Installation Manual UNDER COUNTER GYLCOL REMOTE COOLING UNIT

Transcription

1 CORNELIUS INC One Cornelius Place Anoka, MN Telephone (800) Facsimile (612) Installation Manual UNDER COUNTER GYLCOL REMOTE COOLING UNIT Notice: This manual is for beer applications. For dairy applications refer to manual P/N Part No Revision Date: May 13, 2014 Revision: B THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment CORNELIUS INC; PRINTED IN U.S.A

2 TABLE OF CONTENTS SAFETY INFORMATION RECOGNIZE SAFETY INFORMATION UNDERSTAND SIGNAL WORDS FOLLOW SAFETY INSTRUCTIONS CO2 (CARBON DIOXIDE) WARNING SHIPPING, STORING, OR RELOCATING UNIT GENERAL INFORMATION GENERAL DESCRIPTION SYSTEM DESCRIPTION THEORY OF OPERATION INSTALLATION UNPACKING AND INSPECTION INSTALLING INSULATED BEER TRUNK LINE SELECTING COOLING UNIT LOCATION INSTALLING COOLING UNIT PLACING COOLING UNIT IN OPERATING LOCATION CONNECTING COOLING UNIT GLYCOL LINES TO INSULATED BEER TRUNK LINE FILLING COOLING UNIT TANK WITH PROPYLENE GLYCOL-TYPE ANTI-FREEZE STARTING COOLING UNIT REFRIGERATION SYSTEM INSTALLING DISPENSING STATIONS INSTALLING EQUIPMENT INSIDE WALK-IN COOLER STARTING PROPYLENE GLYCOL ANTI-FREEZE CIRCULATING SYSTEM.. 10 ACTIVATING BEER SYSTEMS OPERATORS INSTRUCTIONS PROPER BEER STORAGE OPERATING CONTROL GLYCOL CIRCULATING PUMP POWER SWITCH DAILY PRE-OPERATION CHECK ADJUSTMENTS ADJUSTING CO2 REGULATORS ADJUSTING COOLING UNIT GLYCOL (COOLANT) TEMPERATURE ADJUSTING BEER DISPENSING RATE ADJUSTING WALK-IN COOLER TEMPERATURE REPLENISHING CO2 SUPPLY REPLENISHING BEER SUPPLY CLEANING AND SANITIZING CLEANING SANITIZING COOLING UNIT MAINTENANCE CLEANING CONDENSER COIL REPLENISHING COOLING UNIT GLYCOL IN (COOLANT) TANK

3 CLEANING COOLING UNIT EXTERIOR CLEANING CO2 GAS CHECK VALVE SERVICE AND MAINTENANCE ADJUSTMENTS ADJUSTING CO2 REGULATORS ADJUSTING COOLING UNIT GLYCOL (COOLANT) TEMPERATURE ADJUSTING BEER DISPENSING RATE REPLENISHING CO2 SUPPLY REPLENISHING BEER SUPPLY CLEANING AND SANITIZING CLEANING SANITIZING COOLING UNIT MAINTENANCE CLEANING CONDENSER COIL CLEANING COOLING UNIT EXTERIOR REPLENISHING COOLING UNIT GLYCOL (COOLANT) TANK CLEANING CO2 GAS CHECK VALVE TROUBLESHOOTING NO CO2 GAS PRESSURE ON BEER SYSTEMS INSUFFICIENT CO2 GAS PRESSURE ON BEER SYSTEMS DISPENSED BEER FLOW RATE TOO LOW DISPENSED BEER FLOW RATE TOO HIGH OFF-TASTE BEER (SOUR AND UNPALATABLE) DISPENSED BEER TEMPERATURE TOO COLD (FLAT BEER, DISAPPEARING FOAM) DISPENSED BEER TEMPERATURE TOO WARM EXCESSIVE FOAMING (WILD BEER) WHILE BEER IS BEING DISPENSED.. 25 COMPRESSOR DOES NOT OPERATE COMPRESSOR WILL NOT STOP AFTER GLYCOL (COOLANT) HAS REACHED RECOMMENDED 265 F TO 285 F TEMPERATURE COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT LOWER GLYCOL (COOLANT) TO 265 F TO 285 F CONDENSER FAN MOTOR NOT OPERATING

4 SAFETY INFORMATION Recognize Safety Information This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potentially of personal injury. Follow recommended precautions and safe operating practices. Understand Signal Words A signal word - DANGER, WARNING, OR CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards. Safety signs with signal word DANGER or WARNING are typically near specific hazards. General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual. DANGER WARNING CAUTION Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair function and/or safety and affect the machine life. CO 2 (Carbon Dioxide) Warning CO 2 Displaces Oxygen. Strict Attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. Shipping, Storing, Or Relocating Unit CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems. All water must also be purged from the plain and carbonated water systems. A freezing ambient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit

