Warnings and Installation Checklist
Benchy Glycol | Warnings and Installation Checklist
Warning
Warning If the Benchy has just been moved do not turn on unless it has been standing for at least 24 hours. Failure to do so will void warranty. Stand the Benchy in an upright position for at least 24 hours before plugging inot the mains socket.
Warning Ensure there is at least 100mm clearance on each side of the Benchy to allow adequate airflow. Not allowing adequate ventilation will void warranty, reduce performance and increase power consumption.
Warning Perform a pressure test on all product lines prior to use
Warning Only use KegLand approved cleaners and sanitisers to clean the product lines
Warning Do not run the pump dry. Ensure the pump is always submerged when in operation. Running the pump dry will damage the pump
Important
Let the Benchy sit for at least 24 hours after delivery or after sitting on its side before turning the unit on.
Whenever the Benchy is operating and cooling the reservoir the agitator pump needs to be operating to keep the liquid in the reservoir agitated and avoid ice formation. The pump is wired into the temperature controller and hence should always be running when the unit is turned on.
Inclusions
1 x KL18203 SS Benchy - Glycol 1 x Standard IEC Lead 2 x KL15523 Flow Control Nukataps & handles 1 x KL13161 Punched Counter Top Drip Tray 1 x KL07672 7 in 1 faucet spanner/tool 1 x Sight Glass Assembly
Sight Glass Assembly
Locate the Sight Glass bracket, mounting screws and Quick Swivel Connector o-ring inside the Benchy Glycol (open the hinged top flap). Install the 0-ring in the Quick Swivel Connector (as shown). Using the supplied screws, fasten the Sight Glass top bracket to the Benchy (as shown)
Once the o-ring and bracket are installed, thread the Quick Swivel Connector on to the bottom sight glass thread and insert the top of the sight glass through the top bracket as shown
Connect The FC Nukataps
Before attaching the Benchy Glycol to your keg first screw your taps onto the two shanks on the front of the Benchy and tighten the shank collar using the included 7 in 1 Facet Tap Wrench/Spanner Tool or a C Spanner
The FC Nukataps need to be quite tight against the shank in order to seal.
Install duotight Fittings to 5/8" BSP Shanks
For easy connection of beer/product lines to the Benchy Glycol, we recommend installing KL06903 duotight - 8mm (5/16”) Female x 5/8” Female Thread. These push fittings allow KL06231 EVABarrier 5mm ID x 8mm OD x 12m Roll - Double Wall EVA to be used for product lines.
Once the KL06903 duotight fittings have been installed, push a length of KL06231 EVABarrier 5mm ID x 8mm into each fitting to serve as product line. The other end of the line will be fitted into a Ball Lock Disconnect (for Ball Lock Corny Kegs) or a Coupler (for commercial kegs)
Leak Testing Product Lines
It is essential to pressure test all product lines prior to running any liquid through them for dispensing.
The product lines need to be pressure tested to a pressure that is at least 1.5 times the pressure that will be used for dispensing to a maximum of 50psi. For example, if your dispensing pressure is 20 psi then your product lines should be pressure tested at 30 psi and your testing pressure shouldn’t exceed 50 psi.
The product lines can be leak tested via multiple methods which are outlined below. It is a good idea to test the system using multiple methods to be certain the system is holding pressure
Pressure Decay Test
Attach a duotight push in fitting to each product line shank (as above)
Push EVA Barrier hosing connected to a regulated pressure source into one of the duotight fittings
Set the pressure on the regulator to 1.5 times the dispensing pressure up to a maximum of 50 psi
Turn the gas cylinder off and leave to sit for a few hours. Then check if the pressure on the regulator has decreased from the set pressure
If the pressure has dropped double check that the leak isn’t occurring externally from the Benchy. Check all duotight connections and connections to your gas cylinder or regulator with a soapy solution to check for the formation of bubbles indicating a leak.
If the pressure remains stable then this product line has passed the leak test.
Perform the above Pressure Decay Test on the other product line.
