Removing From Service ................................................................................................................ 81
Caution:
DANGER
:
ICE CUBER-SAFETY INFORMATION
Special attention should be given to potential hazard labeling on the equipment and the signal
words and symbols that are used throughout this manual. They may also be used to alert against
unsafe practices
Note: Note is used to notify personnel of installation, operation or maintenance information which
is important, but not a cause of personal injury or property damage.
Warning: Indicates a potentially hazardous situation that may result in minor or moderate
injury. The situation may also cause minor damage to the machine
Indicates a potentially hazardous situation that could cause serious injury or death.
The situation may also critically damage the machine
Indicates a potentially hazardous situation that could cause serious injury or death.
The situation may also critically damage the machine
Note:
• Check for freight damage before proceeding with the equipment installation. Be sure to
inspect the equipment carefully for any damage that may not have been evident on the
outside of the carton. Contact the freight carrier immediately to report any damage and file a
claim.
• Read the entire manual before installing, operating or servicing the machine
• To ensure optimal efficiency and productivity follow these installation instructions exactly.
• All machines have been tested and adjusted for correct performance at the factory.
• Knowledge of proper installation and service procedures is essential for the safe operation
and maintenance of KOLD-DRAFT equipment. Refer all installation and service work to
qualified technicians.
• This equipment must be installed in compliance with the applicable federal, state/province,
and/or local plumbing, electrical, and health/sanitation codes and requirements.
• Always disconnect the power supply before servicing the equipment or when the equipment
will not be used for a period of time. Some circuits remain energized when the machine is
switched off.
• Never operate equipment that has been damaged or does not have all the protective covers
in place.
• Never operate equipment that has been altered from the original KOLD-DRAFT
specifications.
• Use of non-approved parts when servicing KOLD-DRAFT equipment will void the equipment
warranty.
Warning: Use only genuine KOLD-DRAFT replacement parts, Use of non-approved parts
when servicing KOLD-DRAFT equipment may create a safety hazard, cause
equipment damage, property damage and will void the warranty.
60 Series Service Manual.rev.1.2012
- 1 –
ICE MAKER IDENTIFICATION
Serial Number Plate Location
See the following for the location of the serial number plate.
KDINDUSTRIES, INC. ERIE, PA. U.S.A.
GB564AK 000000 5HT
208-230V/60HZ/1PH 30oz. R-404a
Note: A complete model number and date code are essential for the accurate selection of
replacement parts. The sticker will be applied to the front of the top cross member of the machine
Date Code Key
YEAR KEY
= 2000
5K
= 2001
5A
= 2002
5B
= 2003
5C
= 2004
5D
= 2005
5E
= 2006
5F
= 2007
5G
= 2008
5H
= 2009
5J
= 2010
6K
= 2011
6A
= 2012
6B
= 2013
6C
= 2014
6D
= 2015
6E
= 2016
6F
= 2017
6G
= 2018
6H
= 2019
6J
= 2020
7K
= 2021
7A
= 2022
7B
= 2023
7C
= 2024
7D
= 2025
7E
= 2026
7F
= 2027
7G
= 2028
7H
7J
= 2029
= 2030
8K
= 2031
8A
= 2032
8B
= 2033
8C
= 2034
8D
= 2035
8E
= 2036
8F
= 2037
8G
= 2038
8H
8J
= 2039
MONTH KEY
= JANUARY
M
= FEBRUARY
N
= MARCH
P
= APRIL
R
= MAY
S
= JUNE
T
= JULY
U
= AUGUST
V
= SEPTEMBER
W
= OCTOBER
X
= NOVEMBER
Y
= DECEMBER
Z
EXAMPLE
= MAY, 2008
5HS
2
208-230 Volt 60 Hz 3 ph (3 wires + ground)
208-230 Volt 60 Hz 1 ph (2 wires + ground)
Model Number Key
Note: Model numbers mentioned in this manual that look like GB56x are used to refer to general
families of machines. The “x” could stand for any combination of a machine’s electrical
characteristics, condenser type and cube size
Do not locate the equipment near any heat source, in direct sunlight, in high ambient areas, or
without proper clearance for ventilation. Placing equipment in these locations will result in
reduced capacities, high system pressures and may cause equipment failure.