5 GENERAL INFORMATION IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and maintaining this system. Refer to Table of Contents for page location of detailed information pertaining to questions that arise during installation, operation, service and maintenance, or troubleshooting this system. GENERAL DESCRIPTION This section gives the description and theory of operation for the glycol-cooled beer system and design data for the Comet Glycol Cooling Unit (hereafter referred to as a Cooling Unit) used in this sytem. This Cooling Unit must be installed and serviced by a qualified Service Person. This Cooling Unit contains no user serviceable parts. SYSTEM DESCRIPTION The glycol-cooled beer system is a complete system designed to provide cold beer to the dispensing stations connected to the system. The system consists basically (see Figure 2) of a Undercounter Glycol Cooling Unit with a glycol circulating pump, an adjustable primary CO 2 regulator which provides CO 2 gas pressure to beer kegs adjustable secondary CO 2 regulators, an insulated beer trunk line, and dispensing stations. The Undercounter Glycol Cooling Unit consists basically of a refrigeration system with a 1/2 horsepower compressor, a refrigerated glycol holding tank to cool the glycol/water solution, and a glycol circulating pump to circulate cold glycol/water solution (coolant) out and back through insulated beer trunk line. Table 1. Design Data Cooling Unit Model Number Overall Dimensions: Width Height Depth Weights: (approximate) Shipping Weight Dry Weight Operating Weight Capacity: Glycol Tank Refrigeration System: Refrigerant Type and Charge Ambient Operating Temperature Electrical Requirements: Operating Voltage Operating Current 18-3/4 inches 24 inches 24-1/2 inches 135 pounds 99 pounds 241 pounds 11 gallons See Cooling Unit Nameplate 40 F to 100 F 120VAC, 60Hz 16 Amps (20 Amp Circuit)

6 REFRIGERATION SWITCH RECIRCULATING SWITCH FIGURE 1. UNDER COUNTER GLYCOL REMOTE COOLING UNIT THEORY OF OPERATION (see Figure 2) Food-grade propylene glycol-type antifreeze and water solution (coolant) is cooled by the Cooling Unit and is circulated through the insulated beer trunk line to cool the beer lines inside the beer trunk line. Direction of the coolant flow is from the Cooling Unit glycol tank, through the glycol circulating pump, through the glycol turnaround inside the walk-in cooler, out through the insulated beer trunk line to the turnarounds inside the dispensing stations, and back through the beer trunk line to the glycol tank inside the Cooling Unit. Cold beer is pushed by regulated CO 2 pressure through the cooled insulated beer trunk lines to the dispensing stations beer faucets when the faucets are opened

7 NOTE: THE COOLING UNIT MAY BE LOCATED NEXT TO THE WALK-IN COOLER OR ANY OTHER LOCATION PROVIDING THE 20-FOOT PYTHON ASSEMBLY (ITEM 14) CAN BE CONNECTED BETWEEN THE COOLING UNIT AND THE INSULATED BEER TRUNK LINE. LINE LEGEND BEER CO 2 GLYCOL GLYCOL TURNAROUND (3) DISPENSING STATION 7 7 INSULATED BEER TRUNK LINE (ORDER SEPARATELY AND NOT TO EXCEED 100-FEET IN LENGTH) 7 UNNUMBERED WALK-IN COOLER BEER KEG SECONDARY CO 2 REGULATOR (3) 4 PRIMARY CO 2 REGULATOR CO 2 SHUTOFF VALVE (3) BEER SHUTOFF VALVE (3) UNNUMBERED ITEM 7 UCGR GLYCOL COOLING UNIT GLYCOL CIRCULATING PUMP BEER KEG TAPPER (3) CO 2 GAS CHECK VALVE CO 2 CYLINDER BEER KEG (3) ITEM 1 ITEM 7 ITEM 9 7 ITEM 5 ITEM 5 È È È È È È È GLYCOL WATER SOLUTION (COOLANT) ÈÈ ÈÈ FIGURE 2. FLOW DIAGRAM (TYPICAL INSTALLATION)

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9 INSTALLATION UNPACKING AND INSPECTION NOTE: The Cooling Unit was thoroughly inspected before leaving the factory and the carrier has accepted and signed for it. Any damage or irregularities should be noted at time of delivery (or not later than 15 days from date of delivery) and immediately reported to the delivering carrier. Request a written inspection report from Claims Inspector to substantiate any necessary claim. File claim with the delivering carrier, not with The Cornelius Company. 1. After Cooling Unit has been unpacked, remove shipping tape and other packing material. 2. Unpack LOOSE-SHIPPED PARTS. Make sure all items are present and in good condition. Table 2. Loose-Shipped Parts Item No. Part No. Name Qty U-Tube, Glycol Wood Screw, Sl Rd Hd, Nickel-pltd Steel, No. 10 by 3/4-in Panel Patch Hanging Strap, Insulated Beer Trunk Line Tubing Clamp (two spares provided #17.0) Insulating Tape, 2-in. Wide by 50-ft. Long Roll Tubing Clamp (two spares provided #14.0) 6 NOTE: Items 8 and 9 are each cartoned separately from the Cooling Unit Propylene Glycol-Type Anti-freeze (5-gallon lot) ordered by customer Python Ass y, 20-ft Long 1 INSTALLING INSULATED BEER TRUNK LINE (see Figure 3) IMPORTANT: Length of insulated beer trunk line used with this Cooling Unit must not exceed 100-feet in length. Under-Floor conduit must be free from water and all debris such as loose pieces of concrete etc. Water left in conduit will stagnate and may penetrate beer lines (tubing) resulting in off-taste dispensed beer. 1. Push electricians fish tape through under-floor conduit from last beer dispensing station to conduit opening in vicinity of walk-in cooler. 2. Fasten clothesline type rope to fish tape, then pull rope through conduit. 3. Unfasten fish tape from rope. PURPOSE OF ROPE IS TO CLEAN CONDUIT AND ALSO TO PULL INSULATED BEER TRUNK LINE THROUGH CONDUIT. 4. Fasten large towel to middle of rope. Pull towel back and forth through conduit as many times as necessary to clean any debris or water from conduit. MAKE SURE ALL DEBRIS AND WATER IS REMOVED FROM CONDUIT. 5. Remove towel from middle of rope. 6. Fasten end of rope to one end of insulated beer trunk line, then pull beer trunk line through underfloor conduit

