THEORY OF OPERATION
The FLASH CHILLER was designed to cool and dispense ice-cold beer.
The water bath holds approximately 22.5 gallons of water. A certain amount of this water will be transformed into ice, approximately 100 pounds. This water reserve and ice bank will act as a reservoir for refrigeration. This reserve is utilized during peak periods when the BTU output of the compressor is not sufficient to meet the demand of the draw.
INSTALLATION
This chapter covers unpacking and inspection, selecting location, installing FLASH
CHILLER and related components, connecting water inlet and electrical requirements.
UNPACKING AND INSPECTION
Upon receiving unit, immediately remove unit from shipping carton and inspect for shipping damage.
NOTE: Before leaving the factory all FLASH CHILLER units were carefully inspected and the carrier has accepted and signed for them. Any damage or irregularities should be noted at the time of delivery and immediately reported to delivering carrier. Request a written inspection report from claims inspector to substantiate any necessary claim. File claim with delivering agency, not International Carbonic Inc.!
SELECTING LOCATION
IMPORTANT: Ambient temperature for FLASH CHILLER should not exceed 100 degrees “F”. Operation of FLASH CHILLER in ambient above 100 degrees “F” can and will contribute to early failure of condensing unit and poor quality of finished product.
LOCATION RECOMMENDATIONS FOR FLASH CHILLER
1. Position unit as close as possible to proper electrical source.
2. Position unit with a minimum of 2” space between bulkhead and cabinet for sufficient ventilation. Allow enough space between ceiling and unit for lid removal.
3. Position unit as close as possible to proper drainage.
4. Place FLASH CHILLER in position. Make sure sufficient space between bulkheads, walls and overheads is available for proper air circulation around cooling unit.
INSTALL DRAIN LINE
1. Connect drain lines on FLASH CHILLER unit with drain using 3/4” I.D. clear plastic pipe or 3/4” PVC to nearest outlet.
2. Do not reduce drain connection from cabinet outlet.
3. Be sure all connections are watertight.
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ELECTRICAL REQUIREMENTS:
The FLASH CHILLER requires a 120 VAC, single phase at 60 Hertz or 230 VAC, single phase at 50-hertz power circuit, and must be wired in accordance with N.E.C. or local ordinance.
NOTE: Check CHAPTER I for running amperage and connect to appropriate electrical circuit.
PREPARATION
All previous steps should be understood and carried out before proceeding.
PREPARING SYSTEM FOR OPERATION
PREPARING AND STARTING REFRIGERATION UNIT
1. FLASH CHILLER refrigeration is pre-set at factory and ready to operate.
2. Remove lid.
3. Fill water bath with clean water until water runs out of drain standpipe, (S-428).
4. Plug FLASH CHILLER power cord into electrical receptacle box. Two things will happen immediately. One, the agitator will come on and the compressor protector yellow light will come on. The yellow compressor protector light will come on only if proper voltage is supplied to the FLASH CHILLER. In approximately 3 minutes the green light will illuminate and the yellow light will de-energize. At this time make sure compressor and condenser fan motor. The process of cooling the water bath will now commence.
With ambient and water temperature of 75 degree “F” initial pull down or formation of complete ice bank will take approximately 7 hrs. When full ice bank has been formed, compressor and condenser fan motor will stop. Agitator will continue to operate, circulating water in water bath.
CHECKING WATER BATH
Periodically check water level in water bath. If it is low more water should be added as instructed for maximum product cooling. This dehydration will normally not occur in normal temperate climate zones. With normal humidity the opposite will occur therefore a condensate drain is installed. Any extra water in the water bath will exit the unit via the drain outlet. When unit is building it's first ice bank it is normal to have water overflow the into the overflow standpipe and out drain hose.
PERIODIC CLEANING
Periodically wash all external surfaces of FLASH CHILLER cabinet, rinse with clean water, and then wipe dry with a clean soft cloth. DO NOT USE ABRASIVE TYPE
CLEANERS.
CLEANING CONDENSER COIL
IMPORTANT: Air circulation through the condenser coil is required to cool the compressor. Air is drawn in through grills on the front of the FLASH CHILLER, through condenser coil and exhausted out vents and sides of FLASH CHILLER. Restricting air circulation through the FLASH CHILLER will decrease its cooling capacity.
