminal positions.

10. For reassembly of upper housing/ switch assembly to pump/motor, refer to Disassembly, working inreverse order.

11. To insure proper pump performance and longevity SHURflo recommends checking the pressure switchadjustment whenever the switch has been removed and reinstalled, or a new assembly installed.


43


Diaphragm/Lower Drive assemblyNOTE: Pumps equipped with the “solid diaphragm” are

assembled as an integral unit at the factory.Diaphragm/drive configurations of this type can onlybe replaced as a complete assembly.

Remove the three screws and piston caps. Take notice ofthe orientation of piston caps within diaphragm locatingdimples. Install new components.Screw torque 20-25 in/Lb [22.5-28 Nm].

Bypass Valve PlateNOTE: Bypass spring length must not be altered.

If bypass pressure exceeds that indicated on the motor label, overload andmotor failure may occur.

Assembly Tips1. Place upper housing so interior is facing up.2. Place springs in their appropriate cavities as noted upon disassembly. Set the

poppet into each spring.3. Set the valve plate into the upper housing making sure the poppets are visible

through the hole in each inlet valve.4. Properly orientated the diaphragm/drive (not shown) assembly to the upper

housing. Carefully press the two assemblies together making sure the diaphragm isn’t pinched.5. Hold the assembly together firmly. Reinstall the three screws that hold the two assemblies together

before installing to the motor.

Screw TorquesNOTE: Pumps models with composite thermo-plastic lower housing require lower torque and gun speed when

using power drivers. The three upper/lower housing screws should be torqued to 22-24 in/Lb. [24-27Nm] with gun speed of 500-600 R.P.M.

• Draw all screws down evenly in a cris-cross pattern before final torque.


44


Pressure Switch/Bypass TestVerify pressure switch (P/S) adjustment and/or bypass operation whenever components are removed orreplaced. The P/S must only be adjusted for the “shut-off” pressure setting indicated on the motor label. The P/S differential (turn-on) is a predetermined internal function of the P/S and is not adjustable.CAUTION: Never exceed the pressure setting(s) indicated on the motor label for the P/S and bypass. Improper

pressure settings cause overload and motor failure.NOTE: P/S is only adjustable within its appropriate range. Normally the set screw will not be recessed or

protrude more than 2-3 threads. Incorrect screw placement may be an indication that the P/S is notwithin the range necessary for that pump. Contact SHURflo for assistance and/or Product Data Sheet if unable to adjust within specification.

P/S Adjustment1. Connect an appropriate gauge (psi/bar) and valve to the output side of the pump. Clamp/secure tubing

for pressurized operation. Insert inlet tubing into water.2. With the valve open apply electrical power (fused) and purge pump of air.3. Slowly close valve until the pump begins to cycle (on/off within 2 sec). Adjust clockwise (raise) or

counterclockwise (lower) the 5/64 allen set screw until the “shut-off” pressure is within 2 psi. [.13 bar] of that indicated on the motor label.

4. Open the valve and repeat step 3 several times to verify P/S adjustment.5. Turn off pump by closing valve. Open the valve slowly and allow pressure to gradually bleed off. Once

enough pressure has been released the pump should start, most models typically range between 15-20psi. [1-1.3 bar]. If the differential is not within range, recheck the “shut-off” pressure adjustment.

Bypass & Bypass with P/S OperationPumps with bypass only; follow steps 1 & 2 above. With the pump operating turn the valve OFF and verifybypass pressure as indicated on the pump label.Bypass with P/S; are intended to bypass at pressures just before “shut-off”. Due to this fact, follow the stepsabove except during step 3 turn the valve OFF slowly, as the pump cannot be made to cycle. The pump shouldbypass for a moment prior to achieving “shut-off”. Verify bypass pressure again by opening the valve so anextremely low flow is released.

