Follett HCD1010N Service Manual

Page 1
HCD1010R/N, HCD1410R/N, HMD1010R/N, HMD1410R/N
Horizon Elite™ Ice Machines (Remote Condensing)
Order parts online www.follettice.com
Following installation, please forward this manual
to the appropriate operations person.
801 Church Lane • Easton, PA 18040, USA
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 1
Toll free (877) 612-5086 • +1 (610) 252-7301 www.follettice.com
01096122R00
Page 2
2 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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Contents
Welcome to Follett. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Before you begin ...............................................................................4
Specications ................................................................................. 5
Electrical ................................................................................... 5
Evaporator unit ..............................................................................5
Condensing unit ............................................................................. 5
Evaporator plumbing ..........................................................................5
Ambient .................................................................................... 5
Refrigeration ................................................................................5
Weight ..................................................................................... 5
Ice production ............................................................................... 6
Dimensions and clearances .................................................................... 7
Operation .....................................................................................9
Cleaning/sanitizing and preventive maintenance (all models) ..........................................9
Service ...................................................................................... 13
Ice machine operation (all models) ............................................................. 13
“Bin full” detection system .....................................................................15
Electrical system ............................................................................ 16
Mechanical System ............................................................................ 21
Evaporator disassembly ...................................................................... 21
Evaporator reassembly ....................................................................... 24
Refrigeration system .........................................................................29
Troubleshooting ..............................................................................32
Replacement parts ............................................................................ 34
Evaporator assembly ........................................................................34
Low-side assembly ..........................................................................36
Electrical box ..............................................................................38
Integration kit – top-mount and RIDE remote ice delivery ........................................... 40
Skins assembly ............................................................................. 42
1010 Single-phase condensing unit ............................................................. 44
1410 Single-phase condensing unit ............................................................. 45
1010 3-phase condensing unit .................................................................46
1410 3-phase condensing unit ................................................................. 47
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 3
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Welcome to Follett
Follett equipment enjoys a well-deserved reputation for excellent performance, long-term reliability and outstanding after-the-sale support. To ensure that this equipment delivers the same degree of service, we ask that you review the installation manual (provided as a separate document) before beginning to install the unit. Our instructions are designed to help you achieve a trouble-free installation. Should you have any questions or require technical help at any time, please call our technical service group at (877) 612-5086 or +1 (610) 252-7301.
Before you begin
After uncrating and removing all packing material, inspect the equipment for concealed shipping damage. If damage is found, notify the shipper immediately and contact Follett Corporation so that we can help in the ling of a claim, if necessary.
Check your paperwork to determine which model you have. Follett model numbers are designed to provide information about the type and capacity of Follett equipment. Following is an explanation of the different model numbers in the series.
Chewblet® Ice Machine Model Number Configurations
HC 1400C SVA
ConfigurationApplication
S RIDE™
(RIDE remote ice delivery equipment)
T Top-mount
MC Maestro™
Chewblet (400 Series)
HC Horizon
Chewblet (1000, 1400, 1650 Series)
HM Horizon
Micro Chewblet
C 208-230/60/1 (icemaking head)
®
Self-contained only.
D 115/60/1 (icemaking head)
Self-contained and remote. If remote unit, high side is 208-230/60/1.
E 230/50/1 (icemaking head)
Self-contained only.
F 115/60/1 (icemaking head)
Remote only. High side is 208-230/60/3.
400 up to
454 lbs
(206kg) 1000/1010 up to
1036 lbs
(471kg) 1400/1410 up to
1450 lbs
(658kg) 1650 up to
1580 lbs
(717kg)
CondenserSeriesVoltageIcemaker
A Air-cooled, self-contained W Water-cooled, self-contained R Air-cooled, remote condensing unit N Air-cooled, no condensing unit for
connection to parallel rack system
V Vision™ H Harmony™ B Ice storage bin J Drop-in M Ice Manager
diverter valve system
CAUTION
• Warranty does not cover exterior or outside installations.
• Moving parts. Do not operate with front cover removed.
• Hot parts. Do not operate with cover removed.
• To reduce risk of shock, disconnect power before servicing.
• Drain line must not be vented.
• Water supply must have particle ltration.
• Most ice machine cleaners contain citric or phosphoric acid, which can cause skin irritation. Read caution label on product and follow instructions carefully.
• Ice is slippery. Maintain counters and oors around dispenser in a clean and ice-free condition.
• Ice is food. Follow recommended cleaning instructions to maintain cleanliness of delivered ice.
4 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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Specications
Electrical
Separate circuit and equipment ground required.
Evaporator unit
Standard electrical: 115/60/1 Maximum fuse: 15A Amperage: 5A
Condensing unit
1010 Single-Phase 1010 3-Phase 1410 Single-Phase 1410 3-Phase
Electrical 208-230V, 60Hz 208-230V, 60Hz 208-230V, 60Hz 208-230V, 60Hz
Max Circuit HVACR breaker size 15A 15A 30A 25A
Min Circuit Ampacity 10.7A 9.9A 19.3A 14.2A
Evaporator plumbing
§ 3/8" OD push-in water inlet (connection inside machine) - 3/8" OD tubing required
§ 3/4" MPT
§ 3/4" drain line must slope a minimum of 1/4" per foot (6 mm per 30.4 cm run).
§ Drain to be hard piped and insulated.
§ Water shut-off recommended within 10 feet (3 m).
§ Follett recommends installation of Follett water lter system (part# 00130286) in ice machine inlet water line.
Ambient
Evaporator unit
Air temperature 100 F/38 C max. 50 F/10 C min. Water temperature 90 F/32 C max. 45 F/7 C min. Water pressure 70 psi max. (483 kPa) 10 psi min. (69 kPa)
Condenser unit
Air temperature 120 F/49 C max. –20F/–29C min.
