GLYCOL-PAK FLUID COOLING SYSTEM

FOR SOFT SERVE MACHINES

OWNER'S MANUAL

INSTALLATION OPERATION

MAINTENANCE

AIRDYNE REFRIGERATION Division A.R.I. Industries, Inc.

1304 East Valencia Drive Fullerton, CA 92831 (800) 487-3710 Fax (714) 526-2911

www.airdyne.com

AIRDYNE

TABLE OF CONTENTS

INTRODUCTION - SYSTEM DESIGN...............................................................................1

Benefits and Features of the Glycol-Pak........................................................................1

Enclosure........................................................................................................................1

Heat Exchanger..............................................................................................................1

Centrifugal Pump...........................................................................................................2

Fan Motors.....................................................................................................................2

Pump Bypass..................................................................................................................2

Glycol Fill Pipe..............................................................................................................2

Air Venting Valve..........................................................................................................2

Fan Cycle Thermostat....................................................................................................2

Control Panel.................................................................................................................3

Glycol Fluid...................................................................................................................3

Fluid Manifolds.............................................................................................................3

Electrical Characteristics...............................................................................................3

Supply and Return Piping.............................................................................................3

Platform........................................................................................................................3

STANDARD GLYCOL-PAK................................................................................................4

PHYSICAL DATA OF THE GLYCOL-PAK.............................................................5

COOLANT PIPING...........................................................................................................6

INSTALLATION...................................................................................................................7

Receipt and Inspection of Equipment..........................................................................7

Choosing a Location for Glycol-Pak............................................................................7

Roof Mounted...........................................................................................................7

Ground Mounted..........................................................................................................7

RIGGING DIAGRAM..........................................................................................................8

LIFTING INSTRUCTIONS.................................................................................................9

Installation Area...........................................................................................................9

Roof Rail Requirements...............................................................................................9

Pitch Pocket.................................................................................................................9

TABLE OF CONTENTS

(continued)

WIRING DIAGRAM........................................................................................................10

ELECTRICAL...................................................................................................................11

Electrical Requirement............................................................................................11

Glycol Piping ..........................................................................................................11

Leak Testing............................................................................................................11

PLATFORM INFORMATION.......................................................................................12

CONNECTION TO SOFT SERVE MACHINES FROM MANIFOLD.....................13

Glycol-Pak Capabilities..........................................................................................13

Glycol/Water Mixture.............................................................................................13

Concentration - Winter Temperatures....................................................................14

Leak Testing...........................................................................................................14

Filling the System...................................................................................................14

Ground Mounted Fluid Cooler...............................................................................15

Pump.......................................................................................................................15

Fans.........................................................................................................................16

Auto Air Vent.........................................................................................................16

Surge Tank..............................................................................................................16

INSTALLING THE GLYCOL-PAK..............................................................................17

SYSTEM CHECK LIST..................................................................................................18

MAINTENANCE.............................................................................................................19

Heat Transfer Surface.............................................................................................19

Electric Motor.........................................................................................................19

TROUBLE SHOOTING CHART..................................................................................20, 21

REPLACEMENT PARTS LIST (Use Only Original Airdyne Parts)............................22

WARRANTY....................................................................................................................Enclosed

FACTORY WARRANTY INFORMATION (to be returned) ......................................Enclosed

INTRODUCTION

SYSTEM DESIGN

The AIRDYNE “GLYCOL-PAK” fluid cooler is a heat exchanger designed to operate

with water cooled dispensing equipment. The hot glycol from the water cooled

condenser is piped to the “GLYCOL-PAK” fluid cooler, whereby the heat is removed

from the fluid and rejected into the outside air. The cooled glycol is then pumped back

to the dispensing equipment and the glycol is re-circulated as required by the operator.

The system is controlled by a thermostat to shut the fans off, on Models GP-4 and up,

when temperature is satisfied. Fluid Cooler is completely piped and prewired for low

cost installation in the field.

BENEFITS OF USING THE GLYCOL-PAK

The closed-loop glycol fluid cooling system’s benefits are two-fold. The soft serve

shop’s air conditioning load is reduced as the compressor heat is not rejected into the

conditioned space. Additionally, there is a dramatic savings in the water usage thus

reducing the water and sewer bills. The cooled glycol is re-circulated in a closed loop

circuit and never comes into contact with the outside air. There is no need for adding

makeup water or the expensive maintenance and chemicals typical of open type cooling

towers.

