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Glykool 130
Water Cooled & Integral Remote Cooler
INSTALLATION MANUAL
DO NOT REMOVE FROM COOLER
SERIAL NUMBER
WDE INS 110 ISSUE 3
APPROVED BY B Tam
DATED July 2006
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CONTENTS
a) Installation Guide
b) Installation Instructions
c) Capacity Guide
d) Fault Diagnostics Charts
e) Technical Specification
f) Spare Parts Identification Sheets
g) System Schematics
h) Heat Dump Installation Instructions
3
Glykool 130 Service Programme
The new 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 products; this is best
achieved by the use of sub-zero glycol.
The Glykool coolers use well-known and well-proven mechanical refrigeration
technology but also encompass 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 thermostatic expansion
valve that allows the system to react to changes in required capacity under a
wider range of operating parameters
This cooler underwent a number of thorough quality checks before leaving the
factory to ensure the minimum number of faults occur during the life. However,
to ensure this cooler can meet the demands it has been designed for it must be
installed and maintained in accordance with the manufactures guidelines.
These can be found later in this booklet, which must remain with the unit at all
times.
INSTALLATION
On installation, a number of important rules must be observed to be sure the
cooler operates correctly. These will be found under the heading
(INSTALLATION GUIDE), which covers both water-cooled and integral
models.
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Glykool130
a) INSTALLATION GUIDE
INTEGRAL UNITS
1. Ensure the cooler is installed in a well-ventilated location with no obstructions to the
condenser or 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, (i.e. below 0°C)
or are in excess of 32°C.
2. Ensure the unit is installed on a level surface and is filled to the overflow, with cold
water/glycol below 24°C. Glycol/Water mixture should be 50%.
3. Dose water tank with Kleencare SP920 in accordance with instructions supplied with the
Kleencare kit, and taking note of heath & safety sheets.
4. Ensure all tubing connections to the product coils and re-circulation pump are well
insulated with Armaflex type insulation to prevent condensation.
5. Ensure that the python run is not excessive, and is routed away from external heat
sources. Maximum lift is 10m, Maximum run 50m.
WATER COOLED UNITS
1. 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, (i.e. below 0°C) or are in
excess of 32°C.
2. Ensure the unit is installed on a level surface and is filled to the overflow, with cold
water/glycol below 24°C. Glycol/Water mixture should be 50%.
3. Ensure that the header tank is filled to its maximum level with the correct ratio of
water/glycol coolant mix (30%) to prevent freezing of the tubes connecting the heat dump
to the base unit, which can be exposed to sub zero temperatures. (See Glycol
Requirement Chart).
4. 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.
5. 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 coolant is freely
returning into the header tank. Top up the header tank to maximum level after priming.
6. The header tank level must be regularly checked and maintained with the correct ratio of
water glycol mix (30%)
7. Ensure all tubing connections to the product coils and re-circulation pump are well
insulated with Armaflex
8. Ensure that the python run is not excessive, and is routed away from external heat
sources. Maximum lift is 10m, Maximum run 50m.
9. All water cooled units are fitting with a auto reset thermal switch to protect the compressor
should the glycol level drop, the heat dump become blocked, or the glycol pump fail.
Note:
The electronic control is fitted with a delay on power up.
The delay allows the control to self-check.
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HEAT DUMP - GENERAL GUIDELINES
1. 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.
2. Ensure the unit is sited on an outside wall (preferably non-south facing) in the correct
orientation out of direct sunlight.
3. 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.
4. 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.
5. Do not exceed the recommended distance and lift from the base unit to the heat dump of
10M Lift / 50M Run.
6. 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.
7. 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.
8. Do not kink the flow and return tubes, which would restrict the coolant flow.
9. Do not insulate the flow and return lines.
10. The flow and return lines must not be strapped together, as heat transfer between the two
will affect the system performance.
11. 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).
12. 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 refer to installation instructions in section h
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b) INSTALLATION INSTRUCTIONS.
NOTE: The unit should be installed and serviced by a suitably trained person.
NOTE: Sealed plugs may be fitted to new units.
