P156909 Pulsar User Manual.indd
Contents
1. fan motor Integral units only MO46782 MO46785 MO46785 SG 85 0260 Box fan not shown bracket for fan motor P147102 P147103 P147103 SG 85 0262 fan blade SG 85 0168 SG 85 0082 SG 85 0082 SG 85 02612 condenser SG 81 0080 SG 81 0080 CN49700 CN73348 ice bank control SG 83 0009 H SG 83 0009 H SG 83 0009 H SG 83 0009 H level control SG 83 0401 H SG 83 0401 H SG 83 0401 H SG 83 0401 H ice bank sensor SG 41 1925 1 SG 41 1953 1 SG 41 1470 2 SG 41 2273 tube water in on request double check valve water SG 42 0857 100 SG 42 0857 100 SG 42 0857 100 SG 42 0857 100 elbow cross piece P144879 P144879 P144879 P144879 threaded adaptor SG 42 0120 SG 42 0120 SG 42 0120 SG 42 0120 at outlet SG 33 0167 30 at inlet carbonator pump 1 SG 42 0035 30 SG 42 0035 30 SG 42 0035 30 SG 42 0035 30 threaded adaptor SG 33 0167 30 SG 33 0167 30 SG 33 0167 30 SG 33 0167 30 circulation pump SG 42 0127 20 SG 42 0127 20 SG 42 0127 20 SG 42 0127 20 carbonator bowl SG 42 0922 20 SG 42 0922 20 SG 42 0906 30 SG 42 0906 30 threaded connector JOHN GUEST on request check valve CO2 SG 42 0955 SG 42 0955 SG 42 0955 SG 42 0955 tube COz in on request tube cross piece carbonator bowl on request cross piece JOHN GUEST on request agitator motor SG 85 0264 10 SG 85 0264 12. 10 C condensing temp 55 C and ambient temp 32 C X i GE H2 Ki SE H1 ae oem ee 4 E ps D q i Nn D cc e N T ae w N 11 Section 4 INSTALLATION INSTRUCTIONS PULSAR SODA CIRCUIT COOLER RANGE INSTALLATION INSTRUCTIONS FOR INTEGRAL amp WATER COOLED UNITS NOTE The unit should be installed and serviced by a suitably trained person NOTE Sealed plugs may be fitted to new units 1 Unpack the unit from its transportation packing and visually check for any signs of damage 2 Site the unit in a convenient location in the cellar or room on a level surface where it is to be located and make sure that a mains electricity supply is within 2 meters and in an area allowing free circulation of air The unit should be fitted with a correctly fused and wired 13 amp plug fitted with the correct fuse as below or alternatively a standard Euro Plug to IEC83 1975 Fuses for standard UK plug Pulsar 40i Integral amp Water Cooled 10 AMP FUSE Pulsar 60i Integral amp Water Cooled 10 AMP FUSE Pulsar 80i Integral amp Water Cooled 13 AMP FUSE Pulsar 100i Integral amp Water Cooled 13 AMP FUSE 3 If the unit is a water cooled version the glycol module and heat dump must be installed and connected as detailed in the GLYCOL MODULE AND HEAT DUMP INSTALLATION INSTRUCTIONS on pages 14 21 in this manual before commissioning the complete system 12 4 Connect the dispense head to the unit using suitable f
3. Multiplex Pulsar 40i 60i 80i 100i Circuit Carbonators EC Declaration of Conformity EC Guideline Electro Magnetic Compatibility 2004 108 EC Machinery Directive 2006 42 EC has been fulfilled The safety targets regarding the Low Voltage Directive 2006 95 EC according to the following co ordinated standards have been applied BSEN 60335 1 2002 A14 2010 Refrigeration Household Safety BSEN 60335 2 89 2003 Refrigeration Motors and Pumps Household and Similar Electrical Appliances Safety particular requirements for US ER INSTALLATION amp commercial refrigerating appliances with an incorporated or remote refrigerant condensing unit or compressor MAI NTEN AN CE MAN UAL BSEN61000 6 3 2001 Electromagnetic emissions compatibility EMC Generic standards PRODUCT CODE PULSAR 40i 02 22XX XXXX BSEN61000 6 1 2001 Radiated and Immunity compatibility EMC Generic standards PULSAR 60i 02 23XX XXXX PULSAR 80i 02 24XX XXXX PULSAR 100i 02 25XX XXXX MANUAL PART No P156909 MANUAL REVISION REV 1 2011 Manitowoc DATE 12 10 11 continuing product improvements may necessitate change of specification without notice Head Office Tel 44 121 501 2566 www manitowocbeverage com Manitowoc Beverage Systems Fax 44 121 500 0873 mbs uk manitowoc com anit Owoc Chancel Way Halesowen anirfowoc West Midlands B62 8SE UK Table of Contents Dear Customer Please read these operating instructions carefully Examine
4. Is the Soda recirc Pump Running Switch pump on atthe switch on the front panel Is there flow of Soda water around the Python and at the dispense head Connect Soda Pump to it s mating connector Are the Pump isolation valves open Open Isolation Valves System is working correctly Check the Python lines are clear from blockages there are no kinks and the coils within the bath arel not frozen Yes 4 Check for air locks within the soda recirc lines Bleed out at the dispense head and re prime Section 11 Clear Blockage unkink or replace damaged pipe De ice coils and rectify over icing problem Thermostat fault Is the flow of Soda water around the Python and at the dispense head Yes gt System is working correctly No Faulty pump head Change pump 31 Section 11 FAULT DIAGNOSIS FLOW CHART PRODUCT TOO WARM Switch Cooler on Allow the cooler to produce a full ice bank before dispensing product 30 IS THE COOLER SWITCHED ON Has the unit got an ice See refrigeration fault bank finding chart See Soda Recirculation pump fault finding chart Is the soda recirculation pump working Possible air lock in soda recirc lines Bleed out at the dispense head reprime Check for recirculation at the dispense head cold pipes condensation etc Is the Agitator motor See Agitator Motor
