Ice-O-Matic ICEU300HA, ICE0520FA, ICE1506HR, ICEU226FW, ICEU220HW User Manual

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SERVICE AND INSTALLATION MANUAL

Part Number 9081270-01

Date 9/10

THE ICE SERIES CUBERS

ICE0250 through ICE2100 SERIES*

*Includes Undercounter and 22 Inch Series

Ice-O-Matic 11100 East 45th Ave Denver, Colorado 80239

ICE Series Notes

Table of Contents

Table of Contents Page A1 General Information

How To Use This Manual Page A2 Model And Serial Number Format Page A3 Electrical And Mechanical Specifications Page A5-A8 Installation Guidelines Page A9 Electrical And Plumbing Requirements Page A10-A17 Remote Condenser Installation Page A18-A19 How The Machine Works Page A20 Undercounter Model Bin Removal Page A21-A22 Warranty Information Page A23-A24

Scheduled Maintenance

Maintenance Procedure Page B1 Cleaning and Sanitizing Instructions Page B1-B2 Winterizing Procedure Page B3 Cabinet Care Page B4

Troubleshooting Trees

How to Use The Troubleshooting Trees Page C1 Troubleshooting Trees Table Of Contents Page C2 Troubleshooting Trees Page C3-C18

Water System

Water Distribution And Components Page D1-D5

Refrigeration System

Refrigeration Cycle And Components Page E1 Harvest Cycle Page E5 Remote System Page E5-E6 Pump Down System Page E7 Refrigerant Specifications Page E8-E20

Electrical System

Control Circuit Page F1 Compressor And Start Components Page F1-F2 Untimed Freeze Cycle Page F3 Timed Freeze Cycle Page F4 Harvest Cycle Page F5-F9 Pump Down System Page F9 Wiring Diagrams Page G1

ICE Series Table Of Contents

Table of Contents

Table of Contents Page A1 General Information

How To Use This Manual Page A2 Model And Serial Number Format Page A3 Installation Guidelines Page A5 Electrical And Plumbing Requirements Page A6-A13 Remote Condenser Installation Page A14-A15 How The Machine Works Page A16 Undercounter Model Bin Removal Page A17-A18 Warranty Information Page A19-A20

Scheduled Maintenance

Maintenance Procedure Page B1 Cleaning and Sanitizing Instructions Page B1-B2 Winterizing Procedure Page B3 Cabinet Care Page B4

Troubleshooting Trees

How to Use The Troubleshooting Trees Page C1 Troubleshooting Trees Table Of Contents Page C2 Troubleshooting Trees Page C3-C18

Water System

Water Distribution And Components Page D1-D5

Refrigeration System

Refrigeration Cycle And Components Page E1 Harvest Cycle Page E5 Remote System Page E5-E6 Pump Down System Page E7

Electrical System

Control Circuit Page F1 Compressor And Start Components Page F1-F2 Untimed Freeze Cycle Page F3 Timed Freeze Cycle Page F4 Harvest Cycle Page F5-F9 Pump Down System Page F9 Electrical Sequence ICE1400-2100 Version 3 Page F10 Wiring Diagrams Page G1

Cuber Performance Data Page H1 Specifications Page I1

Page A1

ICE Series General Information

How To Use This Manual

Ice-O-Matic provides this manual as an aid to the service technician in installation, operation, and maintenance of the ICE Series (electro-mechanical) cube ice machines. If used properly this manual can also assist the service technician to troubleshoot and diagnose most of the problems that may occur with the machine.

The first two sections of this manual provide general information and maintenance information. The remainder of the manual beginning with Section C provides troubleshooting and service information. Section C contains flow charts called troubleshooting trees. Page C-1 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 with 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 malfunctioning. A detailed description of the operation and adjustments of the components as well as other service information is available in the pages that follow Section C.

Sections D, E, and F focus on a particular system in the ice machine: water distribution system, refrigeration system, and it is important that these sections be used together with the Troubleshooting Trees in Section C.

Most aspects of the ICE Series 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. You may also fax, e-mail or write the Ice-O-Matic Technical Service Department:

Ice-O-Matic 11100 E. 45th Ave. Denver, Co. 80239 Attn: Technical Service Department E-Mail: Tech.service@iceomatic.com

Telephone Numbers Any Service communication must include: 800-423-3367 All Department • Model Number 888-349-4423 Technical Assistance Only • Serial number 303-371-3737 • A detailed explanation of the problem

Note the warning symbol where it appears in this manual. It is an alert for important safety information on a hazard that might cause serious injury. Keep this manual for future reference.

The ICE Series Service Parts Manuals are available separately.

Ice-O-Matic products are not designed for outdoor installation.

Page A2

ICE Series General Information

Model and Serial Number Format Model Numbers

040 0 H A

ICE

Cube Size: H=Half (3/8 X 7/8 X7/8) F=Full (7/8 X 7/8 X7/8) Voltage: 0=115V 5=240/50/1 6=208-230/60/1 7=208-230/60/3 Approximate 24 hour ice production: (x 10 @ 70°F/21°C Air and 50°F/10°C Water) Series: Slab ice cuber, Stainless Steel Cabinet

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

1990-1999 MONTH 2000-2004 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.

Reference new serial number format on next page.

Condenser Type: A=Air W=Water R=Remote T=Top Discharge Air Cooled

Page A3

ICE Series General Information

Model and Serial Number Format

Sample Only

This format is 14 characters long and begins with a date code followed by the Ice-O-Matic identifier, and then a sequential number. This is an entirely numerical serial number.

The new serial number will look like the example. 0407 1280 010123

010123 is the serial identifier. 1280 is the identifier. (Ice-O-Matic)

0407 is the date code, in YYMM format. (2004 July)

The date code will change monthly and yearly to reflect the date of manufacture.

Large data plate will be placed on the back of the unit.

Small data plate will be placed by the service

valves.

Page A4

ICE Series 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 outdoor installation. Incoming Water Supply (See Plumbing Diagram for line sizing Page A6-A13)

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: All drain lines must be installed per local codes. Flexible tubing is not recommended.

Route bin drain, purge 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 at the rear, top, and sides of the ice machine for proper air circulation. Stacking: If the ice machines are to be stacked, refer to the instructions in the stacking kit.

Ice-O-Matic does not endorse stacking air-cooled ice machines. Dispenser Application: A thermostatic bin control kit must be installed if the ICE Series ice

machine is placed on a dispenser. A bin top may or may not be required. (Exception is the

CD400 Dispenser) Electrical Specifications: Refer to the serial plate at the rear of the ice machine or the charts

starting on page H1.

Adjustments

Level the machine within 1/8 inch in all directions. Check the bin control for proper adjustment, Page F9 Check the water in the water trough for proper level, Page D1 Check the ice bridge for proper thickness, Page F4 Check the cam switch adjustment. Page F8 Check the water regulating valve adjustment if water cooled, Page E2

Page A5

ICE Series General Information

Electrical and Plumbing Requirements: ICEU150, ICEU200, ICEU205 and ICEU206

Page A6

ICE Series General Information

Electrical and Plumbing Requirements: ICEU150, 220, 225 and 226

ICE MAKER WATER-IN 3/8 FPT OR 1/4 Male Flare

Note: The ICEU150, ICEU220, ICEU225 and ICEU226 do not have a splash curtain.

These models utilize a thermostatic bin control in place of a mechanical bin switch.

Page A7

ICE Series General Information

Electrical and Plumbing Requirements: ICEU300 and 305

ICE MAKER WATER-IN 3/8 FPT OR 1/4 Male Flare

Note: The ICEU300 does not have a splash curtain.

This model utilize a thermostatic bin control in place of a mechanical bin switch.

Page A8

ICE Series General Information

Electrical and Plumbing Requirements: ICE0250, ICE0400, ICE0500, ICE0606, ICE0806 and ICE1006 (30 Inch Wide Cubers)

Page A9

ICE Series General Information

Electrical and Plumbing Requirements: ICE1406, ICE1806, ICE2106 (48 Inch Wide Cubers) Prior to January 2008

Page A10

ICE Series General Information

Electrical and Plumbing Requirements: ICE0320 and ICE0520 (22 Inch Wide Cubers)

Page A11

ICE Series General Information

Electrical and Plumbing Requirements: ICE1400, ICE1800 and ICE2100 Revision 3 (From January 2008)

Page A12

ICE Series General Information

Electrical and Plumbing Requirements: ICE1506 Remote

Page A13

ICE Series General Information

Remote Condenser Installation

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.

Installation Guidelines

Ambient operating temperatures: -20°F (-28.9°C) to 120°F (48.9°C) Maximum refrigerant line length: 60 ft. (18.29 Meters) Maximum vertical rise: 16 ft. (4.88 Meters) Minimum condenser height: ICE Series ice machine remote condensers must not be

installed more than 6 feet (1.3 meters) below the refrigerant line quick connects at the rear of the ice machine. No part of the refrigerant lines, between the ice machine and the remote condenser, should fall below this point. Condensers must have a vertical airflow.

Air Flow

Page A14

ICE Series General Information

The following 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.

ICE Machine Model Number Remote Condenser Model Number

ICE2100R3&4 VRC5061B ICE1800R3&4 VRC5061B ICE1400R3&4 VRC2661B ICE1506HR2&3 VRC2661B ICE1006R3&4 VRC2061B ICE0806R3&4 VRC2061B ICE0606R3&4&5 VRC1061B ICE0500R3&4 &5 VRC1001B

Limitations for new remote machines that have the mixing valve 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

35 ft. rise

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 condenser for compatibility. For more information contact your Ice-O-Matic Distributor.

34 ft. horizontal

10 ft. drop x 6.6 + 34 ft horizontal = 100 equivalent feet line run

Page A15

10 ft. drop

ICE Series General Information

How the ICE Machine Works

A general description of how the ICE Series cubers work is given below. The remainder of the manual provides more detail about the components and systems.

With the ICE/OFF/WASH switch in the ICE position, the compressor, water pump and condenser fan motor (when applicable) will energize starting the freeze cycle.

During the freeze cycle, water is circulated over the evaporator(s) where the ice cubes are formed. When the suction pressure has pulled down to the proper cut-in pressure of the timer initiate (pressure control), the contacts will close and energize the time delay module (timer). See Page F3 for proper cut-in pressures. At this time the cubes will close to completion.

The remaining portion of the freeze cycle is determined by the timer setting. The timer is pre-set at the factory to achieve the proper ice bridge thickness but may need to be adjusted upon initial start-up, see Page F4 for initial timer settings.

Once the amount of time on the timer has passed, the control relay will be energized and the machine will enter harvest. Power is now supplied to the water purge valve, hot gas valve, and the harvest motor. The water purge valve opens, and allows the water pump to purge the water remaining in the water, removing impurities and sediment. This allows the machine to produce clear ice cubes and keep mineral build up at a minimum. The hot gas solenoid opens allowing hot gas to go directly to the evaporator, heating the evaporator and breaking the bond between the evaporator and the ice slab.

