Introduction to the Cornelius CRYOCOOL 100 System for Extra-cold Products and Detailed Information for Surveying, Installation and Commissioning

Issue 2 06/05/05

Contents Page

The System Product Overview 3 Benefits 3 Configuration 3

Survey General Considerations 3 System Constraints 4 Cooler Location 4

Installation System 4 Cellar checklist 5 Bar checklist 6 Commissioning Trace cooling 7 Product Supply Cleaning lines 7 Cleaning Socket Labels 7 Final Checks 7 System Schematics 8-9 CRYO 100 WF Wiring Schematic 10 Spares List and Exploded View 11-12 Product Data Sheet CRYOCOOL System 13-14 Fault Finding 15-17 Temp Controller Setup

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The System Product overview A retail account based glycol cooling system delivering consistently cold temperatures (between 2oC and 4oC) across a maximum of ten dispense points per CRYO 100 WF remote cooler. The system utilises a CRYO 100 WF 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 a super chill python installed between the CRYO 100 WF remote cooler and the dispense point. Benefits Reduced power consumption – Replaces the requirement for both remote and shelf ice bank coolers. Additional space underneath the bar for storage of glassware. Reduced heat input to the bar area. Configuration Product stored at a maximum of 13oC in a temperature controlled cellar is supplied to the product coils in the CRYO 100 WF remote cooler by a standard dispense panel. A super chill python, made using 12 x 3/8” product lines, 2 x 15mm OD recirculation lines and covered with 19mm insulation is connected to the product coil outlets and recirculation pump flow and return. When using a 14 line super chill python connect only the 12 lines which are wrapped within the 19mm insulation, the other 2 are built in for redundancy purposes and should not be used, drinks will be out of specification if they are. The glycol mix in the CRYO 100 WF remote cooler’s coolant bath is pumped around the super chill python to maintain the temperature of the product between the cooler and the point of dispense. Trace cooling is allowed using a “T” piece fitted to the recirculation flow line allowing the glycol to circulate around the trace cooling loop and return into another “T” piece fitted in the recirculation return line. 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 100 WF remote cooler – is the location suitable? • Is there a suitable electrical supply within 2 metres of the chosen location? • The standard super chill python has 12 lines. If the existing python has more than twelve lines, a

second python will be required. Can the existing route to the bar area accommodate an additional python?

• Will the cooler interfere with existing services or storage facilities? Better to ask the manager first! • Routes between bars? New bar layouts may have a raised step to house pythons and cables. Where

bars are simply refurbished there may not be sufficient room in existing channels. Contractors need to know if there will be additional work.

• Can the install be made to allow minimum down time of the dispense system?

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Survey cont. System constraints The main constraints of the system will be the pumping capacity of the vertically-mounted CRYO 100 WF pump. It is desirable to ensure that the maximum distance between the coolers and the pressure differential valve is 40 metres. Beyond this distance, cooling performance may be affected due to the reduction in glycol flow; however 60 meters can be achieved by installing an optional boost pump. The pump priming height (head) is more than sufficient for most installations, including where the cooled cellar is below ground. Cooler location The CRYO 100 WF may be sited within cooled cellars, store rooms or other appropriate internal areas where the ambient air temperature will not exceed 40°C, however when used in the CRYOCOOL system it is better to site the cooler in the temperature controlled product store. A suitable position should be chosen within 2 metres of a 13A socket. The CRYO 100 WF uses conventional remote heat dumps to remove waste heat from the refrigeration unit. The heat dumps can be sited up to 50 metres from the coolers, preferably discharging to an external ambient. The electrical connections between CRYO 100 WF cooler and heat dump must be made with suitable 1.5mm2 cable and 15mm O.D tubing, with a sufficient bore to ensure a minimum flow in this circuit of 4.5litres/minute. Installation CRYO 100 WF and Discharge Cooler Locate CRYO 100 WF in selected position (within 2 metres of a 13A socket) Fill the top tank with glycol and water (mixed at 30% glycol, 70% water). The top tank should be filled with this glycol mix to just above the top of the evaporator coil. Select a suitable position to site the discharge cooler and fit as normal. The CRYO 100 WF 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 discharge cooler circuit. CRYO 100 WF Product line connections From the sub zero python connect the recirculation lines to the flow and return of the top mounted recirculation pump on the CRYO 100 WF. From the dispense panel in the temperature controlled cellar connect the product lines to the inlet of the product coils of the CRYO 100 WF. Connect product lines of the super chill python to the outlet of the product coils of the CRYO 100 WF. Note: All lines to be well insulated! Bypass Valve At a convenient point immediately after the furthest dispense tower from the cooler, the pre-insulated bypass valve needs to be fitted to ensure suitable differential pressure is maintained between the flow and return lines. Connect the valve between the flow and return lines, ensuring the arrow on the valve is pointing in the direction of the return manifold. Connections between python insulation and the valve can be sealed using PVC tape and/or Armaflex tape. See installation checklist below

