Ice-O-Matic EMF, EF User Manual

SERVICE AND INSTALLATION MANUAL
EF and EMF Series
Flaked ICE Machines
ICE-O-Matic 11100 East 45th Ave Denver, Colorado 80239 Part Number 9081325-01 Print Date 1/07
General Information
Model and Serial Number Format A3-A4 Electrical and Mechanical Specifications A5 Installation Guidelines A6 Electrical and Plumbing Requirements A7-A9 Remote Condenser Installation A10 Warranty Information A11 General Operation A12
Scheduled Maintenance
Maintenance Procedure B1 Cleaning and Sanitizing Instructions B2 Winterizing Procedure B3 Cleaning Stainless Steel B4
Troubleshooting Trees
Introduction C1 Machine Runs, Does Not Make Ice C2 Machine Does Not Run C4 Slow Production C5 Low Suction Pressure C6 High Suction Pressure C7 Machine Freezes Up (Auger Seizes) C8 Auger Motor Amperage Fluctuations C9 Water Leaking From Evaporator C10 Machine Produces Wet Ice C11 Hot Evaporator, Low Suction Pressure C12 Noise Coming From Evaporator C13
Water System
Float Valve and Reservoir D1 Water Seal and O-Rings D2 Drip Boot D2
Drive System
Auger Drive Motor and V-Belt E1 Gear Reducer E2 Coupler E2 Evaporator and Internal Components E3 Evaporator Disassembly E3 Evaporator and Auger Inspection E5 Bearing, Water Seal and O-Rings E6 Seal Face Installation E7 Evaporator Reassembly E7
Refrigeration System
Refrigeration System and Components F1 Compressor F1 Refrigerant Pressures F2 Air Cooled Condenser F5 Water Cooled Condenser F6 Water Regulating Valve F6 High Pressure Safety Control F6 Expansion Valve F7 Production Check F8 Evaporator F9 Remote System F10
Refrigeration System (Continued)
Mixing Valve F10 Pump Down System F11 Liquid Line Solenoid F11 Receiver F12 Refrigerant F13
Electrical System
Control Circuit G1 Compressor and Start Components G1 Safety Control G3 Bin Control G3 Auger Motor Relay G4 Auger Motor G4 Compressor Delay G5 Pump Down System G5 Pump Down Control G5
Wiring Diagrams
EF240/255/405, EF450 A/W G6 EF800 A/W G7 EMF450/405 A/W G8 EMF800 A/W G9 EMF705/1005/1006 A/W G10 EMF1106 R G11 EMF2306 A/W G12 EMF2306 R G13 EMF2305L G14
Page A1
Flake Ice Machines How To Use This Manual
ICE-O-Matic provides this manual as an aid to the service technician for installation, operation, and maintenance of flaked ice machines. This manual covers all EF and EMF series flaked ice machines. If used properly, this manual can also help the service technician troubleshoot and diagnose most of the problems that may occur with the machine.
Sections A and B of this manual provide general and maintenance information. The remainder of the manual, beginning with Section C, provides troubleshooting information. Section C contains flow charts called troubleshooting trees. Page C1 provides instructions on using the troubleshooting trees. Each troubleshooting tree is named to describe a particular problem with the operation of the machine.
When following the troubleshooting trees, the service technician will be led through questions and checks and end up at a probable solution. When using the troubleshooting trees it is important that the service technician understand the operation and adjustments of the components being checked and the component suspected of being defective. A detailed description of the operation and adjustments of the components as well as other service information is laid out in the pages that follow Section C.
Each section, after Section C, focuses on a particular system in the ice machine; water system, drive system, refrigeration system and electrical system. It is important that these sections be used together with the troubleshooting trees in Section C.
Most aspects of flake ice machines are covered in this manual. However, should you encounter any conditions not addressed herein, please contact the ICE-O-Matic Technical Service Department for assistance at the numbers listed below, or write the ICE-O-Matic Service Department.
ICE-O-Matic 11100 East 45 Denver CO 80239 Attn: Technical Service Department
Phone: (800) 423-3367 After Hours Only (888) FIX-4-ICE (349-4423) Fax: (303) 576-2944 E-Mail Tech.service@iceomatic.com
Any service communication must include:
Model Number
Serial Number
A detailed explanation of the problem
th
Ave.
