Bartscher 104409, F80, 104436, F125 Service Manual
ELECTRONIC MODULAR
FLAKERS
SERVICE MANUAL
104409 F80
104436 F125
71503
135-0-000 service Flakers GB
GB
3
TABLE OF CONTENTS
S
pecification F 80C pagina 4
Specification F 125C 5
Specification F 120 6
Specification F 200 7
Specification SF 300 8
S
pecification SF 500 9
Specification SFN 1000 10
GENERAL INFORMATION AND INSTALLATION
Introduction 11
Unpacking and Inspection - Ice maker 11
Unpacking and Inspection - Storage bin 11
Location and levelling 12
Electrical connections 13
Water supply and drain connection 13
Final ceck list 13
Installation pratice 14
OPERATING INSTRUCTIONS
Start up 15
Operations checks 17
PRINCIPLE OF OPERATION (how it works)
Water circuit 20
Refrigerant circuit 21
Mechanical system 23
Operating pressures 24
Components description 25
ADJUSTMENT, REMOVAL AND REPLACEMENT PROCEDURES
Adjustment of the evaporator water level 29
Replace of the gear motor magnetic sensor 29
Replace of auger, water seal, bearing and coupling 29
Replacement of the gear motor assy 30
Replacement of freezing cylinder 31
Wiring diagram 32
Service diagnosis 36
MAINTENANCE AND CLEANING INSTRUCTIONS
General 38
Icemakers 38
Cleaning instructions of water system 38
GB
4
TECHNICAL SPECIFICATION
ELECTRONIC MODULAR
FLAKERS mod. F80 (R 134a)
Produzione di ghiaccio in 24 ore fino a
Ice produced for 24 hours up to
Eisproduktion in 24 Stunden bis zu
Production de glace en 24 h jusqu’à
Produccion de hielo en las 24 horas hasta
Raffreddamento unità condensatrice aria o acqua: consumo n. 20 litri per ora*
Condensing unit cooling air or water: consumption n. 20 litres per hour*
Kondensatoreinheit Luft oder Wasser: Verbrauch n. 20 liter pro Stunde*
Refroidissement de l’unité de condensation air ou eau: consommation n. 20 litres par heure*
Refrigeración de la unidad condensadora aire o agua: consumo n. 20 litros para hora*
Potenza assorbita/Absorbed power/Leistungsaufnahme
Puissance absorbée/Potencia Absorbida
Refrigerante/Refrigerant/Kältemittel
Réfrigérant/Refrigerant
Attacco entrata acqua/Water iniet connection
Anschluss für Wasserzufluss/Prise entrée d’eau/conexión entrada agua
Attacco scarico acqua/Water output connection
Anschluss für Wasserabfluss/Prise écoulement d’eau
Conexión desague
Alimentazione monofase/Single phase input/
Einphasige Spannung/Alimentation monophase
Alimentación monofásica
Alimentazione voltaggi speciali: a richiesta
Extra voltages: on request
Andere Spannungen: Lieferbar auf Wunsch
Alimentation voltages spéciaux: sur demande
Otros voltajes especiales: según pedido
Capacità deposito - Storage bin capacity
Inhalt des Vorrats-Eisbehänders
Capacité de la réserve - Capacidad del deposito
Carrozzeria
External structure
Ausfühnrung inox
Carrosserie
Carroceria
Peso netto/Net weight/Netto Gewcht
Poids net/Peso neto
PRODUZIONE DI GHIACCIO
ICE PRODUCTION
EIS PRODUKTION
PRODUCTION DE GLACE
PRODUCICON DE HIELO
RAFFR. AD ACQUA/WATER COOLED
WASSERGEKÜHLT/REFR. A EAU
REFR. A AGUA
Temperatura acqua/Water temperature
Wassertemperatur/Température eau
Temperatura agua
Prod. ghiaccio in 24 h/Ice prod. per 24 h
Eisprod. in 24 h/Prod. de glace en 24 h
Prod. de hielo en 24 h
RAFFR. AD ARIA/AIR COOLED
LUFTGEKÜHLT/REFR. A AIR
REFR. A AIRE
Temperatura acqua/Water temperature
Wassertemperatur/Température eau
Temperatura agua
Prod. ghiaccio in 24 h/Ice prod. per 24 h
Eisprod. in 24 h/Prod. de glace en 24 h
Prod. de hielo en 24 h
°C 32° 21° 15° 10°
10° 78 84 87 90 kg
21° 72 78 81 84 kg
32° 58 63 66 68 kg
38° 48 52 54 56 kg
°C 32° 21° 15° 10°
10°
76 81 84 86 kg
21° 72 77 80 82 kg
32° 68 74 76 78 kg
