Crystal Mountain K2 User manual

Service Manual (220-240VAC)
K2 Water Cooler

Table of Contents
SECTION1:Product Specification .................................................................................................................1-1
SECTION2:Parts Listing and Exploded Views......................................................................... ....................... 2-1
K2 Parts Listing ..................................................................................................................................... 2-1
Exploded Views .....................................................................................................................................2-2
Product Dimensions ...............................................................................................................................2-4
Description of Product Model Number ......................................................................................................2-5
SECTION3: CrystalFlo Replacement......................................................................................................... ... 3-1
SECTION4: Cabinet-Panel Removal and Installation...................................................................................... 4-1
Install Cooler Base ............................................................................................................................... . 4-1
Lower Front Panel Removal & Installation ................................................................................................ 4-2
Side Panel Removal ...............................................................................................................................4-3
Side Panel Installation ...........................................................................................................................4-5
Main Front Panel Removal & Installation ................................................................................................. 4-6
SECTION5: Electrical Component Diagnosis and Replacement....................................................................... 5-1
Wiring Diagram ......................................................................................................................................5-1
Cold Sensor Removal and Installation .....................................................................................................5-2
Water Temperature Adjustment ................................................................................................................5-5
Hot Sensor Removal and Installation ....................................................................................................... 5-6
Hot Tank Limiter Replacement ................................................................................................................5-9
Hot Tank Removal and Replacement ...................................................................................................... 5-11
Hot Tank Heater Band Replacement ........................................................................................................ 5-14
Compressor Relay / Overload Protector Replacement ..............................................................................5-15
SECTION6:Trouble Shooting ...................................................................................................................... 6-1
SECTION7:Cleaning and Sanitization ..........................................................................................................7-1
SECTION8: CrystalFlo Water Cartridge ....................................................................................................... 8-1
.

1 - 1
Product Specification
ITEM
POWER RATING
STANDARD CURRENT
POWER
CONSUMPTION
COLD
HOT
NOISE (SOUND POWER LEVEL)
NET WEIGHT
LOADING QUANTITY
COLD
HOT
COMPRESSOR
REFRIGERANT
TEMP RANGE
HEATER
TEMP RANGE
SAFETY DEVICE
TEMP CONTROL
SPECIFICATIONS
SINGLE PHASE
220-240VAC 50Hz
H&C: 2.5~2.8A
80 W
450 W
SINGLE PHASE MOTOR
R134a: 35g (1.2oz)
4-10°C ( 39.2-50°F )
BAND HEATER
74-92°C ( 165.2-197.6°F )
BIMETAL (MANUAL LIMITER 98°C ( 203°F ) OFF)
ELECTRONIC
44 dB (A)
H&C: 12.8 kg ( 28.2 lb )
20FT: 320 UNITS
40FT: 640 UNITS
Standard Cooler Specifications and Performance Data
Model: K2 220-240VAC
The K2 was specifically developed by Crystal Mountain to
meet customers' needs for a modern and stylish watercooler
with a water reservoir system that could be recycled, having
been easily removed, and replaced with a new one. All
done very easily, hygienically and cost-effectively.
Furthermore, the K2 has been designed with an ergonomic
high dispense point; LED indicator lights; electronic
controls to give improved cold and hot water output, and
easily removable side panels to allow quick access to all
electrical components for easy maintenance and servicing.
K2