10 7. Cut 4-inch diameter hole in walk-in cooler wall. 8. Slide one PANEL PATCH (item 3) up on insulated beer trunk line, then route end of beer trunk line through hole to inside of walk-in cooler. MAKE SURE MINIMUM 12-INCH RADIUS BEND IS MAINTAINED ON ALL BEER TRUNK LINE BENDS. 9. On inside of walk-in cooler, slide other PANEL PATCH (item 3) up on beer trunk line to cooler wall. Secure panel patch to cooler wall with four screws. 10. Slide panel patch on outside of walk-in cooler wall up on beer trunk line to the cooler wall. Secure the panel patch to the cooler wall with four screws. SELECTING COOLING UNIT LOCATION CAUTION: This Unit is intended for indoor installation only. Do not install this Unit in an outdoor environment which would expose it to the outside elements. Locate the Cooling Unit so the following requirements are satisfied. IMPORTANT: Ambient temperature for the Cooling Unit must not exceed 100 F. Several means are available to achieve the proper ambient temperature and air circulation around the Cooling Unit which are wall air intake grilles and ceiling exhaust fans, air conditioning, etc. Check local codes. 1. A location within 20-feet of the insulated beer trunk line to allow connecting Cooling Unit glycol lines to the beer trunk line. WARNING: To avoid possible fatal electrical shock or serious injury to the Operator, it is highly recommended that a GFCI (ground fault circuit interrupt) be installed in the electrical power circuit for the Cooling Unit.. 2. Cooling Unit is accessible to a properly grounded 120VAC, 60Hz electrical outlet with circuit fused at 20-amps (slow-blow) or the circuit be connected through an equivalent HACR circuit breaker.the electrical outlet must be accessible for ease of connecting and disconnecting the Cooling Unit power cord. No other electrical equipment should be connected to this circuit. ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES. CAUTION: Circulating air, required to cool the refrigeration condenser coil, is drawn in through grille on front and is exhausted out through grille on top of the hood. Restricting air in and out of the Cooling Unit will decrease it s cooling efficiency. Do not place or store anything on top of the cooling unit. 3. A minimum of 15-inches clearance must be maintained above the Cooling Unit to the nearest obstruction (shelf, cupboard, ceiling, etc.). The front grille of the Cooling Unit must be unobstructed to allow air to enter the hood. 4. Close to permanent floor drain to route the Cooling Unit drip tray drain hose. INSTALLING COOLING UNIT CAUTION: This Cooling Unit is intended for indoor installation only. Do not install this Cooling Unit in an outside environment which would expose it to the outside elements. PLACING COOLING UNIT IN OPERATING LOCATION 1. Place Cooling Unit in operating location meeting requirements of SELECTING COOLING UNIT LOCATION

11 2. To comply with NSF International (NSF) requirements, the Unit base must be sealed to the countertop and all access holes to the base must be sealed. Proceed as follows to seal Unit base to the countertop. A. Tilt Cooling Unit up (maximum of 45 ) to expose bottom of it s base. B. Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent on base bottom edges. NOTE: Do not move Cooling Unit after positioning or seal from base to floor will be broken. C. Lower Cooling Unit into operating position to complete seal from it s base to the floor. Apply additional sealant around bottom of the base. Seal must have a minimum radius of 1/2-inch to prevent cracks and crevices and to insure a complete seal. CONNECTING COOLING UNIT GLYCOL LINES TO INSULATED BEER TRUNK LINE (see Figures 2 and NO TAG) 1. Connect glycol U-TUBE (item 1) to the unnumbered and No. 7 lines inside the insulated beer trunk line inside the walk-in cooler. Secure connections with TUBING CLAMPS (item 7). 2. Being careful not to cut tubing inside the insulated beer trunk line, open the beer trunk line insulation by making an H patterned cut in the insulation. 3. Cut unnumbered line inside the insulated beer trunk line and remove a two inch section. 4. Connect unlabeled (outlet) line of the PYTHON ASS Y (item 9) to cut end of unnumbered line inside the insulated beer trunk line leading to glycol U-tube inside the walk-in cooler. Make connections using ELBOW FITTING (item 2), TUBING CLAMP (item 5), and TUBING CLAMP (item 7). 5. Connect PYTHON ASS Y (item 9) unlabeled line, to barbed elbow on tube assembly on the Cooling Unit glycol circulating pump with clamp (Item 7). 6. Connect PYTHON ASS Y (item 9) line labeled R (return) to other end of the unnumbered line inside the insulated beer trunk line coming from the dispensing stations glycol turnarounds. Make connection using TUBING CLAMP (item 5), and TUBING CLAMP (item 7). 7. Connect other end of line labeled R (return) inside PYTHON ASS Y (item 9) to glycol return line with 3/8-barbed fitting protruding out front of the Cooling Unit. Secure connection with TUBING CLAMP (item 5). FILLING COOLING UNIT TANK WITH PROPYLENE GLYCOL-TYPE ANTI-FREEZE WARNING: Use only food grade propylene glycol-type anti-freeze such as Cornelius P/N or equivalent. Use of other than food-grade propylene glycol-type anti-freeze such as ethylene glycol (automotive) type antifreeze in the Cooling Unit glycol tank and circulating system will create a health hazard. 1. Lift hood up and off the Cooling Unit