WARNING: Always disconnect electrical power and shut off water supply whenever maintenance or repairs are performed on the ice machine and related equipment.
CAUTION: Always wear protective eyewear whenever maintenance or repairs are performed on the ice machine and related equipment.
Page A2
Flake Ice Machines General Information
Model and Serial Number Format Model Numbers
EF 80 0 A 1
Voltage: 0=115V 5=240/50/1 6=208-230/60/1 Approximate 24 hour ice production: (x 10 @ 70°F/21°C Air and 50°F/10°C Water) Series: E=Environmental Flaker (Uses HFC Refrigerant)
F=Self Contained Flake Ice Machine MF=Modular Flake Ice Machine
Serial Number Date Code
The first letter in the serial number indicates the month and decade of manufacture. The first digit in the serial number indicates the year of manufacture.
Example:
A0XX-XXXXX-Z is manufactured January 2000 A1XX-XXXXX-Z is manufactured January 2001 A4XX-XXXXX-Z is manufactured January 2004
1990-1999 MONTH 2000-2009 M JANUARY A
N FEBRUARY B P MARCH C Q APRIL D R MAY E S JUNE F T JULY G U AUGUST H V SEPTEMBER I W OCTOBER J Y NOVEMBER K Z DECEMBER L
Note: The letter O and letter X are not used.
Revision Level
Condenser Type: A=Air W=Water R=Remote
Page A3
Flake Ice Machines General Information
Electrical and Mechanical Specifications
Production per 24 Hours @ No. of Minimum Max 90°FA 70°FW Compressor wires incl Circuit Fuse ** Refrigerant Model Number Lbs Kg *RLA *LRA Voltage ground Ampacity Size Type Oz. Grams
EF Series / 60 Hertz Machines
EF250A 319 145 5.7 30.2 115/60/1 3 12.4 15 R404A 12 340
EF450A 360 163 7.2 40 115/60/1 3 14.5 15 R404A 17 482
EF800A 616 280 10.4 51 115/60/1 3 18.2 15 R404A 20 567
EMF Series / 60 Hertz Machines
EMF450A 372 169 6.9 40 115/60/1 3 14.1 15 R404A 17 482
EMF450W 472 214 6.8 40 115/60/1 3 13.1 15 R404A 14 397
EMF800A 632 287 10.5 51 115/60/1 3 19.8 20 R404A 25 709
EMF800W 756 343 9.5 51 115/60/1 3 16.5 20 R404A 16 454
EMF1106A 816 370 4.5 34.2 208-230/60/1 3 9.4 15 R404A 34 964
EMF1106W 1008 458 4.4 34.2 208-230/60/1 3 8.5 15 R404A 15 426
EMF1106R 912 414 4.5 34.2 208-230/60/1 3 10.4 15 R404A 160 4536
EMF2306A 1808 821 8.4 61 208-230/60/1 3 14.9 20 R404A 84 2382
EMF2306W 2240 1051 7.3 61 208-230/60/1 3 12.8 20 R404A 36 1021
EMF2306R 1828 830 8.1 61 208-230/60/1 3 15.5 20 R404A 240 6804
EMF Series / 50 Hertz Machines
EMF405A 432 196 3 16.1 230/50/1 3 6.6 15 R404A 19 539 EMF705A 821 373 4.1 34.5 230/50/1 3 8.6 20 R404A 34 964
EMF1005A 1080 490 5.2 42 230/50/1 3 10 20 R404A 34 964
* R.L.A.=Rated Load Amps L.R.A=Locked Rotor Amps ** Use refrigerant charge specified on Serial Plate when charging system.
Page A5
Flake Ice Machines General Information
Installation Guidelines
Note: Installation should be performed by an ICE-O-Matic trained Service Technician. For proper operation of the ICE-O-Matic ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties.
Ambient Operating Temperatures
Minimum Operating Temperature: 50°F (10°C) Maximum Operating Temperature 100°F (38°C), 110°F (43°C) on 50 Hz. Models.