Installation Procedure
Unpack the unit from its transportation packing and visually check for any signs of damage.
Site the unit in a convenient location in the cellar or room where it is to be sited and make sure
that a Mains Electricity Supply is within 2 metres and in an area allowing free circulation of air.
The unit should be fitted with a correctly fused and wired 13 amp plug fitted with a 13 amp fuse
or alternatively a standard Euro Plug to IEC83: 1975. Please refer to installation guide for
further information.
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 refer to installation guide for further information.
Ways the Equipment should not be used
This unit is intended for use as a Cooling unit to cool Beers, Lagers and Ciders and glycol to
the correct temperature. It is designed to be installed in the system between the bulk storage
facility and the Dispense Head with the product(s) passing through the cooling coils(s) where
fitted of the unit.
There are NO other recommended uses for this Equipment.
Correct Safe Handling
The weight of this unit 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” utilising two people, a
Mechanical Lifting Device should be used.
Unit Weight
Shipping 75 kg
Operation 125 kg
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:
a) 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.
b) 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.
c) 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 positions.
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Dismantling / Decommissioning Procedure
Isolate the unit from Mains Water Supply.
Isolate Product Supply from unit where connected
Isolate unit from coolant lines.
Drain glycol mixture into suitable containers.
Siphon or pump out water/glycol from 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.
Adjustment / Maintenance Requirements
It is not recommended that the End User makes any adjustments or carries out any
Maintenance other than:
a) Check the mains lead and plug Visually for condition.
b) Check the unit and its Pipework for evidence of leaks visually.
c) Check that the condenser grill and vents are not choked or obscured.
NOTE: THERE ARE NO USER SERVICEABLE PARTS
Methods of Cleaning
NOTE: Persons performing Cleansing /Sanitizing operations MUST be competent and
fully trained in safe methods of use of Cleansing / Sanitizing Agents and their applications.
NOTE: PERSONAL PROTECTIVE EQUIPMENT SHOULD ALWAYS BE USED.
NOTE: DO NOT USE A WATER OR STEAM HOSE TO CLEAN THE UNIT
WHILST STILL INSTALLED.
NOTE: IT IS IMPORTANT THAT ALL THE VENTS AND GRILLS ARE KEPT
CLEAR (inc.: Condenser grills where applicable)
Weekly: By End User
a) Isolate unit from Mains Electricity Supply.
b) Clean sanitize the units cooling coils and product lines using Proprietary Cleanser /
Sanitiser of the Alkaline Hypochlorite type in accordance with the Manufacturers
recommendations.
Line clean procedure
Warning: Due to the sub-zero temperature of the glycol/water mixture within the water
bath if the following line clean procedure is not followed the line clean water / solution
will freeze in the beer lines and python.
1. 1 to 2 hours before line clean is due to start switch the line clean switch located on the
front of the cooler to the ON position.
2. After 1 to 2 hours line clean may commence.
3. After the full line clean procedure has been completed and beer has been pulled
through from the storage area to the dispense tap the line clean switch should be
switched to OFF position.
4. 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 EFFECT THE OPERATION OF THE UNIT.
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Annually: By a Competent Service / Maintenance Engineer.
a) Isolate unit from Mains Electricity Supply.
b) Remove any extraneous debris from the unit or its casing preferably using a vacuum
cleaner or brush.
c) 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.
a) Switch off the socket that the plug is installed into.
b) Remove the plug from the socket.
WARNING: If the mains lead fitted to this equipment is damaged in any way it should
be replaced. A fully trained engineer must only undertake this change.
Action if product freezing occurs
In the event of a product freeze up it is recommended that the line clean switch be used in the
following way. A product freeze up will only happen if the line clean procedure is not followed.
