GP
Transcript of GP
GLYCOL-PAK FLUID COOLING SYSTEM
FOR SOFT SERVE MACHINES
OWNER'S MANUAL
INSTALLATION OPERATION
MAINTENANCE
AIRDYNE REFRIGERATION Division A.R.I. Industries, Inc.
1304 East Valencia Drive Fullerton, CA 92831 (800) 487-3710 Fax (714) 526-2911
www.airdyne.com
AIRDYNE
TABLE OF CONTENTS
INTRODUCTION - SYSTEM DESIGN...............................................................................1
Benefits and Features of the Glycol-Pak........................................................................1
Enclosure........................................................................................................................1
Heat Exchanger..............................................................................................................1
Centrifugal Pump...........................................................................................................2
Fan Motors.....................................................................................................................2
Pump Bypass..................................................................................................................2
Glycol Fill Pipe..............................................................................................................2
Air Venting Valve..........................................................................................................2
Fan Cycle Thermostat....................................................................................................2
Control Panel.................................................................................................................3
Glycol Fluid...................................................................................................................3
Fluid Manifolds.............................................................................................................3
Electrical Characteristics...............................................................................................3
Supply and Return Piping.............................................................................................3
Platform........................................................................................................................3
STANDARD GLYCOL-PAK................................................................................................4
PHYSICAL DATA OF THE GLYCOL-PAK.............................................................5
COOLANT PIPING...........................................................................................................6
INSTALLATION...................................................................................................................7
Receipt and Inspection of Equipment..........................................................................7
Choosing a Location for Glycol-Pak............................................................................7
Roof Mounted...........................................................................................................7
Ground Mounted..........................................................................................................7
RIGGING DIAGRAM..........................................................................................................8
LIFTING INSTRUCTIONS.................................................................................................9
Installation Area...........................................................................................................9
Roof Rail Requirements...............................................................................................9
Pitch Pocket.................................................................................................................9
TABLE OF CONTENTS
(continued)
WIRING DIAGRAM........................................................................................................10
ELECTRICAL...................................................................................................................11
Electrical Requirement............................................................................................11
Glycol Piping ..........................................................................................................11
Leak Testing............................................................................................................11
PLATFORM INFORMATION.......................................................................................12
CONNECTION TO SOFT SERVE MACHINES FROM MANIFOLD.....................13
Glycol-Pak Capabilities..........................................................................................13
Glycol/Water Mixture.............................................................................................13
Concentration - Winter Temperatures....................................................................14
Leak Testing...........................................................................................................14
Filling the System...................................................................................................14
Ground Mounted Fluid Cooler...............................................................................15
Pump.......................................................................................................................15
Fans.........................................................................................................................16
Auto Air Vent.........................................................................................................16
Surge Tank..............................................................................................................16
INSTALLING THE GLYCOL-PAK..............................................................................17
SYSTEM CHECK LIST..................................................................................................18
MAINTENANCE.............................................................................................................19
Heat Transfer Surface.............................................................................................19
Electric Motor.........................................................................................................19
TROUBLE SHOOTING CHART..................................................................................20, 21
REPLACEMENT PARTS LIST (Use Only Original Airdyne Parts)............................22
WARRANTY....................................................................................................................Enclosed
FACTORY WARRANTY INFORMATION (to be returned) ......................................Enclosed
INTRODUCTION
SYSTEM DESIGN
The AIRDYNE “GLYCOL-PAK” fluid cooler is a heat exchanger designed to operate
with water cooled dispensing equipment. The hot glycol from the water cooled
condenser is piped to the “GLYCOL-PAK” fluid cooler, whereby the heat is removed
from the fluid and rejected into the outside air. The cooled glycol is then pumped back
to the dispensing equipment and the glycol is re-circulated as required by the operator.
The system is controlled by a thermostat to shut the fans off, on Models GP-4 and up,
when temperature is satisfied. Fluid Cooler is completely piped and prewired for low
cost installation in the field.
BENEFITS OF USING THE GLYCOL-PAK
The closed-loop glycol fluid cooling system’s benefits are two-fold. The soft serve
shop’s air conditioning load is reduced as the compressor heat is not rejected into the
conditioned space. Additionally, there is a dramatic savings in the water usage thus
reducing the water and sewer bills. The cooled glycol is re-circulated in a closed loop
circuit and never comes into contact with the outside air. There is no need for adding
makeup water or the expensive maintenance and chemicals typical of open type cooling
towers.