Note: Each Kold-Draft ice machine has successfully completed a quality assurance test and has
been factory inspected before shipping. When receiving the unit please inspect it for physical
damage. If damage is found:
1. Have carrier note the damage on the bill of lading.
2. File a damage claim report with the carrier immediately.
3. Call Kold-Draft with your claim number to arrange replacement or repair.
What’s in the Box
•
Kold-Draft Ice Machine
•
Warranty card attached to the front of the machine
•
Two ice deflectors (four ice deflectors with a GB106x machine)
•
Drain Pan hose with clamp (Two hoses and two clamps with a GB106x machine)
•
Adhesive-backed foam weather-strip tape
•
Information packet
o
Duplicate warranty card
o
Installation And Operation Manual
o
4x 1/4-20 stainless steel bolts
o
4x 1/4” stainless steel washers
o
2x 8-32 pan head stainless steel Philips head screws
Required Tools
•
#2 Philips Head Screwdriver
•
7/16” Socket and Wrench
•
Channel Lock Pliers
4
Pre-Install Checklist
•
Ambient air temperatures at the install location are between 45°F (7°C) and 90°F(32°C), the
machine must be installed indoors.
•
The machine will have the minimum opening sizes listed below. Heights listed are strictly the
ice machine and do not include the height of the bin. Depths listed are adjusted to
accommodate plumbing and electrical hookups.
Each ice maker and each ice bin must enter the drain stack through separate connections.
Models equipped with a liquid condenser that does not recirculate coolant must have a drain
for each condenser that enters the drain stack through separate connections
•
The drain hose or pipe will remain a constant diameter from the machine to the drain
o
The building drain must be able to accommodate all the drain water from the ice
machine operation.
•
Individual drains will not be directly connected to a common manifold, drain or standpipe. If
individual drains are to be discharged into a common manifold, drain or standpipe, a minimum
38mm (1.5”) air gap must be provided at each connection. This is to prevent any backflow of
drain water into the ice maker or ice bin.
•
Drain lines will be installed with a minimum drop of 1” per 3’ run (2.5cm per meter run).
•
The temperatures of the water supply fall between 45°F (7°C) and 90°F(32°C)
•
The water supply must be potable, not laden with sediment and have free chlorine levels no
greater than 0.2ppm.
•
A minimum 5 psig (0.034 MPa) dynamic water supply pressure is required for proper
operation of the ice maker water valve. Please note that on liquid cooled ice machines, where
the same water supply is used for both condenser cooling and the potable water supply, the
demand for condenser coolant may cause the supply pressure to drop. This is most notable
at the time of peak load, at the beginning of the freeze cycle. The maximum water supply
pressure is 100 psig (0.6 MPa).
•
All water lines have been purged before connection.
•
All KOLD-DRAFT models are intended to be installed with a permanent connection to the field
electrical supply. Drop cord connections are not to be used with this equipment. Always be
sure the power supply is the same as the ice machine’s electrical specification, which is listed
on the serial number tag on the front of the top frame cross member
•
Each ice maker must be connected to the grid through its own dedicated fuse or HACR type
circuit breaker.
•
Each ice maker must be connected to a separate protected circuit with no other loads.
•
Fused disconnects, installed adjacent to each ice maker, are recommended and may be
required by local codes. These components must be supplied by the installer.
60 Series Service Manual.rev.1.2012
- 5 –
DANGER:
Failure to comply with these regulations may cause serious injury or death
Water Treatment:
•
Electrical service must fall within the voltage tolerances listed below:
Nominal (V)No-Load Maximum
115 (1 Series)126104
208-230 (4 and 5 Series)250198
230 (7 Series)250210
220/380 (8 Series)420/3 phase210/1 phase
•
Breaker or fuse service must be no greater than the maximum rating as specified on the
rating label attached to the back of the machine.
•
The minimum circuit ampacity listed on the back of the machine does not indicate a typical
running current value. Use the minimum ampacity value for sizing branch circuit conductors
up to 26 feet (8 meters) in length. For a conductor length over this length, increase the wire
gauge as required by code.
and cause damage to the machine and its surroundings.
Warning:
that the ice making supply water is potable and not laden with sediment. The use of
additional water treatment may facilitate or reduce the frequency of the need
for cleaning. Please consult your local water conditioning supplier for specific
recommendations.
Note:
•
Ambient temperatures higher than the maximum specification will result in reduced
capacities and high system pressures in air-cooled models. Temperatures lower than the
minimum will cause the machine to malfunction due to an inability to eject the ice from the
evaporator. Ambient temperatures less than 60°F (15 °C) may cause the bin thermostat to
malfunction.
•
Clearance must be provided for ventilation and access for service. Ventilation is
especially important for models with air-cooled condensers. Failure to provide adequate
clearance may result in reduced capacities and high system pressures.
•
Ice machine drains and bin drains may be insulated to prevent condensation.
•
The use of water treatment may increase the intervals between cleaning operations and
the overall machine life.
•
If a water pressure regulator is used, the recommended setting is 30 to 50 psig (0.2 MPa
to 0.3 MPa) dynamic.