220V K2 Bottled Water Cooler Parts Listing MODEL--K2FM2KHK2CC
NO. PART CODE NO. PART CODE
1PLC-C141020 B4 PCB BOX PLC-C141007
2FAS-C100007 B5 TIMER SWITCH PCB ELE-C100286
3PLC-C141019 B6 PUMP MOTOR ELE-C100276
4FAS-C100091 B7 HOT WATER ADAPTOR PLC-C141009
5FAS-C100129 B8 INNER CHASSIS PLC-C141006
6ELE-C100280
7ELE-C100282 TAP ASSEMBLY
8ELE-C100288 C1 SS PIN, OD 3MM, LENGTH 95MM FAS-C100128
9PLC-C141018 C2 PINCH PLC-C141011
10 PLC-C141037 C3 SS SPRING, FAUCET, OD 7.2, LENGTH 40, WIRE DIAMETER 0.8 FAS-C100125
11
SIL-C141009 C4 MICRO-SWITCH PCB ELE-C100285
12 SIL-C141008 C5 TAP RETAINER
PLC-C141010
13 REF-C100201 C6 DOUBLE TORSION SPRING
FAS-C100127
14 FAS-C100100 C7 FAUCET PIVOT PLC-C141013
15 PLC-C141005 C8 SS SPRING.CATCH.OD4.5.LENGTH 18.5 WIRE DIAMETER 0.5 FAS-C100126
16 ELE-C100306 C9 COLD LEVER (STD) PLC-C141038
17 SUB-C200207 C10 CATCH
PLC-C141012
SUB-C200340 C11 CHILD RESISTANT LEVER, RED PLC-C141014
18A BASE PLATE, LEFT PLC-C141001 C12 HOT LEVER (CHILD RES) PLC-C141039
18B BASE PLATE, MIDDLE PLC-C141003
18C BASE PLATE, RIGHT PLC-C141002 220V HOT TANK ASSEMBLY
SUB-C200334
19 PLC-C141017 D1 HOT SENSOR
ELE-C100283
20 MIS-C100090 D2 HOT SENSOR BRACKET,HOT SENSOR FAS-C100130
21 PLC-C140047 D3 98C CERAMIC MANUAL RESET
ELE-C100170
PLC-C140048 D4 MANUAL RESET COVER, GREY
SIL-C140006
PLC-C140049 D5 HT DRAIN CAP
PLC-C100004
23 PLC-C141015 D6 RED SILICONE DRAIN PLUG
SIL-C100055
24 SUB-C200209 D7 HOT TANK DRAIN
PLC-C120021
D8 SPRING CLIP - 12MM
FAS-C000029
SUB-C200347 D9 SILICONE DRAIN TUBE
SIL-C140004
A1 SEAL, MANIFOLD INLET/OUTLET - OD18 X 11MM SIL-C120006 D10 220V INSULATED HESTER-97MM ID ELE-C100148
21PCS CrystalFloTM IN ONE BULK BOX SUB-C200345
12PCS CrystalFloTM IN ONE BULK BOX SUB-C200349 E1 220V COMPRESSOR RELAY(B30H) REF-C100162
E2
220V COMPRESSOR OVERLOAD PROTECTOR (B30H) REF-C100163
MAIN PCB AND INNER PANEL ASSEMBLY E3 COMPRESSOR COVER REF-C100164
B1 PCB ACCESS COVER PLC-C141034 E4 BACK PANEL
PLC-C140002
B2 PCB COVER PLC-C141008
B3 MAIN PCB ELE-C100287
Mar 18,2015
HT INLET TUBE, OD 15 X ID 12 X 585MM
LENS
E
220V POWER CORD FOR UK-K2
18
C
D
REFRIGERATION SYSTEM
CUP DISPENSER GASKET - ID 70MM (BLACK)
LOWER FRONT PANEL
22
SIDE PANEL, RIGHT ,BLACK-BOXED
CrystalFlo KIT, SINGLE PACKAGE
B
B
HINGE PIN, TOP COVER CLIP
BASE PLATE ASSEMBLY
FOAM TUBE, ID16MM X OD28MM X L310MM
SPRING CLIP - 14MM
COLD SENSOR
DESCRIPTION
DRIP TRAY
TOP COVER CLIP
FAUCET LOCK SPRING
TOP COVER
HOT SWITCH
DESCRIPTION
HINGE PIN, TOP COVER
LIGHT PCB
SIDE PANEL, LEFT , BLACK-BOXED
HT OUTLET TUBE, OD 15 X ID 12 X 380MM
EVAPORATION SHELF
SS CUP DISPENSER SPRING
PISTON, CUP DISPENSER (BLACK)
CUP DISPENSER GASKET - ID 60MM (BLACK)
FRONT PANEL
A

MODEL: K2FM2KHK2CC
K2 BOTTLED WATER COOLER (MAIN)
B. MAIN PCB AND INNER PANEL ASSEMBLY
D
B2
B1
B
B3 B4 B5 B6 B7 B8

MODEL: K2FM2KHK2C
(CrystalFlo ASSEMBLY, TAP ASSEMBLY ,
HOT TANK ASSEMBLY, REFRIGERATION SYSTEM )
D.
D1
D2
D3
D4
D5 D6 D7 D8 D9
D10

2 - 4
1053mm/41.45”
946mm/37.24”
260mm/10.24”
359mm/14.13” 342mm/13.45”
Back
347mm/13.68”
Front Side

2 - 5
You can find your serial and model number at the back of your cooler.
K2 F M 2 K H K 2 C
Cooler Shape Reservoir Type Type of Lid No. of Faucets Body Color Temp. Option Insert Color Voltage Optional
Description of Product Model Number
M- Manifold K – Black H – Hot & Cold K – Black 1 – 220~240V
K2– K2
F – CrystalFlo Water Cartridge
C – with Cup Dispenser