FEATURES OF GLYCOL-PAK

The systems accommodates up to 12 barrels. There are six standard models available

from 2 to 12 barrel soft-serve freezers for frozen soft serve/ice cream. Each system is

equipped with a durable galvanized cabinet, condenser with staggered copper tube coils

with aluminum fins, centrifugal pump, fan motor assembly, fill port, pump bypass with

adjustable pressure relief valve, automatic air venting valve, fan cycle thermostat on

Models GP-4 and up, main fused disconnect and fluid manifolds.

ENCLOSURE

Durable, 16 gauge galvanized steel, processed to resist rust and corrosion.

HEAT EXCHANGER

Staggered copper tube coils with aluminum fins are installed in the glycol system to

reject heat on the roof.

-1-

CENTRIFUGAL PUMP

Centrifugal pump is supplied with bronze impeller, internal overload protection and

weather housing. Pump re-circulates glycol fluid from water cooled condensers to

glycol-pak heat exchanger on the roof.

FAN MOTOR

Glycol-Pak is equipped with fan motors to reject heat. Fan motors are custom designed

for efficient performance with internal overload protection.

PUMP BYPASS

A bypass valve is provided with every system to prevent pump “deadheading” if the

condensing units are not calling for cooling. This prevents possible damage to the pump

seals. The bypass valve is adjustable for different pressures.

GLYCOL FILL PIPE

A Glycol fill pipe is provided for extra fluid in the system. It is very important to have

the pipe filled eliminating air in the system.

AIR VENTING VALVE

All Glycol-Pak’s are provided with automatic air venting valves to insure removal of air

from the glycol system. This prevents system lockout.

FAN CYCLE THERMOSTAT

An energy saving fan cycle thermostat is provided to cycle the fan motors off when no

cooling is required.

-2-

ELECTRICAL JUNCTION BOX

An electrical junction box is provided with each system with main fused disconnect for

fan and pump shut-off switch.

GLYCOL FLUID

A 50% propylene glycol and water solution should be used for cooling media. The

cooling system capacity is approximately 5 to 15 gallons depending on the length of

tubing between the cooling coil and freezers.

FLUID MANIFOLDS

Two fluid manifolds are provided with shut-off and bypass valves. Emergency water

supply should be piped through manifolds for proper working of the system. City

approved backflow preventer to be provided by plumber.

ELECTRICAL CHARACTERISTICS

Each “Glycol-Pak” is equipped with 230 volts, 1-phase, 60 hertz power supply with a

total connected load of 9 to 22.5 amps depending on different model numbers. We can

offer 230 Volts, 3 Phase or 460 Volts System as an option.

SUPPLY AND RETURN PIPING

Installation Contractors shall supply Type “L” copper piping only between “Glycol-Pak’

and manifold. PVC or galvanized piping (zinc) is not recommended.

PLATFORM

Installation Contractor shall supply level build up platform 6” high for Glycol-Pak.

Glycol-Pak should have 36” clear on all four sides.

-3-

STANDARD GLYCOL-PAK

Standard Glycol-Pak fluid cooler package for soft serve machines includes the following:

(1) Fluid cooler system with pump pre-piped, prewired for outside

installation.

(2) Manifold assembly with shut-off valves for each unit, dual check

back flow preventer and shut off valves for Fluid In - Fluid Out.

(3) Premixed 50/50 Propylene Glycol/Water Solution. CAUTION!

DO NOT FURTHER DILUTE OR SYSTEM MAY FREEZE

UP. DO NOT ADD ANTI-FREEZE.

(4) Suggested piping diagrams for field piping.

(5) Suggested installation instructions.

Owner needs to provide the following items:

(1) Supply and return type “L” copper piping or CPVC between fluid

cooler and manifold. Water piping to manifold and drain from

manifold to floor sink.

(2) Roof or outside platform to install Glycol-Pak.

(3) Power supply to Glycol-Pak, 230 Volts, 1 Phase, 60 HZ.

All installation and maintenance is to be performed only by qualified personnel who are

familiar with local codes and regulations and experienced with this type of equipment. If

you do not have a qualified installer, a list of installers is included at the back of this

manual. Should an installer not be listed in your area, contact Airdyne at (800) 487-

3710, you will be given a local installer’s phone number.