Note: ICE-O-Matic products are not designed for walk in cooler applications or outdoor installation.
Incoming Water Supply (See Plumbing Diagram for line sizing Page A7-A9)
Minimum incoming water temperature: 40°F (4.5°C) Maximum incoming water temperature: 100°F (38°C) Minimum incoming water pressure: 20 psi (1.4 bar) Maximum incoming water pressure: 60 psi (4.1 bar)
Note: If water pressure exceeds 60 psi (4.1 bar), a water pressure regulator must be installed.
Drains:
Route bin drain, float drain and water condenser drain individually to a floor drain. The use of condensate pumps for draining water is not recommended by ICE-O-Matic. ICE-O-Matic assumes no responsibility for improperly installed equipment.
Water Filtration
A water filter system should be installed with the ice machine.
Clearance Requirements
Self contained air cooled ice machines must have a minimum of 6 inches (15cm) of clearance around the entire machine.
Stacking
EF and EMF Series ice machines are not designed to be stacked.
Dispenser Application
EF and EMF Series ice machines are not designed to be placed on dispensers.
Electrical Specifications
The machine must be installed on a separate circuit. Refer to the serial plate at the rear of the ice machine or the charts on Page A5.
Adjustments
Level the machine. Check the primary and secondary bin control for proper adjustment, Page G3. Check the safety control for proper adjustment, Page G3. Check the water in the water float for proper level, Page D1. Check the water regulating valve adjustment if water cooled, Page F6.
Page A6
Flake Ice Machines General Information
EF Series
Page A7
Flake Ice Machines General Information
EMF Series
Page A8
Flake Ice Machines General Information
EMF Series (48 Inch Wide)
Page A9
A
Flake Ice Machines General Information
Remote Condenser Installation
The EMF1106R2 and EMF2306R2 remote ice makers incorporate the mixing valve in the condenser. This configuration allows up to a 100 foot calculated remote line set run. Reference the diagram below to calculate the maximum 100 foot line set run.
For proper operation of the ICE-O-Matic ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failure, and may void all warranties.
Remote condensers must be installed per local building codes. A two to four inch diameter roof penetration will be needed for refrigerant lines and electrical conduit. The penetration should be within two feet of where the condenser will be located. A roof jack must be installed at the penetration.
Installation Guidelines
Ambient operating temperatures: -20°F (-28.9°C) to 120°F (48.9°C) Condenser Airflow: Condensers must have a vertical airflow.
ICE Machine Model Number Remote Condenser Model Number
EMF1106R2 VRC1061 EMF2306R2 VRC2061
Limitations for new remote machines that have the headmaster mounted in the condenser.
Maximum Rise is 35 feet. Maximum Drop is 15 feet. Maximum equivalent run is 100 feet.
Formula for figuring maximum equivalent run is as follows:
Rise x 1.7 + Drop x 6.6 + horizontal run = equivalent run. Examples: 35 ft. rise x 1.7 + 40 ft. horizontal = 99.5 equivalent feet line run
40 ft. horizontal
Verify the ICE machine is compatible with the remote condenser. Some ice machines and some remote condensers may or may not have a Mixing Valve (Head Master). Only one valve is required per system. Kits are available to modify the ice machine or condenser for compatibility. For more information contact your ICE-O-Matic Distributor.
35 ft. rise
irflow
10 ft. drop 34 ft. horizontal
10 ft. drop x 6.6 + 34 ft horizontal = 100 equivalent feet line run
Page
A10
Flake Ice Machines General Information
ICE-O-Matic
Parts and Labor
Domestic & International Limited Warranty
Mile High Equipment LLC (the “Company”) warrants ICE-O-Matic brand ice machines, ice dispensers, remote condensers, water filters, and ice storage bins to the end customer against defects in material and factory workmanship for the following:
Cube ice machines, compressed ice machines and remote condensers. - Thirty-six (36) months parts and labor
Flake ice machines - Twenty-four (24) months parts and labor
CD model dispensers - Thirty-six (36) months parts and labor
An additional twenty-four (24) month warranty on parts (excluding labor) will be extended to all cube ice machine evaporator plates and all cube ice and compressed ice machine compressors from the date of original installation. An additional thirty-six (36) month warranty on parts (excluding labor) will be extended to all flake ice machine compressors from the date of original installation The compan y will replace EXW (Incoterms 2000) the Company plant or, EXW (Incoterms 2000) the Company-authorized distributor, without cost to the Customer, that part of any such machine that becomes defective. In the event that the Warranty Registration Card indicating the installation date has not been returned to ICE-O-Matic, the warranty period will begin on the date of shipment from the Company. Irrespective of the actual installation date, the product will be warranted for a maximum of seventy-two (72) months from date of shipment from the Company.
