Download CRYOCOOL 50 AF Installation

Introduction to the Cornelius CRYOCOOL 50 System
for Extra-cold Products and Detailed Information
for Surveying, Installation and Commissioning
Issue 2 06/05/05
Contents
Page
The System
Product Overview
Configuration
Survey
3
3
General Considerations
3
Installation
CRYO 50 AF
Product line connections
Check sheet
4
4
4
Commissioning
5
Product Supply
Cleaning lines
Cleaning Socket Labels
Final Checks
5
5
5
System Schematic
6
Spares List and Exploded View
7-8
Kits Required
9
Product Data Sheet CRYOCOOL System
10-11
Fault Finding
12-14
Temp Controller Setup
2
The System
Product overview
A retail account based glycol cooling system delivering consistently cold temperatures (between 2oC and 4oC)
across a maximum of 5 dispense points per CRYO 50 AF remote cooler. The system utilises a CRYO 50 AF
remote cooler containing a sub zero coolant. Product is cooled in coils which are immersed in the sub zero
coolant. The cooled product temperature is maintained by using two super chill pythons. A 2m feed python is
fitted between the existing cellar python and the CRYO 50 AF cooler and the 2m font python is fitted between
the CRYO 50 AF cooler and the font.
Configuration
Product stored at a maximum of 13oC in a temperature controlled cellar is supplied via the existing ice bank
cooler and product python to the product coils in the CRYO 50 AF remote cooler.
Two super chill pythons, made using up to 5 x 3/8” product lines, 2 x 3/8” OD recirculation lines and covered
with 19mm insulation are connected to the product coil inlet/outlets and recirculation pump flow and return.
These pythons will be a maximum of 2m from the CRYO 50 AF to the font.
The glycol mix in the CRYO 50 AF remote cooler’s coolant bath is used to chill product and is pumped around
the super chill python to maintain the temperature of the product between the cooler and the point of
dispense.
Survey
General considerations
The purpose of the survey is to determine in advance of the installation whether special considerations need
to be raised with the design company or the main contractors. Items to be considered are:
•
•
•
•
•
Location of the CRYO 50 AF remote cooler – is the location suitable?
Is there a suitable electrical supply within 2m of the chosen location?
Location of the CRYO 50 AF is under the bar within 2m of the desired location of the font (existing
storage area may have to be modified to accept the CRYO 50 AF)
The standard super chill python has 5 lines.
Will the cooler interfere with existing services or storage facilities? Better to ask the manager first
3
Installation
CRYO 50 AF
Locate CRYO 50 AF in selected position (within 2m of a 13A socket) Fill the water bath with glycol and water
(mixed at 30% glycol, 70% water, or, 2x4lt bottles of glycol and top up with water). The water bath should be
filled with this glycol/water mix to just above the top of the evaporator coil.
The CRYO 50 AF can be run with the unit switched to ‘clean’ mode (cools to approximately 2°C) and the top
mounted pump disconnected, to ensure the integrity of the unit.
CRYO 50 AF Product line connections
There are two 2m pythons supplied with each CRYO 50 AF cooler, the feed python is connected up between
the main product python from the chilled cellar to the product inlet coils. The font python connects to the flow
and return recirculation lines on the top mounted pump, the product outlet coils on the cooler and in turn to
the recirculation and product lines in the font.
CRYOCOOL Installation Check Sheet
This sheet is intended as a guide to a method of installation of the CRYOCOOL System, for more
comprehensive instructions consult Product Manual.
Bar Installation
1
Site the CRYO 50 AF Cooler in location under the bar
2
Fill CRYO 50 AF Cooler with glycol to correct strength
3
Connect CRYO 50 AF cooler to power supply with Glycol Recirculation pump OFF and unit
in CLEAN MODE
4
Switch on CRYO 50 AF Cooler
5
Install product lines from cellar python to CRYO 50 AF Cooler via feed python – see
schematic below
6
Install super chill font python between CRYO 50 AF cooler position and bar – see schematic
below
7
Install font connect product and recirculation lines ensuring all exposed lines are insulated.
Note: If a condensate font is being installed see below for instructions
Condensate Font
Should a condensate font be required, connect the flow and return lines from the font python to the cooling
lines on the condensate font.
4
Commissioning
Before switching the CRYO 50 AF to ‘cool’ mode ensure that all coils are purged with product!
Commissioning can only be successfully completed when:
Recirculation pump is running and all components are installed and connected
Glycol bath temperature remains between –0.7°C & –1.7°C
Ensure products dispense at between 2°C and 4°C.
Product Supply
Cleaning lines
Before cleaning begins ensure the CRYO 50 AF is switched to “Clean” mode!
All product lines should be sterilised using known procedures and cleaning chemicals. It is absolutely essential
that all traces of water are removed from extra-cold product lines before commissioning begins. Failure to do
this will result in frozen coils and damage may result.