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Installation cont. Trace Cooling To allow trace cooling, a ‘T’ piece is fitted in the recirculation flow line allowing the glycol to circulate around the trace cooling loop and return into another ‘T’ piece fitted in the recirculation return line. To encourage flow through the trace cooling loop a pressure bypass valve is fitted between the flow and return at the end of the super chill python; this creates a pressure difference of approximately 10psi between the recirculation flow and return. The trace cooling flow rate is adjusted using a flow regulator located in the return trace cooling line before it re-enters the ‘T’ piece in the return python line. A nominal flow rate of 1 litre/minute (adjusted when commissioning) ensures adequate cooling under most conditions. Note: Where capillary tube is less than 0.75m long and where the 9.5mm beer line is terminated close to the python exit point, trace cooling may be omitted. For all other instances trace cooling will be required. 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. Cellar Installation 1 Site Cooler(s) 2 Install heat dumps in position 3 Run pipe work and cable to heat dumps 4 Fill Cryo Cooler with glycol to correct strength 5 Fill coil in bottle with glycol 6 Connect cooler to power supply with Glycol Recirculation pump OFF and unit in CLEAN

MODE

7 Switch on Cooler and check for leaks 8 Install product lines from dispense panel to cooler 9 Install python between cooler position and bar, leaving enough length to Top and Tail 10 Connect recirculation tubes to cooler 11 Connect product lines to cooler ensuring all exposed tubing is insulated 3/8 fittings (not

supplied)

12 Install diagnostic system as required

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Bar Installation 1 Run python into position in bar 2 Pull out product lines from python close to and beneath relevant font re-taping as

you go

3 Fit flow control to product lines (not supplied) keeping 3/8 pipe to minimum

between flow control and python

4 Connect restrictor tube between flow controls and taps. Tape and insulate 5 On end of python fit 4 elbows to return into trace cooling ring main Tape and

insulate

6 Fit Tees into trace cooling ring main as required and insulate 7 Fit Pressure Balancing valve between flow and return. (Arrow in direction of Flow)

Tape and insulate

8 Switch Glycol Recirculation pump on. Check for leaks 9 Top cooler tank up with Glycol 10 Draw water through product lines to check for leaks 11 Ensure all connections are taped and insulated 12 Check flow rate with water as per product specification 13 Sanitise Lines 14 Draw beer through each line to font. Adjust flow rate if required 15 Ensure all water has been purged from system before switching the Cooler to ‘run’

mode

16 Commission system

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Commissioning Before switching the CRYO 100 WF 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 –2°C & –4°C Ensure products dispense at between 2°C and 4°C. Note: The temperature controller on the CRYO 100 WF does not require any alteration during set up, it is factory set to the parameters required.

Trace cooling Begin with setting the trace cooling flow on each trace cooling loop. Turn the knurled knob on the flow adjustment valve 1.5 turns anticlockwise from fully closed. This will give approximately 1 litre/minute, which is sufficient for maintaining cooled product in the lines. If temperatures are consistently too cold it is possible to alter the sub zero glycol temperature via the temperature controller in the base of the CRYO 100 WF, however be aware, this will alter the temperature of the casual drink. Product Supply Cleaning lines 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 to the system may result. Suggest, to ensure the CRYO 100 WF is at the correct temperature to perform the cleaning operation switch to “clean” at the end of the evening and perform the cleaning operation the next day. 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, coolers and discharge cooler * Replace any bar furniture including back-panels and shelves * Leave system information pack in a conspicuous position by the CRYO 100 WF * Discuss cleaning regime with Manager/cellar man thoroughly

