Installation Service Manual Sentry III A Glycol Cooling
Contents
1. CLEANING CONDENSER AND AIR REPLENISHING COOLING UNIT GLYCOL TANK Page O NY BWW TABLE OF CONTENTS cont d Page CLEANING COOLING UNIT EXTERIOR 15 LUBRICATION rods toda cnr esce o Per hdd wate 15 CLEANING CO2 GAS CHECK VALVE 16 SERVICE AND MAINTENANCE 17 ADJUSTMENT Stites ade Due ep me CN ot e se een 17 ADJUSTING CO2 REGULATORS 17 ADJUSTING COOLING UNIT GLYCOL COOLANT TEMPERATURE 17 ADJUSTING BEER DISPENSING RATE 19 REPEENISHING CO2 SUPPLY ta x ad MEN nen 19 REPLENISHING BEER 1 20 CLEANING AND SANITIZING 21 CEEANING tee is aer 4 21 SANITIZING 55 cei 2 UR ESPERA Re bine Para ea us 21 COOLING UNIT MAINTENANCE 21 CLEANING CONDENSER AND AIR FILTER 21 CLEANING COOLING UNIT EXTERIOR 22 REPLENISHING COOLING UNIT GLYCOL COOLANT TANK 22 LUBRICATION ae a ha rice Cen 22 CLEANING CO2 GAS CHECK VALVE 23 TROU2. CONNECTING COOLING UNIT GLYCOL LINES TO INSULATED BEER TRUNK LINE etre E ec E Te CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT FILLING COOLING UNIT GLYCOL TANK AND STARTING REFRIGERATION SYSTEM ed INSTALLING DISPENSING STATIONS INSTALLING EQUIPMENT INSIDE WALK IN STARTING PROPYLENE GLYCOL ANTI FREEZE CIRCULATING SYSTEM ACTIVATING BEER SYSTEMS rrr ERR hmm wasa nding rns OPERATOR S INSTRUCTIONS PROPER BEER STORAGE ive eR ERE UR PRA dead a OPERATING CONTROLS b er eet n e Staley mes e edd COOLING UNIT POWER SWITCH GLYCOL CIRCULATING PUMP POWER 5 DAILY PRE OPERATION CHECK rirani aai u errs o ADJUSTMENTS ririri e Rote etin f eh nh yaaa ed wa ADJUSTING CO2 REGULATORS ADJUSTING COOLING UNIT GLYCOL COOLANT TEMPERATURE ADJUSTING BEER DISPENSING RATE ADJ USTING WALK IN COOLER TEMPERATURE REPLENISHING CO2 S UPPLY cui e eene e d REPLENISHING BEER CLEANING AND SANITIZING CLEANING 224422 uie tan SANITIZING 2 mati erit eR ead Rabe bedi COOLING UNIT MAINTENANCE
3. regulator coupling nut then install the regulator on the CO cylinder 6 Open counterclockwise the CO cylinder shutoff valve slightly to allow the lines to slowly fill with gas then open the valve fully to back seat the valve Back seating the valve prevents leakage around the valve shaft 7 Check the connections for leaks Tighten any loose connections COUPLING NUT COMPENSATOR IF APPLICABLE BEER FAUCET FIGURE 5 BEER FAUCET ADJUSTMENT COVER RETAINING SCREW 2 ADJ USTMENT COVER SCREW BEER FAUCET FIGURE 6 BEER DRAFT ARM ADJ USTMENT REPLENISHING BEER SUPPLY 1 Close the and beer line shutoff valves for the empty beer keg 2 Remove the beer keg tapper from the empty beer keg 3 Make sure the tapper and top of the full beer keg is clean then install tapper in the keg 111845000 20 4 Open the and beer line shutoff valves CLEANING AND SANITIZING CLEANING Walk in Cooler The walk in cooler should be cleaned periodically to eliminate a sticky floor and possible unpleasant odors Dispensing Stations The dispensing stations and their drip trays should be cleaned daily DO NOT USE ABRASIVE TYPE CLEANERS SANITIZING The beer systems tappers beer lines and beer faucets internal parts should be completely cleaned and sanitized at least every two weeks using Diversol CX The Diversey Corp or equivalent sanitizer COOLING UNIT MAINTENANCE CLEA
4. Beer flow rate should be approximately 2 ounces per second Adjust beer flow rate as instructed Refer to DISPENSED BEER TEMPERATURE TOO WARM in this section Refrigeration not called for Place Cooling Unit power switch in ON up position Replace fuse or reset circuit breaker Voltage must be atleast 103 volts at compressor terminals when compressor is trying to start Tighten connections or replace broken wiring Trouble COMPRESSOR DOES NOT F OPERATE CONT D COMPRESSOR WILL NOT A STOP AFTER GLYCOL COOLANT HAS REACHED RECOMMENDED 26 F TO 28 TEMPERATURE COMPRESSOR OPERATES A CONTINUOUSLY BUT DOES NOT LOWER GLYCOL COOLANT TO 26 F TO 28 F B Probable Cause Overload protector cut out over heated compressor Condenser fan motor not operating as required Inoperative overload protector or start relay Inoperative glycol tank temperature control Inoperative compressor Glycol tank temperature control inoperative Glycol tank temperature control stuck in closed position Cooling Unit located in excessively hot area Air circulation through air filter and condenser coil restricted Remedy Compressor will cool enough to restart Refer to CONDENSER FAN MOTOR NOT OPERATING in this section Replace inoperative part Replace glycol tank temperature control Replace compressor Replace glycol tank temperature control Replace glycol tank
5. 20 TABLE OF CONTENTS cont d Page LIST OF FIGURES CONT D FIGURE 7 CO2 GAS CHECK VALVE 23 FIGURE 8 WIRING DIAGRAM DROP IN REFRIGERATION ASS Y 24 FIGURE 9 WIRING DIAGRAM LOWER COOLING UNIT CABINET 24 LIST OF TABLES TABLE 1 DESIGN DATA ies rt Ueber ed TABLE 2 LOOSE SHIPPED PARTS SAFETY INFORMATION Recognize Safety Information This is the safety alert symbol When you see this symbol on our machine or in this manual be alert to the potentially of personal injury Follow recommended precautions and safe operating practices Understand Signal Words A signal word DANGER WARNING OR CAUTION is used with the safety alert symbol DANGER identi fies the most serious hazards Safety signs with signal word DANGER or WARNING A WA R N are typically near specific hazards General precautions are listed on CAUTION safety signs CAUTION also calls attention to safety mes A C A UTIO N sages in this manual Follow Safety Instructions Carefully read all safety messages in this manual and on your machine safety signs Keep safety signs in good condition Replace missing or damaged safety signs Learn how to operate the machine and how to use the controls properly Do not let anyone operate the machine without instructions Keep your machine in proper working condition Unauthorized modifications