Installation and Operation InstructionsOnce a Bag-In-Box (B-I-B) container has emptied, and vacuum for shut-off is obtained, the gas pumpautomatically stops. However, carbonated water still flows from the dispenser even though syrup flow hasceased. In the case of “clear beverages” (lemon lime, tonic water, etc.) the user has no visual indicationthe drink is syrup starved.

When syrup line pressure drops below the S.O.S. setting, voltage to the dispensers’ solenoid valves isinterrupted stopping both water and syrup dispensing. By stopping both water and syrup, employeesrealize a new B-I-B needs to be installed. If the L.E.D. light is installed, it illuminates informing the userthat product is “sold-out”. With a new B-I-B connected the pump automatically restarts and pressurizesthe syrup line, resetting the S.O.S. The L.E.D. will go out and drink dispensing resumes, without the needto manually reset.

NOTE: The S.O.S. is only intended for use with B-I-B systems which utilize electric solenoid dispensingvalves. The S.O.S. will not work with transfer tanks (figal system) and/or mechanical valves.

Installation Schematic

S.O.S. Installation1. Turn off the CO2 or pressurized air supply to the syrup pump.

2. Open the dispenser valve of the syrup line that the S.O.S. is being installed in, relieving the pressurewithin the tubing.

3. Install the S.O.S. inside the dispenser cabinet in a convenient location near the solenoid valves.Mount with the terminals facing down to prevent liquid from entering. Cut the syrup line and placeappropriately sized stainless steel, stepless Oetiker® clamps over the tubing. Install the S.O.S. usingthe correct sized barbed “T” fitting (¼” NPT) for that particular tubing I.D. Clamp the tubing to thefittings to prevent leaks.


45

SOLD-OUT SWITCH (S.O.S)94-068-01Low Profile


46

Electrical ConnectionNOTE: The terminals “Normally Open” (N.O.) and “Normally Closed” (N.C.) on the S.O.S. indicate switch

contact positions with pressure not applied.1. Disconnect all power to the dispenser unit.2. Locate the wire(s) (typically black) from the solenoid(s) to the 24VAC transformer, which has

current interrupted with the dispenser switch. Cut the wire and strip back ¼” [6mm] of insulation at both ends.

NOTE: Depending on the dispenser configuration, the valves in the dispenser head may have one solenoidoperating both water and syrup or two solenoids that operate each individually on a separatecircuit.

3. Connect the RED S.O.S. wire (N.O.) to the wire coming from the solenoid using the wire nuts(supplied). Connect the BLACK S.O.S. wire (common) to the other end of the wire that was cut.

4. To install the L.E.D. (optional) locate a position on the front panel that doesn't interfere with internalcomponents of the dispenser. Drill a ¼” [6mm] hole for the L.E.D. retainer clip. Snap the retainer clipin the front side of the panel, then snap the L.E.D. into place from the backside.

5. Wire the L.E.D. by splicing into the other wire (typ. white) from the transformer and connecting eitherlead from the light with a wire nut. Connect the other lead to the WHITE (N.C.) wire from the S.O.S.

Start-up1. Turn the power ON at the dispenser unit. If the L.E.D. was installed it should be illuminated at

this time.2. Restart the gas pump by turning on the gas supply. The pump should start to cycle and pressurize

the syrup line, causing the L.E.D. to go out.3. Open the dispenser valve and purge any air that entered while installing the S.O.S. The system is now

fully operational. 4. To determine if the S.O.S. will function as intended, pinch off the inlet tubing to the pump. Open the

dispenser and pour a drink, causing the pump to obtain vacuum shut-off. At this point the dispensershould stop flowing and the L.E.D. should illuminate. Remove the inlet restriction. The pump shouldoperate causing the S.O.S. to automatically reset.

The S.O.S. is preset to “open” at pressures below 15 psi. [1 bar] and will “close” at syrup pressures above 20 psi. [1.4 bar]. Depending on variables of particular B-I-B installations the S.O.S. may require aslight adjustment. If the S.O.S. is not operating as described (chatters, doesn't turn OFF/ON, interruptsoperation before B.I.B. is emptied) contact SHURflo. Detailed adjustment instructions are outlined inService Bulletin #1031.

