BrewBlast™ 40PPH & 70CPH Checking for Leaks

Applies to: BrewBlast™ 40PPH, BrewBlast™ 70CPH

Does NOT apply to: BrewBlast™ 110CPH

This article covers the systematic procedure for locating and isolating gas leaks on the BrewBlast™ 40PPH and 70CPH. Use this procedure after initial startup, after any service that involved opening gas lines, or whenever the BlastOff™ alarm activates or the system runs more than expected.

▲ AttentionLine leaks cause the unit to run excessively, accelerating wear on the compressor and PSA media. A system that never reaches standby or cycles back to run shortly after reaching standby almost always has a leak. Do not defer leak investigation.

Leak Detection Methods

Two methods are used to find leaks, depending on whether a leak can be heard:

• Audible detection: Listen carefully around all connection ports, fittings, and hoses for hissing or airflow sounds. This is always the first step.
• Leak detection solution: Apply soapy water or an approved gas leak detection solution using a spray bottle. Bubbles will form at any leak point. Use this method only on non-electrical components — never spray solution near electrical connections, the control panel, or the power entry module.

ℹ NotePush-to-connect fittings have an acceptable leakage rate of up to 5 ccm. Small bubbles at a push-to-connect fitting do not necessarily indicate a problem. Leaking threaded fittings and hose connections should be repaired.

Phase 1 — Locate Any Obvious Leaks

1. With the system running, listen carefully at all external connection points — output ports, CO₂ inlet (if blender is present), drain fittings, and all hose connections from the cabinet to the keg system.
2. If an audible leak is found, isolate that section by closing the nearest upstream valve so there is no pressure on the leaking component. Repair or replace the fitting or hose and return the system to operation.
3. If no leak can be heard, proceed to Phase 2 to determine whether the leak is inside or outside the cabinet.

Phase 2 — Determine Whether the Leak Is Inside or Outside the Cabinet

This procedure uses the system's own run/standby cycle to isolate the leak location.

1. With the unit powered on, close all output gas valves at the cabinet. If no ball valve is installed on the output ports, remove the gas lines and install plugs.
2. Allow the system to continue running with the output blocked. Within approximately 1 hour, the system should reach standby mode as the storage tank pressurizes.
3. Once standby is reached, wait 5 minutes without drawing any gas.
   • If the system remains in standby after 5 minutes — the leak is downstream of the cabinet. Proceed to Phase 3A.
   • If the system returns to run mode within 5 minutes — the leak is inside the cabinet. Proceed to Phase 3B.

Phase 3A — Locating an External Leak

The leak is somewhere in the gas lines between the cabinet output ports and the keg system.

1. Reopen the output valves and trace all external gas lines from the cabinet to the kegs.
2. Listen and apply leak detection solution at every fitting, regulator, valve, and connection along the run.
3. Check that each keg is properly tapped — an improperly seated coupler is a common source of leaks.
4. Repair or replace any leaking component. Close the valve on that individual line before working on it.
5. Once repaired, reopen all valves and confirm the system reaches and holds standby. If the BlastOff™ alarm was active, reset it by cycling the power switch off then back on.

ℹ NoteIf the leak cannot be located externally, contact your local installer or South-Tek Systems for further assistance. Do not leave the system running with an unresolved leak.

Phase 3B — Locating an Internal Leak

The leak is somewhere inside the cabinet. Use the red manifold ball valves to narrow the location.

1. Open the front cabinet door and locate the N₂ storage tank and the red manifold with its two manual ball valves.
2. Close the upper ball valve on the red manifold (tank output valve).
3. Watch the exterior pressure gauge for 60 seconds.
   • If pressure is dropping — the leak is between the output ports and the upper (now-closed) ball valve. This includes any blender plumbing if present. Apply leak detection solution to all fittings and lines in this section. Repair and recheck.
   • If pressure is not dropping — proceed to the next step.
4. With the unit still running, close the lower ball valve on the red manifold (tank input valve).
5. Within 5 minutes the system should enter standby mode as the air side pressurizes.
   • If it does not reach standby within 5 minutes — contact South-Tek Systems for further assistance.
6. Once in standby, wait 60 seconds.
   • If the system returns to run mode — the leak is between the check valve and the upper ball valve on the tank. Inspect and repair connections in this section of the internal plumbing.
   • If the system remains in standby — the internal plumbing appears sound. Contact your local distributor or South-Tek Systems for further diagnosis.

⚠ WarningIf internal components need to be repaired or replaced, use only factory-supplied parts from South-Tek Systems or an authorized distributor. Using non-factory parts may result in damage not covered under warranty. Do not attempt to modify the internal control timer or pressure switch settings.

After Repairs — Final Verification

1. Reopen all ball valves that were closed during the isolation procedure, in reverse order from how they were closed.
2. Allow the system to pressurize and reach standby.
3. Let the system hold standby for at least 5 minutes without drawing gas to confirm the leak has been resolved.
4. If the BlastOff™ alarm was active, reset it by turning the power switch off then back on. Do not repeatedly reset the BlastOff™ without resolving the underlying cause — if it activates daily, a real leak is present and must be found before resuming operation.
5. Resume normal operation and monitor system behavior over the next several pour cycles.

When to Escalate

Contact South-Tek Systems if:

• The leak cannot be located using the procedures above.
• The system fails to reach standby even with all output ports closed and plugged.
• The BlastOff™ alarm activates daily or repeatedly after reset.
• Internal plumbing components are damaged and require replacement.

Related Articles

Article	Applies To
BrewBlast™ 40PPH & 70CPH – Installation & Startup	40PPH, 70CPH
BrewBlast™ Alarms & Troubleshooting	All models
BrewBlast™ 40PPH & 70CPH – Specifications & Components	40PPH, 70CPH

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