6. V AHINIS SNHO02 SNLLVINIDUID HOLVINIDIY 202 AYVINIYd de IP aauasWnNNn i O iS x P g YOLVINDAY 00 DIN uaag 1000 N FATVM aauaswnNNn HLON31 NI 1334 08 Q332X3 OL LON Alalvuvdas ANNAL 4338 dalvinsNi 102119 20 uaas GN35313Nr1 la NOL VIS an SNISN3dSIG S S S ANNUAL GALVINSNI OLNI G3L93NNOO HOV3H SINIT 102419 G31VTnSNI 1 02 9NIGIAOHd NOLLV2O H3H LO ANNOYVNYNL YO 431000 NI ATVM OL 1 Q31V201 39 AVN LINN DNITOO 310N d a x 102419 111845000 THIS PAGE LEFT BLANK INTENTIONALLY 111845000 6 INSTALLATION This section covers unpacking and inspection selecting installation location installing the Cooling Unit prepar ing the Unit for operation and Cooling Unit operation UNPACKING AND INSPECTION NOTE The Cooling Unit was thoroughly inspected before leaving the factory and the carrier has ac cepted and signed for it Any damage or irregularities should be noted at the time of delivery or not later than 15 days from date of delivery and immediately reporte
7. then pull the beer trunk line through the underfloor conduit 7 Cuta 4 inch diameter hole in the walk in cooler wall 8 Slide one PANEL PATCH item 5 up on the insulated beer trunk line then route end of the beer trunk line through the hole to inside of the walk in cooler MAKE SURE A MINIMUM 12 INCH RADIUS BEND IS MAINTAINED ON ALL BEER TRUNK LINE BENDS 9 Oninside of the walk in cooler slide the other PANEL PATCH item 5 up on the beer trunk line to the cooler wall Secure panel patch to the cooler wall with four screws 10 On outside of the walk in cooler wall slide panel patch up on the beer trunk line to the cooler wall Secure the panel patch to the cooler wall with four screws SELECTING COOLING UNIT LOCATION Locate the Cooling Unit so the following requirements are satisfied IMPORTANT Ambient temperature for the Cooling Unit must not exceed 100 F Several means are available to achieve the proper ambient temperature and air circulation around the Cooling Unit which are wall air intake grilles and ceiling exhaust fans air conditioning etc Check local codes l The Cooling Unit installation must be within 20 feet of the insulated beer trunk line to allow connecting the Cooling Unit glycol lines to the beer trunk line 2 The Cooling Unit must be accessible to a properly grounded 115VAC 60 Hz electrical outlet with circuit fused at 30 amps slow blow or circuit connected through an equivalent HACR circuit breaker No o
8. A BLK m RN l WHT 9 i TERM BLOCK WHT WHT yee BUSH NG e z 1 pum CORD CIRCULAT NG PUMP amp MOTOR FIGURE 9 WIRING DIAGRAM LOWER COOLING UNIT CABINET 111845000 24 TROUBLESHOOTING IMPORTANT Only qualified personnel should service Cooling Unit components or electrical wiring WARNING Disconnect electrical power from the Cooling Unit to prevent personal injury before attempting any internal maintenance Only qualified personnel should service the internal components or the electrical wiring If repairs are to be made to the CO system close the shutoff valves in the lines leading to the beer keg tappers then shut off the CO supply and relieve the system pressure TROUBLESHOOTING CO SYSTEM Trouble NO GAS PRESSURE ON BEER SYSTEMS INSUFFICIENT CO GAS PRESSURE ON BEER SYSTEMS A gt D Probable Cause Empty cylinder shutoff valve closed at CO cylinder shutoff valves in lines leading to beer kegs tappers closed CO regulators improperly adjusted Leak in CO system Empty cylinder CO shutoff valve in CO system partially closed regulator improperly adjusted Leak in CO system TROUBLESHOOTING BEER SYSTEM DISPENSED BEER FLOW RATE TOO LOW DISPENSED BEER FLOW RATE TOO HIGH OFF TASTE BEER SOUR AND UNPALATABLE A Beer faucet compensator adjusting scr
9. Fasten clothes line type rope to fish tape then pull rope and fish tape through the conduit 3 Unfasten fish tape from rope PURPOSE OF THE ROPE IS TO CLEAN OUT THE CONDUIT AND ALSO TO PULL INSULATED BEER TRUNK LINE THROUGH THE CONDUIT 7 111845000 NOLLVTIVLSNI 1V2IdAL W31SAS 4339 Q31002 102A15 3Hf15I4 LSNIN LINGNOD JO qI WANWNININ 97715 NI d31V201 SINIT JANNYL 9338 GALVINSNI N3HM Bee A a LUNN V III AHIN3S TIV NO Sniavu WniNININ SNLLVINIUID u31002 3710H 27 ig HINVY 4 4339 GALVINSNI 32VdS HO IN3N3SVANI XQ3 1V201 SI 3NITANNAL 4334 GALVINSNI N3HM t IOO 14 NI OSTV YHALNNOI NI AI3UINO3U Y3L3wVId WANWNININ 1V20O1 TVNOLLVN OLWHUOJNOD 15 DNIYIM NOLLY TIVLSNI T1V LNV LYUOdNII Wav lava NOLLVLS SNISN3dSIG A3OS nV3J InOd DM 111845000 4 Fasten a large towel to middle of the rope Pull the towel back and forth through the conduit as many times as necessary to clean any debris or water from inside the conduit MAKE SURE ALL DEBRIS AND WATER IS REMOVED FROM INSIDE THE CONDUIT 5 Remove towel from middle of the rope 6 Fasten end of the rope to one end of the insulated beer trunk line
10. MINERAL CONTENT WATER WHERE ALOCAL WATER PROBLEM EXIST 4 Install plug in glycol fill hole IMPORTANT Make sure the glycol circulating pump motor power switch located on the Cooling Unit electrical box is in the OFF down position before starting the refrigeration system Dry running the glycol circulating pump will result in damage to the pump 5 Make sure the Cooling Unit glycol circulating pump power switch labeled CIRC MOTOR see Figure 4 is in the OFF down position 6 Place the Cooling Unit power switch in the ON up position The refrigeration system will start and begin cooling the glycol coolant solution 7 Allow Cooling Unit refrigeration system to operate for two hours then check temperature of the glycol cool ant If the coolant temperature has not dropped to 26 F to 28 F the temperature control thermostat will have to be readjusted as instructed in SERVICE AND MAINTENANCE section of this manual INSTALLING DISPENSING STATIONS see Figure 2 and 3 Install dispensing stations on countertop Connect dispensing stations to insulated beer trunk line as shown in Figure 3 INSTALLING EQUIPMENT INSIDE WALK IN COOLER see Figure 2 Install and connect equipment inside the walk in cooler as shown in Figure 2 DO NOT INSTALL BEER KEG TAPPERS IN BEER KEGS AT THIS TIME STARTING PROPYLENE GLYCOL ANTI FREEZE CIRCULATING SYSTEM 1 Place the Cooling Unit glycol circulating pump power switch labeled CIRC MOT