ICE-model cube ice machines which are registered in the Water Filter Extended Warranty Program will receive a total of eighty-four (84) months parts and labor coverage on the evaporator plate from the date of original installation. Water filters must be installed at the time of installation and registered with the Company at that time. Water filter cartridges must be changed every six (6) months and that change reported to the Company to maintain the extended evaporator warranty.
No replacement will be made for any part or assembly which (I) has been subject to an alteration or accident; (II) was used in any way which, in the Company’s opinion, adversely affects the machine’s performance; (III) is from a machine on which the serial number has been altered or removed; or, (IV) uses any replacement part not authorized by the Company. This warranty does not apply to destruction or damage caused by unauthorized service, using other than ICE-O-Matic authorized replacements, risks of transportation, damage resulting from adverse environmental or water conditions, accidents, misuse, abuse, improper drainage, interruption in the electrical or water supply, charges related to the replacement of non-defective parts or components, damage by fire, flood, or acts of God.
This warranty is valid only when installation, service, and preventive maintenance are performed by a Company-authorized distributor, a Company-authorized service agency, or a Company Regional Manager. The Company reserves the right to refuse claims made for ice machines or bins used in more than one location This Limited Warranty does not cover ice bills, normal maintenance, after-install adjustments, and cleaning.
Limitation of Warranty This warranty is valid only for products produced and shipped from the Company after October 1, 2006. A product produced or installed
before that date shall be covered by the Limited Warranty in effect at the date of its shipment. The liability of the Company for breach of this warranty shall, in any case, be limited to the cost of a new part to replace any part, which proves to be defective. The Company makes no representations or warranties of any character as to accessories or auxiliary equipment not manufactured by the Company. REPAIR OR REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE CUSTOMER. MILE HIGH EQUIPMENT SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE LENGTH OF THIS WARRANTY.
Filing a Claim All claims for reimbursement outside this time period will be void. The mo del, the serial number and, if n ecessary, proof of installation, must be included in the claim. Claims for labor to replace defective parts must be included with the part claim to receive consideration. Payment on claims for labor will be limited to the published labor time allowance hours in effect at the time of repair. The Company may elect to require the return of components to validate a claim. Any defective part returned must be shipped to the Company or the Company-authorized distributor, transportation charges pre-paid, and properly sealed and tagged. The Company does not assume any responsi bility for any expenses incurred in the field incidental to the repair of equipment covered by this warranty. The decision of the Company with respect to repair or replacement of a part shall be final. No person is authorized to give any other warranties or to assume any other liability on the Company’s behalf unless done in writing by an officer of the Company.
GOVERNING LAW
This Limited Warranty shall be governed by the laws of the state of Delaware, U.S.A., excluding their conflicts of law principles. The United Nations Convention on Contracts for the International Sale of Goods is hereby excluded in its entirety from application to this Limited Warranty.
must be received at the factory within 90 days from date of service to be eligible for credit. All clai ms
Mile High Equipment LLC, 11100 East 45
Ice storage bins -Twenty-four (24) month parts and labor
IOD model dispensers - Twenty-four (24) months parts, Twelve (12)
months labor
Water filter systems - Twelve (12) months parts and labor (not including filter cartridges)
th
Avenue, Denver, Colorado 80239 (303) 371-3737
October 2006
Page A11
Flake Ice Machines General Information
General Operation
A general description of the flake ice machine operation is given below. The remainder of the manual provides more detail about the components and systems.
