Kold-Draft GB440 Manuel de service
ELECTROMECHANICAL AND
®
ELECTRONIC ICE CUBER
SERVICE MANUAL
1525 East Lake Road, Erie, PA 16511-1088
814/453-6761
FAX 814/455-6336
©2004 KDIndustries, Inc., Erie, PA U.S.A.
Printed in U.S.A. 3/04
A Tradition of Excellence In Ice Equipment.
Page No.
Table of Contents
Table of Contents 1B
Key to Electronic Model Numbers 2B
Key to Electro-Mechanical Model Numbers 3B
Installation Specifications- Electronic 4B
Operational Components- Electronic 6B
Sequence of Operation- Electronic 11B
Electrical Circuits 13B
Functional Tests 25B
Trouble, Cause and Remedy 26B
Service and Troubleshooting 33B
Installation and Adjustments 43B
Preventative Maintenance 47B
Operational Components- Electro-Mechanical 49B
Installation Specifications- Electro-Mechanical 53B
Kold-Draft® Service & Parts Manual
-1B-
Key to Model Numbers-Electronic Cubers
GB 4 01 W HK
Cube Size
C = Full Cube (1-1/4” x 1-1/4” x 1-1/4”)
HK = Half Cube (5/8” x 1-1/4” x 1-1/4”)
K = Cubelet (5/8” x 5/8” x 1-1/4”)
Condenser Type
A = Air Cooled Condenser-Self Contained
W = Liquid Cooled Condenser-Self Contained
R = Remote Air Cooled Condenser
Electrical Characteristics/Refrigerant
01 = 115 Volt-60 Hz.-1 Ph. (R-12)
02 = 115-208/230 Volt-60 Hz.-1 Ph. (3-Wire) (R-12)
03 = 208/230 Volt-60 Hz.-1 Ph. (R-12)
04 = 208/230 Volt-60 Hz.-1 Ph. (R-502)
05 = 208/230 Volt-60 Hz.-3 Ph. (3-Wire) (R-502)
06 = 200 Volt-60 Hz.-1 Ph. (R-12)
07 = 230 Volt-50 Hz.-1 Ph. (R-12)
08 = 380/230 Volt-50 Hz.-3 Ph. (5-Wire) (R-502)
Electronic Cuber Series
3 = 300 Series (3/4 HP)
4 = 400 Series (3/4 HP)
5 = 500 Series (1 HP)
6 = 600 Series (1-1/2 HP)
10 = 1000 Series (2 HP Nominal)
12 = 1200 Series (2 HP Nominal)
Cabinet Width
GB = Horizontal Unit (42” Wide)
GT = Slimline Unit (28-1/2” Wide)
Kold-Draft Service & Parts Manual
2-B
Key to Model Numbers-Electro-Mechanical Cubers
GB 1 A N 4 HK E
Electronic
Cube Size
C = Full Cube (1-1/4” x 1-1/4” x 1-1/4”)
HK = Half Cube (5/8” x 1-1/4” x 1-1/4”)
KK = Half Cube (5/8” x 1-1/4” x 1-1/4”)
K = Cubelet (5/8” x 5/8” x 1-1/4”)
Ice Production Per 24 Hours (Nominal)
64 = 75 lbs. w/40 lb. Storage Bin Included
1 = 110 lbs. w/65 lb. Storage Bin Included
2 = 200 lbs. 6 = 600 lbs. 10 = 1000 lbs.
3 = 300 lbs. 7 = 700 lbs. 11 = 1000 lbs.
4 = 400 lbs. 8 = 800 lbs. 12 = 1200 lbs.
5 = 500 lbs. 9 = 900 lbs. 16 = 1600 lbs.
20 = 2000 lbs.
Code Letter
NSF = National Sanitation Foundation Listed
D = 115/230 Volt-60 Hz.,-3-wire, NSF Listed
5 = 500 Series (1 HP)
Condenser Type
A = Air Cooled Condenser-Self Contained
W = Liquid Cooled Condenser-Self Contained
R = Remote Air Cooled Condenser-Precharged
X = Remote Air Cooled Condenser
Compressor Horsepower Rating
0 = No Condensing Unit 3 = 1/3 HP 6 = 1/5 HP
1 = 1 HP 4 = 14,000 BTU 7 = 3/4 HP
2 = 11,000 BTU 5 = 1/2 HP 8 = 3/4 HP
Machine Type
GB = Horizontal Unit, Mounts on a Bin (42” Wide)
GT = Slimline Unit, Mounts on a Bin (28-1/2” Wide)
GY = Self Contained Compact Unit (30” Wide)
GS = Self Contained Compact Unit (24” Wide)
IS = Self Contained Dispenser (31-1/4” Wide)
Kold-Draft Service & Parts Manual
3-B
60 Hertz Electronic Cubers
Installation S
pecification
s
FUSE/HACR
BREAKER SIZEMINIMUMMINIMUM
(AMPS)INCOMINGCIRCUIT
NORMAL MAXIMUM
WIRE SIZEAMPACITYHPMODEL
NOTE: Max i m um Branch Circui t Fuse or
HACR type Circuit Breaker si ze is dependent on the size of the
conductors supplyi ng the Ice Maker. They must be no less than t he minimum ampacit y rating and no
more than "Maximum" rating on the nameplate.
