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Glykool 130+
Water Cooled Remote Cooler
INSTALLATION MANUAL
DO NOT REMOVE FROM COOLER
SERIAL NUMBER
PI52966/ WDS INS 111 ISSUE 1
APPROVED BY B Tam
DATED August 2006
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Contents
Page
Glykool 130+ Service Programme 3
Glykool 130+ Installation Guide 4
Heat Dump General Guidelines 5
Glykool 130+ Installation Instructions 6
Glykool 130+ Dismantling / Decommissioning Procedure 7
Adjustment & Maintenance Requirements 8
Methods of Cleaning 8
Portable Appliance Testing (PAT) 9
Thermal Cut-Out 9
Prevention of Freezing 10
Electronic Control 11
Glycol Concentrations 13
Fault Diagnosis 14
Technical Specification 18
Spare Parts Identification 20
System Schematics 22
Heat Dump Installation Instructions 24
Heat Dump Dismantling / Decommissioning Procedure 26
Methods of Cleaning the Heat Dump 28
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Glykool 130+ Service Programme
The Glykool range of glycol coolers have been designed to be reliable and
simple to operate. The coolers have been designed to offer a technical
solution to the growing demand for colder and colder dispensed product; this
is best achieved by the use of sub-zero glycol.
The Glykool cooler use well-known and well-proven mechanical refrigeration
technology, but also encompasses a number of technical changes, which will
enhance both the performance and reliability of this system.
Refrigerant flow around the system is controlled via a capillary tube that
optimises the capacity of the unit under certain operating parameters.
This cooler underwent a number of through quality checks before leaving the
factory to ensure the minimum number of faults occur during its life. However,
to ensure that this cooler can meet the demands it has been designed for, it
must be installed and maintained in accordance with the manufacturers
guidelines. This information can be found later in this booklet, which must
remain with the unit at all times.
- 4 -
Glykool 130+ Installation Guide
On installation, a number of important rules must be observed to be sure the
cooler operates correctly.
• Ensure the cooler base is installed in a well-ventilated location with no
obstructions to the side and rear panel ventilation slots. The unit must
not be installed in an area where it will be exposed to temperatures that
are likely to cause freezing (below 0°C) in excess of 32°C
• Ensure the unit is installed on a level surface and is filled to the
overflow, with a 50% glycol/cold water mix below 24°C.
• Dose the water tank with Kleencare SP920 in accordance with
instructions supplied with the Kleencare kit, taking note of the health
and safety data sheets provided.
• Ensure the header tank is filled to the maximum level with a 30%
glycol/cold water mix to prevent freezing of the tubes connecting the
heat dump to the base unit, which may be exposed to sub-zero
temperatures (See Glycol Requirement Chart)
• Before switching on the unit, turn the line clean switch to the ‘off’
position to enable the glycol lines to be fully primed. Once this is
complete, turn the switch to the ‘on’ position.
• Ensure that the coolant re-circulation pump and tubing connecting the
heat dump are primed with coolant, that there are no air locks or
restrictions and that the coolant is freely returning to the header tank.
Top up the header tank to the maximum level after priming.
• The header tank level must be regularly checked and maintained with
the correct ratio of 30% glycol/water mix.
• Ensure that all the tubing connections to the product coils and
recirculation pump are well insulated with Armaflex.
• Ensure that the python run is not excessive and is routed away from
external heat sources. Maximum lift is 10 m. Maximum run is 50 m.
Notes:
All water cooled units are fitted with an auto reset thermal switch to protect the
compressor should the glycol level drop, the heat dump become blocked or
the glycol pump fail.
The electronic control is fitted with a delay on the power up. The delay allows
for the control to self-check
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Heat Dump General Guidelines
• It is important that the heat dump is sited correctly to enable it to work
efficiently. The guidelines below should be adhered to wherever
possible.
• Ensure the unit is sited on an outside wall (preferably non-south facing)
in the correct orientation out of direct sunlight.
