Scotsman Glykool 130+ Installation Manual
Glykool 130+
Water Cooled Remote Cooler
INSTALLATION MANUAL
DO NOT REMOVE FROM COOLER
SERIAL NUMBER
PI52966/ WDS INS 111 ISSUE 1
APPROVED BY B Tam
DATED August 2006
Contents
Page
Glykool 130+ Service Programme 3
Glykool 130+ Installation Guide 4
Heat Dump General Guidelines 5
Glykool 130+ Installation Instructions 6
Glykool 130+ Dismantling / Decommissioning Procedure 7
Adjustment & Maintenance Requirements 8
Methods of Cleaning 8
Portable Appliance Testing (PAT) 9
Thermal Cut-Out 9
Prevention of Freezing 10
Electronic Control 11
Glycol Concentrations 13
Fault Diagnosis 14
Technical Specification 18
Spare Parts Identification 20
System Schematics 22
Heat Dump Installation Instructions 24
Heat Dump Dismantling / Decommissioning Procedure 26
Methods of Cleaning the Heat Dump 28
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Glykool 130+ Service Programme
The Glykool range of glycol coolers have been designed to be reliable and
simple to operate. The coolers have been designed to offer a technical
solution to the growing demand for colder and colder dispensed product; this
is best achieved by the use of sub-zero glycol.
The Glykool cooler use well-known and well-proven mechanical refrigeration
technology, but also encompasses a number of technical changes, which will
enhance both the performance and reliability of this system.
Refrigerant flow around the system is controlled via a capillary tube that
optimises the capacity of the unit under certain operating parameters.
This cooler underwent a number of through quality checks before leaving the
factory to ensure the minimum number of faults occur during its life. However,
to ensure that this cooler can meet the demands it has been designed for, it
must be installed and maintained in accordance with the manufacturers
guidelines. This information can be found later in this booklet, which must
remain with the unit at all times.
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Glykool 130+ Installation Guide
On installation, a number of important rules must be observed to be sure the
cooler operates correctly.
• Ensure the cooler base is installed in a well-ventilated location with no
obstructions to the side and rear panel ventilation slots. The unit must
not be installed in an area where it will be exposed to temperatures that
are likely to cause freezing (below 0°C) in excess of 32°C
• Ensure the unit is installed on a level surface and is filled to the
overflow, with a 50% glycol/cold water mix below 24°C.
• Dose the water tank with Kleencare SP920 in accordance with
instructions supplied with the Kleencare kit, taking note of the health
and safety data sheets provided.
• Ensure the header tank is filled to the maximum level with a 30%
glycol/cold water mix to prevent freezing of the tubes connecting the
heat dump to the base unit, which may be exposed to sub-zero
temperatures (See Glycol Requirement Chart)
• Before switching on the unit, turn the line clean switch to the ‘off’
position to enable the glycol lines to be fully primed. Once this is
complete, turn the switch to the ‘on’ position.
• Ensure that the coolant re-circulation pump and tubing connecting the
heat dump are primed with coolant, that there are no air locks or
restrictions and that the coolant is freely returning to the header tank.
Top up the header tank to the maximum level after priming.
• The header tank level must be regularly checked and maintained with
the correct ratio of 30% glycol/water mix.
• Ensure that all the tubing connections to the product coils and
recirculation pump are well insulated with Armaflex.
• Ensure that the python run is not excessive and is routed away from
external heat sources. Maximum lift is 10 m. Maximum run is 50 m.
Notes:
All water cooled units are fitted with an auto reset thermal switch to protect the
compressor should the glycol level drop, the heat dump become blocked or
the glycol pump fail.
The electronic control is fitted with a delay on the power up. The delay allows
for the control to self-check
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Heat Dump General Guidelines
• It is important that the heat dump is sited correctly to enable it to work
efficiently. The guidelines below should be adhered to wherever
possible.
• Ensure the unit is sited on an outside wall (preferably non-south facing)
in the correct orientation out of direct sunlight.