12 FOUR-FAUCET DISPENSING STATION BEER DRAFT ARM IMPORTANT: ALL INSTALLATION WIRING MUST CON- FORM TO NATIONAL AND LOCAL CODES MINIMUM 4-IN. DIAMETER HOLE REQUIRED IN COUNTER, ALSO IN FLOOR WHEN INSULATED BEER TRUNK LINE IS LOCATED IN BASEMENT OR CRAWL SPACE 2-1/2 IN. DIA HOLE GLYCOL CIRCULATING PUMP 4-IN DIA HOLE WALK-IN COOLER 9 INSULATED BEER BRANCH LINE MINIMUM 12-IN. RADIUS ON ALL BENDS COOLING UNIT ÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ WHEN INSULATED BEER TRUNK LINES ARE LOCATED IN SLAB FLOOR MINIMUM I.D. OF CONDUIT MUST BE 8-IN. FIGURE 3. GLYCOL-COOLED BEER SYSTEM (TYPICAL INSTALLATION)

13 2. Remove plug from the drop-in refrigeration assembly platform glycol fill hole. 3. Fill the Cooling Unit tank with coolant made up of a 1 to 1 ratio of FOOD-GRADE PROPYLENE GLYCOL-TYPE ANTI-FREEZE (item 8) and water solution (coolant) until coolant runs out of the overflow notch in the top front corner of the tank. STARTING COOLING UNIT REFRIGERATION SYSTEM WARNING: The Cooling Unit must be electrically grounded to prevent possible fatal electrical shock or serious injury to personnel. The Cooling Unit power cord is equipped with a three-prong plug. If a three-hole (grounded) electrical outlet is not available, use an approved method to ground the Unit. Make sure the glycol circulating pump power switch on the side of the Cooling Unit (see Figure 1.) is in OFF (down) position. Plug the Cooling Unit power cord into (refer to WARNING note) a properly grounded electrical outlet with proper electrical requirements. ADDITIONAL ELECTRICAL EQUIPMENT MUST NOT BE CONNECTED TO THIS CIRCUIT. Allow Cooling Unit refrigeration system to operate for two hours, then check the temperature of the coolant. If the coolant temperature has not dropped to 26 F to 28 F, the temperature control thermostat will have to be adjusted as instructed. INSTALLING DISPENSING STATIONS (see Figures 2 and 3) Install dispensing stations on countertop. Connect dispensing stations to insulated beer trunk line as shown in typical installation. INSTALLING EQUIPMENT INSIDE WALK-IN COOLER (see Figure 2 Install and connect equipment inside walk-in cooler as shown in Figure 2 typical installation. DO NOT INSTALL BEER KEG TAPPERS IN BEER KEGS AT THIS TIME. STARTING PROPYLENE GLYCOL ANTI-FREEZE CIRCULATING SYSTEM 1. Place Cooling Unit glycol circulating pump power switch (see Figure 1.) in ON (up) position to start the circulating pump. 2. After insulated beer trunk line glycol circulating system is in operation, continue adding food grade propylene glycol-type anti-freeze and water at a 1 to 1 ratio to the Cooling Unit tank until coolant is at the level described when filling the tank. 3. Note the circulating pump for quietness of operation. A noisy pump and air bubbles in the return line during operation indicates that air is being drawn into the system on the pump inlet side. If the pump is noisy and air bubbles are present, check the pump inlet tube connection for misaligned gasket or burr on the fitting. OPERATING THE PUMP IN SYSTEM CONTAINING AIR BUBBLES WILL EVENTUALLY RESULT IN PUMP DAMAGE. 4. Check the glycol circulating system connections for leaks and repair if evident. 5. Using INSULATING TAPE (item 6), close insulation on the insulated beer trunk line where the Cooling Unit glycol lines are connected. 6. Using INSULATING TAPE (item 6), insulate the glycol line swivel nut connection on the glycol circulating pump. FAILURE TO INSULATE THE LINE WILL CAUSE LINE SWEATING AND GLYCOL TO WARM UP

