Download Service Manual/Parts List Modular Cubed Ice Maker, Series 900
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.\) .d Service Manual SERIES MODULAR 900 CUBED ICE MAKER 1/91 161951805 T A B L E O F C 4 0 N T E N T S 1 ............................ TABLE OF CONTENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . ...... 3 INSTALLATION AND START-UP . . . . . . . . . . . . . . . . . . . . . 41-10 REFRIGERANT CIRCUIT REMOTE CONDENSER UNITS . . . . . . . . . . . . 11 ELECTRlCAL CIRCUIT SEQUENCE OF OPERATION . . . . . . . . . . . . . . 1 2 ADJUSTMENT FOR I C E BRIDGE THICKNESS . . . . . . . . . . . . . . . . . 12 . ADJUSTMENT AND CHECK-OUT FOR OPTICAL HARVEST - B I N SENSOR . . . . . 13 WIRING AND SCHEMATIC DIAGRAMS . . . . . . . . . . . . . . . . . . . 14-17 S A N I T I Z I N G AND CLEANING PROCEDU'RE . . . . . . . . . . . . . . . . . . 18 WATERTREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 19 WINTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 CLEANING THE CONDENSER . . . . . . . . . . . . . . . . . . . . . . . 20 SERVICE ANALYSIS . . . . . . . . . . . . . . . . . . . . . . . . . . 21-23 INTRODUCTION ." 1 I 5, INSTRUCTIONS FOR REMOVAL AND RE-INSTALLATION .................... PARTS L I S T . . . . . . . . . . . . . . . . . . . . . . . . . . ... ILLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . . . . . . . . . REMOTE CONDENSER TLLUSTRATED PARTS BREAKDOWN . . . . . . . . . . . . OF SOLID STATE CONTROL 2 24 25 26 27 INTRODUCTION Ue have s t r i v e d t o produce a q u a l i t y product. thus i n s u r i n g trouble-free operation. The design has been kept simple, This manual has been prepared t o a s s i s t servicemen and users w i t h information concerning i n s t a l l a t i o n , construction and maintenance of the i c e making equipment. The problems o f the serviceman and user have been given special a t t e n t i o n i n the development and engineering o f our icemkers. Ifyou encounter a problem which i s not covered i n t h i s manual, please f e e l free t o w r i t e o r c a l l . We w i l l be hap,py t o a s s i s t you i n any way we can. - Uhen w r i t i n g , please s t a t e the model and s e r i a l number of the machine. Address a1 1 correspondence to: A Product of IMI Cornclius Americas Inc. 2421 - 15th St. S.W. P.O. Box f527 Mason City, I A 50401 Phone 5 15-424-6150 I 1-800-)83-0385 FAX 5 15-424-4305 1 Specifications Model Number Ambient (Condenser) Temp O F AC-900-SS-MH (Air Cooled) W C-900-SS-MH (Water Cooled) RC-900-SS-MH (Remote Air) Note: Remote unit designed for use with CS-120 remote condenser. 900 incoming Water Temp a 50a 70° 80° 70° 696 620 594 800 650 582 556 900 580 511 494 70° 674 610 552 800 665 610 545 900 666 60 1 529 50° 741 650 620 509 1100 I SERIES I 449 I 4 29 I ..... ........... .............. . .... COMPRESSOR ELECTRICAL RATING COMPRESSOR MODEL CONDENSER. REFRIGERANT CHARGE ( a i r cooled). . . (water cooled). (remote). R E FR IGERANT CONTROL . . . . . . . . . TXV SUPERHEAT SETTING . . . . . . . . I N L E T WATER SUPPLY VULTAGE TOTAL AMP DRAW . . . . . . . . . . . . CRANKCASE PRESSURE REGULATOR SETTING . .......... ............... 3 I 2 H.P. CRDl-0200-PFV Air, water o r remote 70 02. R-502 43 0 2 . R-502 270 0 2 . R-502 TXV 6O 3/8"SAE male f l a r e 208-230/60/1 13.8 amps 50 P S I f l a x . I N S T H U C T I O N S --i N S T A L , - L A ? I O N A. 6. UNPACKING ----__--1. Uncrate machine and/or b i n by removing the staples from around the bottom of cardboard c r a t e and 1 i f t o f f . 2. Remove b o l t s fastening the c r a t e s k i d t o the bottom of t h e u n i t . I f auxiliary.1egs have been purchased f o r the bin, they should be i n s t a l l e d a t t h i s time. LEVELING I f legs are used,.adjust the l e v e l i n g legs of t h e storage b i n u n t i l the u n i t i s l e v e l and a l l four ( 4 ) legs are i n s o l i d contact w i t h the f l o o r . Leveling i s very impartant t o obtain proper d r a i n i n g and t o maintain the proper l e v e l i n the water pan o f the i c e cuber. NOTE: If' the b i n i s t o be i n s t a l l e d f l u s h t o the f l o o r , the machine must be sealed t o the f l o o r w i t h an approved mastic such as Sears rY3803-0 Caulk, Dow R.T.V. 101, 102 o r G. E. 731, 732. This i s an N.S.F. requirement and i s the r e s p o n s i b i l i t y o f the i n s t a l l e r . C. UNIT LOCATION I I _ - 1. Allow a t l e a s t a minimum o f s i x ( 6 ) inches a t the r e a r and side o f the i c e machine f o r proper a i r c i r c u l a t i o n . 