CR-2 Countertop & CR-UC2 Undercounter Installation & Service Manual 100112
IMPORTANT: This manual is a guide for installing, operating, servicing and maintaining this equipment. Refer to Table of Contents for page location of detailed information to answer questions that arise during installation, operating, service and maintenance, or installation of this equipment.
TABLE OF CONTENTS PAGE PREFACE ........................................................................................................................... 1 CHAPTER I GENERAL DESCRIPTION ............................................................................. 2 SYSTEM DESCRIPTION ....................................................................................... 2 DESIGN DATA .......................................................................................................
TABLE OF CONTENTS (cont’d) ................................................................ PAGE CR-2 CABINET MAINTENANCE……………………………………………………...34 CLEANING CONDENSER COIL ......................................................................... 34 CHECKING/CHANGING WATER BATH ............................................................. 35 WATER PUMP MAINTENANCE ......................................................................... 36 CARBONATOR MAINTENANCE ...............................................
PREFACE Crysalli is manufactured on behalf of Western Pacific Distributors by International Carbonic Inc. INTERNATIONAL CARBONIC INC. has enjoyed over 53 years of manufacturing excellence in the field of carbonation and in the beverage related industry. They have had a long and proud history with quality as their standard and innovation as their goal. They enjoyed patents on the first Sodajet type carbonator. This method of carbonation instantaneously carbonated the water to 100% saturation.
CHAPTER I GENERAL DESCRIPTION This chapter gives the description, theory of operation, and design data for the CR-2 and CR-UC2 Crysalli units and related components. SYSTEM DESCRIPTION The Crysalli CR-UC2 series of Undercounter Artisan Water units are a configuration of cold dispensed sparkling and still filtered water, requiring a draft tower to dispense the product.
TABLE I - I DESIGN DATA COOLING UNIT Overall cabinet dimensions: Height Width Depth Weights: Shipping Dry weight Operational Weight Ice Bank CR-2 CR-UC2 24” 20” 22” 20” 20” 20” 160 135 250 25 160 135 250 25 Capacities: CR-2 Unit water bath (no ice bank) Refrigerant requirement (R-134-A) Ambient operating temperature 9 gallons 250 grams 40 F to 100 F. Capacities: CR-UC2 Unit water bath (no ice bank) Refrigerant requirement (R-134-A) Ambient operating temperature 9 gallons 250 grams 40 F to 100 F.
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CR-2 2 1 4 3 6 7 5 8 9 10 13 11 14 12 5 17 19 18 20 21 22 16 15 28 27 23 22 30 24 29 31 25 32 33 26 34 20 36 35 37 38 39 43 40 47 44 41 48 45 42 52 53 49 46 50 54 51 55 INTERNATIONAL CARBONIC INC. ICI 56 57 ADELANTO, CALIFORNIA 5 TITLE SC-BF CR-2 BIG FELLA POST MIX DATE 1/6/05 DRN. BY CHK. BY APPR.
CR-2 SYM QTY PART NO.
CR-2 Cont. SYM QTY PART NO.
CR-UC2 1 4 7 6 5 2 8 3 9 3 11 13 12 14 10 15 4 16 18 19 2 20 17 21 22 26 27 22 23 28 24 29 25 31 32 30 36 34 37 35 43 38 39 40 41 33 47 49 45 42 48 50 51 INTERNATIONAL CARBONIC INC. 44 ICI 52 53 2 55 54 46 ADELANTO, CALIFORNIA 8 SC-R TITLE CR-UC2 SPACE CADET REM OTE DATE 1/6/05 DRN. BY CHK. BY APPR.
CR-UC2 SYM QTY PART NO. DESCRIPTION 1 1 S0680 LID ASSEMBLY 2 4 A0020 SCREW, 8-32 X 3/8 T.H., S.S.
