Ice-O-Matic GEMD520A Service Manual
Installation and Service Manual
GEMD520-GEMD525-GEMD540 Series
Ice-O-Matic
11100 East 45th Ave
Denver, Colorado 80239
Part Number 9081422-01 Date 2/11
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,”GEM” model compressed ice machines ,
“MFI” model flake ice machines and remote condensers. Thirty-six (36) months parts and labor
“EF” model flake ice machines and GEMD maker dispensers-
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 compressors,
“GEM” model compressed ice machine compressors, and “MFI” model flake ice machine compressors from the date of original installation. An additiona l
thirty-six (36) month warranty on parts (excluding labor) will be extended to all “EF” model flake ice machine and “GEMD” maker dispenser compres sors
from the date of original installation. The company will replace EXW (Incoterms 2000) the Company plant or, EXW (Incoterms 2000) the Companyauthorized 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 Compa nyauthorized 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 March 201 1. 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 must be received at the factory within 90 days from date of service to be eligible for credit. All claims outside this time
period will be void. The model, the serial number and, if necessary, 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 req uire 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. Th e
Company does not assume any responsibility 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 pe rson is authorized to give any oth er 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.
Mile High Equipment LLC, 11100 East 45th Avenue, Denver, Colorado 80239 (303) 371-3737
Ice storage bins -Twenty-four (24) month parts and labor
IOD model dispensers - T wenty-four (24) months parts, Twelve (12) months
labor
Water filter systems - Twelve (12) months parts and labor (not including filter
cartridges)
March 2011
Ice‐O‐Maticisdevotedtosustainability ineveryaspectofourbusiness.Sotohelpoffsetour
carbonfootprint,weworkwithAmericanForeststoplantatreeforeveryicemachinewe
sell.Ourultimategoalistoplant150,000treesoverthenextseveralyears.
INTRODUCTION
GEMD520-GEMD525-GEMD540
To the owner or user: The service manual you are
reading is intended to provide you, and the
maintenance or service technician with the
information needed to install, start up, clean,
maintain, and service this ice maker-dispenser.
The machine is a combination GEM ice maker and
countertop dispenser, with the option of wall
mounting.
The ice making section is equipped with the
following features: electronic controls for bin level
and low water; thermostatic expansion valve; front
service for most components; and R-404A
refrigerant. The ice dispensing section is a
seamless plastic storage bin, with a stainless steel
rotating vane to sweep the ice into the dispensing
chute.
Table of Contents
FOR THE INSTALLER: Specifications ····································Page 2
FOR THE INSTALLER: Environmental Limitations······························Page 3
FOR THE INSTALLER ············································Page 4
FOR THE INSTALLER: Wall Mount Kit····································Page 5
FOR THE PLUMBER·············································Page 6
FOR THE ELECTRICIAN ··········································Page 7
FOR THE INSTALLER: Final Check List ···································Page 8
INITIAL START UP ··············································Page 9
COMPONENT DESCRIPTION ········································Page 10
COMPONENT DESCRIPTION ········································Page 11
COMPONENT DESCRIPTION: Control Box ·································Page 12
ELECTRICAL SEQUENCE··········································Page 13
OPERATION: Water ·············································Page 14
OPERATION: Refrigeration ·········································Page 15
OPERATION: Ice Vending ··········································Page 16
DISPENSE AREA SANITATION ·······································Page 17
CLEANING and SANITIZING ········································Page 18
MAINTENANCE AND CLEANING ······································Page 19
SERVICE DIAGNOSIS ············································Page 21
SERVICE DIAGNOSIS: Circuit Board ····································Page 23
REMOVAL AND REPLACEMENT ······································Page 24
REMOVAL AND REPLACEMENT: Bearing And Breaker ··························Page 25
REMOVAL AND REPLACEMENT: Water Seal································Page 27
TO REMOVE AND REPAIR THE GEARMOTOR ASSEMBLY························Page 29
REFRIGERATION SERVICE: R-404A (HP62) ································Page 30
REFRIGERATION SERVICE·········································Page 31
CIRCUIT BOARD SERVICE ·········································Page 32
LIQUID CHARGING ·············································Page 32
Note this symbol when it appears.
It marks a possible hazard.
Page 1
GEMD520-GEMD525-GEMD540
FOR THE INSTALLER: Specifications
This ice maker-dispenser is designed to be
mounted on a machine stand, or a countertop, or
using wall mounting kit KWB3, hung from a wall.
The sink may be retained, or removed and the
optional longer splash panel (KSP5) installed in
place of the original. Instructions for each kit are
included in this service manual.