14 ACTIVATING BEER SYSTEMS (see Figure 2) 1. Make sure the primary and secondary CO 2 regulators assemblies adjustment screws are backed out until all tension is relieved from the adjusting screws springs. 2. Make sure the shutoff valves, located in the CO 2 lines connected between the secondary CO 2 regulators and the beer keg tappers, are in closed positions. 3. Make sure the beer shutoff valves, located in the beer lines between the beer keg tappers and the insulated beer trunk line inside the walk-in cooler, are in closed positions. WARNING: CO 2 displaces oxygen. Strict attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. 4. Open the CO 2 cylinder shutoff valve slightly to allow the primary CO 2 regulator to fill with gas, then open the valve fully to back-seat the valve. Back-seating the valve prevents leakage around the valve shaft. 5. Adjust the primary CO 2 regulator by loosening the regulator adjusting screw lock nut, then turn the adjusting screw to the right (clockwise) until the gage registers 50-psi. Tighten the adjustment screw lock nut after adjustment has been completed. 6. Adjust the beer kegs secondary CO 2 regulators as follows: The beer kegs secondary CO 2 regulators pressures adjustments require calculations of each beer system total beer system pressure. The total beer system pressure, required to push beer from the keg to the faucet, is the result of computing the length of the beer line of a certain size, vertical line lift, and the internal keg pressure. The internal keg pressure differs from one beer brand to another. Contact your local Beer Distributor for the proper secondary CO 2 regulators pressure settings. Adjust the secondary CO 2 regulators by loosening their adjusting screws lock nuts, then turn the adjusting screws to the right (clockwise) until the regulators gages register the recommended pressures. Tighten the adjusting screws lock nuts after adjustments have been completed. IMPORTANT: The walk-in cooler temperature must be maintained between 33 F and 40 F and the Cooling Unit tank glycol (coolant) temperature at 26 F to 28 F for proper cooling of the beer. 7. Install the beer keg tappers in the beer kegs. 8. Open the shutoff valves located in the CO 2 lines connected between the secondary CO 2 regulators and the beer keg tappers. 9. Open the shutoff valves located in the beer lines between the beer keg tappers and the insulated beer trunk line. 10. Dispense from all the beer faucets until air is purged from the systems. 11. Check entire system for leaks and repair if evident. 12. Install hood on the Cooling Unit and secure

15 OPERATORS INSTRUCTIONS This section covers proper beer storage, operators responsibilities for daily pre-operation check, adjustments, replenishing CO 2 and beer supplies, cleaning and sanitizing, and Cooling Unit maintenance. PROPER BEER STORAGE Draft beer is a perishable product that can be materially changed by improper handling. Undesirable dispensed beer can be created by improper cooling of beer stored inside the walk-in cooler or lack of cleaning/sanitizing beer systems. Proper temperature control of stored beer is important. It helps retard growth of mold, yeast, and bacteria that are non-toxic but do affect taste and appearance of the dispensed beer. These organisms can be satisfactorily controlled by maintaining stored beer within a specified temperature range and regularly cleaning the beer faucets and sanitizing the beer systems. The walk-in cooler internal temperature should be maintained at 33 F to 40 F. The walk-in cooler should be used for storage of draft beer exclusively and not for foods, i.e. meats, vegetables, and fruits. The disadvantage of storing these items is that they usually require frequent opening of the walk-in cooler door resulting in a beer temperature warm-up and the possibility of the dispensed beer being wild (excessive foam). Unpleasant odors of the stored food and fungus growth caused by fruit and vegetable pollen, causes conditions which are objectionable. OPERATING CONTROL GLYCOL CIRCULATING PUMP POWER SWITCH The glycol circulating pump power switch, located on the side of the electrical box above the recirculating pump on the Cooling Unit, must be in the ON (up) position before the pump will operate. Place the switch in the OFF (down) position to stop the pump. (See Figure 1.) DAILY PRE-OPERATION CHECK 1. Make sure the CO 2 cylinder regulator assembly 1800-psi gage indicator is not in the shaded ( change CO 2 cylinder ) portion of the dial. If so, CO 2 cylinder is almost empty and must be replaced. 2. Make sure primary CO 2 regulator is set at the specified pressure. 3. Make sure the beer kegs secondary CO 2 regulators are set at the specified pressures. 4. Sufficient beer supply. If not, replenish the beer supply. 5. Make sure the walk-in cooler temperature is at the specified temperature. 6. Make sure the dispensing stations and their drip trays are clean. ADJUSTMENTS ADJUSTING CO 2 REGULATORS The primary CO 2 regulator and the secondary CO 2 regulators for the beer kegs should be checked periodically for proper pressure settings and if necessary, adjusted as instructed. ADJUSTING COOLING UNIT GLYCOL (COOLANT) TEMPERATURE The Cooling Unit tank glycol (coolant) temperature should be periodically checked and if necessary, adjusted as instructed

16 ADJUSTING BEER DISPENSING RATE The beer dispensing rate (2-ounces per second approximate) should be checked periodically and if necessary, adjusted as instructed. ADJUSTING WALK-IN COOLER TEMPERATURE The walk-in cooler temperature (between 33 F and 40 F) should be periodically checked and if necessary, adjusted as instructed. REPLENISHING CO 2 SUPPLY WARNING: CO 2 displaces oxygen. Strict attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation. NOTE: When the indicator on the CO 2 cylinder regulator assembly 1800-psi gage is in the shaded ( change CO 2 cylinder ) portion of the dial, the CO 2 cylinder is almost empty and must be changed. The CO 2 supply should be checked daily and if necessary, replenished as instructed. REPLENISHING BEER SUPPLY The beer supply should be checked periodically and if necessary, replenished as instructed. CLEANING AND SANITIZING CLEANING Walk-in Cooler. The walk-in cooler should be cleaned periodically as instructed to eliminate sticky floor and possible unpleasant odors. Dispensing Stations. The dispensing stations should be cleaned daily as instructed. SANITIZING The beer systems (tappers, beer lines, and beer faucets internal parts) should be completely cleaned and sanitized at least every two weeks as instructed. COOLING UNIT MAINTENANCE CLEANING CONDENSER COIL NOTE: Circulating air required to cool the refrigeration condenser coil is drawn in through a grille on the front and is exhausted out through the grille on top of the hood. Restricting air in and out of the Cooling Unit will decrease it s cooling efficiency