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System Schematic Bar and Cellar area

ΙΜΙ ΧΟΡΝΕΛΙΥΣ (ΥΚ) ΛΤ∆

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System Schematic

Bar area 9

Wiring Schematic

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SPARES LIST CRYO 100 WF

ITEM PART No. DESCRIPTION

1 58 0420 591 TOP PUMP 4 STAGE 2 06 0 105103 GLYCOL BOTTLE 06 0 105104 LID GLYCOL BOTTLE 2MC824A GLYCOL PROPYLENE 4 LTR 15ISV BALL VALVE 15mm 3 58 0440 429 TRANSFORMER BASLER BE30691-002 4 58 0400 098 TEMPERATURE CONTROL PRE 14/04/05 4 58 0400 135 TEMPERATURE CONTROL POST 14/04/05 58 0400 091 FAN SWITCH T/STAT K55 RANCO(bronze phial) 58 0400 092 THERM CUTOUT STAT K36-PI366000(silver phial) 5 44 0000 256 COMP SET – CAJ4511Y 3TS008A COMPRESSOR START RELAY 3TS017A COMPRESSOR START CAPACITOR 3TS026A OVERLOAD 3TS029A RUN CAPACITOR 6 06 0 105127 BEZEL LENS (x2) 7 58 0410 216 FAN MOTOR (COMPRESSOR COOLING) 8 58 0420 570 PUMP GLYCOL n/s 99 2MR400A FAN MOTOR - 24v 50Hz (HEAT DUMP) n/s 58 0450 097 THERMOSTATIC EXPANSION VALVE n/s 58 0450 098 ORIFICE n/s 3SW004A CLEANING SWITCH n/s 58 0400 075 CLEANING SWITCH THERMOSTAT

IMI Cornelius (UK) Limited

Rawson Spring Way, Riverdale Industrial Estate, Sheffield S6 1PG Tel: 44 (0) 1142 855886 Fax 44 (0) 1142 321070

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Exploded View CRYO 100 WF

SYSTEM SPARES CRYOCOOL

PART No. DESCRIPTION CZZ 096 122 402 96VA TRANSFORMER

PART No. DESCRIPTION 07 0 001589 INSULATED STRAINER

PART No. DESCRIPTION 07 0 001587 DIFFERENTIAL PRESSURE VALVE

PART No. DESCRIPTION 38 0 27431 FLOW CONTROL VALVE

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PRODUCT DATA SHEET CRYOCOOL SYSTEM Date: 10th March 2005 Issue No: 2 The CRYOCOOL system consists of three main components, the CRYO 100 WF glycol cooler, the super chill python and the pressure bypass valve. CRYO 100 WF Performance Maximum ambient temperature 40oC Dimensions Base Unit Discharge Unit Height 935mm (inc. pump) 450mm Width 644mm (inc. handles) 640mm Depth 600mm (inc. spacers) 320mm Weight: unloaded 78kg 17kg Packed 79kg 18kg Operational 138kg 19kg Electrical Base Unit Discharge Unit Mains supply 230v 1ph 50Hz 24v 1ph 50Hz Run current 7 amps Start current 34 amps Fuse 10 amps Supply 2m mains cable 3 pin UK

Style plug 1.5mm cable from base unit (supplied by Installer)

Refrigeration Compressor 34cc Compressor starting torque High starting torque Compressor duty (-10oC Evap temp) 1050 watts Evaporator type Copper tube

12.7mm dia x 17.5m Condenser type Coil in bottle Expansion device TEV TH2/Orifice no.2 Refrigerant type charge R134a refer rating plate Discharge Unit Heat exchanger Aluminium fins on copper tube Fan motor: Output 12 watts Speed 1250 rpm Direction Clockwise shaft end Protection Thermal trip Fan blade: Diameter 250mm Pitch 31o