20.5"
14.06"
2.56"
1.88"dia
Before beginning the installation, check that all the
materials and kits required are available at the
installation location.
NAMEPLATE
on back panel
3.54"
4.5"
3/8" FPT
condenser
Water Inlet
(Water Cooled)
ELECTRICAL JUNCTION BOX
3/8" Flare
Potable Water Inlet
Optional for water and
drain lines
22.5"
Serial Number Plate
inside on upper base
SPECIFICATIONS
Model Number Dimensions (w/o stand)
H”xW”xD”
GEMD540A
48.5 x 26 x 20.5
Basic
Electric
115/60/1 Air 24 19.3 25
1/2" FPT
Cond. Drain
(Water Cooled)
Cond.
Type
3/4" FPT
Drain
Ref. Charge,
R-404A in ounces*
12.27"
1.12"
Minimum Circuit
Ampacity
3.12"
GEMD520A 41.0 x 26 x 20.5 115/60/1 Air 24 19.3 25
GEMD525A
41.0 x 26 x 20.5 230/50/1 Air 24 11.5 15
* Always check the nameplate for charge info.
5.12"
6.43"
Maximum
Fuse Size
Page 2
GEMD520-GEMD525-GEMD540
FOR THE INSTALLER: Environmental Limitations
Installation Limitations
This ice system is designed to be installed indoors,
in a controlled environment.
Minimum Maximum
Air Temp 50
Water Temp 40
0
F. 1000F.
0
F. 1000F.
Water Pressure 20 PSI 80 PSI
Voltage (115v) 104 126
Operating the machine outside of the above
limitations, or outdoors, is potentially damaging to
the machine; also it is misuse of the machine,
which may void the warranty.
Ice-O-Matic ice machines are designed and
manufactured with the highest regard for safety
and performance. They meet or exceed the
standards of UL and NSF.
Ice-O-Matic assumes no liability or responsibility of
any kind for products manufactured by Ice-O-Matic
that have been altered in any way, including the
use of any part and/or other components not
specifically approved by Ice-O-Matic.
Ice-O-Matic reserves the right to make design
changes and/or improvements at any time.
Specifications and design are subject to change
without notice.
Service Limitations
Do not install in a location where the top of the
machine is within 6" of a fixed ceiling. Do not install
air cooled models in a location where there is less
than 6" clearance to the left and right of the
cabinet.
CEILING
CUT AWAY
WALL
CUT AWAY
SPACE
ABOVE
FOR
SERVICE
Water Limitations
An ice machine is a food manufacturing plant; it
takes a raw material, water, and turns it into a food
product, ice. The purity of the water is very
important in obtaining pure ice and in maximizing
product life. This section is not intended as a
complete resource for water questions, but it does
offer these general recommendations:
1. Filter the water used to produce ice. That is the
water going to the “potable” water connection.
Water filters vary greatly in ability and function.
Install one that filters out suspended solids to a
dimension of 5 microns or smaller. The finer the
filter the better, but finer filters will clog sooner than
course ones. It may be necessary to add a course
filter ahead of the fine filter to prolong filter life.
2. Check with a water treatment specialist for a
water test, and recommendations regarding filters
and treatment.
6" SPACE
FOR AIR
(A/C)
Airflow
SPACE
FOR
UTILITIES
6" SPACE
FOR AIR
(AIR COOLED)
Page 3
GEMD520-GEMD525-GEMD540
FOR THE INSTALLER
Location
After uncrating and inspection, the unit is ready for
installation. It is important that the machine be
installed in a location where it has enough space
above and behind it for service. Air cooled models
require a minimum of 6 inches to the left and right
of the machine for air circulation.
Machine Stand Installation
Tip the stand on its back and install the legs, return
the stand to the upright position. Adjust leg levelers
so that the stand does not “rock”.
Counter Top or Machine Stand Installation
The base of the icemaker-dispenser must be
sealed to the object it rests upon. Food grade
silastic sealant is recommended.
Place a bead of the sealant on the machine stand
or counter top to match the outside edge of the
cabinet base and sink.
The icemaker-dispenser is heavy: use of a
mechanical hoist is recommended to lift it to the
height required to install it.
The DMS machine stand has holes in the top that
match up with threaded holes in the
icemaker-dispenser. Place the cabinet onto the
machine stand, so that the unit is lined up with the
holes. Secure the ice maker-dispenser to the
machine stand with bolts and washers.
In both counter top and machine stand
installations, wipe off and neatly smooth any
excess sealant. Level the machine stand and
cabinet.