FEATURES OF GLYCOL-PAK
The systems accommodates up to 12 barrels. There are six standard models available
from 2 to 12 barrel soft-serve freezers for frozen soft serve/ice cream. Each system is
equipped with a durable galvanized cabinet, condenser with staggered copper tube coils
with aluminum fins, centrifugal pump, fan motor assembly, fill port, pump bypass with
adjustable pressure relief valve, automatic air venting valve, fan cycle thermostat on
Models GP-4 and up, main fused disconnect and fluid manifolds.
ENCLOSURE
Durable, 16 gauge galvanized steel, processed to resist rust and corrosion.
HEAT EXCHANGER
Staggered copper tube coils with aluminum fins are installed in the glycol system to
reject heat on the roof.
-1-
CENTRIFUGAL PUMP
Centrifugal pump is supplied with bronze impeller, internal overload protection and
weather housing. Pump re-circulates glycol fluid from water cooled condensers to
glycol-pak heat exchanger on the roof.
FAN MOTOR
Glycol-Pak is equipped with fan motors to reject heat. Fan motors are custom designed
for efficient performance with internal overload protection.
PUMP BYPASS
A bypass valve is provided with every system to prevent pump “deadheading” if the
condensing units are not calling for cooling. This prevents possible damage to the pump
seals. The bypass valve is adjustable for different pressures.
GLYCOL FILL PIPE
A Glycol fill pipe is provided for extra fluid in the system. It is very important to have
the pipe filled eliminating air in the system.
AIR VENTING VALVE
All Glycol-Pak’s are provided with automatic air venting valves to insure removal of air
from the glycol system. This prevents system lockout.
FAN CYCLE THERMOSTAT
An energy saving fan cycle thermostat is provided to cycle the fan motors off when no
cooling is required.
-2-
ELECTRICAL JUNCTION BOX
An electrical junction box is provided with each system with main fused disconnect for
fan and pump shut-off switch.
GLYCOL FLUID
A 50% propylene glycol and water solution should be used for cooling media. The
cooling system capacity is approximately 5 to 15 gallons depending on the length of
tubing between the cooling coil and freezers.
FLUID MANIFOLDS
Two fluid manifolds are provided with shut-off and bypass valves. Emergency water
supply should be piped through manifolds for proper working of the system. City
approved backflow preventer to be provided by plumber.
ELECTRICAL CHARACTERISTICS
Each “Glycol-Pak” is equipped with 230 volts, 1-phase, 60 hertz power supply with a
total connected load of 9 to 22.5 amps depending on different model numbers. We can
offer 230 Volts, 3 Phase or 460 Volts System as an option.
SUPPLY AND RETURN PIPING
Installation Contractors shall supply Type “L” copper piping only between “Glycol-Pak’
and manifold. PVC or galvanized piping (zinc) is not recommended.
PLATFORM
Installation Contractor shall supply level build up platform 6” high for Glycol-Pak.
Glycol-Pak should have 36” clear on all four sides.
-3-
STANDARD GLYCOL-PAK
Standard Glycol-Pak fluid cooler package for soft serve machines includes the following:
(1) Fluid cooler system with pump pre-piped, prewired for outside
installation.
(2) Manifold assembly with shut-off valves for each unit, dual check
back flow preventer and shut off valves for Fluid In - Fluid Out.
(3) Premixed 50/50 Propylene Glycol/Water Solution. CAUTION!
DO NOT FURTHER DILUTE OR SYSTEM MAY FREEZE
UP. DO NOT ADD ANTI-FREEZE.
(4) Suggested piping diagrams for field piping.
(5) Suggested installation instructions.
Owner needs to provide the following items:
(1) Supply and return type “L” copper piping or CPVC between fluid
cooler and manifold. Water piping to manifold and drain from
manifold to floor sink.
(2) Roof or outside platform to install Glycol-Pak.
(3) Power supply to Glycol-Pak, 230 Volts, 1 Phase, 60 HZ.
All installation and maintenance is to be performed only by qualified personnel who are
familiar with local codes and regulations and experienced with this type of equipment. If
you do not have a qualified installer, a list of installers is included at the back of this
manual. Should an installer not be listed in your area, contact Airdyne at (800) 487-
3710, you will be given a local installer’s phone number.