2. This u n i t has been designed t o be i n s t a l l e d i n an indoor l o c a t i o n which i s clean and which can be adequately ventilated; t h e a i r and water temperatures should never exceed 100 degrees nor fa1 1 below 50 degrees. (Temperatures above 100 degrees w i l l c u t t h e i c e making capacity below an economical l e v e l ; temperatures below 50 degrees w i l l cause a m a l function o f thermostatic sensors. 3. 0. The u n i t should be located where a i r c i r c u l a t i o n i s n o t r e s t r i c t e d . The u n i t should n o t be located near a k i t c h e n g r i l l . A i r which contains grease vapors w i l l deposit grease on the condenser. The condenser should always be kept clean. U N I T SET-UP 1. Take o f f f r o n t panel of machine arid remove hardware bag o r service manual envelope w i t h the water s t r a i n e r enclosed. 2. Mount the i c e maker t o the top o f the i c e storage b i n o r adapter i n the proper p o s i t i o n over the i c e drop opening. The i c e maker must then be sealed both on the outside and the i n s i d e bottom edges w i t h an approved N.S.F. mastic such as Dow S i l a s t i c #732, 734 o r General E l e c t r i c RTV #101, 102. This i s an N.S.F. requirement and the r e s p o n s i b i l i t y o f the i n s t a l l e r . 3. Remove shipping tape from evaporator c u r t a i n s . 4 I N S T A L L A T I O N E. I N S T R U C T I O N S C O N T ' D . REMOTE CONDENSERS Remote condensers should be i n s t a l l e d above the i c e machine and i n a l e v e l configuration. They are connected t o t h e i c e making u n i t by copper t u b i n g and l i n e valves. The female h a l f o f the l i n e valve i s mounted on the i c e making u n i t and the remote condenser. The male h a l f i s soldered on the tube ends when tubing k i t s illy! provided w i t h the machine. Iftubing k i t s are n o t provided, the male h a l f o f the l i n e valves w i l l be provided i n a valve k i t and t h e i n s t a l l e r w i l l mount them on the tubing he provides. 1. NOTE: WHEN VERTICAL LINES ARE INVOLVED I N THE INSTALLATION, FOLLOW STANDARD REFRIGERATION PRACTICES FOR VERTICAL LINES TO ASSURE POSITIVE O I L RETURN TO THE COMPKESSOR. VERTICAL L I F T TO BE NO MORE THAN 15 FEET. 2. NOTE: WE 00 NOT RECOMMEND TU8ING RUNS OF MORE THAN 40 FEET. 3. THE SEALS FOR THE L I N E VALVES WILL BE FOUND I N AN ENVELOPE MAKE SURE THEY ARE USED. NOTE: ON THE REMOTE CONDENSER. 4. NOTE: REMOVE CAP PLUGS FROM ALL L I N E VALVES BEFORE MAKING VALVE CONNECTIONS WITH THE SEAL I 5. NOTE: A LOW VOLTAGE ELECTRICAL CONTROL CIRCUIT MUST RE F I E L D WIRED BETWEEN THE ICE MACHINE AND THE REMOTE CONDENSER RELAY. THOSE WIRES SHOULD BE RUN WITH THE TUBING DURING INSTALLATION. REFER TO APPLICABLE WIRING DIAGRAMS. 6. WHEN THE L I N E VALVES ARE CONNECTED TO EACH OTHER THE REFRIGERANT CIRCUIT IS COMPLETE. EACH VALVE HALF HAS I T S OWN SHUT OFF WHICH MUST BE FULLY OPENED TO ALLOW THE REFRIGERANT TO FLOW THROUGH THE SYSTEM BEFORE I T IS STARTED. The i c e making u n i t u t i l i z i n g w i t h the r e c e i v e r holding the be r e q u i r e d upon i n s t a l l a t i o n condenser i s operating under, a remote condenser i s shipped from the f a c t o r y r e f r i g e r a n t charge. A d d i t i o n a l r e f r i g e r a n t may depending upon the ambient c o n d i t i o n s the remote the condenser and l i n e s i z i n g . A t h r e e way head pressure c o n t r o l valve i s used t o maintain a r e l a t i v e l y c o n s i s t e n t head pressure between 180 and 200 PSI f o r R-502 i n the r e c e i v e r i n c o l d ambient conditions t o insure a good harvesting o r d e f r o s t i n g of the i c e slabs on the evaporator. 8ecause o f t h i s valve some l i q u i d r e f r i g e r a n t w i l l be h e l d i n the condenser. NOTE: THE HEAD PRESSURE CONTROL VALVE WILL NOT OPERATE CORRECTLY WHEN A TOTAL PRESSURE DROP OF 14 POUNDS OR MORE IS CREATED BETWEEN THE IC€ MAKING UNIT, THROUGH THE TUBING TO THE REMOTE CONDENSER, THE CONDENSER AND THE RETURN TUBING TO THE I C E MAKING UNIT. The remote condenser requires a separate power supply from the i c e making u n i t . Refer t o the remote condenser w i r i n g diagram. 