Intertap beer faucets

[indevrede]

I ordered and received 2 regular SS and 2 Flow Control Intertap faucets from the Aliexpress seller Brewsmaster. I bought these to replace Perlick 525PC models that had started leaking after a few years (also, the chrome had eroded away on the inside of the faucets exposing the brass). After finding ~4 gallons of my homebrew on the floor one morning I'll never trust the Perlick forward seal design again.

Initial Intertap impressions: The stainless steel on the main faucet body is actually chrome-plated stainless (that's why it's so shiny, different from the screw-on spouts). As-received, the chrome was flaking off inside the body of the faucet. I scrubbed at it with a brush and got most of it out, but I was disappointed.

Another issue: Before use I disassembled the faucets, cleaned them in warm PBW, then re-assembled (with a light coating of lube). I then poured a Witbier at 18 psi and found that beer leaked through the bonnet (i.e. the connection to the handle / lever). I tightened down the bonnet cap as hard as I could (even resorted to a wrench) but it still leaked. I had some discussion with the manufacturer (Keg King in Australia) and they said that they've sold ~15,000 faucets without anyone complaining about leaks, but they would send me two replacement gasket sets anyway. They are friendly people and the gaskets were a nice gesture, but not sufficient to stop the leak.

I carefully studied the design and discovered that the lower-most o-ring (below the lever ball) doesn't make a good seal with the lever ball. Keg King confirmed this, saying that the seal is actually made between the ball and the nylon ball washer.

/Side note: in the reference design drawing (pdf on their website), the lower ball o-ring is clearly making contact with the ball, and I think if they actually used the parts they show in that drawing it would work. The issue is that the upper and lower ball washers are generic parts (from the ubiquitous rear-sealing bar faucets) and don't match the design. So, the lower o-ring sits too far away from the ball and doesn't make good contact wit the ball. /end side note

Also, I noticed that out-of-the-box there was a LOT of lube on the ball washers and o-rings, so I think that their design relies on having enough lube to seal properly (again, I'm referring to the seal to the lever handle, not the main faucet seal).

I don't think that's a good design, so I made a modification that works really well: I removed the round o-ring from below the ball washers and replaced it with a hard nylon flat washer (actually two thin ones). Then I put two thin o-rings (1 mm thick, 14.5 mm OD) between the two nylon ball washers. Finally, I added another nylon flat washer right below the bonnet cap as an additional spacer. The two o-rings are the main liquid seal, with the nylon ball washers used only to provide a mechanical seat in which the ball rotates, and the nylon flat washers act only as spacers. This (the sealing double o-ring between two ball washers) is basically the design of the Perlick 425.

The faucet handles work perfectly now, sealing with just a thin coat of lube and very little force, so now I'm happy with the Intertap faucets (price and quality). If I could mashup the perfect faucet it would be: the lever ball seat of the Perlick 630SS with the shuttle forward seal design of the Intertap / ventmatics. And, delete the Chrome plating from the stainless.

Side note: I'm happy with the flow control. Very convenient, with 3 feet of 1/4 tubing and I've poured 5 psi bitters and 21 psi hefeweizens without changing the line.

 

[gromitdj]

I believe Keg King has stated that the faucets available on Aliexpress are unauthorized reproductions. I'm surprised they sent you anything as a warranty replacement.

 

[mintyice]

I believe Keg King has stated that the faucets available on Aliexpress are unauthorized reproductions. I'm surprised they sent you anything as a warranty replacement.

Sounds like people having issues are those who got it from Aliexpress.

I got mine from Keg King and have had zero issues.

 

[PeteNMA]

I didn't have any issues with mine via AliExpress. Can't say that they we're excessively greasy, and they certainly don't appear to be plated steel, they look and feel like polished stainless. And the one I've installed so far has no issues with leaking

 

[lawless317]

Are the ones on eBay legit

 

[lawless317]

I might order three fro Ali and three from eBay if they're legit keg king doesn't have a shipping option to US
Then I can really do a comparison

 

[mintyice]

I might order three fro Ali and three from eBay if they're legit keg king doesn't have a shipping option to US
Then I can really do a comparison

http://www.brewpump.com/SearchResults.asp?Search=intertap&Submit=

Brewpump ships to US. That's how I got mine.

 

[indevrede]

I believe Keg King has stated that the faucets available on Aliexpress are unauthorized reproductions.