-4-
FIGURE 1 - GLYCOL-PAK GENERAL DESCRIPTION
-5-
AIRDYNE
GLYCOL-PAK PHYSICAL DATA
MODEL NO. LENGTH (IN.) WIDTH (IN.) WEIGHT (LBS.)
GP-1 30 22 300
GP-2 50 22 400
GP-3 50 22 500
GP-4 70 22 600
GP-5 90 22 785
GP-6 110 22 900
GP-7 70 60 1200
GP-8 70 60 1225
GP-9 90 60 1250
GP-10 90 60 1400
GP-11 110 60 1400
GP-12 110 60 1800
GP-13 130 68 1800
HEAT EXCHANGER
LIQUID
RESERVOIR
Double
Barrel
Soft-Serve
Machine
Double
Barrel
Soft-Serve
Machine
Double
Barrel
Soft-Serve
Machine
CITY WATER IN
EMERGENCY WATER SUPPLY
UNIONS
PROVIDED BY
INSTALLING
CONTRACTOR
SHUT OFF
VALVE {TYP.}
MANIFOLD IN
MANIFOLD OUT
FLOOR SINK
FLUID COOLER UNIT
RELIEF VALVE
LIQUID OUT
LIQUID IN
PUMP
CHECK VALVE
HAND VALVE
AIR PURGE VALVE
COOLANT PIPING
-6-
INSTALLATION
RECEIPT AND INSPECTION OF EQUIPMENT
Inspect the Glycol-Pak and all accessories shipped for any damage or shortages. Any
damage or shortages should be reported immediately to the delivering carrier. Damaged
material becomes the delivering carrier’s responsibility and it should not be returned to the
manufacturer without prior approval. Do not remove any shipping material until the unit is
installed in its permanent location.
CHOOSING A LOCATION FOR THE GLYCOL-PAK
Unrestricted air flow and unit accessibility are prime concerns in locating the unit. Always
install the unit as close to the dispensing equipment as possible to minimize the pressure on
the pump head. Please contact AIRDYNE if the fluid coolers are to be located further than
25 feet away from soft serve machines. Always allow at least 3 feet of clearance on all
sides. The unit is to be installed on to a level base that is strong enough to support the
unit’s weight plus operating glycol charge.
A. Roof Mounted
Glycol-Pak units are designed to function up to 25’ above the soft serve machines. Vertical
distance within reasonable limits does not affect the performance of the units. The weight
of the descending glycol pulls warmer ascending liquid. However, the length of horizontal
piping, the 90 degree elbows and the valves included in the piping all affect the
performance of the unit. They cause a drop in the system pressure, making the pump work
harder. Due to this, the fluid cooler should be installed in such a way as to minimize the
horizontal stretches of pipe. All valves should be kept fully open during operation of the
unit.
B. Ground Mounted
The Glycol-Pak should have 3’ clearance on all four sides when installed on the ground.
Make sure that the automatic purge valve is higher than the soft serve machines so that all
air can be expelled automatically. If air purge valve is lower than the highest point of
piping, it will lock-out the system and pipes will be full of air. The soft serve machines will
stop running on high head pressure. Installer must install air purge valve model #2P773 at
the highest point in field piping higher than soft serve machine. During start up, purge air
from all vents by manual bleeding. Operate the system for one minute only. Purge all vents
manually. Repeat this until all air is purged out and head pressure is normal
-7-
-8-
AIRDYNE
SPREADER
LIFTING
CABLE
RIGGING
AIRDYNE REFRIGERATION, INC.
LIFTING INSTRUCTIONS (Figure 2)
The FLUID COOLER system is approximately 300 to 900 pounds. Careful consideration
of lifting procedures should be made before the unit is lifted by any means. Particularly,
any cable or other load-bearing devices must not be allowed to press against piping,
electrical conduit of the motor control panel. The only part of the unit designed to carry any
of the lifting load is the base. Lifting loads should be distributed evenly around the base to
avoid any twisting.
It is recommended that whenever the unit is lifted by a crane, frame be used as attachment
points for the lifting cables as shown in Figure 2. The lifting cables should be prevented
from contacting the unit by means of a spreader bar or similar device
INSTALLATION AREA (figure 4)
Figure 4 illustrates the overall dimension and installation requirements.
ROOF RAIL REQUIREMENTS
The total weight of the complete unit is shown in Figure 4. The location and installation of
all equipment should be in accordance with all local code requirements. The unit should be
place directly upon the roof rail. For light roof construction, vibration isolation pads can be
used underneath the supporting frame.