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CRYO 100 WF Python Pump Type 4-stage semi – submersible Output 97 watts Speed 2700rpm Protection Thermal trip Max lift @ min flow 20m Connection size 15mm diameter tube Agitation Continuous Coolant System Coolant Monopropylene Glycol Coolant mixture 30% glycol, 70% water Product coils Material 316 stainless steel Diameter 9.5mm O.D Quantity Up to a maximum of twelve Additional Information: Compressor cooling fan: NMB 230v / 50Hz 120mA 19w Recirculation pump: 3 stage mag drive pump, Max lift @ min flow = 15m Control type: Electronic SUPER CHILL PYTHON 12 x 3/8” product lines 2 x 15mm OD recirculation lines 19mm insulation PRESSURE BYPASS VALVE Connection 22mm Maximum Pressure 10 bar Maximum Temperature 110oC 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 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

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CRYOCOOL SYSTEM Is Cooler

plugged in and No Cooling

Is cooling problem restricted to one cooler?

No

Check cellar temp. and the length of time the product has been stored in the cellar

Yes

Product temp. correct

Correct the cellar temp. and ensure product is stored in the cellar for at least 48hrs before dispensing

No

Yes Is Cooler plugged in and turned on?

No

Plug in cooler and turn on

YesIs the Glycol/water mix between -2o and -4oC?

No

See CRYO 100 WF fault finding below

Yes

Is top pump working correctly?

Yes

CRYO 100 WF is working correctly

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Fault Finding cont.. CRYOCOOL SYSTEM Is Cooler

plugged in and Is cooling problem affecting all products on all towers?

Is pump plug connected to the socket?

Yes

Is recirc top pump running? No

Yes Has CRYO 100 WF been turned off at the socket?

No

Does the pump run?

Switch on the supply at the socket

No

Reset RCD

Yes

Has the CRYO 100 WF RCD tripped?

No

Call service engineer

Refit

Yes

Yes

YesIs the glycol mix in the bath on the CRYO 100 WF full and between -2 & -4oC?

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SERVICE TIP

Install within 2m of an electrical socket.

6.5A run current per unit.

Charred connection indicates poor crimping electrical connection

Voltage range 207V to 253V

a) Check electrical safety frequently.b) Use 1mm 2 wirec) Voltage range 207V to 253V

a) Always isolate electrical supply beforeundertaking 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.

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

1. Totally Inoperative?

Is supply fuse blown or has circuit breaker tripped?

Is fuse or circuit breaker size correct?

Is line voltage within 10% of nameplate voltage?

Is line voltage high or low?

Is other equipment on the same circuit?

Is other equipment on the same circuit?

2. Not Cooling?

Is line voltage within 10% of nameplate voltage?

Is compressor cold

Is compressor cold, fan motor working and green neon on?

Compressor does not start hums & trips on overload.

Compressor starts but start winding does not switch off.

Compressor running hot.Compressor starts and runs but short cycles on overload protector.

POSSIBLE FAULT

Loose connection or broken wire in supplywiring to unit.

Incorrect size device.

Loose connection or broken wire in supplywiring to unit.

Reduce line voltage.

a)Loose or corroded connection.b)Supply wiring undersized.c)Low line voltage.

Circuit overloaded.

Go to 1. Totally Inoperative

a)Faulty Temp Controller.

a)Overload protector is openb)Improper or loose wiring, no power to compressor.

Yesa) 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.

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).

Yesa) Defective overload protector.b) Excessively high discharge pressurec) Suction gas too hot, low charge refrigerant.

REMEDY

Replace or reconnect wire.

Install correctly sized device.

Replace or reconnect wire.

Install a voltage reducing transformer.

a) Replace or reconnect wire.b) Increase wire size.c) Install a voltage increasing inverter.

1.Remove all other equipment from circuit.2.Install new dedicated circuit.

Go to 1. Totally Inoperative

a) Replace

a) Replace overload protector.b) Replace or reconnect wiring.

Yesa) Check connections. Replace capacitor if necessary.b) Check connections. Replace relay if necessary.c) Replace compressor.d) Replace compressor.

a) Replace and reconnect wiring.b) Relay failing to open.c) Excessively high discharge pressure.d) Replace compressor.e) Replace compressor.

a) Replace overload protector.b) Clean condenser or replace fan motor.c) Repair leak and recharge refrigerant.

No

No

No

High

No

Yes

No

Yes

Yes

Yes

Yes

Yes

Yes

Yes

No

Yes

No

No

No

Yes

No

Low

Fault Finding CRYO 100 WF