Refrigeration
§ 3/8" liquid line
§ 5/8" suction line
Note: Rack system installations require a capacity of 10,000 BTU/hr for 1010 machines and 13,000 BTU/hr for
1410 machinesat 0 F (–18 C) evaporator temperature. Evaporator pressure regulator (not supplied) is required.
Weight
Evaporator unit: 125 lbs (57 kg) Condensing unit: 225 lbs (102 kg)
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 5
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Ice production
1010 ice machine capacity/24 hrs.
Ambient Air Temperature F/C
F 60 70 80 90 10 0
C 16 21 27 32 38
50 1051 978 906 834 763 lbs
10 477 444 4 11 379 346 kg
60 994 925 855 796 737 lbs
16 451 420 388 361 335 kg
70 937 871 805 758 7 11 lbs
21 425 395 365 344 323 kg
80 904 839 774 727 680 lbs
27 410 381 351 330 309 kg
90 872 807 743 696 648 lbs
Potable Water Temperature F/C
32 396 366 337 316 294 kg
1410 ice machine capacity/24 hrs.
Ambient Air Temperature F/C
F 60 70 80 90 10 0
C 16 21 27 32 38
50 14 74 1372 1269 1212 115 4 lbs
10 669 623 576 550 524 kg
60 1385 1292 119 8 1148 1097 lbs
16 628 586 544 521 498 kg
70 1296 1212 11 2 7 1083 1039 lbs
21 588 550 5 11 492 472 kg
80 1239 1155 1072 1030 988 lbs
27 562 524 487 468 449 kg
90 90 11 8 1 1099 1017 976 lbs
Potable Water Temperature F/C
32 32 536 499 462 425 kg
6 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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Dimensions and clearances
§ Entire front of ice machine must be clear of obstructions/connections to allow removal.
§ 1" (26mm) clearance above ice machine for service.
§ 1" (26mm) minimum clearance on sides.
§ The intake and exhaust air grilles must provide at least 250 sq in (1615 sq cm) of open area.
§ Air-cooled ice machines – 18" (458 mm) minimum clearance between discharge and air intake-grilles.
1410 ONLY
1410 ONLY
NEMA 5-15 RIGHT ANGLE
A
C (1410 ONLY)
B
K
D (1410 ONLY)
A 21.26" (54.0 cm) B 21.11" (53.6 cm) C 23.77" (60.4 cm)
E
D 2.66" (6.8 cm) E 19.59" (49.8 cm)
F
F 16.00" (40.6 cm) G 2.73" (6.9 cm) H 2.28" (15.3 cm) I 6.04" (5.8 cm)
G
H
I
J
J 22.00" (55.9 cm) K 22.69" (57.6 cm)
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 7
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Condensing unit
26.08"
(662 mm)
36.25"
(921 mm)
25.5"
(648 mm)
8 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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Operation
Cleaning/sanitizing and preventive maintenance (all models)
Note: Do not use bleach to sanitize or clean the icemaker.
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 that follow should be performed at least as frequently as recommended, 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.
Weekly exterior care
The exterior may be cleaned with a stainless cleaner such as 3M Stainless Steel Cleaner & Polish or equivalent.
Monthly condenser cleaning (air-cooled icemaker only)
1. Use a vacuum cleaner or stiff brush to carefully clean condenser coils of air-cooled icemakers to ensure
optimal performance.
2. When reinstalling counter panels in front of remote icemakers, be sure that ventilation louvers line up with condenser air duct.
Semi-annual evaporator cleaning (every 6 months)
WARNING
• Wear rubber gloves and safety goggles (and/or face shield) when handling ice machine cleaner or sanitizer.
CAUTION
• Use only Follett approved SafeCLEAN Plus™ cleaning/sanitizing solution (part #01050863).
• DO NOT USE BLEACH.
• It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.
• Read and understand all labels printed on packaging before use.
Note: Complete procedure for cleaning an sanitizing MUST be followed. Ice must be collected for 10minutes
before putting ice machine back into service.
Fig. 1
1. Press the CLEAN button. The machine will drain. The
auger will run for a short time and then stop. Wait for the LOW WATER light to come on.
LO WATER
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 9
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2. Mix 1 gal. (3.8L) 120 F (49 C) water and one 7oz. (198g) packet of Follett SafeClean Plus (P/N
01050863).
3. Using a 1 quart (1L) container, slowly ll cleaning cup until CLEANER FULL light comes on. Do not overll.
4. Place one Sani-Sponge™ in remaining sanitizing and cleaning solution and retain for Step 9.
Note: Do not use bleach to sanitize or clean the icemaker.
5. Replace cover on cleaner cup. Machine will clean,
then ush 3 times in approximately 15 minutes. Wait until machine restarts.
Fig. 2
CLEANER FULL
Fig. 3
6. To clean/sanitize ice transport tube – Press power
switch OFF
15
Fig. 4
10 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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7. Disconnect coupling as shown.
8. Using disposable food service grade gloves, insert
dry Sani-Sponge.
9. Insert Sani-Sponge soaked in SafeClean Plus (from Step 4).
10. Push both Sani-Sponges down ice transport tube with supplied pusher tube.
Fig. 5
Fig. 6
1
16"
(407 mm)
11. Remove and discard 16 inch (407 mm) pusher tube.
2
3
Fig. 7
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 11
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12. Reconnect coupling. Press power switch ON. Ice pushes Sani-Sponges through ice transport tube.