•
Do not connect the ice machine to a hot water supply line. Insulate the water line from
sources of heat for greater operating efficiency. Supply water temperatures higher than the
recommended maximum will cause reduced capacities.
•
Normal protector size is based on rated voltage and operation at lower than extreme
temperature limits. Branch circuit conductors may be sized to allow increasing the
protector value up to the specified maximum. This may avoid nuisance protector opening
under harsh operating conditions.
There are no specific requirements for water treatment provided
Full-Load Minimum
6
Additional Pre-install Information for Cooling Tower Applications (L models)
The ice machine does not need to be modified for use with a cooling tower provided the cooling
tower is properly designed for the application. Information regarding the amount of heat
rejection, as well as the pressure drop through the condenser and liquid valves is required to
properly select or design a cooling tower application for an ice machine.
Coolant entering the condenser must not exceed 90°F (32.2°C).
Coolant exiting the condenser must not exceed 110°F (43.3°C).
Allow for a pressure drop of 7 psi (48 kPa) between the liquid coolant inlet and outlet of the
condenser.
The condenser liquid control valve will regulate the flow of coolant through the condenser,
thereby controlling the high side pressure in the ice machine.
60 Series Service Manual.rev.1.2012
- 7 –
DANGER:
It is highly recommended that 2 or more people perform this
job
, if the
ASSEMBLY
Unpacking
Unpacking a KOLD-DRAFT machine can be done by prying off the boards that are holding the
cardboard box to the shipping pallet. The box can then be lifted vertically to expose the machine.
Tools to complete this job would include a claw hammer or some other form of pry-bar.
Assembly Procedure
1. Remove the ice machine front-cover panel, top-cover panel and side-cover panels from the
ice machine frame.
2. Remove all shipping materials from the ice machine. Cut off the water plate shipping strap.
3. For proper operation the ice machine and ice bin must be on a level surface. If the surface the
ice bin will be installed on is not level use shims or the adjusters on the ice bin legs to bring
the machine to level. If shims were used, seal the bin to the floor using a sealant with NSF
certification. If there are gaps larger than 1/8” (3mm) install a cove molding around the bottom
of the bin to reduce the gap and seal the cove molding to the floor with the approved sealant.
4. Confirm that the following holes are installed in the bin top: a hole corresponding to the ice
drop zone, drain pan outlet, bin level probe and the threaded mounting holes for the supplied
bolts at the four corners of the machine. The hole for the drain pan outlet should be 2”(5cm) in
diameter to allow sufficient access for the clamp. Drain hoses for drain pan outlets in GT36x,
GT56xA, GB56x and the lower halves of GB106x models get directed through the back of the
ice bin. Drain hoses for drain pan outlets in GT56xL and the upper halves of GB106x models
get directed through pre-cut holes in the back of the ice machine frames. Drain pans should
never be allowed to drain directly into the ice bin. After installation, seal around the drain tube
where it leaves the machine.
Note: All KOLD-DRAFT bins will have a provision for the drain pan outlet tube to exit the rear
of the bin. Ice machines that will be used on bins not manufactured by KOLD-DRAFT will
require a drain riser adapter made by KOLD-DRAFT to allow sufficient clearance for the drain
pan outlet tube to exit the back of the assembly.
5. Install gasketing on top of bin if not already installed. Gasket material must be positioned so
that it extends to the outside edge of the perimeter of the ice maker chassis when the icemaker is in place. To apply the gasket, peel away the white backing strip and press firmly in
place.
6. Carefully lift the ice machine and position it on the ice storage bin. Securely attach the ice
machine to the ice storage bin with the supplied washers and bolts or other non-corroding
hardware if not installed on a KOLD-DRAFT bin. If the ice machine is installed on an installed
with an accessory such as a crusher, follow the installation instructions with the other
equipment.
machine falls it could cause serious injury or death.
8
GB Models
GT
Models
7. Make all plumbing and electrical connections to the ice machine and ice storage bin in
accordance with local regulations.
8. Remove the strap securing the bin level probe and install through the bottom of the ice
machine. Ice machines on top of other ice machines or ice crushers should have the bin
probe stuck through the bottom of the machine directly above the bin. The hole for the bin
probe will be in the same location on all variations of these machines, just to the right of the
ice-making compartment or the ice chute in GT56x applications.
9. Install the ice deflectors.
Front Deflectors:
Rear Deflectors:
60 Series Service Manual.rev.1.2012
- 9 –
INITIAL START PROCEDURE
1. Be sure that the on-off switch is in the “off” position and the ice-clean switch is in the “clean”
position.
2. Turn on the power and water supply and check all supply lines for leaks.
3. Make sure all pump and water tank hoses are connected, then pour 1/2 quart (1/2 liter) of
clean potable water into the circulation system to lubricate and prime the pump(s).