5 S N ------F. S T A L L A T I O N MAKE -ELECTRICAL Requirements: I M -.S-- Y H U C 7 I O N S C O N T ' D . POWER SUPPLY COkNECTION __-__--. 208-230/60hz. 1 ph. o r 220V 50hz. 1 ph. when used REFER TO SERIAL PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM TIME DELAY FUSE SIZE. ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES. G. MAKE PLUMBING CONNECTIONS Water supply - ( I n s t a l l per l o c a l codes) The water i n l e t connection t o the u n i t i s a 3/8" f l a r e male connections located a t the r e a r o f t h e i c e machine. NOTE: If the w a t e r pressure exceeds SO pounds, a w a t e r pressure r e g u l a t o r should be i n s t a l l e d i n the water i n l e t l i n e between the water s h u t - o f f valve and the s t r a i n e r . I n s t a l l a reducer f i t t i n g on the shut-off valve t o accomodate the water s t r a i n e r , which i s supplied w i t h each i c e machine and MUST be used. I n s t a l l the water s t r a i n e r w i t h the arrow i n the proper d i r e c t i o n o f f l o w and w i t h the clean o u t plug down. This i s very important f o r cleaning. Connect e i t h e r 3/8" o r 1/2" copper tubing between the water i n l e t f i t t i n g o f the i c e machine and the water s t r a i n e r . H. For water cooled u n i t s , two water i n l e t connections are provided; one f o r the i c e making (evaporator) section which i s located on the back o f the machine and i s a 3/8" f l a r e d connection. The o t h e r i s f o r the water cooled condenser. The reason f o r t h e separate water i n l e t connections i s t h a t some i n s t a l l a t i o n s use a water tower f o r cooling the water used i n t h e water-t cooled condenser and some i n s t a l l a t i o n s use t r e a t e d water ( f i l t e r e d ) f o r the i c e making i n l e t water connection. Be sure t o i n s t a l l water l i n e (incoming) t o the 3/8" male f l a r e connection on the back o f the u n i t t h a t supplies water t o the water r e g u l a t i n g valve i n s i d e . The s e t t i n g o f the water r e g u l a t i n g valve from the f a c t o r y should be 120 pounds f o r R-12 u n i t s and 250 pounds for R-502 u n i t s . NOTE: Always f l u s h o u t water l i n e s before s t a r t i n g u n i t . Adjustments, ifnecessary, should be done a t i n s t a l l a t i o n . DRAINS Provide a s u i t a b l e trapped open d r a i n as close as possible t o t h e area where the i c e maker i s going t o be i n s t a l l e d . This may be an e x i s t i n g f l o o r o r a 1-1/4" trapped open drain. Two separate d r a i n l i n e s are required f o r a i r cooled u n i t s , one f o r t h e storage b i n and one f o r the apnp Valve drain hose. An a d d i t i o n a l separate d r a i n l i n e w i l l be required f o r water cooled u n i t s from t h e o u t l e t o f the condenser c o i l t o the d r a i n . Run a l l g r a v i t y d r a i n l i n e s w i t h a good f a l l t o the open drain. ALL PLUMBING MUST BE INSTALLED I N ACCORDANCE WITH LOCAL CODES. NOTE: I N SOtIE CASES I T HAY BE NECESSARY TO INSULATE THE WATER SUPPLY LINE AND DRAIN LINE. CONDENSATE DRIPPING TO THE FLOOR CAN CAUSE SERIOUS STAINING OF CARPETS OR HARDWOODS. I N S T A L L A T 1 0 N I N S T R U C T I O N S CONT'D. DRAIN CONHECTXON INSTALLATION INSTRUCTIONS mnnp Valve drain hose Taking care not to kink or collapse vinyl: tubing at any point, route rubes to any open, trapped or vented floor drain. Run'tubing t o drain separately. Do not tee any drain hoses together. Add drain tubing required to reach floor drain. I. ADJUS'IMENT OF WATER LEVEL IN RESERVOIR With the water supply turned ON and the power'supply OFF'adjust froat to maintain water levelk" below the support web insidereservoir (See Illustration B e l o w ) Adjust here Float assembly WAKNINC: i c e b1;lkcr v i 1 1 not o p e r a t e p r o p e r l y when w;iCcr s u p p l y c c m p c r a c u r c i s b e l o w 50'F or a b o v e 100'F. Nntcr supply p r e s s u r e m u s t noc exceed SO PSI. 7 I N S T A L L A T I O N J. I N S T R U C T I O N S CONT'D. STARTING THE UNIT A f t e r the i c e cuber has been unpacked and leveled and a l l plumbing and e l e c t r i c a l connections have been made, s t a r t the u n i t and check f o r proper , opera t i on. A cuber has t h r e e separate c i r c u i t s : A. B. C. The water c i r c u i t The r e f r i g e r a n t c i r c u i t The e l e c t r i c a l c i r c u i t 1. S t a r t checking the water c i r c u i t by making sure t h a t there are no thread o r f l a r e j o i n t leaks, e i t h e r outside the u n i t o r i n the compressor section. Next check the water f l o w over the evaporator and make sure t h a t a l l holes i n t h e water distribu:or are open, and t h a t there i s no undue splash o r l o s s of water i n t o t h e i c e b i n . Also check t o see i f t h e f l o a t valve i s f u n c t i o n i n g p r o p e r l y and the c o r r e c t water l e v e l i s being maintained. Re-adjust i f necessary. 