SOLD-OUT SWITCH (S.O.S)94-068-01Low Profile


47

Automatic Selector ValveAll Models

Installation and OperationThe Automatic Selector Valve (ASV) is for use in Bag In-Box (B-I-B) systems where multiple B-I-B’s of one flavour are needed for high volume dispensing.

The ASV permits two or more B-I-B’s to be connected at eachinlet port (side). The Gas pump draws product through one side(indicated by the pointer) of the ASV until the B-I-B(s) areevacuated. Once vacuum is obtained, the ASV automaticallyswitches, drawing product from the B-I-B(s) connected to theother side. The ASV permits uninterrupted drinks dispense tothe customer, while store personal have the ability to replace B-I-B’s at a convenient time.

Vacuum Switch PointThere are two versions of the ASV, the difference being the levelof vacuum at which the ASV will change sides, ASV’s labelled 18 in. Hg. [61kPa] are used in conjunctionwith Gas Pumps.

For BRIX and Electric pump application the ASV label should indicate 12 in Hg. [40 kPa.] activation.

Installation Guidelines1. Mount the ASV between the B-I-B(s) and the pump. The outlet of the ASV should be mounted with the

outlet port pointed up. Never mount the ASV above the pump.

a. When using general beverage syrup/concentrates (typically 1-40 Centipose/cP.), maximum inlettubing length (horizontal & vertical) from the pump to the B-I-B(s) must not exceed 3M [10ft.]. The length of inlet tubing is dependent upon concentrate viscosity. Heavier viscosity products usemore of the available inlet vacuum. Concentrates above 40 cP. require substantially shorter inlettubing lengths.

b. The maximum vertical rise from the B-I-B(s) to the pump, indicating the ASV is 3ft (1M). The vertical distance that may be achieved is dependent upon concentrate viscosity. High viscosity(thick) products (over 500 CPS); may require 13mm I.D. (1/2”) tubing with minimal vertical lift.

NOTE: High inlet vacuum due to high flow rates, product viscosity, or restrictions can evacuate air suspended in some concentrates causing low brix or premature operation of the ASV.

2. When using multiple B-I-B’s, plumb all B-I-B’s horizontally, not vertically. Placing the B-I-B’s one ontop of the other (vertically), results in the top B-I-B draining into the bottom B-I-B which leads topoor product rotation. However, the B-I-B(s) plumbed to “side one” of the ASV do not necessarily have to be on the same level as the B-I-B(s) plumbed to “side two”.

3. Use 10 or 13mm I.D. (3/8” or 1/2”) heavy wall (3mm (1/8”) clear, NSF listed vacuum tubing from thebag connector, ASV, and the pumps’ inlet.

4. Properly clamp all tubing connections and tie-wrap tubing securely to prevent kinks or sags that mayinhibit performance or cause damage to the pump/ASV fittings.


48

Automatic Selector Valve

Operating GuidelinesTHE BENEFITS OF THE ASV CAN ONLY BE PROVIDED WHEN EMPTY B.I.B’S ARE REPLACED BEFOREBOTH SIDES ARE EMPTIED. At a convenient time store personal should check for empty B.I.B’s.Replace empty B.I.B’s once the pointer indicates the ASV is drawing from the other side. By insuring the full B.I.B’s are in place before the other side is evacuated, the ASV will provide uninterrupted drink dispensing.If both sides are emptied, the ASV will be vacuum locked. Do Not switch the indicator pointer. Connect fullB.I.B’s to both sides. If only a single B.I.B is available, connected the B.I.B. to the side the ASV pointerindicates. Always leave bag connectors (Q.D’s) attached to the empties until full B.I.B’s are available.Doing so prevents air from being drawn into the system and will keep the bag connector clean.NEVER FORCE THE INDICATOR POINTER! During normal use switching of the indicator pointer by hand is not necessary and not recommended. Forcing the pointer to change side during normaloperation (under vacuum) may damage the ASV.