17 The area on top of the hood must be kept free of obstructions at all times. Make sure nothing is stored on top of the hood. The refrigeration condenser coil should be periodically cleaned as instructed to maintain cooling efficiency. REPLENISHING COOLING UNIT GLYCOL IN (COOLANT) TANK WARNING: Use only food-grade propylene glycol-type anti-freeze such as Cornelius P/N or equivalent! Use of other than food grade propylene glycol-type anti-freeze such as ethylene glycol (automotive) type anti-freeze in the Cooling Unit glycol tank and the circulating system will create a health hazard. The cooling Unit tank glycol (coolant) should be periodically checked and if necessary, added to as instructed. CLEANING COOLING UNIT EXTERIOR The Cooling Unit exterior should be periodically cleaned as instructed. CLEANING CO 2 GAS CHECK VALVE (see Figure 2) The CO 2 gas check valves must be inspected and serviced as instructed at least once a year under normal conditions and after any servicing or disruption of the CO 2 system

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19 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the Cooling Unit and beer system. IMPORTANT: Only properly trained personnel should service the beer system or the Cooling Unit internal components and electrical wiring. WARNING: Disconnect electrical power to the Cooling Unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service the internal components or electrical wiring. ADJUSTMENTS ADJUSTING CO 2 REGULATORS (see Figure 2) NOTE: To readjust the CO 2 regulator to a lower setting, loosen the adjusting screw lock nut, then turn the screw to the left (counterclockwise) until pressure gage reads 5-psi lower than the new setting will be. Turn the adjusting screw to the right (clockwise) until gage registers new setting, then tighten the lock nut.adjusting Primary CO 2 Regulator. Adjust the primary CO 2 regulator by loosening the regulator adjusting screw lock nut, then turn the adjusting screw to the right (clockwise) until gage registers 50-psi. Tighten the adjusting screw lock nut after adjustment has been completed. Adjusting Beer Kegs Secondary CO 2 Regulators. The beer kegs secondary CO 2 regulators pressures adjustments require calculations of each beer system total beer system pressure. The total beer system pressure, required to push the beer from the keg to the faucet, is the result of computing the length of beer line of a certain size, vertical line lift, and the internal keg pressure. The internal keg pressure differs from one beer brand to another. Contact your local Beer Distributor for the proper secondary CO 2 regulators pressure settings. Adjust the secondary CO 2 regulators by loosening the adjusting screws lock nuts, then turn the adjusting screws to the right (clockwise) until the regulators gages register the recommended pressures. Tighten the adjustments screws lock nuts after adjustments have been completed. ADJUSTING COOLING UNIT GLYCOL (COOLANT) TEMPERATURE (see Figure NO TAG) NOTE: The Cooling Unit tank glycol (coolant) temperature must be maintained at 26 F to 28 F for proper cooling of the insulated beer trunk line. 1. Loosen the screw securing the Cooling Unit hood, then the remove hood for access to the control box cover. 2. Insert a screwdriver through the hole in the control box cover and place in the thermostat control slotted adjustment screw. Turn the adjustment screw to the right (clockwise) to next higher setting for a colder coolant temperature or turn the adjustment screw to the left (counterclockwise) to the next lower setting for a warmer coolant temperature

20 3. Allow the Cooling Unit to operate for at least two hours after adjustment. Recheck the coolant temperature and adjust the thermostat control as many times as necessary until the proper coolant temperature has been achieved. 4. Install the Cooling Unit hood and secure with a screw. ADJUSTING BEER DISPENSING RATE Dispensing Station With Adjustable Beer Faucet. (see Figure 4) COMPENSATOR (IF APPLICABLE) COUPLING NUT BEER FAUCET FIGURE 4. BEER FAUCET ADJUSTMENT Adjust the beer flow rate at approximately 2-ounces per second by adjusting the compensator adjusting screw located on the right-hand side of the beer faucet. Turn the compensator adjusting screw to the right (clockwise) for decreased beer flow rate or turn the screw to the left (counterclockwise) for increased beer flow rate. Beer System With Adjustable Beer Draft Arm. (see Figure 5) Adjust the beer flow rate at approximately 2-ounces per second by adjusting the adjustment screw located under the cover on top of the draft arm. Turn the adjustment screw to the left (counterclockwise) for increased beer flow rate or turn the knob to the right (clockwise) for decreased beer flow rate. ADJUSTING WALK-IN COOLER TEMPERATURE The walk-in cooler temperature should be between 33 F and 40 F for proper beer storage. Refer to the walk-in cooler refrigeration system manual for the temperature adjustment procedure. REPLENISHING CO 2 SUPPLY WARNING: CO 2 displaces oxygen. Strict attention must be observed in the prevention of CO 2 (carbon dioxide) gas leaks in the entire CO 2 and soft drink system. If a CO 2 gas leak is suspected, particularly in a small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO 2 gas will experience tremors which are followed rapidly by loss of consciousness and suffocation