11. ON up position before the glycol circulating pump will operate DAILY PRE OPERATION CHECK see Figure 4 1 Make sure the CO cylinder regulator assembly 1800 psi gage indicator is not in the shaded change CO cylinder portion of the dial If so the cylinder is almost empty and must be changed 2 Make sure the primary gt regulator is adjusted to specified pressure as instructed in SERVICE AND MAINTENANCE section of this manual 3 Make sure the beer kegs secondary CO regulators are adjusted to specified pressures as instructed in SERVICE AND MAINTENANCE section of this manual 4 Make sure there is a sufficient beer supply and replenish if necessary 5 Make sure the walk in cooler temperature is adjusted to specified temperature as instructed in SERVICE AND MAINTENANCE section of this manual 6 Make sure the dispensing stations and their drip trays are clean 13 111845000 AD USTMENTS ADJ USTING CO REGULATORS The primary gt regulator and the secondary regulators for the beer kegs should be checked periodically for proper pressure settings and if necessary be adjusted as instructed in SERVICE AND MAINTENANCE sec tion of this manual ADJ USTING COOLING UNIT GLYCOL COOLANT TEMPERATURE The Cooling Unit tank glycol coolant temperature should be periodically checked and if necessary be adjusted as instructed in SERVICE AND MAINTENANCE section of this manual ADJ USTING BEER DISPENSING
12. 6 Vacuum or use a soft brush to clean the condenser coil If available use low pressure compressed air 21 111845000 7 Clean dust and dirt from around top of the drop in refrigeration assembly 8 Install air filter on the condenser coil by reversing the removal procedure 9 Install Cooling Unit hood and secure with acorn nut 10 Install screw in hood ground strap to secure strap to the hood 11 Place Cooling Unit power switch in ON up position CLEANING COOLING UNIT EXTERIOR Periodically wash all external surfaces of the Cooling Unit rinse with clean water then wipe dry with a clean soft cloth DO NOT USE ABRASIVE TYPE CLEANERS REPLENISHING COOLING UNIT GLYCOL COOLANT TANK 111521000 or equivalent only Use of other than food grade propylene glycol type anti freeze such as ethylene glycol automotive type anti freeze in the Cooling Unit glycol tank and circulating system will create a health hazard WARNING Use industrial grade propylene glycol type anti freeze such as Cornelius P N 1 Place Cooling Unit power switch in OFF down position 2 Remove top screw from the ground strap securing strap to the hood 3 Remove acorn nut securing hood to the Cooling Unit then lift hood up off the Unit 4 Remove plug from the drop in refrigeration assembly platform glycol fill hole 5 Fill the Cooling Unit glycol tank with coolant made up of 1 to 1 ratio of food grade propylene glycol type anti freeze and water sol
13. Ambient Operating Temperature 40 F to 100 of F A A AAA s efrigeration System Refrigerant Requirement R 134A Refrigerant See Cooling Unit nameplate ectrical Requirements See Cooling Unit nameplate THEORY OF OPERATION See Figure 2 Food grade propylene glycol type antifreeze and water solution coolant is cooled by the Cooling Unit and is circulated through the insulated beer trunk line to cool the beer lines inside the beer trunk line Direction of the coolant flow is from the Cooling Unit glycol tank through the glycol circulating pump through the glycol turn around inside the walk in cooler out through the insulated beer trunk line to the turnarounds inside the dispens ing stations and back through the beer trunk line to the glycol tank inside the Cooling Unit Cold beer is pushed by regulated pressure through the cooled insulated beer trunk lines to the dispensing stations beer faucets when the faucets are opened 111845000 4 NOLLVTIVLSNI IWVH59VIG MOT Z SAN DIA LNV1005 NOLLN10S 102419 DIN A HACGNITAD OD DIH sv a lt g Wadd VL Tau CUT cem D J x 535 Y339
14. BLESHOOTING ink iig ver e i en 25 NO CO2 GAS PRESSURE ON BEER SYSTEMS 25 INSUFFICIENT CO2 GAS PRESSURE ON BEER 5 5 5 25 DISPENSED BEER FLOW RATE TOO 25 DISPENSED BEER FLOW RATE TOO HIGH 25 OFF TASTE BEER SOUR AND UNPALATABLE 25 DISPENSED BEER TEMPERATURE TOO COLD FLAT BEER DISAPPEARING FOAM 26 DISPENSED BEER TEMPERATURE TOO WARM 26 EXCESSIVE FOAMING WILD BEER WHILE BEER IS BEING DISPENSED 26 COMPRESSOR DOES NOT 26 COMPRESSOR WILL NOT STOP AFTER GLYCOL COOLANT HAS REACHED RECOMMENDED 265 TO 285 TEMPERATURE 27 COMPRESSOR OPERATES CONTINUOUSLY BUT DOES NOT LOWER GLYCOL COOLANT TO 2650F TO 285266 F Seed wre ra phi r eee de 27 CONDENSER FAN MOTOR NOT 27 LIST OF FIGURES FIGURE 1 SENTRY GLYCOL COOLING UNIT R 134A REFRIGERANT 3 FIGURE 2 FLOW DIAGRAM TYPICAL INSTALLATION 5 FIGURE 3 GLYCOL COOLED BEER SYSTEM TYPICAL INSTALLATION 8 FIGURE 4 PARTS IDENTIFICATION 18 FIGURE 5 BEER FAUCET ADJUSTMENT 20 FIGURE 6 BEER DRAFT ARM ADJ
15. Co CORNELIUS INC One Cornelius Place EE Anoka MN 55303 6234 Telephone 800 238 3600 Facsimile 612 422 3246 Installation Service Manual SENTRY Ill A GLYCOL COOLING UNIT R 134A REFRIGERANT Part No 111845000 Revised May 13 2014 Revision B THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment CORNELIUS INC 1996 2014 PRINTED IN U S A TABLE OF CONTENTS SAFETY RECOGNIZE SAFETY 1 UNDERSTAND SIGNAL WORDS eens FOLLOW SAFETY INSTRUCTIONS CO2 CARBON DIOXIDE WARNING SHIPPING STORING OR RELOCATING UNIT GENERAL DESCRIPTION SYSTEM DESCRIPTION u 2 20 key eR pionire EU EMI eens ewe Re WARRANTY REFERENCE INFORMATION THEORY OF OPERATION ice CERERI d puq P EAR ba INSTALLATION ne nn UNPACKING AND INSPECTION INSTALLING INSULATED BEER TRUNK LINE SELECTING COOLING UNIT LOCATION INSTALLING COOLING UNIT a seed Ree re ed evene a PLACING COOLING UNIT IN OPERATING LOCATION