The harvest assist motor, which is also energized during harvest, turns a slip clutch, which pushes a probe against the back of the ice slab. Once the evaporator has reached approximately 40°F (4.5°F) in temperature, the slip clutch overcomes the bonding of the ice to the evaporator and pushes the slab of ice off of the evaporator and into the storage bin. The clutch also actuates a switch that rides on the outer edge of the clutch. When the clutch completes one revolution, the switch is tripped and the machine enters the next freeze cycle.

When ice drops into a full bin during harvest, the splash curtain is held open which activates a bin switch shutting the machine off. When ice is removed from the bin, the splash curtain will close and the machine will come back on.

Page A16

ICE Series General Information

Undercounter Bin Removal-ICEU300 and ICEU150-220 (From 6/08) Series

The storage bin can be removed by: 1 Remove the lower grill.

2. Remove two screws securing bin to cabinet base.

3. Remove the thumbscrews from the back wall of the bin.

4. Disconnect bin drain.

5. Lift front of bin slightly and pull bin forward to remove.

Page A17

ICE Series General Information

Undercounter Bin Removal-ICEU150/200 Series (Prior to 6/08)

The storage bin can be removed by:

1. Remove the two screws at the rear of the top panel.

2. Remove the two screws from the front panel.

3. Remove two screws securing bin to cabinet base.

4. Disconnect bin drain.

5. Lift front of bin slightly and pull bin forward to remove.

Page A18

ICE Series General Information

Warranty Information

Every Ice-O-Matic machine is backed by a warranty that provides both parts and labor coverage.

PARTS LABOR

Two years on all parts* Two years on all components* Three years on all ICE Maker parts* Three years on all cube ICE Maker components* Five years on compressors* Five years on cuber evaporators*

Water Filtration System Extended Warranty Program

Purchase a new Ice-O-Matic IFQ or IFI Series Water Filtration System with a new ICE Series ICE Machine, replace the filter cartridge every 6 month and Ice-O-Matic will extend the limited cuber evaporator warranty to 7 years parts and labor.

•New machine and filter must be installed at same time.

•Must send in both the machine and water filter registration cards within 10 days of

installation.

•Must send in additional registration card for each new filter installed. This must be done every 180 days (6 months) or less.

•Program is available with all IFQ and IFI filter systems.

•Replacement filter must be model number IOMQ or IOMWFRC.

•Available in the USA and Canada only.

Warranty If, during the warranty period, customer uses a part for this Ice-O-Matic equipment other than an unmodified new part purchased directly from Ice-O-Matic, Ice-O-Matic Distributors, or any of its authorized service agents and/or the part being used is modified from its original configuration, this warranty will be void. Further, Ice-O-Matic and its affiliates will not be liable for any claims, damages or expenses incurred by customer which arises directly or indirectly, in whole or in part, due to the installation of any modified part and/or part received from an unauthorized service center. Adjustments are not covered under warranty.

Warranty Procedure Matic authorized representative travels to the installation address to perform warranty service, the service representative will advise customer the warranty is void. Such service call will be billed to the customer at the authorized service center’s then-applicable time and material rates.

If the customer is using a part that results in a voided warranty and an Ice-O-

Page A19

ICE Series General Information

•

Ice-O-Matic

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” and “EMF” model 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 compressors, “GEM” model compressed ice machine compressors, and “MFI” model flake 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 “EF” and “EMF” model flake ice machine compressors from the date of original installation. The company 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 d amage caused by unauthori zed 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 nondefective 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 Companyauthorized 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 sh ipped from the Company after January, 2007. 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 n ot 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 DURATI ON 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 ser vice 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 elec t 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 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 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.

Mile High Equipment LLC, 11100 East 45

Parts and Labor

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)

to be eligible for credit. All claims outside

Avenue, Denver, Colorado 80239 (303) 371-3737

January 2007

Page A20

ICE Series Scheduled Maintenance

Maintenance

Note: Maintenance should be performed by an Ice-O-Matic trained Service Technician. Electrical shock and/or injury from moving parts inside this

machine can cause serious injury. Disconnect electrical supply to machine prior to performing any adjustments or repairs.

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 machine, the following maintenance is required every 6 months.

Maintenance Procedure

1. Clean the ice-making section per the instructions below. Cleaning should be performed a minimum of every 6 months. Local water conditions may require that cleaning be performed more often.

2. Check ice bridge thickness. See page F4 for proper thickness and adjustment procedure.

3. Check water level in trough. See page D1 for proper water level and adjustment.

4. Clean the condenser (air-cooled machines) to insure unobstructed air flow.

5. Check for leaks of any kind: Water, Refrigerant, Oil, Etc.

6. Check the bin switch for proper adjustment. See page F9 for bin switch adjustment.

7. Check the cam switch adjustment. See page F8 for cam switch adjustment.

8. Check the water valve (water-cooled machines) for proper adjustment. See page E2.

9. Check all electrical connection.

10. Oil the fan motor if the motor has an oil fitting. (Self contained air-cooled models only)

Cleaning and Sanitizing

1. Harvest problems may occur if the following procedures are not performed every 6 months.

2. Remove the ice machine front panel.

3. Make sure that all the ice is off of the evaporator. If ice is being made, wait for cycle completion, then turn the machine “OFF” at the ICE/OFF/WASH selector switch.

4. Remove or melt all ice in the storage bin.

Page B1

ICE Series Scheduled Maintenance

Cleaning and Sanitizing (continued)

5. Add recommended amount of approved Nickel Safe ice machine cleaner to the water trough according to label instructions on the container.

6. Initiate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “WASH” position. Allow the cleaner to circulate for approximately 15 minutes to remove mineral deposits.

7. Depress the purge switch and hold until the ice machine cleaner has been flushed down the

drain and diluted by fresh incoming water.

8. Terminate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “OFF”

position. Remove the splash curtain and inspect the evaporator and water spillway to assure all mineral residue has been removed.

9. If necessary, wipe the evaporator, spillway and other water transport surfaces with a clean soft

cloth to remove any remaining residue. If necessary, remove the water distribution tube, disassemble and clean with a bottlebrush, see page D2. Reassemble all components and repeat steps 4 through 7 as required to remove residue.

10. Turn OFF ice machine water supply and clean the water trough thoroughly to remove all scale or slime build-up. If necessary, remove the water trough to reach all splash areas and float.

11. Prepare 1½ to 2 gallons (5.7 to 7.5 liters) of approved (EPA/FDA) sodium hypochloride food equipment sanitizer to form a solution with 100 to 200 ppm free chlorine yield.

12. Add enough sanitizing solution to fill the water trough to overflowing and place the ICE/OFF/WASH switch to the “WASH” position and allow circulation to occur for 10 minutes and inspect all disassembled fittings for leaks. During this time, wipe down all other ice machine splash areas, plus the interior surfaces of the bin, deflector and door with the remaining sanitizing solution. Inspect to insure that all functional parts, fasteners, thermostat bulbs (if used), etc. are in place.

13. Depress the purge switch and hold until sanitizer has been flushed down the drain. Turn ON the ice machine water supply and continue to purge to the diluted sanitizing solution for another 1 to 2 minutes.

14. Place the ICE/OFF/WASH switch to the “ICE” position and replace the front panel.

15. Discard the first two ice harvests.

Page B2

ICE Series 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 off of the evaporator(s). If ice is being made, initiate harvest or wait for cycle completion.

3. Place the ICE/OFF/WASH switch to the “OFF” position.

4. Disconnect the tubing between the water pump discharge and water distribution tube.

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.

Page B3

ICE Series 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 cloth. and scale. Rinse with clean water and

dry.

Page B4

ICE Series 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 (Hexagon) 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

ICE Series Troubleshooting Trees

Troubleshooting Trees Table Of Contents

Machine Does Not Run C3 Machine Runs, Does Not Make Ice C4 – C5 Slow Production (Cube Formation Good) C6 Low Suction Pressure C7 High Suction Pressure C8 Cubes Are Hollow C9 Uneven Bridge Thickness C10 Ice Bridge Thickness Varies Cycle To Cycle C11 Machine Produces Cloudy Ice C12 Poor Water Distribution Over Evaporator C13 Machine Does Not Enter Harvest C14 Machine Enters Harvest, Then Returns To Freeze Prematurely C15 Length Of Harvest Excessive C16 Ice Does Not Release From Evaporator C17 Hot Evaporator, Low Suction Pressure (Remote Only) C18

Page C2

ICE Series Troubleshooting Trees

Machine Does Not Run

Is the selector

switch set to

ICE?

Set selector

Switch to the

ICE position

YES NOT OK

Check for correct

power supply to the

Pressure Safety

Temperature Safety

machine

Check High

Control

Check High

Control

TRIPPED

OPEN

Correct field

wiring deficiency

Reset and

identify reason

for high head

pressure

Replace or identify reason for being open.

Check Bin Control

for proper

adjustment, see

page F9

GOOD

Is this a Remote

unit?

Is the Liquid line

Solenoid energized

and open?

BAD

NOT O

Adjust as

required or

replace if defective

Selector Switch

could be

defective, see

page F1

Find reason for

non-activity or

replace if defective

Page C3

ICE Series Troubleshooting Trees

Machine Runs, Does Not Make Ice

Is water

running over

the

evaporator?

Go to the

Troubleshooting

Tree on page

C12

Check High

Pressure reset if

necessary

YES GO TO PAGE C5

Check for power to

the compressor

YES

Is the

compressor

running?

GOOD

bad contactor or coil.

contactor coil

Does the unit

have a remote

condenser?

Check contactor for Replace if defective

Compressor or

Start

Components

could be

defective, see

page F2

Continue if the

machine has a

remote

condenser

Check the suction

pressure, is it low or

high?

LOW

Check refrigerant

charge

HIGH

Check Selector

Switch,

Replace if defective

Pumpdown

Control possibly

bad

Liquid Line

Solenoid not

opening

Page C4

ICE Series Troubleshooting Trees

Machine Runs, Does Not Make Ice (continued)

Is water

leaking out of

the Purge

Drain or Water

Trough?

YES

Repair water

leakage defect

Check refrigerant

pressures, see page

LOW SUCTION OK

Recover and weigh

in refrigerant charge

Low side

restriction or

defective TXV

HIGH OR NORMAL SUCTION

If head pressure is

also high, make sure

Condenser is clean

and machine has

good air flow

Check Hot Gas

Valve for leakage

during freeze, see

page E5

Check for inefficient

Compressor

Page C5

ICE Series Troubleshooting Trees

Slow Production (Cube Formation Good)

Does

installation

meet

guidelines?

Correct any

installation

defects

YES

Check for excessive

head pressure

TOO HIGH

Is this unit air

cooled or

water cooled?

AIR

Condenser

Is the Air

clean?

Check refrigeration

system, Section E

YES

Check refrigeration

system, Section E

WATER

Check Water

Regulating Valve,

See page E2

See Condenser

service information

page E2

NOT OK

Clean Condenser and Condenser Fan

Blade

Adjust or

replace Water

Regulating

Valve

Page C6

ICE Series Troubleshooting Trees

Low Suction Pressure

Does

installation

meet

guidelines?

YES

Is the water

flow over the

Evaporator

correct?

YES

Check for correct

head pressure, see

page E10

NOT OK

Is the

machine a

remote unit?

