KL04114 Icemaster Beverage Chiller G40.1 Glycol/Icebank with Digital Control | User Guide
The Icemaster Beverage Chiller G40.1 Glycol is a commercial grade compact chilling dispensing solution. The G40.1 offers high performance for small to medium volume customers. Suits small bars, cafés, restaurants or even the increasingly popular travelling bars.
Comes with flooding impeller pump as standard, all enclosed inside the unit for efficiency and ease in transport. The G40 is also completely enclosed including the removable lid, this will aid in cooling performance due to less heat loss.
8mm 304 Stainless tubing ideal for compression fittings to 6mm barbs for product lines located at the side of the unit making them easier to install under commercial bar tops where height restriction is limited. The barbs are natively duotight compatible as well, for easy istallation with our 5mm x 8mm EVABarrier.
Ideally suited to be used for a glycol system, but can be used as an icebank.
We would like to make clear that with one pass through, through the G40.1 will only be able to drop the temperature of your product by ~15°C. Hence we highly reccomend if you are dispensing in an area that will be over 30°C, that you use the G40.1 only for two product lines, and double them up through the unit. e.g. passes through the chiller twice in a loop.
Pump: Impeller+Pump Combination 35watts (6.5meter Head, approx 2000L/hour)
Product Lines: 4 Stainless Steel Product Lines (4 x 11meter Coils)
Product Line Size: 304 Stainless Steel Coils (8mm OD x 7mm ID - duotight compatible)
KL04114 | KL47364 | Icemaster Beverage Chiller G40.1 Glycol/Icebank with Digital Control | Fermentation Control
It is strongly recommended to use a dedicated glycol chiller such as a G20 or G40 Fermentation Glycol Chiller with Digital Control for fermentation control.
Although the G40 can be used to control fermentation temperature it should primarily be used to flood a font or dispense product, instead we would highly advise a G20 primarily be used for fermentation control. If you were going to use the G40 for fermentation control then it is suggested you adhere to the following advice and steps.
It is not advised to use the agitator pump to supply glycol to cool a fermenter, this is due to this pump not being powerful enough to overcome the resistance of the cooling coils or large fermenter jacket, and hence it is advised that an external pump be used connected to an external temperature controller (KL01946).
Furthermore, it is not advisable to use the temperature controller on the G40 as a temperature controller for fermentation control. This is because if the fermentation temperature is set on the temperature controller on the G40 it will result in the temperature of the reservoir being set to your fermentation temperature and hence there will not be a high enough temperature differential between the temperature of the glycol and the temperature of the fermenter to maintain stable fermentation temperatures. Instead, the following method should be employed to setup your G40 to cool a jacketed fermenter up to 500L.
Connect an external pump to an external temperature controller
Attach tubing to the ½ inch drainage port on the G40 and connect this tube to your external pump
Attach tubing to the outlet of the external pump and attach this tube to the cooling coils on your fermenter
KL04114 | KL47364 | Icemaster Beverage Chiller G40.1 Glycol/Icebank with Digital Control | Flooding Fonts
The G40.1 is an ideal unit for a Flooded Font setup.
Under the product lines are 2 x 10mm OD barbs labelled WATER IN and WATER OUT
These are connected to the agitator pump and thus can be used without modification to flood a font.
To connect a flooded font, run a length of KL18142 from the WATER OUT to the glycol inlet of the flooded font.
Run a corressponding length fomr the WATER IN to the glycol outlet of the flooded font.
It is strongly recommended to insulate the lines of the silicone tubing between the G40.1 and the flooded font to minimise thermal losses.
Once the flooded font is connected and the agitator pump turned on, the reservoir of the G40.1 may need to be topped up in order to compensate for the glycol solution in the lines and the font.