25 351022.73/4GT301A
20 2512173/4GT301W
25 40/3510253/4GT401A/GB401A
20 2512183/4GT401W/GB401W
25 351020.93/4GT401R/GB401R
20 2012163/4GT402A/GB402A
15 2014153/4GT402W/GB402W
20 251216.93/4GT402R/GB402R
15 201414.41GB503A
15 201413.31GT503W/GB503W
15 201412.21GT503R/GB503R
20 30122011,000 BTUGB603A
15 20141511,000 BTUGT603W/GB603W
20 301218.911,000 BTUGT603R/GB603W
20 25121714,000 BTUGB903/1003W
20 301219.314,000 BTUGB903/1003R
30 451028.227,600 BTUGB1204W
30 451028.227,600 BTUGB1204R
20 301217.822,500 BTUGB1205W
20 301217.922,500 BTUGB1205R
30 4010303/4IS401A
25 3010233/4IS401W
15 2014151IS503W
15 1514151/3GY3A
15 1514151/3GY3W
25 351022.73/4GT7A
20 2512173/4GT7W
Supplement fuses (install ed on the Ice Maker)
required f or continuous operation without nuisance blowing, up to the indi cated nameplate "Max imum"
rating to compensate for ambient conditions.
SPECIAL NOTE: Wire sizes on this chart are good up to 80 feet.
Kold-Draft
do NOT prov ide prim ary protect ion and may be sized as
Anything 80 feet to 150 feet increase wire 1 size.
Any runs 150 feet to 250 feet increase the wire 2 sizes.
-4B-
®
Service & Parts Manual
Water Levels, Pressures, Cycles and Charges
Installation Specifications
(higher than average temperatures increase pressures and cycle times)
Model
Cube Size
Full Water Level Distance
below top of tank
Suction Pressure after Defrost
Suction Pressure before
Defrost
Defrost Pressure
Cycle Times (approximate)
Refrigerant Charge
Remotes (R) see note below
Refrigerant Type
Approximate lbs. of ice per
batch
Compressor Size
Model
Cube Size
Full Water Level Distance
below top of tank
Suction Pressure after Defrost
Suction Pressure before
Defrost
Defrost Pressure
Cycle Times (approximate)
Refrigerant Charge
Remotes (R) see note below
Refrigerant Type
Approximate lbs. of ice per
batch
Compressor Size
70 psig max. 100-110
with CPR valve psig
GB1205: 22,500 BTU
TXV controlled
GB1204: 27,600 BTU
TXV controlled
7-1/2 7 lbs. 4 lbs.
lbs.
9,800 BTU
TXV controlled
with CPR valve psig
15 lbs. 14 lbs. 8 lbs. 15 lbs. 14 lbs. 8 lbs.
14,000 BTU
TXV controlled
3 lbs.3 lbs.
7-1/2 7 lbs. 4 lbs.
lbs.
6,800 BTU
TXV controlled
GB600/GT600GB903/GB1000GB1200
C HK K C HK K C HK K
2-5/8" 2-3/4" 3-1/2" 2-5/8" 2-3/4" 3-1/2" 2-5/8" 2-3/4" 3-1/2"
20 psig20 psig55-60 psig
0-2 psig0-2 psig 10-15 psig
40-60 psig 55 psig max. 40-60
21 min. 17 min. 12 min.27 min. 22 min. 15 min.19 min. 17 min. 11 min.
3 lbs.3 lbs.3 lbs.
R-12 R-12R-502
7-1/2 7 lbs. 4 lbs.
lbs.
11,000 BTU
TXV controlled
GT300GB400/GT400/IS400GB500/GT500/IS500
C HK K C HK K C HK K
2" 3" 2-5/8" 2-3/4" 3-1/2" 2-5/8" 2-3/4" 3-1/2"
11-13 psig20-25 psig15-20 psig
03 psig0
40 psig40-60 psig40-60 psig
28 min. 21 min. 15 min.28 min. 25 min. 14 min.26 min. 20 min. 13 min.
13 oz. GT301A
10 oz. GT301W
R-12 R-12R-12
3-3/4 3-1/2 lbs. 2 lbs.
lbs.
6,800 BTU
cap. tube controlled
NOTE: Remote condenser application cubers require a total minimum charge of 10-1/2
lbs. GB1200 series cubers use R-502, all others use R-12.
{
For maximum fuse size check electrical rating plate on left rear of cuber.
Kold-Draft® Service & Parts Manual
-5B-
Kold-Draft® Electronic Cuber Construction
Operational Components
Skins
The skins consist of the top, left end, back, right end panels and front inspection panel.
Condensing Units
Varies with each model. For compressor size and charge, refer to the Water Levels,
Pressures, Cycles and Charges Chart on the previous page.
Evaporator
The GB series Full Cube (C) evaporator is made up of 108 cells, 1-1/4" each way.The
Cubelet (K) evaporator is made up of 216 cells, 1-1/4" x 1-5/8" x 5/8" deep. The Half
Cube (HK) evaporator is made up of 216 cells, 5/8" x 1-1/4" x 1-1/4" deep. The material
is copper and the entire assembly is tinned, preventing corrosion and making its use
acceptable to any sanitary board. A seal is not required between the evaporator and
water plate, normally there is an approximately 1/32" clearance between them. Refer to
Water Plate-Evaporator Alignment for adjustments.
Note: GT300 evaporators contain 1/2 the number of cells of a GB evaporator.
Refrigerant Control
1. Thermostatic expansion valves are used on all GB and IS models and GT400,
GT500 and GT600 models. For replacement of the valve, consult the Parts
Price List for type of expansion valve. It has been regulated properly on test
before being shipped, to give minimum superheat and maximum flooding of the
evaporator and should not require adjustment.