5. E EEEE AE sais seins SECTION 5 Maintenance requirements es scsi AEN Ed ANE eet EEN Gaia ba KEE ANS d SECTION 6 Exploded drawing and spare parts of Pulsar i eee ce eee eee eee ene e teen enneee SECTION 7 FOR QUALIFIED ENGINEERS ONLY Exploded drawing and spare parts of Glycol Module SECTION 8 FOR QUALIFIED ENGINEERS ONLY Flow Diagram SECTION 9 FOR QUALIFIED ENGINEERS ONLY Wiring EI EL ET REES SECTION 10 FOR QUALIFIED ENGINEERS ONLY Fault Analysis SECTION 11 FOR QUALIFIED ENGINEERS ONLY Fault Diagnosis flow chart product too warm Fault Diagnosis flow chart soda recirculation pump 0c cece eee eet ee eee e eens Fault Diagnosis flow chart agitator motor 0 cece cece ee tee eee eee eee tenes Fault Diagnosis flow chart refridgeneration system 00 cece cece eee eect eee ee eee Fault Diagnosis flow chart heat dump water cooled units 0 scene eee ee eens Fault Diagnosis flow chart glycol module water cooled units 0e seen eee eee 11 12 16 15 16 16 21 17 18 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 Section 11 FAULT DIAGNOSIS FLOW CHART GLYCOL MODULE WATER COOLED UNITS Is the pump plugged into its mating connector Check for 240V supply at connection Yes Faulty pump motor IS THE GLYCOL PUMP OPERATING Is the glycol level Plug pump into in the header tank connector between Max and Min marks
6. FOR EVIDENCE OF LEAKS VISUALLY INCLUDING THE HEAT DUMP CHECK THAT THE CONDENSER GRILL AND VENTS ARE NOT CHOKED OR OBSCURED INCLUDING THE HEAT DUMP IF THERE IS ANY SPILLAGE OF LIQUID ONTO THE UNIT ISOLATE THE POWER SUPPLY BEFORE CLEANING UP MAKE ANY NECESSARY ADJUSTMENTS AS RECOMMENDED BY THE SYRUP SUPPLIER NOTE THERE ARE NO USER SERVICEABLE PARTS UNIT WEIGHTS Pulsar 40i Integral 75 kg Dry Pulsar 40i Water Cooled 73 kg Dry Pulsar 60i Integral 79 kg Dry Pulsar 60i Water Cooled 77 kg Dry Pulsar 80i Integral 92 kg Dry Pulsar 80i Water Cooled 90 kg Dry Pulsar 100i Integral 145 kg Dry Pulsar 100i Water cooled 143 kg Dry GLYCOL MODULE 13 kg Dry HEAT DUMP 9kg Dry Warning ONLY LIFT THIS EQUIPMENT IN ITS DRY STATE Section 2 Section 10 METHODS OF CLEANING Cleaning instructions for Pipeline FAULT ANALYSIS beer line cleaner NOTE Kind of malfunction Reason Solution Persons performing Cleansing Sanitizing opera tions MUST be competent and fully trained in safe methods of use of Cleansing Sanitizing Agents and their applications Personal protective equipment should always be used Do not use a water or steam hose to clean the unit whilst still installed It is important that all the vents and grills are kept clear including condenser grills where applicable otherwise cooling performance decreases and the system overheats RECOMMENDED LINE CLEANING METHOD
7. use Keep cylinder away from heat Drop or throw cylinders Try to unscrew fittings from containers Ventilate area after CO2 leakage This information should be displayed in a position adjacent to the CO2 supply cylinder at all times FAULT DIAGNOSIS FLOW CHART REFRIGERATION SYSTEM Is the system fault light if fitted on WATER COOLED ONLY IS COMPRESSOR RUNNING WATER COOLED UNITS No compressor Compressor Section 11 AIR COOLED UNITS temperature 32 C No Has the unit been subjected to heavy product draw F Are the coils H bank thermostat yes Was E Ve GE the compressor ui CSL will not switch off will not switch off Yes No Yes Is there 230 Follow a Go Se p 9 thermostat thermostat Yes Y_ Change Is the Heat Follow heat Faulty fan motor S Is the condenser fan ay capacitor and Dump fan No gt dump fault rani No or wiring start relay running guide g connection yes Is the glycol Is the 5 SE Is the Condenser Clean condenser compressor Yes End aler Follow Glycol blocked or airflow Yes ensure good running andisit No gt Module fault restricted airflow guide T recirculating T No adequately No Fault Change Is the unit sited in an y g Yes excessive ambient Yes Resite unit Leave unit to recover Yes
8. 0 SG 85 0264 10 SG 85 0264 10 2 off cross piece tube circulation pump on request carbonator bowl tube prechill coil on request housing tube soda recirc pump on request 83 0401 0001 if with carbonator pump time out facility 1 in stainless steel on request Electrical components for other voltages frequencies than 230 VAC 50 Hz on request For water cooled units and versions with still water boost Not shown PI51293 Plate heat exchanger Not shown SG 82 1006 Thermostatic expansion valve Not shown SG 82 0055 Penn valve Not shown SG 82 0108 Dryer accumulator Not shown SG 83 0018 High pressure switch Only for water cooled units Not shown SG 83 0775 10 PCB still water boost Not shown SG 83 0775 0500 PGB still water boost via electrical demand Not shown SG OP73971 Solenoid Not shown SG 33 0462 Crosspiece for pressure switch Not shown SG OP74246 Water pressure regulator Not shown SG 83 0868 Low pressure switch Only for versions with still water boost 25 Section 6 24 EXPLODED DRAWING AND SPARE PARTS OF PULSAR i Section 4 14 Switch on the unit at the mains power supply and allow ice bank to build Mains plug must be accessible 15 If the unit is a water cooled version ensure that the glycol lines prime correctly and that the glycol module is topped up to the corre