My SS faucets are labeled batch #1507 and the FC faucets are batch 8473. The boxes said "Keg King" although the Aliexpress product page never mentioned that name. I've studied the photos on the Intertap website carefully and the ones I received look identical in every way. The replacement gasket set I received from Keg King matches the gaskets originally installed in the faucets. If these are knock-offs, then the manufacturer has done a very convincing job. (They also might be factory seconds, given the chrome plating imperfections I found.)

 

[gromitdj]

If these are knock-offs, then the manufacturer has done a very convincing job. (They also might be factory seconds, given the chrome plating imperfections I found.)

Notice that I did not call them "knock-offs". They may be a production over-run of the same parts used by Keg King. I suppose that is one of the dangers of manufacturing in China.

But, considering the fact that you did not purchase them from an authorized Keg King distributor, I'm surprised that they extended any sort of customer service to you. When telling them that your "Intertap" faucets leaked, did you let them know they were purchased from Aliexpress?

 

[duelerx]

I ordered and received 2 regular SS and 2 Flow Control Intertap faucets from the Aliexpress seller Brewsmaster. I bought these to replace Perlick 525PC models that had started leaking after a few years (also, the chrome had eroded away on the inside of the faucets exposing the brass). After finding ~4 gallons of my homebrew on the floor one morning I'll never trust the Perlick forward seal design again.



Initial Intertap impressions: The stainless steel on the main faucet body is actually chrome-plated stainless (that's why it's so shiny, different from the screw-on spouts). As-received, the chrome was flaking off inside the body of the faucet. I scrubbed at it with a brush and got most of it out, but I was disappointed.



Another issue: Before use I disassembled the faucets, cleaned them in warm PBW, then re-assembled (with a light coating of lube). I then poured a Witbier at 18 psi and found that beer leaked through the bonnet (i.e. the connection to the handle / lever). I tightened down the bonnet cap as hard as I could (even resorted to a wrench) but it still leaked. I had some discussion with the manufacturer (Keg King in Australia) and they said that they've sold ~15,000 faucets without anyone complaining about leaks, but they would send me two replacement gasket sets anyway. They are friendly people and the gaskets were a nice gesture, but not sufficient to stop the leak.



I carefully studied the design and discovered that the lower-most o-ring (below the lever ball) doesn't make a good seal with the lever ball. Keg King confirmed this, saying that the seal is actually made between the ball and the nylon ball washer.



/Side note: in the reference design drawing (pdf on their website), the lower ball o-ring is clearly making contact with the ball, and I think if they actually used the parts they show in that drawing it would work. The issue is that the upper and lower ball washers are generic parts (from the ubiquitous rear-sealing bar faucets) and don't match the design. So, the lower o-ring sits too far away from the ball and doesn't make good contact wit the ball. /end side note



Also, I noticed that out-of-the-box there was a LOT of lube on the ball washers and o-rings, so I think that their design relies on having enough lube to seal properly (again, I'm referring to the seal to the lever handle, not the main faucet seal).



I don't think that's a good design, so I made a modification that works really well: I removed the round o-ring from below the ball washers and replaced it with a hard nylon flat washer (actually two thin ones). Then I put two thin o-rings (1 mm thick, 14.5 mm OD) between the two nylon ball washers. Finally, I added another nylon flat washer right below the bonnet cap as an additional spacer. The two o-rings are the main liquid seal, with the nylon ball washers used only to provide a mechanical seat in which the ball rotates, and the nylon flat washers act only as spacers. This (the sealing double o-ring between two ball washers) is basically the design of the Perlick 425.



The faucet handles work perfectly now, sealing with just a thin coat of lube and very little force, so now I'm happy with the Intertap faucets (price and quality). If I could mashup the perfect faucet it would be: the lever ball seat of the Perlick 630SS with the shuttle forward seal design of the Intertap / ventmatics. And, delete the Chrome plating from the stainless.



Side note: I'm happy with the flow control. Very convenient, with 3 feet of 1/4 tubing and I've poured 5 psi bitters and 21 psi hefeweizens without changing the line.

Can you share a picture of your faucet with your new o rings?

 

[indevrede]

I'm surprised they sent you anything as a warranty replacement.

Notice that I did not call it a "warranty replacement".