13. Place a sanitary (2 gal. or larger) container in bin or dispenser to collect Sani-Sponges and ice for 10 minutes.
14. Collect 5.5 lbs (3 kg) of ice from unit. Discard ice and Sani-Sponges.
Fig. 8
Fig. 9
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Service
Ice machine operation (all models)
Follett’s ice machine consists of ve distinct functional systems covered in detail as follows:
§ Water system
§ Electrical control system
§ Mechanical assembly
§ Refrigeration system
§ Bin full
The Horizon ice machine overview
The Follett Horizon ice machine uses a horizontal, cylindrical evaporator to freeze water on its inner surface. The refrigeration cycle is continuous; there is no batch cycle. The evaporator is ooded with water and the level is controlled by sensors in a reservoir. A rotating auger (17 RPM) continuously scrapes ice from the inner wall of the evaporator. The auger moves harvested ice through the evaporator into an ice extrusion canal. The ice is forced through a restrictive nozzle that squeezes out the water and creates the Chewblet. The continuous extrusion process pushes the Chewblets through a transport tube into a dispenser or bin.
A solid state PC board controls and monitors the functionality of the ice machine. In addition to sequencing electrical components, the board monitors various operational parameters. A full complement of indicator lights allows visual status of the machine's operation. Additionally, the PC board controls the self-ushing feature of the ice machine. The evaporator water is periodically drained and replenished to remove minerals and sediment.
A unique “bin full” detection system is incorporated in the Horizon ice machine. A switch located at the ice discharge port of the machine detects the position of the transport tube. When the bin lls up with ice, the transport tube moves out of the normal running position, and the switch turns the ice maker off. A domed housing at the end of the transport tube contains the ice extrusion loads during shut down.
Harvest system diagram
Ice Transport Tube
Water Inlet
Compression Nozzle
Auger
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 13
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Water system
The water level in the evaporator is controlled by a feed solenoid and level detecting sensors. Referencing the diagram below, water sensing probes extend down into the reservoir at the end of the evaporator assembly. The system works via electrical conductivity as follows:
The probe labeled B is the common. When water is between any of the other probes and the common, the PC board will sense the activation. During normal operation, the water level rises and falls between the Normal High and Normal Low probes. As water is consumed to make ice, the level will fall until the Normal Low probe is exposed, triggering the water feed solenoid on. Water will ll until the Normal High sensor is activated.
Note: The potable water total dissolved solids (TDS) content must be greater than 10 ppm for the water control
system to function properly. If using reverse osmosis water ltration system, ensure TDS level is greater than 10 ppm.
Water system diagram
Water level diagram
Common
Normal Hi
Normal Lo
Normal
Operating
Range
14 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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“Bin full” detection system
The Follett Horizon ice machine incorporates a unique “bin full” detection system that consists of the shuttle and actuator. The shuttle incorporates a ag and switch. Referencing the gure below, the normal running position of the ag is down, and the switch is closed. When the bin lls to the top and ice can no longer move through the tube, the machine will force the shuttle ag up, opening the switch and shutting the machine off. The shuttle actuator, located above the ice bin allows the ice to curl up within it when the bin is full. In this way, there are no loads generated that would tend to lift off the lid of the bin.
Shuttle ag and sensor
Shuttle actuator
Running
Running Off
Off
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 15
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Electrical system
FLASHINGON or OFF
Legend:
OFFON
ATTENTION!
To prevent circuit breaker/Hi-amp overload, wait 5 minutes before restarting this unit. This allows the compressor to equalize and the evaporator to thaw.
Normal control board operation
The PC board indicator lights provide all the information necessary to determine the machine's status. Green indicator lights generally represent “go” or normal operation; Yellow indicators represent normal off conditions; Red indicators generally represent alarm conditions, some of which will lock the machine off.
A ashing green light labeled POWER indicates power to the machine. All other normal operation status indicators are covered as follows:
Ice machine disposition Operating conditions
1. Ice machine is making ice.
.
2. Ice machine is not making ice.
DIP Switch Settings
1. Normal running.
2. Normal time delay. When the bin lls with ice, the LOW BIN light goes out momentarily and the refrigeration and auger drive systems immediately shut down. (Note: The fan motor will continue to run for 10 minutes to cool condenser) The TIME DELAY light comes on, initiating the time delay period. When the time delay expires, the machine will restart provided that the LOW BIN light is on.
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Error faults:
The Horizon PC board monitors various operating parameters including high pressure, auger gearmotor amperage limits, clogged drain, and low water alarm conditions. There are three types of errors namely “soft” (time delay) "hard" (reset), and “run”.
§ Soft errors will automatically reset after the 1 hour time delay or can be reset by cycling power.
§ Hard errors must be reset on the control board.
§ Run errors will give an indication of a problem, but will allow continuous normal operation.
Soft errors:
HI AMPS: The PC board monitors the amperage of the auger motor. Should the gear motor experience current draw above the allowable limit, the machine will shut down and the TIME DELAY and HI AMP will be illuminated. After the time delay the machine will restart and the TIME DELAY and HI AMP will clear.
LO WATER: During operation, the water level cycles between the normal low and normal high sensors. Should the water be shut off to a running machine, a soft error will occur. The error sequence is as follows: During operation, the water level falls to the normal low sensor, and when it does the water feed solenoid is energized. If water is not detected at the normal low sensor within 10 seconds, a soft error will occur. The machine will shut down, but the water feed solenoid will remain energized. Should water return, it will ll to the normal low sensor and the machine will resume normal operation. The error will clear automatically.
HI PRESSURE: Should the refrigeration pressure rise above 425 psi, the machine will shut down and the TIME DELAY and HIGH PRESSURE will be illuminated. After the time delay, and if the pressure has fallen back below the reset point of 295 psi, the machine will restart and the TIME DELAY and HIGH PRESSURE will clear.
Hard error:
DRAIN CLOG: The drain clog sensor, located in the chassis will detect the presence of water just below the top edge of the chassis. After the sensors are dired off, the machine must be reset on the control board to resume operation.
Run errors:
DRAIN CLOG: When the machine shuts down on a full bin and there has been 30 minutes of cumulative compressor run time, the machine will purge before starting. During this purge, if water does not get below the low probe in the reservoir within 20 seconds, the Drain Clog LED will light. The machine will continue to run but this is an indication of a poorly draining machine and must be addressed.