38° 64 70 71 72 kg
Temperatura ambiente
Ambient temperature
Raumtemperatur
Température ambiante
Températura ambiente
Temperatura ambiente
Ambient temperature
Raumtemperatur
Température ambiante
Températura ambiente
(*) con temperatura acqua 15 °C
with water temperature 15 °C
mit Wassertemperatur 15 °C
avec température eau 15 °C
con temperatura agua 15 °C
kg. 90
W 400
R 134a
3/4” Gas
mm. Ø 20
220V-240V - 50 Hz
kg. 53
kg. 20
Dimensioni / Dimensions / Masse / Dimensions / Dimensiones
835
600
570
695
624
218
5044
570
GB
5
TECHNICAL SPECIFICATION
ELECTRONIC MODULAR
FLAKERS mod. F125 (R 134a)
Produzione di ghiaccio in 24 ore fino a
Ice produced for 24 hours up to
Eisproduktion in 24 Stunden bis zu
Production de glace en 24 h jusqu’à
Produccion de hielo en las 24 horas hasta
Raffreddamento unità condensatrice aria o acqua: consumo n. 24 litri per ora*
Condensing unit cooling air or water: consumption n. 24 litres per hour*
Kondensatoreinheit Luft oder Wasser: Verbrauch n. 24 liter pro Stunde*
Refroidissement de l’unité de condensation air ou eau: consommation n. 24 litres par heure*
Refrigeración de la unidad condensadora aire o agua: consumo n. 24 litros para hora*
Potenza assorbita/Absorbed power/Leistungsaufnahme
Puissance absorbée/Potencia Absorbida
Refrigerante/Refrigerant/Kältemittel
Réfrigérant/Refrigerant
Attacco entrata acqua/Water iniet connection
Anschluss für Wasserzufluss/Prise entrée d’eau/conexión entrada agua
Attacco scarico acqua/Water output connection
Anschluss für Wasserabfluss/Prise écoulement d’eau
Conexión desague
Alimentazione monofase/Single phase input/
Einphasige Spannung/Alimentation monophase
Alimentación monofásica
Alimentazione voltaggi speciali: a richiesta
Extra voltages: on request
Andere Spannungen: Lieferbar auf Wunsch
Alimentation voltages spéciaux: sur demande
Otros voltajes especiales: según pedido
Capacità deposito - Storage bin capacity
Inhalt des Vorrats-Eisbehänders
Capacité de la réserve - Capacidad del deposito
Carrozzeria
External structure
Ausfühnrung inox
Carrosserie
Carroceria
Peso netto/Net weight/Netto Gewcht
Poids net/Peso neto
PRODUZIONE DI GHIACCIO
ICE PRODUCTION
EIS PRODUKTION
PRODUCTION DE GLACE
PRODUCICON DE HIELO
RAFFR. AD ACQUA/WATER COOLED
WASSERGEKÜHLT/REFR. A EAU
REFR. A AGUA
Temperatura acqua/Water temperature
Wassertemperatur/Température eau
Temperatura agua
Prod. ghiaccio in 24 h/Ice prod. per 24 h
Eisprod. in 24 h/Prod. de glace en 24 h
Prod. de hielo en 24 h
RAFFR. AD ARIA/AIR COOLED
LUFTGEKÜHLT/REFR. A AIR
REFR. A AIRE
Temperatura acqua/Water temperature
Wassertemperatur/Température eau
Temperatura agua
Prod. ghiaccio in 24 h/Ice prod. per 24 h
Eisprod. in 24 h/Prod. de glace en 24 h
Prod. de hielo en 24 h
°C 32° 21° 15° 10°
10° 102 111 115 120 kg
21° 95 104 108 110 kg
32° 84 90 94 97 kg
38° 75 81 85 87 kg
°C 32° 21° 15° 10°
10°
97 108 117 120 kg
21° 95 105 115 117 kg
32° 90 100 107 110 kg
38° 87 97 102 105 kg
Temperatura ambiente
Ambient temperature
Raumtemperatur
Température ambiante
Températura ambiente
Temperatura ambiente
Ambient temperature
Raumtemperatur
Température ambiante
Températura ambiente
(*) con temperatura acqua 15 °C
with water temperature 15 °C
mit Wassertemperatur 15 °C
avec température eau 15 °C
con temperatura agua 15 °C
kg. 120
W 480
R 134a
3/4” Gas
mm. Ø 20
220V-240V - 50 Hz
kg. 64
kg. 27
Dimensioni / Dimensions / Masse / Dimensions / Dimensiones
680
90595~
750
510 680
150
90
45
GB
6
A INTRODUCTION
the step-by-step procedures for the installation,
start- up and operation, maintenance and
cleaning for the F80 - F125 Modular Icemakers.
