Kold-Draft GB561AK Service Manual

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Installation, Operation, Technical

Service and Replacement Parts Manual

Ice Cube Makers

Stacking Instructions

charged Remote Air

This manual is updated periodically. Visit

GT36x, GT56x, GB56x, GB106x

Multiple GB56x or GB106x

RC214APV

http://www.kold

draft.com/resources/literature.php

for the latest version.

Pre-

Ice Cube Crushers - T27x

-Cooled Condenser -

GT36x

GT56x GB56x

KDIndustries, Inc.

1525 East Lake Road

Erie, PA 16511-1088 U.S.A.

(800) 840-9577

FAX: (800) 548-9392

www.kold-draft.com

April 2013

- -

GB106x

KOLD-DRAFT

Installation, Operation, Technical Service Specifications and Replacement Parts Manual Ice Cube Makers

GT36x, GT56x GB56x, GB106x Stacking Instructions

Multiple GB56x or Multiple GB106x

Ice Cube Crushers T27x

Pre-charged Remote Air-Cooled Condenser

RC214APV (For GB106xR)

gain. It is not guaranteed that this service manual is up to date, technically correct, complete, or free

from writing problems or that the product is free from minor flaws or that it meets the needs of the customer.

April 2013

Table of Contents

SAFETY INFORMATION ................................................................................................................. 4

ICE MAKER IDENTIFICATION ....................................................................................................... 2

Serial Number Plate Location ...................................................................................................... 2

Date Code Key ............................................................................................................................. 2

Model Number Key ...................................................................................................................... 3

ICE CUBER Installation ................................................................................................................... 4

What’s in the box ......................................................................................................................... 4

Required Tools ............................................................................................................................. 4

Pre-Install Checklist ..................................................................................................................... 5

Additional Pre-install Information for Cooling Tower Applications (L models) .............................. 7

ASSEMBLY ..................................................................................................................................... 8

Unpacking .................................................................................................................................... 8

Assembly Procedure .................................................................................................................... 8

INITIAL START PROCEDURE ...................................................................................................... 10

ICE MACHINE CLEANING PROCEDURE .................................................................................... 11

SPECIFICATIONS ......................................................................................................................... 12

Machine Capacities .................................................................................................................... 12

Electrical Use and Machine Dimensions/Weight ........................................................................ 13

Water Fill Levels, Cycle Times and Harvest Weights ................................................................. 14

Cube Information ....................................................................................................................... 14

Typical Refrigerant Operating Pressures ................................................................................... 14

COMPONENTS ............................................................................................................................. 15

Mechanical Components ............................................................................................................ 15

GB106x Series Unique Components ......................................................................................... 18

Controller ................................................................................................................................... 19

ERROR-CODE TROUBLESHOOTING ......................................................................................... 22

SEQUENCE OF OPERATION ...................................................................................................... 26

Ice Making Sequence................................................................................................................. 26

Ice Bin Full/Cleaning Mode ........................................................................................................ 27

Description of Each Process ...................................................................................................... 27

Fill ........................................................................................................................................... 27

Freeze .................................................................................................................................... 27

Lower ...................................................................................................................................... 28

Harvest ................................................................................................................................... 28

Raise ...................................................................................................................................... 28

Ice Bin Full .............................................................................................................................. 28

Cleaning Mode ....................................................................................................................... 28

Water Plate Closure Problems ............................................................................................... 28

Shutdown-High Pressure ........................................................................................................ 28

START METHODS ........................................................................................................................ 29

Ice Making Mode Start Up .......................................................................................................... 29

Cleaning Mode Start Up ............................................................................................................. 29

GT36X, GT56X, GB56X WIRING DIAGRAM ................................................................................ 30

GB1064 A & L WIRING DIAGRAM ................................................................................................ 31

GB106XR WIRING DIAGRAM ...................................................................................................... 32

COMPRESSOR TEST PROCEDURE ........................................................................................... 33

Test Procedure for a Short Circuit to Ground (Ground Fault) ..................................................... 34

Test Procedure for Continuity And Proper Resistance ............................................................... 34

Test Procedure for Compressor Electrical Components ............................................................ 35

Testing The Run Capacitor: ....................................................................................................... 35

Testing The Start Capacitor: ...................................................................................................... 35

Additional Service Information ................................................................................................... 36

WATER PLATE REPLACEMENT ................................................................................................. 36

WATER PLATE ALIGNMENT ....................................................................................................... 38

WATER PLATE UP/DOWN POSITION AND ADJUSTMENT ....................................................... 38

ACTUATOR MOTOR KIT APPLICATION LIST ............................................................................. 40

PROBE TEST PROCEDURE ........................................................................................................ 41

INSTRUCTIONS FOR GB1064 WATER FILL ADJUSTMENT ...................................................... 42

TROUBLESHOOTING................................................................................................................... 44

PARTS DIAGRAMS ...................................................................................................................... 49

GT36x Parts ............................................................................................................................... 50

GT56x Parts ............................................................................................................................... 51

GB56x Parts ............................................................................................................................... 53

GB106x Parts ............................................................................................................................. 54

PARTS LIST .................................................................................................................................. 58

ACTUATOR MOTOR KIT APPLICATION LIST ............................................................................. 61

STACKING INSTRUCTIONS ........................................................................................................ 62

ICE CUBE CRUSHERS - T27X ..................................................................................................... 65

ICE CRUSHER SAFETY INFORMATION ..................................................................................... 66

ICE CRUSHER INSTALLATION ................................................................................................... 67

Pre-Install Checklist ................................................................................................................... 68

Assembly/Installation ................................................................................................................. 69

Initial Start-Up ............................................................................................................................ 73

ICE CRUSHER OPERATION ........................................................................................................ 73

ICE CRUSHER CLEANING PROCEDURE ................................................................................... 73

ADJUSTMENT AND LUBRICATION ............................................................................................. 73

WIRING DIAGRAM ....................................................................................................................... 74

PRE-CHARGED REMOTE AIR COOLED CONDENSER ............................................................. 75

PRE-CHARGED REMOTE AIR COOLED INSTALLATION .......................................................... 76

Pre-Install checklist .................................................................................................................... 76

Installation .................................................................................................................................. 79

Specifications ............................................................................................................................. 79

Minimum Total Charge Required ............................................................................................... 78

Electrical Information.................................................................................................................. 81