16. G UNIT GLYCOL COOLANT TEMPERATURE see Figure 4 NOTE The Cooling Unit tank glycol coolant temperature must be maintained at 26 F to 28 F for proper cooling of the insulated beer trunk line 1 Remove top screw from ground strap securing hood to the Cooling Unit 2 Remove acorn nut securing hood to the Cooling Unit then remove hood for access to the electrical control box cover 17 111845000 ELECTRICAL CONTROL BOX HOOD RETAINING ACORN NUT COMPRESSOR CONDENSER COIL AIR FILTER GLYCOL FILL HOLE CONDENSER S COIL s CONDENSER GLYCOL CIRCULATING FAN MOTOR MOTOR POWER SWITCH GLYCOL CIRCULATING AGITATOR PUMP MOTOR MOTOR COOLING UNIT POWER SWITCH SHIPPING NUT 4 UNIT ELECTRICAL ACCESS PANEL RETAINING A SCREW 4 LOWER ACCESS GRILLE CAUTION The refrigeration assembly condenser coil and air filter must be cleaned every 30 days Excessive accumulation of dust lint and grease on air filter and coil will restrict cooling air flow through the coil and cause coil and refrigeration system to overheat Operating refrigeration system in an overheated condition will eventually lead to compressor failure FIGURE 4 PARTS IDENTIFICATION 111845000 18 3 Insert a screwdriver through the hole in the electrical control box and place in the thermostat control slotted adjustment screw Turn the a
17. NING CONDENSER COIL AND AIR FILTER see Figure 4 every 30 days An excessive accumulation of dust lint and grease on the air filter and condenser coil will restrict air flow through the coil and cause the refrigeration system to overheat Operating the refrigeration system in an overheated condition will eventually lead to compressor failure which may void the factory warranty WARNING The drop in refrigeration assembly condenser coil and air filter must be cleaned Note circulating air required to cool the refrigeration system condenser coil is drawn in through air filter and condenser coil on front of the Cooling Unit and is exhausted out through grilles on sides and back of the Cooling Unit Restricting air in and out of the Cooling Unit will cause the refrigeration system to overheat which will decrease it s cooling efficiency The area in front of and around the Cooling Unit must be kept free of obstructions at all times Make sure nothing is stored on top of the hood Clean the condenser coil and air filter as follows 1 Place Cooling Unit power switch in OFF down position 2 Remove top screw from ground strap securing hood to Cooling Unit 3 Remove acorn nut securing hood to the Cooling Unit then lift hood up off the Unit 4 Slide air filter straight up out of the condenser coil frame side rails to remove 5 Wash out air filter with water and detergent solution then rinse with clean water and allow to air dry
18. OR see Figure 4 in the ON up position 2 After insulated beer trunk glycol circulating system is in operation continue adding food grade propylene glycol type anti freeze and water at a 1 to 1 ratio to the Cooling Unit glycol tank until coolant runs out of the glycol tank overflow hose 3 Note the circulating pump for quietness of operation A noisy pump and air bubbles in the return line during operation indicates air is being drawn into the system on the pump inlet side If the pump is noisy and air bubbles are present check the pump inlet tube connection for a misaligned gasket or a burr on the fitting OPERATING PUMP IN SYSTEM CONTAINING AIR BUBBLES WILL EVENTUALLY RESULT IN DAM AGE TO THE PUMP 4 Checkthe glycol circulating system connections for leaks and repair if evident 5 Using INSULATING TAPE item 8 close insulation on the insulated beer trunk line where the Cooling Unit glycol lines are connected FAILURE TO INSULATE THE LINES WILL CAUSE THE LINES TO SWEAT AND GLYCOL COOLANT TO WARM UP 11 111845000 ACTIVATING BEER SYSTEMS see Figure 2 1 Make sure the primary and secondary CO regulators adjustment screws are backed out until all tension is relieved from the adjusting screws springs 2 Make sure shutoff valves located in the CO lines connected between the secondary regulators and the beer keg tappers are in closed positions 3 Make sure the beer shutoff valves located in the beer lines betw
19. RATE The beer dispensing rate approximately two ounces per second should be checked periodically and if neces sary be adjusted as instructed in SERVICE AND MAINTENANCE section of this manual ADJ USTING WALK IN COOLER TEMPERATURE The walk in cooler temperature between 33 F and 40 should be periodically checked and if necessary be adjusted as instructed in SERVICE AND MAINTENANCE section of this manual REPLENISHING CO SUPPLY WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of gas will experience tremors which are followed rapidly by loss of consciousness and suffocation NOTE When indicator on the CO cylinder regulator assembly 1800 psi gage is in the shaded change CO cylinder portion of the dial the CO cylinder is almost empty and must be changed The CO supply should be checked daily and if necessary be replenished as instructed in SERVICE AND MAINTENANCE section of this manual REPLENISHING BEER SUPPLY The beer supply should be checked periodically and if necessary be replenished as instructed in SERVICE AND MAINTENANCE section of this manual 111845000 14 CLEANING AND SANITIZING CLEANING Walk in Cool