Water enters a reservoir through the float valve and is gravity fed into the evaporator barrel through an opening in the bottom of the barrel. Water fills the evaporator to the same level as the water in the reservoir. A float valve, which stops the flow of water into the reservoir when the reservoir becomes full, maintains this water level.
When the ON/OFF switch is turned on or when the bin control closes, the auger motor energizes. The compressor is delayed for 2 to 4 minutes. After the compressor delay period, the condenser fan motor (air cooled machines only) and compressor start and the temperature of the evaporator barrel drops. The water in the evaporator freezes to the inner walls of the evaporator barrel.
A belt driven gear reducer continuously turns the auger inside the evaporator. As the auger turns, it pushes the ice upward and forces it out of the top of the barrel, through the delivery chute, and into the storage bin. As ice is pushed out through to top of the evaporator, make-up water enters the bottom of the evaporator.
Evaporator
Float
Gear Reducer
V-Belt
Auger Motor
Page A12
Flake Ice Machines Scheduled Maintenance
Danger!
Electrical shock and/or injury from moving parts inside this machine can cause serious injury or death. Disconnect electrical supply to machine prior to performing any adjustments or repair.
Maintenance Procedure
Warning!
Failure to perform the required maintenance at the frequency specified will void warranty coverage in the event of a related failure.
To insure economical, trouble free operation of the ice maker, it is recommended that the following maintenance be performed every 6 months by a qualified service technician.
1. Check the float reservoir for mineral build-up or check the auger drive motor amp draw to determine if the water system needs cleaning. Clean the water system, if necessary, per the instructions on Page B2. Local water conditions may require that cleaning be performed more often than 6 month intervals.
2. Check the water level in the float tank as described on Page D1.
3. Clean the condenser (air cooled machines) to insure unobstructed airflow.
4. Check for leaks of any kind, water, refrigerant, oil, etc.
5. Check the Primary Bin Control for proper adjustment as described on Page G3.
6. Check the Secondary Bin Control for proper adjustment as described on Page G4
7. Check the Safety Control for proper adjustment as described on Page G3.
8. Check the water requlating valve (water cooled machines) for proper adjustment by measuring the water temperature at the outlet of the condenser drain. It should be between 100°F (37.7°C) and 110°F (43.3°C).
9. Check the TXV bulb to make sure that it is securely fastened and properly insulated.
10. Check all electrical connections tightness. Warning: Disconnect electrical supply.
11. Oil the auger motor if the motor has oil fittings.
12. Check the V-Belt for wear and proper tension as described on Page E1.
Page B1
Flake Ice Machines Scheduled Maintenance CAUTION: Protective eyewear and gloves should be worn when using
cleaning products.
CLEANING AND SANITIZING INSTRUCTIONS
1. Turn the machine and water supply to the float off.
2. Remove or melt all ice in the bin.
3. Prepare one gallon (3.75l) of non-chlorine ice machine cleaner i.e. Nu-Calgon Nickel Safe, as directed on container.
4. Turn the machine on, remove the float reservoir cover and add cleaning solution to the reservoir.
5. As the machine makes ice, keep the reservoir filled with the cleaning solution until the entire gallon is used up.
6. Turn the machine off.
7. Prepare 1 gallon (3.75l) of approved (U.S. FDA 21 CFR, 178-1010) food equipment sanitizer to form a solution with 100 – 200 ppm free chlorine yield. Reserve about 1/3 gallon for step #14 below.
8. Turn the machine on and add the sanitizer to the reservoir, keeping the reservoir filled with sanitizer until 2/3 gallon is used up.
9. Turn the machine off.
10. Replace the float reservoir cover and turn the water supply back on.
11. Turn the machine on and allow the machine to make ice for 15 minutes.
12. Turn the machine off and remove and discard all of the ice from the bin made during the cleaning operation.
13. Clean the inside of the bin, bin door, and door frame with warm soapy water and rinse.
14. Using the remainder of the sanitizing solution, wipe all areas of the bin liner, door and door frame, etc. and rinse.
15. Turn machine back on.
Page B2
Flake Ice Machines Winterizing Procedures
Winterizing Procedures Important!
Whenever the ice machine is taken out of operation during the winter months, the procedure below must be performed. Failure to do so may cause serious damage and will void all warranties.