• Ensure there are no other heat sources, i.e. a condensing unit or
another heat dump, in the immediate vicinity, where hot air may be re-
circulating.
• Use the recommended tubing (15mm O/D, 10mm I/D Special EVA) to
connect the base unit to the heat dump. Do not use PVC braided tube,
as this is not compatible with glycol and will degrade over a period of
time.
• Do not exceed the recommended distance and lift from the base unit to
the heat dump of 10 m lift / 50 m run.
• The heat dump must be connected using a minimum of 1.5mm two
core cable. If a smaller cable is used, a voltage drop will occur which
may cause the fan motor to run at a reduced speed.
• If the unit is to be installed inside a building or room, ensure that there
is adequate ventilation within the room to enable the heat to be
dissipated effectively. Temperatures within the room should not exceed
32°C.
• Do not kink the flow and return tubes, which would restrict the coolant
flow.
• Do not insulate the flow and return lines.
• The flow and return lines must not be strapped together, as heat
transfer between the two will affect the system performance.
• Ensure that the heat exchanger matrix of the heat dump is kept clean
and free from obstructions. It is recommended that it should be cleaned
with a soft brush at regular intervals (see maintenance schedule).
• To enable the heat dump to be mounted on a flat surface, a floor
standing mounting kit is available as an option. (Order part number 09-
0203-01)
For details on use and mounting of the heat dump, refer to installation
instructions on page 24.
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Glykool 130+ Installation Instructions
This unit should be installed and serviced by a suitably trained person.
Sealed plugs may be fitted to new units.
Installation Procedure
• Unpack the unit from its transportation packaging and visually inspect
for any signs of the damage.
• Site the unit in a convenient location in the cellar or room and ensure
that the mains electricity supply is within 2 m and in an area allowing
free circulation of air.
• The unit should be fitted with a correctly fused and wired 13 amp plug
or alternatively to a standard Euro plug to IEC83: 1975.
• Site the heat dump in a convenient location, preferably in a non-heat
sensitive and shaded area on the outside of the building. If it cannot be
installed outside, ensure that the area is well ventilated and free from
other heat sources. Please check the Heat Dump General Guidelines
on page 5 for further details.
WARNING: THIS EQUIPMENT MUST BE EARTHED
The Wires in this Mains Lead are Coloured in accordance with the following
Code:
Green and Yellow Earth
Blue Neutral
Brown Live
As the Colours of the Wires in the Mains Lead of this Appliance may not
correspond with the Coloured Markings identifying the Terminals in the Plug to
be fitted proceed as follows:
• The Wire which is coloured Green and Yellow MUST be connected to
the terminal in the Plug that is marked with the letter‚ E™ or by the
earth symbol, coloured Green or Green and Yellow.
• The Wire which is coloured Blue MUST be connected to the Terminal
in the Plug that is marked with the letter‚ N™ or coloured Black.
• The Wire which is coloured Brown MUST be connected to the Terminal
in the Plug that is marked with the letter‚ L™ or coloured Red.
The mains plug must be located in an accessible position.
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Ways the Glykool 130+ should NOT be used
This unit is intended for use as a cooling unit to cool beers, largers and ciders
and glycol to the correct temperature. It is designed to be installed in the
system between the bulk storage facilities and the dispense head with the
product(s) passing through the cooling coil(s) where fitted in the unit.
There are NO other recommended uses for the equipment
Correct Safe Handling
The weight of the units is such that other than moving it across flat ground
(which is facilitated by integral castors/wheels) or lifting to a relatively safe
height of 12 inches (30 cm) utilising two people, a mechanical lifting device
should be used.
Unit Weight
Shipping Weight: 75 kg
Operational Weight: 125 kg
WARNING: THIS UNIT IS UNSUITABLE FOR USE BY UNSUPERVISED
CHILDREN, THE ELDERLY AND THE INFIRM
Dismantling / Decommissioning Procedure
• Isolate the unit from the mains electricity supply.