9. 3 0009 H Controller ANNUALLY By a competent service maintenance engineer Isolate unit from mains electricity supply Remove any extraneous debris from the unit or its casing preferably using a vacuum cleaner or brush including the heat dump Check unit for electrical safety PREVENTION OF FREEZING ACTION RE QUIRED IF FREEZING OCCURS It is recommended that the unit is sited In such a way as not to expose it to temperatures likely to cause freezing i e below 0 C If the unit is to be sited in an unheated area then insulate all pipework and provide some form of emergency heating which should be controlled by a frost thermostat sited in close proximity to the unit It should be noted that heat dumps may require to be sited where freezing may occur which is why a 30 glycol water mixture is used as a coolant Failure to adhere to this recommendation could result in damaging consequences The concentration of the coolant should not be compromised and in the event of spillage the lost volume should be replenished with the correct mixture NOTE A 30 glycol mixture is suitable for operation in temperatures as low as 12 C For operation in temperatures as low as 25 C a 50 glycol mixture is required In the event of freezing up occurring the following action is recommended 1 Isolate the unit from mains electricity supply 2 Disconnect the heat dump power cable 3 Isolate product supply from unit 4 Vent
10. 3630 BRASS TAIL A57021 3 STAGE MAG DRIVE PUMP OP73168 SHUT OFF VALVE OP73326 CHECK VALVE OP74396 TRANSFORMER wlolrjalujalwin a OP73829 SEALED PLUG 2 WAY OP73828 SEALED SOCKET 2 WAY HEIGHT 435mm WIDTH 380mm DEPTH 220mm DRY WEIGHT 13kg TEM PART No N51290 G OPERATION WEIGHT 25kg DESCRIPTION 3 ROW HEAT DUMP COIL P142728 IN LINE HINGE P148354 10 SUCKER FAN BLADE MO46688 25 WATT Q MOTOR EBM P145861 HEAT DUMP COWL VISION Section 3 Technical Data f Pulsar 40i Pulsar60i Pulsar80i Pulsar 100i Electr Power 230V 50Hz 230V 50Hz 230V 50Hz 230V 50Hz 230V 60Hz 230V 60Hz 230V 60Hz 230V 60Hz Input Power 1000W 1200W 1300W 1650W Compressor SC12 G SC18 G SC21G CAJ4511 12cm3 18cm3 21cm3 33cm3 3 8HP 2 3HP 4 5HP 1 3HP Danfoss Danfoss Danfoss Danfoss Cooling 464W 684W 792W 1252W capacity 1 Refrigerant R134a R134a R134a R134a Integral 375g 375g 425g 1100g W Cooled 275g 275g 275g 800g Water Bath 38 litres 51 litres 65 litres 114 litres Ice Bank Size 13 2 kg 20 kg 25 kg 50 kg Height H1 560mm 590mm 630mm 830mm Height H2 480mm 510mm 550mm 670mm Width W 700mm 750mm 865mm 1100mm Depth D 430mm 460mm 535mm 625mm Weight dry 75 kg 79 kg 92 kg 145 kg Heat Dump 9 kg dry Weight Glycol Module 13 kg dry 1 at evaporation temp
11. 4V TRANSFORMER FAILURE 7 WIRING FAULT THE SYSTEM WILL RESET ITSELF BUT IF THE FAULT PERSISTS IT SHOULD BE RECTIFIED BEFORE FURTHER OPERATION Section 4 HEAT DUMP INSTALLATION INSTRUCTIONS NOTE The unit should be installed and serviced by a suitably trained person 1 Unpack the unit from its transportation packaging and visually inspect for signs of damage N Site the dump in a convenient location preferably in a non heat sensitive and shaded area on the outside of the building If it cannot be installed outside ensure that the area is free from other heat sources and is adequately ventilated to prevent heat build up from the hot exhaust air from the heat dump In either situation the heat dump should be sited to allow free circulation of air The maximum recommended height of the heat dump above the cooler is 9 meters w Remove the wall mounting bracket from the assembly mounted on lift off hinges Slacken the two fixing screws securing the cover fan assembly to the condenser matrix swing the cover open and lift off the assembly 4 With reference to the above drawing drill the surface onto which the heat dump is to be fitted at the stated mounting hole centers ensuring that adequate clearance is allowed around the heat dump to allow future access for cleaning The wall mounting bracket can be used as a guide for marking its hole centers Ensure that the wall mounting bracket is mounted squarely
12. AND REPRESENT THE CURRENT STANDARD OF TECHNOLOGY SAFETY DURING INSTALLATION OPERATION AND DECOMMISSIONING CAN ONLY BE ENSURED BY FOLLOWING THE INSTRUCTIONS IN THIS USER MANUAL ANY WORK OR MAINTENANCE MUST BE CONDUCTED IN ACCORDANCE WITH THE FOLLOWING SAFETY INSTRUCTIONS TECHNICAL CHANGES TO SAFETY OR ELECTRICAL DEVICES OR THE MAINS LEAD ARE STRICTLY FORBIDDEN INSTALLATION MAINTENANCE AND REPAIR ON THIS EQUIPMENT MUST BE CARRIED OUT BY SUITABLY TRAINED PERSONNEL ONLY USE GENUINE SPARE PARTS NON COMPLIANCE WITH THESE INSTRUCTIONS MAY RESULT IN SERIOUS INJURY OR DEATH MANITOWOC AND ITS LEGAL ENTITIES ENSURE NO LIABILITY FOR DAMAGE CAUSED BY THE USE OF NON GENUINE SPARE PARTS OR BY IMPROPER TREATMENT OF THE EQUIPMENT Warning SYSTEM PRESSURE THE CARBONATOR IS AN INTEGRAL PART OF THE UNIT AND IT SHOULD BE NOTED THAT THE CARBONATION PROCESS INVOLVES THE USE OF HIGH PRESSURES AND POTENTIALLY NOXIOUS GAS AND AS SUCH DUE CARE SHOULD BE TAKEN WHEN HANDLING INSTALLING AND MAINTAINING THE EQUIPMENT WITH PARTICULAR REGARD TO THESE HAZARDS Section 2 1 ALWAYS 2 NEVER 3 NEVER 4 ALWAYS 5 ALWAYS 6 NEVER 7 NEVER 8 ALWAYS AX Warning CARBON DIOXIDE Connect the CO2 or gas cylinder to a REDUCING VALVE Try to connect cylinder directly to product container Interconnect soft drinks CO2 or gas cylinder equipment with other equipment Secure cylinder upright whilst in