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

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

= 2001

= 2002

= 2003

= 2004

= 2005

= 2006

= 2007

= 2008

= 2009

= 2010

= 2011

= 2012

= 2013

= 2014

= 2015

= 2016

= 2017

= 2018

= 2019

= 2020

= 2021

= 2022

= 2023

= 2024

= 2025

= 2026

= 2027

= 2028

= 2029

= 2030

= 2031

= 2032

= 2033

= 2034

= 2035

= 2036

= 2037

= 2038

= 2039

MONTH KEY

= JANUARY

= FEBRUARY

= MARCH

= APRIL

= MAY

= JUNE

= JULY

= AUGUST

= SEPTEMBER

= OCTOBER

= NOVEMBER

= DECEMBER

EXAMPLE

= MAY, 2008

5HS

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

GB 5 6 1 A HK

Cube Size

Full Cube

Half Cube

Condenser Type

Air Cooled Condenser, Self Contained

Liquid Cooled Condenser, Self Contained

Remote Air Cooled Condenser

Series

Cabinet Width

42" Wide

30" Wide

Electrical Characteristics

Modification Code

R-404a Tecumseh compressor/POE lubricant/Energy Efficient

300 Series

500 Series

1000 Series

115 Volt 60 Hz 1 ph (2 wires + ground)

1 4 5

230 Volt 50 Hz 1 ph (2 wires + ground)

220-380 Volt 50 Hz 3 phase plus neutral (4 wires + ground)

60 Series Service Manual.rev.1.2012

- 3 –

ICE CUBER INSTALLATION

Warning:

•

Do not operate equipment that has been damaged.

•

Refer all maintenance to qualified personnel.

•

Instruct all personnel in the proper use of the equipment.

•

Clean up any liquid spills immediately.

•

Always install equipment on a stable and level surface.

•

All models are intended for indoor use only. Do not install the equipment in unprotected

outdoor areas.

•

Always securely attach individual component sections together. (Bins, Bagging Machines,

Dispensers, Crushers, Ice Machines etc.

•

Do not install the equipment in wet areas.

•

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

Duplicate warranty card

Installation And Operation Manual

4x 1/4-20 stainless steel bolts

4x 1/4” stainless steel washers

2x 8-32 pan head stainless steel Philips head screws

Required Tools

•

#2 Philips Head Screwdriver

•

7/16” Socket and Wrench

•

Channel Lock Pliers

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.

Width Depth Height

Model

GT36xA & GT36xL GT56xA & GT56xL

GB56xA GB56xL GB106xA GB106xL GB106xRC

(in) (cm) (in) (cm) (in) (cm)

38 97 29 74 17 43 38 97 29 74 32 81

54 137 38 97 17 43 54 137 29 74 17 43 54 137 38 97 40 102 54 137 29 74 40 102 54 137 33 84 40 102

•

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

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) 126 104

208-230 (4 and 5 Series) 250 198

230 (7 Series) 250 210

220/380 (8 Series) 420/3 phase 210/1 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

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.

GB Models

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.

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.

6. Mix a sanitizing solution containing 0.5 ounce (15 mL) 5-1/4% sodium hypochlorite

(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

Lb (Kg) per 24hr Lb (Kg) per 24hr

90/70 Ambient/Water 70/50 Ambient/Water GT361AC 216 (98) 7.95 (631) 270 (122.47) 5.96 (473) 22 (1.84) n/a 63 GT361AHK 255 (116) 7.31 (581) 332 (150.59) 5.12 (406) 23.6 (1.97) n/a 126 GT361LC 262 (119) 5.56 (441) 309 (140.16) 4.56 (362) 22.2 (1.85) 165.3 (13.79) 63 GT361LHK 316 (143) 5.18 (411) 373 (169.19) 4.25 (337) 22.9 (1.91) 180.7 (15.08) 126 GT364AC 215 (97) 7.57 (601) 269 (122.01) 5.68 (450) 22.1 (1.8) n/a 63 GT364AHK 255 (116) 6.91 (548) 332 (150.59) 4.84 (384) 23.6 (1.97) n/a 126 GT364LC 255 (115) 5.76 (457) 301 (136.53) 4.72 (374) 22 (1.8) 163.4 (13.63) 63 GT364LHK 303 (137) 5.34 (424) 358 (162.38) 4.38 (347) 23.2 (1.94) 188.5 (15.73) 126 GT561AC 369 (167.22) 6.63 (526) 458 (207.74) 5.04 (400) 16.6 (1.39) n/a 108 GT561AHK 453 (205.44) 6.19 (491) 575 (260.81) 4.52 (358) 20.4 (1.7) n/a 216 GT561LC 447 (202.56) 5.15 (408) 510 (231.33) 4.43 (351) 13.2 (1.1) 137.4 (11.47) 108 GT561LHK 500 (226.89) 4.85 (384) 580 (263.08) 4.07 (323) 17.1 (1.43) 175.9 (14.68) 216 GT564AC 380 (172.19) 6.88 (545) 471 (213.64) 5.23 (415) 16.7 (1.39) n/a 108 GT564AHK 433 (196.49) 5.99 (475) 550 (249.47) 4.37 (346) 18.4 (1.54) n/a 216 GT564LC 429 (194.43) 5.14 (407) 489 (221.80) 4.42 (350) 16.9 (1.41) 175.6 (14.65) 108 GT564LHK 494 (224.26) 4.73 (375) 573 (259.90) 3.97 (315) 15.9 (1.33) 144.2 (12.03) 216 GB561AC 360 (163) 7.1 (563) 446 (202.30) 5.40 (428) 25 (2.1) n/a 108 GB561AHK 428 (194) 6.6 (524) 544 (246.75) 4.82 (382) 25 (2.1) n/a 216 GB561LC 420 (190) 5.5 (437) 479 (217.27) 4.73 (375) 25 (2.1) 142 (11.9) 108 GB561LHK 500 (227) 5.0 (397) 580 (263.08) 4.20 (333) 25 (2.1) 148 (12.4) 216 GB564AC 357 (162) 7.2 (571) 443 (200.94) 5.47 (434) 25 (2.1) n/a 108 GB564AHK 424 (192) 6.5 (516) 538 (244.03) 4.75 (377) 25 (2.1) n/a 216 GB564LC 460 (209) 5.2 (413) 524 (237.68) 4.47 (354) 25 (2.1) 150 (12.5) 108 GB564LHK 460 (209) 5.2 (413) 534 (242.21) 4.37 (346) 25 (2.1) 165 (13.8) 216 GB1064AC 725 (329) 6.1 (484) 906 (411) 4.58 (363) 23 (1.9) n/a 216 GB1064AHK 823 (373) 5.6 (445) 1045 (474) 4.09 (324) 26.5 (2.2) n/a 432 GB1064LC 835 (379) 4.46 (354) 952 (432) 3.84 (304) 16.1 (1.34) 141.8 (11.83) 216 GB1064LHK 900 (408) 4.6 (365) 1044 (473) 3.86 (306) 24 (2.0) 163 (13.6) 432 GB1064RC &