• Isolate the product supply from where the unit is connected.
• Isolate the unit from the coolant lines.
• Drain the glycol mixture in the header tank into suitable containers.
• Siphon or pump out the water mixture from the bath
WARNING: FAILURE TO REMOVE ALL WATER/GLYCOL COULD
RESULT IN SUBSTANTIAL AMOUNTS OF WATER/GLYCOL BEING
RELEASED FROM THE UNIT WHICH MAY BE DETRIMENTAL TO THE
UNIT AND/OR ITS SURROUNDINGS AND INCREASE THE MAXIMUM
WEIGHT OF THE UNIT.
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Adjustment & Maintenance Requirements
It is not recommended that the End User makes any adjustments or carries
out any maintenance other than:
• Visual checks on the mains leads and the plug for their condition
• Visual checks of the unit and piper work for evidence of leaks
• Visual checks of the condenser grills and vents that they are not
choked or obscured.
Note: There are no user serviceable parts
Methods of Cleaning
• Persons performing cleansing and sanitising operations MUST be
competent and fully trained in safe methods of use of cleansing and
sanitising agents and applications.
• Personal protective equipment should always be used.
• DO NOT use a water or steam hose to clean the unit whilst still
installed.
• It is important that all vents and grills are kept clear (including
condenser grills where applicable).
Weekly Line Clean Procedure: By the End User
WARNING: IF THE LINE CLEAN PROCEDURE IS NOT FOLLOWED, THE
SUB-ZERO TEMPERATURE OF THE GLYCOL MIXTURE IN THE BATH
WILL FREEZE THE CLEANSING SOLUTION IN THE BEER LINES AND
PYTHON.
• Isolate unit from mains electricity supply.
• Clean and sanitise the unit’s cooling coils and product lines using
proprietary cleanser/sanitizer of Alkaline Hypochlorite type in
accordance to the manufacturer’s recommendations
• Start the line clean switch located on the front of the cooler to the ON
position and leave for 1 to 2 hours before commencing the line clean.
• After the line clean procedure has been completed and the beer has
been pulled through from the storage area to the dispense tap, the line
clean switch should be switched to the OFF position.
• The unit should be allowed to pull down to its normal operating
temperature before normal operation is resumed.
The middle position on the line clean switch should not be used, as this will
affect the operation of the unit.
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Annual Cleaning: By a competent Service/Maintenance Engineer
• Isolate unit from mains electricity supply.
• Remove any extraneous debris from the unit or it’s casing, preferably
with a vacuum cleaner or brush.
• Check unit for electrical safety.
Power Isolation Method
The unit is fitted with a single phase, 3 pin, 13 amp plug, fitted with a 13 amp
fuse or alternatively a standard Euro Plug to IEC83: 1975
• Switch off unit at the socket the plug is installed into
• Remove the plug from the socket
WARNING: IF THE MAINS LEAD FITTED TO THIS EQUIPMENT IS
DAMAGED IN ANY WAY, IT SHOULD BE REPLACED. ONLY A FULLY
TRAINED ENGINEER MUST UNDERTAKE THIS CHANGE.
Portable Appliance Testing (PAT)
An additional test point has been fitted to the top of the rear panel of the unit
to provide a connection for PAT testing of the units on site. The tank drain
exits the unit via a 1/2 “ bulk head situated on the lower part of the left hand
panel. The shut-off valve can be accessed by removing the front lower grill.
Glycol flow and return connections are indicated by a coloured disc (red disc
for flow to the heat dump and blue for return from the heat dump).
Decommissioning of the glycol lines should be undertaken before
decommissioning of the 24V electrical socket in order to prevent the ingress of
glycol/water into the electrical socket.
Thermal Cut-Out
The unit is fitted with a thermal cut-out which will protect the refrigeration
system in the unlikely event of a fault in the glycol /heat dump system. The
thermal cut-out will isolate the power supply to the compressor if the heat of
the discharge lines increases above 65°C. The compressor will not cut back
in until the temperature in this line falls to below this temperature.