Set the temperature on the G40 to -2°C (if using glycol) or to 2°C (if only using water in the reservoir)
Attach 10mm ID silicone tube to the “Water Out” barb and connect this silicone tube to the adjacent “Water in” barb. Run the agitator continuously to keep the reservoir agitated and prevent the reservoir from freezing
Insert the temperature probe of the external temperature controller into the thermowell on your fermenter
Set the temperature on your external temperature controller to your set fermentation temperature. This will cycle the pump on and off to supply cold glycol solution only when the temperature of the fermenter increases above the set fermentation temperature. When under load such as when cooling a fermenter it can take a longer time to cool the reservoir down to the set temperature on the glycol chiller. This time is dependent on a number of variables including but not limited to: • Jacketing of the fermenter (jacketed or non-jacketed) • Number of fermenters being cooled • Ambient temperature • Heat ingress
Icebank: 22kg Icebank (when using water)
Tank Capacity: 30L Water Capacity
Refrigerant: r600a isobutane
Cooling Power: 400W (0.54hp) (Rated at 22°C)
Input Power: 210W
Typical Product Cooling Capacity: 90Litres in the first hour, 35Litres each additional hour
Dimensions: 410mm x 410mm x 660mm
NOTE: Flooding font is used primarily to keep the product lines in the font as cool as possible to enjoy cold beverages even in hot or humid climates. The 'icing' effect of a flooded font is secondary to this. Your flooded font may or may not develop ice externally depending on a number of factors such as ambient temeprature and humidity levels, insulation of lines, thermal losses, reservoir temperature etc.
KL04114 | KL47364 | Icemaster Beverage Chiller G40.1 Glycol/Icebank with Digital Control | Maintenance & Troubleshooting
If the glycol solution has been stored for an extended period of time then it is suggested to replace the solution, despite glycol having antimicrobial properties. It is recommended to replace the glycol if it has changed colour dramatically or between 12 to 24 months of usage at a minimum. To replace the glycol solution empty the reservoir using the drainage port and then refill with the required concentration of glycol using a refractometer to confirm the concentration.
We recommend changing glycol solution every 12 months in order to avoid degraded performance
KL04114 | KL47364 | Icemaster Beverage Chiller G40.1 Glycol/Icebank with Digital Control | Dispensing
To dispense from the G40.1 first please enusre that all Setup and Testing steps have been performed.
The keg may need to be passed once or twice through the product lines.
A single pass through the lines will drop the temperature approximately 15°C.
If you are dispensing a keg that is already in cold storage or otherwise chilled then a single pass may be sufficient.
If the keg is at ambient or room temperature then a double pass may be required to sufficiently chill the beverage for dispensing. If the temperature of the keg is more than 15°C above the desired serving temperature then two passes through the product lines may be required to acheive the correct serving temperature.
Please refer to the below diagrams to see how to connect a keg for a single or double pass through the G40.1 product lines.
Please note that the above diagrams are for demonstration purposes only. You may have a different style coupler or tap and shank setup to what is shown in the above diagrams
The pressure the regulator is set to will differ depending on the ambient temperature of the keg and the carbonation level.
As most kegs that are dispensed through a glycol chiller are not chilled, the dispensing pressure will normally be higher than the typical dispensing pressure for a short draw, chilled system such as a kegerator. The rule of thumb is that the higher the temperature of the beverage, the higher the CO2 pressure will need to be to ensure the beverage stays adequatley carbonated and does not foam excessively due to CO2 coing out of solution.
For most styles of beer, you should be aiming for a carbonation level of between 2.3-2.8 volumes of carbonation with the average carbonation level being 2.6 volumes (if you are unsure of the carbonation level of the beer i.e. if it is a commercial keg then assume it is at 2.6 volumes of carbonation).
To achieve a specific carbonation level during carbonation or priming refer to the table in the link below and correlate the temperature of the keg with the desired carbonation level.
For example, if dispensing a standard ale at 2.6 volumes at 25°C ambient temperature, the pressure required to dispense would be ~34.7psi. Please note more or less pressure may be required due to other factors such as line length and diameter. It is always best to start at a lower than expected pressure and increase it if necessary.
NOTE: Do not try to fix a slow or fast pour rate by adjusting the dispensing pressure. The dispensing pressure should be adjust to suit the temperature and carbonation level of the keg.
Bubbles or foam in the beverage line between the keg and the G40.1 are a good indication that the dispensing pressure is loo low.
Adjusting the dispensing pressure to control the flow speed will result in your beer either going flat or over carbonated. It is best to adjust the beverage line length and diameter.