PITCH POCKET
A 6” x 4” pitch pocket must be provided for electrical and glycol lines. After lines are
installed, backfill opening with hot pitch to prevent water leakage into the building.
-9-
Before Starting a Glycol-Pak, check that all breakers and motor protective devices are in
place and that all wiring is secure. The following are wiring diagrams:
Glycol-Pak GP-3
TO MAIN SWITCHBOARD
230 VOLTS, SINGLE PHASE, 60 HERTZ
CONNECTED LOAD 9.1 AMPS
MAIN FUSE DISCONNECT
15 A
Glycol-Pak GP-4
TO MAIN SWITCHBOARD
230 VOLTS, SINGLE PHASE, 60 HERTZ
CONNECTED LOAD 12.7 AMPS
MAIN FUSE DISCONNECT
20 A
Glycol-Pak GP-5
TO MAIN SWITCHBOARD
230 VOLTS, SINGLE PHASE, 60 HERTZ
CONNECTED LOAD 14.5 AMPS
MAIN FUSE
DISCONNECT
20 A
WARNING: PRIME PUMP BEFORE STARTING UNIT
WIRING DIAGRAM
-10-
FAN
PUMP
PUMP
FAN
FAN
PUMP
FAN
FAN
FAN
ELECTRICAL REQUIREMENT (Table 1)
To insure the proper operation of equipment and reduce the possibility of electrical power
interruption, the following precautions must be observed:
1. All electrical work must be completed in accordance with the National Electrical
code and existing local codes.
2. The power supply must be the same as that which appears on the data plate of the
motors.
3. An adequate power supply must be provided.
4. Voltage fluctuations in excess of plus or minus 10% should be corrected.
5. Electrical Contractor before start up should amp the motor and pump per data plate
Before starting a Glycol-Pak, check that all breakers and motor protective devices are in
place and that all wiring is secure. A complete wiring diagram for trouble-shooting the unit
is included.
WARNING: PRIME PUMP BEFORE STARTING UNIT
GLYCOL PIPING
1. PIPING
Connect return and supply lines to manifold at soft serve machines. Table 1 lists line sizes
used based on model number.
All piping must be adequately supported with hangers that can withstand the combined
weight of tubing, and fluid in the tubing.
2. LEAK TESTING
After both Glycol lines are connected, the system must be leak tested for 24 hours with
water under pressure. Particular care should be given to those parts which will be
inaccessible later. Contractor must test the system for all leaks prior to final start up.
-11-
PLATFORM INFORMATION
W”
2”
*Confirm Dimension When Ordering
-12-
RAIL PLACEMENT
MODEL NO. LENGTH (IN.) WIDTH (IN.)
GP-1 30 22
GP-2 50 22
GP-3 50 22
GP-4 70 22
GP-5 90 22
GP-6 110 22
GP-7 70 or 108* 60 or 22*
GP-8 70 60
GP-9 90 60
GP-10 90 60
GP-11 110 60
GP-12 110 60
GP-13 130 68
AIRDYNE
2”
5”
2” 8”
AIRFLOW
FUSED DISCONNECT
4” × 4” REDWOOD RAIL
L” (O.C.)
SERVICE SIDE
(FRONT)
(TYP. OF TWO)
3. CONNECTION TO SOFT SERVE MACHINES FROM MANIFOLD
High pressure washing machine hoses are recommended for connecting each machine to
the manifold inlet and outlet. The hose must allow maximum flow of glycol from the
system. Enlarged fittings may be necessary to fit the drain and supply of soft serve
machines. Page 1 illustrates a typical fluid cooler installation. Note the emergency city
water input and drain provided with the manifold for easy change-over from glycol system
to city water system. Dual check back flow preventer is provided for emergency city water
input to the system. These are available from Airdyne with appropriate fittings.