YES

Correct

deficiency in

installation

Go to

Troubleshooting

Tree on page

C12

Low charge,

locate and

repair leak,

evacuate and

recharge

system

Check TXV for

moisture based

restriction

WET SYSTEM

Replace drier, evacuate and

recharge

system

See

Troubleshooting

Tree page C18

DRY SYSTEM NOT OK

Check for refrigerant

tubing restriction,

Check Evaporator

coil separation, see

crimps, etc.

NOT OK

page E4

TXV possibly

defective, see

page E3 and

page E4

Correct

restricted tubing

Replace

defective

Evaporator

Page C7

ICE Series Troubleshooting Trees

High Suction Pressure

Have you

checked the

“Slow

Production”

Tree?

Is the head

pressure also

high?

Is the machine

installed to

specifications?

YES

Correct

installation

defects

Go to “Slow Production”

Troubleshooting

Tree

Check Hot Gas

Valve, see page E5

NOT OK

Hot Gas Valve

is possibility

defective

Replace

Compressor

NOT O

Check Compressor,

see page E1

TXV could be

defective, see

Expansion

Valve, see page

E3 and E4

YES

Is the

Condenser

dirty?

Check for leaking

Purge valve

YES

Repair or

replace

defective part

Clean the

Condenser

OK OK

Check Condenser

Fan Motor and

Blade for proper

operation, and/or

Water Valve or

Mixing Valve

NOT OK

TVX Thermal

bulb loose or

TXV could be

defective

STILL TOO HIGH

Evacuate and

recharge system

Page C8

ICE Series Troubleshooting Trees

Cubes Are Hollow

Is the water

temperature

above 100°F

(38°C)?

YES

Water

temperature too

high, correct

water

temperature

Is there good

water flo w

over the

Evaporator?

Go to the “Poor

Water Distribution

Over Evaporator”

Troubleshooting

Tree, page C13

YES

Is water

leaking from

the Purge

Drain?

Check Timer for

proper setting, see

page F4

NOT O

Timer Initiate Control out of adjustment of

defective

YES

Purge Valve has

an obstruction

or could be

defective

Timer Module

requires

adjustment or

could be

defective

Page C9

ICE Series Troubleshooting Trees

Uneven Bridge Thickness

Make sure

supply water

temperature is

below 100°F

(38°C)

Check for water

leaking out of Purge

Drain

Dirty or

defective Purge

Valve

Is water

running into

the bin?

Are the

Evaporator(s)

flooded? See page E4 and

Check the suction

pressure, is it high or

low? See pageE1

YES

HIGH

Problem in water syst em, see pages D1

and D2.

Serpentine coil

on back of

evaporator

could be

separated, see

page E4

Hot Gas Valve

could be

leaking, see

page E5

LOW

Make sure the

system is charged

properly, recover the

charge and weigh in

the correct amount

Refer to page

E3 and E4 for

TXV diagnosis.

Page C10

ICE Series Troubleshooting Trees

Ice bridge Thickness Varies Cycle To Cycle

Is air and

water temps

consistent and

within

guidelines?

YES

Check the Purge

Valve for water leaks

Check Hot Gas

valve for proper

operation

NOT OK

Correct

installation

deficiency

Clean Purge

Valve or replace

if defective

Replace Hot

Gas Valve

Check Timer Initiate

Control for proper

operation

Check Solid State

Timer for proper

operation

TXV(s) could be

defective, see

page E3 and E4

NOT OK

Replace Timer

Initiate

Adjust Timer or

replace if defective

Page C11

ICE Series Troubleshooting Trees

Machine Produces Cloudy Ice

Is water

running evenly

across the

evaporator?

YES

Doe machine

meet

installation

guidelines?

See Section A

YES

Cloudiness is a

result of properties

in the incoming

supply water

See “Poor

Water Running

Over Evaporator

Troubleshooting

Tree page C13

Correct

installation

deficiency

Page C12

ICE Series Troubleshooting Trees

Poor Water Distribution Over The Evaporator

Is the machine

level?

Level the

machine

YES

OBSTRUCTED CLEAR

Is the water

level in the

Water Trough

correct? See

Section D

YES

Check Water

Distribution Tube for

obstructions or

improper assembly

See Section D

Is the supply

water

pressure

correct?

Is water

leaking from

the Purge

Drain?

YES

Correct deficiency in supply water

pressure

Purge valve

stuck open,

clean or replace

if defective

Float Valve not

adjusted

properly or

could be

defective

Clean Water

Distribution

Tube; insure

that it is

assembled

correctly

Check Water Pump

for proper operation

BAD

Water Pump

obstructed or

may be

defective

GOOD

Clean

Evaporator and

Spillway. See

Section B for

cleaning

instructions

Page C13

ICE Series Troubleshooting Trees

KOK

Machine Does Not Enter Harvest

Will suction

pressure drop below cut-in of Timer Initiate?

YES

Does the

manual Purge

Switch

energize the

Purge Valve?

Is the freeze

pattern on the

Evaporator

even?

Check for signs of a

weak Compressor,

see page E1

YES

Check Timer Initiate

Control for correct

cut-in pressure

Check Purge Valve

to make sure it is not

leaking, if it is

replace valve or

remove obstruction

Make sure system is

not overcharged

NOT OK

Hot Gas Valve

could be leaking

TXV(s) may be

stuck open, see

page E3 and E4

Timer Initiate Control out of

adjustment or

may be

defective

High

Temperature Safety Control may be open,

see page F8

Check Timer

Number 1 for proper

setting and

operation

Check Timer

Number 2

Relay Number 1

or Relay Base

may be

defective

Page C14

NOT OK

Timer may be

defective

ICE Series Troubleshooting Trees

Machine Enters Harvest, Then Returns To Freeze Prematurely

Is the Harvest

Assist working

properly? See

page F6

Adjust as

required or

replace

defective part

YES

Check the Manual

Purge Switch

Normally Closed

contacts. See page

CLOSED

Check High

Temperature Safety

Control. See page

CLOSED

Relay 1 or relay

Base may be

defective

OPEN

Purge Switch is

defective

High

Temperature

Safety Control is

defective

Page C15

ICE Series Troubleshooting Trees

Length Of Harvest Excessive

Does the

machine meet

installation

guidelines?

YES

Check Harvest

Assist Assembly for

proper operation,

see page F6

NOT OK

Adjust or

replace

defective part

Correct

installation

deficiency

OK NO

Is the ice formation

even on the

Evaporator?

YES

Does the

machine have

a remote

condenser?

YES

Low refrigerant

charge, repair

leak and weigh

in proper charge

Remote: Check

Mixing Valve

operation, page E6

Water Cooled: check

Water Valve for

proper adjustment

Check suction

pressure during

harvest. See page

Clean Evaporator per instructions in

Section B

TOO LOW

STILL TOO LONG

Hot Gas Valve

may be

defective

Go to “Ice Does

Not Release”

Troubleshooting

Tree, page C17

Page C16

ICE Series Troubleshooting Trees

Ice Does Not Release From Evaporator

Is the ice

bridge

correct? See

page F4

Set proper

bridge

thickness, see

page F4

Check Purge valve

and Tubing for

obstructions and

proper operation,

see page D2

YES

NOT OK

Is the machine

level?

YES

Does water

run over the

Evaporator

during

harvest?

Replace Purge Valve or repair

tubing

obstruction

Clean the

Evaporator, see

page B2

Level the

machine

Check Harvest

Assist for proper

operation, see page

NOT OK

Repair Harvest

Assist as

required

Check Relay 1 and

Relay Base for

proper operation,

see page F5

Selector

Switch may be

defective,

WASH contacts

closed in ICE

mode

Relay or Relay Base defective

Check suction

pressure during

harvest, see page

TOO LOW

Check discharge

pressure during

freeze, see page E2

TOO LOW

Low ambient or

Water regulating

Valve set too

low

GOOD

Evaporator may

be defective, see page E4

and E5

Hot Gas valve

may be

restricted or

defective, see

page E5

Page C17

ICE Series Troubleshooting Trees

Hot Evaporator, Low Suction And Discharge Pressure (Remote Only)

Does the

machine meet

the installation

guidelines?

YES

Does the

machine have

the proper

refrigeration

charge?

YES

Correct

installation

deficiency

Mixing Valve

may be

defective, see

page E6

Repair leak,

evacuate and

weigh in

refrigerant

charge per

nameplate

Page C18

ICE Series Water System

Water Distribution and Components

Water enters the machine through the float valve located in the water trough. The water trough holds water used for ice making. The float valve is used to maintain the proper water level in the water trough. During the freeze cycle water is continuously circulated over the evaporator by the water pump. When the machine enters harvest, the purge valve (not shown) opens and mineral laden water is pumped out of the water trough to the drain. After water is purged from the trough, the water pump and purge valve are de-energized and the trough refills.

Float Valve

The water level can be adjusted by carefully bending the arm of the float. The water level should be ½ inch (13mm) above the top of the water pump impeller housing during the freeze cycle.

If the float valve does not allow water into the trough or water flow is slow, the float valve may be restricted. Remove and disassemble the float valve and clean the orifice. If the water flow is still slow, check the water pressure to be sure it is at least 20 PSI (1.4 bar).

If the float valve does not stop the water flow, make sure the water pressure to the machine does not exceed 60 PSI (4.1 Bar). Install a water pressure regulator if the pressure is too high. If the water pressure is not the problem, the float plunger or the entire float valve assembly may need to be cleaned or replaced.

Page D1

ICE Series Water System

Water Distribution Tube

Water is pumped to a distribution tube located at the top of the evaporator and is used to distribute water evenly over the evaporator. The distribution tube can be removed and dissembled for cleaning if the hole becomes plugged or if there is excessive mineral build-up in the water system. The water distribution tube is a tube within a tube. Water enters and fills the inner tube and exits through a series of holes along the top of the inner tube. Water then fills the outer tube and exits through a series of holes along the bottom of the outer tube. For proper water flow over the evaporator, it is important that the tube be assembled correctly after cleaning. The tube can be checked for proper assembly by checking the “bump” on the flanges at the tube ends, the “bump” should be at the top.

Water Distribution Disassembly

Remove 2 screws holding the distribution tube to the evaporator spillway. Remove the clamp holding the water tube to the distribution tube. Twist the end caps of the distribution tube counterclockwise and pull to remove the inner tube halves from the outer tube. To reassemble, push the inner tube halves into the outer tube with the holes facing the same direction. Make sure the inner tube halves seat together completely. Twist the end caps clockwise ½ turn to lock the inner tubes in place. The holes in the tubes will now be facing in the opposite directions. e directions.

Important! For proper water flow over the evaporator, the inner tube holes must face up. Important! For proper water flow over the evaporator, the inner tube holes must face up.

Turn counterclockwise to remove

Page D2

ICE Series Water System

Water Splash Curtain

The water splash curtain covers the evaporator to prevent water from splashing into the bin and is also used to actuate the bin switch. When the bin becomes full of ice, the splash curtain is held open when the ice drops off of the evaporator. The actuator tab or wire bale on the splash curtain will release pressure on the bin switch and the machine shuts off. See bin control on page F9.