Note: this can be done by either pouring the water directly onto the evaporator, the evaporator
is equipped with drain holes for this purpose and to allow melted frost to drain into the water
tank. In tight spaces a funnel and hose can be used to pour water onto the evaporator.
Alternatively the water can slowly be poured into the clear control stream box on the front of
the water plate or between the evaporator and the top left wall of the water plate.
4. Move the on-off switch to the “on” position and observe the water flowing from the distributor
tube filling the water tank. Also, observe that the water pump is circulating water through the
system. A momentary sucking cavitation sound is normal at the beginning of the process when
the water level is low. The water fill is complete when the water level in the probe tube reaches
the high-level probe. Observe that the water valve is de-energized by ensuring water has
stopped flowing through the distributor tube. Check that there are no water leaks from the
hoses or water tank into the drain pan.
Note: For GB106x models, observe that the water fill difference between the upper and lower
water tanks measured from the top of the control stream box is less than ⅛ inch (3 mm) for “C”
models and ¼ inch (6 mm) for “HK” models.
5. Pull down on the right side of the water plate, stretching the springs until the water plate switch
is disengaged, observe that the pump stops and the actuator motor rotates the cam arms
counter-clockwise. Observe that the cam arms continue to turn, opening the water plate fully,
dumping the water in the tank. After a moment, the cam arm rotation will reverse and close the
water plate. The cam arm rotation will stop when the water plate is fully closed and the water
fill process will repeat.
6. Move the ice-clean switch to the “ice” position, the water plate will cycle down and up one
more time dumping the water. When this completes the machine will begin to make ice,
observe that the compressor and the condenser fan motor, if so equipped, begin to run. If
possible with liquid cooled models ensure there is water flow during the ice making cycle.
7. Test the bin level control operation by holding ice against it. Adjust the controller, if required, to
shut off the ice machine within 30 seconds of contact between the ice and probe.
8. Make sure that the drain pan, ice deflectors and stacking chute (GB106x models and stacked
ice machines only) are properly installed. Replace and secure all the cabinet panels. The front
panel gets secured to the machine with the provided stainless steel sheet metal screws.
9. Discard all the ice from the start-up cycles, then clean and sanitize the ice storage bin
according to the instructions provided with the bin.
10. Complete and mail the registration certificate to the factory. Leave all instructions with the
owner/user.
10
ICE MACHINE CLEANING PROCEDURE
It is recommended to perform this cleaning procedure at a minimum twice per year.
Note: Use a clean plastic bottle fitted with a stopper or cap that has a pouring tube and a
vent to facilitate mixing and pouring of the specified solutions.
1. Mix 3 oz. (500023 ) KD Nickel-Safe Ice Machine Cleaner per gallon of warm water.
2. If the ice machine is operating, wait until the ice falls out of the evaporator, then move the
Ice-Clean Switch to the “Clean” position.
3. Empty the storage bin and turn off any other ice machines on the same bin.
4. After the water fill is complete, turn off the ice machine. While pinching the water level
control tube, remove it from the probe cap. Hold the water level control tube high enough
so that the water does not overflow, release the control tube and pour about half the
cleaning solution into the top of the probe tube. Pinch the control tube again and
reassemble the probe tube to the cap. Pour the remaining cleaning solution into the
control stream box.
5. Turn on the ice machine and allow the solution to circulate for 15 minutes then pull down
on the right side of the water plate. This will cause it to open and dump the cleaning
solution and then refill with water. Repeat the dump process three times to be sure all the
cleaning solution is rinsed out of the machine.
(household bleach or equivalent) and 1 quart (3.8 Liter) clean water.
7. Using the same process as in step #4, pour half of the sanitizing solution into water level
probe tube and the other half into the control stream box.
8. Allow the solution to circulate for 15 minutes. Pull down on the right side of the water plate,
to cause it to open and dump the sanitizing solution and then refill with water. Repeat this
process two times to be sure all the cleaning solution is rinsed out of the machine. If
necessary, adjust the water level probes to the proper levels.
9. While the cleaning and sanitizing solutions are circulating, clean and rinse all accessible
parts and surfaces of the ice machine with clean towels and . Mix a cleaning solution
containing 8 tablespoons (1/2 cup) (96g) baking soda and 1 Gal. (3.8 Liter) of warm water
and a sanitizing solution containing 1 teaspoon (5 mL) 5-1/4% sodium hypochlorite and
two quarts (1.9 Liter) of clean water.
10. After cleaning has been completed, move the Ice-Clean Switch to the “Ice” position. Check
the operation of the machine, particularly the water level and subsequent ice cube
formation. Adjust the water level probes if needed.