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Prevention of Freezing
Unit Freezing
It is recommended that the unit be sited in such a way as not to expose it to
temperatures likely to cause freezing. If the unit is to be sited in an unheated
area, it would be wise to the insulate all the pipe work and provide some form
of emergency heating, which should be controlled by a frost-stat and sited in
close proximity to the unit.
In the event of freezing up occurring, the following action is recommended:
• Isolate unit form the mains electricity supply
• Isolated product supply from unit
• Apply gentle warmth to the general area of the unit and its pipe work
• Check for obvious leaks
• Turn on water supply whilst continually watching for leaks
• Reconnect product supply
• Reconnect mains electricity supply
• Observe unit running for a short period watching out for leaks, strange
noises and the any other form of malfunction
• If no problems are observed, then normal operation of the unit may be
resumed.
Product Freezing
A product freeze up will only occur if the line clean procedure is not followed.
In the event of a product freeze up, the following procedure should be
followed:
• Switch the line clean to the ON position.
• Allow the unit to run in ‘line clean’ mode for one hour.
• Check to see if the lines are still frozen by opening the dispense tap.
• If no flow is observed from the dispense tap, the unit should remain in
‘line clean’ mode for another hour before checking the dispense tap
again for flow.
• When flow is observed from the dispense tap, switch the line clean to
the OFF position.
Operational Temperature Range
Minimum Temperature: 5°C
Maximum Temperature: 32°C
This unit may contribute to the ambient temperature
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Electronic Control
The electronic control is intended to the used to control the temperature within
the water/glycol bath. There are no other recommended uses for this
electronic control. The control is fitted with a delayed start and the
compressor will start within 4 minutes of the unit being turned on.
Adjustment & Maintenance Requirements
The electronic control has no serviceable parts and requires no maintenance.
It is not recommended that the end user make any adjustments to the
electronic control as this may change the function /operation of the control.
Electronic Control Setting Procedure
This unit has been supplied with an electronic control thermostat. The
electronic control is of the ELREHA type and is preset to cut-out at a
temperature of –2°C. The control is factory set and a fully trained engineer
should only undertake any adjustments. If a lower temperature setting is
required adjustment of the electronic thermostat is as follows:
• With the unit switched on, press button ‘P’ and the display will show
‘P01’
• Using the ‘UP’ arrow key, press in single operations until ‘P09’ is
displayed
• Press button ‘P’ to display the preset code ‘00’ and scroll using the
arrow keys until ’21’ is displayed
• Press button ‘P’ to enter the programming mode and then scroll back to
‘P02’ using the arrow keys and press button ‘P’ again
• The preset temperature will now be shown and using the arrow keys,
adjust the display to the required temperature.
• Press button ‘P’ to confirm the temperature and either wait for
approximately 1 minute or turn the unit off/on to revert the display back
to showing the bath temperature
Elreha Electronic Control
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Parameter List for Elreha TARN1179 K004
No. Description Code Default
Setting
Range
P01
Actual sensor temperature in °C
(display only)
- -
-40°C …110°C
P02
Control set point can be changed
at any time within the limits set by
P04 and P05
-
-2.0°C
P04…P05
P03
Switching differential (hysteresis)
of control set point
21 0.2K 0.2K…10K
P04
Highest adjustable set point 21
5.0°C -35°C…100°C
P05
Lowest adjustable set point 21
-10°C -35°C…P04
P06
Sensor Correction 21 0.0K -10.0K…10.0K
P07
Minimum idle time of refrigeration 21 3 min 0…99 min
P08
Minimum run time of refrigeration 21 3 min 0…99 min
P09
Access code - 0 -100…100
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Glycol Concentrations
Food grade mono propylene glycol should only be used with this unit. The
freeze point of glycol depends on the concentration of glycol to clean water
mixture. If insufficient concentrations of glycol are used, the system may
freeze.