• Ensure there are no other heat sources, i.e. a condensing unit or
another heat dump, in the immediate vicinity, where hot air may be recirculating.
• Use the recommended tubing (15mm O/D, 10mm I/D Special EVA) to
connect the base unit to the heat dump. Do not use PVC braided tube,
as this is not compatible with glycol and will degrade over a period of
time.
• Do not exceed the recommended distance and lift from the base unit to
the heat dump of 10 m lift / 50 m run.
• The heat dump must be connected using a minimum of 1.5mm two
core cable. If a smaller cable is used, a voltage drop will occur which
may cause the fan motor to run at a reduced speed.
• If the unit is to be installed inside a building or room, ensure that there
is adequate ventilation within the room to enable the heat to be
dissipated effectively. Temperatures within the room should not exceed
32°C.
• Do not kink the flow and return tubes, which would restrict the coolant
flow.
• Do not insulate the flow and return lines.
• The flow and return lines must not be strapped together, as heat
transfer between the two will affect the system performance.
• Ensure that the heat exchanger matrix of the heat dump is kept clean
and free from obstructions. It is recommended that it should be cleaned
with a soft brush at regular intervals (see maintenance schedule).
• To enable the heat dump to be mounted on a flat surface, a floor
standing mounting kit is available as an option. (Order part number 090203-01)
For details on use and mounting of the heat dump, refer to installation
instructions on page 24.
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Glykool 130+ Installation Instructions
This unit should be installed and serviced by a suitably trained person.
Sealed plugs may be fitted to new units.
Installation Procedure
• Unpack the unit from its transportation packaging and visually inspect
for any signs of the damage.
• Site the unit in a convenient location in the cellar or room and ensure
that the mains electricity supply is within 2 m and in an area allowing
free circulation of air.
• The unit should be fitted with a correctly fused and wired 13 amp plug
or alternatively to a standard Euro plug to IEC83: 1975.
• Site the heat dump in a convenient location, preferably in a non-heat
sensitive and shaded area on the outside of the building. If it cannot be
installed outside, ensure that the area is well ventilated and free from
other heat sources. Please check the Heat Dump General Guidelines
on page 5 for further details.
WARNING: THIS EQUIPMENT MUST BE EARTHED
The Wires in this Mains Lead are Coloured in accordance with the following
Code:
Green and Yellow Earth
Blue Neutral
Brown Live
As the Colours of the Wires in the Mains Lead of this Appliance may not
correspond with the Coloured Markings identifying the Terminals in the Plug to
be fitted proceed as follows:
• The Wire which is coloured Green and Yellow MUST be connected to
the terminal in the Plug that is marked with the letter‚ E™ or by the
earth symbol, coloured Green or Green and Yellow.
• The Wire which is coloured Blue MUST be connected to the Terminal
in the Plug that is marked with the letter‚ N™ or coloured Black.
• The Wire which is coloured Brown MUST be connected to the Terminal
in the Plug that is marked with the letter‚ L™ or coloured Red.
The mains plug must be located in an accessible position.
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Ways the Glykool 130+ should NOT be used
This unit is intended for use as a cooling unit to cool beers, largers and ciders
and glycol to the correct temperature. It is designed to be installed in the
system between the bulk storage facilities and the dispense head with the
product(s) passing through the cooling coil(s) where fitted in the unit.
There are NO other recommended uses for the equipment
Correct Safe Handling
The weight of the units is such that other than moving it across flat ground
(which is facilitated by integral castors/wheels) or lifting to a relatively safe
height of 12 inches (30 cm) utilising two people, a mechanical lifting device
should be used.
Unit Weight
Shipping Weight: 75 kg
Operational Weight: 125 kg
WARNING: THIS UNIT IS UNSUITABLE FOR USE BY UNSUPERVISED
CHILDREN, THE ELDERLY AND THE INFIRM
Dismantling / Decommissioning Procedure
• Isolate the unit from the mains electricity supply.
• Isolate the product supply from where the unit is connected.