Troubleshooting The B.I.B’s on one side of the ASV are not completely evacuated: but, the ASV indicator has changed over.The pointer may have been moved manually, or the inlet vacuum level may have exceeded the switch pointcausing the ASV to switch prematurely. High vacuum may be caused by one or more of the following:3 (High dispenser flow rate(s), max flow is 60m/per second3 (Kinked, pinched, improperly installed bag connectors or other restriction within the inlet tubing.3 (Substantial increase in the product viscosity (decrease in product temperature)3 (Changes in B-I-B position relative to pump/ASV mounting (see Installation Guidelines)The B-I-B’s on one side are empty; although the ASV will not switch to the full B.I.B’s on the other side.This indicates the pump is unable to maintain the level of vacuum necessary to switch the ASV. Vacuumleaks and/or air within the B-I-B’s will cause the ASV not to switch. Vacuum leaks/air may be caused byone or more of the following:3 (Are any bag connectors (Q.D’s) not attached to a B-I-B? An open or unused bag connector may be a

source of the vacuum leak. Always leave bag connectors (Q.D’s) attached to the empty B-I-B’s untilfull B-I-B’s are available.

3 Air bubbles in the inlet tubing when the dispenser is operated. Inspect all the bag connectors, tubingconnections and inlet side fitting for air bubbles which is an indication of a vacuum leak.

3 B-I-B’s contain excessive amount of air due to improper fill process. Stand bag vertically and run dispenser until air is purged.

3 Has the ASV been manually forced causing damage to internal components?3 Gas pump CO2/air pressure supply. Has the system pressure been reduced.The ASV ability to switch by vacuum may be tested.

1. Remove a bag connector (Q.D.) from each side of the ASV. Depress both bag connector (Q.D.) plunges toinsure the ASV is not vacuum locked. Reconnect to B.I.B’s that are sufficiently full.

2. With the vacuum released the indicator can be switched manually. Switch the indicator back and forthseveral times. The force and feel when switching the indicator should be the same in the both direction.If it isn’t the ASV has been damaged and should be replaced.

3. The dispense valve must be flowing, to test the ASV. With the dispenser open, fold-over/kink (by hand) theinlet tubing on the side the ASV pointer indicates it is drawing through. After the pump strokes several timesto obtain the necessary level of vacuum, the ASV should switch sides. After switching sides release the kinkand kink the (other side) tubing the ASV is now drawing through. After several strokes of the pump, the ASVshould switch back.

4. If the ASV doesn’t function as described check for the problems indicated above. If none of the causes above exist replace the ASV and re-test.


49


ASV SanitisingThe SHURflo ASV is only one piece of a beverage dispensing system. Therefore, frequent sanitising of theASV and ALL equipment in the system is required. Sanitisation is dependent on the concentrate type andits’ manufacturers requirements. Factors which also effect the frequency of this procedure are, temperature, facility conditions, installation, and equipment. Consult other equipment manufacturer’sinstructions for their sanitising requirements. Perform the following procedure to assure compliance withNSF listed sanitising requirements for the SHURflo ASV (only).

Materials RequiredUses a non-sudsing liquid detergent, such as Diversol CX or equivalent.Sanitising procedure requires a solution containing Sodium Hypochlorite; 5.25% (household bleach)or equivalent mixed with water.From two discarded B-I-B’s remove the filter neck assembles. The filter necks will be your adaptorcoupling Place the adaptor coupling onto the quick disconnect fittings. This will open the plunger inthe Q.D. allowing the sanitising solutions to be vacuumed through the ASV.You need two large containers to pump the cleaning solutions.