RC214APV GB1064RHK & RC214APV

760 (345) 5.9 (468) 950 (431) 4.43 (351) 25 (2.1) n/a 216

850 (386) 5.6 (444) 1080 (490) 4.09 (324) 25 (2.1) n/a 432

kWh/100#

(kJ/kg)

Potable Condenser

Cubes per cycleModel Number kWh/100# (kJ/kg)

Electrical Use and Machine Dimensions/Weight

Amps Amps

Model Number GT361AC 12 15 1

GT361AHK 12 15 1 GT361LC 11.1 15 2 GT361LHK 11.1 15 2 GT364AC 6.5 15 2 GT364AHK 6.5 15 2 GT364LC 6 15 1 GT364LHK 6 15 2 GT561AC 18.6 30 1 GT561AHK 18.6 30 1 GT561LC 17.7 30 1 GT561LHK 17.7 30 1 GT564AC 9.5 15 1 GT564AHK 9.5 15 1 GT564LC 9.1 15 1 GT564LHK 9.1 15 1 GB561AC 18.6 30 1 GB561AHK 18.6 30 1 GB561LC 17.7 30 1 GB561LHK 17.7 30 1 GB564AC 9.5 15 1 GB564AHK 9.5 15 1 GB564LC 9.1 15 1 GB564LHK 9.1 15 1 GB1064AC 16.3 25 1 GB1064AHK 16.3 25 1 GB1064LC 15.4 25 1 GB1064LHK 15.4 25 1 GB1064RC &

RC214APV GB1064RHK & RC214APV RC214APV

Min Circuit

18.1 30 1 42.3 (107.4) 25.7 (65.3) 33.7 (85.6) 335 (152)

Max

Fuse/Breaker

CA Power

Tier

W D H Ship Weight #(kg)

30.1 (76.5) 25.7 (65.3) 16.9 (42.9) 180 (82)

30.1 (76.5) 25.7 (65.3) 16.9 (42.9) 174 (79)

30.1 (76.5) 25.7 (65.3) 16.9 (42.9) 180 (82)

30.1 (76.5) 25.7 (65.3) 16.9 (42.9) 174 (79)

30.1 (76.5) 25.7 (65.3) 30.7 (78) 228 (103)

30.1 (76.5) 25.7 (65.3) 30.7 (78) 218 (99)

30.1 (76.5) 25.7 (65.3) 30.7 (78) 228 (103)

30.1 (76.5) 25.7 (65.3) 30.7 (78) 218 (99)

42.3 (107.4) 31.1 (79) 17 (43.2) 207 (94)

42.3 (107.4) 25.63 (65.1) 17 (43.2) 185 (84)

42.3 (107.4) 31.1 (79) 17 (43.2) 207 (94)

42.3 (107.4) 25.63 (65.1) 17 (43.2) 185 (84)

42.3 (107.4) 31.1 (79) 33.7 (85.6) 348 (158)

42.3 (107.4) 25.7 (65.3) 33.7 (85.6) 312 (142)

40.75 (103.5) 22.75 (57.8) 30.2 (76.6) 160 (73)

Dimensions - inches (cm)

Ship Weight

60 Series Service Manual.rev.1.2012

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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)

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

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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.

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.

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

Rev 1.6 and higher fault 10 removed >20 Rev 1.1, 1.2, 1.3,1.4,1.5

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

- 19 –

>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

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.

ERROR-CODE TROUBLESHOOTING

CODE:

FAULT CODE INDICATES: POSSIBLE CAUSE: SOLUTION:

(Rev. 1.1/1.2/ 1.3 )

Evaporator temp over 120F

10>

(Rev. 1.1)

Water Plate failed to close

after three consecutive

attempts.

(Rev. 1.2 / 1.3)

After 3 attempts to close, machine

20>

30>

60 Series Service Manual.rev.1.2012

goes into a 30-minute shutdown, with the Plate open. It will repeat this routine (

30-min wait

on Code 20. The Code 20 LED will flash as this routine is in process, and then light solid after the routine tries 4 times and ends in Code 20.

w/ the Plate closing 3 times & then a

) four times, before going out

(Rev 1.1 / 1.2)

Freeze time exceeds 60 min.

(Rev. 1.3)

Freeze time exceeds 45 min.

three times consecutively.

- 23 –

- -Before troubleshooting, first check the Control Board and verify your software Revision Level (Rev. 1.1, 1.2, or 1.3)

1) Bad Evaporator Probe (shorted) or wiring.

2) Hot Gas Valve stuck open - Cuber stuck in extended harvest mode.

3) Bad Control Board

4) Actuator Motor won't raise Water Plate.

1) Cam Arm or Cam Pin is broken.

2) Cam Spring disengaged or broken.

3) Plate-Up Switch stuck open or not actuating.

4) Over-freeze causing ice to stick on waterplate.

5) Silicone coating on Waterplate worn away.

6) During harvest, the Evaporator Probe is out of adjustment (reads too warm) or is defective.

7) Arms-Up Switch stuck closed - Plate stays down.

8) Bin Probe is out of position or faulty, and not shutting off ice maker when the ice bin is full. Ice back-up onto the Water Plate is blocking the Plate from closing.

1) Not enough air or liquid flow through condenser.

2) Low-level (harvest) probe shorted or touching side of glass tube.

3) Inoperative water pump.

4) Refrigeration problem.

5) Bad Contactor (Compressor would be off !)

6) Inlet Water Valve stuck open. Water Tank will be overflowing.

7) Controller not shutting off Water Valve.

8) Hot Gas Valve (HGV) stuck partially open, (or with a liquid-cooled compressor, HGV stuck fully open, but Evaporator never gets hot enough (> 120F) to give a an Error Code 10.

1) Repair/replace wiring or replace Probe.

2) Pull down the Water Plate and verify that Hot Gas Valve closes after the Water Plate closes. Repeat, with power to the Hot Gas Valve coil disconnected. If Hot Gas Valve does not close, replace it.

3) Replace Control Board

4) Replace Actuator Motor. (Motor never raises Plate to actuate Plate Switch, so HGV stays open & Evap temp rises >120F.

1) Replace Cam Arm or Cam Pin.

2) Reinstall springs or replace as needed.

3) Adjust switch actuator or replace as needed. Check to insure that the Plate-Up Switch actuates before the Arms-Up Switch actuates.

4) Lower the short water level probe, in 1/16" increments, until cubes have a pea-sized dimple in the center.

5) Replace the Water Plate if the factory coating is severely warn and is causing ice to stick to it. Use a Foodgrade silicone spray to provide a temporary improved surface, until the waterplate can be replaced.