1. Should a freeze up occur switch the line clean, switch to the ON position
2. Allow the unit to run in line clean made for 1 hour
3. After 1 hour check to see if the lines are still frozen by opening the dispense tap.
4. If flow from the tap is observed the line clean switch should be moved to the OFF position
5. If no flow is observed from the tap the unit should remain in line clean mode for a further 1hr
6. After the second hour has passed repeat points 3 onwards.
Prevention of Freezing / Action required if Freezing occurs
It is recommended that the unit is sited in such a way as not to expose it to temperatures likely
to cause freezing i.e. below 0°C. If the Unit were to be sited in an unheated area then it would
be wise to insulate all Pipe work and provide some form of Emergency Heating, which should
be controlled by a Frost Stat. and sited in the close proximity to the Unit.
In the event of Freezing Up occurring the following action is recommended: -
Isolate the unit from Mains Electricity Supply.
Isolate Product Supply from unit.
Apply gentle warmth to the general area of the unit and its Pipework.
Check for obvious leaks.
Turn water supply on 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 or any other
form of malfunction, if no problems are observed then normal operation of the unit may be
resumed.
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Max. / Min. Ambient Temperatures
Minimum 5°C
Maximum 32 °C
WARNING: THIS EQUIPMENT CAN CONTRIBUTE TO THE AMBIENT
TEMPERATURE.
WARNING: THIS UNIT IS UNSUITABLE FOR USE BY UNSUPERVISED
CHILDREN, AGED OR INFIRM PERSONS.
Electronic control
Ways the control should not be used:
The electronic control is intended to be used to control the temperature within the water/glycol
bath.
There are no other recommended uses for this electronic control.
Adjustment / Maintenance requirements.
It is not recommended that the end user makes any adjustment to the electronic control as this
may change the function / operation of the control.
NOTE: The electronic control has no serviceable parts and requires no maintenance.
Electronic control delayed start.
The control is fitted with a delayed start therefore the compressor will not start as soon as the
unit is turned on. The compressor will then start within 4 minutes.
Thermal cut-out (water cooled units only)
The unit is fitted with a thermal cut-out. The function of which is to 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 line increases to above
65ºC the compressor will not cut back in until the temperature of this line falls.
Additional Notes to the Engineer
An additional test point has been fitted to the top of the rear panel of the unit to provide a
connection for P.A.T testing of the units on site. The tank drain now exits the unit via a ½” 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
disk (Red disk for Flow to the Heat Dump).
Decommissioning of the Glycol lines should be undertaken before Decommissioning of the 24
Volt electrical socket in order to prevent the ingress of Glycol / Water into the electrical socket.
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Elreha Electronic Control
Electronic control setting procedure.
This unit has been supplied with an electronic control thermostat
The electronic control thermostat will be of the ELREHA type and is preset at a cutout
temperature of –2°C.
If a lower temperature setting is required, adjustment of the electronic thermostat is as follows:
ELREHA
With the unit switched on, press button “P” the screen will show P01, using the up arrow key
press in single operations until P09 shows on the screen.
Press button “P” to display the preset code (00) scroll up, using the arrow key, until 21 shows
on the display of the control.
Press button “P” to enter programming mode. Scroll back, using the arrow key, to PO2. Press
button “P” (pre-set temperature will be shown), using the up or down arrows, adjust the display
figure to the required temperature.
Press “P” and either wait for approximately 1 minute for the display to revert back to showing
temperature or switch the supply to the unit off/on.
NOTE:
The control is factory set any adjustments should only be undertaken by a fully trained
engineer. Adjustments to the operating parameters of the control will effect the operation of the
unit.
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c) CAPACITY GUIDE
Glycol Requirement For Glykool water cooled heat dump Installation
30% Glycol/70% Clean Water Mix (System Protection Down To -20°C)
Pipe work Length
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
Note: Add 2.5 pints (1.4 litres) for glycol tank
The information given above is based on the use of the
correctly specified tube with an internal bore of 10mm.
Length is given as total run and includes return.