On single evaporator units, the splash curtain can be opened or removed during the freeze cycle and the machine will continue to run until the ice drops from the evaporator. On dual evaporator units, if the curtain is opened or removed during the untimed freeze cycle, or during defrost, the machine will shut down. If the curtain is opened or removed during the timed freeze cycle, the unit will continue to operate.

The splash curtain can be removed by swinging the bottom of the curtain away from the evaporator and lifting the right side of the curtain up and out of the hinge pin slot. To reinstall the curtain, position the left side pin into the slot first, then insert the right hand side with the actuator tab of the curtain behind the bin switch.

Note: The ICE0250 and ICE0305 utilize a curtain-retaining clip. The ICE Undercounter Series ice machines do not

utilize a splash curtain.

Proper position of wire bale switch actuator

Water splash curtain actuator tab positioned behind bin switch

Page D3

ICE Series Water System

Water Purge Valve

When the machine enters the harvest cycle, the water pump continues to run and the purge valve opens. This allows mineral laden water to be pumped from the water trough to the drain. This helps keep the water system clean. The water pump and purge valve de-energizes once the water is flushed from the water trough. The cam switch controls the length of time that the water pump and purge valve remains energized see page F7. The purge valve can also be energized manually by pushing the purge switch. The purge switch is used when cleaning the water system to flush cleaning solution down the drain. See page B1 for cleaning instructions.

The purge valve must be completely closed during the freeze cycle. If water leaks through the purge valve during the freeze cycle, the freeze cycle will be extended due to the float allowing warm water into the trough and poor ice formation will result. The purge valve may be defective or need cleaning.

The purge valve can be disassembled for cleaning by:

1. Disconnect electrical power form the ice machine.

2. Lift and remove the coil retainer cap.

3. Leave the coil wires attached to the coil and lift coil from the valve body. (Note coil orientation)

4. Rotate the enclosing tube ¼ turn counterclockwise to remove.

5. Remove the enclosing tube, plunger and diaphragm from the valve body

6. Reverse procedure to reassemble. The purge valve can be easily cleaned or rebuilt without

removing the entire valve body. Dirty or clogged purge valves are not considered a warranty repair.

Coil Cap Enclosing Tube Diaphragm

Coil Plunger Body

Page D4

ICE Series Water System

Water Trough

The water trough can be easily removed by the following procedures:

1. Disconnect power to the ice machine.

2. Shut the water supply off to the ice machine.

3. Remove water splash curtains when applicable.

4. Remove water trough mounting screws.

5. Carefully remove water trough from the ice machine.

6. Reverse procedure to reassemble.

Mounting Screws

ICE 30 Inch Wide Models

ICE 22 Inch Wide Models

ICEU150/200 Models

Mounting Screws

ICE 48 Inch Wide Models

Version 3 Water Trough

Mounting Screws

ICEU300

ICE1506 Model

Page D5

ICE Series Refrigeration System

Refrigerant Cycle and Components

Before diagnosing the refrigeration system, it is very important that the refrigerant charge be correct. Whenever the refrigeration system has been opened, the filter-drier must be replaced and the proper refrigerant charge must be weighed in. See refrigerant charge data on page A5–A8.

Refrigerant Pressures

The suction pressure at the beginning of the freeze cycle can vary +/- 10 psi (.7 bar) depending on operating conditions. Reference Chart on page I1-I6. Pressures less than this may indicate an undercharge. The discharge pressure on water-cooled units should be 250 psi (17.01 bar) for R404a units and 150 psi (10.21 bar) for R134a units. The discharge pressure on air cooled units will vary with ambient conditions but will typically run higher than water cooled units. Remote condensers located in ambient temperatures below 70°F (21°C) will typically run a lower discharge pressure. See Mixing Valve later in this section.

Refrigerant in a gas state is pumped throughout the refrigeration system by a hermetic compressor to the condenser. Heat is removed from the refrigerant either by forced air movement through an air-cooled condenser or transferring heat from the refrigerant to water through a water-cooled condenser. The refrigerant changes to a liquid when cooled.

The refrigerant in a liquid state passes through a filter drier. The filter drier traps small amounts of moisture and foreign particles from the system. The filter drier must be replaced whenever the refrigeration system is opened or if the refrigerant charge has been completely lost.

Compressor

The compressor runs during the entire cycle. If the valves in the compressor are damaged, the compressor will be unable to pump refrigerant efficiently. Damaged valves are usually the result of another problem in the refrigeration system such as liquid refrigerant returning to the compressor, oil slugging or high head pressure. When a compressor is replaced it is important that the refrigerant charge be weighed in and the system checked for proper operation to prevent a repeat failure.

An inefficient compressor will usually have a higher than normal suction pressure at the end of the cycle. The freeze cycle will be longer than normal and/or the harvest cycle may be excessively long. Check the compressor amperage draw 5 minutes into the freeze cycle. If the compressor amp draw (Reference data plate on ice machine back panel) is less than 70% of rated full load amps, the compressor may be inefficient. These symptoms may also be caused by other problems, therefore it is important to use the troubleshooting trees when diagnosing a problem. See Electrical System for more information on the compressor and compressor start components.

Page E1

ICE Series Refrigeration System

Air Cooled Condenser (Self Contained)

The air condenser is located in the back of the cabinet. Air is pulled through the condenser by a fan motor and discharged through the right hand side panel. The ICE1400 has 2 fan motors and discharges through the right side and left side panels. The ICE Undercounter air intake and discharge is through the front panel. A top air discharge is available on the ICE250-ICE0606.

Do not block airflow as it will cause premature failure of the machine and will void the warranty.

Water Cooled Condenser

If the machine has been properly installed, the water flow through the condenser will be in a direction opposite the refrigerant flow. The water condenser supply pressure must be between 20 psi (1.4 bar) and 60 psi (4.1 bar). A water-regulating valve is used to control the flow of water into the condenser. In areas that have poor water quality, the condenser may eventually become coated with mineral deposits. This will decrease the efficiency of the condenser resulting in high head pressure. Water cooled condensers replaced due to excessive mineral build up or freezing will not be covered under warranty.

Water Regulating Valve

The water-regulating valve controls the head pressure by regulating the amount of water flow through the condenser. The bellows of the regulating valve are connected to the high-pressure side of the refrigeration system. As the head pressure rises, the bellows expand increasing the water flow through the water condenser. Adjusting the spring pressure screw on top of the water valve can vary the rate of water flow. The valve should be adjusted to maintain a discharge pressure of 250 psi (17.01 bar) on R404a units and 150 psi (10.21 bar) on R134a units. Water exiting the condenser should be between 100°F (38°C) and 110°F (43°C). When the machine is off, the water valve will close completely, stopping the flow of water through the condenser. If the water flow does not stop when the machine is off, the valve may need cleaning or replaced.

Air Cooled Condenser (Remote)

See Pages E5 and E7

High Pressure Safety Control (Manual Reset)

If the discharge pressure becomes excessive, the high-pressure safety control will open and shut the machine off. The high-pressure safety control opens at 450 psi (30.62 bar) on R404a units and 250 psi (17.01 bar) on R134a units. The high-pressure safety control is used on all water-cooled and remote units and select air-cooled units.

High Pressure Safety Control (Automatic Reset)

The automatic reset high pressure control opens at 450 psi (30.62 bar) and closes at 338 psi (23.00 bar). The high-pressure safety control is used on all water-cooled and remote units and select air-cooled units.

Page E2

ICE Series Refrigeration System

Thermostatic Expansion Valve (TXV)

The thermostatic expansion valve meters the flow of refrigerant into the evaporator changing its state from a high-pressure liquid to a low-pressure liquid. This drop in pressure causes the refrigerant to cool. The cooled refrigerant absorbs heat from the water circulating over the evaporator. As the evaporator fills with liquid refrigerant, the evaporator becomes colder.

The flow of refrigerant into the evaporator is controlled by the temperature at the outlet of the evaporator. The expansion valve bulb, mounted to the top of the suction line, senses the evaporator outlet temperature causing the expansion valve to open or close. As ice forms on the evaporator, the temperature drops and the flow of refrigerant into the evaporator decreases, resulting in a drop in suction pressure.

The evaporator should become completely flooded (filled with liquid refrigerant) during the freeze cycle. A completely flooded evaporator will have a uniform freeze pattern (ice formation across the evaporator). A starved evaporator (not enough liquid refrigerant) will have poor or no ice formation at the top of the evaporator, and the tube(s) exiting the evaporator will not frost. All tubes should be within 10 degrees of each other and frosted approximately 5 minutes from the start of the freeze cycle.

An expansion valve that is restricted or not opening properly will starve the evaporator resulting in lower than normal suction pressure. A low refrigerant charge will also starve the evaporator and cause low suction and discharge pressures. If not sure of the amount of charge in the system, the refrigerant should be recovered and the correct charge be weighed in before a defective valve can be diagnosed.

If the evaporator is starved but the suction pressure is higher than normal, the TXV is not the problem; refer to the troubleshooting tree in section C. If the TXV sticks open or if the thermal bulb is not making good contact with the suction line, the flow of refrigerant into the evaporator will be too great and liquid refrigerant will flood the compressor. The suction pressure will remain higher than normal and the machine will remain in an extended freeze cycle. Ice will build evenly but will be very thick.

Symptom Problem Possible Remedy Evaporator flooded but suction 1 TXV thermal bulb not making 1 Tighten bulb clamp and pressure not dropping. good contact with suction insulate bulb. Compressor has been checked line or uninsulated and appears to be good. 2 TXV bulb installed incorrect 2 Locate bulb on top of Suction line at compressor may suction line be colder than normal 3 System overcharged 3 Recharge system 4 TXV stuck open 4 Replace TXV

Evaporator starved, no frost 1 Machine low on charge 1 Recover refrigerant on line(s) exiting evaporator. and weigh in proper Suction pressure is low. charge See Evap. Diagram Pg.E4 2 TXV restricted or stuck 2 Replace TXV and closed drier

Continued Page E4

Page E3

ICE Series Refrigeration System

Thermostatic Expansion Valve (Continued)

A dual evaporator machine will have one TXV for each evaporator. If one TXV sticks open and the other is operating normally, the suction pressure will be higher than normal and both evaporators will build thick ice. It is recommended that both valves be replace if one sticks open.

If one TXV sticks closed and one is operating normally, the suction pressure will be normal or low but the evaporator with the defective valve will be starved (thick ice at the bottom and thin ice at the top).

Evaporator

As water is circulated over the front of the evaporator, liquid refrigerant is circulated through the tubing attached to the back of the evaporator. As the liquid refrigerant in the tubing vaporizes, it absorbs heat from the water causing the water to freeze. The evaporator should be completely flooded throughout most of the freeze cycle. A flooded evaporator will build ice evenly across the evaporator. A starved evaporator will have uneven ice formation. Most problems with ice formation or harvesting are not related to a defective evaporator, use the Troubleshooting Trees in section C for additional help.