• Isolate the unit from the coolant lines.
• Drain the glycol mixture in the header tank into suitable containers.
• Siphon or pump out the water mixture from the bath
WARNING: FAILURE TO REMOVE ALL WATER/GLYCOL COULD
RESULT IN SUBSTANTIAL AMOUNTS OF WATER/GLYCOL BEING
RELEASED FROM THE UNIT WHICH MAY BE DETRIMENTAL TO THE
UNIT AND/OR ITS SURROUNDINGS AND INCREASE THE MAXIMUM
WEIGHT OF THE UNIT.
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Adjustment & Maintenance Requirements
It is not recommended that the End User makes any adjustments or carries
out any maintenance other than:
• Visual checks on the mains leads and the plug for their condition
• Visual checks of the unit and piper work for evidence of leaks
• Visual checks of the condenser grills and vents that they are not
choked or obscured.
Note: There are no user serviceable parts
Methods of Cleaning
• Persons performing cleansing and sanitising operations MUST be
competent and fully trained in safe methods of use of cleansing and
sanitising agents and applications.
• Personal protective equipment should always be used.
• DO NOT use a water or steam hose to clean the unit whilst still
installed.
• It is important that all vents and grills are kept clear (including
condenser grills where applicable).
Weekly Line Clean Procedure: By the End User
WARNING: IF THE LINE CLEAN PROCEDURE IS NOT FOLLOWED, THE
SUB-ZERO TEMPERATURE OF THE GLYCOL MIXTURE IN THE BATH
WILL FREEZE THE CLEANSING SOLUTION IN THE BEER LINES AND
PYTHON.
• Isolate unit from mains electricity supply.
• Clean and sanitise the unit’s cooling coils and product lines using
proprietary cleanser/sanitizer of Alkaline Hypochlorite type in
accordance to the manufacturer’s recommendations
• Start the line clean switch located on the front of the cooler to the ON
position and leave for 1 to 2 hours before commencing the line clean.
• After the line clean procedure has been completed and the beer has
been pulled through from the storage area to the dispense tap, the line
clean switch should be switched to the OFF position.
• The unit should be allowed to pull down to its normal operating
temperature before normal operation is resumed.
The middle position on the line clean switch should not be used, as this will
affect the operation of the unit.
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Annual Cleaning: By a competent Service/Maintenance Engineer
• Isolate unit from mains electricity supply.
• Remove any extraneous debris from the unit or it’s casing, preferably
with a vacuum cleaner or brush.
• Check unit for electrical safety.
Power Isolation Method
The unit is fitted with a single phase, 3 pin, 13 amp plug, fitted with a 13 amp
fuse or alternatively a standard Euro Plug to IEC83: 1975
• Switch off unit at the socket the plug is installed into
• Remove the plug from the socket
WARNING: IF THE MAINS LEAD FITTED TO THIS EQUIPMENT IS
DAMAGED IN ANY WAY, IT SHOULD BE REPLACED. ONLY A FULLY
TRAINED ENGINEER MUST UNDERTAKE THIS CHANGE.
Portable Appliance Testing (PAT)
An additional test point has been fitted to the top of the rear panel of the unit
to provide a connection for PAT testing of the units on site. The tank drain
exits the unit via a 1/2 “ bulk head situated on the lower part of the left hand
panel. The shut-off valve can be accessed by removing the front lower grill.
Glycol flow and return connections are indicated by a coloured disc (red disc
for flow to the heat dump and blue for return from the heat dump).
Decommissioning of the glycol lines should be undertaken before
decommissioning of the 24V electrical socket in order to prevent the ingress of
glycol/water into the electrical socket.
Thermal Cut-Out
The unit is fitted with a thermal cut-out which will protect the refrigeration
system in the unlikely event of a fault in the glycol /heat dump system. The
thermal cut-out will isolate the power supply to the compressor if the heat of
the discharge lines increases above 65°C. The compressor will not cut back
in until the temperature in this line falls to below this temperature.
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