Relay output indication: Each relay on the board has an indicator light associated with its output. For example, when the relay for the water feed solenoid is energized, the adjacent indicator light glows green.
Evaporator ushing sequence:
During operation, the purge solenoid will open in order to drain water. There are two drain settings to choose from: High TDS or Low TDS. (There is a rocker switch behind the front cover of the machine.) The intent is to drain the Total Dissolved Solids from the machine while it makes ice.
While ice is being made, the TDS of the water in the evaporator increases in TDS concentration. Without periodic draining, the TDS levels will climb to very detrimental levels, levels that will cause scale to form and cause poor machine operation. The Low TDS setting will allow the machine to operate for one hour before going through the ushing sequence; the High TDS setting will allow the machine to run for 10 minutes before going through the ushing sequence.
The ushing sequence toggles the purge and ll solenoids three times. That is, the purge solenoid will energize until the water level drops below the low probe. The ll solenoid then energizes until water reaches the high probe, and so on for 3 cycles.
Typically, High TDS might be considered levels above 200 PPM, but local experience and varying water chemistry may compel a High TDS setting for best performance in even lower TDS levels.
Off cycle: At the completion of off-cycle time delay, the machine checks for a cumulative 30 minutes of ice making time since the last off-cycle ush. If the cumulative ice making time exceeds 30 minutes, the machine will open the drain valve for 60 seconds to drain the evaporator in its entirety. It will then rell with water and begin making ice. If the ice making time is less than 30 minutes, the machine will start and begin making ice without draining the evaporator.
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 17
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Wiring diagram, evaporator unit
Gearmotor data
Gearmotor current 2.8A @ 115 V Gearmotor torque-out (high amp) trip point: 5.6A
18 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Resistance of windings 115 vac gearmotor (Bison):
White to Black: 3 White to Red: –3 Red to Black: 6
Page 19
Single-phase condensing unit wiring diagram
FAN 1
FAN 2
POWER SUPPLY
230-60-1
COMPRESSOR
TERMINAL
GRD
L3
L2
L1
CRANK CASE
HEATER
S
T3
T2
T1
C
R
COMPRESSOR
CONTACTOR COIL
see note A
RECEIVER
HEATER
COMPRESSOR CONTACTOR
NC AUXILIARY SWITCH
BLACK
YELLOW
HP LP
HEATER
THERMOSTAT
COMPRESSOR
CONTACTOR
RED
TERMINAL
BOARD
FC
P1
L1
L2
T2
T1
L2
L1
L3
T3
L3 T3T1F1 F2
START
CAPACITOR
WITH BLEEDER
RESISTOR
BLACK RED
YELLOW
POTENTIAL RELAY
see note B
4
5
6
1
2
RUN
CAPACITOR
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 19
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3-phase condensing unit wiring diagram
FAN 1
FAN 2
COMPRESSOR
CONTACTOR
POWER SUPPLY
230-60-3
COMPRESSOR
TERMINAL
COIL
see note A
L3
L2
L1 T1
CRANK CASE
HEATER
S
GRD
T3
T2
C
R
HP LP
RECEIVER
HEATER
COMPRESSOR
CONTACTOR NC
AUXILIARY SWITCH
BLACK
RED
D.T.
HEATER
THERMOSTAT
TO "Y-OUT"
AT PHASE MONITOR
TERMINAL
TERMINAL
BOARD
BOARD
A
P1
L1T2L2
T1
TO "230 VAC" AT PHASE
B
MONITOR
TO "C"
C
AT PHASE MONITOR
L2 L3 T3T1 F1 F2
L1
L3
T3
TO "P1"
AT TERMINAL
BOARD
Y
A
Y­OUT
ICM402
3 PHASE
MONITOR
L1
FFC
C
C
L2 L3
115 VAC
TO "L2" AT TERMI BOARD
TO "L1"
B
AT TERMINAL BOARD
230 VAC
NAL
YELLOW
20 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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Mechanical System
Evaporator disassembly
1. Press CLEAN button to purge evaporator. Turn power
OFF when LO WATER lights.
2. Unscrew and disconnect transport tube from louvered docking assembly.
3. Remove gearbox insulation..
Fig. 10
Fig. 11
4. Disconnect gear motor wires.
5. Remove screws (with 3/16" allen wrench) and auger
retaining fork:
Fig. 12
Fig. 13
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Page 22
6. Remove gear motor bolts (1/2" wrench).
7. Remove gear motor and wipe auger shaft clean.
8. Remove main housing insulation and shuttle
insulation:
Fig. 14
WIPE AUGER SHAFT
Fig. 15
Fig. 16
9. Remove front feed water tube from push-in tting,
shuttle drain tube, and shuttle switch.
22 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
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10. Remove 3 screws (with 3/16" allen wrench) then remove auger and main housing together.
Note: Auger is sharp - wear protective gloves.:
11. Rotate auger to align opening in auger ange with stream divider.
12. Pull out auger.:
Fig. 17
Fig. 18
Fig. 19
13. Remove and discard the ceramic mating ring and
shaft seal.
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Page 24
Evaporator reassembly
14. Install ceramic mating ring and shaft seal.
Caution: Do not touch the sealed surface of either part. Oil from bare skin will cause premature seal failure.
15. Use liquid hand soap on the rubber part of the ceramic seal when installing in main housing. Use supplied cardboard disc to press into recess.
16. Apply liquid hand soap to raised area of auger shaft and interior rubber portion of shaft seal before installing seal.
1 7. Clean O ring groove. Lubricate O ring with petrol-gel
and reinstall.
18. Carefully install auger.
19. Rotate auger to position shown to clear main housing
stream divider.
Fig. 20
Cardboard disc
Do NOT
touch!
Fig. 21
20. Install rear shuttle insulation (Fig. 22.1) and slide main housing (Fig. 22.2) onto auger.
2 1. When installing new water seal, use screwdriver to
compress the spring (Fig. 22.3), which allows for easier installation of the three screws.