20. d to the delivering carrier Request a written inspection report from the Claims Inspector to substantiate any necessary claim File claim with the delivering carrier not with Cornelius Inc 1 After Cooling Unit has been unpacked remove shipping tape and other packing material 2 Unpack LOOSE SHIPPED PARTS Make sure all items are present and in good condition Hood Ass y Elbow Fitting 3 8 Glycol Turnaround Wood Screw SI Rd Hd Nickel Pltd Steel No 10 by 3 4 inch 5 Panel Patch Hanging Strap Insulated Beer Trunk Line 7 Tubing Clamp Insulating Tape 2 inches Wide by 50 foot Long Roll OTE Items 9 is not included with the Cooling Unit and must be ordered by the Customer 111521000 Propylene Glycol Type Anti F reeze 5 gallon lot provided by the Customer 10 398025013 Acorn Nut INSTALLING INSULATED BEER TRUNK LINE see Figure 3 Table 2 Loose Shipped Parts EM o Rie IMPORTANT The length of the insulated beer trunk line used with this Cooling Unit must not exceed 80 feet in length The underfloor conduit must be free from water and all debris such as loose pieces of concrete etc Water left in the conduit will stagnate and may penetrate the beer lines tubing resulting in an off taste dispensed beer 1 Push electricians fish tape through underfloor conduit from the last beer dispensing station to the conduit opening in vicinity of the walk in cooler 2
21. djustment screw to the right clockwise to next higher setting for a colder coolant temperature or turn the adjustment screw to the left counterclockwise to the next lower setting for a warmer coolant temperature 4 Allow the Cooling Unit to operate for at least two hours after adjustment Recheck the coolant temperature and adjust the thermostat control as many times as necessary until the proper coolant temperature has been achieved 5 Install the Cooling Unit hood and secure with acorn nut 6 Install screw in hood ground strap to secure strap to hood ADJ USTING BEER DISPENSING RATE Dispensing Station With Adjustable Beer Faucet see Figure 5 Adjust the beer flow rate at approximately 2 ounces per second by adjusting the compensator adjusting screw located on the right hand side of the beer faucet Turn the compensator adjusting screw to the right clockwise for decreased beer flow rate or turn the screw to the left counterclockwise for increased beer flow rate Beer System With Adjustable Beer Draft Arm see Figure 6 Adjust the beer flow rate at approximately 2 ounces per second by adjusting the adjustment screw located under the cover on top of the draft arm Turn the adjustment screw to the left counterclockwise for increased beer flow rate or turn the knob to the right clockwise for decreased beer flow rate ADJUSTING WALK IN COOLER TEMPERATURE The walk in cooler temperature should be between 33 F and 40 F fo
22. een the beer keg tappers and the insu lated beer trunk line inside the walk in cooler are in the closed positions CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation WARNING CO displaces oxygen Strict attention must be observed in the prevention of 4 Open cylinder shutoff valve slightly to allow primary CO regulator to fill with gas then open valve fully to back seat the valve Back seating the valve prevents leakage around the valve shaft 5 Adjustthe primary CO regulator to 50 psi 6 Adjustthe beer kegs secondary CO regulators as follows The beer kegs secondary CO regulators pressures adjustments require calculations of each beer system total beer system pressure The total beer system pressure required to push beer from the keg to the faucet is the result of computing the length of the beer line of a certain size vertical line lift and the internal keg pressure The internal keg pressure differs from one beer brand to another Contact your local Beer Distributor for the proper secondary regulators pressure settings Adjust the secondary regulators by loosening their adjusting screws lock nuts then tu
23. er The walk in cooler should be cleaned periodically as instructed to eliminate a sticky floor and possible unpleas ant odors Dispensing Stations The dispensing stations should be cleaned daily as instructed in SERVICE AND MAINTENANCE SECTION of this manual SANITIZING The beer systems tappers beer lines and beer faucets internal parts should be completely cleaned and sani tized at least every two weeks as instructed in SERVICE AND MAINTENANCE SECTION of this manual COOLING UNIT MAINTENANCE CLEANING CONDENSER COIL AND AIR FILTER Note circulating air required to cool the refrigeration system condenser coil is drawn in through air filter and condenser coil on front of the Cooling Unit and is exhausted out through grilles on sides and back of the Cooling Unit Restricting air in and out of the Cooling Unit will cause the refrigeration system to overheat which will decrease it s cooling efficiency The area in front of and around the Cooling Unit must be kept free of obstructions at all times Make sure nothing is stored on top of the hood The drop in refrigeration assembly condenser coil and air filter should be cleaned every 30 days as instructed in SERVICE AND MAINTENANCE section of this manual REPLENISHING COOLING UNIT GLYCOL TANK WARNING Use only food grade propylene glycol type anti freeze such as Cornelius P N 111521 000 or equivalent Use of other than food grade propylene glycol type anti freeze such as ethy
24. ew or draft arm adjustment screw improperly adjusted Insufficient gt gas pressure on beer system Beer faucet compensator adjusting screw or draft arm adjustment screw improperly adjusted Beer system needs to be cleaned and sanitized Beer spoilage secondary fermentation due to inadequate walk in cooler or Cooling Unit refrigeration problem 25 Remedy Replenish CO supply as instructed Open shutoff valve at CO cylinder Open shutoff valves in lines leading to beer kegs tappers Adjust CO regulators as instructed Repair leak in CO system Replenish CO supply as instructed Open shutoff valve all the way Adjust CO regulator as instructed Repair leak in CO system Adjust dispensed beer flow rate as instructed Refer to INSUFFICIENT GAS PRESSURE ON BEER SYSTEM in this section Adjust dispensed beer flow rate as instructed Clean and sanitize beer system as instructed Correct walk in cooler temperature and or Cooling Unit refrigeration problem then clean and sanitize beer system as instructed 111845000 Trouble OFF TASTE BEER SOUR AND UNPALATABLE CONT D DISPENSED BEER TEMPERATURE TOO COLD FLAT BEER DISAPPEARING FOAM DISPENSED BEER TEMPERATURE TOO WARM EXCESSIVE FOAMING WILD BEER WHILE BEER IS BEING DISPENSED Probable Cause Mixed beers Dirty beer glasses Beer too cold Walk in cooler temperature t