CR-UC2 Cont. SYM QTY PART NO. DESCRIPTION 26 1 S0663 EVAPORATOR ASSEMBLY 27 1 S0509 ACCUMULATOR 28 1 Z0010 CAP TUBE, 9' - .050 29 1 S0656 BUCKET COMPLETE W/INSULATION 30 1 S0655 FRAME, COMPLETE 31 12 S1325 SQUARE GROMMET NUT 32 12 A0014 SCREW, #10 X 1/2" PH T.H., S.S.
Common parts list for both Models 11
S-68-B ELECTRICAL SCHEMATIC 120 VOLT FAN M OTO R C S 3 R M 1 1 S ICE BANK CONTROL CO MPR ESSOR TRANSFORMER GREEN GREEN WHITE 120 VAC BLACK ON /OFF ON/OFF INTERNATIONAL CARBONIC INC.
DIRECT WIRE CARB-RECIRC DIRECT WIRE BLACK DIRECT WIRE WHITE DIRECT WIRE (GREEN) GROUND "USE COPPER CONDUCTOR WIRE ONL Y" TERMINAL BLOCK BOARD #1 BLACK CONDENSING UNIT BLACK WHITE BOARD #1 WHITE WHITE CONDENSING UNIT GREEN BOARD #1 GREEN BLACK ON/OFF TOGGLE FROM DIRECT WIRE BAR CONDENSING UNIT WHITE GREEN ON/OFF TOGGLE GREEN FROM DIRECT WIRE BAR WHITE 120 VAC BLACK ON/OFF I BC1 POW ER ON/OFF ON/OFF B1 G1 G2 G3 G4 A2 A3 A4 A5 B2 B3 B4 B5 I BC2 CU 1 CU 2 MOTOR2 BLACK SHO
THEORY OF OPERATION The Crysalli was designed to manufacture and dispense carbonated and non-carbonated water much like your local bottling plant that cans or bottles your favorite carbonated or non-carbonated water. Initially water is chilled and then carbonated to dispense a quality drink. To chill the water the water is routed through a water coil that is submerged in an ice-cold water bath. The temperature of the incoming water is at ambient temperature as it enters the water coil.
The level of the carbonated water within the stainless steel mixing tank is used to operate the motor driven pump. The liquid level control, in conjunction with a probe housed in the carbonator tank, controls the pump motor. The motor will come on when the carbonated water within the mixing tank recedes to a predetermined low level and stops the pump motor when the carbonated water reaches a predetermined high level.
CAUTION: In order to have even distribution of cold water, the cold-water circulating lines must always be run in series even on multiple station installations. IMPORTANT: Be sure to leave all connections and fittings exposed until after the entire system has been pressure tested. In order to insure maximum heat transfer between the braided plastic lines (through which the water and soda are carried) and the circulating tubing, it is necessary to tape these lines firmly together.
CHAPTER II INSTALLATION This chapter covers unpacking and inspection, selecting location, installing CR-UC# and related components, connecting water inlet and electrical requirements. UNPACKING AND INSPECTION Upon receiving unit, immediately remove unit from shipping carton and inspect for shipping damage. NOTE: Before leaving the factory all CR-UC# units were carefully inspected and the carrier has accepted and signed for them.
LOCATION RECOMMENDATIONS FOR CR-UC2 1. Position unit as close as possible to proper electrical source, 120V 60HZ. 2. Position unit with a minimum of 6” space between bulkhead and cabinet for sufficient ventilation (air in and air out). Pour ventilation can cause the unit to overheat and shut down or have pour performance characteristics. Allow enough space between ceiling and unit for lid removal. 3. Position unit as close as possible to water source.
SAMPLE OF POSSIBLE INSTALLATION (CR-UC2 to two towers) 19
CR-UC2 INSTALL UNDERCOUNTER 1. Select a counter location for your draft tower and a well ventilated undercounter or remote location for your CR-UC# Crysalli unit. Place the CR-UC# unit as close as possible to water filter connection & 120-volt electrical outlet. 2. Mount the draft tower and drain pan. Plumb drain line from pan to the floor sink. Use silicone on bottom and edges of pan to create a good seal. 3.