Sanitising Procedure1. Disconnect the syrup B-I-B from the Bag-In-Box and connect to adaptor coupling. (Bag valve

removed from an empty Bag-In-Box package).2. Flush: Immerse the B-I-B connector/adaptor syrup inlet lines in a container of warm water (49-82ºC

(120-180ºF).3. Prepare suitable container for draining from fountain dispenser head.4. Manually switch B-I-B indicator on ASV to position 1.5. Pump 4 litres of warm water thru port 1 of ASV by depressing dispenser head bar switch. Stop

dispenser head momentarily then manually switch indicator knob to port 2. Pump 4 litres of warmwater through port 2 of ASV.

6. Clean: Prepare 6 litres of detergent solution in clean container.7. Place B-I-B connector/adaptor syrup inlet lines in detergent solution.8. Pump approx 2 litres of detergent solution through each port of the ASV (using the same method as

Step:5) into separate drain container.9. Let the solution remain in the ASV and pump for a contact time of two minutes.10. Sanitise: Prepare 6 litres of sanitising solution (Hypochlorite) in clean container to a concentration of

200 ppm.11. Place B-I-B connector/adaptor syrup inlet lines in sanitising solution.12. Pump approx. 2 litres of sanitising solution through each port of ASV. Let the solution remain in the

ASV and pump for a contact time of two minutes.13. Pump the remaining sanitising solution through ASV and pump.14. Product Purge: Remove adaptor couplings and connect B-I-B connectors to Bag-In-Box.15. Pump until a steady stream of syrup flows through dispensing head. Repeat for other ASV port.16. Repeat Step: 9.17. Pump approx, 0.25 litres of syrup through each port of ASV.18. Stop pump. Test dispensing valve for proper operation. Taste dispensed product to insure there is no

off-taste. If off-taste is found, additional syrup purging may be necessary.


50


WinterizingIf the SHURflo ASV and pump are subjected to temperatures of 32ºF (ºC) or lower, the system must bedrained of all liquid to prevent damage due to freezing. It is suggested that when taking a ASV/pump out of service, the ASV/pump and lines, etc. must be sanitised and purged as follows:

1. Perform steps 1-7 of the Sanitising Procedure.2. Adjust the CO2/air pressure the pump to a maximum of 1.4 bar (20 psi)3. Open the dispenser and allow air to enter in through the bag connector on one side of the ASV.

When the inlet tubing is purged of sanitising solution turn OFF the CO2/air supply to the pump.Manually switch the ASV to the other side.

4. Turn ON the CO2/air supply to the pump, allowing the remaining solution to purge through the otherbag connector and out to the dispenser.

CAUTION: If there is any chance the solution may drain back to the ASV or pump, remove the fittings from the ports. The products outlet fitting at the pump may also need to be removed and purgedof any remaining solution. Refer to the other equipment manufacturer’s recommendation onpurging lines and dispense equipment.


51

BIB Rack Assembly &Accessories

Note: Pump & BIB tubing and accessories not included with Rack (94-484-01) Nor Overhead Pump Mount (94-486-01). Shown for illustration purposes only.

94-486-01Optional Over-head Pump Mount

94-481-00 End Cap Kit (x8)

Optional94-483-00Rack Leveler Kit (x4)

94-482-00Extended LengthTube Joiner Kit (x12)

94-484-01Expanding MetroStyle BIB RackIncludes followingfittings:End Cap KitTube Joiner Kit

Rack comes disassembled in box:36” x 40” x 20”


52

SHURflo Expanding MetroStyle BIB Rack AssemblyInstructions

Unpack and identify rack components & qty. per illustration below before beginning assembly procedure.

94-484-01 Expanding Metro Style BIB Rack – 4 shelves high Components: • 8 x Shelve-sides • 4 x Shelves-flats • 16 x Collets (pairs) • 12 x Tube joiners • 8 x End-caps

Part # Description


53

SHURflo Expanding MetroStyle BIB Rack AssemblyInstructions continued

Assembly Procedure1. Place a SIDE-SHELF at each end of FLAT SHELF, as the picture below shows. Note that slide rail must

face out at each end of the shelf to allow mounting pumps.