Refrigerant enters the evaporator through the bottom tube and exits through the top tube. On (Prior to 0801) models ICE800, 1000, 1800 and 2100 the refrigerant line at the TXV outlet splits into two feeder tubes. This split occurs at the distributor, which is a fitting that is soldered to the TXV. One feeder tube from the distributor feeds the top of the evaporator; the other tube feeds the bottom of the evaporator. The evaporator tubes run parallel, in opposite directions, along the back of the evaporator creating a dual pass.

If the evaporator is flooded but not building ice evenly, it is possible the evaporator has coil separation. Evaporator coil separation is the separation of the refrigerant tubing from the back of the evaporator plate. This is very rare but occasionally occurs.

To confirm coil separation, remove and check the back of the evaporator. If the coil is separated, the evaporator must be replaced. If the outlet(s) of the evaporator is not frosted, the problem is not with coil separation (Refer to the troubleshooting trees, section C).

ICE800, 1000, 1800 and 2100 Prior to Jan, 2008

Out

Page E4

ICE Series Refrigeration System

Note: Permanent discoloration of the evaporator plating is normal and will cause no problems with

harvesting the ice or sanitary conditions. Before condemning the evaporator for plating problems, be certain it is not just discoloration. Good evaporators will not be covered under warranty. If the spillway (plastic evaporator top) becomes damaged, it can be replaced. It is not necessary to replace the entire evaporator.

As liquid refrigerant leaves the evaporator, it changes to a low-pressure gas before returning to the compressor. Liquid refrigerant must not return to the compressor or damage will result. Frost on the suction line at the inlet of the compressor indicates liquid returning to the compressor. Check for frost at the end of the freeze cycle. If liquid is returning to the compressor, the problem must be located and corrected. See Refrigerant Charge, Thermostatic Valve and Evaporator.

Harvest Cycle

Once the freeze cycle is complete, the machine enters the harvest cycle. The hot gas valve opens to allow hot discharge gas to enter the evaporator.

Hot Gas Valve

When the machine enters harvest the hot gas valve coil is energized opening the hot gas valve. Discharge gas is pumped through the hot gas valve directly into the evaporator. The evaporator temperature will reach approximately 40°F (4.5°C). The suction pressure during harvest should be a minimum of 70 psi (4.8 bar) for R404a units or 50psi (3.4 bar) for R134a units. The discharge pressure will drop during harvest.

If the hot gas valve does not completely open during harvest, there will not be enough hot gas in the evaporator to defrost the ice. If there is not enough hot gas entering the evaporator, the suction pressure will be lower than the above stated pressures. It is important when making this check that the machine has the proper refrigerant charge, normal head pressure and the compressor is functioning properly. If the hot gas valve leaks during the freeze cycle, ice will not form on the top of the evaporator and suction pressure will be higher than normal. To check if the hot gas valve is leaking, let the machine run in the freeze cycle for approximately 5 minutes. Now feel the temperature between the inlet and outlet of the valve. A definite temperature difference should be felt. If the lines are the same temperature and the suction pressure is higher than normal; the valve is leaking and should be replaced. Use Troubleshooting Trees in section C.

Remote System

Machines that use remote condensers have several components that are not used in self contained machines. A mixing valve controls the head pressure when the ambient temperature at the condenser drops below 70°F (21°C). When the bin fills with ice or is turned off at the selector switch, the machine will pump all the refrigerant into the receiver before shutting off.

Remote Condenser

For proper operation, the remote condenser must be installed properly. Improper installation will void the warranty. See remote guidelines on page A14. The location of the remote condenser should be such that the ambient air temperature does not exceed 120°F (48.9°C). If ambient temperature exceeds 120°F (48.9°C) ice production will decrease until the ambient temperature decreases.

Air Flow

Page E5

ICE Series Refrigeration System

Remote Condenser (Continued)

If the airflow is restricted or the condenser is dirty, the head pressure will be excessively high, slow production will result and the compressor may overheat and eventually become damaged. The condenser coil and fan blades must be kept clean. The condenser can be cleaned with compressed air or by using a brush. If a brush is used, brush in the direction of the fins taking care not to bend the fins. If the condenser fins are bent, this will restrict the airflow through the condenser and the fins will need to be straightened with a fin comb. Problems related to a dirty condenser or poor airflow will not be covered under warranty. Note: The condenser fan motor runs continually, it will shut off when the icemaker shuts off.

Mixing Valve

When the temperature at the condenser is above 70°F (21°C), the refrigerant flow from the compressor is directed by the mixing valve through the condenser and into the receiver. When the temperature at the condenser drops below 70°F (21°C), the pressure in the bellows of the mixing valve becomes greater than the pressure of the liquid refrigerant coming from the condenser. This change allows the valve to partially restrict the flow of refrigerant leaving the condenser and allows discharge gas to by-pass the condenser and flow directly into the receiver, mixing with the liquid refrigerant from the condenser. The amount of discharge gas that bypasses the condenser increases as the ambient temperature decreases. This action of the mixing valve allows the discharge pressure to be maintained at approximately 240 psi (16.5 bar) during low ambient conditions. If the refrigerant system is undercharged and the ambient temperature is below 70°F (21°C), the mixing valve will not work properly. The mixing valve will allow too much refrigerant to bypass the condenser.

Problem Possible Cause Remedy 1 Head pressure low, Line between A. Valve Defective, not allowing A. Replace valve

valve and receiver cold. Ambient discharge gas into receiver condenser temp. below 70°F (21°C)

2 Head pressure low, Line between A. System low on charge. A. Leak check. Recover valve and receiver hot. B. Valve defective, not refrigerant and weigh allowing liquid in proper charge. into receiver. B. Replace valve

3. Head pressure low, Line A. Valve defective not A. Replace valve.

returning from condenser allowing refrigerant is cool. Ambient condenser to circulate through temperature is above 70°F (21°C) condenser.

Page E6

ICE Series Refrigeration System

Pump Down System (Remote Only)

The pump down system prevents liquid refrigerant from migrating to the evaporator and compressor during the off cycle and prevents the compressor from slugging or starting under an excessive load.

Liquid Line Solenoid

When a machine with a remote condenser shuts off, the liquid line solenoid valve, located at the outlet of the receiver, is de-energized causing the valve to close completely restricting the flow of refrigerant. The compressor will pump all of the refrigerant into the condenser and receiver.

As the system pumps down, the pressure on the low side of the system drops. When the suction pressure drops to 10 psi (.68 bar), the pump down control opens and shuts the machine off. See page F9 for pump down control operation. Liquid refrigerant is stored in the condenser and receiver while the machine is off. It is normal for the machine to pump down once or twice an hour as the pressures equalize.

When the machine comes back on (the bin switch closes or the selector switch placed to the ICE position), the liquid line solenoid valve opens and the refrigerant is released from the receiver. When the suction pressure rises to 35 psi (2.38 bar) the pump down control closes and the machine comes back on. If the machine will not pump down, the valve may not be closing all the way. A weak compressor will also prevent the machine from pumping down. Check for signs of a weak compressor before replacing the liquid line solenoid. Prior to replacing the valve, disassemble and check for obstructions that may not allow the valve to seat.

Receiver

If the system has a remote condenser, the refrigerant will enter a receiver before passing through the filter drier. The receiver holds reserve liquid refrigerant during the freeze cycle. The receiver also stores liquid refrigerant during the off cycle.

Page E7

ICE Series Refrigeration System

Refrigerant

Refrigerant in a high-pressure liquid form is fed to an expansion valve where the refrigerant is reduced to a low-pressure liquid. Under this low pressure, the liquid will absorb heat from the evaporator causing the liquid to change to a vapor. This vapor is the drawn into the compressor where the temperature and pressure of the vapor are increased. The high temperature, high pressure vapor flows to the condenser where the heat is removed, causing the vapor to return to the liquid form, making the refrigerant ready to flow back to the evaporator to pick up more heat.

Most Ice-O-Matic ice machine use R134a or R404a refrigerant. Always check the serial number data plate for the proper type of refrigerant and the amount used in the machine you are servicing.

R404a and R134a are both HFC refrigerants, which result in no ozone depletion factor. R404a cylinders are orange in color, R134a cylinders are light blue in color.

Important: When discharging refrigerant from an icemaker, recover as much of the refrigerant as possible with a recovery device or some other means to prevent the refrigerant from entering the atmosphere.

Method of Charging Refrigerant

In order to achieve a properly charged refrigeration system, the system must be completely evacuated.

To achieve a complete evacuation you will need a service gauge manifold with properly maintained hoses, and a vacuum pump capable of pulling a 50-micron vacuum. This will require a two-stage pump.

Connect the service gauge manifold to the high and low side service ports and vacuum pump. Make sure the valves on the gauge manifold are closed, then start the pump.

Note: Do not use a refrigeration compressor as a vacuum pump. Compressors are able to pull only a 50,000-micron vacuum.

After the vacuum pump has been started, open the valves on the gauge manifold. This will allow the refrigeration system to start being evacuated.

If there has not been an excessive amount of moisture in the system, allow the vacuum pump to pull the system down to about 200 microns or 29.9 inches or less. Once this has been achieved, allow the vacuum pump to operate for another 30 minutes. Then close the valves on the gauge manifold and stop the vacuum pump. Then watch your gauges. A rise to 500 microns in three (3) minutes or less indicates a dry system under a good vacuum.

If your gauge registers a more rapid rise, the system either has moisture remaining or there is a leak in the system, requiring a check for the leak, and repair and another complete evacuation.

Note: Seal the ends of the gauge manifold hose and pull them into a deep vacuum to determine if the leak is not in the hoses. The gauge manifold should be able to hold the vacuum for three (3) minutes.

Page E8

ICE Series Refrigeration System

If the refrigeration system is extremely wet, use radiant heat to raise the temperature of the system. This action will cause the moisture to vaporize at less of a vacuum.

The use of two (2) valves, one between the vacuum pump and gauge manifold and the other between the refrigerant cylinder and the gauge manifold allows you to evacuate and charge the system without disconnecting any hoses. If the hoses were disconnected, air or moisture will have the opportunity to enter the hoses and then the system.

A properly charged icemaker is a service technician’s greatest ally. Proper charging will allow any concern with the icemaker to be accurately diagnosed.

The refrigerant charge must be weighed into the icemaker either by using a charging scale or with a dial-a-charge.

The amount of proper refrigerant required for the icemaker is printed on the serial data plate attached to the icemaker and is listed on the following pages. Never vary the amounts from those listed.

Remote models with sixty (60) foot lineset runs will need an additional fifteen (15) ounces of refrigerant added.

In some cases the complete refrigerant charge may not enter the refrigeration system. In those instances, close the gauge manifold high side valve and disconnect the manifold from the high side port.

When the icemaker is completely charged, secure the caps to the service ports and check to make sure the ports are not leaking refrigerant.

Reference Tables on Page I6 and I16.

Page E9

ICE Series Electrical System

Control Circuit

All machines in this manual are electro-mechanical controlled; however the control circuitry on the single evaporator units differs from the dual evaporator units and is detailed below.

Selector Switch

The selector switch is used to put the machine into the ICE making or WASH cycle or to turn the machine OFF. The WASH position allows only the water pump to run and is used during the cleaning process to circulate cleaning solution throughout the water system. When the selector switch is turned to the ICE position, the machine begins the freeze cycle.