2. Check the r e f r i g e r a n t c i r c u i t by making sure t h a t the condensev fan i s running. (This w i l l be evident by a i r noise.) I s the compressor running? (Feel the casing f o r v i b r a t i o n . ) Is the evaporator g e t t i n g cold? 3. Check b i n - h a r v e s t s w i t c h o p e r a t i o n . 8 (See p r o c e e d u r e i n manual) STACKING KIT INSTALLATION INSTRUCTIONS 5 2 1 1 1 - #857 screw 8/32 x 3/8 #$9449 t i e strap - #39450 i c e s l i d e d i v e r t e r - #39454 r e t a i n e r s h i e l d assembly #39379 i n t e r f a c e cable PLEASE SEE ILLUSTRATIONS FOR REFERENCE FOR THE FOLLOWING INSTALL PROCEDURE 1. A f t e r the bottom u n i t o f the stack has been positioned on the bin, the s e a l i n g gasket supplied w i t h second u n i t must be cemented t o the base. Nearly any adhesive can be used, however i t should n o t be: water soluble. This i s an N.S.F. requirement and the r e s p o n s i b i l i t y o f the i n s t a l l e r . 2. Remove the top and f r o n t panels from both u n i t s . 3. Mount t h e u n i t on top o f the bottom one o f the stack. t o stack more than one u n i t . ) 4. Remove evaporator c u r t a i n cover. 5. NIA 6. Put the i c e s l i d e d i v e r t e r through the top u n i t evaporator s e c t i o n and hook over the f r o n t edge o f the top u n i t water reservoir. 7. Secure i c e s l i d e d i v e r t e r t o the back w a l l o f the lower u n i t w i t h a provided screk 8. I n s e r t the r e t a i n e r s h i e l d from the f r o n t o f the lower u n i t evaporator section and a l i g n the holes t o the d i v e r t e r and support bracket and secure w i t h the screws provided. 9. Remove e l e c t r i c a l box covers from both u n i t . ( I t i s n o t recommended . 10. Remove lowest grommet f r o m the l e f t side o f each e l e c t r i c a l box 11. I n s e r t the i n t e r f a c e cable through each hole and i n s e r t i n t o the s p l i t grommets. -,the cable w i l l ’ f a l l across the f r o n t o f both machines w i t h the f r o n t covering the cable. 12. R e i n s t a l l g r o m e t s i n t o e l e c t r i c a l box. 13. Plug t h e i n t e r f a c e cable end i n t o the open middle l e f t socket on each s o l i d s t a t e board being careful t o make sure o f a good connection. 14. Replace e l e c t r i c a l box covers. 15. Plug t h e weld nut hole found t o the r i g h t o f the compressor w i t h RTV sealant. 16. Remove t h e screws from both sides o f both u n i t s and i n s e r t the t i e straps. Rei ns t a l 7 screws. 17. When r e i n s t a l l i n g the f r o n t panels, take care i n the p o s i t i o n i n g of the i n t e r f a c e cable. 9 STACKING KIT ILLUSTRATION W J J> 10 R E F R I G E R A N T C I R C U I T - R E M O T E C O N D E N S E R U N I T S I UCHECK EXPANS IO N VALVE -1 EVAPORATOR VALVE U RECEIVER fl fl COMPRESSOR PRESSuRE CONTROL VALVE I W ACCUM. VALVES I 4 REMOTE CONDENSER 11 -_ 1 ELECTRICAL S m - T T P CIRCUIT V - m N An L.E.D. digit display mounted on the solid state control board will show a status number 6 , 1 , 2 , 4 , &6 and a decimal point to indicate what is happening in the operation of the unit. The electrical sequence of operation you will see on the digit display for a riormal ice making cycle will be as follows: The status number 0 will be shown telling you the unit is making ice. The solid state control DELAYS the start of the water pump until the evaporator temperatures reachesTFF. Approximately six minutes after the start up in the freeze cycle a decimal point will appear to the lower right of the "0" to tell you that the evaporator sensor has been switched on. After the evaporator temperature has pulled down low enough for the correct amount of ice to be on the