Theory Of Operation - ICI TOPPER Installation And Service Manual

THEORY OF OPERATION

The TOPPER was designed to manufacture and dispense carbonated or non-carbonated
beverages much like your local bottling plant that cans or bottles your favorite carbonated
or non-carbonated drink.
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. In both
cases, carbonated or juice drinks, this procedure is performed. If the TOPPER is a
carbonated unit the 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, (soda water), and
then routed to a valve where it will be mixed with a syrup concentrate and dispensed. In
the case of the juice or non-carbonated drinks the carbonator tank is not needed so the
chilled water is directed straight to the valve. Again it is mixed with a syrup concentrate
and then dispensed.
The water bath holds approximately 5 gallons of water. A certain amount of this water
will be transformed into ice, approximately 12 pounds. 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 TOPPER 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 70 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. The second path of C02
is routed through low-pressure regulator to be regulated at pressures suitable for the
syrup concentrate being dispensed. The low-pressure regulator may be set at many
different settings but primarily the settings are directed towards B.I.B. or transfer tank
type installations. The average settings may vary from 10 to 60 PSI, this of course will be
influenced by length of run, ambient temperature and baume of product. Typically B.I.B.
installations are set at an average of 40 PSI and transfer tank installations are set at an
average of 30 PSI.
As discussed earlier plain water enters the TOPPER 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 drinks 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 a carbonated valve.
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