25. he insulated beer trunk line leading to the glycol turnaround inside the walk in cooler Make connection using ELBOW FITTING item 2 and TUBING CLAMPS item 7 Connect Cooling Unit return line connected to the Cooling Unit glycol tank return line to other cut end of the unnumbered line inside the insulated beer trunk line coming from the dispensing stations glycol turn arounds Make connection using ELBOW FITTING item 2 and TUBING CLAMPS item 7 CONNECTING ELECTRICAL POWER CIRCUIT TO COOLING UNIT see Figure 4 1 Make sure the Cooling Unit power switch located on front of the Cooling Unit is in the OFF down position Connect 115 VAC 60 Hz electrical power circuit fused at 30 amps slow blow or circuit connected through an equivalent HACR circuit breaker to electrical box on front of the Cooling Unit ALL ELECTRICAL WIR ING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES FILLING COOLING UNIT GLYCOL TANK AND STARTING REFRIGERATION SYSTEM see Figure 4 1 2 Make sure plug in end of Cooling Unit glycol tank drain hose is secure Remove plug from the drop in refrigeration assembly platform glycol fill hole 111845000 10 NOTE Use low mineral content water where a local water problem exist 3 Fill the Cooling Unit glycol tank with coolant made up of a 1 to 1 ratio of FOOD GRADE PROPYLENE GLYCOL TYPE ANTI FREEZE item 9 and water until the coolant runs out of the glycol tank overflow tube USE LOW
26. igure 2 NOTE To readjust the CO regulator to a lower setting loosen the adjusting screw lock nut then turn the screw to the left counterclockwise until pressure gage reads 5 psi lower than the new setting will be Turn the adjusting screw to the right clockwise until gage registers new setting then tighten the lock nut Adjusting Primary Regulator Adjust the primary gt regulator by loosening the regulator adjusting screw lock nut then turn the adjusting screw to the right clockwise until gage registers 50 psi Tighten the adjusting screw lock nut after adjustment has been completed Adjusting Beer Kegs Secondary Regulators The beer kegs secondary CO regulators pressures adjustments require calculations of each beer system total beer system pressure The total beer system pressure required to push the beer from the keg to the faucet is the result of computing the length of beer line of a certain size vertical line lift and the internal keg pressure The internal keg pressure differs from one beer brand to another Contact your local Beer Distributor for the proper secondary regulators pressure settings Adjust the secondary regulators by loosening the adjusting screws lock nuts then turn the adjusting screws to the right clockwise until the regulators gages register the recommended pressures Tighten the adjustments screws lock nuts after adjustments have been completed ADJ USTING COOLIN
27. lene glycol automotive type anti freeze in the Cooling Unit glycol tank and the circulating system will create a health hazard The cooling Unit tank glycol coolant should be periodically checked and if necessary added to as instructed in SERVICE AND MAINTENANCE section of this manual CLEANING COOLING UNIT EXTERIOR The Cooling Unit exterior should be periodically cleaned as instructed in SERVICE AND MAINTENANCE section of this manual LUBRICATION The glycol circulating pump motor bearings must be periodically lubricated as instructed in SERVICE AND MAINTENANCE section of this manual 15 111845000 CLEANING GAS CHECK VALVE see Figure 2 The CO gas check valves must be inspected and serviced as instructed in SERVICE AND MAINTENANCE section of this manual at least once a year under normal conditions and after any servicing or disruption of the system 111845000 16 SERVICE AND MAINTENANCE This section describes service and maintenance procedures to be performed on the Cooling Unit and beer system IMPORTANT Only properly trained personnel should service the beer system or the Cooling Unit internal components and electrical wiring before attempting any internal maintenance Only qualified personnel should service the internal components or electrical wiring WARNING Disconnect electrical power to the Cooling Unit to prevent personal injury ADJ USTMENTS ADJ USTING CO REGULATORS see F
28. oo warm Cooling Unit tank glycol coolant too warm Cooling Unit power cord unplugged or electrical circuit fuse blown or circuit breaker tripped Glycol circulating pump power cord unplugged switch in OFF position or inoperable pump or motor Inoperable Cooling Unit refrigeration system Dispensed beer flow rate too high Dispensed beer temperature too warm TROUBLESHOOTING COOLING UNIT REFRIGERATION SYSTEM COMPRESSOR DOES NOT OPERATE 111845000 A Glycol coolant at recommended 26 F to 28 oF temperature Cooling unit power switch in OFF down position No power source blown fuse or tripped circuit breaker Low voltage Loose disconnected or broken wiring 26 Remedy Clean and sanitize beer system as instructed then install new beer supply Glasses must be free of all film Maintain walk in cooler temperature between 33 F and 40 oF and Cooling Unit tank glycol coolant between 26 F to 28 F Adjust temperature as instructed Maintain walk in cooler temperature between 33 F and 40 oF Adjust temperature as instructed Glycol coolant in Cooling Unit tank should be maintained between 26 F to 28 F Adjust temperature as instructed Make sure power cord is plugged in or circuit fuse is not blown or circuit breaker is not tripped Make sure power cord is plugged in or repair or replace pump or motor Repair Cooling Unit refrigeration System