6) Adjust Evaporator Probe colder (turn CW), or replace if adjustment does not help.

7) Free up, adjust or replace stuck/shorted Arms-Up Switch, or repair wiring.

8) Re-position or replace Bin Probe.

1) Reset high-pressure safety, if tripped. Clean the condenser, on air-cooled units. Check water/coolant supply, on liquidcooled units.

2) Check/repair shorted wiring to this probe, or gently move probe away from glass surface. Make sure probe is not pushed up/down out of vertical adjustment when moving it away from glass.

3) Unplug the pump and confirm that the impeller is not jammed with foreign material. Put machine in Wash Mode & check voltage at pump-cable connector. On the Controller Board's AC output buss, check wires P5-2 and P5-6, during Wash Mode, for line voltage. If rated line voltage is present, and the pump's impeller is not obstructed, replace faulty Water Pump.

4) Check for low refrigerant charge.

5) Replace Contactor.

6) Replace Water Valve.

7) Replace Controller.

8) Replace Hot Gas Valve

ERROR-CODE TROUBLESHOOTING

CODE:

40>

FAULT CODE INDICATES: POSSIBLE CAUSE: SOLUTION:

(Rev 1.1/1.2/1.3)

Freeze time less than 5 min.,

for 3 consecutive times.

(Water level in the glass Probe Tube is prematurely falling below the low-level probe, during the first 5 minutes of the freeze cycle, or, the Low-level probe circuit is open)

(Rev 1.1 / 1.2 / 1.3)

Harvest cycle exceeds 20 min.

50>

- -Before troubleshooting, first check the Control Board and verify your software Revision Level (Rev. 1.1, 1.2, or 1.3)

1) Slushing, in Pump, water lines or Water Tank, due to Expansion Valve mis-adjustment or not being wrapped in insulating foam, or failure.

2) Low-level Probe circuit is open, or the Water- Level Probe Assy is bad.

3) Water is being lost somewhere (leaking), causing premature harvest to occur.

4) During harvest, Evaporator Probe out of adjustment (too warm).

5) High-level Probe possibly short circuiting during fill, causing short fill and hollow cubes.

1) Evaporator Temperature Probe out of adjustment (reads too warm), or is defective (open).

2) Actuator Motor won't raise Water Plate.

3) Actuator Motor won't lower Water Plate.

4) Controller Board is defective.

5) Arms-Down Switch stuck open (Lowering) Cam rotates CCW & wraps spring around cam shaft, causing Cam or Spring damage.

6) Arms-Down Switch stuck closed (Plate supposed to lower, but is staying up)

7) Hot Gas Valve won't open

8) During harvest, Evaporator Probe out of adjustment (reads too cool) or defective. (Ice production may be low!)

9) Bad Contactor (Compressor would be off !)

1) Insure Expansion Valve (TXV) is covered with insulating foam. Adjust TXV as needed. As a starting point, gently turn the TXV in CW direction until it stops, then turn it CCW 5-1/2 turns. Adjust in 1/4-turn increments as needed.

2) Repair wiring to Low-Level Probe or replace Probe Assy.

3) Inspect hoses, water tank, water pump, water plate and water level probe assembly to locate leak. Repair or replace part as needed.

4) Adjust colder (CW)

5) Locate & repair short circuit.

1) On the Controller, adjust Evaporator Probe pot CW, to a colder setting, so that the Water Plate returns to the closed position about 5 sec. after ice releases. If Evaporator Probe is non-responsive, and Actuator Motor is confirmed operational, then replace the Evaporator Probe.

2) Replace Actuator Motor - (Motor should drive up when Water Plate is down & Evaporator Probe is > 38 F. (35-45F. ))

3) Replace Actuator Motor

4) Replace Controller Board (When Water Plate is down & Evap Probe is > 38F, there should be line voltage to the Actuator Motor, between Pins 2 & 8*, on the green output connector of the Controller. If voltage not present, replace the Controller.

5) Free up, adjust or replace Arms-Down Switch or repair open wiring.

6) Free up, adjust or replace Arms-Down Switch or repair shorted wiring.

7) Check power from the Controller to the Valve Coil, to determine if problem is electrical or the Valve is just stuck closed. Replace Coil, Controller, wiring or Valve, as required.

8) Adjust Evaporator Probe warmer, or replace if not responding.

9) Replace Contactor

(*Check pins 2 & 10, for upper Actuator Motor, on a dual-Evaporator machine)

ERROR-CODE TROUBLESHOOTING

CODE:

60>

70>

FAULT CODE INDICATES: POSSIBLE CAUSE: SOLUTION:

(Rev 1.1/1.2)

Water fill exceeds 5 min.

(Rev 1.3)

Water fill exceeds 3 min,

then the Valve closes & waits 10 minutes, as Code 60 LED 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.

(Rev 1.1/1.2)

Evaporator Temperature < 31F,

during water fill only.

(

System opens Hot Gas Valve to compensate, until an Evaporator temp of about 38 F is reached. This temp range is adjustable from about 35-46 F

Both Arm-Up/Arm Down Switches Closed

same time (not allowed)

)

(Rev 1.3)

(un-actuated)

(Cam)

at the

- -Before troubleshooting, first check the Control Board and verify your software Revision Level (Rev. 1.1, 1.2, or 1.3)

1) Water supply off or major leak in the water tank, or water lines.

2) External water filter plugged.

3) Water solenoid valve inoperative.

4) Upper (short) Probe, in the Water-Level Probe Assy, may have a loose wire connection (open).

5) Common (longest) Probe, in the Water-Level Probe Assy, may have a loose connection (open).

6) Controller is bad.

(Rev 1.1/1.2)

1) This is not necessarily a fault condition, but could indicate that the incoming water temp is very cold, which can slow down ice production, as the Hot Gas Valve continually reopens to warm the Evaporator to >38F.

(Rev 1.3)

2) Switches are loose.

3) Switches are mis-wired.

4) Switch Bracket bent & switches not in position.

5) Switch Cams loose and/or in the wrong position

6) Arms-Up Switch stuck closed - Plate stays down.

7) Arms-Down Switch stuck closed - Plate stays up.

1) Turn on water supply or check for leaks.

2) Replace, bypass or eliminate external water filter.

3) Place in Wash Mode and pull down on water plate, to lower it. On return up, water valve will energize to fill, until the short probe is reached. If water solenoid valve has power & water, but does not open, replace the valve.

4) Verify wire connection is securely crimped on top of probe & back to Controller.

5) Verify wire connection is securely crimped on top of probe & back to Controller.

6) Replace Controller.