Fig. 22
1
2
3
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Page 25
22. Install shuttle switch.
§ Align holes with pins (Fig. 23.1) and depress switch button (Fig. 23.2) to clear shuttle tab.
23. Install shuttle drain tube and front feed water tube (Fig.24).
Fig. 23
Fig. 24
24. Install main housing insulation and shuttle insulation:
25. Apply a coat of petro gel to auger shaft.
Fig. 25
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26. Slide gear motor onto auger and Install gear motor bolts (9/16" wrench).
2 7. Connect gear motor wires.
Fig. 26
Fig. 27
28. Pry auger forward and roate auger using 1/2" wrench
to align keyways.
29. Insert key fully.
30. Pry shaft forward to install retainer fork.
Fig. 28
Fig. 29
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3 1. Rotate retainer fork to align screw holes.
32. Install screws to secure retainer fork.
33. Install gearbox insulation..
Fig. 30
Fig. 31
34. Connect transport tube to louvered docking assembly.
Fig. 32
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 27
Page 28
Reservoir/rear bushing disassembly
1. Press CLEAN button to purge
evaporator. Turn power OFF when LO WATER lights.
Note: In many applications,
removing the gearmotor, main housing, and auger will allow for the ice machine to be pulled out further for better access to rear components.
2. Slide ice machine forward to gain access.
3. Use Fig. 32 as disassembly guide.
Note: Use petrogel when
installing/reinstalling o-rings.
Fig. 33
28 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 29
Refrigeration system
Condenser unit operation
The condensing unit is weatherproof and equipped to operate in ambient temperatures from –20 F to 120 F (–29C to 48.9 C). The condensing unit is controlled by a low pressure control, which works in concert with a refrigerant solenoid valve on the evaporator module. On start-up, the refrigerant solenoid valve opens and suction pressure rises above the “on” set point of the control. The compressor and fan turn on and the refrigeration system operates. Upon shut down, the refrigerant solenoid closes. The compressor will pump down the ice machine evaporator and suction line until the low “off” set point is reached, at which point the compressor and fan will turn off.
Low ambient operation: Reliable operation at low outdoor ambient temperature is achieved with a pumpdown cycle, a crankcase heater and a head pressure control valve. When the outdoor ambient falls, the condensing pressure falls. This causes the discharge pressure to fall as well. When the discharge pressure falls below the dome pressure, the valve modulates open to the discharge port which allows discharge gas to bypass the condenser. Mixing the discharge gas with the liquid creates a high pressure at the condenser outlet, reducing the ow and causing liquid to back up in the condenser. Flooding the condenser reduces the area available for condensing. This reduction in effective condenser surface area results in a rise in condensing pressure. During summer conditions, the discharge pressure is high, thus closing the discharge port of the valve. Hence, there is full liquid ow from the condenser to the receiver.
A check valve is installed in the liquid line between the liquid receiver and the condenser to prevent liquid migration from the receiver to the condenser during the off cycle. A second check valve is installed in the discharge outlet of the motor compressor to prevent any oil from migrating onto the compressor head during an off cycle. A low pressure control will start the condensing unit anytime the low side pressure rises above the C/I setting of the control. The system contains a crankcase heater which is energized via the contactor of the compressor during any off cycle. It is de-energized whenever the compressor is energized. This keeps the oil temperature in the compressor sump warmer than any other wetted surface to prevent liquid migration from settling into the compressor sump to prevent ooded compressor starts in extreme outdoor temperatures. The liquid receiver also contains a heater which is controlled by a thermostat to be energized at temperatures below 60°F and de-energized above 80°F. This is to maintain sufficient refrigerant pressure at extreme outdoor temperatures to activate the pressure control.
1010 - Refrigerant pressure data
Air-cooled condensers (air) 60 F/16 C 70 F/21 C 80 F/27 C 90 F/32 C 100 F/38 C
Pressure (psig) discharge/suction 202/33 229/35 255/37 275/38 295/39
Note: The water control valve is factory set to maintain 260 ± 15 psi discharge pressure @ 70 F/21 C water.
1410 - Refrigerant pressure data
Air-cooled condensers (air) 60 F/16 C 70 F/21 C 80 F/27 C 90 F/32 C 100 F/38 C
Pressure (psig) discharge/suction 198/31 233/32 268/34 287/36 305/37
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 29
Page 30
Refrigeration system diagram
CONDENSER UNIT
CONDENSER
HEAD CONTROL VALVE
EVAPORATOR UNIT
SOLENOID VALVE
LOW SIDE
SERVICE VALVE
W/ SERVICE PORT
HIGH PRESSURE SWITCH
CHECK VALVE
CHECK VALVE
HEAT EXCHANGER
SIGHT GLASS
COMPRESSOR
HIGH SIDE
SERVICE PORT
HIGH SIDE
SERVICE VALVE
W/ SERVICE PORT
SUCTION ACCUMULATOR
HIGH SIDE
HIGH SIDE SERVICE VALVE
SERVICE VALVE W/ SERVICE PORT
W/ SERVICE PORT
FILTER
RECEIVER
FILTER-DRIER
SIGHT GLASS
HIGH SIDE SERVICE VALVE W/ SERVICE PORT
LOW SIDE SERVICE VALVE W/ SERVICE PORT
THERMOSTATIC EXPANSION VALVE
HIGH PRESSURE VAPOR
LOW SIDE SERVICE PORT
LOW SIDE SERVICE VALVE W/ SERVICE PORT
LOW PRESSURE VAPORLOW PRESSURE LIQUIDHIGH PRESSURE LIQUID
30 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 31
Refrigeration charge
All service on refrigeration systems must be performed in accordance with all federal, state and local laws. It is the responsibility of the technician to ensure that these requirements are met. Recharging ice machine to other than factory specications will void the warranty.