29. product that can be materially changed by improper handling Undesirable dispensed beer can be created by improper cooling of beer stored inside the walk in cooler or lack of cleaning sanitizing beer systems Proper temperature control of stored beer is important It helps retard growth of mold yeast and bacteria that are non toxic but do affect taste and appearance of the dispensed beer These organisms can be satisfactorily controlled by maintaining stored beer within a specified temperature range and regularly cleaning the beer faucets and sanitizing the beer systems The walk in cooler internal temperature should be maintained at 33 F to 40 The walk in cooler should be used for storage of draft beer exclusively and not for foods i e meats vegetables and fruits The disadvantage of storing these items is that they usually require frequent opening of the walk in cooler door resulting in a beer temperature warm up and the possibility of the dispensed beer being wild excessive foam Unpleasant odors of the stored food and fungus growth caused by fruit and vegetable pollen causes conditions which are objectionable OPERATING CONTROLS see Figure 4 COOLING UNIT POWER SWITCH The Cooling Unit power switch must be in the ON up position before the Cooling Unit will operate GLYCOL CIRCULATING PUMP POWER SWITCH The glycol circulating pump power switch labeled CIRC PUMP located on the electrical box under the hood must be in the
30. r proper beer storage Refer to the walk in cooler refrigeration system manual for the temperature adjustment procedure REPLENISHING CO SUPPLY WARNING CO displaces oxygen Strict attention must be observed in the prevention of CO carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Personnel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation NOTE When indicator on the CO cylinder regulator assembly 1800 psi gage is in the shaded change CO cylinder portion of the dial the CO cylinder is almost empty and should be changed 1 Fully close clockwise the CO cylinder shutoff valve 2 Slowly loosen the primary regulator assembly coupling nut allowing CO pressure to escape then remove the regulator assembly from the empty CO cylinder 3 Unfasten the safety chain and remove the empty CO cylinder WARNING To avoid personal injury and or property damage always secure the CO cylinder with a safety chain to prevent it from falling over Should the valve become accidentally damaged or broken off CO cylinder can cause serious personal injury 19 111845000 4 Position the full cylinder and secure with a safety chain 5 Make sure a gasket is in place inside the
31. rn the adjusting screws to the right clockwise until the regulators gages register the recommended pressures Tighten the adjusting screws lock nuts after adjustments have been completed IMPORTANT The walk in cooler temperature must be maintained between 33 F and 40 F and the Cooling Unit tank glycol coolant temperature at 26 F to 28 F for proper cooling of the beer 7 Install beer keg tappers in the beer kegs 8 Open shutoff valves located in the CO lines connected between the secondary regulators and the beer keg tappers 9 Open shutoff valves located in the beer lines between the beer keg tappers and the insulated beer trunk line 10 Dispense from all beer faucets until air is purged from the systems 11 Check entire system for leaks and repair if evident 12 Install HOOD ASS Y item 1 on the Cooling Unit and secure with ACORN NUT item 10 13 Install screw in hood ground strap to secure strap to hood 111845000 12 OPERATOR S INSTRUCTIONS This section covers proper beer storage Operator s responsibilities for daily pre operation check adjustments replenishing and beer supplies cleaning and sanitizing and Cooling Unit maintenance N WARNING Disconnect electrical power from the Unit to prevent personnel injury before attemping any internal maintenance Only qualified personnel should service the internal components or electrical wiring PROPER BEER STORAGE Draft beer is a perishable
32. temperature control Refer to IMPORTANT note at Startof SELECTING COOLING UNIT LOCATION in INSTALLATION SECTION Clean air filter and condenser coil as instructed NOTE If overload protector cuts out compressor condenser fan motor will continue to operate otherwise troubleshooting condenser fan motor problems are same as for COMPRESSOR DOES NOT OPERATE paragraph plus the following CONDENSER FAN MOTOR A NOT OPERATING J umper cord loose or disconnected from condenser fan motor or compressor terminals Broken wire in cord Fan blade obstructed Inoperative condenser fan motor 27 Tighten connections or replace cord Remove obstruction Replace condenser fan motor 111845000 111845000 28 THIS PAGE LEFT BLANK INTENTIONALLY 29 111845 000 CORNELIUS INC CORPORATE HEADQUARTERS One Cornelius Place Anoka M innesota 55303 6234 612 421 6120 800 238 3600
33. the following procedure to install the Cooling Unit 1 Place Cooling Unit in operating location meeting requirements of SELECTING COOLING UNIT LOCATION 9 111845000 2 3 Tilt the Cooling Unit up to expose bottom of the Unit base Liberally apply silastic sealant such as Dow Corning RTV 731 or equivalent on the Unit base bottom edges NOTE Do not move the Cooling Unit after positioning or seal from the Cooling Unit base to the floor will be broken 4 Lower the Cooling Unit into operating position to complete seal from Unit base to the floor Apply additional sealant around bottom of the base Seal must have a minimum radius of 1 2 inch to prevent cracks and crevices and to ensure a complete seal Route Cooling Unit glycol tank drain and overflow hoses to a permanent floor drain CONNECTING COOLING UNIT GLYCOL LINES TO INSULATED BEER TRUNK LINE see Figure 2 and 4 1 Connect GLYCOL TURNAROUND item 3 to the insulated beer trunk line unnumbered and No 7 lines inside the walk in cooler Secure connections with TUBING CLAMPS item 7 Being careful not to cut tubing inside the insulated beer trunk line open the beer trunk line insulation by making patterned cut in the insulation Cut unnumbered line inside the insulated beer trunk line and remove a 2 inch section Connect Cooling Unit glycol outlet line connected to the Cooling Unit glycol circulating pump outlet to cut end of unnumbered line inside t