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FAULT DIAGNOSIS FLOW CHART No.1
COMPRESSOR
Is the unit in a
high ambient
temp (+40°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
ensure 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
15
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
Pump 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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e) TECHNICAL SPECIFICATION
Glykool 130 Water Cooled & Integral Remote Coolers
Unit Type
Product Code
Glykool 130 Water
Cooled Remote Cooler
Glykool 130 Integral
Remote Cooler
Compressor
Cubic Capacity
Refrigeration Capacity
Starting Current
Run Current
Totally Sealed Hermetic
34cc
1128 Watts per/hr @ -10°C
32 Amps
7.6 Amps
6.8 Amps
Water Pump
Lift
Flow Rate
Motor Output
IP Rating
Motor Speed
Electrical Connection
Water Connection
Totton 3 Stage Top Mounted
16 metres
13 Litres Per Minute
80 Watts
IP 52
1475 RPM
Euro Plug/Socket (Dura Plug in lead)
15mm Plain Tails for John Guest
Glycol Pump (Water Cooled)
Drive
Motor Output
Motor Speed
IP Rating
Lift
Flow Rate
Totton 2 Stage Base Mounted
Magnetically Coupled
80 Watts
1475 RPM
IP 52
12 metres
13 Litres Per Minute
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 Watts
1400 RPM
IP 22
Fan
Diameter
Material
Rotation
10” (250mm)
Aluminium
Counter Clockwise (back to front)
Water Bath
Material
Insulation
Capacity
ABS
CFC free PU foam ES65 low density
60 litres
Glycol Tank (Water Cooled)
Material
Capacity
Medium density polyethylene (Natural)
9 Pints (See Glycol Requirement Chart)
Heat Exchanger (Water Cooled)
Type
Material
Brazed Joints
20 Plate
Stainless Steel
99% Copper
17
Unit Type
Product Code
Glykool 130 Water
Cooled Remote Cooler
Glykool 130 Integral
Remote Cooler
Overall Dimensions
Height
Depth
Width
950mm
660mm
540mm
Weight
Lid
Base
Heat Dump
Total Shipping Weight
Total Operating Weight
13kgs
52kgs
8.6kgs
75kgs
125kgs
Power Requirements
Mains Supply
Protection
Power Consumption
Fuse Requirements
Transformer (Water Cooled only)
Input Voltage
Output Voltage
VA Rating
Primary Fusing
Secondary Fusing
220v – 240v 50Hz
Must be installed using RCD
1543 Watts
13 Amps
220v – 240v AC
24 V AC
90 VA
1 Amp ( F1AMP)
6.25 Amp (T 6.3 AMP)
1100 Watts
Product Coils
Length options
Diameter
Material
No. Off 3.5m
No Off 12m
3.5 metre up to 12 metre
3/8” OD (10mm)
316 Grade
10 Max.
8 Max
Refrigerant
Type
Amount
R134a (HFC)
875grams
R134a (HFC)
800 grams
Heat Dump (Water Cooled)
Fan Motor
Fan Blade
Cover
Water Connections
Weight
Height
Depth
Width
Flat Roof Mounting Bracket
10 Watt 24v AC
10” x 31° Pitch
ABS
15mm Copper tube for John Guest fittings
8.6kgs
360mm
310mm
600mm
Option for floor standing operation
Expansion Valve
Type
Orifice
Ten 2
01
Liquid Receiver
Capacity
Pressure Rating
700 grams
20 bar
Kleencare Kit
3 x 50ml Bottles
Application Label
One kit supplied with each unit
Electronic Control Specification
Dimensions H x W x D
Voltage
Switch Capacity
Peak switching capacity
Power consumption
Protection class
Probe accuracy
35mm x 76mm x 56mm
220/240 volts 50-60 HZ
14Amps
30Amps for 4 seconds
0.2VA
IP54 from front
+/- .05ºc @Temperature range –1ºc to –18ºc
18
f) Spare parts identification sheet
CM46450
34cc Compressor
MO46690
Condenser fan motor 240
Volt
OP71381
Fan blade 10” sucker
PI42413
Expansion Valve
19
Spare parts identification sheet
PI42589
Thermal protection switch
PU42641
SPC4
3 Lid mounted water
pump
PU72046-01
Base mounted
glycol/water pump
MO46688
Heat Dump fan motor 24
Volt
20
Spare parts identification sheet
PI42544
90 VA Transformer
PI51518
Electronic Control
PU73983
RG 500 Pump
/
