Follett D5A-W Service Manual

R5A/W, T5A/W

D5A/W Icemaker

Operation, Service and Parts Manual

Service number 5022501 and above

207654R01

R5A icemaker with countertop dispenser

T5A/W icemaker mounted on ice storage bin

R5A icemakers with undercounter dispenser

801 Church Lane • PO Box D, Easton, PA 18044
Toll free [phone] • (888) 2-FOLLETT
[phone] • Fax [phone] • www.follettice.com

Order parts online
www.follettice.com

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Welcome to Follett

Follett icemakers enjoy a well-deserved reputation for excellent performance, long-term reliability and outstanding
after-the-sale support. To ensure that your icemaker delivers this high performance, we ask that you review the
cleaning instructions on this page and retain this manual on file for use by the service technicians maintaining the
unit. Should you have any questions or require technical help at any time, please call our technical service group
at [phone], (888) 2-FOLLETT or [phone].

Table of contents

Preventive maintenance information Page 1
Cleaning instructions 2 - 3
Overview of Follett icemaking process 3
Normal operation circuit sequences 4 - 6
Diagnostic circuit sequences 7 - 8
T5A/W icemaker circuitry (used on ice storage bin) 9
Refrigeration cycle diagram 9
Test data 10
Refrigeration system 11
Disassembly instructions 12
Troubleshooting guide 13 - 14
Replacement parts 15 - 23

Important operator information

Cleaning procedures

Recommended monthly cleaning of condenser (air-cooled icemaker only)

1. Use vacuum cleaner or stiff brush to carefully clean condenser coils of air-cooled icemaker to ensure optimal
performance.

2. When reinstalling counter panels in front of remote icemakers, be sure ventilation louvers line up with
condenser air duct.

Preventive maintenance

Periodic cleaning of Follett’s icemaker system is required to ensure peak performance and delivery of clean,
sanitary ice. The recommended cleaning procedures which follow should be performed at least as frequently as
recommended below and more often if environmental conditions dictate.

Cleaning of the condenser can usually be performed by facility personnel. Cleaning of the icemaker system in
most cases should be performed by your facility’s maintenance staff or a Follett authorized service agent.
Regardless of who performs the cleaning, it is the operator’s responsibility to see that this cleaning is performed
according to the schedule below. Service problems resulting from lack of preventive maintenance will not be
covered under the Follett warranty.

Recommended quarterly cleaning of icemaking system

The icemaking system can be cleaned in place without disassembling the water system. This cleaning process
should be performed at least every 3 months, and more often if local water conditions dictate.

1. Disconnect power to icemaker.

2. Remove any icemaker panels required to gain access to water reservoir and electrical control box.

3. Turn compressor switch on electrical box of icemaker to OFF position.

4. Remove water reservoir cover and block up reservoir float.

5. Drain water from reservoir and evaporator by removing tygon hose from bottom of reservoir.

Note: Some models have an evaporator drain hose teed off evaporator supply hose.

6. Following manufacturer's instructions, prepare 3 pints (1.4L) of Calgon Ice Machine Cleaner or equivalent.

Cleaning solution temperature must be 65° – 85°F (18° – 29°C).

7. Replace tygon hose on bottom of reservoir or plug evaporator drain hose, and pour part of cleaning solution

into reservoir, filling it almost to overflowing.

Note: If your icemaker has a stainless steel compression nozzle, remove it and submerge it in a cup of

cleaning solution while cleaning rest of system.

8. Restore power to icemaker (gearmotor will now run, but compressor and fan motor will not run).

9. After 15 minutes, turn power off and drain cleaning solution from reservoir and evaporator.

10. Replace tygon hose on reservoir, close evaporator drain valve or plug drain hose.

11. Rinse compression nozzle in clean water and reinstall on evaporator outlet.

12. Following manufacturer's instructions, prepare 1 gallon (3.8L) of Calgon Ice Machine Sanitizer or equivalent.
Sanitizing solution temperature must be 65° - 85°F (18° - 29°C).

13. If ice bin cleaning is also needed at this time, remove all ice from ice storage area and allow ice made during
the sanitizing process to fall into ice bin area.

Note: If bin will not be cleaned at this time, place a large pan in bin storage area to catch ice or connect a

separate ice transport tube to evaporator and divert ice into separate container.

14. Fill reservoir almost to overflowing with sanitizing solution.

15. Restore power to icemaker and turn compressor switch to ON position.

16. As unit starts to make ice, continue to pour sanitizing solution into reservoir, maintaining level just below
reservoir overflow.

17. Continue to make ice until you have used 1/2 gallon (1.9L) of sanitizing solution.

18. Unblock float, replace reservoir cover, and continue to make ice for at least 15 minutes to flush all sanitizing
solution from system (icemakers installed in remote locations with long ice transport hoses may take longer).

19. Switch compressor switch to OFF position.

20. Wash bin with remaining sanitizing solution and rinse with potable water.

21. Switch compressor switch to ON position.

22. Replace any panels removed prior to cleaning.

Important preliminary information

Follett's icemaker consists of four distinct functional systems.