R404A ice machine charge specications
Model Line Run Charge
1010/1410 0-100 ft (0-30.5 m) 12.5 lbs (5.44 kg)
Refrigerant replacement requirements
1. Non-contaminated refrigerant removed from any Follett refrigeration system can be recycled and returned to
the same system after completing repairs. Recycled refrigerant must be stored in a clean, approved storage container. If additional refrigerant is required, virgin or reclaimed refrigerant that meets ARI standard 700-88 must be used.
2. In the event of system contamination (for example, a compressor burn out, refrigerant leak, presence of non-condensibles or moisture), the system must be repaired, evacuated and recharged using virgin or reclaimed refrigerant that meets ARI standard 700-88.
3. Follett Corporation does not approve of recovered refrigerants. Improper refrigeration servicing procedures will void the factory warranty.
Evacuation
Evacuate the system to a level of 500 microns. When the 500 micron level is reached, close all valves. Allow the system to sit for approximately 20 minutes. During this period the system pressure should not rise. If the system pressure rises and stabilizes there is moisture in the system and further evacuation is needed. If the pressure continues to rise check the system for leaks.
Ambients Minimum Maximum
1
Air temperature
Water temperature
1
Ambient air temperature is measured at the air-cooled condenser coil inlet.
2
Ambient water temperature is measured in the ice machine water reservoir.
50 F/10 C 100 F/37.8 C
2
45 F/7 C 90 F/32.2 C
Ice capacity test
Ice machine production capacity can only be determined by weighing ice produced in a specic time period.
1. Replace all panels on ice machine.
2. Run ice machine for at least 15 minutes.
3. Weigh and record weight of container used to catch ice.
4. Catch ice for 15 or 20 minutes.
5. Weigh harvested ice and record total weight.
6. Subtract weight of container from total weight.
7. Convert fractions of pounds to decimal equivalents (ex. 6 lbs 8oz = 6.5 lbs).
8. Calculate production using following formula:
1440 min. x wt. of ice produced Total test time in minutes
Production capacity/24 hr.
=
9. Calculated amount per 24 hours should be checked against rated capacity for same ambient and water temperatures in Ice Production Tables.
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 31
Page 32
Troubleshooting
Please see “Service” section for a description of each function.
Ice machine disposition Possible causes Corrective action
Legend:
1. Ice machine is in running condition but not making ice.
.
2. Machine in TIME DELAY without full bin.
3. Ice machine is not making ice. HI AMPS.
.
4. Ice machine is not making ice. Drain clog.
OFFON
FLASHINGON or OFF
1. Defective compressor.
2. Defective start relay.
3. Defective start capacitor.
4. Defective run capacitor.
5. Defective main contactor.
6. No output from PC board.
1. Ice jamming due to improperly installed transport tube causing a false shuttle.
2. Shuttle stuck in up position.
3. Damaged or improperly installed thermostat (open).
4. Transport tube backed-out of coupling.
1. Poor water quality causing ice to jam auger.
2. Damaged shuttle mechanism.
3. Intermittent drive output from PC board. Evaporator will freeze causing a HI AMPS error.
4. Gearmotor is unplugged.
1. Internal water leak touching chassis sensor.
1. Replace compressor.
2. Replace start relay.
3. Replace start capacitor.
4. Replace run capacitor.
5. Replace main contactor.
6. Replace PC board.
1. Correct transport tube routing.
2. Repair or replace shuttle mechanism.
3. Replace or reposition thermostat.
4. Correct coupling installation.
1. Clean ice machine. Increase ushing frequency. Position TDS switch to High TDS setting.
2. Replace or repair shuttle mechanism.
3. Replace PC board.
4. Plug in gearmotor.
1. Identify and repair leak. Clean/dry chassis and sensors and restart machine.
.
5. Ice machine is making ice. Drain clog.
.
1. Improper ow in drain system. 1. Correct/clean drain system.
32 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 33
Ice machine disposition Possible causes Corrective action
Legend:
OFFON
6. Ice machine is making ice.
Excessive water in bin or coming into bin from transport tube.
7. Ice machine is not making ice.
Lo water.
FLASHINGON or OFF
1. Failed water sensors. Processor assumes there is no water when there is water.
2. Blocked reservoir vent.
3. Defective water feed solenoid valve. Stuck in open position.
1. Water supply is insufficient.
2. Low water pressure.
3. Defective water feed solenoid valve. Stuck in closed position.
4. No water feed output from PC board.
5. Plugged screen on inlet side of ll solenoid.
6. Plugged check valve.
1. Clean or replace water probe assembly. Check wiring connections.
2. Clean or replace vent tubes.
3. Replace water feed solenoid valve.
1. Restore water supply and check water lters. If evaporator was completely empty the reset button may have to be pressed to restart the ice machine.
2. Ice machine will eventually start when water reaches normal lo level.
3. Replace water feed solenoid valve.
4. Replace PC board.
5. Remove and clean screen.
6. Remove and clean.
ATTENTION!
To prevent circuit breaker overload, wait 5 minutes before restarting this unit. This allows the compressor to equalize and the evaporator to thaw.