But, considering the fact that you did not purchase them from an authorized Keg King distributor, I'm surprised that they extended any sort of customer service to you. When telling them that your "Intertap" faucets leaked, did you let them know they were purchased from Aliexpress?

Is it snarky to say I'm surprised at your surprise?

My discussion with Keg King was about the design and how I perceived the design and/or execution to have flaws. These could have been faucets purchased used off Craigslist and it wouldn't have made a difference. I wasn't making a warranty claim. In fact, they never asked where I got the faucets (probably because they understood it wasn't relevant). The relevant relationship was designer:tester, not vendor:customer.

On my end, I did several hours of careful R&D for their product (I tested 3 or 4 designs and spent about $30 on o-rings and washers, most of which didn't work), plus took the time to promote their product on this forum (again, I am generally happy with the faucets and I would buy more, especially because I know how to fix them). On their end, they sent a handful of o-rings and washers that probably wholesale for pennies. Now, I enjoy tinkering and I don't mind being a beta tester for bleeding-edge products, so I'm not complaining, I'm just explaining why my conscience is clear on this matter.

Or maybe methinks I doth protest too much

 

[indevrede]

Can you share a picture of your faucet with your new o rings?

How about a drawing and links?

Quantity 1: Nylon 6/6 Flat Washer, Plain Finish, Black, 7/16" Hole Size, 0.44" ID, 0.75" OD, 0.06" Nominal Thickness (Pack of 100)

Quantity 2: 1mm X 12.5mm V75 Viton O-ring Black

Quantity 1: Nylon 6/6 Flat Washer, Plain Finish, Off-White, 5/16" Hole Size, 0.38" ID, 0.57" OD, 0.03" Nominal Thickness (Pack of 100) (two of these thin washers are used, but they come in packs of 100)

 

[lawless317]

The nylon washer links do not give exact washer
You have to choose the exact dimensions
Perhaps a screen shot?

 

[indevrede]

The nylon washer links do not give exact washer
You have to choose the exact dimensions
Perhaps a screen shot?

Images attached.

 

[indolent]

Is it snarky to say I'm surprised at your surprise?

My discussion with Keg King was about the design and how I perceived the design and/or execution to have flaws. These could have been faucets purchased used off Craigslist and it wouldn't have made a difference.

I wasn't making a warranty claim. In fact, they never asked where I got the faucets (probably because they understood it wasn't relevant). The relevant relationship was designer:tester, not vendor:customer.

...

On my end, I did several hours of careful R&D for their product (I tested 3 or 4 designs and spent about $30 on o-rings and washers, most of which didn't work), plus took the time to promote their product on this forum.

You're not promoting their product, you don't even know if you have their product. You're pointing out a design flaw that may or may not even exist in their product.

You said they could be knock offs, since we don't know where the aliexpress ones come from. Like gromitdj, I'm suprised they're providing any service without first verifying you're looking at their product. From keg king's point of view, it very much should matter where they came from, since you are trying to solve a problem with a design flaw that may only exist in the aliexpress faucets, and not the official Intertap faucets.

I'm not saying what you did isn't helpful, because it could be very beneficial to those of us on the forum that bought from aliexpress. It is just odd that keg king didn't follow up a bit more before discussing the apparent flaws in your faucets.

 

[skatz]

One of the three I got from brewpump did leak slightly from the bonnet. I think the issue was the nylon washers were not seated well. I was able to get it to stop, but the keg kicked a few days later, so I can't talk long term.

The leak was very minor and I only noticed it when I touched the bottom of the faucet body and noticed a bit of stickiness. First time I noticed it I wiped it up and it took a few days to return to a noticeable amount.

As for the retrofit, it would be great if you could put together a seperate post with photos and links.

 

[cuda6pak]

Just ordered 6 Intertaps from Brewpump after debating back and forth between the V2G and V3S from CMB. Hoping I don't have the same leaking issues.

 

[indevrede]

You're pointing out a design flaw that may or may not even exist in their product.

... you are trying to solve a problem with a design flaw that may only exist in the aliexpress faucets, and not the official Intertap faucets

I emailed the photos attached here and Keg King conceded that's how official Intertap ball levers look and how they are supposed to fit & function. (minus the leaking part, of course). Maybe mine are fakes, unauthorized, whatever, but that's immaterial. They confirmed that their actual product doesn't match their reference drawing and that the lack of a seal between ball and o-ring is expected and OK. I believe that gap was the source of my leak, and I took steps to correct it. No hard feelings, I think they are nice people and Intertaps (unauthorized or otherwise) are nice faucets. OK?