-4-

FIGURE 1 - GLYCOL-PAK GENERAL DESCRIPTION

-5-

AIRDYNE

GLYCOL-PAK PHYSICAL DATA

MODEL NO. LENGTH (IN.) WIDTH (IN.) WEIGHT (LBS.)

GP-1 30 22 300

GP-2 50 22 400

GP-3 50 22 500

GP-4 70 22 600

GP-5 90 22 785

GP-6 110 22 900

GP-7 70 60 1200

GP-8 70 60 1225

GP-9 90 60 1250

GP-10 90 60 1400

GP-11 110 60 1400

GP-12 110 60 1800

GP-13 130 68 1800

HEAT EXCHANGER

LIQUID

RESERVOIR

Double

Barrel

Soft-Serve

Machine

Double

Barrel

Soft-Serve

Machine

Double

Barrel

Soft-Serve

Machine

CITY WATER IN

EMERGENCY WATER SUPPLY

UNIONS

PROVIDED BY

INSTALLING

CONTRACTOR

SHUT OFF

VALVE {TYP.}

MANIFOLD IN

MANIFOLD OUT

FLOOR SINK

FLUID COOLER UNIT

RELIEF VALVE

LIQUID OUT

LIQUID IN

PUMP

CHECK VALVE

HAND VALVE

AIR PURGE VALVE

COOLANT PIPING

-6-

INSTALLATION

RECEIPT AND INSPECTION OF EQUIPMENT

Inspect the Glycol-Pak and all accessories shipped for any damage or shortages. Any

damage or shortages should be reported immediately to the delivering carrier. Damaged

material becomes the delivering carrier’s responsibility and it should not be returned to the

manufacturer without prior approval. Do not remove any shipping material until the unit is

installed in its permanent location.

CHOOSING A LOCATION FOR THE GLYCOL-PAK

Unrestricted air flow and unit accessibility are prime concerns in locating the unit. Always

install the unit as close to the dispensing equipment as possible to minimize the pressure on

the pump head. Please contact AIRDYNE if the fluid coolers are to be located further than

25 feet away from soft serve machines. Always allow at least 3 feet of clearance on all

sides. The unit is to be installed on to a level base that is strong enough to support the

unit’s weight plus operating glycol charge.

A. Roof Mounted

Glycol-Pak units are designed to function up to 25’ above the soft serve machines. Vertical

distance within reasonable limits does not affect the performance of the units. The weight

of the descending glycol pulls warmer ascending liquid. However, the length of horizontal

piping, the 90 degree elbows and the valves included in the piping all affect the

performance of the unit. They cause a drop in the system pressure, making the pump work

harder. Due to this, the fluid cooler should be installed in such a way as to minimize the

horizontal stretches of pipe. All valves should be kept fully open during operation of the

unit.

B. Ground Mounted

The Glycol-Pak should have 3’ clearance on all four sides when installed on the ground.

Make sure that the automatic purge valve is higher than the soft serve machines so that all

air can be expelled automatically. If air purge valve is lower than the highest point of

piping, it will lock-out the system and pipes will be full of air. The soft serve machines will

stop running on high head pressure. Installer must install air purge valve model #2P773 at

the highest point in field piping higher than soft serve machine. During start up, purge air

from all vents by manual bleeding. Operate the system for one minute only. Purge all vents

manually. Repeat this until all air is purged out and head pressure is normal

-7-

-8-

AIRDYNE

SPREADER

LIFTING

CABLE

RIGGING

AIRDYNE REFRIGERATION, INC.

LIFTING INSTRUCTIONS (Figure 2)

The FLUID COOLER system is approximately 300 to 900 pounds. Careful consideration

of lifting procedures should be made before the unit is lifted by any means. Particularly,

any cable or other load-bearing devices must not be allowed to press against piping,

electrical conduit of the motor control panel. The only part of the unit designed to carry any

of the lifting load is the base. Lifting loads should be distributed evenly around the base to

avoid any twisting.

It is recommended that whenever the unit is lifted by a crane, frame be used as attachment

points for the lifting cables as shown in Figure 2. The lifting cables should be prevented

from contacting the unit by means of a spreader bar or similar device

INSTALLATION AREA (figure 4)

Figure 4 illustrates the overall dimension and installation requirements.

ROOF RAIL REQUIREMENTS

The total weight of the complete unit is shown in Figure 4. The location and installation of

all equipment should be in accordance with all local code requirements. The unit should be

place directly upon the roof rail. For light roof construction, vibration isolation pads can be

used underneath the supporting frame.