Cleaning socket labels
Cleaning reminder labels (supplied) should be installed adjacent to the extra-cold cleaning sockets in the
cellar. In accounts where it is felt that the cleaning regime may be overlooked, additional labels (not supplied)
can be fitted to the keg connectors.
Final checks
*
*
*
*
*
*
Clean shelves of debris and discarded fluid (beer and/or glycol)
Check that all joints have been sealed against moisture ingress
Ensure there are no leaks – under bar and from coolers
Replace any bar furniture including back-panels and shelves
Leave system information pack in a conspicuous position by the CRYO 50 AF
Discuss cleaning regime with Manager/cellar man thoroughly
5
System Schematic
6
SPARES LIST
CRYO 50 AF
ITEM
1
2
3
4
5
6
7
8
9
10
11
12
13
14
A
B
PART No.
58 0420 592
58 0400 075
06 0 130247
06 0 105113
44 0000 207
99 0420 090
99 0420 059
99 2914 201
58 0431 015
06 0 131111
06 0 135103
06 0 138205
58 0400 135
58 0475 214
06 0 135203
06 0 130283
06 0 132238
06 0 132237
DESCRIPTION
No 15 PUMP ASSY
THERMOSTAT WATERBATH
CASSETTE COIL
HANDLE
COMP SET FR11GX HST
COMPRESSOR START RELAY
COMPRESSOR CAPACITOR
FAN MOTOR
FAN BLADE
FAN BRACKET
SERVICE PANEL
LOGO
CONTROLLER
HANDLE – LID
HATCH - INSPECTION
2P COIL BASKET 3/8 (9.5MM O.D x 5M)
COIL OUTER
COIL MIDDLE
IMI Cornelius (UK) Limited
Rawson Spring Way, Riverdale Industrial Estate, Sheffield S6 1PG
Tel: 44 (0) 1142 855886
Fax 44 (0) 1142 321070
7
Exploded View
Cryo 50 AF
8
Fittings Kit
All tube is 3/8 OD
P1 P2 P3 "Brewmaster" striped tube
2 x 2m Long Pythons
2
2
7
5
2
2
x
x
x
x
x
x
P12312S---3/8 2 way divider
P10812S---3/8 plug
P10412S---3/8 straight connector
P10312S---3/8 equal elbow
PM0415E---15mm straight connector
NC478---15mm x 3/8 male reducing connector
9
CRYOCOOL SYSTEM
PRODUCT DATA SHEET
Date:
30th March 2005
Issue No:
1
The CRYOCOOL system consists of two main components, the CRYO 50 AF and the super chill python.
CRYO 50 AF
Performance
Maximum ambient temperature:
40oC
Dimensions
Height:
Width:
Depth:
Weight: unloaded
Packed
Operational
653mm
424mm
424mm
36kg
38.5kg
65kg
Electrical
Mains supply:
Run current:
Start current:
Fuse:
Supply:
230v 1ph 50Hz
2 amps
10 amps
10 amps
2m mains cable 3 pin UK
Style plug
Refrigeration
Compressor:
Compressor starting torque:
Compressor duty: (-10oC Evap temp)
Evaporator type:
Condenser type:
Expansion device:
Refrigerant type charge:
11cc
High starting torque
350 watts
Copper tube
9.52mm dia x 11.4m
Air Cooled – Steel Construction
Capillary 3m x 0.042” I.D.
R134a refer rating plate
Fan Motor
Output:
Speed:
Direction:
Protection:
Fan blade: Diameter
Pitch
5 watts
1250 rpm
Counter clockwise shaft end
Thermal trip
8” (5 blades)
30o
10
CRYO 50 AF
Python Pump
Type:
Output:
Speed:
Protection:
Max flow rate @ no pressure:
Max lift @ min flow:
Connection size:
Semi-Submersible
80watts
2800rpm
Thermal trip
28 litres per minute
15m
9.5 mm barbed fitting
Controls
Control type:
LAE Electronic
Agitation
Type:
Continuous
Product coils
Material:
Diameter:
Length/Quantity
316 stainless steel
9.5mm O.D
3x5mt std – up to 2x5mt
optional cassettes
SUPER CHILL PYTHON
5 x 3/8” product lines
2 x 15mm OD recirculation lines
19mm insulation
Compliance To Standards And Legislation
All coolers comply with Brewers Society Code of Practice for Electrical Safety in Beer Dispense in
License Premises. Designed to EN60335 part1 (Safety of Household and Similar Electrical
Appliances-General Requirements) Product coils are made from 316 stainless steel. Product
complies with the current EMC Directive.
IMI Cornelius (UK) Limited
Rawson Spring Way, Riverdale Industrial Estate, Sheffield S6 1PG
Tel: +44 (0) 1142 855886
Fax +44 (0) 1142 321070
www.corneliusuk.com
11
CROCOOL SYSTEM
No
Cooling
Yes
Is cooling problem
restricted to one
cooler?