1) No action required. (Increase incoming water temp to > 45F for best results)

2) Tighten switches

3) Wiring should be to the Common & Normally Closed (NC) positions, with black wire to the bottom-front NC terminal and red wire to bottom-rear NC terminal. White wires should go to the Common terminals on top.

4) Straighten bracket.

5) Cam flats should be almost opposite each other. See Water Plate Up/Down adjustment, page 35 of Service Manual.

6) Replace stuck/shorted Arms-Up Switch or check solutions 2-5 above.

7) Replace stuck/shorted Arms-Down Switch or check solutions 2-5 above.

(Rev 1.3 only)

80>

Machine is in Full-Rinse Mode.

(

Left Jumper is pulled, on Controller

(Rev 1.3 only)

Ice Bin Full

90>

(A cold Bin Probe will shut down the icemaker

right after the next harvest is complete)

60 Series Service Manual.rev.1.2012

1) This is an optional mode, that is not as energy efficient. 1) Replace jumper to restore normal energy-efficient minimum-

)

1) This is a normal- condition, indicating that the Bin is full. (Bin Probe is cold !)

2) If Code 90 is indicated, but Bin is not full, check for faulty Bin Probe, bad wiring to Bin Probe or faulty Controller Board.

- 25 –

rinse mode.

1) No action required.

2) Repair wiring, replace Bin Probe or replace Controller.

Step 1

Step 2

Step 3

Step 4

Step 5

SEQUENCE OF OPERATION

The following tables describe the general states and sequence of operation for the ice machine models in ice-making mode with an additional table depicting the status when the ice bin is full and the cleaning mode. The charts provide information about the inputs to the controller and the corresponding AC outputs associated with each part of the ice making cycle.

Note:

•

Abnormal operation of the ice machine is covered in the Fault Condition section of the

manual.

•

The sequence of operation for GB106x models is identical to the GB56x and all models

utilize the same controller.

Note: GB106x models employ two each of the following electrical components and controls:

•

Condenser Fan Motor (air cooled models only)

•

Actuator Motor

•

Water Pump

•

Defrost Valve

•

Water Plate Switch

•

Arms-Up Switch

•

Arms-Down Switch

Ice Making Sequence

Control Status Status Status Status Status Bin Level Probe Warm/Not Full Warm/Not Full Warm/Not Full Warm/Not Full Warm/Not Full

Ice-Clean Switch Ice Ice Ice Ice Ice Contactor Closed Closed Closed Closed Closed Water Plate Switch Up Up Down Down Down Evaporator

Temperature Probe Water Level Control Arms-Up/Down

Switches Ice None Forming Fully Formed Fully Formed None Compressor

(Condenser Fan) Water Plate Closed Closed Opening Open Closing Water Pump On On Off Off Off

Defrost Valve Water Valve Actuator Motor Off Off

Control Stream Low Low to High Off Off Off

N/A Cold Cold Warming Warm Low

Level/Rising Arms Up Arms Up Arms Lowering Arms Down Arms Rising

On On On On On

Closed/ De-energized

Open/ Energized

Fill

Freeze

High/Level Falling

Closed/ De-energized

Lower

Low Low Low

Open/ Energized

On/CCW Rotation

Harvest

Open/ Energized

Closed/ De-energized

Off

Closed/ De-energized

Open/ Energized

On/CW Rotation

Raise

Cleaning

Ice Bin Full/Cleaning Mode

Ice Bin Full

Mode

Control Status Status Bin Level Probe Cold/Bin Full Warm or cold Ice-Clean Switch Ice Clean Contactor Open Open Water Plate Switch Up or Down Up Evaporator Temperature Probe Warm or Cold Warm Water Level Control Low or High High* Arms-Up/Down Switches Water Plate Up or Down Water Plate Up Ice None or Fully Formed None Compressor (Condenser Fan) Off Off Water Plate Open or Closed Closed Water Pump Off On Defrost Valve Closed Closed Water Valve Closed Closed* Actuator Motor Off Off Control Stream Off Low

*Note: If the water level is low, the water valve will open to fill the water tank.

Description of Each Process

The following sequence begins with the cuber as shipped from the factory with the water plate(s) closed and ready to begin a normal ice making cycle.

Fill: The water solenoid valve will be energized only until the water level reaches the high water level probe, and the water pump will run when the water plate is closed.

REV 1.70

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 ) OR CIRULATE ( CLEAN MODE STATE

Freeze: Once the water fill cycle has been completed, the water solenoid valve will remain de-

energized until the following harvest cycle. The water level in the liquid level probe tube lowers as the water is frozen, but no additional water will be introduced during the freeze cycle. The control stream runs continuously during the freeze cycle with the water returning to the water tank through the hole which can be seen through the control stream box to the left of the dam in the box. The control stream is a "safety valve" to insure the ability to initiate harvest rather than an ice quality control, and it should never need to go over the dam for more than 15 seconds before harvest begins.

Note: No water, other than condensation, should drip or run to the drain pan from the

60 Series Service Manual.rev.1.2012

- 27 –

control stream or from the water tank during the freeze cycle. The water level in the liquid level probe tube must get below the level of the low water level probe initiate the harvest cycle. If there is an excess of water in the water tank, the water pump outlet pressure increases when the evaporator cells are full, and the control stream rises and flows over the dam to the drain pan to evacuate the liquid level control tube.

Lower: When the water level in the liquid level probe tube is below the low water level probe the controller senses the absence of continuity between the probes. Power is applied to the defrost valve coil allowing hot gas to circulate through the evaporator. The evaporator begins to defrost, and the water plate begins to open immediately. When the cam arms down switch is activated the water plate will stop.

Harvest: As long as the evaporator remains cold, the water plate(s) remain in the open position with the water solenoid valve de-energized. The defrost valve remains energized, and the evaporator(s) become warm enough to release the ice which drops by gravity into the ice storage area.

Raise: After the ice is out and the evaporator(s) warm to the reset temperature required by the controller the actuator motor(s) will be energized to close the water plate(s) The water solenoid valve will be energized to begin the water fill for the next ice-making cycle, the defrost valve will be de-energized, and the evaporator will begin to cool.

Ice Bin Full: When the level of ice reaches the bin probe, the ice maker stops automatically, and it remains off until the bin probe warms up when the ice level is lowered.

Note: in remote condenser models (r), the compressor continues to run after bin control shutdown until the low-side is pumped down to the setting of the pumpdown controller. This pressure should be between 5 and 10 psig and must never be vacuum.

Cleaning Mode: All of the cuber's operational components except refrigeration are able to function with the make ice/clean switch in the clean position. Simply placing this switch in the cleaning position does not complete the cleaning and sanitizing of the cuber. Instructions pertaining to the cleaning of a machine can be found on page 11 of this manual.