13. IMPORTANT Persons performing Cleansing Sanitizing operations MUST be competent and fully trained in safe methods of use of Cleansing Sanitizing Agents and their applications IMPORTANT Personal Protective Equipment Should Always Be Used IMPORTANT Do Not Use A Water Or Steam Hose To Clean The Unit Whilst Still Installed Clean and sanitize the cooling coils and product lines using a proprietary cleanser sanitizer of the Alkaline Hypochlorite type in accordance with the manufacturer s recommendations MBS recommends the use of Pipeline beer line cleaner which changes colour according to the condition of the product lines It is available from beer and soft drinks wholesalers or direct from Chemisphere UK Ltd 143 149 Bath Road Kettering Northants NN16 8NE See above for detailed cleaning instructions Draw clean water through the system until it all traces of product have disappeared Mix the beer line cleaner with clean water in the ratio specified in the instructions typically 1 capful per 4 5 litres gallon The solution will be purple in colour NOTE use the appropriate personal protective equipment to avoid splash burns or damage to eyes from splashes Connect the line cleaning solution to the lines to be cleaned Draw the line cleaning solution through the dispense tap If the lines are particularly contaminated with yeast or bacterial growth the run off will be green grey blac
14. Internal wiring Is the glycol fault or faulty Top upto mixture electrical feed met recirculating Yes land check for leaks from base unit adequately Are the shut off valves open on the connections to the pump Open shut off valves Yes Are the glycol lines connecting the heat dump blocked collapsed or restricted in any way Ensure tubing is the correct type Cobracol and ensure pipes are not secured together and are away from heat sources Clear blockage or restriction Yes Possible air lock in system Bleed air lock out of system and re prime Is the glycol mixture recirculating adequately Yes System OK No Is the heat dump sited more than 12m lift away from No Faulty pump the glycol module Yes Re site heat dump closer to glycol module 35 Section 11 FAULT DIAGNOSIS FLOW CHART HEAT DUMP WATER COOLED UNITS Is there 24 V at the heat dump No Check for 24V supply at the socket on the glycol module Check for 24V output at transformer in glycol module Check for 240V on input to transformer Yes Yes Yes Yes Replace fan motor Broken wire between glycol module and heat dump Internal wiring fault between transformer and socket Replace transformer Internal wiring fault or power supply problem from base unit Is the condenser matrix blocked with debris No Is th
15. No Is the python length excessive or exposed to high temperatures No Check for refrigerant leaks Re route python and resite unit closer to dispense point Yes Repair refrigerant leak Yes 33 Section 11 FAULT DIAGNOSIS FLOW CHART AGITATOR MOTOR Is the unit switched on Yes Is the Agitator Motor electrical connector plugged into it s mating socket Yes Can the Agitator shaft be rotated by hand Yes Agitator motor electrical fault Change the Motor and or start capacitor sited in the control box 32 Is the Agitator Motor running System operating correctly Plug the connector into it s mating socket Agitator motor seized Change the Motor Section 2 warning CARBON DIOXIDE CARBON DIOXIDE LEAKS ARE POTENTIALLY FATAL IF CONCENTRATIONS RISE TO DANGEROUS LEVELS IN VIEW OF THIS THE INSTALLATION SHOULD BE REGULARLY CHECKED FOR INTEGRITY AND THE GENERAL AREA OF INSTALLATION PROPERLY VENTILATED AT ALL TIMES warning WARNING THIS EQUIPMENT MUST BE EARTHED THE WIRES IN THIS MAINS LEAD ARE COLOURED IN ACCORDANCE WITH THE FOLLOWING CODE Green and Yellow Earth EI Neutral BROW Ms esseistinen Live As the Colours of the Wires in the Mains Lead of this Appliance may not correspond with the Coloured Markings identifying the Terminals in the Plug to be fitted proceed as follows a The wi
16. RMETIC CIRCUIT CAN ACHIEVE EASILY 10 C WITHOUT TAKING PREVENTIVE STEPS THIS CAN BE A POTENTIAL SOURCE OF ACCIDENTS WHILST CLEANING OR MAINTENANCE OF PARTS AT SUCH TEMPERATURES Warning PUMP PRESSURE TO THE CARBONATOR BOWL CAN REACH 13 6 BAR 200PS1 Warning THIS APPLIANCE IS NOT INTENDED FOR USE BY PERSONS INCLUDING CHILDREN WITH REDUCED PHYSICAL SENSORY OR MENTAL CAPABILITIES OR LACK OF EXPERIENCE AND KNOWLEDGE UNLESS THEY HAVE BEEN GIVEN SUPERVISION OR INSTRUCTION CONCERNING USE OF THE APPLIANCE BY A PERSON RESPONSIBLE FOR THEIR SAFETY CHILDREN SHOULD BE SUPERVISED TO ENSURE THAT THEY DO NOT PLAY WITH THE APPLIANCE warning HEAT THE COMPRESSOR CONDENSER HIGH PRESSURE REFRIGERATION TUBES AND MOTORS WILL BECOME HOT DURING OPERATION PLEASE AVOID ANY CONTACT TO THESE PARTS DURING AND AFTER OPERATION UNTIL THEY HAVE COOLED DOWN warning SHARP EDGES MANITOWOC TRY TO AVOID ANY SHARP EDGES BASED ON THE METHODS OF PRODUCTION AND THE MATERIAL USED THIS CAN NOT ALWAYS BE GUARANTEED THEREFORE HANDLE THE UNIT WITH CARE TO AVOID POSSIBLE CUTS FAULT DIAGNOSIS FLOW CHART SODA RECIRCULATION PUMP Has the Soda Pump been switched off Is the Soda recirc Pump electrical connector plugged into it s mating socket Disconnect the pump head from the motor and switch back on Does the motor run No Faulty pump motor Change motor
17. TALLATION INSTRUCTIONS NOTE The unit should be installed and serviced by a suitably trained person Site the glycol pump module within 2 meters of the base unit and use the bracket supplied to secure the module to a wall Alternatively position the unit on a flat level surface 2 Connect the glycol modules power supply to the 240V power outlet socket on the base unit DO NOT SWITCH ON YET 3 Using Cobracol tubing connect the 6 N OO Section 4 Finally connect the 1 5mm twin wire coming from the heat dump to the 24V outlet socket on the glycol module using the two pin plug supplied with the glycol module It does not matter which way the wires are connected as they are not polarised Ensure the lines are correct and secured neatly and free from kinks Fill the glycol module reservoir tank with a quantity of coolant mixed 30 glycol to 70 water ensuring a quantity remains for topping up the system when priming NOTE A 30 glycol mixture is suitable for Operation in temperatures as low as 12 c For operation in temperatures as low as 25 c a 50 glycol mixture is required In the event of freezing up occurring the following action is recommended COOLANT FLOW from the glycol module to the COOLANT IN on the It is important that all the vents and grills base unit are kept clear including condenser grills where applicable 4 Install the heat dump as describ