Contactor

When the selector switch is in the ICE position, the contactor coil is energized and pulls in the contactor contacts. This energizes the compressor start components, which starts the compressor.

Purge Switch

The purge switch is a momentary switch used to manually energize the purge valve. It is used during the cleaning process to flush the cleaning solution from the water trough. The purge valve will remain energized as long as the purge switch is depressed.

Note: Single Evaporator Units. The normally closed contacts of the purge switch also create a circuit to relay 1. These contacts should remain closed unless the switch is depressed. If the switch is defective and the normally closed contacts are open when the machine enters harvest, the machine will return to freeze when the timer initiate control opens.

Compressor and Start Components

The compressor should run during the entire cycle. If the machine is in the ICE position but the compressor is not running, check the compressor contactor to see if it is engaged. If the contactor is not engaged, the problem is not with the compressor or the compressor start components. If the contactor is engaged and there is correct voltage through the contactor, there could be a problem with one of the starting components or the compressor. It is recommended that the compressor starting components be replaced when replacing a compressor.

Compressor Check If the compressor uses an internal overload, be certain that the compressor has cooled and the overload has reset before diagnosing the compressor. If the compressor is cool and is still not running, check the compressor motor windings by first removing the wires at the compressor terminals. With an ohmmeter, check for continuity between all three terminals, if an open circuit exists between any of the terminals, the compressor may need to be replaced. Check for continuity from each terminal to the compressor body, if continuity is found from any terminal to the compressor body, the compressor windings are shorted to ground and the compressor will need to be replaced. If the compressor appears to be good at this point, it is advisable to use a compressor analyzer to isolate the compressor from the start components while checking for a locked rotor. If an analyzer is not available, the compressor starting components must be checked.

Disconnect power before servicin

Page F1

ICE Series Electrical System

Compressor Check (Continued)

If all starting components are good, check the voltage from the common terminal of the compressor, making sure proper voltage is supplied to the compressor and all wiring is properly connected. If the compressor does not start and there is excessive amperage draw, (see locked rotor amps on compressor tag) the compressor has a locked rotor and should be replaced.

Important: Compressors returned to the factory for warranty are tested and will not be covered under the warranty policy if they are not defective.

Overload (External)

If there is no amperage draw check the compressor overload. The compressor overload can be checked for continuity after removing it from the compressor and letting it cool to room temperature. If there is no continuity between the two terminals, replace the overload. If the overload is suspected of opening prematurely, it should be replaced with an overload, which is known to be good.

Capacitors

The start capacitor is an electrical storage device used to provide starting torque to the compressor. If a start capacitor is defective, the compressor will not start properly.

The run capacitor is an electrical storage device used to improve the running characteristics and efficiency of the compressor.

Before checking a capacitor, it should be discharged by shorting across the terminals. If a run or start capacitor is cracked, leaking or bulging it should be replaced. If a capacitor is suspected of being defective, it can easily be checked by replacing it with a capacitor of the correct size, which is known to be good. If the compressor starts and runs properly, replace the original capacitor. A capacitor tester can also be used.

Start Relay

The start relay breaks the electrical circuit to the start windings when the compressor motor speed increases. If the relay is defective, the compressor will not start or it may start but will run for a very short time.

A compressor relay can be checked by removing the relay and checking the relay contacts for damage and check for continuity across the closed relay points. Check the relay coil with an ohmmeter. If no continuity is read, replace the relay.

Page F2

ICE Series Electrical System

Untimed Freeze Cycle

During the freeze cycle the compressor, water pump and condenser fan motor(s) (if used) are running. On remote systems the liquid line solenoid is also energized, see Refrigeration System. As ice forms on the evaporator, the suction pressure drops. The machine is in the untimed portion of the freeze cycle and will remain in untimed freeze until the suction pressure drops low enough to close the timer initiate control. See page I1-I6 for operating pressures.

Timer Initiate

The timer initiate is a low-pressure control that closes (cut in) on a drop in suction pressure. When the timer initiate control closes, the freeze timer is energized and the machine enters the timed portion of the freeze cycle. When the machine enters harvest, the suction pressure rises and opens the control. The timer initiate control should be adjusted per the chart on page I1-I6.

The timer initiate is factory set and does not normally need to be adjusted. If the ice bridge thickness is incorrect, the freeze timer should be adjusted rather than the timer initiate. See page F4 for freeze timer adjustment procedure. The timer initiate may need to be adjusted if excessive time (more than 7 minutes) is needed on the timer to achieve proper bridge thickness of if very little time (less than 1 minute) is needed on the timer to achieve proper bridge thickness.

If the timer initiate is suspected of being out of adjustment or not operating properly, check the control as follows. Make sure the high temperature safety control is not open, see page F8. Turn the machine off and disconnect incoming power by unplugging the machine or switching the circuit breaker OFF. Attach one lead of a voltmeter to terminal 1 and the other lead to terminal 2 of the timer initiate control. Reconnect incoming power and turn the machine to the ICE position. Connect a low pressure gauge to the machine. The volt meter should read line voltage until the timer initiate control closes at which point the voltmeter should read zero volts. Note the suction pressure at this point. Adjust the timer initiate if necessary. Turning the adjustment screw counter clockwise will lower the cut in pressure, turning the adjustment screw clockwise will raise the cut in pressure. The differential is preset and does not require adjustment. If the control cannot be adjusted to the correct pressure setting or if the cut in point is erratic the control must be replaced. If the suction pressure is not dropping properly, see the Troubleshooting Tree “Machine Does Not Enter Harvest” in Section C.

Relay 1

Relay 1 is used to energize the fan motor on air-cooled units. The fan is energized through the common and normally closed contacts.

Relay 2 (Note: Relay 2 is not used on Undercounter models)

On single evaporator machines, relay 2 is used only to bypass the bin control during the freeze cycle and the first part of the harvest cycle. Relay 2 is energized through the normally closed contacts of the cam switch at the beginning of the freeze cycle. When energized, Relay 2 will prevent the machine from shutting off if the bin switch opens. The relay will remain energized until the cam switch is lifted onto the high part of the cam during harvest. At this time the machine will shut off if the bin switch is open.

Relay 3 and Relay 4 (ICE1506 Applications) Relay 3 and Relay 4 bypass the bin switches to allow the curtains to open and close during the freeze cycle on an ice dispenser application. This will prevent the ice machine from shutting off during dispenser agitation.

Adjustment Screw

Page F3

ICE Series Electrical System

Timed Freeze

When the freeze timer is energized, the machine is in the timed portion of the freeze cycle. The freeze timer will time out the remainder of the freeze cycle. Once the time has passed, the machine will enter the harvest cycle.

Freeze Timer

The freeze time is an adjustable timer used to control the ice bridge thickness. The freeze timer is factory set but may need to be adjusted upon initial start up of the machine. When time is added to the freeze timer, the length of the freeze cycle is increased, therefore the ice bridge thickness is increased. When time is removed from the timer, the freeze cycle is decreased and the ice bridge thickness is decreased.

The freeze timer can be adjusted by sliding one or more switches to either the ON or OFF position to obtain the setting which will produce the proper bridge thickness. A timer setting of 128 and 256 switched ON will provide an initial timer setting.

The ice bridge thickness should be approximately 3/16” (5mm) on the ICEU undercounter series, ICE0250 and ICE0305, and 1/8” (3 mm) on ICE0400 and larger units. If the bridge is too thick, remove enough time from the timer to achieve proper thickness. If the bridge is too thin, add enough time to the timer to achieve proper thickness.

Check the freeze timer for proper operation as follows: Make sure that the high temperature safety control is not open, see page F8. Turn the machine OFF and disconnect the incoming power by unplugging the machine or switching the circuit breaker OFF. Attach one lead of a voltmeter to terminal 1 and the other lead to terminal 3 of the timer.

Reconnect incoming power and turn the machine to the ICE position. The volt meter should read zero volts until the timer initiate closes at which point the timer will energize and line voltage should be read.

When the timer counts out, the voltmeter will again read zero volts. The time it takes the freeze timer to time out, once it has been energized should match the timer adjustment. If it does not or if the timer never closes, the timer is defective.

Note: The hot gas delay timer utilized on the ICE1400, ICE1506, ICE1606, ICE1800 and ICE2100 Series cubers should always be set at 4 seconds. (Not applicable on Version 3 & 4)

Sample Timer

Combine time in seconds

Bridge Thickness

Page F4

ICE Series Electrical System

Harvest Cycle Single Evaporator Machines

Once the freeze timer has timed out, power is sent to relay 1 and the machine enters the harvest cycle. Once in harvest motor, the purge valve, hot gas valve and harvest motor are energized. The water pump continues to run during the first part of the harvest cycle so that mineral laden water remaining in the water trough can be pumped through the purge valve to the drain. The harvest motor turns the clutch assembly to actuate the cam switch.

The cam switch is in the normally closed position during freeze and at the beginning of harvest. Once the clutch turns far enough to actuate the cam switch, the water pump and purge valve is deenergized. The harvest motor continues to turn the clutch. When the cam switch returns to the normally closed position, the machine returns to the freeze cycle. If the bin switch is open when the cam switch is actuated by the high part of the cam, the machine will shut off. Remote units pump down before shutting off.

Relay 1

When relay 1 is energized, the normally open contacts (1-B) close sending power to the hot gas valve and harvest motor and (1-A) close sends power to the purge valve and the coil of relay 1 to keep the coil energized when the timer initiate opens. The fan motor on self contained air cooled model are wired through the NC contacts of relay 1, when the contacts open during harvest, the condenser fan motor is de-energized.

Relay 2 See Page F4. Dual Evaporator Machines (Prior to Jan 08)

Once the freeze timer has counter out, power is sent to: (A) harvest motor 1 and relay coil 1 through the normally closed contacts of cam switch 1, (B) to harvest motor 2 and relay coil 2 through the normally closed contacts of cam switch 2. The contacts of relay 1B and 2B closing, energizes the 4-second hot gas delay timer (Right Hand Timer)

This 4-second delay will allow the harvest motors to rotate and allow the cam switches to switch to the normally open position before the low-pressure control opens during hot gas. The cam switches are now in the normally open position and will continue to energize the harvest motors and relays until the cam rotates and the switch returns to the normally closed position.

Once the 4-second delay timer has timed out, the hot gas valves and purge valve will energize and allow hot gas into the evaporators. The bin control switches are by passed through the normally open contacts of relay 1A and 2A.

The bin switches are bypassed to allow the cam switch to return to the normally closed position prior to the machine shutting down if the curtain is open. Each harvest assist motor will only make one revolution prior to shutting down on full bin or advancing to the next freeze cycle.

Both hot gas valves and the water purge valve remain energized until both harvest assist motors complete one revolution. The water pump is energized throughout the harvest cycle. The unit will shut down if the curtains are open during the freeze cycle. Remote units pump down before shutting off. The fan motors on self contained air cooled model are wired through the NC contacts of relay 1B, when the contacts open during harvest, the condenser fan motors are de-energized.