PITCH POCKET

A 6” x 4” pitch pocket must be provided for electrical and glycol lines. After lines are

installed, backfill opening with hot pitch to prevent water leakage into the building.

-9-

Before Starting a Glycol-Pak, check that all breakers and motor protective devices are in

place and that all wiring is secure. The following are wiring diagrams:

Glycol-Pak GP-3

TO MAIN SWITCHBOARD

230 VOLTS, SINGLE PHASE, 60 HERTZ

CONNECTED LOAD 9.1 AMPS

MAIN FUSE DISCONNECT

15 A

Glycol-Pak GP-4

TO MAIN SWITCHBOARD

230 VOLTS, SINGLE PHASE, 60 HERTZ

CONNECTED LOAD 12.7 AMPS

MAIN FUSE DISCONNECT

20 A

Glycol-Pak GP-5

TO MAIN SWITCHBOARD

230 VOLTS, SINGLE PHASE, 60 HERTZ

CONNECTED LOAD 14.5 AMPS

MAIN FUSE

DISCONNECT

20 A

WARNING: PRIME PUMP BEFORE STARTING UNIT

WIRING DIAGRAM

-10-

FAN

PUMP

PUMP

FAN

FAN

PUMP

FAN

FAN

FAN

ELECTRICAL REQUIREMENT (Table 1)

To insure the proper operation of equipment and reduce the possibility of electrical power

interruption, the following precautions must be observed:

1. All electrical work must be completed in accordance with the National Electrical

code and existing local codes.

2. The power supply must be the same as that which appears on the data plate of the

motors.

3. An adequate power supply must be provided.

4. Voltage fluctuations in excess of plus or minus 10% should be corrected.

5. Electrical Contractor before start up should amp the motor and pump per data plate

Before starting a Glycol-Pak, check that all breakers and motor protective devices are in

place and that all wiring is secure. A complete wiring diagram for trouble-shooting the unit

is included.

WARNING: PRIME PUMP BEFORE STARTING UNIT

GLYCOL PIPING

1. PIPING

Connect return and supply lines to manifold at soft serve machines. Table 1 lists line sizes

used based on model number.

All piping must be adequately supported with hangers that can withstand the combined

weight of tubing, and fluid in the tubing.

2. LEAK TESTING

After both Glycol lines are connected, the system must be leak tested for 24 hours with

water under pressure. Particular care should be given to those parts which will be

inaccessible later. Contractor must test the system for all leaks prior to final start up.

-11-

PLATFORM INFORMATION

W”

2”

*Confirm Dimension When Ordering

-12-

RAIL PLACEMENT

MODEL NO. LENGTH (IN.) WIDTH (IN.)

GP-1 30 22

GP-2 50 22

GP-3 50 22

GP-4 70 22

GP-5 90 22

GP-6 110 22

GP-7 70 or 108* 60 or 22*

GP-8 70 60

GP-9 90 60

GP-10 90 60

GP-11 110 60

GP-12 110 60

GP-13 130 68

AIRDYNE

2”

5”

2” 8”

AIRFLOW

FUSED DISCONNECT

4” × 4” REDWOOD RAIL

L” (O.C.)

SERVICE SIDE

(FRONT)

(TYP. OF TWO)

3. CONNECTION TO SOFT SERVE MACHINES FROM MANIFOLD

High pressure washing machine hoses are recommended for connecting each machine to

the manifold inlet and outlet. The hose must allow maximum flow of glycol from the

system. Enlarged fittings may be necessary to fit the drain and supply of soft serve

machines. Page 1 illustrates a typical fluid cooler installation. Note the emergency city

water input and drain provided with the manifold for easy change-over from glycol system

to city water system. Dual check back flow preventer is provided for emergency city water

input to the system. These are available from Airdyne with appropriate fittings.