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 33
Page 34
Replacement parts
3
27
10
2
Evaporator assembly
29
10
1
4
7
8
9
17
11
17
31
20
15
27
3
5
14
13
12
2
21
32
17
16
31
25
24
13
19
36
33
13
6
18
17
17
13
22
26
28
28
23
30
35
34
34 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 35
Reference # Description Part #
1 Tube, ice transport, insulated 01118 1 8 1
2 Shuttle assembly 01118 1 3 2
2 Shuttle assembly, IMDV 01118 1 3 2
3 Switch, shuttle 00986083
4 Compression nozzle 01058072
5 O-ring, shuttle 01118 1 4 8
6 Screw, reservoir (3 required) 01118 1 4 0
7 Auger hardware (includes screws, key, retainer) 01117944
8 Key 01069913
9 Bolt, gearmotor mounting (2) (remote condensing units), includes washers 01125 012
10 Cartridge assembly, shuttle spring 01118033
10 Cartride, shuttle spring, IMDV 01118041
11 Gearmotor, 120 V (includes capacitor) 01065572
12 Main housing 01117977
13 O ring 01004472
14 Seal, auger shaft 01039437
15 Cup, sanitizer 01118645
16 Cap, sanitizer 01118637
Not shown Tubing, water, 3/8" OD 502719
Not shown Tubing, water, 1/4" OD 502079
17 Retainer kit, evaporator 01118652
18 Solenoid, water feed (120 V) 01117523
19 Reservoir lid and sensors (includes screws and o-ring) 01118 10 8
20 Valve, shut-off, water 502921
21 Auger, 1010 remote condensing (includes seal, key, and auger hardware) 01117944 (1010 only)
21 Auger, 1410 remote condensing (includes seal, key, and auger hardware) 01117951 (1410 only)
22 Evaporator, 1010 01118066 (1010 only)
22 Evaporator, 1410 01118074 (1410 only)
23 Rear bushing housing and bushing (includes (1) o-ring) 01118082
24 Reservoir assembly, water (includes lid) 01118116
25 Tube, vent (17" required) 502079
26 Tube, sanitizer 01118660
27 Kit, MicroChewblet 00997585
28 Tube, shuttle drain, insulated 01118678
29 Insulation, gearbox, 120 V 01098185
30 Solenoid, purge, 120 V 01115782
31 Insulation kit, evaporator/reservoir 01068063
32 Check valve 01122381
33 Tube, drain, reservoir, insulated 01118 1 2 4
34 Tube, drain, 1010 01099662 (1010 only)
35 Tube, drain, 1410 01099654 (1410 only)
36 O-ring, reservoir lid 01085588
Not shown Kit, scale (includes reservoir, purge solenoid, drain tubes and tting) 01122662
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 35
Page 36
Low-side assembly
4
8
13
14
5
3
6
1
2
12
10
7
9
11
36 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 37
Reference # Description Part #
1 Tubing, liquid line (includes insulation) 01071448
2 Tubing, suction line (includes insulation) 01121391
3 Sight glass 00107045
4 Electrical box support 00121292
5 Valve, expansion, thermal (includes TXV insulation) 01118942
6 Insulation, TXV (bulb and body) 502830
7 Valve, shut-off, liquid line 00107060
8 Valve, liquid line solenoid 011119 6 2
9 Insulation, bulb, TXV 00106534
10 Valve, shut-off, suction line 00107078
11 Base, split system 01096171
12 Insulation, service valve 01121284
13 Solenoid, liquid line 011119 70
14 Heat Exchanger 01121409
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 37
Page 38
Electrical box
1
2
8
3
4
5
6
7
38 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 39
Reference # Description Part #
1 Cover, electrical box, air/water-cooled 01118975
2 Board, control, 120 V (includes stand-offs) 01117829
3 Stand-offs (set of 8) 00130906
4 Switch, TDS 00114371
5 Switch, evaporator clean 00117036
6 Switch, ice machine power 208867
7 Cord, power, 120 V 00190561
8 Cable, IMDV 01071596
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 39
Page 40
Integration kit – top-mount and RIDE remote ice delivery
Top mount configuration
12
10
13
2
2
3
5
6
7
8
11
4
1
RIDE model configuration
1
14
12
14
11
3
2
4
5
6
7
8
10
9
2
40 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 41
Reference # Description Part #
1 Shuttle actuator 00171322
2 Clamp 500377
3 Actuator elbow (includes 00167122 and 209100) 00171264
4 Screws 209100
5 Gasket 00167122
6 Actuator body 00171272
7 Gasket, coupling 00126532
8 Ring, locking (includes 00126532) 00171371
9 Ice transport tube, 10' (3m) 00171280
9 Ice transport tube, 20' (6m) 00171298
10 Insulation, transport tube 501176
Not shown Insulated polywire ice transport tube, per foot 00174896
11 Insulation, elbow 00168922
12 Insulation, actuator 00168930
13 Ice transport tube, top mount, 30" (762mm) 00171306
Not shown Extension-ll tube, 9" 00135723
Not shown Extension-ll tube, 4" 00153684
Not shown Integration kit, top mount, Harmony or Bin 00171389
Not shown Integration kit, RIDE model, Harmony or Bin, (includes 10' (3m) of tube and
00171397
insulation)
Not shown Integration kit, drop in 00145334
Not shown Integration kit, Cornelius PR150 00144774
Not shown Integration kit, Vision (does not include ice tube) 00997171
Not shown Diverter plate (single agitator Cornelius dispensers and left-hand dispense chute on
307277
dual-agitator Cornelius dispensers)
Not shown Diverter plate (right-hand dispense chute on dual-agitator dispensers) 00996207
Not shown
Follett SafeCLEAN Plus ice machine cleaner and sanitizer (case of 24 x 7oz packets)
01050863
Not shown Sani-Sponge kit 00132068
Not shown High-capacity lter system 00978957
Not shown Primary lter (1) 00978965
Not shown Primary lter (6) 00978973
Not shown Pre-lter (1) 00130211
Not shown Pre-lter (12) 00954305
Not shown IMSII or IMSIII sanitizer concentrate - 16 oz. 00979674
Not shown Sponge, sanitary, pack of 24 01075431
Not shown Kit, IMDV (included IMDV cartridge and communication cable) 01116 1 7 7
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 41