Sometimes after shipping or storage, the expansion valve sticks and allows
more refrigerant to pass than necessary, increasing the low side pressure
and temperature, thus excessive frostback and a long cycle. If this condition
does not correct itself during the second cycle, it will be necessary to adjust the
superheat on the expansion valve, closing the valve clockwise 1/8 to 1/4 turn to
increase superheat, reducing the suction pressure and preventing frostback. If
valve hunts (varies suction pressure up and down) more than 2 to 3 lbs. when
suction pressure is below 13 lbs., it indicates that the valve should be opened
more.
2. The GT300 series are capillary systems and do not have an expansion valve.
Water Plate
The water plate is made of approved plastics and is used to distribute the water
through jet holes into the freezing cells of the evaporator, and also to return water
through two drain holes in each cell in the water plate. On the front of the water plate is
a control stream, that should be set at the base of the dam once the water fill is
complete. Backing the screw out increase the flow. At the end of a cycle when cubes
are virtually frozen there is an increasing water pressure in the system causing the
stream to rise and go over the dam dumping dreg water.
Circulation Tank
The circulation tank is secured to the bottom of the water plate. It serves as a reservoir
to hold enough water to make one batch of ice.
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-6B-
Circulation Strainer
Operational Components
The circulation strai ner has a large screen inserted i n the tank outlet to prevent dirt or
particles of precipitated mineral from clogging the jet holes or the control stream. It also
protects the pump impeller. If the screen becomes clogged with precipitated minerals, it
is advisable to clean the whole circulation system with ice machine cleaner.
Water Pump
The water pump is a centrifugal type, direct with sealed bearings that require no
lubrication. The inlet tube is at the bottom of the water circulation tank, and the outlet at
the top of the pump is connected to the header of the water plate.
Water Level Probe Assembly (GBR-03170)
This probe is connected to the main water circulation tank by means of flexible tubing.
The height of water in the probe assembly indicates the height of water in the
circulation tank. Thermistor probes determine water valve on/off levels. Refer to the
Water Levels, Pressures, Cycles and Charges chart for the correct setting per model
for the upper probe. The bottom probe is positioned so that 15-30 seconds after the
water flows over the dam on the control stream box on the water plate, the water level
is below the glass tip and harvest is initiated.
Pump and Defrost Switch
A spring loaded switch is mounted in the control box. It controls the defrost circuit and
water pump, and is operated by an adjustable screw in the lift plate attached to the
water plate. As the water plate closes after defrost, the adjustable screw lifts up and
makes contact with the pump switch to cut one connection to the defrost circuit and
start the circulation water pump.
Water Inlet Valve
The water inlet valve is mounted int front left of the freezing compartment and controls
the rate of flow of water into the water tank when the cuber is filling. It is a constant flow
type requiring a minimum 15 psi. An external "Y" type strainer is used with the valve.
For pressures over 100 psi or if there i s water hammering, a pressure regulator should
be used.
Actuator Motor and Cam Assembly
The assembly is located just to the right and front of the evaporator. The actuator motor
drives the cam shaft directly and i s reversible. A cam on each end of the shaft forces
the water plate down, separating the water plate from the ice in the evaporator. The two
springs on the cams pull the water plate up at the end of the defrost cycle, and hold the
water plate against the bottom of the cams during the freeze cycle. To prevent the
water plate from opening after current has stopped flowing to the actuator motor, a drift
stop spring with a plastic end (GBR-00965) presses against the actuator motor shaft,
on the front of the motor. If the drift stop is not aligned with the motor shaft it can be
removed easily and bent into shape.
Evaporator Probe (GBR-03176)
Resistance values of the probe change due to temperature changes on the evaporator.
These changes are transmitted to the printed circuit card and allows one probe to
perform three functions; 'cold water control', 'actuator control' and 'overheated
evaporator cut out'.
1. COLD WATER CONTROL opens the hot gas valve during the fill cycle when the
evaporator cools to 45} F. (red L.E.D. shines bright on P.C. card). The hot gas
Kold-Draft® Service & Parts Manual
-7B-
will shut-off when the water fill is complete or when the evaporator warms to 50
Operational Components
F. (red L.E.D. off or dimly lit).
2. ACTUATOR CONTROL resets cold when the evaporator reaches 26} F.
(orange L.E.D. shines bright) and will send power through the actuator toggle
switch to the actuator motor at harvest. It also sends power to the actuator
motor when the evaporator warms to 40} F. after harvest, to return the water
plate (orange L.E.D. off).
3. OVERHEAT TEMPERATURE FUNCTION shuts the cuber down when the
evaporator temperature reaches 140} F., should the hot gas valve stick open. It
will re-energize the cuber when the evaporator cools to 120} F.
Bin Probe (GBR-03177)
The bin probe is mounted to a flexible probe holder on the ice chute or through a
bracket in the bin. Its resistance values change with temperature fluctuations at the
probe tip due to the proximity of ice. These changes are transmitted to the Bin Control
on the P.C. card and turn the ice maker on or off.
To Set Bin Control
}
1. Do not attempt to set the Bin Control while the unit is filling with water. The P.C.
card has a circuit to fill the water tank befor eshutting off on "Full Bin Condition".
2. Once the water fill is complete, hold ice to the tip of the probe. The ice maker
should shut off in 15-30 seconds. if longer, adjust the bin potentiometer on the
P.C. card slowly counter-clockwise until the unit shuts off.
3. After the ice maker stops, remove the cubes from the probe tip. the ice maker
should start within one minute, if the ambient air is above 50} F.
The bin probe is a standard length, but when stacking units check the chart below to
determine whether a stacked cuber will require a bin probe extension (GBR-03240) in
addition to the bin probe (GBR-03177) to reach into the bin.