Unpack and install the sink brackets. Fit the sink
assembly onto the two sink brackets, and press
onto the bead of sealant. Wipe off and neatly
smooth any excess sealant from under the sink
edge.
SEAL THE
UNIT TO
THE
COUNTER
OR STAND
Unpack and install the water spout.
Water Spout: Slide over stainless steel water
discharge tube, locate and match up with notches
in the base. Rotate clockwise to move spout into
installed position.
Water
Spout
Page 4
GEMD520-GEMD525-GEMD540
FOR THE INSTALLER: Wall Mount Kit
CAUTION
It is recommended that the wall mounting
installation be done by an experienced contractor.
The weight of the machine when in use may
exceed 350 pounds. The unit should be mounted
on a solid, rigid wall with proper fasteners for that
type of wall and of adequate strength to support
the weight of the machine when in use.
Clearance between the wall and the icemaker is a
maximum of 1 inch. Check utility connections first.
The electrical junction box will have to be removed,
and the electrical connections made inside the
cabinet in compliance with local codes. The
plumbing connections may be made through the
base, or at either side through the pre-punched
holes, using standard plumbing practices.
Interior plumbing lines must be disconnected from
the original connections and plugged when
routing through the side or base.
1. Remove machine top. Attach bracket “A” to
machine using (3) nuts, (3) flat washers, (3) lock
washers, and (3) 5/16-18 bolts received with the
kit.
GEMD540=38.6"
GEMD525=30"
7.83
1" CLEARANCE
BASE
HOLE
SIDE
ROUTIN
16"
16"
A
DO NOT LIFT ON SINK
2. Mount brackets “B” and “C” to the wall at the
dimensions shown for the unit. (hardware for this is
not included).
B
Use fasteners and wall of sufficient strength to
carry the use and weight of the
icemaker-dispenser.
3. Lift unit up and hook bracket “A” over bracket
12"
12"
C
“B”. Slide unit until the two remaining holes are
aligned and secure with the remaining (2) 1/4-20
bolts, flat washers and lock washers.
Page 5
GEMD520-GEMD525-GEMD540
FOR THE PLUMBER
CONFORM TO ALL APPLICABLE CODES
Water Inlet
Air Cooled Models: The recommended water
supply is clean, cold water. Use 3/8" O.D. copper
tubing, connect to the 3/8" male flare at the back of
the cabinet. Install a hand valve near the machine
to control the water supply.
Water Treatment: In most areas, a water filter of
some type will be useful. In areas where the water
is highly concentrated with minerals the water
should be tested by a water treatment specialist,
and the recommendations of the specialist
regarding filtration and/or treatment should be
followed.
Water Cooled Models: A separate 3/8" O.D.
copper line is recommended, with a separate hand
valve to control it. It is connected to a 3/8" FPT
condenser inlet at the back of the cabinet. The
water pressure to all lines must always be above
20 psig, and below 80 psig.
WATER INLET
CABINET
DRAIN
OPTIONAL
WATER
FILTER
Drains
Air Cooled Models: There is one 3/4" FPT drain
at the back of the cabinet, the drain line is of the
gravity type, and 1/4 inch per foot fall is an
acceptable pitch for the drain tubing. There should
be a vent at the highest point of the drain line, and
the ideal drain receptacle would be a trapped and
vented floor drain. Use only 3/4" rigid tubing.
Water Cooled Models: In addition to the above
mentioned drain, a separate condenser drain must
be installed. Connect it to the 1/2" condenser drain
connection at the back of the cabinet.
WATER INLET
SHUT OFF
VALVE
VENTED
DRAIN TUBE
FLOOR DRAIN
WATER COOLED DETAIL
Condenser
WATER INLET
Page 6
POTABLE
WATER INLET
CABINET
DRAIN
Condenser
DRAIN
FOR THE ELECTRICIAN
CONFORM TO ALL APPLICABLE CODES
The electrical power to the unit is
supplied through the junction box at the
rear of the machine.
Check the nameplate (located on the
back panel) for the voltage
requirements, and for the minimum
circuit ampacity. The machine requires
a solid chassis to earth ground wire.
The ice maker should be connected to
its own electrical circuit so it would be
individually fused. Voltage variation
must remain within design limitations,
even under starting conditions.
All external wiring must conform to
national, state, and local electrical
codes. The use of a licensed
electrician is required to perform the
electrical installation.
GEMD520-GEMD525-GEMD540
INDIVIDUAL CIRCUIT
FOR ICE DISPENSER
JUNCTION
BOX
Page 7
GEMD520-GEMD525-GEMD540
FOR THE INSTALLER: Final Check List
1. Is the icemaker-dispenser installed indoors, in a
location where the air and water temperatures are
controlled, and where they do not go beyond
design limitations?