18. ct level 16 Switch on re connect the carbonator pump and allow the bowl to fill Until the pump cuts out 17 Prime the dispense head by operating the valves and ensure all pockets of CO2 are removed from system 18 Switch on reconnect the soda pump 19 Connect the syrup containers and operate dispense valves until syrup is dispensed 20 Refit the top cover to the base unit 21 The dispense head can now be brixed and the system will be ready to use 13 Section 4 HEAT DUMP AND GLYCOL MODULE INSTALLATION WATER COOLED UNITS HEAT DUMP GENERAL GUIDELINES 1 It is important that the heat dump is sited correctly to enable it to work efficiently The guidelines below should be adhered to wherever possible 2 Ensure the unit is sited on an outside wall preferably non south facing in the correct orientation out of direct sunlight 3 Ensure there are no other heat sources Le a condensing unit or another heat dump in the immediate vicinity where hot air may be re circulating 4 Use the recommended tubing 15mm O D 10mm I D Special EVA to connect the base unit to the heat dump Do not use PVC braided tube as this is not compatible with glycol and will degrade over a period of time 5 Do not exceed the recommended distance and lift from the base unit to the heat dump of 9m lift 40m run 6 The heat dump must be connected using a minimum of 1 5mm two core cable If a smaller cable is used a volta
19. e compressor plug and finish the installation up to point 21 Water cooled unit equipment connection schematic HEAT DUMP 230V Mains Supply 24V Supply BASE UNIT GLYCOL MODULE w A 230V Supply C gt Coolant Flow lt 16 9 After the condenser matrix is fully fitted to the mounting surface hang the cover fan assembly onto its hinges With the cover fan assembly open connect the wires from the fan to the terminal block Note Ensure that the wiring from the fan is routed through the plastic clip provided to prevent the possibility of the wires becoming entangled in the fan blade Ensure That Fan POWER ISOLATION METHOD 1 SWITCH OFF THE SOCKET THAT THE BASE COOLER UNIT IS INSTALLED INTO 2 REMOVE THE PLUG FROM THE SOCKET CORRECT SAFE HANDLING HANDLING OF THIS UNIT OFFERS NO SPECIFIC HAZARD UNIT WEIGHT 9KG 20LB DRY Wiring is routed through Retaining Clip Section 4 10 Connect the wiring and the Pipework to the cooler following the instructions supplied with the cooler Recommended materials for heat dump to cooler connections Pipework 15mm OD x 10mm ID COBRACOL tubing Cable 1 5 mm sq 2 core white PVC covered no earth 21 Section 4 Fit Condenser Matrix Close Condenser Matrix Against Mounting Surface and Mark Fixing Hole Position Do not strap the flow and return pipes together as heat transfer between the tw
20. e heat dump sited in full sunlight or near other heat sources without adequate ventilation Is the glycol recirculating adequately No Refer to Glycol Pump fault guide Clean radiator matrix Re site heat dump 34 The Pepsi Intellicarb Standard Thank your for purchasing this product You have chosen equipment which has been developed together with and approved by Pepsico to meet the new Intellicarb standards The Pepsi Intellicarb standard marks a new quality benchmark for dispensed soft drinks To ensure that the quality of the dispensed drinks is as expected we recommend the following e Ensure that the CO2 pressure is between 75 and 90 psi 5 1 6 1 bar e The use of high flow valves i e Flomatic 464 to keep the break out of CO2 during dispense as low as possible Follow recommended brix ratios and flow rates If you have any questions or need technical support please contact us on the telephone numbers on the back of this manual Section 1 warning WAYS THE EQUIPMENT SHOULD BE USED THE UNITS ARE INTENDED FOR USE AS A COOLING AND RECIRCULATION UNIT FOR SYRUPS AND CARBONATED WATER TO PROVIDE THE CORRECT CONDITIONING FOR SERVING DRAUGHT SOFT DRINKS AND AS SUCH SHOULD ONLY BE USED FOR THAT PURPOSE THERE ARE NO OTHER RECOMMENDED USES FOR THIS EQUIPMENT warning SAFETY INSTRUCTIONS THE UNITS COMPLY WITH THE CURRENT STANDARDS AND REGULATIONS OF THE EU
21. ed on pages 14 21 9 On the base unit locate the compressor switch and ensure that it is in the OFF position This will aid with priming of the cooling system 5 Again using Cobracol tubing connect the COOLANT OUT from the base unit to the FLOW on the heat dump Connect the RETURN on heat dump to the COOLANT RETURN on the glycol module to complete the circuit Alternatively if the unit only has a power on switch unplug the compressor plug from the distribution board NOTE Maximum Lift 9m Maximum Run 40m DISTANCE FROM BASE UNIT TO HEAT DUMP 5m 4 25 Itr APPROX VOLUME OF GLYCOL APPROX VOLUME OF WATER 8 25 Itr 9 00 Itr 9 25 Itr 10 00 Itr 10 60 Itr 15m 4 50 Itr 20m 4 75 ltr 30m 5 00 Itr 40m 5 40 Itr 22 15 Section 4 10 Refer back to the base unit installation instructions on page 12 and complete the installation up to point 14 Upon switching the unit on the pump in the glycol module will start together with the heat dump fan the refrigeration remaining off As the system primes the level will drop in the coolant header tank Keep topping this up until the system is full there are no air locks and that coolant is returning freely into the header tank If the system trips out on the thermal switch whilst priming this will have to cool before it automatically restarts 11 Switch the compressor switch to ON or re connect th