60 Series Service Manual.rev.1.2012
- 11 –
SPECIFICATIONS
Machine Capacities
Water Use, gal/100# (l/kg)Capacity and Energy Input Ratings
Water Fill Levels, Cycle Times and Harvest Weights
Model Group and Cube Type
Water Fill Level inches (mm) * 2.75 (70) 2.75 (70) 2.75 (70) 2.75 (70)
Approximate Cycle Time (Minutes) 31 24 31 24
Approximate Harvest Weight-lbs. (kg)
Note: Rough measurement from top edge of water tank to water level in control tube after
water fill is complete. Additional fine adjustments may be required.
Cube Information
Cube Type Cube Dimensions in. (mm) Cube Weight oz. (g)
C (Full Cube) 1.25 x 1.25 x 1.25 (31 x 31 x 31) 1.15 (32.6) 108 216
HK (Half Cube) 1.25 x 1.25 x .62 (31 x 31 x 15) .53 (15.0) 216 432
GB56x GB106x
C HK C HK
7.70
(3.49)
7.10
(3.22)
15.40
(6.98)
Cubes per Cycle
GB56x GB106x
14.20
(6.44)
Typical Refrigerant Operating Pressures
High Side
Measurement Point
Beginning of Freeze Cycle
Just Before Defrost Cycle Begins
During Defrost Cycle
Note 1- High side pressure in air cooled models, at the beginning of the freeze cycle, is likely to
be higher than 250 PSI (1720 kPa)
Note 2- High side pressure in air-cooled models, at the end of the freeze cycle, is likely to be
lower than 250 PSI (1720 kPa).
Note 3- 240 PSI (1650 kPa) is equivalent to 101°F (38°C) condensing temperature
Approximate Low Side
(Suction Pressure)
50 PSI
(345 kPa)
12 to 20 PSI
(80 to 140 kPa)
70 to 150 PSI
(480 to 1030 kPa)
(Discharge Pressure) (R-404a)
Approximate
Air Cooled
See Note 1
See Note 2
150 PSI
(1030 kPa)
Approximate
Liquid Cooled
1650 kPa
(See Note 3)
1650 kPa
(See Note 3)
150 PSI
(1030 kPa)
14
COMPONENTS
Mechanical Components
Refrigerant Compressor: Provided to pump refrigerant through the refrigeration system. See
the serial number plate for refrigerant specification and electrical characteristics.
Condenser: All air-cooled and liquid-cooled models are provided with a self-contained refrigerant
condenser to remove heat from the refrigeration system. These condensers are designated in
the model number as (“A”) air-cooled and (“L”) liquid-cooled. Remote air-cooled condensers are
also available for some models. These are designated as (“R”) in the model number. (See the
remote air-cooled section of the manual for information on these models.)
Condenser Fan and Motor: Provided with all air-cooled (“A”) models to draw air through the
condenser.
Liquid Regulator Valve: Provided with all liquid-cooled (“L”) models to regulate the flow of
coolant through the condenser and maintain a specified refrigerant discharge pressure.
Heat Exchanger: Provided to sub-cool the refrigerant, ensuring that the refrigerant is liquid at the
inlet of the expansion valve.
Filter Drier: Provided as insurance that all moisture and impurities are removed from the
refrigeration system.
Thermostatic Expansion Valve: Maintains the proper flow of refrigerant, through the system, as
the load changes during the ice making cycle.
Evaporator: A plated copper evaporator is found in all models. The evaporator provides the five
freezing surfaces for ice cube formation.
Defrost Valve: Directs compressor discharge gas to the evaporator, warming it to release the ice
cubes during the harvest cycle.
Water Tank: Provided as a sump to hold the water required to make one batch of ice cubes.
Water Solenoid Valve: Opens to allow potable water to enter the ice machine and closes when
the water tank is filled to the correct level.
Note: There is a strainer in the water valve inlet, which protects the water valve from
particles in the water supply. If the need for cleaning this strainer is frequent, an external
water filter should be provided.
Water Plate: Functions as a water manifold with a flat surface and to regulate the web thickness
between the cubes. This surface is positioned close to the evaporator and acts to form the sixth
side of the ice cubes. The water plate surface has one spray hole for each cell in the evaporator,
to provide water to the freezing surfaces. The water plate surface also has two drain holes
under each cell, to allow unfrozen water to return to the water tank to be re-circulated. The water
plate swings down during the harvest cycle to allow the ice cubes to fall out of the evaporator.
Note: If at any time during the Fill, Freeze, or Circulate cycle the water plate is manually
opened the controller will switch to the step 3 of the ice making sequence on page 26.