Note: The frequency of the need for cleaning is determined by the supply water characteristics. The cuber should be cleaned no less frequently than once each 6 months, and it may require more frequent cleaning. The requirement for sanitizing frequency may be contained in local health code regulations.

Water Plate Closure Problems: If the plate up switch is not properly actuated, due to misadjustment, weak springs, or an obstruction to the water plate travel, such as ice which did not slide off of the plate, the actuator motor will immediately reverse and re-open the water plate.

Shutdown-High Pressure: All models are provided with a high pressure cutoff which interrupts power only to the compressor, and to the condenser fan motor if so equipped, when the high-side pressure rises to the cutoff setting. The high pressure cutoff requires manual resetting to restore power in all models. When this happens in air and remote cooled models be sure there is sufficient airflow, a clean condenser, and a properly functioning fan motor. In liquid cooled models make sure the liquid regulator valve is adjusted properly and that there is sufficient flow of coolant.

START METHODS

Ice Making Mode Start Up

At power up in the ice making mode the electronic control will monitor the following criteria:

If the evaporator temperature is colder than the Harvest Termination temperature at start up the controller will switch to the Lower state.

If there is an obstruction preventing the water plate from closing the Plate Up switch at startup, the controller will switch to the Lower state.

If the water plate is not in the up position at start up and the evaporator temperature is warmer than the Harvest Termination temperature, the controller will switch to the Raise state.

Cleaning Mode Start Up

At power up in the wash mode the electronic control will monitor the following criteria:

If there is an obstruction preventing the water plate from closing the Plate Up switch at startup, the controller will switch to the “Lower” state.

If the water plate is not in the up position at start up, the controller will switch to the “Raise” state.

60 Series Service Manual.rev.1.2012

- 29 –

GT36X, GT56X, GB56X WIRING DIAGRAM

GT361 Models Only

Compressor Wiring

GT36x, GT56x, GB56x

GB1064 A & L WIRING DIAGRAM

Note: A wiring diagram for remote condenser models (GB106xR) is on the following page.

60 Series Service Manual.rev.1.2012

- 31 –

Compressor Wiring

GB106XR WIRING DIAGRAM

Never reset a circuit breaker or replace a fuse without checking for a short circuit to ground.

Caution:

COMPRESSOR TEST PROCEDURE

Warning:

•

Refer all service work to qualified technicians.

•

Knowledge of proper installation and service procedures is essential to the safe maintenance

of KOLD-DRAFT equipment.

•

Do not operate equipment that has been damaged.

•

Always disconnect the power supply before servicing the equipment. Some circuits remain

energized when the ice machine is switched off.

•

Never operate the ice maker with any covers, panels or other parts removed or not properly

secured.

•

Never modify the circuitry of KOLD-DRAFT equipment from the original specifications.

•

Use only genuine KOLD-DRAFT replacement parts.

•

Use of non-approved parts when servicing KOLD-DRAFT equipment may create a safety

hazard or cause equipment and property damage.

•

Use of non-approved parts, when servicing KOLD-DRAFT equipment, will void the equipment

warranty.

•

Disconnect all electrical power before removing the protective terminal cover.

•

Never energize the system unless the protective terminal cover is securely fastened.

•

Never energize the system unless the compressor is properly connected to ground.

•

An open fuse or tripped circuit breaker is an indication of a ground fault. Energizing a compressor with a ground fault may cause terminal pin ejection, which will allow oil and refrigerant to spray out of the system. This oil spray, combined with an electrical spark, can ignite causing harm to personnel and property.

•

Discharge all capacitors with a 20,000 ohm resister before working with them or removing

them from the ice machine. This must be done to avoid damage to measuring devices and the risk of electrical shock.

Failure to comply with all KOLD-DRAFT service guidelines may cause personal injury, equipment or property damage and voiding of the product warranty.

Note:

•

When servicing KOLD-DRAFT ice machine refrigeration systems, all work performed must

be consistent with the best refrigeration service practices. These systems must remain clean, dry and properly charged with refrigerant, in order for the ice machine to operate as designed.

•

See the Remote Air-Cooled Condenser section of the manual for additional service

information related to these ice machines.

•

All KOLD-DRAFT ice machine models utilize CSR (capacitor start/capacitor run)

compressors. Each model includes a potential start relay, a start capacitor and a run capacitor, in the compressor circuitry, to start and operate these compressors properly and with maximum efficiency. All compressors also include thermal protectors—external on GT36x, GT56x, and GB56x models and internal on GB106x models. This procedure will help diagnose problems with these compressors and all related components.

60 Series Service Manual.rev.1.2012

- 33 –

Test Procedure for a Short Circuit to Ground (Ground Fault)

1. Disconnect all electrical power to the system, making sure all power legs are open.

2. Remove the protective terminal cover. Inspect for evidence of overheating at any connection. Overheating is an indication that a compressor motor problem exists. Disconnect all leads from the terminal pins.

3. Check the compressor for a ground fault using an ohm meter or a high potential ground tester. Connect one lead to the copper suction line and connect the other lead to one of the terminal pins. Repeat this procedure for the two remaining terminal pins. If the instrument indicates any resistance less than 2 mega ohms between any pin and the suction line (compressor housing), a ground fault exists.

4. If a ground fault exists, replace the compressor. Do not reconnect the compressor or re-use any leads or terminal connectors that exhibit signs of overheating.

Test Procedure for Continuity and Proper Resistance

1. If no ground fault has been found, determine if there is an open or short circuited motor winding or if the thermal protector is open.

2. Allow time for the thermal protector to reset. This may take as long as an hour for internal type thermal protectors.

3. For single phase compressors, test the continuity of the start winding by measuring between terminal pins C and S. Test the continuity of the main winding by measuring between terminal pins C and R. If there is no continuity in either winding, replace the compressor.

4. For three phase compressors, test the continuity of the windings by measuring between each pair of terminal pins: 1-2, 2-3 and 1-3. If there is no continuity between any set of terminal pins, replace the compressor.

5. If continuity is found in all motor windings, measure the resistance (ohms) of the windings.

6. For single phase compressors, measure between each pair of terminal pins: C-S, C-R and S-R. The sum of the resistance measured between C-S and C-R should equal the resistance measured between S-R, plus or minus a small deviation. Proper resistance may be confirmed by comparing the measured resistance to the resistance specifications for specific compressor models. If the resistance is not correct, replace the compressor. If the specifications are not found on the ice machine, please contact the factory.

7. For three phase compressors, measure between each pair of terminal pins: 1-2, 2-3 and 1-3. The resistance measured between each pair of pins should always be greater than zero and within 10% of one another. Proper resistance may be confirmed by comparing the measured resistance to the resistance specifications for specific compressor models. If the resistance is not correct, replace the compressor. If the specifications are not found on the ice machine, please contact the factory.