If the pour is too fast and is producing a lot of froth then increase the length of the beverage line between the G40 and the tap. Alternatively if the pour is too slow then decrease the length of the beverage line between the G40 and the tap.
When adjusting your beverage line length to achieve the perfect pour it is always best to start with a longer length of beverage line as you can always trim a longer length of hose.
For most G40.1 setups, KL06231 is recommended.
Wider diameter line may be required for very long runs.
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 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
Beer not cold enough
If the beverage is not sufficiently chilled in the glycol chiller then it will not pour well. Typically there will be lots of foam. You may need to change the setup to sufficiently chill the beverage. Refer
Reservoir not cold enough
Using 20-25% glycol solution and setting a reservoir temperature below 0°C will generally give the best results. Ensure that the reservoir temperature is not so low that the beverage freezes in the lines. Check the and adjust if needed.
Pouring too quickly
If the beverage is dispensing too quickly this can cause foaming and also flat beer. Refer for more information
Beer not dispensing
Frozen Lines/Product
If the reservoir temperature is lower than the freezing point of the beverage then the product lines may freeze. Check the and adjust if needed.
Incorrect Check Valve Installation
If using a commercial coupler such as an or check the installation of the liquid check valve. If this is not corect the liquid flow will be blocked.
Incorrect Flow Control Adjustment
If using Flow Control taps check that the Flow Control is not set too low as this can prevent liquid from pouring.
No CO2/gas
If there is no headspace pressure in the keg it is not possible to dispense from the keg. Refill or replace the CO2 cylinder with a full one
Reservoir not reaching Set Point Temperature
Set Point may be incorrect
Check the Set Point Temperature and adjust if needed.
Insufficient Clearance
A minimum of 100mm clearance is required on each side of the glycol chiller to ensure adequate heat dissipation for the condensers. Move the unit into open space to improve cooling efficiency
Glycol percentage not correct
Refer to the Glycol Percentage Chart and adjust if needed
Glycol degraded
Replace the glycol solution with fresh solution. It is recommended to replace the glycol solution every 12 months
Agitator pump not working
Not plugged in
Check that the supplied IEC is correctly plugged in
Not turned on
Check that the Agitator Pump is turned on
Beer too foamy/frothy
Insufficient CO2 pressure
The CO2 pressure generally needs to be set higher for a glycol setup to keep CO2 in solution. Refer Dispensing Pressure and adjust
Incorrect Beer Line
KL06231 5mm x 8mm EVABarrier is recommended. Wider or narrower diameter line may cause pouring issues
Replace propylene glycol solution every 12 months to avoid potential damage to pumps, lines or reservoir
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
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
Run the IEC cable for the agitator pump through the cable outlet and plug it into the external socket as shown
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.
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
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
1: KL14601 monotight - 8mm (5/16”) Female x ½' Male Thread 2: KL07481 duotight - 6.35mm (1/4'') Female x 8mm (5/16'') Female Reducer 3: KL06934 duotight – 8mm (5/16”) Female Ball Valve/Shut Off Valve 4: KL06897 duotight – 8mm (5/16”) Female x 1/4 Inch BSP Male Thread (With Seated O-Ring) 5: KL24631 duotight - 8mm (5/16) Screwlock x 8mm (5/16) Elbow 6: KL02370 duotight – 8mm (5/16”) Female x 8mm (5/16”) Female Push In Joiner with KL06958 8mm duotight plug 7: KL02370 duotight – 8mm (5/16”) Female x 8mm (5/16”) Female Push In Joiner 8: KL02400 duotight – 8mm (5/16”) Female x 8mm (5/16”) Female Push In Elbow
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)
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.
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
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)
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
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)
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
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
Hold the ‘S’ button until F1 is displayed
Press ‘S’ again which will enter temperature adjustment mode
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).
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.
The reservoir temperature is controlled with the STC-1000 Temperature Controller.
Setting the reservoir temperature:
Locate the STC-1000 Temperature Controller
Hold the S Button until F1 is displayed
Press S Button again which will enter temperature adjustment mode
Then hold the S Button 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
0
0.0°C
1.000
10
-3.3°C
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.
Once the desired temperature has been entered, press and release the power key to save the parameter
1.006
20
-7.8°C
1.015
30
-13.3°C
1.024