GLYCOL-PAK CAPABILITIES - TABLE #1

No. Of Total

Soft Heat Of Fluid Fluid Hot Cold Total Ship

Model Serve rejection Volume Flow Fluid Fluid System Weight

No. Barrels (BTU) (Gal)* GPM (Inlet) (Outlet) Length Width Height Amps (lbs)

GP-1 2 30,000 4 4 7/8” 3/4” 30 22 36 5.7 300

GP-2 4 55,000 6 8 1 1/8” 1 1/8” 50 22 36 7.5 400

GP-3 6 81,000 8 10 1 1/8” 1 1/8” 50 22 36 9.1 500

GP-4 8 108,000 10 13 1 3/8” 1 3/8” 70 22 36 12.7 600

GP-5 10 135,000 12 16 1 5/8” 1 5/8” 90 22 36 14.5 785

GP-6 12 165,000 14 20 1 5/8” 1 5/8” 110 22 36 18.2 900

GP-7 14 190,000 15 22 1 5/8” 1 5/8” 70 60 36 22.2 1200

GP-8 16 225,000 16 25 1 5/8” 1 5/8” 70 60 36 22.2 1225

GP-9 18 260,000 18 29 1 5/8” 1 5/8” 90 60 36 22.2 1250

GP-10 20 290,000 22 32 2 1/8” 2 1/8” 90 60 36 27.5 1400

GP-11 22 330,000 26 37 2 1/8” 2 1/8” 110 60 36 27.5 1400

GP-12 24 362,000 28 40 2 1/8” 2 1/8” 110 60 36 27.5 1800

GP-13 26 408,000 30 44 2 1/8” 2 1/8” 130 68 54 27.5 1800

NOTES: *Based on 25’ Run only

Heat of rejection is calculated at ambient temperature os 120 degrees Fahrenheit. (208V/1PH/60HZ)

Provide sufficient valves and union to permit easy access to parts subject to possible repair

or maintenance. All elbows, bends and horizontal pipes should be installed as to allow any

air in the system to exit. Automatic operated vents must be installed on the top of any pipe

run which can trap air. Venting is necessary to rid the system of air which can vapor lock

the pump and prevent proper flow of the liquid.

GLYCOL/WATER MIXTURE

A. TYPE OF GLYCOL

The cooling fluid used in the Glycol-pak is a mixture of propylene glycol and water. There

are two widely used types of glycol; propylene and ethylene (anti-freeze). Local codes must

be adhered to, use only propylene glycol. DO NOT USE ANTI-FREEZE OR

ETHYLENE GLYCOL IN THE SYSTEM.

-13-

B. CONCENTRATION

The concentration of the glycol/water mixture to be used depends upon the climate of the

region. The concentration has to be strong enough to prevent the liquid from freezing in the

pipes during the winter. Based on the lowest ambient winter temperature. Table 2 helps

determine which glycol-to-water ratio is advisable.

WINTER TEMPERATURES

PROPYLENE GLYCOL Lowest Winter

Temperature

Degrees Fahrenheit

% GLYCOL

to -8 50%

-8 to -32 60%

-33 to -60 70%

C. MIXING GLYCOL AND WATER

Regardless of the strength of the mixture, you must pre-mix the glycol and water prior to

adding it to the system. The chemical reaction between the two will release oxygen, which

is extremely undesirable in a closed-loop system.

LEAK TESTING

The system should be tested for leaks before adding glycol. Special attention should be

paid to any area which will be of difficult access later. The system can be tested with air or

water. If the ambient temperature is at or below freezing, the use of air is recommended.

Test pressure should not exceed 50 psi.

FILLING THE SYSTEM

A. ROOF-MOUNTED FLUID COOLER

To fill the system, pour the premixed water and glycol into the system. Fill the system until

is full, then purge the air from ALL vents. Operate the system for a minute, then purge

ALL vents again, and add glycol as required. Repeat the purging of ALL vents after the

first hour of operation and again after several hours of operation. The unit has an automatic

air vent which should eliminate the residual oxygen release. Method for ground-mounted

unit can also be used.

-14-

CAUTION: DO NOT START THE PUMP UNTIL THE GLYCOL/WATER

SOLUTION IS IN THE SYSTEM. RUNNING THE PUMP DRY WILL RESULT

IN DAMAGE TO THE PUMP SEALS.

IMPORTANT: ALL THE AIR MUST BE PURGED FROM THE SYSTEM.

Pockets of air will vapor lock the pump and prevent proper circulation of the liquid. If this

happens, the soft serve machines will continually cut out on high pressure overload and you

will damage the fluid cooler pump. To ensure purging of air, all elbows and unions must

be upward, all horizontal stretches of pipe must be slanted for trapped air to flow upward.