2. While holding FLAT-SHELF as shown(BIB wire-frame facing you) slide SIDE-SHELF legs through rings, such that slide rail faces out.

RINGS

SIDE-SHELF leg

FLAT-SHELF BIB wire frame facing out

Slide rail faces outwardon each end


54


3. Turn partially assembled shelf upside down as shown to snap collets in groove on each leg.

4. Once collets have been snapped into grooveon each leg, turn assembly upright.

5. With shelf assembly in the upright positionproceed to secure assembly by using arubber mallet on the FLAT-SHELF’s squaretubing at each corner.

RINGS

6. With shelf fully assembled and secured, turn shelf on one sideas shown to extend to expanded length.Use feet to hold SIDE-SHELF on the floor while pulling with both hands the otherSIDE-SHELF to expand shelf required width.

Repeat steps 1 through 6 for each shelf.

NOTE: for 2-BIB wide use, skip step 6 and proceed to step 7.

Collets-groove


55


7. With shelf assembled and secured insert tubes joiner on each leg, as shown (do not hammer top of tube joiner).

9. Use rubber mallet (on top FLAT SHELF’s squaretubing at each corner) to fully insert tube joiners onshelves’legs, thus connecting together bottom andtop shelves.

8. With tube joiners on each leg (on bottomshelf) proceed to mount top shelf on tubesjoiner as shown.

10. Repeat steps 7 through 9 as necessary upto 4th shelves high rack.

11. Once rack is fully assembled insert endcaps at each end leg (top & bottom).


56

Fob-Stop®

94-211-XX

INSTALLATION AND OPERATION INSTRUCTIONSFOBSTOP VENTED EMPTY KEG SENSOR

PART NO.

RESET VALVE

BEER FLOWCONTROLHANDLE

VENT TUBE

KEG SENSOR

VENT VALVE

• Fobstop shuts off beer when keg empties eliminating beerwaste while changing kegs.

• Fobstop can be cleaned in either direction.

• Unique design reduces the riskof microbiological growth frombeer stored in a traditional fob detector, making it especially ideal for areas of high ambienttemperature.

PUSH BUTTON

94-211-21 (5/8 inch)94-211-22 (1/2 inch)


57

Fob-Stop®

Operating Instructions for beer

Keg Mount Installation I

1. Disconnect keg coupler from keg

2. Open faucet to relieve line pressure and then close faucet.

3. Disconnect beer line from keg cou-pler and drain beer from the line.

4. Connect drained beer line to top/outletof Fobstop by using (A) flat seal and washer or (B) push-in connector.

5.

Insert seal washer supplied into coupling nut on Fobstop and coupleto the keg coupler.

6.

Connect Fobstop to the keg couplerand tap keg.

7. See tapping procedures on opposite

page.

(A) Flat sealConnectionand washer

Fobstop andsealingwasher

Wall Mount Installation1. Disconnect the keg coupler from keg. If the system includes beer pumps,

the beer pumps gas supply should be disconnected as well.

2. Remove beer from the system by opening the faucet, disconnecting the beer line at the wall bracket in the walk-in cooler. Drain the beer from the line.

3. If the system includes a beer pump, the Fobstop should be installed after the beer pump.

4. See tapping procedures on opposite page.

For proper performance, the Fobstop must be installed in the vertical position.IMPORTANT!

(B) Push-inconnection


58

Fob-Stop®

Cleaning Instructions – 1For use with pressurised container systems only

Tapping & Cleaning ProceduresBeer Flow Control Handle

Operating Positions

Fig. 1RESET/CLEAN

Fig. 2ON

1. Turn Beer Flow Control handle to RE -SET/CLEAN position (see Fig. 1) .

2. Tap Fresh Keg.3. Open the beer faucet. When solid beer

appears, close the faucet. The line is full.4. TurnBeer Flow Control Handle to the ON

position (see Fig. 2) .