Glycol Concentration for Glycol Bath
It is recommended that a 50% glycol / 50% clean water mix is used for the
glycol bath. This will protect a system down to –15°C and below
Glycol Concentration for Heat Dumps
A 30% glycol / 70% clean water mix will protect the system down to –13°C.
The amount of glycol required for the heat dump, Add 2.5 pints (1.4 Litres) for
the glycol tank to the length of pipe work as shown in the following table:
Glycol Quantities for Heat Dump Pipe Work Length (flow and return)*
Feet 10 20 30 40 50 60 70 80 90 10 11 12 13 14 17 19
Pints .5 1.0
1.5
2.0
2.5
3.0
3.5
4.0
4.5
5.0
5.5
6.0
6.5
7.0
7.5
8.0
Metres 3 6 9 12 15 18 21 24 27 30 33 36 39 42 45 48
Litres .3 .6 .9 1.2
1.5
1.8
2.1
2.4
2.7
3.0
3.3
3.6
3.9
4.2
4.5
4.8
*based on the use of the correctly specified tube with an internal bore of
10mm
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FAULT DIAGNOSIS FLOW CHART No.1
COMPRESSOR
Is the unit in a
high ambient
temp (+32°C)?
Has there been
excessive
product draw?
Switch line clean off
Re-site Unit
Leave unit to
recover
Re-route python
and re-site unit
closer to dispense
point
Check for
refrigerant leaks
Is the
compressor
running?
Faulty Compressor
End
Change capacitor
and start relay
Is line clean
switch on?
Yes
Yes
No
Yes
Yes
No
No
Is the python
length excessive
or exposed to high
temperatures?
No
Yes
Yes
No
Is the unit’s bath
temperature at
its set point?
Yes
No
No
No
Is the
compressor
running?
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FAULT DIAGNOSIS FLOW CHART No.2
GLYCOL PUMP (HEAT DUMP)
No
Is header tank
glycol level
between max-
min
marks?
Are the John
Guest shut off
valves open on
the pump?
Plug pump into
connection
Top up to maximum
level and check for
leaks
Go to Diagnostic
Chart No.3
Clear blockage or
restriction and
ensur
e tubing is the
correct type
Open shut off
valves
Internal wiring fault
Faulty pump motor
Is pump plugged
into its mating
connection?
Yes
No
Yes
Check for 240v
supply at
connection
Yes
No
No
Have the glycol
lines collapsed,
been restricted,
blocked or
secured together?
Ensure pipes are
not secured
together and away
from heat sources
Is the glycol
mixture
recirculating?
Faulty Pump
No
No
Yes
Yes
Is the glycol
mixture re-
circulating?
No
No
Yes
Yes
Does the pump
run?
Yes
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FAULT DIAGNOSIS FLOW CHART No.3
HEAT DUMP
Is the radiator
matrix blocked,
restricting air-
flow?
Change transformer
Is the heat dump
connected to
unit?
Check for 24v
supply at heat
dump
Yes
No
Is the heat dump
fan running?
Plug heat dump
connection into
socket
Check outlet
socket on base
unit for 24 volts
Clean radiator
matrix
Replace Fan Motor
Heat dump is sited in full
sunlight or near other
sources of heat without
adequate ventilation
Re-site heat dump
Wiring fault
between base unit
and heat dump
Check if fuses in
transformer have
blown
Replace Fuses
Check for wiring
fault before
restarting unit
Yes
Yes
Yes
Yes
Yes
No
No
No
No
No
- 17 -
FAULT DIAGNOSIS FLOW CHART No.4
LID PUMP
Is there flow
around the
system?
Check pump is
plugged into
socket
Yes
No
Is the lid pump
running?