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NOTE: Cleaning condenser coil should be done during non-use periods.
1. Unplug refrigeration unit power cord from electrical socket.
3. Vacuum or use a soft brush to clean fins of condenser coil. Use low-pressure compressed air or C02 gas to blow through condenser fins. This should only be performed after normal business hours to prevent dust contamination. A damp cloth on backside of condenser coil will prevent some dust contamination
4. Replace service panels.
S. Plug FLASH CHILLER power cord in electrical socket.
CHECKING / CHANGING WATER BATH
Periodically check water level in water bath. If it is low, more water should be added for maximum product cooling. Before adding more water, water bath and ice bank should be checked for excessive mineral deposit build up.
NOTE: The water in water bath should be changed and all components in water bath should be cleaned as often as necessary to keep it clean. A convenient time to perform this operation is when the system is being sanitized.
1. Unplug refrigeration unit power cord from electrical socket.
2. Remove lid from unit.
3. Look down into water bath (if necessary, use flashlight) and inspect water bath, ice bank and all components for cleanliness. Water, ice bank and all components should be clear and free of foreign particles. If ice bank is clear of foreign particles, it does not have to be melted down. Proceed to step 10 if foreign particles are present in the ice bank, proceed to step 4.
4. Siphon out water with short hose or pull out over flow standpipe.
5. Allow ice bank to melt. Hot water may be used to speed melting.
CAUTION: Never use an ice pick or other sharp instruments to remove ice from evaporator coil. Such practice can result in puncture to the refrigeration circuit.
6. Use fiber brush and carefully clean mineral deposit from all components.
7. Wash evaporator coil with a mild soap solution. Copper cleans well with mild solution of citric acid (1 cup of citric acid for 2 gallons of water). Stainless steel cleans well with carbonated water. Then rinse with clean water.
6. Rinse out water bath with clean water until water running out of siphon hose is clean.
9. Insert standpipe in drain hole
10. Fill water bath to top of standpipe.
11. Replace lid.
12. Plug refrigeration unit power cord in electrical socket.
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SANITIZING PROCEDURES
Your local health department rules and general area cleanliness should determine the frequency at which the unit should be sanitized.
EQUIPMENT REQUIRED:
1. Stainless Steel containers (product tanks), or large volume container.
2. CO2 Supply if applicable (Same as used with dispensing unit).
3. Cleaning Agent.
4. Sanitizing Solution.
5. Phenolphthalein.
NOTE: One recommended cleaning agent and sanitizing agent is manufactured by:
MT. HOOD CHEMICAL CORP.
4444 N.W. Yeon Avenue
Portland, Oregon 97210
Trade names are: STAR - CHLORINATED CLEANER
CROWN - 12.5% SODIUM HYPOCHLORITE BLEACH
Use STAR at 18 oz. per 1 gallon of water yields 2% Sodium Hydroxide Solution.
Use Crown at 2 ounce per 9 gallons of water (gives 200 PPM of available chlorine) at a minimum contact time of 10 minutes.
1. Disconnect syrup containers and remove product from tubing by purging with carbon dioxide or flushing with warm water.
2. Visually inspect valve by removing nozzle and inspecting nozzle and valve cavity. Clean nozzle with cleaning agent, then sanitizing solution, then with potable water. Inspect valve cavity and if dirty clean with soft bristle brush. Clean exteriors of valve with a soft clothe and warm water. Replace valve nozzle then go to step #3.
3. Fill syrup lines with a caustic-based (low sudsing, non-perfumed, and rinsed) detergent solution,
(STAR). The solution should be prepared in accordance with the manufacturers recommendations, but should be at least 2 percent sodium hydroxide. Make sure the syrup lines are completely filled and allow standing for at least 10 minutes.
4. Flush the detergent solution from the syrup lines with clean water. Continue rinsing until testing with phenolphthalein shows that the rinse water is free of residual detergent.
5. Fill the syrup lines with a low PH (7.0) chloride solution containing maximum 200-PPM chlorine.
Make sure that lines are completely filled and allow standing for 30 minutes.
6. Reconnect syrup containers and ready Unit for operation.
7. Draw drinks to refill syrup lines and flush the chloride solution from the dispenser.
8. Taste the beverage to verify that there is no off taste.
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