3 - 1
A flashing yellow light above the faucet levers will alert you to when the CrystalFlo™ Water Cartridge
should be replaced. The system has been pre-set to provide indication after a period of 12 months
of use. User may operate the cooler as normal until the bottle has been emptied. It is also advised to
replace the CrystalFlo™ cartridge if there is a leak from the cartridge, taste problem or discoloration to
the water.
Note: To reset the life timer system, the CrystalFlo™ is required to be removed from the dispenser for a
minimum of 15 seconds while the unit is connected to the mains power supply.
1. Place a glass or other container below the water outlets (to catch drips)(Figure 3-1), and unlatch
the Top Cover Locking Clip (located inside of the Bottle Installation area)(Figure 3-2), and open
Top Cover (Figure 3-3).
2. Pull CrystalFlo™ Water Cartridge upwards to remove (Figure 3-4). Do not squeeze the water
reservoir as water could leak out. In addition, it may be helpful to have a bucket nearby to place
the used CrystalFlo™ in.
3. Please recycle the CrystalFlo™ whenever possible, otherwise dispose of responsibly.
4. Ensure seal is properly installed on the Inlet/Outlet tube of the CrystalFlo™ Water Cartridge
assembly (Figure 3-5) (may have shifted during shipment or un-packaging).
Figure 3-1 Figure 3-2 Figure 3-3
Figure 3-4
Replacement of CrystalFlo™ Water Cartridge
Figure 3-5

3 - 2
5. Align CrystalFlo™ Water Cartridge with openings in cooler, and push downwards into place (Figure
3-6). Ensure that foam seal is pushed down and seals the reservoir completely.
6. Close the top cover (push downwards to lock into place) (Figure 3-7 and Figure 3-8). If cover
does not close completely, make sure that CrystalFlo™ is inserted completely.
7. Install replacement bottle (Figure 3-9).
Note: To prevent water leaks, a NON-SPILL Bottle Cap MUST be installed on the bottle.
8. Prime water system (See K2 Quick Start guide “Prime Water System” for instructions if needed).
Figure 3-7 Figure 3-8
Figure 3-9
Figure 3-6

4 - 1
Install Base Plate
1. Stand cooler upright on flat, smooth surface floor.
2. Align side plate with base (Figure 4-1-1), and slide into base to locked position. (Figure 4-1-2
and Figure 4-1-3). The side plates are inserted so that the inner faces mount flush in the rear of the
cooler. There will be an open triangular area in the front.
3. Repeat for opposite side. (Figure 4-1-4 and Figure 4-1-5)
Figure 4-1-1 Figure 4-1-3
Figure 4-1-4 Figure 4-1-5
SECTION 4: Cabinet Panel Removal and Installation
Notice:
The information and/or procedures presented in the following demonstration(s) should be performed by a trained Water Cooler
Service Technician only.
Never attempt to service or repair a water cooler while it is plugged into any power supply.
Prior to any service or repair of the water cooler, ensure that the water has been completely drained from the system.
Figure 4-1-2

4 - 2
Lower Front Panel Removal & Installation
1. Remove Drip Tray by pulling outwards from the body (Figure 4-2-1).
2. Using a Philips screwdriver, remove the screw from the lower front panel (located behind
Drip tray assembly location) (Figure 4-2-2).
3. Pull outwards on the lower front panel to disengage locking tabs from the front of the cooler
(Figure 4-2-3). The front panel and cup dispenser on this model are separate parts. Only the front
panel will be removed.
4. Install in reverse order.
Figure 4-2-1
Figure 4-2-2
Figure 4-2-3
SECTION 4: Cabinet Panel Removal and Installation
Notice:
The information and/or procedures presented in the following demonstration(s) should be performed by a trained Water Cooler
Service Technician only.
Never attempt to service or repair a water cooler while it is plugged into any power supply.
Prior to any service or repair of the water cooler, ensure that the water has been completely drained from the system.

4 - 3
Side Panel Removal
1. Remove Lower front panel (Figure 4-3-1)(Refer to Lower Front Panel Removal & Installation).
2. Remove the 2 side panel installation screws from the front of the cooler (located mid way up
the front panel) (Figure 4-3-2).
3. Remove the 2 side panel installation screws from the back of the cooler (located mid way up
the back panel) (Figure 4-3-3).
Figure 4-3-1
Figure 4-3-2
Figure 4-3-3
SECTION 4: Cabinet Panel Removal and Installation
Notice:
The information and/or procedures presented in the following demonstration(s) should be performed by a trained Water Cooler
Service Technician only.
Never attempt to service or repair a water cooler while it is plugged into any power supply.
Prior to any service or repair of the water cooler, ensure that the water has been completely drained from the system.