21 COVER RETAINING SCREW (2) COVER ADJUSTMENT SCREW BEER FAUCET FIGURE 5. BEER DRAFT ARM ADJUSTMENT NOTE: When indicator on the CO 2 cylinder regulator assembly 1800-psi gage is in the shaded ( change CO 2 cylinder ) portion of the dial, the CO 2 cylinder is almost empty and should be changed. 1. Fully close (clockwise) the CO 2 cylinder shutoff valve. 2. Slowly loosen the primary CO 2 regulator assembly coupling nut allowing CO 2 pressure to escape, then remove the regulator assembly from the empty CO 2 cylinder. 3. Unfasten the safety chain and remove the empty CO 2 cylinder. WARNING: To avoid personal injury and/or property damage, always secure the CO 2 cylinder with a safety chain to prevent it from falling over. Should the valve become accidentally damaged or broken off, CO 2 cylinder can cause serious personal injury. 4. Position the full CO 2 cylinder and secure with a safety chain. 5. Make sure a gasket is in place inside the CO 2 regulator coupling nut, then install the regulator on the CO 2 cylinder. 6. Open (counterclockwise) the CO 2 cylinder shutoff valve slightly to allow the lines to slowly fill with gas, then open the valve fully to back-seat the valve. (Back-seating the valve prevents leakage around the valve shaft). 7. Check the CO 2 connections for leaks. Tighten any loose connections. REPLENISHING BEER SUPPLY 1. Close the CO 2 and beer line shutoff valves for the empty beer keg. 2. Remove the beer keg tapper from the empty beer keg. 3. Make sure the tapper and top of the full beer keg is clean, then install tapper in the keg. 4. Open the CO 2 and beer line shutoff valves

22 CLEANING AND SANITIZING CLEANING Walk-in Cooler. The walk-in cooler should be periodically cleaned to eliminate sticky floor and possible unpleasant odors. Dispensing Stations. The dispensing stations and their drip trays should be cleaned daily. DO NOT USE ABRASIVE-TYPE CLEANERS. SANITIZING The beer systems (tappers, beer lines, and beer faucets internal parts) should be completely cleaned and sanitized at least every two weeks using Diversol CX (The Diversey Corp.) or equivalent sanitizer. COOLING UNIT MAINTENANCE CLEANING CONDENSER COIL NOTE: Circulating air required to cool the refrigeration condenser coil is drawn in through a grille on the front and is exhausted out through a grille on top of the hood. Restricting air in and out of the Cooling Unit will decrease its cooling efficiency. IMPORTANT: Cleaning the condenser coil should be performed during non-dispensing period. 1. Unplug the Cooling Unit power cord from electrical outlet. 2. Loosen screw securing the Cooling Unit hood, then remove the hood. 3. Vacuum or use a soft bristle brush to clean the condenser coil. If available, use low-pressure compressed air. 4. Install hood on the Cooling Unit and secure with a screw. 5. Plug the Cooling Unit power cord into an electrical outlet. CLEANING COOLING UNIT EXTERIOR Periodically wash all external surfaces of the Cooling Unit, rinse with clean water, then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE-TYPE CLEANERS

23 QUAD RING BALL SPRING RETAINER BODY *QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED FIGURE 6. CO 2 GAS CHECK VALVE REPLENISHING COOLING UNIT GLYCOL (COOLANT) TANK WARNING: Use industrial grade propylene glycol-type anti-freeze such as Cornelius P/N or equivalent only! Use of other than food-grade propylene glycol-type anti-freeze such as ethylene glycol (automotive) type anti-freeze in the Cooling Unit glycol tank and circulating system will create a health hazard. 1. Loosen screw securing the hood on the Cooling Unit, then remove the hood. 2. Remove plug from the drop-in refrigeration assembly platform glycol fill hole. 3. Fill the Cooling Unit tank with coolant made up of 1 to 1 ratio of industrial grade propylene glycol-type anti-freeze and water solution until coolant runs out of the overflow notch in the top front corner of the tank. 4. Install plug in the drop-in refrigeration assembly platform glycol fill hole. 5. Install hood on the Cooling Unit and secure with a screw. CLEANING CO 2 GAS CHECK VALVE (see Figures 2 and 6) The CO 2 gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO 2 system. ALWAYS REPLACE THE QUAD RING SEALS EACH TIME THE CHECK VALVES ARE SERVICED

24 FIGURE 7. WIRING DIAGRAM (UCR 40)

25 FIGURE 8. WIRING DIAGRAM (UCC/UCCR 40)

26 FIGURE 9. WIRING DIAGRAM (UCP/UCPR 40)

27 TROUBLESHOOTING IMPORTANT: Only qualified personnel should service Cooling Unit components or electrical wiring. WARNING: Disconnect electrical power from the Cooling Unit to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service the internal components or the electrical wiring. If repairs are to be made to the CO 2 system, close the CO 2 shutoff valves in the lines leading to the beer keg tappers, then shut off the CO 2 supply and relieve the system pressure. TROUBLESHOOTING CO 2 SYSTEM Trouble Probable Cause Remedy NO CO 2 GAS PRESSURE ON BEER SYSTEMS. INSUFFICIENT CO 2 GAS PRESSURE ON BEER SYSTEMS. TROUBLESHOOTING BEER SYSTEM DISPENSED BEER FLOW RATE TOO LOW. DISPENSED BEER FLOW RATE TOO HIGH. OFF-TASTE BEER (SOUR AND UNPALATABLE). A. Empty CO 2 cylinder. A. Replenish CO 2 supply as instructed. B. CO 2 shutoff valve closed at CO 2 cylinder. C. CO 2 shutoff valves in lines leading to beer kegs tappers closed. D. CO 2 regulators improperly adjusted. B. Open CO 2 shutoff valve at CO 2 cylinder. C. Open CO 2 shutoff valves in lines leading to beer kegs tappers. D. Adjust CO 2 regulators as instructed. E. Leak in CO 2 system. E. Repair leak in CO 2 system. A. Empty CO 2 cylinder. A. Replenish CO 2 supply as instructed. B. CO 2 shutoff valve in CO 2 system partially closed. C. CO 2 regulator improperly adjusted. B. Open CO 2 shutoff valve all the way. C. Adjust CO 2 regulator as instructed. D. Leak in CO 2 system. D. Repair leak in CO 2 system. A. Beer faucet compensator adjusting screw or draft arm adjustment screw improperly adjusted. B. Insufficient CO 2 gas pressure on beer system. A. Beer faucet compensator adjusting screw or draft arm adjustment screw improperly adjusted. A. Beer system needs to be cleaned and sanitized. B. Beer spoilage (secondary fermentation) due to inadequate walk-in cooler or Cooling Unit refrigeration problem. A. Adjust dispensed beer flow rate as instructed. B. Refer to INSUFFICIENT CO 2 GAS PRESSURE ON BEER SYSTEM in this section. A. Adjust dispensed beer flow rate as instructed. A. Clean and sanitize beer system as instructed. B. Correct walk-in cooler temperature and/or Cooling Unit refrigeration problem, then clean and sanitize beer system as instructed