So, If you are reading this post and you have an Intertap or "Intertap" faucet and the faucet leaks around the bonnet, try removing the o-ring and adding o-rings and washers according to the drawing and links in post #493. And please post here to let us know whether you have authorized or unauthorized Intertaps.

 

[indolent]

Ah, so keg king did verify that it was the same design. That wasn't completely clear in your initial post, which I think is what gromitdj was alluding to as well. Thanks for the details.

On another note, did you ask them about your chrome plating issues, or if in fact the faucets are supposed to be chrome plated at all?

 

[skatz]

So your basic thought is the beer is seeping between the nylon and the lever ball because the included rubber is only sealing the outside edge? Your retrofit essentially is creating a double seal around the ball with the nylon only providing spacing?

 

[indevrede]

On another note, did you ask them about your chrome plating issues, or if in fact the faucets are supposed to be chrome plated at all?

Yes, and they told me to just clean it.

Attached are two images from their website. The first is chrome-plated brass, the second is stainless. You can see the stainless spout on the stainless faucet is a different color, that's because the stainless spout is not plated. The stainless body is plated chrome, which is why it's a different color. I inspected a Perlick 630SS closely and it appeared to be chrome plated on the outside, but I saw no plating inside. I imagine that bars prefer for all their faucets to look the same color silver.

Also, if you look hard you can find Ventmatics for sale on the web, and there are two options: chrome plated stainless and regular stainless. I would have preferred that option for the Intertaps.

 

[indevrede]

So your basic thought is the beer is seeping between the nylon and the lever ball because the included rubber is only sealing the outside edge? Your retrofit essentially is creating a double seal around the ball with the nylon only providing spacing?

Basically. The O-ring doesn't make contact with the ball unless you squeeze down really hard, and then it makes marginal contact. Supposedly that's not the sealing surface, so it shouldn't matter.

When I removed, cleaned, and replaced the washers the first time I lubricated them, but didn't goop it on. After I got the leak, I re-assembled with a lot more lube and then it didn't leak. To me, that's a bad design, so my retrofit uses lightly-lubed, slightly deformed o-rings to seal.

Again, this is just the Perlick 425 design (image below). I just added the lower spacer washers and found o-rings that fit. I also replaced their top rubber flat washer with a nylon flat washer (to better transfer the force from the bonnet cap to the top ball washer), but that's probably not necessary.

 

[duelerx]

I emailed the photos attached here and Keg King conceded that's how official Intertap ball levers look and how they are supposed to fit & function. (minus the leaking part, of course). Maybe mine are fakes, unauthorized, whatever, but that's immaterial. They confirmed that their actual product doesn't match their reference drawing and that the lack of a seal between ball and o-ring is expected and OK. I believe that gap was the source of my leak, and I took steps to correct it. No hard feelings, I think they are nice people and Intertaps (unauthorized or otherwise) are nice faucets. OK?



So, If you are reading this post and you have an Intertap or "Intertap" faucet and the faucet leaks around the bonnet, try removing the o-ring and adding o-rings and washers according to the drawing and links in post #493. And please post here to let us know whether you have authorized or unauthorized Intertaps.

Thanks for the pictures!

 

[skatz]

I wonder if a properly sized flat washer or x-shaped o-ring would work.

Good job figuring out this fix.

 

[mintyice]

Alright so I've only been using 2 of my 3 faucets since I've had them but I just hooked up the third. The level action feels looser compared to the other two and I noticed it dripped a little more than the others.

 

[indevrede]

I wonder if a properly sized flat washer or x-shaped o-ring would work.

I looked for an x-shaped o-ring and couldn't find one small enough.

duelerx asked for a picture before, here it is:

 

[cuda6pak]

So, the Intertap inside body of the main faucet that beer flows through is actually chrome plated on top of the stainless?

Pretty disappointing...

 

[jmark]

Even if the outside of the faucet is chrome-plated, which I actually kinda doubt based on what their website indicates, the insides are certainly NOT chrome plated.

 

[lawless317]

I heard the inside is made with unicorn tears and dragon sweat

 

[eulipion2]

I heard the inside is made with unicorn tears and dragon sweat

That's the Special Edition model.