Procedure When Line is Empty

1. Remove coupler from empty keg and tap new keg.

2. Keep Flow Control Handle ON (see Fig. 2).

3. Press vent button releasing gas from line connecting coupler and Fobstop. When solid beer comes through the vent, release the button.

4. Turn Beer Flow Control Handle to RE -SET/CLEAN position (see Fig. 1) . Wait

ON position for five seconds then turn to(see Fig. 2) .

Procedure When Line is Full

1. Untap keg in usual manner.2. Open bar tap to relieve pressure and close

tap when flow ceases.3. Disconnect beer line from keg coupler

and attach to cleaning ring main orcleaning bottle.

4. Turn Fob Stop Beer Flow Control handle to RESET/CLEAN (see Fig. 1) and clean line as usual.

5.

After cleaning lines and flushing with clear potable water (in accordance with normal cleaning procedures), keep the Fob Stop Beer Flow Control handle inRESET/CLEAN (see Fig. 1) and re-tap keg.

6.

To restore service, see tapping procedurefor when line is empty.

Cleaning Procedure

Warning: Always follow manufacturer’s instructions on safe and effectivehandling of line cleaning solutions


59

Fob-Stop®

Cleaning Instructions – 2For wall mounted cleaning systems with Fob-Stop manifold vent lines.

Troubleshooting

Beer Flow Control Handle is in RESET/CLEAN position.

Slowly turn Beer Flow Control Handle to ON position.

Fobstop has locked up. Turn Beer Flow Control Handle to

position. Wait five seconds then slowly turn BeerRESET/CLEAN

Flow Control Handle to ON position.

Fobstop is dirty. Clean Fobstop.

Re-establish gas flow. Out of gas.

Problem:

Probable Cause:

Solution:

Problem:

Probable Cause:Solution:



Beer flow is slower with Fobstop than withstandard coupler.

Beer does not flow after keg is tapped.


60

Water Boost Systems804-XXInstallation and Operating Instructions

WARNING: “Risk of electrical shock.” The pump is supplied with a grounding connector and grounding-type attachment plug. To reduce the risk of electrical shock, be certain that it is connected only to a properly grounded, grounding-type receptacle. To prevent electrical shock, disconnect power before initiating any work. In the case of pump failure, the motor housing and/or the pumped fluid may carry highvoltage to components normally considered safe.

CAUTION: DO NOT adjust the pump pressure switch setting. Switch setting will not significantly alter flow-rate or pressure. Improper adjustment may cause severe overload or premature failure, not covered under warranty.

CAUTION: DO NOT operate the pump at pressures which cause the motor to exceed the amperes ratingindicated on the name plate. The pump is equipped with thermal breakers to interrupt operation due toexcessive heat. Once the temperature of the motor is within proper limits it will automatically reset, andthe pump will start operation without warning. The motor is equipped with an integral non-serviceablefuse. Pumps which have an “open” fuse are not covered under the limited warranty.

Accumulator Storage/Flow-Rates SHURflo Water Boost Systems are for applications when low, fluctuating, or no water pressure exists. The pump and accumulator maintain consistent water pressure to a source (for a given duration) as longas incoming water is sufficient. Depending upon the Water Boost System model, support of up to 4 non-carbonated valves in moderate volume accounts is achievable. The pump pressurizes the accumulator to 60 psi. or 90 psi. (depending on the pump model). Consult the models flow-chart for projected length of flow and/or back-up. Maxi Boost Systems may be used to supply water to a carbonator for back-up, during short periods of insufficient water pressure fluctuations and to guardagainst high spikes in incoming pressure. The pump is N.S.F. and U.L. & C-UL listed.

InstallationThe water booster system is to be installed between the water source and non-carbonated valve(s) or carbonator.

Remove Accumulator Air Fitting Cap and pre-charge with clean pressurized air, or nitrogen as indicated by specifications for theparticular model accumulator. Replace AirFitting Cap.