Page 42
Skins assembly
1
10
4
3
2
5
9
6
8
11
7
42 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 43
Reference # Description Part #
1 Cover, front 01121417
2 Coupling (includes O-ring) 00171207
3 O-ring 00144675
4 Bulkhead tting 00171215
5 Nut 00145342
6 Hose clamp 500377
7 Plate, strain relief 00192070
8 Louvered docking assembly, 1010 (includes strain relief plate, bulkhead
tting)
8 Louvered docking station, 1410 (includes strain relief plate, bulkhead
tting)
9 Screw 203460
10 Bulkhead connector kit 00171223
11 Cord and plug, power 00984278
01121425 (1010 only)
00121433 (1410 only)
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 43
Page 44
1010 Single-phase condensing unit
Top View
13
4
2
5
20
9
10
14
12
11
7
4
6
7
3
1
17
8
Side View
5
15
8
16
13
19
12
18
Reference # Description Part #
1 Shroud 01018290
2 Condenser 01018324
3 Head pressure control valve 01021401
4 Condenser fan motor 01018266
5 Condenser fan guard 00123067
6 Receiver 01122514
7 Filter drier, liquid 01122522
8 Compressor (includes start and run capacitors, relay, suction and liquid drier) 01122605
9 Shut-off valve, suction line 00107078
10 Shut-off valve, liquid line 00107060
11 Sight glass 01018357
12 Condenser fan blade 00173088
13 Filter drier, suction 00991075
14 Low pressure control 01018 316
15 Contactor 00155952
16 Starting relay 00173021
17 Suction valve 01122530
18 Run capacitor 00141689
19 Starting capacitor 01036748
20 Accumulator, suction, insulated 01122506
Not shown Check valve 00175893
Not shown High pressure switch 01018308
Not shown Fan cycling switch 01021393
Not shown Crankcase heater 00185827
Not shown Overload 01036722
Not shown Heater, receiver 01076942
Not shown Thermostat, heater, receiver 01122548
44 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 45
1410 Single-phase condensing unit
Top View
13
4
2
5
20
9
10
14
12
11
7
4
6
7
3
1
17
8
Side View
5
15
8
16
13
19
12
Reference # Description Part #
1 Shroud 01018290
2 Condenser 01018324
3 Head pressure control valve 01021401
4 Condenser fan motor 01018266
5 Condenser fan guard 00123067
6 Receiver 01122514
7 Filter drier, liquid 01122522
8 Compressor (includes start and run capacitors, relay, suction and liquid drier) 01122639
9 Shut-off valve, suction line 00107078
10 Shut-off valve, liquid line 00107060
11 Sight glass 01018357
12 Condenser fan blade 00173088
13 Filter drier, suction 00991075
14 Low pressure control 01018 316
15 Contactor 00155952
16 Starting relay 00173021
17 Suction valve 01067438
18 Run capacitor 00155879
19 Starting capacitor 00185793
20 Accumulator, suction, insulated 01122506
Not shown Check valve 00175893
Not shown High pressure switch 01018308
Not shown Fan cycling switch 01021393
Not shown Compressor crankcase heater 00123042
Not shown Heater, receiver 01076942
Not shown Thermostat, heater, receiver 01122548
Note: Overload is internal to compressor.
18
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 45
Page 46
1010 3-phase condensing unit
Top View
13
4
2
5
18
9
10
14
12
11
7
4
6
7
17
19
1
3
8
Side View
5
15
8
16
13
12
Reference # Description Part #
1 Shroud 01018290
2 Condenser 01018324
3 Head pressure control valve 01021401
4 Condenser fan motor 01018266
5 Condenser fan guard 00123067
6 Receiver 01122514
7 Filter drier, liquid 01122522
8 Compressor (includes crankcase heater, check vale and lter driers) 01122621
9 Shut-off valve, suction line 00107078
10 Shut-off valve, liquid line 00107060
11 Sight glass 01018357
12 Condenser fan blade 00173088
13 Filter drier, suction 00991075
14 Low pressure control 01018 316
15 Contactor 00155952
16 Starting relay 00173021
17 Suction valve 01122530
18 Accumulator, suction, insulated 01122506
19 Check valve 00175893
Not shown High pressure switch 01018308
Not shown Fan cycling switch 01021393
Not shown Compressor crankcase heater 00123042
Not shown Overload 01036722
Not shown Kit, receiver heater (RH-6) 01076942
Horizon, Harmony, Ice Manager, SafeCLEAN, Sani-Sponge and Vision are trademarks of Follett Corporation.
Not shown Thermostat, heater, receiver 01122548
Chewblet, RIDE and Follett are registered trademarks of Follett Corporation, registered in the US.
46 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
Page 47
1410 3-phase condensing unit
Top View
13
4
2
5
18
9
10
14
12
11
7
4
6
7
19
1
17
3
8
Side View
5
8
15
13
16
12
Reference # Description Part #
1 Shroud 01018290
2 Condenser 01018324
3 Head pressure control valve 01021401
4 Condenser fan motor 01018266
5 Condenser fan guard 00123067
6 Receiver 01122514
7 Filter drier, liquid 01122522
8 Compressor (lter driers) 01122647
9 Shut-off valve, suction line 00107078
10 Shut-off valve, liquid line 00107060
11 Sight glass 01018357
12 Condenser fan blade 00173088
13 Filter drier, suction 00991075
14 Low pressure control 01018 316
15 Contactor 00155952
16 Starting relay 00173021
17 Suction valve 01122530
18 Accumulator, suction, insulated 01122506
19 Check valve 00175893
Not shown High pressure switch 01018308
Not shown Fan cycling switch 01021393
Not shown Compressor crankcase heater 00123042
Not shown Heater, receiver 01076942
Not shown Thermostat, heater, receiver 01122548
Note: Overload is internal to compressor.
HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W 47
Page 48
801 Church Lane • Easton, PA 18040, USA Toll free (877) 612-5086 • +1 (610) 252-7301
48 HCD1010A/W, HCD1010A/W, HCD1410A/W, HCD1410A/W
www.follettice.com
© Follett Corporation 4/16
01096122R00
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