Page F5

ICE Series Electrical System

Harvest Assist Assembly

The harvest assist assembly has several purposes: to assist in moving the ice off of the evaporator, to control the length of harvest and to terminate harvest. When the machine enters harvest, power is sent to the harvest motor which turns a slip clutch. A probe is attached to the rotating clutch and is pushed against the back of the ice slab. The clutch begins to slip when the probe applies approximately 25 ounces of pressure against the ice slab.

It takes approximately 1 minute for hot gas to heat the evaporator enough to loosen the ice from the evaporator plate. At this point the clutch pressure overcomes the capillary attraction of the ice to the evaporator plate and the ice begins to move off of the evaporator. As the ice is being pushed, the clutch stops slipping and begins to turn, extending the probe enough to push the ice completely off of the evaporator.

Harvest Motor

The harvest motor is energized at the beginning of harvest and will remain energized until the machine returns to the freeze cycle. A defective harvest motor will usually not run. The harvest motor rotates in a clockwise direction. It is possible for a defective motor to run backwards (counterclockwise). If this happens the motor must be replaced. It is also possible for a defective motor to “bump” backwards immediately when entering harvest. This will activate the cam switch and cause the machine to return to the freeze cycle immediately after entering harvest. If the machine is in harvest only for a split second, the harvest motor may be defective. Verify the motor is defective by watching the clutch closely when the machine enters harvest.

Clutch Assembly

The clutch assembly consists of a slip clutch and cam. A probe is attached to the clutch assembly and the harvest motor turns the clutch during harvest. As the harvest motor turns, the clutch will slip while the probe is pushed against the ice. The clutch will continue to slip as long as the pressure required to move the ice is greater than the 25 oz. Once the evaporator has heated enough to break the bond of ice to the evaporator, the pressure required to move the ice becomes less than the 25 oz. And the clutch begins to move.

The clutch assembly is not adjustable. If the clutch tension is weak (less than 25 oz.) a slow harvest or excessive ice meltage during harvest will result. If the clutch pressure becomes too tight, the force of the probe against the back of the ice may cause the slab to break and the ice may not fall off of the evaporator. If the clutch tension is suspected of being too tight or loose, turn the clutch by hand. The clutch should turn smoothly without “grabbing”, but should offer some resistance. If in doubt as to whether or not the clutch is defective, compare the tension with one that is known to be good.

Page F6

ICE Series Electrical System

Probe Tip and Swivel

The probe tip is attached to the clutch and makes contact with the back of the ice slab during harvest. The swivel allows the probe tip to pivot as the clutch turns so that the probe is pushed straight through the evaporator probe guide.

The tip of the probe should be flush with the back of the evaporator or recessed up the 1/16 of an inch (.16cm). The probe tip must not extend into the freezing area of the evaporator during freeze.

(Note: Units manufactured after June 2004 utilize a non adjustable probe.)

The length of the probe is adjustable by loosening the locknut and adjusting the probe in or out of the swivel. Once the probe has been adjusted to the proper length, tighten the locknut. If the probe tip binds during operation it may cause the clutch to slip unnecessarily. This may occur if the harvest motor mounting bracket is not aligned properly or if the probe tip has excessive mineral deposits on it. Remove and clean the probe if necessary.

To check the probe tip for binding, remove the shoulder bolt holding the swivel to the clutch and simulate the movement of the swivel and probe by moving the swivel in a circular motion around the outer portion of the clutch. The swivel should also move freely. If any resistance is felt the bracket should be adjusted by loosening the bracket mounting screws and repositioning the bracket until the probe moves freely.

Cam Switch Operation-Single Evaporator Machines

The actuator arm of the cam switch rides on the edge of the clutch assembly and is actuated by the high and low portion of the cam. When the machine is in the freeze cycle the actuator arm of the cam switch is in the low part of the cam. During freeze, power is supplied to the water pump and relay 2, through the normally closed contacts of the cam switch. When the machine enters harvest, power is supplied to the water pump and purge valve through the normally closed contacts of the cam switch and through the normally open contacts of relay 1 (closed during harvest). The water pump, purge valve and relay 1 remain energized until the cam switch is lifted on to the high part of the cam. Relay 2 will also de-energize at this time allowing the machine to shut off if the bin switch opens. Undercounter machines manufactured after July of 2004 will have the water pump run continually until the machine shuts down.

Cam Switch Operation-Dual Evaporator Machines (Prior to January 2008)

Once the freeze timer has counted out, power is sent to: (A) harvest motor 1 and relay coil 1 through the normally closed contacts of cam switch 1, (B) to harvest motor 2 and relay coil 2 through the normally closed contacts of cam switch 2.

The bin switches are bypassed to allow the cam switch to return to the normally closed position, prior to the machine shutting down if the curtain is open. Each harvest assist motor will only make one revolution prior to shutting down on full bin or advancing to the next freeze cycle.

Page F7

ICE Series Electrical System

Cam Switch Adjustment

Check the cam switch for proper adjustment by slowing turning the clutch by hand in a counterclockwise direction while listening for the switch contacts to change. The switch should have an audible “click” as the roller reaches the high part of the cam. Now slowly turn the clutch in a clockwise direction and the switch should have an audible “click” as the roller reaches the low part of the cam. Adjust the switch by loosening the mounting screws and moving the position of the switch. If the cam switch is suspected of being defective it should be checked with an ohmmeter. It should not be assumed that the switch is good because a “click” can be heard

when moving the actuator arm.

High Temperature Safety Control

The high temperature safety control is a thermal disc that protects the machine if the machine “sticks” in the harvest cycle. The high temperature safety is clamped to the suction line near the expansion valve thermal bulb. It opens when the suction line temperature reaches 120ºF (48.8ºC) and closes when the temperature drops to 80ºF (26.6ºC). If the high temperature safety opens during harvest, it will de-energize the harvest components. If the high temperature safety is defective and fails open during the freeze cycle, it will not allow the relay(s) to energize and the machine will not enter harvest. Remove the high temperature safety control and check it with an ohmmeter to verify that it is defective.

Note 1: ICE0500R3, ICE0606R3, ICE0806R3 and ICE1006R3: The high temperature safety

control specifications have been changed to open at 120ْ F and close at 100ْ F.

Note 2: On models where the high temperature safety control is mounted on the hot gas valve

outlet tube, the specifications are open at 180ºF and close at 120 ºF. Additionally the high temperature safety control is wired in series with the contactor. If the high temperature safety control opens for any reason, the compressor will shut down. This is an automatic reset control. Do not allow the machine to operate without the

high temperature safety control. Damage to the machine may result and the warranty will be void.

Bin Control Operation

The bin control is used to shut the machine off when the bin fills with ice. The bin control must be checked upon installation or initial start-up and when performing maintenance. Adjustments are

not covered under warranty.

There is one bin switch for each evaporator. The actuator arm of the bin switch comes in contact with the splash curtain. When the bin is full of ice, the splash curtain is held open when ice drops off of the evaporator. This releases the pressure of the bin switch actuator arm allowing the switch to open.

Single evaporator machines: If the bin switch opens during freeze, or the first part of harvest, relay 2 bypasses the bin switch and the machine will continue running. If the bin switch is opened during harvest, when the cam switch is lifted onto the high part of the cam, the machine will shut off. When the bin switch closes again, the machine will restart.

Dual evaporator machines: If either bin switch opens during the freeze cycle, the machine will shut off. Relay 1 and relay 2 will bypass the bin switches during defrost. If either bin switch is open when the machine returns to the freeze cycle, the machine will shut off.

Page F8

ICE Series Electrical System

Undercounter machines: A thermostatic bin control is used on the undercounter models. The bin

thermostat is located in the control box with a capillary tube, which is in a brass thermo-well mounted to the water trough. When ice comes in contact with the capillary tube thermo-well, the bin thermostat opens and the machine will shut off.

Bin Control Adjustment All Models (Except Undercounter Models): Check the bin switch for proper adjustment by

swinging the bottom of the curtain away from the evaporator. Slowly bring the curtain towards the evaporator. The switch should close when the bottom edge of the curtain is even with the outer edge of the water trough. Adjust the switch by loosening the screws the hold the switch in place. Move the switch to the proper position and retighten the screws. Recheck the adjustment.

Adjustments are not covered under warranty. Undercounter Models and ICE1506R

Hold ice against the brass thermal-well making sure the ice is in contact with at least 6 inches (15 cm) of the thermal-well. The bin control should open in approximately 1 minute. Remove the ice. The bin control should close in approximately 3 minutes. If a major adjustment is required, turn the adjustment screw counterclockwise (warmer) until it stops then turn the adjustment screw clockwise (colder) 1/8 of a turn. This should put the control close to the proper adjustment, recheck and make a minor adjustment if needed. If a minor adjustment is required, turn the adjustment screw clockwise (colder) or counterclockwise (warmer). Adjustments are not covered

under warranty. Pump Down System (Remote Only)

If a remote machine is shut down by the selector switch or bin control, the liquid line solenoid valve is de-energized allowing the valve to close. This blocks the flow of refrigerant causing all the refrigerant to be pumped into the receiver and condenser. This is done to prevent liquid refrigerant from migrating into the compressor during the off cycle, which could damage the compressor on start-up. Also see Pump Down System in the Refrigeration Section on page E7. As the refrigerant is pumped into the receiver, the suction pressure begins to drop. Once the suction pressure reaches approximately 10 psi (.68 bar) the pump down control contacts open, which will deenergize the compressor contactor. When the machine is turned back on, power is supplied to the liquid line solenoid which opens the valve and allows the suction pressure to rise enough to close the pump down controls contacts.

Pump Down Control

The pump down control is a low pressure control that shuts the machine off when the suction pressure drops during the pump down phase. The control is factory set to open at 10 psi (.68 bar) and close at 30 psi (2.04 bar). The pump down control does not normally need to be adjusted, however an adjustment may be made by turning the adjustment screw. Note: Later model machines have a non adjustable pump down control.

Fan Control

On models utilizing a fan control, the fan will cycle on at 250 psi (17.01) and cycle off at 200 psi (13.61 bar).

Page F9

ICE Series Electrical System

Electrical Sequence for the ICE1400 Series Version 3&4, ICE1800 Series Version 3&4 and the ICE2100 Series Version 3&4 Cubers. (Manufactured from January, 2008)

ICE1400A/W3&4, 1800W3&4 and 2100W3&4 Electrical Sequence (Includes 50 hz. And 3 Phase)

1. Suction Pressure starts out at approx 60 psi and slowly drops to close the LP Control.

2. The LP Control energizes Relay Number 2 Coil.

3. Relay Number 2A contacts C and NO close to bypass the bin switches, Relay Number 2B contacts close and energize the timer.

4. The Timer times out and energizes Relay Number 1 Coil.

5. Relay Number 1A contacts C and NO close to send power to Cam Switch Number 2 contacts C

and NC which energizes Harvest Motor 2, Hot Gas 2 and Relay Number 3 Coil.

