Service manual

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.
As the incoming water passes through the water coil the heat is removed from the water
in the water coil and chilled to a temperature acceptable for a quality drink. The chilled
water is now routed into a carbonator tank where this cold water is mixed with CO2. This
water is now transformed into a carbonic acid, (sparkling water). The cold sparkling water
and still is plumbed to the Carbonation Adjustment Valve which blends still water into the
sparkling water. At this point the still and sparkling water ration can be adjusted and set
to achieve a specific bubble texture and size.
The units contain a water bath. A certain amount of this water will be transformed into ice.
This water reserve and ice bank will act as a reservoir for refrigeration. This reserve is
utilized during peak periods when the BTU output of the compressor is not sufficient to
meet the demand of the draw.
It should be recognized that without refrigeration your carbonation system would not
produce a drink that will hold carbonation. There is a direct relationship between
dispensed temperature and the volumes of C02 that can be held in liquid form.
The following will give a general overview of the flow of individual circuits and a clearer
understanding of our mini bottling plant.
Carbon dioxide gas (CO2) passes from a C02 cylinder through high-pressure regulator
(S-101). The high-pressure regulator regulates the CO2 feeding the Crysalli and should
be set at 70-75 PSI. The gas, after leaving the high-pressure regulator, is routed through
flexible tubing to a low-pressure regulator. The flow of CO2 is teed to go in two directions
at the low-pressure regulator. One path takes the gas, set at 55 to 75 PSI, to the
carbonator tank. This gas must be at a pressure greater than the incoming water by at
least 25-PSI to assure the proper function of the carbonator
As discussed earlier plain water enters the Crysalli through the incoming water line. This
water proceeds through the water coil where it is chilled prior to entering the carbonator
tank or in the case of non-carbonated water chilled prior to going directly to a valve. Prior
to entering the carbonator tank an optional regulator (S-208A) may be installed. This
assembly is utilized to maintain water pressure feeding a non-carbonated valve when
used in conjunction with carbonated valves.
The water source should be regulated, this is normally performed by the use of an in line
water regulator. If the water is not regulated and the water pressure is equal or greater
than the incoming CO2 the act of carbonation will be greatly inhibited or completely
eliminated.
At the proper settings, the gas pressure will stop the water from entering the carbonator
tank. To force the water into the tank a liquid level control and motor/pump will be used.
This combination will force the water into the tank mixing the water and CO2 together.
The carbonator utilizes a Soda Jet Recirculating Principle. This process was pioneered
in the early 1950's. This principle produces instantaneous carbonation at extremely large
capacities of 100 gallons per hour minimum.
14