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  • Nano Chiller Setup Advice

    We are trying to figure out the best way to configure our glycol setup based on the equipment we have.

    We have (2) 2bbl fermenters and (1) 4 bbl fermenter. Down the road we want to add another 4 bbl.

    As far as glycol goes we bought two used units that are designed for beer lines. One is a Perlick 4414QC and it is 3/4 HP with 6,000 btu/h cooling but only a 1.75g bath (dunno why it is so low) and can be used with 2 pumps.

    the other one is a 1/3 hp unit that support two pumps and has an 11 gallon bath but is older and probably unreliable.

    Ideally we want to create a closed loop system but I wasn't sure if we could even do that with the larger one because of how small the bath is. I also didn't know if we had to replace the 1/3 hp pump that is on there with a bigger one if we did that type of setup. Is replacing a pump as simple as buying on from granger or do I need to go to Perlick and buy an expensive kit?

    The other method would be to use 1/3 hp pump per each fermenter but this seems like an expensive way to go once you add up all the pumps.

    Any advice you can give to help spec this out for us would be great, we are getting ready to hook it all up and are a bit lost on what the best/easiest way to do it is.

    Thanks so much!

  • #2
    We actually had the same problem in the beginning. We picked up 2 chillers from restaurant auctions for about $100 each and we are making it work. If your fermenters are insulated and jacketed, I think the single 3/4hp chiller could handle the job for you. We actually use the same type of beer line chiller for 2 3bbl fermenters and 2 1bbl fermenters but ours is only a 1/2hp perlick chiller. Even with a crude pvc non insulated glycol line, it can easily bring each of the fermenters down to 40 degrees in a day. We have a separate 1/2hp cornelius beer line chiller that can bring our other 2 3.5bbl fermenters down to about 37 overnight.

    You can set up a typical brewery glycol system with supply/return lines and all the necessary actuated valves with that 3/4hp chiller even though it only has a small reservoir. What we ended up doing was to raise the chiller above the level of the tallest fermenter so the glycol can not drain back into the chiller and overflow it. By having the chiller sit at a high point, you basically use each of the fermenters to hold the reservoir of glycol. Since you have the chiller raised up, the pump doesn't have to overcome gravity which means the small pump on that chiller should easily push the liquid through the lines. Just check on the level of the glycol bath about once a month to make sure the level is still staying high enough otherwise you will burn out the pump.
    Kaskaskia Brewing Company

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    • #3
      Originally posted by KaskaskiaBrew View Post
      We actually had the same problem in the beginning. We picked up 2 chillers from restaurant auctions for about $100 each and we are making it work. If your fermenters are insulated and jacketed, I think the single 3/4hp chiller could handle the job for you. We actually use the same type of beer line chiller for 2 3bbl fermenters and 2 1bbl fermenters but ours is only a 1/2hp perlick chiller. Even with a crude pvc non insulated glycol line, it can easily bring each of the fermenters down to 40 degrees in a day. We have a separate 1/2hp cornelius beer line chiller that can bring our other 2 3.5bbl fermenters down to about 37 overnight.

      You can set up a typical brewery glycol system with supply/return lines and all the necessary actuated valves with that 3/4hp chiller even though it only has a small reservoir. What we ended up doing was to raise the chiller above the level of the tallest fermenter so the glycol can not drain back into the chiller and overflow it. By having the chiller sit at a high point, you basically use each of the fermenters to hold the reservoir of glycol. Since you have the chiller raised up, the pump doesn't have to overcome gravity which means the small pump on that chiller should easily push the liquid through the lines. Just check on the level of the glycol bath about once a month to make sure the level is still staying high enough otherwise you will burn out the pump.
      That is really good to hear you are using it similarly to how we are wanting to. The odd thing is the natural place for us to put the chiller is 4 feet off the ground which is level with the top of the jackets of our smaller ones.

      Did you replace the pump or are you still using the 1/3 hp pumps that came with them? Do you think the distance we have would be an issue (I don't know how far it travels to get through a jacket of my fermenters). Have you had any pressure related issues. I was told that we need to do something to make sure we don't blow out a jacket with pressure. I dont really know how this would be an issue unless there was an obstruction somewhere.

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      • #4
        As long as the lowest part of the chiller sits above the highest point in the system, you shouldn't have any worries about having it overflow on you. Regarding the high pressure, it should all depend on how you have your system set up. It's not a 100% closed system so the pressure should never build up in the tanks. The only way you could build up enough pressure would be if somehow the return line got clogged with something and the pump just continued to pump away. I'm not sure how much pressure that pump could build up but you may want to install a pressure relief in the return line. If you aren't quite sure how to pipe up the lines, use the diagram from this manual: http://www.prochiller.com/files/AllAboutGlycol.pdf

        We actually burned up the pump that was on our chiller but it was our own fault. Somebody set the chiller temp too low for the glycol mix and froze the system and that burned out the pump. Instead of buying a new pump, we just went on ebay and got a cheap centrifugal pump to replace it and it works fine. The biggest headache of the whole thing is that the outlets on the chiller are meant for 3/8'' lines but the jackets on our fermenters are 1'' so you have to create a mess of adapters to make it work. PM me your email address and I will try to get you some pictures this weekend of our setup if I remember.

        Cheers,
        Kaskaskia Brewing Company

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        • #5
          Help

          So we have a 3/4hp beer line chiller. When the fermenter solenoid valve opens and the line pressure drops, the pressure switch turns the glycol pump on but seems like it doesnt have enough reserve. It turns on and off every 3 seconds or so. This will obviously burn up the pump from turning on and off so much. I have read elsewhere that a pressureized tank after the pump will correct this (similar to an air compressor or RO system).
          How is the glycol pump on your systems turning on and off or is it cycling all of the time? What do you guys think of this?

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          • #6
            Glycol systems

            Sounds like you are using a machine that is not deisgned or configured for the duty you are attempting to run.
            The beer line chillers I have run do not have any pressure switches involved. They are meant to run continuous through u bend returns so you have a constant temp always on the draft line system. The pumps are deisgned for a certain pressure and GPM through 3/8 beer cooling line runs. Typical fermenter connections are 1 inch.
            Typical large glycol chiller systems used on fermentation vessels have a bypass regulator on the pump discharge line with the " loop " pump also being meant to run all the time. They also have a separate pump for the chiller heat exchanger.
            If the horsepower and pump capability are workable, then the said chiller could be electrically and mechanically reconfigured for the duty. Its possible you may need a different pump, and the chiller controls definitely have to be reconfigured.
            Warren Turner
            Industrial Engineering Technician
            HVACR-Electrical Systems Specialist
            Moab Brewery
            The Thought Police are Attempting to Suppress Free Speech and Sugar coat everything. This is both Cowardice and Treason given to their own kind.

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            • #7
              programing the perlick 440

              I need help on the programing of the perlick chiller. I am almost at the end of my installation and launch of my brewery. I will have a bigger chiller down the road once the bank release more funds. But since I started with the perlick in my plan I have to use it. I have 2 (3.5 bbl) currently I have 1 pump conected to only one for testing. I have search how too program and every pdf comes back to model 4400. I have a 440L but looking at the picture is the same.

              Now I try to follow the pdf instruction but they are not user friendly. yesterday I got a code HA 59 so is HA,HA in your face? what I am trying to get is program the bath to let say 50 degrees and wait until the compressor stop. SO I know is working right any link or hel really apreciate

              Charles

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