22. er 5 Siphon or pump out water from the waterbath to a suitable drainage point Allow ice bank to melt the careful use of hot water may be used to accelerate this process Remove any remaining water from melting the ice 7 Drain all the glycol water from water cooled units into a suitable container and dispose of it in accordance with the instructions given by the dispense equipment owner LA CH 10 IMPORTANT FAILURE TO REMOVE ALL ICE WATER COULD RESULT IN SUBSTANTIAL AMOUNTS OF WATER BEING RELEASED FROM THE UNIT WHICH MAY BE DETRIMENTAL TO THE UNIT AND OR ITS SURROUNDINGS AND INCREASE THE MAXIMUM WEIGHT OF THE UNIT Section 8 FLOW DIAGRAM BEEE HOI BEBE BEAL o 0 O q d q Water filter and pressure reducer min dyn pressure 2 bar l d CO pressure regulator 6 bar Css S Keen n SE Ser p A E co IT Water Kiel Carbonated Water CO bottle soda recirc coil prechilling coil evaporator coil P1 carbonator pump brass P2 soda recirc pump INOX 27 Section 7 EXPLODED DRAWING AND SPARE PARTS OF GLYCOL MODULE o 26 ITEM PART No DESCRIPTION OP73718 FILLER PLUG OP73363 15mm ELBOW OP7
23. everage is foaming Dispense rate too high Reduce dispense rate Syrup too old or saturated Change syrup Beverages too warm Look at section Beverages too warm Flat Drinks CO2 cylinder empty Change CO gt 2 cylinder Pressure regulator is shut off Open valve Pressure regulator frozen due to dispense rate too high Either split CO2 feed to several cylinders or install a pressure regulator heater Mains water pressure higher Modify pressure than CO2 pressure settings Valve dispenses only gas Carbonator pump defective Exchange pump Water valve shut off or carbonator not connected to mains water Open valve or connect unit to mains water Level control defect Exchange level control Soda circuit frozen Melt ice bank search for the reason and repair see section soda circuit frozen Soda circuit frozen Ice bank control defect Change ice bank control Agitator defect Change agitator Beverage is too sweet Wrong brix adjustment at dispense valve Modify brix adjustment 29 Section 9 WIRING DIAGRAM 28 Waterbath Level electrodes Ice bank E probes Recirc pump Carbonator pump Compressor Agitator motor Solenoid valve Transformer Fixed at the Machine area PE mains connector Fixed at the housing Thermo contact 83 0401 H 8
24. ge drop will occur which may cause the fan motor to run ata reduced speed 14 7 If the unit is to be installed inside a building or room ensure that there is adequate ventilation within the room to enable the heat to be dissipated effectively Temperatures within the room should not exceed 40 C 8 Do not kink the flow and return tubes which would restrict the coolant flow 9 Do not insulate the flow and return lines 10 The flow and return lines must not be strapped together as heat transfer between the two will effect the system performance 11 Ensure that the heat exchanger matrix of the heat dump is kept clean and free from obstructions It is recommended that it should be cleaned with a soft brush at regular intervals 12 To enable the heat dump to be mounted on a flat surface a floor standing mounting kit is available as an option Order part number 09 0203 01 PREVENTION OF FREEZING ACTION REQUIRED IF FREEZING OCCURS It is recommended that all exterior Pipework to the unit is insulated to prevent freezing In the event of freezing up occurring the following action is recommended 1 Isolate the unit from base coolers electricity supply 2 Apply gentle warmth to the general area of the unit and its pipework taking care not to scorch burn the insulation tubing surrounding the pipes 3 Check for obvious leaks 4 Reconnect the base cooler mains electricity supply 5 Observe t
25. he unit running fora short time watching out for leaks strange noises or any form of malfunction If no problems are observed the normal operation of the unit may be resumed MAX MIN ambient temperatures Minimum 25 C dependant on glycol mix Maximum 40 C Section 5 DISMANTLING DECOMMISSIONING PROCEDURE 1 Isolate the unit from the base cooler or glycol module electricity supply 2 Disconnect the recirculating coolant inlet and outlet pipes Warning THIS UNIT CAN CONTRIBUTE TO THE AMBIENT TEMPERATURE Warning THIS UNIT IS UNSUITABLE FOR USE BY UNSUPERVISED CHILDREN INFIRM OR AGED PERSONS 23 Section 5 ADJUSTMENTS MAINTENANCE REQUIREMENTS IT IS NOT RECOMMENDED THAT THE END USER MAKES ANY ADJUSTMENTS OR CARRIES OUT ANY MAINTENANCE OTHER THAN 1 Check the 24V cable and connections visually for condition 2 Check the unit and its pipework for any evidence of leaks visually NOTE THERE ARE NO USER SERVICEABLE PARTS Methods of cleaning TWICE ANNUALLY By a competent service maintenance engineer 1 Isolate the unit from the Base Cooler electricity supply 2 Open the unit to access both sides of the condenser matrix and remove any extraneous debris from the unit or its casing preferably using a vacuum cleaner or brush 3 Check unit for electrical safety Do not use a water or steam hose to clean the unit whilst still installed GLYCOL MODULE INS