6. Relay Number 1B contacts C and NO close to energize Harvest Motor 1 and Hot Gas 1

7. Relay Number 1B contacts C and NC open to de-energize the fan motors.

8. When the LP Control opens during hot gas, the circuit is latched through the Purge Switch contacts C and NC.

9. Relay Number 3A contacts C and NO close to send power to the Selector Switch and Hot Gas Valves when the curtain is open.

10. Once Cam Switch 2 contacts C and NO close (High Side of the Cam) it will remain energized

from the Selector Switch until contacts C and NC close. (Rotates 360 degrees)

11. Once Cam Switch 1 contacts C and NO close (High Side of the Cam) the Harvest Motor will be

energized and the Water Pump and Purge Valve will be de-energized when contacts C and NC open.

12. With the bin switches open, Relay Number 3 Coil de-energized due to Cam Switch 2 contacts

C and NC closing, the unit will shut off on full bin.

Notes:

●C=Common

●NC=Normally Closed

●NO-Normally Open

●Relay Number 9 & 12=Common

●Relay Number 1 & 4=Normally Closed

●Relay Number 5 & 8=Normally Open

●The Fan Control on the air cooled model cycles only one fan.

●Relay 1, Puts unit into defrosts.

●Relay 2, Bypasses the Bin Switches and initiates the Timer.

●Relay 3, Bypasses the bin Switches during harvest when Relay 2 is de-energized from a rise in

the suction pressure opening the Low Pressure Control.

Page F10

ICE Series Electrical System

Electrical Sequence for the ICE1400 Series Version 3&4, ICE1800 Series Version 3&4 and the ICE2100 Series Version 3&4 Cubers. (Manufactured from January, 2008)

ICE1400R3&4, 1800R3&4 and 2100R3&4 Electrical Sequence (Includes 50 hz. And 3 Phase) This unit incorporates a timer upstream of the Low Pressure Control for Low Ambients.

1. Timer number 2 (Six Minutes) is energized from the Selector Switch through Relay Number 3B contacts C and NC.

2. Timer Number 2 (Six Minutes) times out and energizes Relay Number 2 Coil.

3. Relay Number 2B contacts C and NO close which energizes the Low Pressure Control.

4. The Low pressure Control closes and energizes Timer Number 1.

5. The Timer times out and energizes Relay Number 1 Coil.

6. Relay Number 1A contacts C and NO close to send power to Cam Switch Number 2 C and NC which energizes Harvest Motor 2, Hot Gas Valve 2 and Relay Number 3 Coil.

7. Relay Number 1B contacts close to energize Harvest Motor 1 and Hot Gas Valve 1.

8. When the Low Pressure Control opens during hot gas defrost, the circuit is latched through the Purge Switch contacts C and NC.

9. Relay Number 3A contacts C and NO close to send power to the Selector Switch and Hot Gas Valves when the curtain is open.

10. Once Cam Switch 2 contacts C and NO close (High side of the Cam) it will remain energized

from the Selector Switch until contacts C and NC close. (Rotates 360 degrees)

11. Once Cam Switch 1 contacts C and NO close (High Side of the Cam) the Harvest Motor will be

energized and the Water Pump and Purge Valve will be de-energized when contacts C and NC open.

12. With the bin switches open, Relay Number 3 Coil de-energized due to Cam Switch 2 contacts

C and NC closing, the unit will shut off on full bin.

Notes:

●C=Common

●NC=Normally Closed

●NO-Normally Open

●Relay Number 9 & 12=Common

●Relay Number 1 & 4=Normally Closed

●Relay Number 5 & 8=Normally Open

●Relay 1, Puts unit into defrosts.

●Relay 2, Bypasses the Bin Switches and initiates the Low Pressure Control

●Relay 3, Bypasses the Bin Switches during harvest when Relay 2 is de-energized from a rise in

the suction pressure opening the Low Pressure Control and energizes Timer Number2

Page F11

ICE Series Electrical System

Electrical Sequence for theICE1506 Series Version 3 (Manufactured from January, 2008) This unit incorporates a timer upstream of the Low Pressure Control for Low Ambients.

1. When the Selector Switch is set to ICE, Relay Number 2 Coil is energized through Cam Switch contacts C and NC (Bypasses the Bin Controls)

2. Relay Number 4B contacts C and NC energize Timer Number 2 (6 Minutes)

3. Timer number 2 times out and energizes Relay Number 3 Coil.

4. Relay Number 3B contacts C and NO close and energizes the Low Pressure Control.

5. The Low Pressure Control closes to energize Timer Number 1.

6. Timer Number 1 times out and energizes Relay Number 1 Coil

7. Relay Number 1A contacts C and NO close and send power Cam Switch Number 2 C and NC which energizes Harvest Motor 2, Hot Gas valves and Relay Number 4 Coil.

8. Relay Number 1B contacts C and NO close to energize Harvest Motor 1 and Hot Gas Valve 1.

9. When the Low Pressure Control opens during hot gas, the circuit is latched through the Purge Switch contacts C and NC.

10. Once Cam Switch 2 contacts C and NO close (High side of the Cam) it will remain energized from the Selector Switch until contacts C and NC close (Rotates 360 degrees)

11. Once Cam Switch 1 contacts C and NO close (High side of the Cam) the Harvest Motor will be energized and the Water Pump, Purge Valve and Relay Number 2 Coil will be de-energized when contacts C and NC open.

12. When Relay Number 2 Coil is de-energized and if the curtain switches or bin stat are open, the unit will pump down and shut off on full bin.

Notes:

●C=Common

●NC=Normally Closed

●NO-Normally Open

●Relay Number 9 & 12=Common

●Relay Number 1 & 4=Normally Closed

●Relay Number 5 & 8=Normally Open

●Relay 1, Puts unit into defrosts.

●Relay 2, Bypasses the Bin Switches.

●Relay 3,Energizes the Low Pressure Control

●Relay 4,Resets Timer Number 2

Page F12

ICE Series Notes

Table of Contents

Table of Contents Page A1 General Information

Scheduled Maintenance

Maintenance Procedure Page B1 Cleaning and Sanitizing Instructions Page B1-B2 Winterizing Procedure Page B3 Cabinet Care Page B4

Troubleshooting Trees

How to Use The Troubleshooting Trees Page C1 Troubleshooting Trees Table Of Contents Page C2 Troubleshooting Trees Page C3-C18

Water System

Water Distribution And Components Page D1-D5

Refrigeration System

Refrigeration Cycle And Components Page E1 Harvest Cycle Page E5 Remote System Page E5-E6 Pump Down System Page E7 Refrigerant Specifications Page E8-E20

Electrical System

Control Circuit Page F1 Compressor And Start Components Page F1-F2 Untimed Freeze Cycle Page F3 Timed Freeze Cycle Page F4 Harvest Cycle Page F5-F9 Pump Down System Page F9 Wiring Diagrams Page G1

ICE Series Wiring Diagram

ICEU150/200/205/206 Air and Water Wiring Diagram

Page G1

ICE Series Wiring Diagram

ICEU150/200/205/206 Air and Water Wiring Schematic

Page G2

ICE Series Wiring Diagram

ICEU150/220/225/226 Air and Water Wiring Diagram

Page G3

ICE Series Wiring Diagram

ICEU150/220/225/226 Air and Water Wiring Schematic

Page G4

ICE Series Wiring Diagram

ICE0250 Air and Water Wiring Diagram

Page G5

ICE Series Wiring Diagram

ICE0250 Air and Water Wiring Schematic

Page G6

ICE Series Wiring Diagram

ICE0400 Air and Water Wiring Diagram

Page G7

ICE Series Wiring Diagram

ICE0400 Air and Water Wiring Schematic

Page G8

ICE Series Wiring Diagram

ICE0405/0406 Air and Water Wiring Diagram

Page G9

ICE Series Wiring Diagram

ICE0405/0406 Air and Water Wiring Schematic

Page G10

ICE Series Wiring Diagram

ICE0500 Air and Water Wiring Diagram

Page G11

ICE Series Wiring Diagram

ICE0500 Air and Water Wiring Schematic

Page G12

ICE Series Wiring Diagram

ICE0500 Remote Wiring Diagram

Page G13

ICE Series Wiring Diagram

ICE0500 Remote Wiring Schematic

Page G14

ICE Series Wiring Diagram

ICE0605/0606/0805/0806/1005/1006 Air and Water Wiring Diagram

Page G15

ICE Series Wiring Diagram

ICE0605/0606/0805/0806/1005/1006 Air and Water Wiring Schematic

Page G16

ICE Series Wiring Diagram

ICE0605/0606/0805/0806/1005/1006 Remote Wiring Diagram

Page G17

ICE Series Wiring Diagram

ICE0605/0606/0805/0806/1005/1006 Remote Wiring Schematic

Page G18

ICE Series Wiring Diagram

ICE1007 Air and Water Wiring Diagram

Page G19

ICE Series Wiring Diagram

ICE1007 Air and Water Wiring Schematic

Page G20

ICE Series Wiring Diagram

ICE1007 Remote Wiring Diagram

Page G21

ICE Series Wiring Diagram

ICE1007 Remote Wiring Schematic

Page G22

ICE Series Wiring Diagram

ICE1405/1406/1806/2005/2106 Air and Water Wiring Diagram

Page G23

ICE Series Wiring Diagram

ICE1405/1406/1806/2005/2106 Air and Water Wiring Schematic

Page G24

ICE Series Wiring Diagram

ICE1405/1406/1806/2005/2106 Remote Wiring Diagram

Page G25

ICE Series Wiring Diagram

ICE1405/1406/1806/2005/2106 Remote Wiring Schematic

Page G26

ICE Series Wiring Diagram

ICE1407/1807/2107 Air and Water Wiring Diagram

Page G27

ICE Series Wiring Diagram

ICE1407/1807/2107 Air and Water Wiring Schematic

Page G28

ICE Series Wiring Diagram

ICE1407/1807/2107 Remote Wiring Diagram

Page G29

Ice-O-Matic ICEU300HA, ICE0520FA, ICE1506HR, ICEU226FW, ICEU220HW User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

How To Use This Manual

Model and Serial Number Format

Maintenance

Cleaning and Sanitizing (continued)

ICE Series Winterizing Procedures

Cleaning Activity Cleaning Agent Method of Application

How To Use The Troubleshooting Trees

Troubleshooting Trees Table Of Contents

Water Distribution and Components

Float Valve

Water Distribution Disassembly

Water Splash Curtain

Water Purge Valve

Water Trough

Refrigerant Cycle and Components

Refrigerant Pressures

Air Cooled Condenser (Self Contained)

High Pressure Safety Control (Manual Reset)

High Pressure Safety Control (Automatic Reset)

Thermostatic Expansion Valve (TXV)

Continued Page E4

Thermostatic Expansion Valve (Continued)

Evaporator

Harvest Cycle

Hot Gas Valve

Remote System

Remote Condenser

The pump down system prevents liquid refrigerant from migrating to the evaporator and compressor during the off cycle and prevents the compressor from slugging or starting under an excessive load.

Liquid Line Solenoid

Receiver

All machines in this manual are electro-mechanical controlled; however the control circuitry on the single evaporator units differs from the dual evaporator units and is detailed below.

Selector Switch

Contactor

Purge Switch

Compressor and Start Components