28 Trouble OFF-TASTE BEER (SOUR AND UNPALATABLE).CONT D DISPENSED BEER TEMPERATURE TOO COLD (FLAT BEER, DISAPPEARING FOAM). Probable Cause Remedy C. Mixed beers. C. Clean and sanitize beer system as instructed, then install new beer supply. A. Dirty beer glasses. A. Glasses must be free of all film. B. Beer too cold. B. Maintain walk-in cooler temperature between 33 F and 40 F and Cooling Unit tank glycol (coolant) between 26 F to 28 F. Adjust temperature as instructed. DISPENSED BEER TEMPERATURE TOO WARM EXCESSIVE FOAMING (WILD BEER) WHILE BEER IS BEING DISPENSED. A. Walk-in cooler temperature too warm. B. Cooling Unit tank glycol (coolant) too warm. C. Cooling Unit power cord unplugged or electrical circuit fuse blown or circuit breaker tripped. D. Glycol circulating pump power cord unplugged, switch in OFF position, or inoperable pump or motor. E. Inoperable Cooling Unit refrigeration system. A. Dispensed beer flow rate too high. B. Dispensed beer temperature too warm. A. Maintain walk-in cooler temperature between 33 F and 40 F. Adjust temperature as instructed. B. Glycol (coolant) in Cooling Unit tank should be maintained between 26 F to 28 F. Adjust temperature as instructed. C. Make sure power cord is plugged in or circuit fuse is not blown or circuit breaker is not tripped. D. Make sure power cord is plugged in, or repair or replace pump or motor. E. Repair Cooling Unit refrigeration system. A. Beer flow rate should be approximately 2-ounces per second. Adjust beer flow rate as instructed. B. Refer to DISPENSED BEER TEMPERATURE TOO WARM in this section. TROUBLESHOOTING COOLING UNIT REFRIGERATION SYSTEM COMPRESSOR DOES NOT OPERATE. A. Glycol (coolant) at recommended 26 F to 28 F temperature. B. Cooling unit power cord unplugged. C. No power source (blown fuse or tripped circuit breaker). A. Refrigeration not called for. B. Plug in Cooling Unit power cord. C. Replace fuse or reset circuit breaker. D. Low voltage. D. Voltage must be at least 103 volts at compressor terminals when compressor is trying to start. E. Loose, disconnected, or broken wiring E. Tighten connections or replace broken wiring.

29 Trouble COMPRESSOR DOES NOT OPERATE. (CONT D) COMPRESSOR WILL NOT STOP AFTER GLYCOL (COOLANT) HAS REACHED RECOMMENDED 26 F TO 28 F TEMPERATURE. COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT LOWER GLYCOL (COOLANT) TO 26 F TO 28 F. Probable Cause F. Overload protector cut out; over-heated compressor. Condenser fan motor not operating as required. G. Inoperative overload protector or start relay. H. Inoperative glycol tank temperature control. Remedy F. Compressor will cool enough to restart. Refer to CONDENSER FAN MOTOR NOT OPERATING in this section. G. Replace inoperative part. H. Replace glycol tank temperature control. I. Inoperative compressor. I. Replace compressor. A. Glycol tank temperature control inoperative. B. Glycol tank temperature control stuck in closed position. A. Cooling Unit located in excessively hot area. B. Air circulation through condenser coil restricted. A. Replace glycol tank temperature control. B. Replace glycol tank temperature control. A. Refer to IMPORTANT note at start of SELECTING COOLING UNIT LOCATION in INSTALLATION SECTION. B. Clean condenser coil as instructed. NOTE: If overload protector cuts out compressor, condenser fan motor will continue to operate; otherwise; troubleshooting condenser fan motor problems are same as for COMPRESSOR DOES NOT OPERATE paragraph plus the following: CONDENSER FAN MOTOR NOT OPERATING. A. Jumper cord loose or disconnected from condenser fan motor or compressor terminals. Broken wire in cord. A. Tighten connections or replace cord. B. Fan blade obstructed. B. Remove obstruction. C. Inoperative condenser fan motor. C. Replace condenser fan motor

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31 CORNELIUS INC. CORPORATE HEADQUARTERS: One Cornelius Place Anoka, Minnesota (612) (800)