1. Turn off water to machine.
2. Make sure all ice is out of the evaporator(s)
3. Place the ON/OFF switch to the “OFF” position.
4. Disconnect the tubing between the evaporator and water float.
5. Drain the water system completely.
6. On water cooled machines, hold the water regulating valve
open by prying upward on the water valve spring with a screwdriver while using compressed air to blow all the water out of the condenser.
7. Remove all of the ice in the storage bin and discard.
Disconnect tubing from float to evaporator and drain water from the evaporator
Page B3
Flake Ice Machines Cabinet Care Cleaning Stainless Steel
Commercial grades of stainless steel are susceptible to rusting. It is important that you properly care for the stainless steel surfaces of your ice machine and bin to avoid the possibility of rust or corrosion. Use the following recommended guidelines for keeping your stainless steel looking like new:
1. Clean the stainless steel thoroughly once a week. Clean frequently to avoid build-up
of hard, stubborn stains. Also, hard water stains left to sit can weaken the steel's corrosion resistance and lead to rust. Use a nonabrasive cloth or sponge, working with, not across, the grain.
2. Don't use abrasive tools to clean the steel surface. Do not use steel wool, abrasive
sponge pads, wire brushes or scrapers to clean the steel. Such tools can break through the "passivation" layer - the thin layer on the surface of stainless steel that protects it from corrosion.
3. Don't use cleaners that use chlorine or chlorides. Don't use chlorine bleach or
products like Comet to clean the steel. Chlorides break down the passivation layer and can cause rusting.
4. Rinse with clean water. If chlorinated cleansers are used, you must thoroughly rinse the
surface with clean water and wipe dry immediately.
5. Use the right cleaning agent. The table below lists the recommended cleaning agents
for common stainless steel cleaning problems:
Cleaning Activity Cleaning Agent Method of Application
Routine cleaning Soap, Ammonia, Windex, or Apply with a clean cloth detergent with water. or sponge. Rinse with Fantastik, 409 Spic’nSpan clean water and wipe dry.
Liquid are also approve for Stainless Steel.
Removing grease or Easy-Off or similar oven Apply generously, allow fatty acids cleaners. to stand for 15-20 minutes. Rinse with clean water. Repeat as required.
Removing hard water spots Vinegar Swab or wipe with clean and scale. Rinse with clean water
cloth.
and dry.
Page B4
Flake Ice Machines Troubleshooting Trees
How To Use The Troubleshooting Trees
The troubleshooting trees were developed to be used in conjunction with the service information in the sections that follow. If used together as intended, these two parts of the manual will allow the ice machine service technician to quickly diagnose many of the problems encountered with the ice machines. When used as designed, the troubleshooting trees can lead you from a general symptom to the most likely component to suspect as the cause of the problem. The trees are not designed to be “parts changer guides”: please do not use them as such.
Components returned to the factory for warranty are tested by the factory and will not be covered under the warranty policy if they are not defective.
The troubleshooting trees are made of three types of boxes:
QUESTION boxes (Circle) ask a yes/no question and the answer will lead to either another question box, a check box or a solution box.
CHECK boxes (Rectangle) will suggest a point to check for proper operation, and will often refer you to a page in the service information sections of this manual. The result of the check may lead to another box, or a solution box.
SOLUTION boxes (Triangle) suggest the most likely component to cause the malfunction described in the heading of the tree. When reaching a solution box, DO NOT immediately assume the component is defective. The final step is to verify that the component is indeed defective, by using the service information in the sections that follow.
To use the troubleshooting trees, first find the page with the heading describing the type of problem occurring. Begin at the top of the page and follow the tree, step-by-step. When a check box is reached, it may be necessary to refer to another section in the manual.
Once a solution box is reached, refer to the appropriate section to verify that the component in the solution box is, indeed, the problem. Adjust, repair or replace the component as necessary.
Page C1
Flake Ice Machines Troubleshooting Trees
Machine Runs, Does Not Make Ice
Page C2
Flake Ice Machines Troubleshooting Trees
Machine Runs, Does Not Make Ice
Page C3
Flake Ice Machines Troubleshooting Trees
Machine Does Not Run
Page C4
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