The Electronic Flakers and Superflakers are
quality designed, engineered and manufactured. Their ice making systems are thoroughly
tested providing the utmost in flexibility to fit the
needs of a particular user.
B. UNPACKING AND INSPECTION
Icemaker
1 Call you rauthorizedI Distributor or Dealer for
proper installation.
2 Visually inspect the exterior of the packing
and skid. Any severe damage noted should
be reported to the delivering carrier and a
concealed damage claimformfilled in subjet
to inspection of the contents with the carrier’s
representative present.
3 a) Cut and remove the plastic strip securing
the carton box to the skid.
b) Cut open the top of the carton and remove
the polystyre protection sheet.
c) Pull out the polystyre posts from the cor-
ners and then remove the carton.
d) Lift the whole carton and pull it out from
the device.
4 Remove top and sides panels of the unit and
inspect for any concealed damage.
Notify carrier of your claim for the concealed
damage as stated in step 2 above.
5 Remove all internal support packing and
masking tape.
6 Check that refrigerant lines do not rub again-
st or touch other lines or surfaces, and that
the fan blades move freely.
7 Check that the compressor fits snugly onto
all its mounting pads.
8 See data plate on the rear side of the unit and
check that local main voltage corresponds
with the voltage specified on it.
NOTE. To retain the safety and performance
built into this icemaker, it is important that
installation and maintenance be conducted
in the manner outlined in this manual.
GENERAL INFORMATION AND INSTALLATION
GB
7
C. LOCATION AND LEVELLING
1 Position the storage bin in the selected per-
manent location. Criteria for selection of location include:
a) Minimum room temperature 10°C (50°F)
and maximum room temperature 40°C
(100°F).
b) Water inlet temperatures: minimum 5°C
(40°F) and maximum 35°C (90°F).
c) Well ventilated location for air cooled
models (clean the air cooled condenser at
frequent intervals).
d) Service access: adequate space must be
left for all service connections through the
rear of the ice maker.
A minimum clearance of 15 cm (6")must be
left at the sides of the unit for routing cooling
air drawn into and exhausted out of the compartment to maintain proper condensing
operation of air cooled models.
2 Level the Storage Bin Assy in both the left to
right and front to rear directions by means of
the adjustable legs.
D. ELECTRICAL CONNECTIONS
See data plate for current requirements to determine wire size to be used for electrical connections. All icemakers require a solid earth
wire.
All ice machines are supplied from the factory
completely pre-wired and require only electrical
power connections to the wire cord provided at
the rear of the unit.
Make sure that the ice machine is connected to
its own circuit and individually fused (see data
plate for fuse size).
The maximum allowable voltage variation
should not exceed -10% and +10% of the data
plate rating. Low voltage can cause faulty
functioning and may be responsible for serious
damage to the overload switch and motor windings.
Check voltage on the line and the ice maker’s
data plate before connecting the unit.
WARNING. This Modular Flaker and
Superflaker is designed for indoor installation only. Extended periods of operation at
temperature exceeding the following limitations will constitute misuse under the terms
of the Manufacturer’s Limited Warranty
resulting in LOSS of warranty coverage.
NOTE: This ice flake maker contains sensiti-
ve and highly precise parts. Knocks and
heavy blows must therefore be avoided.
NOTE. All external wiring should conform to
national, state and local standards and regulations.
GB
8
E. WATER SUPPLY AND DRAIN
CONNECTIONS
When choosing thewater supply for the ice flaker
consideration should be given to:
a) Length of run
b) Water clarity and purity
c) Adequate water supply pressure
Since water is the most important single ingredient in producting ice you cannot emphasize
too much the three items listed above.
Low water pressure, below 1 bar may cause
malfunction of the ice maker unit.
Water containing excessive minerals will tend to
produce scale build-up on the interior parts of
the water system while too soft water (with too lo
contents of mineral salts), will produce a very
hard flaker ice.
Dark chlorinated or iron-containing water can be
improved through the active carbon filter
If water contains a high level of impurities, it is advisable to consider the installation of an appropriate
water filter or conditioner.