Bubble Test
Fill the reservoir with water
Screw a 8mm x 5/8” duotight fitting onto each all thread shank on the rear of the Benchy (as above)
Push EVA Barrier hosing connected to a regulated pressure source into one of the duotight fittings
Set the pressure on the regulator to 1.5 times the dispensing pressure up to a maximum of 50 psi
Look for bubbles forming in the reservoir which may indicate a leak from the product lines.
Perform the above Bubble Test on the remaining product line.
Hydrostatic Leak Test
Empty the reservoir (if filled)
Screw a 8mm x 5/8” duotight fitting onto each all thread shank on the rear of the Benchy (as above)
Push EVA Barrier hosing connected to a regulated pressure source into one of the duotight fittings. The pressure of the water source can be regulated using a KL15035 inline regulator for example or by connecting a keg full of water pressurised at 1.5 times the dispensing pressure up to a maximum of 50psi
Look for any leaks in the reservoir from the product lines.
Repeat the test for the other product line.
Test Agitator Pump and Compressor
Perform a cooling test on your system to ensure that all connections are water tight, the pumps are operational and the glycol chiller is chilling the reservoir correctly
With the Benchy unplugged fill the reservoir with water, ensuring that all cooling coils and the impeller of the agitator pump are submerged
Check for any signs of leaks around the exterior of the Benchy.
Plug the Benchy in using the provided IEC cable and turn the red power switch on
Set the temperature on the STC-1000 controller on the front of the Benchy to 2°C
Hold the ‘S’ button until F1 is displayed
Press ‘S’ again which will enter temperature adjustment mode
Then hold ‘S’ and up or down buttons simultaneously to adjust the set point temperature of the reservoir
Once the desired temperature has been entered, press and release the
power key to
save the parameter
Leave the Benchy on for 12 hours to ensure that it drops the temperature of the reservoir to the set temperature on the temperature controller
NOTE: Refer here for the full STC-1000 Instruction manual
The system has now been tested for cooling and leaks and is ready to be used to chill a font or dispense from a keg (or both).
Filling the Reservoir
The Benchy can be operated with either just water in the reservoir or both water and glycol to reduce the freezing point of water.
For most use cases a glycol mix is greatly preferred as the cooling power of the Benchy will be much higher than if used with water alone. This is because the glycol lowers the freezing point so the reservoir can be set to -5°C or lower (depending on ambient, the water/glycol mix and other factors such as ABV of product)
IMPORTANT: If you are only using water in the reservoir and not glycol then do not set the temperature of the reservoir below 2°C
Always determine the freezing point of the beverage you are dispensing and use this as a lower limit for the reservoir set temperature to not exceed.
Ensure the impeller and the cooling coils are submerged before operating the G40.1
if the reservoir is filled with water set the reservoir temperature controller to 2°C. If using glycol solution the reservoir temperature can be set below 2°C according to the table below.
Ensure the cooling coils are submerged. The amount of glycol required to be added to the reservoir depends on the desired set temperature of the reservoir which is dependent on a number of factors including how many fermenters are being cooled, the ambient temperature the fermenters are in and heat ingress etc. Use the table below to determine what percentage of glycol you require.
Settting Reservoir Temperature
The reservoir temeprature is controlled with the STC-1000 Temperature Controller.
To set the reservoir temperature:
Hold the ‘S’ button until F1 is displayed
Press ‘S’ again which will enter temperature adjustment mode
Then hold ‘S’ and up or down buttons simultaneously to adjust the set point temperature of the reservoir
Once the desired temperature has been entered, press and release the
power key to
save the parameter
NOTE: Refer here for the full STC-1000 Instruction manual
Do not set the Set Point Temperature of the reservoir below 2°C if using water (instead of a glycol solution) in the reservoir (AKA an icebank setup)
Refer to the Glycol Percentage Chart below for recommended Set Point Temperatures with corresponding glycol percentage
Glycol Percentage Chart
0
0.0°C
1.000
10
-3.3°C
1.006
20
-7.8°C
1.015
30
-13.3°C
1.024
You can measure the glycol percentage using a calibrated refractometer and comparing to the specific gravity at 21°C in the above table.
We would advise running a 20% glycol solution. The pump is not designed to be run with a glycol concentration higher than 30% hence it is not advised to exceed this glycol concentration. Doing so may damage the pump/impeller.
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