34. ther electrical equipment should be connected to this circuit ALL ELECTRICAL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES Note circulating air required to cool the refrigeration system condenser coil is drawn in through air filter and condenser coil on front of the Cooling Unit and is exhausted out through grilles on sides and back of the Cooling Unit Restricting air in and out of the Cooling Unit will cause the refrigeration system to overheat which will decrease it s cooling efficiency Operating the refrigeration system in an overheated condition will eventually lead to refrigeration compressor failure which may void the facto ry warranty 3 A minimum of 36 inches clearance must be provided above the Cooling Unit to the nearest object shelf cupboard ceiling etc to allow removal of the Unit hood and the refrigeration system The front grille of the Cooling Unit must be open to the room to allow sufficient amount of cool circulating air to enter the hood A minimum of 6 inches clearance must be provided on sides and back of the Unit to allow warm circulating air to escape from inside of the hood 4 The Cooling Unit must be located close to a permanent floor drain to route the Cooling Unit overflow and glycol tank drain hoses INSTALLING COOLING UNIT PLACING COOLING UNIT IN OPERATING LOCATION To comply with National Sanitation Foundation NSF requirements the Cooling Unit base must be sealed to the floor P erform
35. to the machine may impair function and or safety and affect the machine life CO Carbon Dioxide Warning CO Displaces Oxygen Strict Attention must be observed in the prevention of carbon dioxide gas leaks in the entire CO and soft drink system If a CO gas leak is suspected particularly in a small area immediately ventilate the contaminated area before attempting to repair the leak Person nel exposed to high concentration of CO gas will experience tremors which are followed rapidly by loss of consciousness and suffocation Shipping Storing Or Relocating Unit CAUTION Before shipping storing or relocating this Unit the syrup systems must be sanitized and all sanitizing solution must be purged from the syrup systems All water must also be purged from the plain and carbonated water systems A freezing ambient temperature will cause residual water remaining inside the Unit to freeze resulting in damage to internal components of the Unit 1 111845000 THIS PAGE LEFT BLANK INTENTIONALLY 111845000 2 GENERAL DESCRIPTION This manual is a guide for installing operating and maintaining this equipment Refer to Table of Contents for page location of detailed information pertaining to questions that may arise during installation operation service and maintenance or troubleshooting this equipment This section gives the description and theory of operation for the glycol cooled beer system and design data for the Sentr
36. ution until coolant runs out of the glycol tank overflow tube 6 Install plug in the drop in refrigeration assembly platform glycol fill hole 7 Install hood on the Cooling Unit and secure with a acorn nut 8 Install screw in hood ground strap to secure strap to hood 9 Place Cooling Unit power switch in ON up position LUBRICATION The glycol circulating pump motor bearings must be oiled periodically Refer to oiling instructions on the motor DO NOT OVER OIL 111845000 22 CLEANING CO GAS CHECK VALVE see Figures 2 and 7 The CO gas check valves must be inspected and serviced at least once a year under normal conditions and after any servicing or disruption of the CO system ALWAYS REPLACE THE QUAD RING SEALS EACH TIME THE CHECK VALVES ARE SERVICED O QUAD RING Pa 183294000 BALL 183296000 SPRING 183297000 RETAINER 183298000 BODY 183295100 QUAD RING SEAL MUST BE REPLACED EACH TIME CHECK VALVE IS SERVICED FIGURE 7 CO2 GAS CHECK VALVE 23 111845000 CONTROL BOX FAN MOTOR RUN CAPACITOR 24 START CAPACITOR H fi ICE BANK CONTROL 1 4 peas AD LO in WHITE OR O o_O GREN BLUE 7 BLACK ELEC SOCKET E SWITCH CIRCULATING MOTOR x
37. y III A Glycol Cooling Unit with R 134A Refrigerant hereafter referred to as a Unit used in this system SYSTEM DESCRIPTION The glycol cooled beer system is a complete system designed to provide cold beer to the dispensing stations connected to the system The system consist basically see Figure 2 of 1 a Sentry III A Cooling Unit with a glycol circulating pump 2 an adjustable primary gt regulator which provides gas pressure to 3 beer kegs adjustable secondary regulators 4 an insulated beer trunk line and 5 dispensing stations The Sentry III A Glycol Cooling Unit with R 134A Refrigerant consist basically of a drop in refrigeration system with a 3 4 horsepower compressor a refrigerated glycol holding tank to cool the glycol water solution and a glycol circulating pump to circulate cold glycol water solution coolant out and back through the insulated beer trunk line WARRANTY REFERENCE INFORMATION Warranty Registration Date to be filled out by customer Unit Part Number Serial Number Install Date Local Authorized Service Center FIGURE 1 SENTRY Ill A GLYCOL COOLING UNIT R 134A REFRIGERANT 3 111845000 Table 1 Design Data ooling Unit Part Number 111844000 ooling Unit Data ooling Unit Overall Dimensions with hood in place 36 T T inche I9 inche 27 inche A EA Weights approximate Shipping 220 Pound Weight W O Cartoning N A Pound apacities 6 8 Gallon
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