WATER SUPPLY
Connect the 3/4" GAS male of the water inlet fitting,usingthefoodgradeflexiblehosesupplied to
thecoldwater supply linewith regularplumbing
fitting and a shut-off valve installed in an accessible position between the water supply line and
the unit.
If water contains a high level of impurities, it is
advisable to consider the installation of an
appropriate water filter or conditioner.
WATER SUPPLY - WATER COOLED MODELS
The water cooled versions of Ice Makers require
two separate inletwater supplies, one for the
water making the flaker ice and the other for the
water cooled condenser.
Connect the 3/4" GAS male fitting of the water
inlet, using the flexible hose supplied to the cold
water supply linewith regular plumbing fitting
and a shut-off valve installed in an accessible
position between the water supply line and the
unit.
WATER DRAIN
The recommended drain tube is a plastic or flexible hose with 18mm(3/4") I.D. which runs to an
open trapped and vented drain. When the drain
is a long run, allow 3 cm pitch per meter (1/4"
pitch per foot). Install a vertical open vent on
drain line high point at the unit drain connection
to ensure good draining.
Theidealdrainreceptacleisatrappedandvented
floor drain.
WATER DRAIN - WATER COOLED MODELS
Connect the 3/4" GAS male fitting of the condenser water drain, utilizing a second flexible
hose to the open trapped and vented drain.
This additional drain linemust not interconnect to
any other of the units drains.
F. FINAL CHECK LIST
1 Is the unit in a room where ambient tempera-
tures are within a minimum of 10°C (50°F)
even in winter months?
2 Is there at least a 15 cm (6") clearance
around the unit for proper air circulation?
3 Is the unit level? (IMPORTANT)
NOTE. The water supply and the water drain
must be installed to conform with the local
code. In some case a licensed plumber and/
or a plumbing permit is required.
ATTENTION. The use of fully hardened
water (without or nearly without mineral
salts) with electric cable capability of
under 30 μS blocks the flow of low voltage
electricity between the lowest sensors in
the swimming pool and therefore causes
the device to be switched off or to stop
working
GB
9
4 Have all the electrical and plumbing con-
nections been made, and is the water supply
shut-off valve open?
5 Has the voltage been tested and checked
against the data plate rating?
6 Has the water supply pressure been che-
cked to ensure a water pressure of at least 1
bar (14 psi). been checked to ensure that the
compressor is snugly fitted onto the mounting pads?
8 Check all refrigerant lines and conduit lines
to guard against vibrations and possible failure.
9 Have the bin liner and cabinet been wiped
clean?
10 Has the owner/user been given the User
Manual and been instructed on the importance of periodic maintenance checks?
11 Has the Manufacturer’s registration card
been filled in properly?
Check for correct model and serial number
against the serial plate and mail the registration card to the factory.
12 Has the owner been given the name and the-
phone number of the authorized Service
Agency serving him?
G. INSTALLATION PRACTICE
WARNING. This icemaker is not designed for outdoor installation and will not function in
ambient temperatures below 10°C (50°F) or above 40°C (100°F). This icemaker will malfunction with water temperatures below 5°C (40°F) or above 35°C (90°F).
1 Hand shut-off valve
2 Water filter
3 Water supply line
4 3/4" GAS male fitting
5 Power line
6 Main switch
7 Drain fitting
8 Vented drain
9 Vented drain
10 Open trapped vented drain
GB
10
OPERATING INSTRUCTIONS
START UP
A
fter having correctly installed the ice maker and
co mple ted the p lumb ing a nd electr ical
connections, perform t he f ollowing “Start-up” procedure.
A. Open the water supply line shutoff valve
and put the unit under electrical power by moving
the main switch, on the power supply line, to the
ON position.
The first LED - GREEN - will glow to signal that
unit is under power.
NOTE. Every t ime t he unit i s put under power,
after being kept for sometime in shut-off
conditions (electrically disconnected) the
RED LED will blink for 3 minutes (60' on MF
66 only) after which the unit will start up with
the immediate operation of the gear motor
assembly and, af ter few seconds, of the
compressor (Fig.1).
B
. Elapsed the stand by period the unit starts
operating with the activation in sequence of the
following assemblies:
GEAR MOTOR/S
COMPRESSOR
FAN MOTOR/S (if unit is an air cooled version)
kept under control by the condenser temperature sensor which has i t s probe within t he condenser
fins (Fig.2).
C. After 2 or 3 minutes from the compressor
start up, observe that flaker ice begins dropping
off the ice spout to fall through the ice chute into
the storage bin.