GBR-03177 Probe
& GBR-03240 Extension
GBR-03177 Probe
& GBR-03240 Extension
GBR-03177 Probe
& GBR-03240 Extension
GBR-03177 Probe
& GBR-03240 Extension
GBR-03177 Probe
& GBR-03240 Extension
GBR-03177 Probe
& GBR-03240 Extension
GBR-03177 ProbeGBR-03177 Probe
Kold-Draft® Service & Parts Manual
T-100 CrusherGBR-03177 Probe
Any Kold-Draft® BinAny Kold-Draft® Bin
-8B-
Printed Circuit Card
Operation
al Components
GBR-03135-02 type P.C. cards have been used since August, 1980. Refer to
Engineering Bulletin #10-80 for pre-August, 1980 detail s, but note that all of the older
P.C. cards should have been updated with retrofit kits offered by the factory after
August, 1980.
GBR-03135-02-E P.C. cards replaced the GBR-03135-02 from October, 1982 through
December, 1990.
Since January, 1991, we have been providing 102 1165 01 as a replacement for both
GBR-03135-02 and GBR-03135-02-E P.C. cards. To replace a GBR-03135-02 card, a
GBR-03122 wiring adapter kit is required.
TB2 (upper left of P.C. Card)
1. B: Pins 1 and 2, location of
bin probe which turns the
cuber on and off according to
ice demand.
2. E: Pins 3 and 4, location to
connect evaporator probe
which relays evaporator
temperature to P.C. card,
allowing card to set to the
cold or warm side, the cold
water control, actuator control
and thermal over temperature
protector.
3. WL: Pins 5, 6, 7 and 8,
location to connect water level probes, which turn the water inlet valve on and
off (W). It initiates harvest when water falls below the lower probe (L) when
actuator control is set cold.
Adjustable Potentiometers and L.E.D.'s (located beneath TB2)
1. Bin Potentiometer: Adjustment to turn unit off on
contact of bin probe with ice in 15-30 seconds,
provided the water fill is satisfied.
2. Actuator Potentiometer: Adjust to raise water plate
15-30 seconds after ice harvest.
3. Cold Water Potenti ometer: Adjustment to open hot
gas valve should evaporator cool to 45} F. during
water fill cycle.
Kold-Draft® Service & Parts Manual
-9B-
4. Cold Water L.E.D. (red): Il luminates when the evaporator is colder than 45} F.
Operation
al Components
Off when CW control is set at 50} F. or above.
5. Actuator L.E.D. (orange): Illuminates when the evaporator temperature is colder
than 26} F. Off when actuator control is set warm at 40} F. or above.
Bin Relay (lower right corner of P.C. Card)
On P.C. cards made since January, 1984, this relay is replaceable, should it ever fail.
Output Sockets and Relays 2, 3 & 4 (upper right corner of P.C. Card)
The connections for output supply from the P.C. card to the small motors and valves
when sequenced by the relays.
Transformer (upper center of P.C. Card)
The same P.C. card is used on all Electronic cubers. The transformer has 2 leads
(brown and white) attached to a plug which mates to a plug from the front wire channel.
On 115 volt ice makers, the plugs mate white-to-white (brown open on transformer
plug). On 208/230 and 115/230 (3 wire) volt ice makers, the plug mate brown-to-brown
(white open on transformer plug).
Kold-Draft® Service & Parts Manual
-10B-
With the Electronic cuber mounted to a bin, the water turned on, the electricity
Sequence of Operation
connected and the wash switch in the 'ON' position, we can follow through one
complete cycle.
The bin, actuator and cold water controls are set to the warm side (L.E.D.'s 'OFF'-dimly
lit). The water plate is in the 'UP' position. The pump and defrost switch is held up by
the lift bolt on the water plate energizing the pump. The water inlet valve is open and
the evaporator is cooling. The water level in the main water tank is rising and the
corresponding water level is indicated in the water level probe assembly. Water is
being pumped from the bottom of the circulation tank into the header at the left end of
the water plate, through the lateral tubes under each row of cells, through the squirt
holes in the center of each cell. The water stream hits the top of each cell then
cascades down the 4 sides of each cell and returns to the main water tank through
drain holes on each side of the squirt hole. When enough water to make one batch is in
the main water tank and the water level probe assembly, water will touch the upper
thermistor probe and the water inlet valve shuts off. The control stream at the front l eft
corner of the water plate should be fl owing at the base of the dam. The screw at the
inlet of the control stream may be adjusted to obtain a proper setting.
When the evaporator temperature reaches 45} F. the evaporator thermistor probe
signals the P.C. card to set the cold water control 'cold' (red L.E.D. 'ON'-comes on
bright).
The evaporator continues to co ol, at 32} F. minute layers of ice form on the top and the
4 sides of each cell. As this proce ss continues, the water level will decrease in the main
water tank and the water level probe assembly.
NOTE: When the circulating water reaches a temperature of 32} F., it MAY be
supercooled and it MAY partially crystallize in the water tank. If this occurs, the flow of
water in the control stream nozzle will stop or fluctuate considerably and most of the
circulation will stop for about 30 seconds. This is STRICTLY A NORMAL OPERATION
AND THE CONTROL STREAM SHOULD NOT BE ADJUSTED AT THIS TIME.
When the evaporator temperature reaches 26} F., the evaporator thermistor probe
signals the P.C. card to set the actuator control 'cold' (orange L.E.D. 'ON'-comes on
bright).
