Initial Startup & Testing

If Glycol Chiller has been moved/delivered do not turn it on unless it has been standing upright for at least 24 hours. Failure to do this will void warranty and may damage the unit. Leave the Glycol Chiller upright for at least 24 hours before plugging in mains power after receiving and unboxing

Ensure there is at least 100mm of clearance on each side of the Glycol Chiller to allow adequate airflow. Faailure to allow adequate ventilation will reduce performance, increase power consumption and void warranty

This Glycol Chiller is not intended for cooling wort from boiling or temperqawtures above 50°C. Using the chiller to cool liquids above 50°C can overload the compressor and will void warranty

Do not run the pumps dry or allow the reservoir to ice over. Ensure the pumps are always submerged when in operation. Running the pumps dry or incresed resistance due to ice formation can damge the pumps.

Whenever the glycol chiller is operating and cooling the reservoir the pumps should be operating to keep the liquid in the reservoir agitated and avoid ice formation

Replace propylene glycol solution every 12 months to avoid potential damage to pumps, lines or reservoir

Before Installation

1. Let the glycol chiller sit for at least 24 hours after delivery or after sitting on its side before turning the unit on

2. Ensure there is adequate ventilation (at least 100mm on each side of the glycol chiller)

3. Check for any signs of damage which may have occurred during shipping

4. Remove the top service cover of the G40 by removing the 4 screws holding it in place. Under this cover you will find an IEC cable, castor wheels and screws, brass push in fitting for the drainage pipe and an STC-1000 instruction manual

Assembly

Install the temeprature probes - push the male connector of the temperature probe into the female socket by each temeprature controller.

Reservoir Drain Outlet

Attach the ½ inch brass fitting onto the outlet/drainage pipe. This brass fitting is a push fitting and can be attached by firmly pushing the ½ inch brass fitting onto the pipe and then pulling back to ensure the fitting is secured into place.

To remove this ½ inch brass fitting from the drainage pipe, pull the blue collar towards you while pulling on the brass fitting. Do not rotate the brass fitting as you try and remove it as this can result in it cutting the drainage pipe and it not sealing upon reassembly.

Install Castor Wheels (optional)

• Make sure the G40 is empty

• Carefully lay the G40 on its side on a soft surface such as carpet, cardboard or a towel

• Attach each castor wheel to the base of the G40 using 4 screws

• Install the two locking castor wheels at whichever position will be most accessible for you

• Position the G40 back upright and leave for a minimum of 1 hour before turning on to allow the refrigerant to settle

Attach tubing to the IN & OUT ports for each fermenter

This G40 has 10mm barbs as standard for the inlet and outlet of each pump. KL18142 10x15mm Heavy Duty Silicone Tubing is suitable to be used with these barbs. Simply push the hose over the IN and OUT barbs under the temperature controller you wish to use and secure with a clamp.

For best performance, insulate the hosing between the G40 and the fermenter and try and minimise the distance between the G40 and fermenter.

Testing the system

Perform a leak test and 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

1. With the G40 unplugged fill the reservoir with water until it reaches the top of the sight glass

2. Check for any signs of leaks around the exterior of the G40

3. Attach 10mm ID silicone tube (KL18142) to the first OUT barb and either loop this back into the IN barb or run it to a fermenter and then back into the IN barb

4. Plug the G40 in using the provided IEC cable and turn the red power switch on

5. Set the temperature on each temperature controller on the front of the G40 to 2°C

   1. Hold the ‘Up’ button for 3 seconds until the number is flashing (this flashing number is your set temperature)

   2. Press the ‘Down’ button to decrease the set temperature and press the ‘Up’ button to increase the set temperature

6. Check that each pump is operating correctly

   1. This can be determined by looking for water flow through the silicone tubes or by placing the outlet hose into a jug and ensuring that liquid is being pumped out of the hose into the jug

7. Set the temperature on the STC-1000 controller on the rear of the G20 above the IEC plug to 2°C

   1. Hold the ‘S’ button until F1 is displayed

   2. Press ‘S’ again which will enter temperature adjustment mode

   3. Then hold ‘S’ and up or down buttons simultaneously to adjust the set point temperature of the reservoir

   4. 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

Repeat the above steps for all four temperature controllers to determine whether all pumps are working correctly and there are no leaks in the system.

Prior to putting any beer into the fermenter for cooling you should leak test your whole system to ensure that there are no leaks in the system including on the inlet/outlet of the fermenter itself.

Performing this test you can get a rough guide of the cooling factor of the glycol chiller when not under load. To determine this note the starting temperature of the water in the reservoir and then measure how long it takes to drop the temperature to 2°C

Leak Testing

Prior to putting any beer into the fermenter for cooling you should leak test your whole system. This can be done by connecting the silicone tubing from the OUT barb to the cooling coil of the fermenter and then connect the silicone tube from the fermenter to the IN barb on the G40.

Set the temperature on the temperature controller to 2°C and test that there are no leaks in the system including into the fermenter itself.

After all testing is complete, empty the reservoir by removing the plug on the bottom 3/8” duotight fitting on the nylon sight tube. This can be achieved by removing the blue retaining clip on the duotight fitting and pushing in on the collar as you pull on the plug. After you have drained the reservoir put the plug retaining clip back in place.

The system has now been tested for cooling and leaks and is ready to be used to cool a fermenter.

Filling the Reservoir

The G40 can be operated with either just water in the reservoir or both water and glycol to reduce the freezing point of water.

For fermentation control, a glycol mix is greatly preferred as the cooling power of the G20 will be much higher than if used wit 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)

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

Fill the reservoir to the top of the sight galss with water or a water/glycol mix

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.

Glycol Percentage Chart

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. However, if you do not have a jacketed fermenter or have the fermenter in a very warm environment you can run it at a higher glycol concentration. The pumps are 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 pumps.