Test Procedure for Compressor Electrical Components

1. Testing The Potential Relay:

2. Before testing the relay, be sure it is the one specified for use with the ice machine compressor and the mounting position of the relay is correct.

3. Measure for continuity between terminals 5 and 2—if there is no continuity, replace the relay.

4. Measure for continuity between terminals 2 and 1—if there is no continuity, the contacts are open and the relay must be replaced.

5. The relay may also malfunction if the supply voltage is 10% higher or lower than the rated voltage or if the relay is loosely mounted, allowing it to vibrate or if it is used in conjunction with an incorrect start capacitor.

Testing the Run Capacitor:

1. Before testing the run capacitor, be sure it is the one specified for use with the ice machine compressor.

2. After making sure the capacitor is discharged, disconnect it and test the value with a capacitance meter. If the measured value is more than 10% higher or lower than the rated value, replace the run capacitor.

3. The capacitor may also malfunction if the supply voltage is more than 10% higher than the rated voltage.

Testing the Start Capacitor:

1. Before testing the start capacitor, be sure it is the one specified for use with the ice machine compressor.

2. After making sure the capacitor is discharged, disconnect it and test the value with a capacitance meter. If the measured value less than the rated value or more than 20% higher than the rated value, replace the start capacitor.

3. As an alternative, test the run capacitor by determining if there is continuity across the terminals. Use a meter set to the R x 1 scale. If there is continuity the capacitor is shorted and must be replaced.

4. Another alternative is to set the meter to the R x 100,000 scale. If there is no needle deflection on an analog meter when placing the probes across the capacitor terminals or if infinite resistance is indicated on a digital meter, the capacitor is open and needs to be replaced.

5. The capacitor may also malfunction if the relay contacts are not working properly, or if the capacitor is subjected to prolonged operation of the start cycle, because the start relay is incorrect, the starting load is too high, or the supply voltage is more than 10% lower than the rated voltage.

60 Series Service Manual.rev.1.2012

- 35 –

Additional Service Information

•

Testing the External Thermal Protector:

•

After allowing sufficient time for the thermal protector to reset, disconnect it and test for

continuity across the terminals. If there is no continuity, replace the thermal protector.

•

Disconnect and test the compressor wiring by confirming that there is continuity between relay

terminal 5 and compressor terminal C and also between terminals 2 and S as well as 4 and R.

•

Replace the potential relay if all other tests do not reveal the problem. A new relay will

eliminate any electrical problems that cannot be determined with the previous testing. If a new relay does not correct the operation, the compressor may have a mechanical problem.

Note: Excessive short cycling may be caused by a faulty thermal protector, but it also may be caused by other malfunctioning system components such as the bin thermostat, Ice-Off-Wash switch, and contactor or high pressure cut-out.

WATER PLATE REPLACEM

Turn off water and open plate until cams are in the 9:00 position then turn off the power.

Remove the control stream drain hose.

Remove water level probe assembly by sliding it to the right beyond the control stream box

lift. Disconnect tube assembly from main tank.

Remove the pump mounting screw holding the water plate brace, the inlet, and outlet hoses

Pry plastic hinge brackets away from the plate.

Unhook the main springs from the water plate.

e the screws that mount the control module box. Pull the module forward to disconnect

Slide the water plate and tank to the right without turning and slide it forward out of the

Remove the spring bosses, water plate brace, water

ctor, pressure pads and the four screws

holding the tank to the water plate. Remove plastic

bolt from shoulder on water plate and place in new

Attach the tank to new water plate with two #6

mach. screws on the left side and two #10 sheet

s on the front and back.

The speed nuts on the front and back holes

With the open end of the water plate to the right,

slide it back into the machine and to the left of its

Hook up the main springs to the w

Hook on and snap into place the plastic hinge

Secure the pump mounting screw holding the water

Remove the water level probe assembly and

reposition the control stream drain tube. Position

the control module box to mounting

bracket. Check adjustment of plastic lift bolt.

Reconnect harvest switch, if present.

Water plate must be aligned with the evaporator per

ENT

3. and

4. from the pump.

7. Remov front cam.

8. machine.

9. defle

plate.

10. metal screw

Note: are no longer required.

11. normal position.

12. spring first.

13. brackets

14. plate brace.

15. and secure

16. drawing illustration.

ater plate, rear

60 Series Service Manual.rev.1.2012

- 37 –

WATER PLATE ALIGNMENT

If the water plate is not aligned with the evaporator, the cubes may appear cloudy or misshapen.

Dimension “A” is not adjustable. If this dimension is out of tolerance, the evaporator or water plate mounting components may be damaged.

Adjustments to dimension “B” can be made by sliding the front and rear hinges along the left edge of the water plate. Lightly tap the hinges as required to align the water plate with the evaporator. Alignment is correct when the space between the evaporator and the water plate is equal in front and in back.

“A” = 1.5” ± 3/32” (38 mm ± 2.5 mm) “B” = 5/16” ± 1/16”(8 mm ± 1.5 mm)

WEB THICKNESS ADJUSTMENT

The web thickness between cubes (the gap between the bottom of the evaporator and the water plate surface) can be adjusted by inserting or removing shims between the support channels and the evaporator support posts or the cam shaft bearing brackets. Loosen the actuator motor mounting screws before inserting or removing shims between the channels and cam shaft bearing brackets. The web thickness specification for both C and HK models is 1/16” (2mm)

WATER PLATE UP/DOWN POSITION AND ADJUSTMENT

When the water plate is up (closed), the spring end of the cam arm must be in the 12 o’clock position, with the spring on the left side of the cam arm hub. The arms up switch lever (front) will be down and the arms down switch lever (back) will be up. When the water plate opens, the cam arm turns counter clockwise until the arms down switch operator allows the arms down switch lever to drop. When the water plate is fully down (open), the cam arm should be in the seven o’clock position; the spring should be aligned with the cam arm. When closing again, the cam arm will turn clockwise, until the arms up switch operator allows the arms up switch lever to drop.

The positions of the cam arms, when the water plate is open and closed, may be adjusted by loosening the set screws and rotating the switch operators as required. Baseline positions of the switch operators for the front and back are 11 and 4 o’clock when the water plate is up. When the water plate is down, positions for the front and back switch operators are 6 o’clock and 11 o’clock Note: The front operator is for adjusting the arms up switch and the back operator is for adjusting the arms down switch.