NOTE. The first ice bits that drop into the ice
storage bin are not so hard as t he e v aporating
temperature has not yet reached the correct
operating value. It is necessary to allow the
ice - just made - to cure itself and wait for
about ten minutes for the evaporating temperature to reach the correct value so to
make more hard bits of ice.
FIG. 1
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
DATA PROCESSOR
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T>1°C
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
GB
11
FIG. 3
FIG. 2
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
C
ONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
R
ESET
S E N S O R S
W
ATER
LEVEL
GEAR MOTOR ROTATION
C
ONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T 40÷50°C
DATA PROCESSOR
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
DATA PROCESSOR
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T>-1°C
11
10
9
1
2
L
N
8
7
6
5
4
3
10
9
1
2
L
N
8
7
6
5
4
3
12
11
13
1
3
12
GB
12
NOTE. If, after ten minutes from the
compressor start-up, the evaporating temp
erature has not dropped down to a value
lower than -1
°
C (30°F) the evaporating tem-
perature sensor detects such an abnormal
s
ituation and stops consequently the unit
operation (first the compressor and 3' later
the gear reducer).
I
n t his c ircustanc e , t he 5th w arning YELLOW
LED will blink.
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
After having diagnosed and eliminated the
cause of the too hi evaporating temperature
(insufficient refrigerant in the system or
compressor not running) it is necessary to
unplug and plug in again to restart the
machine. The unit, before resuming the
normal operation, will go through the usual
3 minutes STAND-BY period.
OPERATION CHECKS UPON THE UNIT
START UP
D. Remov e front service panel and, if
necessary, install the refrigerant service gauges
on the corresponding service valves to check
both the HI and LO refrigerant pressures.
NOTE. On air cooled models, the condenser
temperature sensor, which is located within
th e con denser fins, keeps the head
(condensing) pressure between preset
values.
In the event of condenser clogged - such to
prevent the proper flow of the cooling air - or,
in case the fan motor is out of operation, the
condenser temperature rises and when it
reaches 70° C (160°F) for air cooled version -
a
nd 60
°
C (140
°
F
) - for water cooled version -
the condenser temperature sensor shuts-off
t
he ice maker (first the compressor and 3'
later the gear reducer) with the consequent
light-up o f t he R E D W ARNING LIGHT ( F ig.3).
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
After having diagnosed the reason of the
temperature rise and removed its cause, it is
necessary to proceed as per the previous
“NOTE” to start up again the operation of the
ice maker.
E. Check for the correct CUT-OUT and
CUT - I N o f t he water l evel sensor by f irst s hutting
closed the water shutoff valve on the water
supply line.
FIG. 4
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T>75°C
DATA PROCESSOR
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
GB
13
After 3 minut e s t he unit resumes i ts t o t al operation
w
ith the immediate start-up of the gear motor
and, few seconds later, of the compressor.
F. Check for the correct operation of the
electronic eye (one per each ice chute on model
M
F 66) of the optical ice level control, by closing
t
he bottom opening of the vertical ice chute.
Wait the built up of the ice into the ice chute till it
cuts the light beam of the sensing "eyes".
This interruption will c ause an immediate blinking
of the Bin Full YELLOW LED located on the front
of the P.C. Board and after about 6 seconds
causes the shutoff of the unit (compressor first
and 3' later the gear reducer) with the
simultaneous lighting (steady) of the Same LED
signalling the full bin situation (Fig.5).
Discharge the ice from the ice chute so to resume
the light beam previously interrupted (YELLOW
LED blinking fast) and after about 6 seconds the
flaker will re-start - t hrough t he 3 minutes S TANDBY period - wit h t he e xtinguishing o f t he Y E LLOW
LED.
This will cause a gradual decrease of the water
level in the float reservoir and as soon as the
level gets below the two vertical metal pins, the
flaker stops to operate (compressor first and 3'
later t he gear reducer) and t he YELLOW w arning
LED will glow to signal the shortage of water
(Fig. 4)
NOTE. The water level sensor detects the
presence of water in the float reservoir and
confirms it to the micro processor by
maintaining a low voltage current flow
between the two metal pins using the water
as conductor.
WARNING. The use of de-mineralized
water (water with no salt content) having
an electrical conductivity lower than 30
μS, will cause break with the consequent
CUT-OUT of the flaker and the glowing of
the YELLOW LED of water shortage, even
with water in the reservoir.
Opening the water supply line shutoff valve to fill
up again the float reservoir, the YELLOW LED
goes off while the RED LED starts blinking.
FIG. 5
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
DATA PROCESSOR
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
Loading...