GLYCOL-PAK CAPABILITIES - TABLE #1
No. Of Total
Soft Heat Of Fluid Fluid Hot Cold Total Ship
Model Serve rejection Volume Flow Fluid Fluid System Weight
No. Barrels (BTU) (Gal)* GPM (Inlet) (Outlet) Length Width Height Amps (lbs)
GP-1 2 30,000 4 4 7/8” 3/4” 30 22 36 5.7 300
GP-2 4 55,000 6 8 1 1/8” 1 1/8” 50 22 36 7.5 400
GP-3 6 81,000 8 10 1 1/8” 1 1/8” 50 22 36 9.1 500
GP-4 8 108,000 10 13 1 3/8” 1 3/8” 70 22 36 12.7 600
GP-5 10 135,000 12 16 1 5/8” 1 5/8” 90 22 36 14.5 785
GP-6 12 165,000 14 20 1 5/8” 1 5/8” 110 22 36 18.2 900
GP-7 14 190,000 15 22 1 5/8” 1 5/8” 70 60 36 22.2 1200
GP-8 16 225,000 16 25 1 5/8” 1 5/8” 70 60 36 22.2 1225
GP-9 18 260,000 18 29 1 5/8” 1 5/8” 90 60 36 22.2 1250
GP-10 20 290,000 22 32 2 1/8” 2 1/8” 90 60 36 27.5 1400
GP-11 22 330,000 26 37 2 1/8” 2 1/8” 110 60 36 27.5 1400
GP-12 24 362,000 28 40 2 1/8” 2 1/8” 110 60 36 27.5 1800
GP-13 26 408,000 30 44 2 1/8” 2 1/8” 130 68 54 27.5 1800
NOTES: *Based on 25’ Run only
Heat of rejection is calculated at ambient temperature os 120 degrees Fahrenheit. (208V/1PH/60HZ)
Provide sufficient valves and union to permit easy access to parts subject to possible repair
or maintenance. All elbows, bends and horizontal pipes should be installed as to allow any
air in the system to exit. Automatic operated vents must be installed on the top of any pipe
run which can trap air. Venting is necessary to rid the system of air which can vapor lock
the pump and prevent proper flow of the liquid.
GLYCOL/WATER MIXTURE
A. TYPE OF GLYCOL
The cooling fluid used in the Glycol-pak is a mixture of propylene glycol and water. There
are two widely used types of glycol; propylene and ethylene (anti-freeze). Local codes must
be adhered to, use only propylene glycol. DO NOT USE ANTI-FREEZE OR
ETHYLENE GLYCOL IN THE SYSTEM.
-13-
B. CONCENTRATION
The concentration of the glycol/water mixture to be used depends upon the climate of the
region. The concentration has to be strong enough to prevent the liquid from freezing in the
pipes during the winter. Based on the lowest ambient winter temperature. Table 2 helps
determine which glycol-to-water ratio is advisable.
WINTER TEMPERATURES
PROPYLENE GLYCOL Lowest Winter
Temperature
Degrees Fahrenheit
% GLYCOL
to -8 50%
-8 to -32 60%
-33 to -60 70%
C. MIXING GLYCOL AND WATER
Regardless of the strength of the mixture, you must pre-mix the glycol and water prior to
adding it to the system. The chemical reaction between the two will release oxygen, which
is extremely undesirable in a closed-loop system.
LEAK TESTING
The system should be tested for leaks before adding glycol. Special attention should be
paid to any area which will be of difficult access later. The system can be tested with air or
water. If the ambient temperature is at or below freezing, the use of air is recommended.
Test pressure should not exceed 50 psi.
FILLING THE SYSTEM
A. ROOF-MOUNTED FLUID COOLER
To fill the system, pour the premixed water and glycol into the system. Fill the system until
is full, then purge the air from ALL vents. Operate the system for a minute, then purge
ALL vents again, and add glycol as required. Repeat the purging of ALL vents after the
first hour of operation and again after several hours of operation. The unit has an automatic
air vent which should eliminate the residual oxygen release. Method for ground-mounted
unit can also be used.
-14-
CAUTION: DO NOT START THE PUMP UNTIL THE GLYCOL/WATER
SOLUTION IS IN THE SYSTEM. RUNNING THE PUMP DRY WILL RESULT
IN DAMAGE TO THE PUMP SEALS.
IMPORTANT: ALL THE AIR MUST BE PURGED FROM THE SYSTEM.
Pockets of air will vapor lock the pump and prevent proper circulation of the liquid. If this
happens, the soft serve machines will continually cut out on high pressure overload and you
will damage the fluid cooler pump. To ensure purging of air, all elbows and unions must
be upward, all horizontal stretches of pipe must be slanted for trapped air to flow upward.