evaporator, the decimal point will begin to flash and ,stay flashing for approximately 20 seconds. If evaporator stays below the set point, the harvest cycle will start. A number ''1" on the digit display will indicate that the machine is in its harvest cycle with the hot gas valve open. The water pump continues t o operate and the water dump solenoid valve is now open. The water pump shuts off approximately 15 seconds later after the water reservoir is pumped out. PLEASE NOTE: During the freeze cycle in low ambient condition the condenser fan motor will be cycled on and off through the condenser sensor and solid state control board. The fan cycling pressures in relation to the temperatures sensed will be approximately 180# for cut out and 230# for cut in of the fan motor. ADJUSTMENT FOR ICE BRIDGE THICKNESS An ice bridge connecting all cubes is necessary for a proper harvest or discharge of cubes from the evaporator. To increase ice "bridge" thickness carefully turn adjustment screw counter clockwise no more than one turn at a time. Wait and check thickness before re-adjusting. UERE f-% INCREASE ClRCUl T BOAR0 12 F O R H A R V E S T - B I N S W I T C I - I E S CHECKOUT PROCEUDRE T u r n o n t h e i c e m a c h i t l e q n d move t h " e e v a p o r a t o r c u r t a i n ( s ) a w a y f r o m t h e e v a p o r a t o r ( s ) . The i ' c e m a c h i n e s h o u l d t h e n s h u t o f f i n a p p r o x i m i t l y 8 seconds.(See d e t a i l A&B) Slowly l e t t h e e v a p o r a t o r c u r t a i n ( s ) move b a c k t o w a r d t h e e v a p o r a t o r ( s ) u n t i l t h e b o t t o m edge o f t h e c u r t a i n ( s ) i s a t l e a s t a t t h e b e n t e d g e o f t h e w a t e r r e s e r v o i r o r c l o s e r t o t h e evaporat'ojla. W i t h t h e c u r t a i n ( s ) a t t h a t p o s i t i o n , the machineshould s t a r t . ( S e e d e t a i l C ) ADJUSTMENT PROCEDURE I f a d j u s t m e n t i s n e c t $ ~ s a r y , l o o s e n a c o r n n u t s a n d move p r o x i m i t y s w i t c h c l o s e r t o t h e c u r t a i n ( s ) a n d make s u r e t h e c u r t a i n i s p r o p e r l y m o u n t e d . (See d e t a i l A ) Re-check p e r above proceedure. 13 I RD I 1 I d I Power Relay Unit Switch Compressor Start Relay RD Manual Reset High PtWsun Control ON RD Condensot Fan Motor RD 1 R (W/C only) OR Solonoid I . I Water pump WWH- I BL sw2 I Ira GY I <!Optional I Control To stacked UnitDc2 DC2 if reauired I G- Reset Switch Harvest 8 Bin Switch p B I 4- I & Remote -0AlarmBox I I IokI DC4 DC I R - ~ I ---t horn Light Quiet Switch RD BL 1 208/230 VOLTS 60 HZ AC & WC-900-MH NOT€: - The solid state control DELAYS the start of the water pump until the evaporator temperature reaches 20° F. White and black connector blocks ore lMPoRTANir JKEYED'and MUST be inserted correctly on circuit board.. 00 NOT U S E FORCE. 14 PARTNO. ARTWORK REV. H 40564 5 0 5 39 JBK Outlet Bat Heater Compressor Power Compressor Comprmwr Start Compressor Start Relay I RD Unit CLEAN FT t Water Pump I Reset switch Horn Light Switch Quirt ds=4Dc4 GY Harves!a B d D C I Bin Switch J JJ I- -- 208/230 VOLTS 6 0 H Z R C - 9 0 0 -MH NOTE: Th:e solid state control DELAYS the start of the water pump until the evaporator temperature reaches 20° F, IMPORTANT White and black connector blocks are "KEYE0"and jvlUS1 be inserted correctly on circuit board, DO NOT USE FORCE. 15 PART NO. 4 0 5 6 5 ARTWORK 5 0 5 4 0 REV. I I P o w e r Relay BK 1 I BK RO Coolinq Fan 4 0 0 0 Automatic Reset High Pressure Control (W/C only 1 O R #jFi @ * w L.......4 Condensor e I . Water Pump - suctiy Bfl To stacked Unit DC2 if required JjJ I DC2 1 1 + Optional Remote -2oAlarrn Box P: : =&::,- RCV-1 Control Rev E OR f , Horn Light Quiet 208/230 VOLTS 60 Hi! 3 PHASE AC &WC-S OO-MH 4EE3 The a o l i d a t a t e control DELA Y S the a t o r t o f the v a t e c Dum0 until the e v o g o r o t o r t e m p e r a t u r e r e o c h e s 20 F . U h i t e and black connector blocks a r e 'KEVED' and HUST be inserted correct tu on c i r c u i t board-- 16 PART NO. 41280 ARTWORK N O . SO563 REV. E J' W BK1 RO CoolingFan I fBK 10 OR OFF ON r Field Wirina RO L . BR I t u I I . '.I I r RC-900-MH The s o l i d s t a t e c o n t r o l D f L A Y S the the v o t e r P U ~ Duntil the e v o g o r o t o r t e m p e r a t u r e r e o c h e s 20 F. White and block connector blocks a r e ond MUST be inserted c o r r e c t l y on c i r c u i t board.M 'KEVED' 17 PART NO. 4 1 2 8 1 flRTUORK N O . 