17. Check draft tower and connections for leaks. Wrap all exposed lines with insulation. 18. Once unit has built the ice bank you are ready to dispense chilled still and chilled sparkling water.
CR-2 INSTALL Countertop 1. Select a location for you chilled water dispenser. Place unit as close as possible to water filter connection & 120-volt electrical outlet. Make sure sufficient space between bulkheads, walls and overheads is available for proper air circulation around cooling unit 2. Connect water inlet line from unit to your water filter system. 3. Connect a High Pressures CO2 regulator (CR-3741) to CO2 cylinder then connect CO2 line from unit to regulator.
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INSTALLATION Cont 1. Make all connections: C02 gas, plain water . 2. Place CR-UC2 in position. Make sure sufficient space between bulkheads, walls and overheads is available for proper air circulation around cooling unit. INSTALL HIGH PRESSURE C02 REGULATOR, C02 CYLINDER AND LINES 1. Install high pressure C02 regulator (CR-3741), on C02 cylinder using a new seal gasket. MAKE SURE NEW WASHER IS INSIDE REGULATOR ASSEMBLIES COUPLING NUT BEFORE CONNECTING TO CYLINDER.
INSTALL WATER FILTER ASSY. 1. Install water filter assembly on wall or other supporting structure. 2. Connect water filter assembly to inlet of valve on water supply line using minimum 3/8" I.D. water line. Everpure QC71 Twin filter heads have ¾” fmp and must be reduced down. 3. Connect water filter assembly outlet to SCR plain water inlet fitting using minimum 3/8" I.D. water line. See CONNECTING WATER INLET.
INSTALL OVER FLOW DRAIN LINE 1. Rout drain hose or connect hose on CR-UC# unit with drain using 1/2” I.D. clear plastic pipe or 1/2” copper or PVC to nearest outlet or floor sink to capture over flow upon startup and for drain out of water bath for maintenance. If running to a floor sink run drain to local plumbing codes. 2. Do not reduce drain connection from cabinet outlet. 3.
CONNECTING THE DRAFT TOWER (CBR-V2) TO CR-UC2 The CBR-V2 draft tower contains two water lines plumbed to the faucets, one for carbonated sparkling water the other for still water. Connect these lines to the labeled braided lines from the trunk line, which extends from the CR-UC2 unit. The CBR-V2 also has two re-circ line which should be connected to the clear re-circ lines also from the trunk line. Care should be taken to wrap any exposed lines with foam tape to insulate them.
TWO CBR-V2 TOWERS INSTSALL DETAIL. ELECTRICAL REQUIREMENTS: The CR-UC# requires a 120 VAC, single phase, 60-Hertz power circuit, and must be wired in accordance with N.E.C. or local ordinance. NOTE: Check CHAPTER I for running amperage and connect to appropriate electrical circuit.
CHAPTER III PREPARATION All steps in previous chapters should be understood and carried out before proceeding. PREPARING SYSTEM FOR OPERATION Be sure that electrical power is unplugged, valve on C02 cylinder is closed, and valve on water supply line is closed, and release pressure of C02 gas and water from carbonator tank. PREPARING AND STARTING REFRIGERATION UNIT 1. CR-UC# refrigeration is pre-set at factory and ready to operate. 2. Remove lid. 3.
CHAPTER IV OPERATORS INSTRUCTIONS This chapter covers operator’s responsibilities for daily pre-operation check, adjustments, replenishing C02 and syrup supplies, cleaning, and sanitizing. DAILY PRE-OPERATION CHECK 1. Make sure high-pressure C02 regulator's pound per square inch indicator is not in shaded portion of dial. If so, C02 cylinder is almost empty and must be replaced. NOTE: This reading should be carried out at normal room temperature.