Is Cooler plugged
in and turned on?
No
Plug in cooler and
turn on
Yes
Is the Glycol/water mix
between -0.7o and -1.7oC?
No
Yes
See CRYO 50 AF
fault finding below
Is top pump
working correctly?
No
Yes
Check cellar temp.
and the length of
time the product has
been stored in the
cellar
No
CRYO 50 AF is
working correctly
Yes
Product temp. correct
Correct the cellar temp. and
ensure product is stored in the
cellar for at least 48hrs before
dispensing
12
Fault Finding cont..
CRYOCOOL SYSTEM
Is Cooler
plugged in and
Is cooling problem
affecting all products on all
towers?
Has CRYO 50 AF been
turned off at the
socket?
Yes
Switch on the supply at
the socket
Yes
Has the CRYO 50 AF
RCD tripped?
No
Yes
Is recirc top pump
running?
Reset RCD
Is pump plug
connected to the
socket?
No
Yes
No
Refit
Does the pump
run?
Yes
Is the glycol mix in the bath
on the CRYO 50 AF full and
between -0.7 & -1.7oC?
Call service
engineer
13
No
Yes
Fault Finding CRYO 50 AF
Maintenance and repairs must only be carried out by a properly qualified and trained person. Always switch off and unplug the equipment before servicing or repairing the unit.
PROBLEM
POSSIBLE FAULT
REMEDY
SERVICE TIP
Loose connection or broken wire in supply
wiring to unit.
Replace or reconnect wire.
Install within 2m of an electrical socket.
Incorrect size device.
Install correctly sized device.
6.5A run current per unit.
No
Loose connection or broken wire in supply
wiring to unit.
Replace or reconnect wire.
Charred connection indicates poor crimping
electrical connection
High
Reduce line voltage.
Install a voltage reducing transformer.
Voltage range 207V to 253V
No
a)Loose or corroded connection.
b)Supply wiring undersized.
c)Low line voltage.
a) Replace or reconnect wire.
b) Increase wire size.
c) Install a voltage increasing inverter.
a) Check electrical safety frequently.
b) Use 1mm 2 wire
c) Voltage range 207V to 253V
Circuit overloaded.
1.Remove all other equipment from circuit.
2.Install new dedicated circuit.
Go to 1. Totally Inoperative
Go to 1. Totally Inoperative
a)Faulty Temp Controller.
a) Replace
a)Overload protector is open
b)Improper or loose wiring, no power
to compressor.
a) Replace overload protector.
b) Replace or reconnect wiring.
Yes
a) Start capacitor shorted or blown.
b) Start relay will not close or is burned out.
c) Compressor motor has opened or shorted
out windings.
d) Compressor stuck, it.trips on overload.
Yes
a) Check connections. Replace capacitor if
necessary.
b) Check connections. Replace relay if
necessary.
c) Replace compressor.
d) Replace compressor.
Yes
a) Improper wiring.
b) Relay failing to open.
c) Excessively high discharge pressure.
d) Open or shorted windings in compressor
motor.
e) Tight compressor (binding internally).
a) Replace and reconnect wiring.
b) Relay failing to open.
c) Excessively high discharge pressure.
d) Replace compressor.
e) Replace compressor.
Yes
Yes
a) Replace overload protector.
a) Defective overload protector.
b) Clean condenser or replace fan motor.
b) Excessively high discharge pressure
c) Repair leak and recharge refrigerant.
c) Suction gas too hot, low charge refrigerant.
1. Totally Inoperative?
Yes
Yes
No
Is supply fuse blown or has circuit breaker
tripped?
Is fuse or circuit breaker size correct?
Is line voltage within 10% of nameplate
voltage?
Low Is line voltage high or low?
No
No
Is other equipment on the same circuit?
Yes
Is other equipment on the same circuit?
Yes
2. Not Cooling?
Yes
Is line voltage within 10% of nameplate
voltage?
No
Is compressor cold
No
Yes
Is compressor cold, fan motor working and
No green neon on?
Yes
Compressor does not start hums & trips on
overload.
No
Yes
Compressor starts but start winding does not
switch off.
No
Compressor running hot.
Compressor starts and runs but short cycles
on overload protector.
a) Always isolate electrical supply before
undertaking repairs.
b) Check electrical safety regularly.
a) Check for paper debris of blown capacitor.
b) Relay will rattle if OK.
c) See rating plate for gas charge.
d) Always fit new drier.
a) Always isolate electrical supply before
undertaking repairs.
b) Ensure correct relay is used.
c) Use vacuum cleaner or soft brush.
d) See rating plate for gas charge.
e) Always fit new drier.
a) Always isolate electrical supply before
undertaking repairs.
b) Leave 100mm gap around unit.
c) Traces of oil are a good indicator of leaks.