50564 REV. F S A N I T I Z I N G A N D C L E A N I N G P R O C E D U R E 1. Remove front panel to gain access to the on-off-clean switch. 2. Push switch to "clean" and allow the ice on the evaporator to release or melt away. 3. Remove all ice from storage bin. 4. Mix a sanitizing solution of 1/4 0 2 . "Calgon Ice Machine Sanitizer" to one gallon of water. Using a non-metallic bristle brush scrub the following: a. b. c. Inside surfaces of ice bin including top and door. Inside surfaces of the icemaker to include evaporator section in the ice machine including the top, front panel and evaporator splash curtain. Make sure splash curtain is correctly positioned. oz. of "Calgon Niekel-Safe Ice Machine Cleaner" directly into water reservoir. Circulate for approximately 4 5 minutes. 5. Add 2 6. Remove cap from reservoir drain and allow cleaner to drain away. Replace cap. 7. Fill reservoir with clean fresh water, circulate for approximately 1 minute. Remove cap from reservoir drain and allow water to drain away. Repeat three times. 8. Flush all waste water from ice storage bin with clean fresh water. 9. Push switch from "clean" to "on" position. 10. Replace front panel. t here assemb Reservoir drain cap 18 W A T E R T R E A T M E N T Automatic ice-making machines can q u i t working for any number of reasons, mechanical, e l e c t r i c a l o r f a u l t y r e f r i g e r a t i o n , but water problems f o u l them up f a s t e r than almost anything else. While i c e machines vary i n design, you can apply these water treatment t i p s t o a l l of them. 1. START WITH THE WATER The mineral content o f water varies i n d i f f e r e n t areas and as the chart shows, high hardness and a l k a l i n i t y counts combine t o form insoluble calcium carbonate o r lime scale. I f t h i s condition i s constant, the i n t a k e water must be treated constantly t o prevent scale formation i n the i c e machine. 2. PREVENT LIME SCALE FORMATION We recomnend the i n s t a l l a t i o n o f a Calgon Microment Feeder on the incoming water l i n e . No. X-88 Feeder 4s recommended f o r i c e machines with a capacity o f 400-450 lbs. per day. F i l l the feeder w i t h 6R Micromet, the slowly soluble poly-phosphate which l a s t s s i x months before renewing the 8-oz. charge. Constant treatment w i t h 6R Micromet w i l l c o n t r o l lime scale and prevent minerals f r o m s t i c k i n g t o the freezing surfaces i n i c e machines. Result smooth movement of i c e slabs, good harvest of i c e cubes, e f f i c i e n t , automatic production. - 3. REMOVE OBJECTIONABLE TASTE OR ODOR Ifthe bad t a s t e o r odor i s traceable t o the water source, i n s t a l l a Calgon Fine Carbon F i l t e r t o the incoming water l i n e . The No. 1-1/28 Fine Carbon F i : t e r i s ideal f o r machines making up t a 500 pounds o f i c e per day and w i l l remove bad taste, odors, and problems caused by c h l o r i n e i n the water supply. I n some instances, slime growths may cause odor problems and these growths can be removed by the use of 1i q u i d i c e machine cleaner. 4. SERVICE REGULARLY A service program t o clean the i c e machine a t regular i n t e r v a l s and check on f i l t e r and feeder charges i s important. I n the long run, i t w i l l assure adequate water treatment, reduce emergency c a l l s and a i d i n the trouble-free performance o f automatic i c e making machines. 19 W I N T E R S T O R A G E I f the u n i t i s t o be stored i n an area where the temperature w i l l drop below freezing, i t i s most important t h a t a l l water l i n e s be drained t o prevent them from freezing and possible rupture. To blow out the water l i n e , disconnect the water supply a t the cabinet i n l e t and use a i r pressure t o force the water i n t o the water reservoir pan. This can then be removed from the water pan. CLEANING T H E C O N D E N S E R I n order t o produce a t f u l l capacity, the r e f r i g e r a t i o n condenser must be kept clean. The frequency o f cleaning w i l l be determined by surrounding condition. A good maintenance plan c a l l s for an inspection a t l e a s t every two months. Remove the lower f r o n t panel o f the machine. With a vacuum cleaner, remove a l l accumulated dust and l i n t t h a t has adhered t o the finned condenser. CAUTION: CONOENSER COOLING FINS ARE SHARP. USE CARE WHEN CLEANING. 