CHANGING WATER BATH Drain water bath a minimum of twice a year. This can be accomplished by siphoning water with short hose into bucket or removing over flow standpipe. Once water is drained and ice bank is melted, water bath, water coils, bath walls, tank, etc. should be cleaned. Fill water bath to the top of the standpipe, (S-657). ADJUSTMENTS Periodically C02 regulators should be checked for proper pressure settings and if necessary, adjust as instructed.
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CHAPTER V SERVICE AND MAINTENANCE This chapter describes service and maintenance procedures to be performed on SCR units and related components. PERIODIC INSPECTION AND CLEANING 1. If Sparkling water no longer has any bubble, check the CO2 tank and pressures. It is likely the CO2 is empty or at a lower pressure than the water pressure. Replace the CO2. 2.
Monthly: 1. Clean condenser fins or filter to make sure the refrigeration unit has adequate airflow. 2. Inspect components of cooling unit water bath for cleanliness. 4. Check entire system for leaks or damaged components. Repair as necessary. 5. Check the inlet water lines, if any discoloration such as green or black can be seen they system should be sanitized.
CHECKING / CHANGING WATER BATH Semi-Annually check water level in water bath. If it is low, more water should be added for maximum product cooling. Before adding more water, water bath and ice bank should be checked for excessive mineral deposit build up. NOTE: The water in water bath should be changed and all components in water bath should be cleaned as often as necessary to keep it clean. A convenient time to perform this operation is when the system is being sanitized. 1.
WATER PUMP MAINTENANCE (RECOMMEND THIS BE DONE BY A TRAINED SERVICE TECH) Warning: The water pump inlet strainer screen must be inspected and serviced at least once a year under normal circumstances of after any disruptions (plumbing work, earthquake, etc.), to the water supply systems that might cause clogged flow of water through system. Water pump with no screen or a defective screen in the strainer would allow foreign particles into water system and create a health hazard. 1.
CARBONATOR MAINTENANCE SAME AS WP 1. Unplug refrigeration unit power cord from electrical socket. 2. Remove lid from unit. 3. Look down into water bath (if necessary, use flashlight) and inspect carbonator tank for leak. Air bubbles will arise from place of leak, if leak is below surface of water. If leak is above surface of water soap bubbles should be used to find any leak. 4. Shut off plain water supply to water pump by closing shutoff valve in water supply line. 5.
ALWAYS INSTALL NEW “O” RING, (S-13). 5. Assemble check valves together as shown. 6. Connect water inlet line to double check valve assembly. 7. Activate the system as outlined in CHAPTER III.
SYM QTY PART NO. DESCRIPTION 1 1 S-14 HOUSING, CHECK VALVE 1/4" M.F. 2 3 S-13 SEAT "O" RING CHECK VALVE 3 3 S-12 SLEEVE, SEAT RETAINER CHECK VALVE 4 3 S-11 BALL, CHECK VALVE 5 3 S-10 SPRING, CHECK VALVE 6 3 S-9 GASKET, CHECK VALVE 7 2 S-6 1/8 8 1 S-16 ADAPTOR HOUSING, DOUBLE CHECK VALVE 9 1 S-15 HOUSING, CHECK VALVE 3/8" M.F. 10 1 S 11 1 12 1 13 1 14 1 15 1 2 1 5 1 / 8 BODY, BASE, CHECK VALVE 1 S 2 2 1/4" M.P.I., S.S. INLET PLUNGER WITH SEAT SPRING, 275 P.
REPLENISHING C02 SUPPLY 1. Close empty C02 cylinder shutoff valve. 2. Disconnect high pressure C02 regulator, then remove empty C02 cylinder 3. Install full C02 cylinder and connect high pressure C02 regulator. See installation procedure in CHAPTER II. MAKE SURE C02 CYLINDER IS POSITIONED IN UPRIGHT POSITION AND FASTENED WITH SAFETY CHAIN. ALWAYS OPEN C02 VALVE COMPLETELY OR UNTIL BACK SEATED DURING OPERATION. WHEN BOTTLE IS EMPTY ALWAYS CLOSE VALVE ASSEMBLY COMPLETELY.