The water continues to freeze until each cell is al most completely full of ice. As the ice
comes closer to the jet stream in the center of each cell, the head pressure in the water
plate increases, causing the contr ol stream to rise and flow over the dam in the control
stream box. This water will be dissipated to the drain pan, lowering the level in the
water level probe assembly. Within 15-30 seconds the water will leave the bottom
thermistor probe and expose it to air.
The harvest cycle is initiated, every circuit in the system is simultaneously engaged.
The hot gas valve opens sending hot gas to warm the evaporator. The water inlet valve
opens and the water rinses the water plate. The actuator circuit is energized through
the actuator control, through the actuator toggle switch to the actuator motor, causing
the actuator motor to turn counter-clockwise and separate the water plate from the
evaporator. When the water plate opens approximately one inch the pump and defrost
switch drops, turning the water pump off. The pump switch now completes a second
Kold-Draft® Service & Parts Manual
-11B-
circuit to the defrost val ve to keep it open duri ng the harvest cycle. The actuator motor
Sequence of Operation
shaft continues to turn a 1/2 turn revolution until the trip lever on the actuator motor
snaps the actuator toggle to the right and breaks the actuator circuit stopping the
actuator motor in the down position.
As the evaporator warms, the cubes on the left edge of the evaporator slide out of the
evaporator and rest on the water plate. There is a small fin connecti ng the bottom of
the cubes together so that they will come down in unison and clearing the water plate,
slide into the bin where they will break apart.
After the ice is out of the evaporator, the evaporator and the evaporator thermistor
probe warm up rapidly. When the evaporator probe senses a temperature between
40}-45} F., its resistance change signals the P.C. card and the actuator control sets
'warm' (orange L.E.D. 'OFF'-dimly lit)and completes the circuit from the defrost circuit to
the reversing side of the actuator toggle switch and actuator motor.
NOTE: The actuator control does not start the defrost cycle; it only ends it after the ice
falls out. The motor revolves clockwise raising the water plate. When the water plate is
almost closed, the lift bolt on the water plate pushes up the pump and defrost switch
lever starting the pump and breaking one circuit to the hot gas valve. The water plate
continues to the full 'UP' position when the actuator toggle arm will snap the actuator
toggle to the left causing the actuator motor to stop. When the evaporator temperature
reaches 50} F., the cold water control will switch to the warm side shutting off the hot
gas valve (red L.E.D. 'OFF'-dimly lit). When the water level is high enough to touch the
upper thermistor probe, it breaks the circuit to the water plate.
NOTE: Should some ice cubes be left on the water plate, keeping it partially open
when the water plate comes up, the actuator motor will continue to operate and the
springs will stretch to allow the cams to take their vertical position and snap the
actuator toggle switch. Since the lift plate cannot push up the defrost switch, the circuit
is complete through this switch to the stop 'up' side of the actuator toggle switch. When
the actuator toggle arm snaps the actuator toggle switch to the stop 'up', the actuator
motor will immediately reverse itself and open the plate allowing the captive ice to fall
off. When the plate i s in the open position, the actuator toggle arm will again reverse
the actuator toggle switch and the actuator motor and cause the plate to close. This will
continue until the water plate is clear and the l ift plate can push up the defrost switch,
breaking the circuit through this switch to the stop 'up' side of the actuator toggle
switch, so that the motor will stop with the cams up when the actuator toggle arm
pushes the actuator toggle to the stop 'up' position.
The ice maker has now completed its full cycle and started another freezing cycle. This
will be regularly repeated until the bin i s full and the bin control shuts off the ice maker
automatically. When some ice i s removed from the bin, the ice maker will start up and
refill the bin.
Kold-Draft® Service & Parts Manual
-12B-
The schematic wiring diagrams, provided on these pages, show the flow of electric
Electrical Cir
cuits
current at several steps in the operation of the ice maker. The dark lines show current
flow on all wiring diagrams. Following the diagrams is a description of the operation
specificall y related to the circui ts that are used at each step. These circuits appl y to all
electronic and electromechanical ice makers built since 1964 and to those ice makers
in the field which have been revised to the 1964 wiring.
'EC' refer to Thermostatically controlled ice makers
'EEC' refer to Electronically controlled ice makers
EC1: Water fill (circulating water above 45} F.) - Current to condensing unit, water
pump and water valve. Water filling circulation tank and control tank. Water pump
circulating water through water header, distri bution laterals and jet holes to indi vidual
evaporator cells. Evaporator is cooling water (approximately 2 minutes).
EEC1: Water fill (circulating water above 45} F.) - Current to condensing uni t, water
pump and water valve. Water filling circulation tank and water level probe assembly.
Water pump circulati ng water through water header, distribution laterals and jet holes
to individual evaporator cells. Evaporator is cooling water (approximately 2 minutes).
Kold-Draft® Service & Parts Manual
Water Fill
-13B-
Water Fill
E
lectrical Circuit
s
EC2: W ater fill (ice maker with cold water thermostat-circulating water below 40} F.) -
Current to condensing unit, water pump, water valve and through blue circuit through
cold water thermostat, pink circuit to defrost valve. When the incoming water is cold
and the compressor can cool the water below 40} F. during the 'Fill Cycle', the cold
water thermostat will switch to the cool side connecting the pink and blue circuits giving
power to the defrost valve allowing hot gas from the compressor to go through the
evaporator warming up the circulating water. GS models have no cold water
thermostat.
EC2a: Water fill (ice maker with cold water thermostat-circulating water warms up to
50} F.) - If the water warms up to 50} F. before the water fill is complete and the weight
control switch drops, the cold water thermostat will switch to the warm side shutting the
defrost valve and the compressor will start to cool the water again.