B. GROUND-MOUNTED FLUID COOLER

The Glycol-Pak Fluid Cooler may be the lowest point in the system. Consequently, the

premixed water and glycol has to be pumped up into the system. To do this, close the shut-

off valve. Open the hose bibbs.

Connect a pump and a hose to hose bibb Number 2. Set the pump inside a bucket of

premixed glycol and water. Begin pumping the glycol mixture into the system at FULL

PRESSURE. Allow the mixture to flow through the system, out of hose bibb Number 3,

and back to the bucket of glycol. For the return hose, close the hose bibb so that there is

only a small flow of fluid or air. This builds a head of fluid which forces the air from the

system. Once all the air is out, there will be a steady flow of fluid only. At this point, close

off the two hose bibbs and open the shut-off valve. The unit has an automatic air vent

which eliminates any residual oxygen release.

IMPORTANT: To use this method, in order to circulate the glycol through the system,

you have to pass through one of the soft serve machine’s condensers. For the inlet valve on

the machine to open and allow flow through its condenser, the compressor of that machine

must be operating. This is due to the fact that the valve opens or closes in relation to freon

pressure and temperature. Do not forget to put mix in the machine.

HOW THE FLUID COOLER WORKS

A. PUMP The pump of a Glycol-Pak Fluid Cooler will run continuously. As the soft serve machines

turn on and off, the glycol will circulate through their condensers and cool the freon within.

This action will keep the compressors cool. When no machine is operating, the fluid will

circulate from the pump through the bypass valve set at 15 psi and back to the Fluid Cooler.

-15-

B. FANS

If the Glycol-Pak has 2 or 3 fans, the first fan will run continuously. The second two are

thermostatically controlled. You simply set the dials inside the electrical box to a

temperature for which the second and third fans will come on. When the temperature of the

glycol leaving the Fluid Cooler reaches these temperatures, the second and third fans will

come on automatically. After the glycol is cooled 7 to 10 degrees below the dial setting, the

fans will shut off. For moderate climates, the second and third fans can be set at 70 and 60

degrees Fahrenheit, respectively. This will vary with the ambient temperature in your area.

Choose a dial setting that works best for your particular climate.

C. AUTO AIR VENT

The pump will pump air bubbles from the glycol/water solution and direct them into the

auto air vent. Inside of this vent is a float. When the float hits the bottom of the vent

(meaning the vent is filled with air), it will automatically open and release the air until the

float reaches the top. There is also a Schraeder pin on the top of the air vent for manual

bleeding upon start up.

D. SURGE TANK

It is a system filling port for roof-mounted units. Also, it is a reservoir of glycol to replace

the air released by the system.

-16-

INSTALLING GLYCOL-PAK

A. Uncrate the machines

B. Remove the side panels

C. Remove the protective plastic from machine side panels

D. Leak test the machines

E. Set machines in place

F. Install water fittings to inlet and outlet pipes

G. OPEN INLET WATER VALVE TO FULLY OPEN POSITION

H. Connect hoses from inlet and outlet pipes on machine to the main inlet and

outlet pipes on the fluid cooling system manifold (provided with the unit)

I. Clean and sanitize machine (hopper, cylinder, beater)

J. When fluid cooling system is operational, open all valves

K. Check compressor pressures, which should be: High side - 125 to 150 PSiG,

Suction side - 8 to 10 PSIG

L. After machine cycles off, check product temperature. Product temperature

should be between 25 degrees F. and 29 degrees F. (Adjust rear microswitch

accordingly)

M. Replace side panels on machine

-17-

SYSTEM CHECK LIST

1) Is the Airdyne unit properly sized for the number and type of machines?

2) Is the Glycol-Pak located in a position which allows for unrestricted air flow and unit

accessibility?

3) Is the Glycol-Pak located within a reasonable distance from the Soft Serve machine?

4) Is the Glycol-Pak securely mounted to a base or frame?

5) Are the proper electrical requirements fulfilled?

6) Is the correct pipe size used?

7) Has the piping system been designed with as few 90 degree bends as possible?

8) Are the soft serve machines; water inlet valves fully open? Are all other service valves

open or closed as requires?

9) Has the system been tested for leaks?

10) Has the proper type and concentration of glycol been selected?

11) Was the pre-mixed 50/50 glycol solution used? Caution: Do Not Dilute Further

12) Is ALL of the air bled from the system?

13) Are the pressures on low side and high side of compressor on the soft serve machines

correct?

