Ice-O-Matic GEMD790 Service Manual

Installation and Service Manual

GEMD790

Ice-O-Matic 11100 East 45th Ave Denver, Colorado 80239 Part Number 9081424-01 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‐Maticisdevotedtosustainability ineveryaspectofourbusiness.Sotohelpoffsetour carbonfootprint,weworkwithAmericanForeststoplantatreeforeveryicemachinewe sell.Ourultimategoalistoplant150,000treesoverthenextseveralyears.



INTRODUCTION

GEMD790

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 GEMD790 is a combination GEM ice maker and countertop dispenser. A water station is standard.

Table of Contents

FOR THE INSTALLER: Specifications ······························ Page 2

FOR THE INSTALLER ······································ Page 3

FOR THE PLUMBER ······································· Page 4

FOR THE ELECTRICIAN ····································· Page 5

FOR THE INSTALLER: Final Check List ····························· Page 6

INITIAL START UP ········································ Page 7

COMPONENT DESCRIPTION ·································· Page 8

COMPONENT DESCRIPTION ·································· Page 9

CONTROL BOX ········································· Page 10

ELECTRICAL SEQUENCE ···································· Page 11

OPERATION: Water ······································· Page 12

OPERATION: Refrigeration ··································· Page 13

OPERATION: Ice Vending ···································· Page 14

DISPENSE AREA SANITATION ································· Page 15

CLEANING and SANITIZING ··································· Page 16

SENSOR MAINTENANCE ···································· Page 17

BEARING MAINTENANCE ···································· Page 18

AUGER MAINTENANCE ····································· Page 19

SERVICE DIAGNOSIS ······································ Page 20

CONTROL SYSTEM DIAGNOSTICS ······························ Page 21

REMOVAL AND REPLACEMENT ································ Page 22

REMOVAL AND REPLACEMENT: Bearing And Breaker ···················· Page 23

REMOVAL AND REPLACEMENT ································ Page 24

REMOVAL AND REPLACEMENT: Water Seal ························· Page 25

REMOVAL AND REPLACEMENT ································ Page 26

TO REMOVE AND REPAIR THE GEARMOTOR ASSEMBLY ·················· Page 27

REFRIGERATION SERVICE ··································· Page 28

WIRING DIAGRAMS ······································· Page 29

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 ice agitator at the bottom to sweep the ice into the dispensing chute.

This manual was printed on recycled paper. Keep it for future reference.

Note this symbol when it appears.

It marks a possible hazard.

Page 1

GEMD790

FOR THE INSTALLER: Specifications

This ice maker-dispenser is designed to be mounted on a machine stand, or a countertop. Before beginning the installation, check that all the materials and kits required are available at the installation location.

Ice-O-Matic ice machines are designed and manufactured with the highest regard for safety and performance. They meet or exceed the standards of U.L., N.S.F., and C.U. L.

3/8" FPT

Cond. Water

Inlet

(W/C)

1/2" FPT

Cond. Drain

(W/C)

3/4 FPT

Drain

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 parts 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 designs are subject to change without notice.

BACK VIEW

Water Limitations:

An ice machine is a food manufacturing plant; it takes in 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.

General recommendations

Electrical Junction

Box

3/8" Flare

Water Inlet

are:

1. Filter the water used to produce ice.

2. Check with a water treatment specialist for a water test, and any

6.63"

12.5"

4.63"

recommendations regarding filters and treatment.

.75"

3/4" FPT

Drain

3.84"

5.59"

17.59"

Model Number Dimensions

(w/o stand)

H"xW"xD"

2.63"

Condenser

Type

Refrigerant

7.93"

Charge

(R-404A)

Basic

Electrical

Minimum

Circuit

Ampacity*

GEMD790 45.80 x 35.20 x 27.31 Air 32 115/60/1 18.1 25

*Minimum circuit ampacity is used to determine wire size and type per National Electric Code. Options: Machine stand GEMD5 or GEMD7.