Reconnect plug
with socket
P
ump is ok and
there is no fault
Replace Motor
Ensure service valves
are open
Change Pump
Yes
Yes,
But
Slow
Yes
No No
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Technical Specification
Unit Type Glykool 130+ Water Cooled Remote Cooler
Compressor
Cubic Capacity
Refrigeration Capacity
Starting Current
Run Current
Totally Sealed Hermetic Compressor
34 cc
1320 W @ -6C
32 A
7.2 A
Water Pump
Lift
Flow Rate
Motor Output
Motor Speed
IP Rating
Electrical Connection
Water Connection
Totten 3 Stage Top Mounted
16 m
13 Litres/min
80 W
1475 rpm
IP 52
Euro Plug/Socket (Dura plug in lead)
15 mm Plain Tails (John Guest)
Glycol Pump
Lift
Flow Rate
Drive
Motor Output
Motor Speed
IP Rating
Totten 2 Stage Base Mounted
12 m
13 Litres/min
Magnetically Coupled
80 W
1475 rpm
IP 52
Switches & indicators
Compressor On
Line Clean Switch
Red neon located on electronic control
Single pole switch with red neon located on
front of unit
Condenser/Compressor Fan Motor
Motor Output
Motor Speed
IP Rating
10 W
1400 rpm
IP 22
Fan
Diameter
Material
Rotation
10” (250 mm)
Aluminium
Counter Clockwise (back to front)
Water Bath
Material
Insulation
Capacity
ABS
CFC free PU foam ES65 low density
60 Litres
Glycol Tank
Material
Capacity
Medium density polyethylene (Natural)
9 Pints (see Glycol Requirement Chart)
Heat Exchanger
Type
Material
Brazed Joints
20 Plate
Stainless Steel
99% Copper
- 19 -
Unit Type Glykool 130+ Water Cooled Remote Cooler
Overall Dimensions
Height
Depth
Width
950 mm
660 mm
540 mm
Weight
Lid
Base
Heat Dump
Total Shipping Weight
Total Operating Weight
13 kg
52 kg
8.6 kg
75 kg
125 kg
Power Requirements
Mains Supply
Protection
Power Consumption
Fuse Requirements
220 V – 240 V 50 Hz
Must be installed with RCD
1597 W
13 A
Transformer
Input Voltage
Output Voltage
VA rating
Primary Fusing
Secondary Fusing
220 V – 240 V 50 Hz
24 V AC
90 VA
1 A (F1Amp)
6.25 A (T6.3Amp)
Product Coils
Length Options
Diameter
Material
No. Off 3.5m (short)
No. Off 8 m (medium)
No Off 12 m (long)
3.5 m up to 12 m
3/8” OD (10 mm)
316 Grade Stainless Steel
12 max
10 max
8 max
Refrigerant
Type
Amount
R134a (HFC)
375 g
Expansion Valve
Type
0.64 mm Capillary
Kleencare Kit
3 x 50ml Bottles
Application Label
One kit supplied with each unit
Electronic Control
Dimensions (HxWxD)
Voltage
Switch Capacity
Peak Switching Capacity
Power Consumption
Protection Class
Probe Accuracy
35 mm x 76 mm x 56 mm
220 V – 240 V 50-60 Hz
14 A
30 A for 4s
0.2 VA
IP 54 from front
+/- 0.05°C (-1°C to –18°C temperature range)
Heat Dump
Dimensions (HxWxD)
Weight
Fan Motor
Fan Blade
Cover
Water Connections
Flat Roof Mounting Bracket
360 mm x 3410 mm x 600 mm
8.6 kg
10 W 24 V AC
10” x 31° Pitch
ABS
15 mm Copper Tube (John Guest)
Option for floor standing operation
- 20 -
Spare Parts Identification Sheet
CM46450
34cc Compressor
MO46690
Condenser fan motor 240 Volt
OP71381
Fan blade 10” sucker
PI42589
Thermal protection switch
PU42641
SPC43 Lid mounted water pump
PU72046-01
Base mounted glycol/water pump
/