B. GROUND-MOUNTED FLUID COOLER
The Glycol-Pak Fluid Cooler may be the lowest point in the system. Consequently, the
premixed water and glycol has to be pumped up into the system. To do this, close the shut-
off valve. Open the hose bibbs.
Connect a pump and a hose to hose bibb Number 2. Set the pump inside a bucket of
premixed glycol and water. Begin pumping the glycol mixture into the system at FULL
PRESSURE. Allow the mixture to flow through the system, out of hose bibb Number 3,
and back to the bucket of glycol. For the return hose, close the hose bibb so that there is
only a small flow of fluid or air. This builds a head of fluid which forces the air from the
system. Once all the air is out, there will be a steady flow of fluid only. At this point, close
off the two hose bibbs and open the shut-off valve. The unit has an automatic air vent
which eliminates any residual oxygen release.
IMPORTANT: To use this method, in order to circulate the glycol through the system,
you have to pass through one of the soft serve machine’s condensers. For the inlet valve on
the machine to open and allow flow through its condenser, the compressor of that machine
must be operating. This is due to the fact that the valve opens or closes in relation to freon
pressure and temperature. Do not forget to put mix in the machine.
HOW THE FLUID COOLER WORKS
A. PUMP The pump of a Glycol-Pak Fluid Cooler will run continuously. As the soft serve machines
turn on and off, the glycol will circulate through their condensers and cool the freon within.
This action will keep the compressors cool. When no machine is operating, the fluid will
circulate from the pump through the bypass valve set at 15 psi and back to the Fluid Cooler.
-15-
B. FANS
If the Glycol-Pak has 2 or 3 fans, the first fan will run continuously. The second two are
thermostatically controlled. You simply set the dials inside the electrical box to a
temperature for which the second and third fans will come on. When the temperature of the
glycol leaving the Fluid Cooler reaches these temperatures, the second and third fans will
come on automatically. After the glycol is cooled 7 to 10 degrees below the dial setting, the
fans will shut off. For moderate climates, the second and third fans can be set at 70 and 60
degrees Fahrenheit, respectively. This will vary with the ambient temperature in your area.
Choose a dial setting that works best for your particular climate.
C. AUTO AIR VENT
The pump will pump air bubbles from the glycol/water solution and direct them into the
auto air vent. Inside of this vent is a float. When the float hits the bottom of the vent
(meaning the vent is filled with air), it will automatically open and release the air until the
float reaches the top. There is also a Schraeder pin on the top of the air vent for manual
bleeding upon start up.
D. SURGE TANK
It is a system filling port for roof-mounted units. Also, it is a reservoir of glycol to replace
the air released by the system.
-16-
INSTALLING GLYCOL-PAK
A. Uncrate the machines
B. Remove the side panels
C. Remove the protective plastic from machine side panels
D. Leak test the machines
E. Set machines in place
F. Install water fittings to inlet and outlet pipes
G. OPEN INLET WATER VALVE TO FULLY OPEN POSITION
H. Connect hoses from inlet and outlet pipes on machine to the main inlet and
outlet pipes on the fluid cooling system manifold (provided with the unit)
I. Clean and sanitize machine (hopper, cylinder, beater)
J. When fluid cooling system is operational, open all valves
K. Check compressor pressures, which should be: High side - 125 to 150 PSiG,
Suction side - 8 to 10 PSIG
L. After machine cycles off, check product temperature. Product temperature
should be between 25 degrees F. and 29 degrees F. (Adjust rear microswitch
accordingly)
M. Replace side panels on machine
-17-
SYSTEM CHECK LIST
1) Is the Airdyne unit properly sized for the number and type of machines?
2) Is the Glycol-Pak located in a position which allows for unrestricted air flow and unit
accessibility?
3) Is the Glycol-Pak located within a reasonable distance from the Soft Serve machine?
4) Is the Glycol-Pak securely mounted to a base or frame?
5) Are the proper electrical requirements fulfilled?
6) Is the correct pipe size used?
7) Has the piping system been designed with as few 90 degree bends as possible?
8) Are the soft serve machines; water inlet valves fully open? Are all other service valves
open or closed as requires?
9) Has the system been tested for leaks?
10) Has the proper type and concentration of glycol been selected?
11) Was the pre-mixed 50/50 glycol solution used? Caution: Do Not Dilute Further
12) Is ALL of the air bled from the system?
13) Are the pressures on low side and high side of compressor on the soft serve machines
correct?