1. Ifthe condenser i s being cleaned from the back o f the machine, remove a l l accumulated dust, d i r t etc., t h a t has adhered t o the finned surface w i t h a vacuum cleaner. 2. I f the u n i t i s being cleaned from the front, remove lower panel, t u r n the power switch o f f and blow through the finned surface o f the condenser past the fan blade t o remove accumulated dust, etc. 20 STATUS INDICA'IDR POSSIBLE CAUSE STATUS E3BLANATION 0 Unit is in freeze cycle, mking ice, no problems. 1 Unit is in harvest cycle, ice should drop shortly, no problems. 4 Decimal Point OFF Indicates a full bin condition, unit off, water curtain being held open with ice. If "2" is sham txt bin isn't f u l l , check for individual cube holding curtain open. Harvest Bin switch not adjusted properly. Unit OFF due to suction line not p l l l i F b m to at least 40°F. bkmual. reset required. b w on refrigerant. Defective Txv. Canpressor defective or inefficient. Defective pawer relay, wn't close. Defective start relay, wnlt start anpressor. Law voltage to ampressor no s t a r t . Defective C.P.R. valve. Defective sensor (brawn wire). SENSOR NYT INSULATED PROPERLY. Unit is OFF due to mndenser tenperature climbing too high. Manual reset required. Dirty condenser. Defective fan motor or blade.* Gross overcharge. EXtremly high ambient tanperatwe, above 120°F. Defective sensor (orange wire).** Indicates that all sensors, except condenser, are switched off for first six minutes of freeze cycle. Normal time delay, approximately 6 minutes. Decimal mint ON Indicates that evaporator and suction line sensors have switched "ON1@. Decimal Point Indicates evaporator tenperature has pulled down and unit will go into harvest after time delay. RdSHING * krmal time delay of approximately 20 seconds before harvest cycle begins. Not applicable to Water-0301ed units. ** Not applicable to Ranote units. 21 T R O U B L E , S H O O T I N G T H E C O N T R O L S O L 1 0 S T A I L B O A R D T o determine if the c i r c u i t board and sensors are functioning c o r r e c t l y under a l l operating parameters, the adverse conditions must he simulated t o check out the d i g i t a l display status numbers. P R O C E D U R E To check Y6 To check 14 - To check Y2 - TO check Y1 - To check #O - Block condenser fan blade on s t a r t up. Condenser should get hot w i t h i n two minutes and shut u n i t o f f on Y6, condenser too hot. Remove suction l i n e sensor from themowell anytime during freeze cycle. Machine should shut o f f on 1 4 , suction l i n e too w a r m when the evaporator temperature gets low enough t o s t a r t t h e harvest cycle. Hold water c u r t a i n open anytime a f t e r u n i t goes i n t o harvest. Machine should shut down w i t h i n approximately 8 seconds on #2, f u l l bin. Push defrost button anytime during freeze cycle and u n i t should go i n t o harvest. # I i n d i c a t e s a harvest cycle, no problems. A "0" indicates t h a t the u n i t i s i n the freeze c y c l e and there a r e no problems. PLEASE NOTE: I n rare cases a "0" can be displayed on the control board and the compressor n o t running i n water cooled and m o t e a i r cooled machines. I f t h i s occurs, the manual reset high pressure c o n t r o l w i l l he open and must be r e s e t for proper operation. The c o n t r o l i s located i n the upper rear, r i g h t corner o f the compressor compartment. A f t e r reset, check o u t the machine f o r the possible causes o f the problem. 22 TROUBLESHOOTING ’ T H E S . E N S O R S 1. Turn o f f power t o machine. 2. Remove the f r o n t panel and e l e c t r i c a l box cover o f the machine. 3. Cut the suspected sensor w i r e a t l e a s t s i x inches from the thermowell i n which i t i s located. 4. Remove the sensor from the thermowell. 