EEC2: W ater fill control (circulating water below 40 to 45} F.) - Current to condensing
unit, water pump, water valve and through blue circui t through cold water thermostat,
pink circuit to defrost valve. W hen the incoming water is col d and the compressor can
cool the water below 40} F. during the 'Fill Cycle', the cold water thermostat will switch
to the cool side connecting the pi nk and blue circuits giving power to the defrost valve
allowing hot gas from the compressor to go through the evaporator warming up the
circulating water.
EEC2a: W ater fill control (circulating water warms up to 50 to 55} F.) - If the water
warms up to 50} F. before the water fill is complete and water touches the top
thermistor water level probe, the cold water control will switch to the warm side shutting
the defrost valve, and the compressor will start to cool the water again. A red L.E.D. is
mounted on the printed circuit card below the cold water control potentiometer as a
service aid. It is on (bright) when the cold water control is in the cold position.
Kold-Draft® Service & Parts Manual
-14B-
Start of Freeze Cycle
Electrical Circuits
EC3: Tanks full, weight switch drops (freeze cycle evaporator above 20} F.) - Sufficient
water is in the ci rculation tank and control tank so that the weight of the water in the
control tank pulls the weight control switch down shutting the water valve. If the cold
water thermostat is still on the cool side and the circulating water is still being warmed
as the weight control switch drops, this switch cuts off power to the blue circuit and
through the cold water thermostat to the defrost valve shutting the defrost valve. Water
level should settle in the control tank at a preset distance below the top of the main
circulation tank. (Refer to the Water Levels, Pressures, Cycles and Charges chart.)
Current to condensing unit and water pump. Water freezing in cells. Springs hold water
plate edges against bottom of cams. Cams and hinge leaves hold water plate
approximately 1/32" from evaporator to adequate fin between the cubes.
EEC3: Tank and water level probe assembly full-freeze cycle evaporator above 26
Sufficient water is in the circulati on tank and water level probe assembly so that water
touches the top thermistor probe and the water valve shuts off.
Kold-Draft® Service & Parts Manual
-15B-
}
F. -
Freeze Cycle
Electrical C
ircuits
EC4: Freeze cycle with evaporator below 20} F. - During the freeze cycle, the
evaporator and the actuator thermostat get cold enough (approximately 20} F.) to reset
the actuator control ready for the next defrost cycle. The particular time when this
happens is unimportant since the water control stays off and prevents defrost until the
cubes are full and the water is used up, and there is no change in the current flow at
this step. During this peri od the water is being used up in the formation of ice and the
water level drops slowly in the circulation tank and the water level probe tube.
EEC4: Freeze cycle with evaporator below 26} F. - During the freeze cycle, the
evaporator and the thermistor probe get cold enough (approximately 26} F.) to reset
the actuator control ready for the next defrost cycle. The particular time when this
happens is unimportant since the water control stays off and prevents defrost until the
cubes are full and the water is used up, and there is no change in the current flow at
this step. During this peri od the water is being used up in the formation of ice and the
water level drops slowly in the circul ation tank and the water level probe tube.
L.E.D. i s
a service aid. It is on (bright) when the actuator control is in the cold position.
mounted on the printed circuit card bel ow the actuator control potentiometer as
An orange
Kold-Draft® Service & Parts Manual
-16B-
End of Freeze Cycle- Start of Defrost
Electrical Circuits
EC5: Start of defrost - Cubes are full and some have almost frozen over jet holes
forcing some of the remaining water faster through the control stream over the control
stream dam, lowering the water level rapi dly in the control tank until it i s light enough
for the weight control switch to snap up. Current flows to condensing unit, water pump,
through the weight control switch and the blue circuit to the water valve, also from blue
through the actuator thermostat, first connection is complete to the red defrost circuit.
From red, current flows through the actuator toggle switch givi ng 115 vol ts on the gray
actuator motor circuit; current through the capacitor which changes phase and boosts
the voltage to 200 vol ts on the yellow actuator motor circuit giving counter-clockwise
rotation. Current from the blue circuit flows through the cold water thermostat to the
pink circuit and defrost valve. Cams start rotating counter-clockwise pressing on the
cam brackets on the water plate to release it from the ice (approximately 15 seconds).
The open defrost valve allows hot refrigerant gas from the compressor to go through
the evaporator coil to start releasing the cubes.
EEC5: Start of defrost - Cubes are full and some have almost frozen over jet holes
forcing some of the remaining water faster through the control stream over the control
stream dam, lowering the water level rapidly in the water level probe assembly until the
bottom thermistor probe is exposed to air and trips the water level control on in 5-20
seconds. Current flows to condensing unit, water pump, through the weight level
control and the blue circuit to the water valve, also from blue through the actuator
control, first connection is complete to the red defrost circuit. From red, current flows
through the actuator toggle switch giving 115 vol ts on the gray actuator motor circuit;
current through the capacitor which changes phase and boosts the voltage to 200 volts
on the yellow actuator motor circuit giving counter-cl ockwise rotation. Current from the
blue circuit flows through the cold water control to the pink circuit and defrost valve.
Cams start rotating counter-clockwise pressing on the cam brackets on the water plate
to release it from the (approximately 15 seconds).The open defrost valve allows hot
refrigerant gas from the compressor to go through the evaporator coil to start releasing
the cubes.
Kold-Draft® Service & Parts Manual
-17B-
Defrost
Elec
trical Cir
c
uits
EC6: Water plate lowering - The pump and defrost switch lever drops, stopping the
pump and completing the second connection to the red defrost circuit. The actuator
motor and cams continue to rotate counter-clockwise lowering the water plate. The
open water valve allows water to begin rinsing off the water plate. Current to the
condensing unit, actuator motor, water valve and defrost solenoid (approximately 20
seconds).