60 Series Service Manual.rev.1.2012
- 15 –
Caution:
Water Pump: Continuously circulates the water from the water tank, through the water plate
during the ice making cycle. The water pump also operates during the wash cycle to circulate
cleaning and sanitizing solution.
Actuator Motor: Rotates the cam arms counter-clockwise, at the beginning of the ice harvest
cycle, to lower the water plate, so the ice can fall out of the evaporator. It then rotates clockwise,
at the end of the harvest cycle, to close the water plate for the next ice making cycle.
Actuator Motor Capacitor: Installed between the two actuator motor windings, the function of
this capacitor is to determine the direction of the rotation of the actuator motor.
Cam Arms: These are attached to the actuator motor output shaft and function initially to
separate the water plate from the evaporator and then to support the water plate as it opens fully.
Water Plate Springs: Function as the connection between the cam arms and the water plate.
They also act as a safety mechanism, stretching if any ice remains on the water plate surface as
it is closing against the evaporator.
Drain Pan: Provided to catch the dreg water at the end of the ice making / cleaning and
sanitizing cycles and directs it to the drain.
Ice Deflectors-Front and Rear: Provided to direct the falling ice to the storage bin.
Controller: Controls the ice machine utilizing multiple sensors. Provides power directly to many
of the ice machine components, through solid-state relay outputs and indirectly to the compressor
and condenser fan motor, if so equipped, by operation of a contactor. The controller also
provides status indication of the ice machine and components as well as diagnostics for service
personnel.
On-Off Switch: The “On” position provides power to the controller to operate the ice machine.
The “Off” position interrupts power to the controller to shut down the ice machine.
Switching the machine “off” does not de-energize circuits, disconnect power before
servicing.
Ice-Clean Switch: The “Ice” position signals the controller to provide full operation of the ice
machine. The “Clean” position signals the controller to exclude operation of the contactor and
thereby the compressor and condenser fan motor if so equipped
This position is useful for cleaning the ice machine and for test procedures where operation of the
compressor is not required or desired.
Ice Level Probe: Senses when the ice bin is full- Contact between this probe and the ice in the
storage bin will signal the controller to shut off the ice machine. When ice is removed from the
probe, the ice machine will restart.
Adjustment: While holding ice against the probe tube, turn the adjustment knob on the controller
to shut off the ice machine within one minute. A warmer (CCW Bottom blue knob) adjustment will
shut off the ice machine sooner. A colder (CW) adjustment will delay shut off.
16
Evaporator Temperature Probe: Senses the temperature of the evaporator. During the defrost
cycle, the evaporator must warm sufficiently to release the ice. This probe signals the controller to
terminate the defrost cycle, after the ice has fallen out of the evaporator, and start the next ice
making cycle.
Note: A secondary function of this probe is to signal the controller to shut off the ice
machine if the evaporator should overheat.
Adjustment: Turn the adjustment knob on the controller warmer (CCW Top blue Knob), only if the
defrost time is insufficient to drop all the ice from the evaporator, before the water plate begins to
close. The defrost time should be increased no more than is required to ensure all the ice has
fallen from the evaporator.
Control Stream: This is a small clear box, divided into two sections and located on the front face
of the water plate. It is a “safety valve” that ensures evacuation of the water reservoir so that
harvest cycles will begin without undue delay. Water flowing into the left section of the box is
returned to the water tank and re-circulated through the system. Water flowing into the right
section of the box is drained out of the system. The velocity of the stream flowing in the box,
during the ice making cycle, is an indicator of the water pressure inside the water plate. This
pressure will increase as the ice cubes fill out in the evaporator, covering the drain holes provided
for each cell. This pressure increase will cause the stream, normally flowing into the left section of
the box, to flow over the partition and into the right section, draining the system of excess water.
Adjustment: Turn the Philips head screw located behind the expansion valve such that the stream
of water falls to the left of the control stream box partition, during the early portion of the ice
making cycle, before the cubes are full.
Water Level Probe Assembly: This assembly consists of three stainless steel probes which are
positioned in a clear water level tube. The water level tube is mounted in front of the water tank
and is connected to it by a hose. The water level in the tank is visible in the tube. The water level
probes are positioned in the water level tube. The longest is a reference probe and the tip of this
probe is at the bottom of the tube. The next longest probe is the “LOW PROBE.” When the water
level is low enough to separate from the tip of this probe, the controller is signaled to start the
harvest cycle. The shortest probe is the “HIGH PROBE.” When the water level touches the tip of
this probe during the water fill, the controller will de-energize the water inlet valve.