5. C a r e f u l l y separate t h e wires and s t r i p the i n s u l a t i o n o f f the end. 6. Pack a glass o r container w i t h i c e and add some water t o make an ice-water s o l u t i o n . Check t h e temperature o f t h e i c e water w i t h an accurate thermometer, I c e water must be 32O F, 7. I n s e r t the sensor i n t o t h e i c e water and soak f o r a minimum of two m i nut e s 8. With a zerod ohmmeter measure the resistance across the two wires o f t h e sensor lead. I t should read 2815 ohms + o r -10% (281 ohms). . NOTE: I f the above ohm reading i s n o t w i t h i n the range stated, the sensor i s bad and should be replaced. RECONNECTION S E N S O R O F A F T E R A G O O D O R REPLACEMENT TROUBLESHOOTING 1. C a r e f u l l y separate the wires o f the sensor leads coming from t h e s o l i d s t a t e c o n t r o l and s t r i p the i n s u l a t i o n o f f the end o f each wire. 2. Reconnect t h e sensor leads and t w i s t the s t r i p p e d ends t i g h t l y . w i t h the proper sized w i r e nuts. 3. Tape a l l t h e w i r e n u t connections t o i n s u l a t e connections f r o m each other. 23 Secure REMOVAL CAUTION: O F S O L I D S T A T E CONTROL F R O M M A C H I N E THE C I R C U I T BOARD I S FRAGILE, HANDLE WITH CARE. 1. Turn o f f power t o machine. 2. Remove f r o n t panel. 3. Remove e l e c t r i c a l box l e f t f r o n t cover. 4. Disconnect the through w i r e p l u g connections from c i r c u i t board. 5. C a r e f u l l y l i f t any corner o f t h e c i r c u i t board w h i l e pinching closed t h e top p a r t o f t h e p l a s t i c "stand aff" support w i t h needle nose p l i e r s . The c i r c u i t board has t o be g r a d u a l l y worked up over a l l f i v e of t h e "stand o f f " supports. The c i r c u i t board w i l l n o t "pop o f f " u n t i l a l l supports have been pinched closed and the board i s tihen h o l d i n g them i n t h a t p o s i t i o n . R E I N S T A L L A T I O N O F S O L I D S T A T E CONTROL 1. A l i g n a l l holes i n the c i r c u i t board over the p l a s t i c stand-off supports. 2. C a r e f u l l y push downward a t a l l hole l o c a t i o n s u n t i l board seats on a l l the stand-off su ports. (Sometimes a snap w i l l be heard as t h i s seating takes p l ace. P 3. A f t e r the c i r c u i t board i s seated, c a r e f u l l y connect the three plugs t o the c i r c u i t board. Note: Plug connects are polarized, make sure the plug i s inserted correctly. 24 \ 1 /i PARTS LIST ~ ~ ,' / ' , ILLUS. NO. 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 DESCRIPTION PART NO. 900 SERIES 161079003 37356 40285 40713 40284 27765 37 4 39 26275 20654 21214 23988 40569 39899 39898 40586 39897 38703 39144 26269 38703 40712 38790 45681 41448 21924 45922 45680 Tee 987 Hose 43412 O r i f i c e , restrictor 29784 Evaporator 45905 End c a p 22279 D i s t r i b u t o r , water 43056 Curtain, evaporator 45907 B r a c k e t , f r o n t c u r t a i n mount 43530 Condenser c o i l , water cooled 8823 Valve, w a t e r r e g u l a t i n g 1211 B r a c k e t , back cover mount 38743 Valve, water dump s o l e n o i d 42781 S w i t c h , harvest-bin proximity 43446 Valve, c h e c k 41275 C o n t r o l v a l v e , head p r e s s u r e 37351 C o n t r o l , high p r e s s u r e sensor 39644 Valve, l i n e female 27173 Valve, l i n e male 27171 Seal, l i n e valve 27176 Accumulator 27186 Receiver 38057 Transformer, 24 v o l t 23683 Heater, c r a n k c a s e 40602 C o n t r o l high pressure, manual reset (W/C c remote o n l y ) 39358 Sensor, evaporator 38703 S w i t c h , reset 42680 S p l a s h guard 41464 Swich, dump valve 25 45866 C o n t r o l , c i r c u i t board S w i t c h , on-of f - c l e a n Relay, compressor s t a r t R e l a y , power Contactor C a p a c i t o r , compressor s t a r t C a p a c i t o r , compressor r u n Drier Valve, c r a n k c a s e p r e s s u r e r e g u l a t i n g Valve, Schrader Core, Schrader valve Cap, Schrader v a l v e Compressor Motor, condenser f a n Blade, condenser f a n Shroud, condenser Condenser S e n s o r , condenser temp. Pump, water Valve, t h e r m o s t a t i c expansion S e n s o r , s u c t i o n l i n e temp. Valve, h o t g a s Tube, w a t e r pan t o pump i n l e t Cap, r e s e r v o i r d r a i n R e s e r v o i r , water F l o a t and v a l v e B r a c k e t , f l o a t and v a l v e Hose - \ 26 REMOTE CONDENSER lLLUSTRATED PARTS BREAKDOlJN Illus. No. 1 2 3 4 5 6 7 8 9 10 11 P a r t no. Description 35832 27183 27185 27181 27171 27173 28627 27384 27150 35769 271 76 Clip, retainer B1ade , condenser fan Motor, condenser fan Re1ay Line valve (male connection 5/8" tube) L i n e valve (female connection 5/8" tube) Bracket, fan motor mounting Bracket, mounting Shroud, condenser Condenser Seal, l i n e valve for #27171 27