26. ittings and python refering to the connection diagram on the lid of the cooler and those supplied with the dispense head 5 Connect a mains water supply of 2 5 bar to 4 bar to the tube labelled WATER IN do not turn on yet 6 Connect all products to the unit as labelled do not connect to the syrup containers yet 7 Connect CO2 gas supply of 5 bar to 6 3 bar to the cooler using the tube labelled CO2 IN do not turn on yet 8 Fill the water bath with fresh clean COLD water until the overflow level is reached 9 Connect the unit to the mains electricity supply do not turn on yet 10 Remove the top cover and turn on the CO2 supply Vent the carbonator bowl using the relief valve located on the top of the bowl Additionally operate the dispense valve until the air in the python lines is purged 11 Turn on the mains water supply 12 Check for obvious leaks and rectify before proceeding any further 13 Ensure that the soda recirculation pump and carbonator pump are switched off NOTE If the unit is a version that only has a single power on switch unplug the carb pump amp soda pump connections from the distribution board Pulsar 40i Pulsar 60i description Pulsar 80i Section 6 Pulsar 100i motor for carbonator pump M074685 M074685 M074685 M 74685 motor for circulation pump MO46595 MO46595 MO46595 MO46595 compressor CM44820 CM73570 CM73433 CM46450
27. k Close the tap and leave for 10 minutes Repeat stages 4 and 5 twice or until the run off is purple in colour The purple colour denotes lines which are clean and free from contamination Disconnect the line cleaning solution and draw fresh water through the system Dispense some water into a glass or other clear vessel and check that there is no purple colour remaining If necessary draw more clean water through the system until the run off is clear The lines are now clean safe and ready for reconnection to the product Reconnect the Keg in the storage cellar area and pull product through to the tap Beverages too warm Cooler switched off or not connected to mains electricity Switch cooler on or insert plug Control damaged Change Control Compressor defective Change compressor only skilled persons Refrigerant leakage Find and repair leakage and refill circuit only skilled persons Waterbath empty Fill waterbath with clean water until over flow level is reached Recirculation pump defective or switched off Exchange recirc pump or switch it on Dispense rate too high Either reduce dispense rate or install larger capacity machine Condenser dirty or blocked Clean condenser or remove restriction blockage Agitator motor not working or blade missing Replace agitator or blade B
28. o will effect the systems performance 7 Route a twin core 24 volt supply cable 1 5mm csa through the lower guide tube and then through the strain relief grommet positioned below the two way terminal block on the condenser matrix The wires are not polarised and may be fitted either way round Rectangle Clamp 8 Ensure that the amount of cable entering through the main cover is not excessive and cannot become entangled in the fan blade Tighten the strain relief grommet to support the cable This should not be the only means of support for the cable therefore fix back to the mounting surface at regular intervals along the cable length Route 24V Supply Cable Through Lower guide Tube In Condenser Matrix Fix 24V Supply Cable 20 To Mounting Surface At Regular Intervals warning WAYS THE EQUIPMENT SHOULD BE USED THIS UNIT IS INTENDED FOR USE IN CONJUNCTION WITH COOLING UNITS MANUFACTURED BY MANITOWOC IT IS DESIGNED TO BE CONNECTED AT THE END OF THE WATER GLYCOL RECIRCULATION LINES AS MEANS OF REMOVING HEAT FROM THE COOLING SYSTEM THERE ARE NO OTHER RECOMMENDED USES FOR THIS UNIT Warning ALL WATER COOLED UNITS ARE FITTED WITH AN AUTO RESET THERMAL SWITCH TO PROTECT THE COMPRESSOR IF A FAULT OCCURS IT IS LIKELY TO BE ONE OF THE FOLLOWING 1 LOW WATER GLYCOL LEVEL 2 COOLANT LEAK 3 BLOCKAGE WITHIN COOLING SYSTEM 4 HEAT DUMP FAN FAILURE 5 WATER PUMP FAILURE 6 2
29. pressure lines by opening dispense tap 5 Isolate from heat dump coolant lines using service valve Section 2 6 Apply gentle warmth to the general area of the unit and its pipework 7 Check for obvious leaks 8 Turn water supply on whilst continually watching for leaks 9 Reconnect product supply 10 Reconnect mains electricity supply and heat dump supply 11 Observe unit running for a short period watching out for leaks strange noises or any other form of malfunction If no problems are observed then normal operation of the unit may be resumed Section 2 MAX MIN AMBIENT TEMPERATURES COOLER UNIT Minimum 5 C Maximum 40 C HEAT DUMP UNIT Minimum 25 C Maximum 40 C WITH A 50 GLYCOL MIXTURE MAX MIN WATER PRESSURES Minimum 20 PSI 1 4 BAR Maximum 60 PSI 4 1 BAR MAX MIN CO PRESSURES Minimum 75 PSI 5 1 BAR Maximum 90 PSI 6 2 BAR DISMANTLING DECOMMISSIONING PROCEDURE 1 lsolate the unit from mains electricity supply and the mains water supply 2 Drain off all post mix products including the syrup and carbonated water clean syrup lines as recommended by the syrup supplier Turn the CO off and disconnect all lines associated with the regulator also vent pressure from lines by purging the product valves as required 4 Disconnect all post mix pipework and remove dispense head equipment including the python and remove as recommended by the equipment own