• Refrigeration system

•Water system

• Harvesting system

• Electrical control system

These four systems work together to accomplish the production and harvesting of ice. A problem in any one of
these system areas will result in improper operation of the entire ice production cycle. When troubleshooting the
icemaker, it is important to analyze the entire system operation to determine which system is not functioning
properly, then pinpoint the component within that system that is malfunctioning. Determine what corrective action
must be taken before making any adjustments or replacing any components.

2

WARNING: Most ice machine cleaners contain citric or phosphoric acid which can
cause skin irritation. Read caution label on product and follow instructions carefully.

!

The icemaking process

The Follett icemaker uses a wrapped tube evaporator and operates on a continuous freezing cycle. Water is supplied
to the evaporator from the water reservoir where the water level is controlled by a float valve. This valve also shuts off
the water supply when the icemaker is not running.

When the icemaker is running, a layer of ice forms on the interior surface of the evaporator. This ice is continuously
removed by a slowly rotating (12 RPM) auger. The auger carries the ice upward into the cavity formed by the top
bearing housing and the compression loop, where it is compressed to remove excess water. When the ice reaches
the desired hardness it rotates within the cavity and is forced through a discharge port and compression nozzle and
into the ice transport tube. The discharge tube and compression nozzle are slightly restricted to further compress the
ice and produce the desired high quality. As the formation of ice continues, ice in the transport tube is pushed through
the tube to the storage compartment in the ice dispenser or ice storage bin.

A solid state control board located in the electrical box of the icemaker controls the normal operation of the icemaker
and monitors gearmotor torque on an ongoing basis. This control board will shut down the icemaker should an over
torque condition occur. It is very important that you familiarize yourself with the operational sequences detailed in this
manual before attempting to service the icemaker.

Operational and diagnostic sequences

The wiring diagrams which follow illustrate the circuitry of Follett icemakers used with ice dispensers. Both normal
operation of the icemaker (stages 1 - 6) and non-normal diagnostic sequences showing torque-out (stages 7 - 9)
for use in troubleshooting icemaker problems are shown.

Follett icemakers used on top of an ice storage bin have a slightly different circuitry. A diagram for this type of
icemaker is shown on page 9. The operational and diagnostic stages for these icemakers will be otherwise the
same as stages 1 - 9 that follow.

3

When the icemaker is used with a dispenser it receives power from two sources –
the main power supply and the bin control signal power from the dispenser.
Disconnect both power sources before performing mechanical service. When
performing electrical service, always use a meter to determine whether or not the
components being serviced are energized.

!

Circuitry notes

• Hi-temp safety thermostat (water-cooled only) opens at 125°F/50°C, and closes at 115°F/46°C

• Compressor switch should read open in ON position

• Alternate input power for some non-domestic units will be 230V, 50Hz

• Compressor start relay is position sensitive. See label on start relay for proper orientation.

• Bin signal may be 120V, 60Hz; 230V, 50Hz; or 24V, 60Hz. If bin signal is 24V, 60Hz, black wire must be
moved from LINE VAC terminal to 24V terminal.

• Flashing water LED at any time indicates that water signal to board had been lost for more than one second

• Ten-second delay: There is a 10 second delay in reaction to loss of water (WTR) or bin (B-E) signals. If
signals are not lost for more than 10 seconds, no reaction will occur.

Normal operation – Stage 1

Power is supplied to L1 of the control board. The ice level control in the dispenser is closed and calling for ice,
supplying signal voltage to the control board. The control board will now go through the start up sequence. Less
than 30 seconds will elapse as the water sensor located in the float reservoir checks for water in the reservoir.
The Bin Empty LED (B-E) will be on.

Normal operation – Stage 2

The water sensor verifies water in the float. The Water OK LED (WTR) comes on. At the same time, the
gearmotor, compressor, and condenser fan motor come on, lighting the Drive LED (DR) and compressor LED
(C). The compressor is started through a current style relay that is pulled in by the initial high current draw of the
compressor. The B-E and WTR LED remain on.

X

4

X

INPUT
POWER

W

B

COMPRESSOR

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

M

R

ORANGE

RED

BLACK

WHITE

BLACK

G

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

S

BLACK

WATER
SENSOR

GRD

L1
L1
L2

L2
L2

L2
L2

COMPRESSOR

FAN
DRIVE

BLACK

L1

3

GEARMOTOR

CONTROL
BOARD

LINE VAC

L2

4

COMMON

24V

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

WHITE

BLACK

RED

RED

COMPRESSOR
SWITCH

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

INPUT
POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

RED

BLACK

WHITE

G

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

S

BLACK

BLACK

WATER
SENSOR

CONTROL

GRD

BOARD

L1
L1
L2

L2
L2

L2
L2

COMPRESSOR

FAN
DRIVE

L1

3

4

GEARMOTOR

PWR

RESET

DR

C

20M

60M

24V

2ND

WTR

B-T

B-E

COMPRESSOR
SWITCH

WHITE

BLACK

RED

LINE VAC

COMMON

L2

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

Normal operation – Stage 3

The gearmotor comes up to its normal running speed and the centrifugal switch located in the gearmotor opens,
dropping out the start winding. As the compressor comes up to normal running speed, the compressor start relay
contacts open, dropping out the start winding of the compressor. The icemaker is now in a normal icemaking
mode. The icemaker will begin to produce ice and continue to produce ice until the bin level control in the ice
dispenser is satisfied. The B-E, DR, C and WTR LEDs are all on.