EEC6: Same as EC6
Kold-Draft® Service & Parts Manual
-18B-
Defrost
Electrical Circuits
EC7: Defrost - W ater pl ate is wide open and actuator toggle rod on the actuator motor
coupling pushes the actuator toggle switch to the left, stopping the motor with the water
plate in the 'down' position and completing the third connection to the red defrost
circuit. Current to the condensi ng unit, water valve and defrost solenoid. Excess water
concentrated with minerals, drains from the water tank. Freshes water washes water
plate and tank. Hot refrigerant gas continues flowing through the evaporator releasing
the ice slowly. Edge of the evaporator and actuator thermostat bulb remain cool (32 to
}
35
F.) as long as ice remains in the evaporator (approximately 2 to 4 minutes
depending on ambient and hot gas temperature). Ice releases on the left side first and
rests on the water plate, then the ice falls out substantially all at one time as the fin
between cubes tends to hold them together until they drop into the bin. After ice falls
out, the side of the evaporator warms up rapidly to 45} F. (approximately 30 seconds).
The actuator toggle pushed left al so completes yellow/orange circuit but with no power
in the orange circuit, the actuator motor gets no power during the defrost period.
EEC7: Defrost - Water plate is wide open and actuator toggle lever on the actuator
motor rear shaft pushes the actuator toggle switch to the right, stopping the motor with
the water plate in the 'down' position and completing the third connection to the red
defrost circuit. Current to the condensing unit, water valve and defrost solenoid. Excess
water concentrated with minerals, drains from the water tank. Freshes water washes
water plate and tank. Hot refrigerant gas continues flowing through the evaporator
releasing the ice slowly. Edge of the evaporator and evaporator probe remain cool (32
to 35
}
F.) as long as ice remains in the evaporator (approximately 2 to 4 minutes
depending on ambient and hot gas temperature). Ice releases on the left side first and
rests on the water plate, then the ice falls out substantially all at one time as the fin
between cubes tends to hold them together until they drop into the bin. After ice falls
out, the side of the evaporator warms up rapidly to 45} F. (15-30 seconds). The
actuator toggle pushed right also completes yellow/orange circui t but with no power in
the orange circuit, the actuator motor gets no power during the defrost period.
Kold-Draft® Service & Parts Manual
-19B-
End of Defrost-Water Plate Starts Closing
E
lectrical Circuits
EC8: Water plate starts closing - Warm actuator thermostat bulb on the side of the
evaporator switches actuator thermostat from cold position disconnecting the first
circuit to red; the current from black/green to the red circuit continues through the
actuator toggle and pump toggle switches. The actuator thermostat switching to the
warm position completes the red/orange circuit and through the actuator toggle gives
115 volts to the yellow winding on the actuator motor. The capacitor changes the phase
and boosts the voltage to 200 volts to the gray winding of the motor to give clockwise
rotation. Cams rotating clockwise pull up the springs and water plate. Current to
condensing unit, defrost water valve and actuator motor (approximately 20 seconds).
The cold water thermostat bulb on the edge of the evaporator will warm up at about this
time or dur ing closing and switch the cold water thermostat to the warm side connecting
the red to the pink circuit; since red is energized, the defrost valve stays open.
EEC8: Water plate starts closing - Warm evaporator probe on the side of the
evaporator switches actuator control from cold positi on disconnecti ng the first circuit to
red; the current from black/green to the red circuit continues through the actuator
toggle and pump toggle switches. The actuator control switching to the warm position
completes the red/orange circuit and through the actuator toggl e gi ves 115 volts to the
yellow winding on the actuator motor. The capacitor changes the phase and boosts the
voltage to 200 volts to the gray winding of the motor to give clockwise rotation. Cams
rotating clockwise pull up the springs and water plate. Current to condensing unit,
defrost water valve and actuator motor (approximately 20 seconds). The cold water
control will warm up at about this time or during closing and switch to the 'warm' side
turning off the red L.E.D. Models with GBB-03135-02-E P.C. cards will turn off the hot
gas valve at this time, regardless of the water plate position. Refer to model wiring
diagrams for circuit details.
Kold-Draft® Service & Parts Manual
-20B-
End of Defrost-Water Plate Finishes Closing
Electrical C
ircuits
EC9: Water plate almost closed - Lift plate pushes up the pump and defrost toggle
switch, starting pump and disconnecting the second circuit to red, but current from
black/green to red continues through actuator toggle switch. Current to all operating
parts of the cuber. W ater starting to fill the tank. Hot gas from the defrost valve keeps
the evaporator warm to melt any small piece of ice that may be left on the water plate
as it closes. Cams continue rotating to upright position (approximately 5 seconds).
EEC9: Same as EC9
Kold-Draft® Service & Parts Manual
-21B-
Start of New Cycle
Electrical Circuits
EC10: Water plate closed - End Defrost - Front cam in upright position pushes actuator
toggle switch to the right disconnecti ng the third and final circuit to red, stopping the
actuator motor with the water plate up and closing the defrost valve (cycle
completed-same circuit as EC1 - Water fill). Current to condensing unit, water pump
and water valve, cycle starts.
EC11: (Circuit not shown) - Bin full - Ice against bin thermostat tube opens bin
thermostat shutting off all parts of the ice maker. W hen ice is removed, bin thermostat
closes; ice maker will start up and operate regardless of what part of the cycle it was in
when it was shut off.