61

Water Boost SystemInstallation and Operating Instructions

CAUTION: DO NOT pre-charge the accumulator with CO2. If the bladder separating the water and CO2 wereto leak, the water could become carbonated and cause a reaction with brass components in other systemequipment.

Use only flexible high pressure tubing to connect the inlet/outlet ports. Clamp and tie-wrap tubing toprevent kinks or sags that inhibit performance or cause damage to the pump. Cap 3/8” Flair Fittingsthat is not used.

Turn ON incoming water supply.

The pumps power cord plug must only be connected to a grounding-type receptacle (wall outlet).When the power cord is plugged in, the pump will operate. The pump may not operate if the incoming water pressure is sufficient and has had time to pre-charge the tank.

CAUTION: Electrical outlet (receptacle) wiring should be performed by a qualified electrician, in accordance with all local electrical codes. Circuit protection is dependent on the individualapplication requirements. Failure to provide proper circuit protection may result in a motor failure, which is not covered under warranty.

Open the dispenser and purge air in the tubing/accumulator. The pump may not obtain shut-off pressure if excessive air is trapped within the tubing.

NOTE: The accumulator tank precharge should be checked bi-monthly. All outlet water pressure must bedepleated prior to checking or recharging.


62

Silver Series R.O. Booster Pump Range

The Silver Series R.O. Booster pump line streamlines our pump offering to three basic pump models,which meet the demands of most R.O. applications.

The Silver Series pump-head design, features a one piece piston-diaphragm design proven to significantlyreduced the potential for leaks as well as increased the life of the pump and a precision bypass system,which maintains a constant safe outlet pressure regardless of changes in incoming city water pressure.This enables your R.O. system engineers to design systems with precise product water quality andproduction rates.

Features include:Ultra quiet operation. Ideal for 50-150 GPD [190-570 LPD].

Reliable, long lasting performance. Longest pump life in the industry.

Patented diaphragm, and bypass design. 24VAC/24VDC

Silver Series R.O. Pump PerformancesNote: GPD performance based on 25% recovery rates.


63

High Performance Brushless D.C.R.O. Booster Pump

The new High Performance Brushless-D.C. R.O. Booster pump expands our performance range whilemaintaining all of the design elements, which have made SHURflo R.O. pumps well known for providingthe longest pump life in the industry. The pump-head design features a one piece-piston diaphragm designproven to significantly reduced the potential for leaks as well as increased life. The pump precision bypasssystem maintains a constant safe outlet pressure regardless of changes in incoming city water pressure.These advanced features enable your R.O. system engineers to design systems with precise product waterquality and production rates.

With its unique two speed switch, one pump meets the performance requirements of 150 or 200 GPD withthe flip of a switch.

Features include:High Flow Rate supports 150 - 200+ Extended motor life with brushlessGPD [570 - 760 LPD] systems at technology.standard recovery rates.

Quiet operation at any flow and Pressures up to 140 PSI [9.6 BAR]pressure range.

Model # 8075-192-319 Performances


64

R.O. Pump Power Supply

The SHURflo R.O. Pump power supply (60-044-00) will fit the power requirements of the entire rangeSHURflo R.O. pump Line.

The power supply switch mode design makes it an efficient energy consumption power supply that meetsthe demand of most R.O. applications.

Specifications Part number: 60-044-00

Input: 100-240 VAC 50/60 Hz 1.2 Amps

Output: 24 VDC 2.5 Amps

Agency Approvals: UL, CE, GS

Overall Dimensions: 4.5” x 2.4” x 1.5” [115 x 62 x 38mm]

Connectors: US plug 4.5’ power cord & 4.5’ lowvoltage cord w/ AMP connector

Pentair Process TechnologiesIndustriepark Wolfstee, Toekomstlaan 30B-2200 Herentals, BelgiumTel: 32-14-283504 Fax: 32-14-283505

[email protected]

TM-1117-ODL ISSUE: 2013/1© 2004–2013 Pentair. All Right Reserved.

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