SANITIZING PROCEDURES Your local health department rules and general area cleanliness should determine the frequency at which the unit should be sanitized. EQUIPMENT REQUIRED: When using an Everpure Water filter system, use the JT Flushing/Sanitizing Cartridge (EV9608-00) and Plug, instructions included with cartridge. 1. Fill JT cartridge with sanitizing agent and install into the last position in filter manifold, plug front position with filter plug. 2. Turn the water back on and the CO2 off. 3.
TROUBLE SHOOTING IMPORTANT: Only qualified personnel should service the SCR unit and components. WARNING: To avoid personal injury and or property damage, always disconnect electrical power, shut off plain water and CO2 supplies before starting any repairs. If repairs are to be made to the carbonated water system, bleed carbonated water system pressure before proceeding.
Frozen water bath Cooling or condensing unit nonoperational Agitator motor not operating 1. 2. 3. 4. Bad ice bank control. Refrigerant leak causing undercharge. Defective agitator motor. Dirty water bath. 3. 4. 1. No electrical power. 1. 2. Defective ice bank control. 2. 3. 4. Dirty condenser unit. Improper voltage/amperage 3. 4. 5. Loss of refrigerant. 5. 6. 7. 8. Bad overload and relay. Compressor bad. Restriction (pinched or crimped line). Agitator propeller obstructed or lost.
Note: Ice bank freezes from bottom of evaporator upward. A refrigerant leak or insufficient charge might show ice at bottom and not at top of evaporator. Compressor will 1. Ice bank control capillary tube 1. Replace ice bank control. not stop after kinked or broken. sufficient ice 2. Ice bank control stuck in closed 2. Replace ice bank control. bank is position. produced Note: During overload protector shut off condenser fan motor will continue to work.
Dispensed product makes foam as it leaves dispensing valve Dispensed product comes out clear but foams in cup or class 1. Pressure of CO2 to high. 1. 2. 2. 3. Dirty nozzle and valve cavity. 3. 4. Temperature above quality limits. 4. 1. Oil film or soap scum in cup or glass. Ice used for finished drink is subcooled. 1. 2. 2. Adjust high-pressure regulator as instructed. Clean contaminated nozzle and sanitize as instructed. See refrigeration/machine specifications vs volume requirements.
CARBONATION TROUBLE SHOOTING FLOW CHART #1 MOTOR/PUMP NOT OP ERATIONAL Valves dispensing gas & syrup only Electrode Carbonator short Disconnect electrical Remove spades f rom terminal Motor #1 on LLC & install on any open "A" terminal Re-connect electrical cycles Disconnect electrical Check ground connection at board and box Remove spade f rom long & short elect.
CARBONATION TROUBLE SHOOTING FLOW CHART #2 MOTOR/PUMP DOES NOT COME ON Non-carbonated water & syrup bei ng dispensed only Check water pressure Water pressure greater than or clos e to CO2 pres sure will stop the carbonation process Check CO2 s upply C02 cy linder is empty Install or adjust water Change C02 cy linder regulator Hi press ure regulator is set to low or malfunctioning Adjust CO2 press ure at a minimum of 25 PSI abov e water pres sure 47
CARBONATION TROUBLE SHOOTING FLOW CHART #3 CARBONATOR NOT OPERATIONAL Water Pump Motor runs continuously NO EXCESSIVE PRESSURE AT VALVE OR PRESSURE RELIEF SYMPTONS Valve will dispense syrup and gas only. Possible loud noise from water pump EXCESSIVE PRESSURE AT VALVE SYMPTONS Valve will dispense syrup only and/or pressure relief may engage Little or no water volume Install holding tank/increase water feed I.D.
NOTE SECTION Frequently Called Numbers: __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ __________________________________ ____________________________ CO2 SETTINGS: High Pressure ________________________ PSI Low Pressure _____