2. Is there an electrical disconnect (switch or plug
as required) within sight of the installed machine?
Is the machine on a separate circuit? Has the
voltage been checked and compared to nameplate
requirements?
3. Have all of the plumbing connections been
made and checked for leaks?
4. Has the machine been leveled?
5. Is there a minimum of 6 inches of clearance at
the left and right sides of an air cooled machine?
6. Is there a minimum of 6 inches of clearance at
the top and back of the machine for service and
utility connections?
BACK VIEW OF COMPLETED INSTALLATION
ELECTRICAL?
LEVELED?
ICEMAKER
DISPENSER
PLUMBING?
Wall mounted only: Is the machine properly
installed and secured to the wall?
7. Is there a water shut off valve installed near the
machine?
MACHINE
STAND
Page 8
GEMD520-GEMD525-GEMD540
INITIAL START UP
Pre Start Inspection
1. Remove the two front panels.
2. Check that all shipping blocks have been
removed.
3. Remove any and all packing tape (check inside
the storage bin).
4. Inspect the interior of the machine for loose
screws or wires. Check that no refrigerant lines are
rubbing each other. Check that the fan blade on air
cooled models turns freely.
5. Check that the machine is installed correctly
according to the final check list.
Start Up
1. Go through the pre start inspection.
2. Open the water hand valve, observe that water
enters the water reservoir, fills the tube from the
reservoir to the evaporator and then shuts off.
Check for leaks.
3. Switch the master switch on. The electrical start
up sequence is automatic; there will be a short (15
second) delay before the machine starts.
4. On air cooled models, warm air will begin to flow
from the condenser. Water cooled models will
begin to discharge warm water down the drain.
5. The unit should soon be making ice. If desired,
the low side pressure may be checked: it should
be 38 PSIG + or - 2 PSIG.
The air cooled discharge pressure will depend
upon air and water temperatures, but should be
between 240 PSIG and 340 PSIG.
Water cooled discharge pressure should be about
245 PSIG. If needed, adjust the water regulating
valve.
The above numbers are for new, clean machines.
Field values may be somewhat higher or lower.
6. There are no adjustments to make, so replace
the panels.
8. Switch off the icemaker-dispenser, remove the
top panel and the top of the ice storage bin.
Sanitize the interior of the ice storage bin by wiping
it with a mixture of 1 ounce of household bleach to
2 gallons of water, allow to air dry. Replace all
covers and panels. Switch the icemaker-dispenser
back on.
9. Give the owner/user the service manual, instruct
him/her in the operation and maintenance
requirements of the unit. Make sure they know who
to call for service.
10. Fill out the Customer Evaluation and Warranty
Registration form, and mail it in to Ice-O-Matic.
7. Check ice dispensing by holding a container in
front of the Touch Free ice sensor (just below the
ice delivery spout). Ice should flow from the spout
when a container is present, and stop dispensing
when the container is removed.
Page 9
GEMD520-GEMD525-GEMD540
COMPONENT DESCRIPTION
High Pressure Cut Out Switch: A manual reset
switch sensing the high side refrigeration pressure.
It is set to shut the machine off if the discharge
pressure should ever exceed 450 psig.
Evaporator: A vertical stainless steel tube,
refrigerated, and water filled. In it there is a
stainless steel auger.
Reservoir: Float operated, it maintains the water
level in the evaporator at a constant level, it also
contains the water level sensor.
Water Level Sensor: Senses if there is water in
the reservoir to make ice out of. Will shut the
machine off it there is none.
Ice Level Sensor: An electronic “eye”, it senses
the presence of ice in the
bottom of the ice discharge
chute. Operates to turn the ice
machine on and off
automatically as the level of ice
in the bin changes.
Drain Tube: When uncapped
and lowered, drains the
evaporator.
ICE LEVEL SENSORS
WATER LEVEL
SENSOR
EVAPORATOR
Condenser: Air or water
cooled, where the heat
removed in ice making is
discharged.
Ice Storage Bin Assembly: A
plastic lined, insulated cylinder
that receives, stores and
dispenses the ice. Fresh ice
enters at the top, and when the
bin is full enough the ice will be
between the ice level sensors,
and the ice making will stop.
Ice is dispensed through a
chute at the bottom front when
the bin vane sweeps the ice
over the chute.
RESERVOIR
DRAIN TUBE
HIGH PRESSURE
CUT OUT
ICE STORAGE BIN
CONDENSER
TOUCH FREE SENSOR
Page 10
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