-18-

MAINTENANCE

Inspect the unit regularly for loose bolts and connections, rust, corrosion and dirty or

clogged heat transfer surface (cooling coil). Check all lines for leaks and deformation.

HEAT TRANSFER SURFACE

Dirt and dust should be removed by brushing the fins and tubes and blowing loose dirt off

with air hose. Should the surface be greasy, the motor should be removed and the fins and

tubes brushed or sprayed with a mild alkaline solution or a non-flammable degreasing fluid.

Follow up with a hot water rinse and dry thoroughly.

ELECTRIC MOTOR

Properly selected and installed pump and fan electric motors are capable of operating for

years with minimal maintenance. Periodically clean dirt accumulations from open-typ

motors, especially in and around vent openings, preferably by vacuuming (avoid imbedding

dirt in windings). Check running amps and voltage. Fan and pump motor is provided with

sealed ball bearings. Relubrication of the bearings is not normally required.

PROPER MIXTURE OF PROPYLENE GLYCOL & WATER

To check the Propylene Glycol and Water mixture use a Hydrometer. Place a small amount

of mixture in a container. Have the mixture at 20 Celsius. Check that the Specific Gravity

is at 1.048 or a little higher (i.e. 1.049) but no less.

-19-

TROUBLE SHOOTING CHART

SYMPTOM CAUSE REMEDY

Pump will not prime 1. Air leak in suction line 1. Repair or replace

or retain prime after suction line.

operating 2. Clogged strainer. 2. Clean or replace

strainer

3. Low Glycol Charge 3. Add glycol

Flow rate is Low 1. Piping is fouled or 1. Clean or replace

or damaged piping

2. Clogged impeller 2. Clean or replace

or worn impeller impeller

3. Discharge line restricted 3. Remove restric-

or undersized tions

4. Plumbing restrictions 4. Remove restric-

tions

5. Low glycol charge 5. Add glycol

6. Air in system 6. Purge

Pump runs but no 1. Faulty suction 1. Replace piping

fluid is pumped piping

2. Valves closed 2. Open valves

3. Clogged strainer 3. Clean or replace

strainer

4. Refrigeration 4. Start refrig. sys.

valves closed adjust valves

Liquid drips from 1. Damaged mechanical 1. Replace mech-

point where shaft seal anical seal

enters the pump 2. Temperatures over 2. Replace with

casing, when pump 210 F liquid are

is full of liquid not compatible w/seal

Excessive noise while 1. Pump not secured 1. Secure pump

pump in operation 2. Piping not supported to 2. Do adjustments

relieve strain on pump

3. Restricted suction line 3. Clean or correct

4. Low glycol charge 4. Add Glycol

-20-

Ground Mount Installation 1. Air Trap Causing 1. Add Air Vent

Pump is running but soft soft serve machines at highest point

serve machines are on high to have high head in field piping

head

Product is runny 1. Water valve is not 1. Open water valve

open all the way

2. Hose is kinked 2. Make sure the hose

is not kinked

-21-

USE ONLY ORGINAL AIRDYNE PARTS

AIRDYNE PARTS LIST

STOCK NUMBER

AIRDYNE 4A107S

AIRDYNE 6A656S

AIRDYNE 4A219S

AIRDYNE 3CC04S

AIRDYNE 1MC1C1E0

AIRDYNE 1MC1E1C0

AIRDYNE 1MC1C1A0

AIRDYNE 1ST1H1A4

AIRDYNE 2P070A

AIRDYNE 2P773A

AIRDYNE 2P774A

AIRDYNE 2P775A

AIRDYNE 1G05F

AIRDYNE 1G05P

AIRDYNE 4M105G

AIRDYNE 1F107B

AIRDYNE G3722T

AIRDYNE 3M307C

AIRDYNE 4M407C

AIRDYNE 4M507C

DESCRIPTION

½ HP MOTOR

CAPACITOR

RAIN SHEILD

PUMP FEET

½ HP PUMP

1 HP PUMP

2 HP PUMP

3 HP S/S PUMP

½’’ RELIEF VALVE

AIR VENT

1” × 12” HOSE

1½” × 12” HOSE (GP-6 & UP)

5 GALLON GLYCOL 50/50

5 GALLON PURE GLYCOL

GUARD MOTOR MOUNT

FAN BLADE

GLYCOL TANK

GP-3 CONDENSER

GP-4 CONDENSER

GP-5 CONDENSER

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