30. re which is coloured Green and Yellow MUST be connected to the terminal in the Plug that is marked with the letter E or by the earth symbol coloured Green or Green and Yellow b The wire which is coloured Blue MUST be connected to the Terminal in the Plug that is marked with the letter N or coloured Black c The wire which is coloured Brown MUST be connected to the Terminal in the Plug that is marked with the letter L or coloured Red All mains voltage components are hazardous Any electrical work must be carried out by a qualified competent person Warning POWER ISOLATION METHOD ALL UNITS ARE FITTED WITH A SINGLE PHASE 3 PIN 13 AMP PLUG THE PULSAR 40 AND 60 ARE FITTED WITH A 10 AMP FUSE THE PULSAR 80 AND 100 WITH A 13 AMP FUSE ALTERNATIVELY A STANDARD EURO PLUG TO IEC83 1975 BEFORE COMMENCING ANY WORK MAINTENANCE A SWITCH OFF THE SOCKET THAT THE PLUG IS INSTALLED IN TO B REMOVE THE PLUG FROM THE SOCKET C A HEAT DUMP IS INCLUDED WITH ALL WATER COOLED UNITS THE CONNECTING PLUG SHOULD BE REMOVED FROM THE GLYCOL MODULE Section 2 Warning ROTATING PARTS SOME COMPONENTS WILL ROTATE FOR A SHORT PERIOD AFTER THE POWER TO THE UNIT HAS BEEN SWITCHED OFF THESE COMPONENTS SHOULD BE AVOIDED UNTIL STATIONARY Warning THIS EQUIPMENT CAN CONTRIBUTE TO AN INCREASE IN THE AMBIENT TEMPERATURE warning DANGER BY LOW TEMPERATURES THE EVAPORATION TEMPERATURE IN THE HE
31. running fault finding chart Has the propellor come off the agitator shaft Replace propellor Check the length and condition of the Python and installation in general If the python insulation is damaged or considered too thin for the installation it will need to be replaced Check that the python does not exceed the run as stated in the manual for the particular cooler If it does the base unit must be sited closer to the dispense head s Check there are no external heat loads between the base unit and the dispense head Python run in warm areas ducting Check that the mains water temperature is not excesively high and that the product is not stored in a high ambient area CORRECT SAFE HANDLING Pulsar 40i 60i amp 80i The weight of these units is such that other than moving it across flat ground which is facilitated by integral castors wheels option or lifting to a relatively safe height of 12 utilising two people a mechanical lifting device should be used Pulsar 100i The weights of this unit is such that other than moving it across flat ground which is facilitated by integral castors wheels a mechanical lifting device should be used Section 2 Warning ADJUSTMENT MAINTENANCE REQUIREMENTS IT IS NOT RECOMMENDED THAT THE END USER MAKES ANY ADJUSTMENTS OR CARRIES OUT ANY MAINTENANCE OTHER THAN CHECK THE MAINS LEAD AND PLUG VISUALLY FOR CONDITION CHECK THE UNIT AND ITS PIPEWORK
32. the equipment immediately after supply for transport damages Contact the manufacturer and or carrier if necessary Damage which arises by inappropriate treatment or operation is not subject to guarantee Manitowoc Beverage Systems constantly develop the products further according to their policies Manitowoc Beverage Systems reserve therefore the right to modify and to improve the products described in this documentation without previous announcement 2009 Manitowoc Beverage Systems All rights reserved Reproduction of any kind without previously written permission of Manitowoc Beverage is not allowed Pulsar is a brand of Manitowoc Beverage Systems All Other brand names specified in this documentation refer to the appropriate companies or their products Manitowoc Beverage systems are not the owner of those brand names Please read the operating instructions carefully before operating this unit SECTION 1 PepsiintelliCarb standard ssascevarinarscaaess samme SEENEN SECTION 2 Warning amp Safety IMStructions eege AEN SEA pa ned detain SECTION 3 Technical Data sue EE ET EE EE dE SECTION A Installation Inte ANE EENS EEN SE E EE EN Heat dump iandigl col medule 45 EE nade SEN E RE EEN ENER C Glycol module installation instructions uge rinni ENN ESCHER od KE ES ER EN Water cooled unit equipment connection schematic 0 cece eee eee e eee e eens Heat dump installation instructions eege NEE RENE n
33. to ensure level movement of the condenser matrix when fitted 17 Section 4 Minimum distances for mounting the Heat Dump from vertical and horizontal surfaces 30 00cm From Wall 18 2 50cm 30 00cm From Wall 13 00cm from Ceiling Mounting Holes 250 00cm From Floor 57 00cm B With cover assemby fully open lift off Either mark the position of the third mounting screw at the time of marking the wall mounting bracket position or after fitting the wall mounting bracket hang the condenser matrix on close against the mounting surface and mark the fixing position The third fixing screw will pass through the hole in the condenser matrix The retaining clamp is fitted over the screw which can then be tightened to retain the condenser matrix Section 4 Removable Wall Mounting Bracket Cover Assembly Fixing Screws 6 Connect the flow and return pipework from the glycol module and base unit to the fittings on the heat dump labelled FLOW and RETURN Secure the pipes to the mounting surface so that the weight of the pipes is not being carried on the heat dump fittings Do not kink the pipework as this will restrict coolant flow Do not insulate the pipework pipework mounted on an exterior surface may be insulated if it is felt that due to extreme conditions freezing may occur 19
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