4 - 4
4. Open the Top Cover by pressing the cover lock (Figure 4-3-4), and lifting the front of the
Top Cover upwards (rotate upwards to rear of the cooler) (Figure 4-3-5).
5. Grip the top edge of the side panel and lift slightly (approximately 1/2inch) and pull out-
wards from cooler to remove (Figure 4-3-6 to Figure 4-3-7).
Figure 4-3-4 Figure 4-3-5
Figure 4-3-6 Figure 4-3-7

4 - 5
Side Panel Installation
1. Identify which panel belongs on which side of the cooler (Figure 4-4-1 to Figure 4-4-2). The
Locking clip (located approximately 10 inches/250mm up from the base of the panel on the inside
surface) is to be installed towards the front of the cooler.
2. Gripping the top edge of the side panel, insert the screw support into the slot on the Front
Panel (near Drip Tray area) (Figure 4-4-3 to Figure 4-4-4), and align the locking clip, bottom edge,
upper clips, and slide downwards to lock into place (Figure 4-4-5 to Figure 4-4-8). Install the screw
into the front/back screw supports to secure in place (Figure 4-4-9 to Figure 4-4-10).
Figure 4-4-1 Figure 4-4-2
Figure 4-4-3 Figure 4-4-4 Figure 4-4-5 Figure 4-4-6
Figure 4-4-7 Figure 4-4-8 Figure 4-4-9 Figure 4-4-10
SECTION 4: Cabinet Panel Removal and Installation
Notice:
The information and/or procedures presented in the following demonstration(s) should be performed by a trained Water Cooler
Service Technician only.
Never attempt to service or repair a water cooler while it is plugged into any power supply.
Prior to any service or repair of the water cooler, ensure that the water has been completely drained from the system.

4 - 6
Main Front Panel Removal & Installation
Note: Begin with the unit unplugged, the reservoir removed and the lower front and side
panels removed.
1. Remove the cup dispenser spring first (Figure 4-5-1 and Figure 4-5-2) and faucet
handles (Figure 4-5-3, Figure 4-5-4, Figure 4-5-5 and Figure 4-5-6)
2. To remove the front panel, remove the two screws on top (Figure 4-5-7), the two
screws in the middle (Figure 4-5-8), the two screws on the bottom (Figure 4-5-9) .
Figure 4-5-1 Figure 4-5-2 Figure 4-5-3 Figure 4-5-4
Figure 4-5-5 Figure 4-5-6
Figure 4-5-7 Figure 4-5-8 Figure 4-5-9
SECTION 4: Cabinet Panel Removal and Installation
Notice:
The information and/or procedures presented in the following demonstration(s) should be performed by a trained Water Cooler
Service Technician only.
Never attempt to service or repair a water cooler while it is plugged into any power supply.
Prior to any service or repair of the water cooler, ensure that the water has been completely drained from the system.

4 - 7
3. With all the screws removed, remove the protective cover from the PCB (Figure
4-5-10 ), and disconnect the cold sensor terminal from the PCB (Figure 4-5-11).
pull the front panel near the base plate forward to remove (Figure 4-5-12 and Figure 4-5-
13).
4. For reassembly align the bottom of the front panel with the appropriate guides in the
base plate (Figure 4-5-14). Then follow the above steps in reverse order.
Figure 4-5-10 Figure 4-5-11 Figure 4-5-12 Figure 4-5-13
Figure 4-5-14

Models:K2 Hot & Cold
Wiring Diagram
5 - 1
SECTION 5: Electrical Component
Diagnosis and Replacement

5 - 2
SECTION 5: Electrical Component
Diagnosis and Replacement
Cold Sensor Removal and Installation
1. In the event that the Cold Sensor requires to be replaced, the Blue indicator light (above Cold Dis-
pense Lever) will flash (Figure 5-2-1).
2. Turn off hot tank power switch (located at top/back of dispenser) (Figure 5-2-2) and unplug the water
cooler (Figure 5-2-3).
3. Remove CrystalFlo™ Assembly from the water dispenser (Figure 5-2-4) (see section for CrystalFlo™
Removal Instructions).
4. Remove the Side Panels from the water dispenser (see section for Side Panel Removal Instructions).
Figure 5-2-1
Figure 5-2-2
Notice:
The information and/or procedures presented in the following demonstration(s) should be performed by a trained Water Cooler
Service Technician only.
Never attempt to service or repair a water cooler while it is plugged into any power supply.
Prior to any service or repair of the water cooler, ensure that the water has been completely drained from the system.
Figure 5-2-3
Figure 5-2-4

5 - 3
5. Remove the protective cover from the PCB, and disconnect the cold sensor terminal from the
PCB. (Figure 5-2-5 and Figure 5-2-6).
6. If required, cut the ties holding the wires together, taking care not to damage any of the wires
(Figure 5-2-7).
7. Pull the sensor tube out from the Evaporator Insulation to remove (Figure 5-2-8).
8. Install the replacement Cold Sensor into the Evaporator Insulation (insertion length approxi-
mately 5 inches/125mm) (Figure 5-2-9 and Figure 5-2-10).
Note: Care should be taken while installing the cold sensor that the end within the evaporator insu-
lation is in the proper position.
Figure 5-2-7
Figure 5-2-8
Figure 5-2-9 Figure 5-2-10
Figure 5-2-5 Figure 5-2-6