EEC10: Water plate closed - End Defrost - Front cam in upright position pushes
actuator toggle switch to the left disconnecting the third and final circuit to red, stopping
the actuator motor with the water plate up and closing the defrost valve (cycle
completed-same circuit as EC1 - Water fill). Current to condensing unit, water pump
and water valve, cycle starts.
EEC11: (Circuit not shown) - Bin full - Ice against bin probe after water fill cycle is
completed, opens bin control rel ay shutting off all parts of the ice maker. When ice is
removed, bin control relay closes; ice maker will start up and operate regardless of
what part of the cycle it was in when it was shut off.
Kold-Draft® Service & Parts Manual
-22B-
Abnormal Opening of Water Plate
E
lectrical circuit
s
EC12: Abnormal opening of water plate - Sometimes a cube may stick to the water
plate while it is closing (EC8) and by stretching the springs, prevents the water plate
from closing enough to push the pump and defrost toggle switch up as it normally does
(EC9). The ci rcuit through the pump and defrost toggle switch will remain complete to
the defrost 'red' circuit to the lowering (counter-clockwise) side of the actuator toggle
switch so that, when the front cam pushes the actuator toggle switch to the ri ght, the
actuator motor will immediately reverse and, with cams rotating counter-clockwise, the
water plate will re-open. Current to condensing unit, water valve and through the pump
and defrost toggle switch to the actuator motor. Any other obstruction between the
water plate and the evaporator can cause the same effect as a cube on the water plate.
If the collar on the pump and defrost switch lift rod is set incorrectly so the switch will
not go all the way up, abnormal opening will occur. Further, if the water level is set
much too high and/or spring is unhooked, allowing the water plate to sag during the
water fill so that the defrost switch goes down, the circuit will be completed to the
actuator motor and the plate will open. Likewise, abnormal opening can be created
during the water fill or the beginning of the freeze cycle if the water plate is pulled down
by hand, stretching the springs until the pump and defrost switch goes down,
completing the circuit to the actuator motor. This is done to rinse the ice machine after
using ice machine cleaner. Opening by hand is also used to observe the jet streams by
allowing the cams to go down to horizontal, then pushing up on the pump toggle rod.
Further opening by hand allows a quick partial check of the weight control switch as the
water drains from the control tank and the switch snaps up with a small amount of water
left in the tank (during this check the the control tank tube, it must be a full 11" long to
prevent binding between the control tank and the control stream box on the water
plate).
EEC12: Same as EC12
Kold-Draft® Service & Parts Manual
-23B-
Water Plate Closing After Abnormal Opening
Electrical C
ir
cuits
EC13: W ater plate cl osing after abnormal opening - Since the evaporator and actuator
control are warm during abnormal opening, a circuit is complete through the actuator
control to the orange circuit of the actuator toggle switch. As soon as the water plate is
wide open and the actuator toggle rod on the motor coupling pushes the actuator
toggle switch to the left, the motor will immediately reverse and with cams turning
clockwise, close the water plate.
EEC13: Same as EC13
If the obstruction remains, EC12 and EC13 will repeat. If the obstruction is removed,
such as the cube falling out, EC13 will be followed by EC9 and EC10 and normal
operation will resume.
Kold-Draft® Service & Parts Manual
-24B-
Without the use of special tools or testers, these tests can quickly determine any major
S
peedy F
unction
al Tests
faults with the control module P.C. card, probes, or functional components. A small
screwdriver is required to fit the slots on the potentiometers.
Before starting the test, be sure that there is power to the ice maker and check
the fuses in the control module box and the supplemental line fuses (if installed).
A "Open" terminals simulate a 'Cold' signal to the
P.C. card.
B "Short" terminals simulate a 'Hot' signal to the
P.C.card.
C Turn the wash switch to "Wash" to prevent
compressor short cycling during tests. To
perform a speedy test, induce the following
conditions on TB2.
D A screwdriver may be used to short the pins.
LWEB
OpenOpenOpenShortOpen
H**
Cuber stops, Orange and Red L.E.D.'s ON brightOpenOpenOpenOpenOpen
Cuber runs, Orange and Red L.E.D.'s ON brightOpenOpenOpenOpenShort
Cuber stops, Orange and Red L.E.D.'s OFF (may glow dimly)OpenOpenOpenShortShort
Harvest begins (allow plate to open fully), both L.E.D.'s ON brightOpenShortOpenOpenShort
Press relay #1 plunger*, water plate closes, both L.E.D.'s OFF or
dim
* If Relay #1 plunger is not accessible, CAREFULLY jumper the CONTACTS (B to
B/G)
** Used only with optional Status Indicator. See text for details if necessary.
To Test Probes
A The nominal resistance of all probes at +32o F is 5650 ohms. The only practical
accurate method is to test resistance of the probe in ice water (as near to +32
F as possible). The ranges of acceptable resistances are :
Acceptable RangeProbe
5400-5900 OHMSBin (GBR-03177)
5530-5770 OHMSEvaporator (GBR-03176)
4650-6650 OHMSWater Level (GBR-03170)
B To ROUGHLY test probes using the P.C. card, connect each probe in turn to the
'E' pins with all other pins left open. Turn the cold water potentiometer to
mid-range (12 O'clock). A warm probe will turn BOTH L.E.D.'s 'OFF'.
Submerging the probe in ice water will turn the RED L.E.D. 'ON'. Reaction time
is 5-20 seconds. Be sure to return the cold water potentiometer to its original
position after the probe tests.
o
Kold-Draft® Service & Parts Manual
-25B-
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