-18-
MAINTENANCE
Inspect the unit regularly for loose bolts and connections, rust, corrosion and dirty or
clogged heat transfer surface (cooling coil). Check all lines for leaks and deformation.
HEAT TRANSFER SURFACE
Dirt and dust should be removed by brushing the fins and tubes and blowing loose dirt off
with air hose. Should the surface be greasy, the motor should be removed and the fins and
tubes brushed or sprayed with a mild alkaline solution or a non-flammable degreasing fluid.
Follow up with a hot water rinse and dry thoroughly.
ELECTRIC MOTOR
Properly selected and installed pump and fan electric motors are capable of operating for
years with minimal maintenance. Periodically clean dirt accumulations from open-typ
motors, especially in and around vent openings, preferably by vacuuming (avoid imbedding
dirt in windings). Check running amps and voltage. Fan and pump motor is provided with
sealed ball bearings. Relubrication of the bearings is not normally required.
PROPER MIXTURE OF PROPYLENE GLYCOL & WATER
To check the Propylene Glycol and Water mixture use a Hydrometer. Place a small amount
of mixture in a container. Have the mixture at 20 Celsius. Check that the Specific Gravity
is at 1.048 or a little higher (i.e. 1.049) but no less.
-19-
TROUBLE SHOOTING CHART
SYMPTOM CAUSE REMEDY
Pump will not prime 1. Air leak in suction line 1. Repair or replace
or retain prime after suction line.
operating 2. Clogged strainer. 2. Clean or replace
strainer
3. Low Glycol Charge 3. Add glycol
Flow rate is Low 1. Piping is fouled or 1. Clean or replace
or damaged piping
2. Clogged impeller 2. Clean or replace
or worn impeller impeller
3. Discharge line restricted 3. Remove restric-
or undersized tions
4. Plumbing restrictions 4. Remove restric-
tions
5. Low glycol charge 5. Add glycol
6. Air in system 6. Purge
Pump runs but no 1. Faulty suction 1. Replace piping
fluid is pumped piping
2. Valves closed 2. Open valves
3. Clogged strainer 3. Clean or replace
strainer
4. Refrigeration 4. Start refrig. sys.
valves closed adjust valves
Liquid drips from 1. Damaged mechanical 1. Replace mech-
point where shaft seal anical seal
enters the pump 2. Temperatures over 2. Replace with
casing, when pump 210 F liquid are
is full of liquid not compatible w/seal
Excessive noise while 1. Pump not secured 1. Secure pump
pump in operation 2. Piping not supported to 2. Do adjustments
relieve strain on pump
3. Restricted suction line 3. Clean or correct
4. Low glycol charge 4. Add Glycol
-20-
Ground Mount Installation 1. Air Trap Causing 1. Add Air Vent
Pump is running but soft soft serve machines at highest point
serve machines are on high to have high head in field piping
head
Product is runny 1. Water valve is not 1. Open water valve
open all the way
2. Hose is kinked 2. Make sure the hose
is not kinked
-21-
USE ONLY ORGINAL AIRDYNE PARTS
AIRDYNE PARTS LIST
STOCK NUMBER
AIRDYNE 4A107S
AIRDYNE 6A656S
AIRDYNE 4A219S
AIRDYNE 3CC04S
AIRDYNE 1MC1C1E0
AIRDYNE 1MC1E1C0
AIRDYNE 1MC1C1A0
AIRDYNE 1ST1H1A4
AIRDYNE 2P070A
AIRDYNE 2P773A
AIRDYNE 2P774A
AIRDYNE 2P775A
AIRDYNE 1G05F
AIRDYNE 1G05P
AIRDYNE 4M105G
AIRDYNE 1F107B
AIRDYNE G3722T
AIRDYNE 3M307C
AIRDYNE 4M407C
AIRDYNE 4M507C
DESCRIPTION
½ HP MOTOR
CAPACITOR
RAIN SHEILD
PUMP FEET
½ HP PUMP
1 HP PUMP
2 HP PUMP
3 HP S/S PUMP
½’’ RELIEF VALVE
AIR VENT
1” × 12” HOSE
1½” × 12” HOSE (GP-6 & UP)
5 GALLON GLYCOL 50/50
5 GALLON PURE GLYCOL
GUARD MOTOR MOUNT
FAN BLADE
GLYCOL TANK
GP-3 CONDENSER
GP-4 CONDENSER
GP-5 CONDENSER
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