Page 2

Max. Fuse

Size

FOR THE INSTALLER

GEMD790

Location

This ice system is designed to be installed indoors, in a controlled environment.

Minimum Maximum

Air Temp 50 Water Temp 40

F. 1000F.

F. 1000F. Water Pressure 20 psi 80 psi Voltage 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.

Service Limitations

Do not install in a location where the top of the machine is within 6" of a fixed ceiling. Air cooled models require a minimum of 6 inches to the left and right of the machine for air circulation. It is important that the machine be installed in a location where it has enough space above and behind it for service.

After uncrating and inspection, the unit is ready for installation.

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 base of the machine. Secure the machine stand to the base with 4 5/16" bolts.

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. Connect the sink drain to the dispenser drain system.

Airflow

SEAL

ICEMAKER-

DISPENSER TO

THE COUNTER

TOP OR

MACHINE STAND

Page 3

GEMD790

FOR THE PLUMBER

CONFORM TO ALL APPLICABLE CODES

Water Inlet

Air Cooled Models: Connect a clean, potable

and cold water supply to the back of the cabinet. Install a hand valve near the machine to control the water supply. Use copper tubing.

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: Connect a separate O.D. copper line, with a separate hand valve to

control it, to the

” FPT condenser inlet at the

back of the cabinet. The water pressure to all lines must always be above 20 psig, and below 120 psig.

” male flare at the

” O.D.

”

INLET WATER

Drains

Air Cooled Models: Connect a drain tube to the

one ¾” FPT drain fitting (plastic) at the back of the cabinet, the drain line is of the gravity type, and ¼ 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 ¾” rigid tubing.

WATER COOLED

CONDENSER

WATER INLET

CONDENSER

DRAIN

Water Cooled Models: In addition to the above

mentioned drain, a separate condenser drain line must be installed. Connect it to the ½ " condenser drain connection at the back of the cabinet.

VENTED

DRAIN

OPTIONAL

WATER

FILTER

SHUT OFF VALVE

FLOOR DRAIN

Page 4

FOR THE ELECTRICIAN

CONFORM TO ALL APPLICABLE CODES

Connect the electrical power supply for the unit to the wires in 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.

GEMD790

POWER SUPPLY

ELECTRICAL

CONNECTION

Page 5

GEMD790

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 service disconnect 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?

ELECTRICAL?

LEVELED?

6. Is there a minimum of 6 inches of clearance at the top and back of the machine for service and utility connections?

7. Is there a water shut off valve installed near the machine?

8. Have all of the shipping blocks been removed?

WATER

INLET?

DRAINS?

Page 6

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 mode switch to ON. The auger drive motor and compressor start, beginning the ice making process.

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.

GEMD790

7. Check ice dispensing by pushing in on the glass filler lever. Ice dispenses are portion controlled; by turning a knob, the length of time the unit dispenses when the glass filler lever is pushed (and the amount of ice dispensed) is adjusted.

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 with a locally approved sanitizer. A possible sanitizer is a mixture of 1 ounce of household bleach to 2 gallons of water. Wash the interior of the bin with the sanitizing solution. Replace all covers and panels. Switch the icemaker-dispenser back on.

5. The unit should soon be making ice. If desired, the low side pressure may be checked: it should be 38 PSIG + or - 4 PSIG.

The air cooled discharge pressure will depend upon air and water temperatures, but should be between 200 PSIG and 300 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.

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.

Page 7

GEMD790

COMPONENT DESCRIPTION

ICE LEVEL SENSOR

EVAPORATOR

DRAIN

TUBE

RESERVOIR

WATER

LEVEL

SENSOR

ICE STORAGE BIN

CONTROL BOX

CONDENSER

PRESSURE

CUT OUT

Control Box: Contains the electrical controls that

operate the machine. High Pressure Cut Out Switch: An automatic

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.

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 icemaking will stop. Ice is dispensed through a chute at the bottom front when the agitator assembly sweeps the ice through the chute.

Page 8

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