Adjustment: The reference probe should be adjusted all the way down. The “Low Probe” should
be adjusted so the tip is approximately .60” (15 mm) from the bottom of the probe tube. The “High
Probe” determines how much water is taken into the system at the beginning of a cycle. It is
adjusted as required by the size of the cube (“C” or “HK”) and the desired fullness (dimple size) of
each cube. Typically all cubes should have a small dimple at the end of the freeze cycle. Lack of
a dimple in the cubes is an indicator that the water tank level is too high at the start of the cycle.
Note: Making cubes without a dimple will reduce ice machine capacity and may damage
the water plate surface in extreme cases. If the control stream is draining water for more
than 15 seconds, at the end of the ice making cycle, the water level in the tank is too high.
Lower the high probe or raise the low probe slightly, until proper operation is evident.
60 Series Service Manual.rev.1.2012
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Plate Up Switch: This switch is actuated by the water plate and informs the controller about the
position of the plate—fully up or not fully up. If this switch is not actuated when the water plate
closes, because ice is remaining on the water plate surface, the actuator motor will reverse and
reopen the water plate. This will continue until the surface is clear.
Adjustment: The switch should be actuated when the front cam arm is between the 10 o’clock
and 11 o’clock positions. The switch is closed when the “plate up” LED is lit. Adjust the actuation
point by adjusting the height of the white actuation screw on the water plate.
Note: Do not bend the switch lever to make this adjustment.
Arms Up Switch: This switch acts to limit the clockwise rotation of the actuator motor. It informs
the controller when the cam arms are in the “12 o’clock” position (water plate up), so the actuator
motor can be de-energized.
Adjustment: The switch operator, which is attached to the output shaft of the actuator motor, can
be rotated on the shaft and fixed in place with a set screw. When adjusted properly, the cam arm
will stop in the “12 o’clock” position. The motor stops when the flat spot on the switch operator
allows the switch lever to drop down.
Note: The front water plate spring must be on the left side of the cam hub when the water
plate is fully closed (cam arm in the 12 o’clock position).
Arms Down Switch: This switch acts to limit the counter-clockwise rotation of the actuator motor.
It informs the controller when the cam arms are in the “7 o’clock” position (water plate down), so
the actuator motor can be de-energized.
Adjustment: The switch operator, which is attached to the output shaft of the actuator motor, can
be rotated on the shaft and fixed in place with a set screw. When adjusted properly, the cam arm
will stop in the “7 o’clock” position. The motor stops when the flat spot on the switch operator
allows the switch lever to drop down. Do not allow under-travel or over-travel so that the water
plate is not in the most fully-open position (critical with HK models)
Contactor: Provided with all models to carry the compressor load. On self-contained and remote
air-cooled models, the condenser fan motor is also connected to the contactor. The contactor coil
is rated for line voltage and the contacts are rated for definite purpose applications (FLA and LRA).
High Pressure Cutoff: A manual reset pressure switch is provided, which will open the circuit to
the contactor coil if the discharge pressure should reach 435 psig (2.38 MPa gauge).
GB106x Series Unique Components
Stacking Chute: Provided to direct the ice, from the upper ice making section, down through the
lower ice making section of these machines.
Ice Deflectors-Upper Front and Rear: Provided to direct the falling ice, from the upper ice
making section, to the stacking chute.
18
Controller
Programming Port
Machine Status
Sequence
Input Status
FaultCodes
Water Rinse
Jumper (Left)
DualEvaporator
Jumper (Right)
Water Level Sensor
Evaporator Temperature
Reset Button
Temperature Sensor Port
Bin Full Adjustment
Switch Input Port
Factory Use Only
AC Outputs
Machine Status:
Sequence:
Input Status:
Displays the current stage of the ice making process. (See Page 26 for more information)
Displays the status of the individual sensors for the ice making process.
Displays the position of the Ice/Clean switch or an Alarm.
Fault Codes: The electronic control will monitor for the following conditions and shut down the ice
machine as required to prevent damage to the equipment.
>10 Rev 1.1, 1.2, 1.3,1.4,1.5
down the ice maker and provide LED fault indicators.
If at any time the evaporator temperature exceeds 120F the controller will shut
obstruction the controller will shut down the ice maker and provide LED fault indicators.
If the water tray automatically cycles 3 times in a row due to a water plate
Rev 1.6 and higher After 3 cinsecutive failed attempts at raising the water plate,the
machine will defrost in 5 minutes then try again. Led20 will flash during the 5 minute
defrost. Machine willshut down if it fails after this defrost period.
>30
REV 1.3,1.4,1.5,1.6 If the Freeze cycle exceeds 45 minutes three times in a row the controller will shut down
Rev 1.1, 1.2, If the Freeze cycle exceeds 60 minutes the controller will shut down the ice maker and provide
LED fault indicators.
the ice maker and provide LED fault indicators.