Normal operation – Stage 4

Once the ice level control opens, the B-E LED goes out. After a 10 second delay the LED (C), compressor, and
fan motor go off. (Should the ice level control not remain open for 10 seconds, the ice maker will continue to run.)
The gearmotor continues to run for 60 seconds. The purpose of this function is to drive the remaining ice out of
the evaporator and to boil off any refrigerant remaining in the evaporator.

X

5

X

INPUT
POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

RED

BLACK

WHITE

G

WATER

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

S

BLACK

SENSOR

GRD

L1
L1
L2

L2
L2

L2
L2

COMPRESSOR

FAN
DRIVE

BLACK

L1

3

GEARMOTOR

CONTROL
BOARD

LINE VAC

COMMON

L2

4

24V

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

WHITE

RED

COMPRESSOR
SWITCH

BLACK

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

INPUT
POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

S

RED

BLACK

WHITE

G

WATER

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

BLACK

BLACK

SENSOR

CONTROL

GRD

BOARD

L1

L1

L2

L2
L2

L2
L2

COMPRESSOR

FAN

DRIVE

L1

3

4

GEARMOTOR

PWR

RESET

DR

C

20M

60M

2ND

24V

WTR

B-T

B-E

WHITE

BLACK

RED

COMPRESSOR
SWITCH

LINE VAC

COMMON

L2

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

Normal operation – Stage 5

The B-T LED will remain on for 20 minutes. The icemaker will not start while the B-T LED is on. To restart the
icemaker for troubleshooting purposes, depress the reset button to clear the control board.

Normal operation – Stage 6

When the dwell time of 20 minutes has expired, the B-T LED goes off. The icemaker will go through the normal
start up sequence when the bin level control signals the control board for ice. The WTR LED will remain on as
long as the water sensor in the float reservoir senses water

X

6

X

INPUT
POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

S

RED

BLACK

WHITE

G

WATER

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

BLACK

BLACK

SENSOR

CONTROL

GRD

BOARD

L1
L1
L2

L2
L2

L2
L2

COMPRESSOR

FAN

DRIVE

L1

3

4

GEARMOTOR

L2

LINE VAC

COMMON

24V

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

WHITE

RED

COMPRESSOR
SWITCH

BLACK

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

INPUT
POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

RED

BLACK

WHITE

G

WATER

GRD

L1
L1

L2

L2
L2

L2
L2

COMPRESSOR

FAN
DRIVE

BLACK

L1

3

GEARMOTOR

SENSOR

CONTROL
BOARD

LINE VAC

L2

4

COMMON

24V

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

WHITE

RED

COMPRESSOR
SWITCH

BLACK

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

S

BLACK

Diagnostic sequence – Stage 7

The 20 Minute Error LED (20M) is on indicating that the control board has sensed an over-torque condition
(above 3.5 AMPS on the gearmotor). The 20M LED will remain on for 20 minutes after an over-torque condition
has occurred. The icemaker will remain off as long as the 20M LED is on. When the 20M LED goes off, the
control board will try to go through a normal start up sequence. The WTR LED remains on as long as the water
sensor in the float reservoir senses water.

Diagnostic sequence – Stage 8

When the 20M LED goes off, the 60 Minute Timer LED (60M) comes on. The 60M LED will remain on for 60
minutes from restart. A lighted 60M LED tells the technician that the icemaker has experienced an over-torque
condition. If the icemaker runs without problems for 60 minutes and no additional torque errors occur, the 60M
LED will go off.

X

7

X

INPUT

INPUT
POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

RED

BLACK

WHITE

G

WATER

GRD

L1
L1
L2

L2
L2

L2
L2

COMPRESSOR

FAN
DRIVE

BLACK

L1

3

GEARMOTOR

SENSOR

CONTROL
BOARD

LINE VAC

L2

4

COMMON

24V

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

WHITE

RED

COMPRESSOR
SWITCH

BLACK

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

S

BLACK

POWER

W

B

COMPRESSOR

R

C

S

HI-TEMP SAFETY
T-STAT (W/C ONLY)

FAN

BLACK

M

ORANGE

RED

BLACK

WHITE

G

WATER

GRD

WHITE

WHITE

BLACKBLACK

1

M

L

S

BLACK

BLACK

SENSOR

CONTROL

GRD

BOARD

L1

L1

L2

L2
L2

L2
L2

COMPRESSOR

FAN

DRIVE

L1

3

4

GEARMOTOR

PWR

RESET

DR

C

20M

60M

24V

2ND

WTR

B-T

B-E

COMPRESSOR
SWITCH

WHITE

BLACK

RED

LINE VAC

COMMON

L2

RED

WHITE

BIN T-STAT

RED

BIN SIGNAL
FROM DISPENSER
JUNCTION BOX