Initial Startup & Testing

KL04114 | KL47364 | Icemaster Beverage Chiller G40.1 Glycol/Icebank with Digital Control | Setup

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

Perform a pressure test on all product lines prior to use

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

Always have the agitator pump running. If the reservoir freezes over in can result in damage to the cooling coils

Never set the reservoir temperature below the freezing point of the beverage being cooled through the product lines

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

Before Installation

Let the glycol chiller sit for at least 24 hours after delivery or after sitting on its side before turning the unit on
Ensure there is adequate ventilation (at least 100mm on each side of the glycol chiller)
Check for any signs of damage which may have occurred during shipping
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 for the agitator pump, glycol reservoir access flap, brass push in fitting for the drainage pipe and set of castor wheels

Assembly

Agitator Pump

Run the IEC cable for the agitator pump through the cable outlet and plug it into the external socket as shown

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

Connecting EVABarrier to Product Lines

NOTE: Perform a leak and cooling test befor connecting EVABarrier. This is required to ensure that hte connections are watertight, the agitator is operational and the chiller is cooling the reservoir correctly.

The barbs on the G40.1 are designed to accept all 8mm duotight fittings. EVABArrier tubing can thus be attached to the barbs using 8mm duotight fittings. KL06231 EVABarrier 5mm ID x 8mm OD x 12m is recommended for a glycol setup.

Examples as shown below

Typically, KL24631 duotight - 8mm (5/16) Screwlock x 8mm (5/16) Elbow and KL02370 duotight – 8mm (5/16”) Female x 8mm (5/16”) Female Push In Joiner are the most common and most useful duotight fittings for this purpose. KL24631 duotight - 8mm (5/16) Screwlock x 8mm (5/16) Elbow are particularly suited as these are a screw lock and thus will help keep the fittings secured even if the G40.1 is moved (for example)

Looping Water Inlet/Outlet

If the G40.1 is not going to be used for a flooded font setup, then the Water Inlet and the Water Outlet must be looped.

To do this, take a short piece of 10mm ID silicone tubing and use this to connect the Water Inlet and Water Outlet as pictured.

Leak Testing Product Lines

It is essential to pressure test all four 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 (as above)
Push EVA Barrier hosing connected to a regulated pressure source into the duotight Fitting on the Beer Inlet Tube 1
Plug the duotight fitting on the Beer Outlet Tube 1 with a KL06958 8mm duotight plug
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 G40.1. 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 Beer Outlet Tube 1 has passed the leak test.

Perform the above Pressure Decay Test on the remaining beer Inlet/Outlet pairs (Beer Inlet/Outlet 2-4)

Bubble Test

Fill the reservoir with water
Attach a duotight push in fitting or elbow to each product line (as above)
Push EVA Barrier hosing connected to a regulated pressure source into the duotight Fitting on the Beer Inlet Tube 1
Plug the duotight fitting on the Beer Outlet Tube 1 with a KL06958 8mm duotight plug
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 beer Inlet/Outlet pairs (Beer Inlet/Outlet 2-4)

Hydrostatic Leak Test

Empty the reservoir (if filled)
Attach a duotight push in fitting or elbow to each product line (as above)
Push EVA Barrier hosing connected to a regulated water source into the duotight Fitting on the Beer Inlet Tube 1. 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
Plug the duotight fitting on the Beer Outlet Tube 1 with a KL06958 8mm duotight plug

Test Agitator Pump and Compressor

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

With the G40 unplugged fill the reservoir with approximately 30L of 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 G40.1
Attach 10mm ID silicone tube (KL18142) to the Water OUT barb and either loop this back into the Water IN barb
Plug the G40.1 in using the provided IEC cable and turn the red power switch on
Set the temperature on the STC-1000 controller on the G40.1 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
Plug the agitator pump into the external IEC Socket
Turn the agitator pump on and ensure that it is operating
Leave the G40 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

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.

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 G40.1 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 G40.1 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.

The reservoir will hold 30L of liquid. 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

Glycol Volume %

Freezing Point (°C)

Specific Gravity at 20°

0.0°C

1.000

-3.3°C

1.006

-7.8°C

1.015

-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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