Rev 1.63 and higher Reworked: Now flashes after 3 consescutive cycles over 35
minutes, but will not shut down the machine. Stops flashing once a cycle is under 35
min.
60 Series Service Manual.rev.1.2012
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>40 Rev 1.1, 1.2, 1.3,1.4,1.5 I
automatic harvest the controller will shut down the ice maker and provide LED fault indicators.
Rev 1.6 and higher After 3 consecutive occuerences of fault 40 the machine will
attempt to remove any blockages by defrosting and cycling water – LED40 will be
flashing (5Hz ) during this defrost and water cycle-defrost will last for 5 minutes –
Water will cycle for 10 minutes –if the machine has 3 more consecutive short freeze
cycles,LED40 will be solid and the machine will shut down.
>50 Rev 1.1, 1.2 ,1.3,1.4,1.5
maker and provide LED fault indicators.
Rev 1.6 and higher Fault 50 Removed Ice Mode –Added a Max defrost time (5
minutes) –Ice maker will attempt to begin a new cycle after 5 minutes of defrost or
when the Evaporator Temp. Probe reaches the set tenpeature.
>60 Rev 1.1, 1.2 I
fault indicators.
f the Fill cycle exceeds 5 minutes the controller will shut down the ice maker and provide LED
REV 1.3 and higher Water fill exceeds 3 minutes then the Valve closes & waits 10
minutes,as LED60 Flashes. Valve then opens & tries again. This routine repeats 3X and
results in a solid Code 60, if the fill is not completed on the third try.
>70 Rev 1.1, 1.2 I
the Defrost Valve until the evaporator temperature reaches 41F and provide a temporary LED fault indicator.
f the evaporator temperature during the Fill cycle is less than 31F the controller will energize
REV 1.3 Both Arm-Up/Arm Down (Cam ) Switches Closed (un-actuated ) at the same time
(not allowed ).
>80 REV 1.3 Only Indicates that the machine is in full rinse mode (left jumper pulled)
>90 REV 1.3 Only Indicates bin full, Ice machine will be shut down after current batch is
complete.
ICE MODE and CLEAN MODE: WATER WILL NOW HIT HIGH PROBE, THEN TURN ON
WATER PUMP( WATER VALVE OFF ) AND THEN REFILL TO HIGH PROBE.
CHANGED HIGH AND LOW WATER DEBONUNCE
-0.5 –SECOND DELAY NOW APPLIES WHEN RETURNING TO THE FILL STATE
-ENTIRE FILL ROUTINE WILL NOT BE REPEATED IF RETURNING TO THE FILL STATE
FROM THE HI WATER DEBOUNCE STATE,ONLY REFILLING TO THE HI WATER PROBE
-0.5-SECOND DELAY NOW APPLIES WHEN RETURNING TO THE FREEZE ( ICE MODE )
Note:
•
The controller will need to be reset to clear these error codes.
•
Board Revision numbers are found on the sticker placed on a processor chip in the middle
of the control board. Example: K4B-1.2 indicates a board revision number 1.2
f the Freeze cycle lasts less than 5 minutes 3 times in a row before an
If the Harvest cycle exceeds 20 minutes the controller will shut down the ice
REV 1.70
OR CIRULATE ( CLEAN MODE STATE
20
Stacked Jumpers:
•
Under normal operation all machines will have a jumper across the left pins. If this jumper is
removed the water valve will stay energized to thoroughly rinse the water plate during the
water plate lowering, harvest and water plate rising cycles.
Note: The machine will need reset for the controller to acknowledge this change.
•
The right jumper is used to tell the controller when it is being used on a dual evaporator
machine (GB1064 models only). This is set at the factory and should never be removed.
Programming Port: Used by service technicians to alter or update the controllers software.
Water Level Sensor: Port for water level sensor probes.
Evaporator Temperature Adjustment: To increase the temperature of the evaporator at which
the water plate closes, turn this dial counterclockwise. To decrease, turn the dial clockwise. The
operator can adjust the harvest termination temperature between 35 and 60F.
Note: After adjustment the controller must be reset.
Reset Button: Reboots the controller.
Temperature Sensor Port: For evaporator and bin temperature sensor probes.
60 Series Service Manual.rev.1.2012
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Bin Full Adjustment: To increase the temperature at which the ice level probe reacts to contact
with ice in the bin turn the dial clockwise. To decrease, turn the dial counterclockwise. The
temperature range for this adjustment is between 33 and 45F.
Note: After adjustment the controller must be reset.
Switch Input Port: For the on/off, ice/clean and limit switches
Factory Use Only: Used to display diagnostic codes to a LCD monitor used only by service the
factory.
Output: AC output for powering the fan(s), compressor, water pump(s), actuator motor(s),
Contactor(s) and valves.
22
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