Up Position

•

If the cam arm in the up position is too far clockwise from 12 o’clock rotate the front switch

operator clockwise to stop the arm’s rotation earlier

•

If the cam arm in the up position is too far counterclockwise from 12 o’clock rotate the front

switch operator counterclockwise to stop the arm’s rotation later Down Position

•

If the cam arm in the down position is too far clockwise from 7 o’clock rotate the back switch

operator clockwise to stop the arm’s rotation later

•

If the cam arm in the down position is too far counterclockwise from 7 o’clock rotate the back

operator counterclockwise to stop the arm’s rotation earlier

Note: Component relationships and/or operation, other than described, indicate component failure, maladjustment or improper reassembly when servicing the ice machine.

60 Series Service Manual.rev.1.2012

- 39 –

ACTUATOR MOTOR ELECTRICAL TESTS

The following tests are for troubleshooting the actuator motor and related circuits: Use an AC voltmeter set for the proper range. Voltages in the tables are measure across the motor reversing capacitor (between the colored motor lead wires.

If there is no ice in the evaporator(s) and the water plate(s) is (are) not fully closed (with the water plate switch(es) pushed up and the “ARMS UP” LED on), the actuator motor(s) and pump(s) should be running. If not, be sure there is power to the motor(s) and also that the motor(s) is(are) not overheated and off due high temperature. Allow the motor to cool down before starting the test procedure.

Always refer to the proper wiring diagram when troubleshooting.

Motor winding resistances at 75˚ F (24˚ C) out of the circuit are as follows: REX 115 volt motors, white to black or yellow, approximately 95 ohms REX 230 volt motors, white to red or yellow, approximately 400 ohms

Voltages for Actuator Motor Electrical Tests

Actuator Motor Test Parameters Voltage Reading Capacitor Motor Remedy 115 volt motors, reads 180-240 or

230 volt motors, reads 290-370 Line voltage for any voltage motor Open Good Replace capacitor

Line voltage for any voltage motor in one actuator switch position and 0 volts in the other position

Good Good Tap gear case to align

bearings

Open and → One motor

winding open

Replace capacitor and

115 volt motors, reads 180-240 or 230 volt motors, reads 290-370 in one actuator switch position and 0 volts in the other position

0 volts in both actuator switch positions. Be sure there is power to the motor (line voltage) by leaving one probe on either capacitor lead and placing the other probe on the white motor lead.

Good One motor

winding open

Shorted or → Both motor

windings open

Replace motor

Disconnect the actuator motor from the circuit and test the winding resistance. If approximately 500 ohms from white to red or yellow, replace the capacitor. If the resistance is erratic, replace the motor.

PROBE TEST PROCEDURE

Water Level Probes:

Water level probes can be tested at any temperature and are good if they exhibit continuity (0 ohms resistance) along the length, between the probe wire and the connector at the controller.

It is advisable to flex the probe at the two connections, while testing for continuity, to eliminate the possibility of an intermittent failure.

Evaporator Temperature and Ice Level Probes:

The evaporator temperature probe and the ice level probe are designed to have a nominal resistance of 5650 ohms at 32° F (0°C). To test the se probes they must be placed in ice water 32°F (0°C) for a minute and then checked for resist ance while the tube is still in the ice water. A probe is considered good if it exhibits a resistance value between 5400 and 5900 ohms at 32° F (0°C). Probes with values outside this range should be replaced.

60 Series Service Manual.rev.1.2012

- 41 –

FOR GB1064 MACHINES BUILT BEFORE 607945

WATER FILL ADJUSTMENT INSTRUCTIONS

Note: This applies only for GB1064 machines with serial numbers before 607945. Machines built after 607945 have an upgraded water valve which equalizes the amount of water in each tank per load.

Since supply pressures vary between the factory and install locations, water fill levels between the top and bottom water tanks will also vary. The water fill difference between the upper and lower water tanks should be less than 1/8 in (3 mm). A dynamic water pressure of 30 psig (0.2 MPa) minimum is required to ensure consistent water fill performance. Before adjusting the water fill levels be sure that the Water Level Probes are properly adjusted and no hoses are kinked. Refer to the Service Manual for the adjustment specifications according to cube size.

To Adjust For Equal Fill:

1. Place the selector in the “CLEAN” mode, switch the Power Switch to “ON”.

2. Pull down on the right side of either water plate, stretching the springs until the actuator motors rotate the cam arms counter-clockwise. Observe that the cam arms continue to turn, opening the water plates fully, dumping the water in the tanks. It may be necessary to turn the power off with the water plates fully open in order to completely drain the water tanks. At this point, the cam arm rotation will reverse and close the water plates. The cam arm rotation will stop when the water plates are fully closed and the water fill will occur. When the fill water reaches the “high-level probe” the water fill valve is de-energized and the water fill stops. A small amount of water will drain back from the water fill tubing to the lower water tank.

3. Compare the water levels in the probe tube and the upper section control stream overflow as seen on the next page to determine if the upper and lower water tanks are filling within the specified maximum difference

4. If the top tank level is lower than the bottom tank level by more than ⅛ inch (3 mm) for “C” models and ¼ inch (6 mm) for “HK” models, squeeze the restrictor clamp to reduce the bottom tank fill rate. If the top tank level is more than ⅛ inch (3 mm) for “C” models and ¼ inch (6 mm) for “HK” models 1/8” higher than the lower tank level, open the restrictor clamp to increase the lower tank fill rate. Small adjustments are recommended. When the adjustment appears to be correct, dump the water by pulling down on a water plate, as above, allow the water tanks to fill again and re-check the levels.

60 Series Service Manual.rev.1.2012

- 43 –

TROUBLE SHOOTING

Problem Possible Cause Solution

On-Off switch in "Off" position Move switch to "On" position.

Ice machine is not

operating.

No power at ice machine. Circuit protector open.

Ice machine off because bin is full of ice.

Ice machine off because bin level probe is defective.

Ice machine off as if bin is full. Ambient temp below 50°F (10°C).

Ice-Clean switch in "Clean" position. Move switch to "Ice" position.

Replace fuse or reset breaker. Check circuit for overload condition.

Use ice or move ice away from bin level probe.

Replace bin level probe. Ambient temperature must be 60°F

(15°C) minimum.

Compressor is not

operating. Water

pump and other

components are

operating normally.

See compressor test

procedure for more

information.

High pressure cut-out open on air cooled models. Condenser dirty.

High pressure cut-out open on air cooled models. Air circulation through condenser is insufficient or hot air is recalculating through the condenser.

High pressure cut-out open on liquid cooled models. Coolant liquid interrupted or insufficient

High pressure cut-out open on liquid cooled models. Interior of condenser has a mineral build-up.

High pressure cut-out open. Refrigeration system is overcharged.

Compressor thermal protector open because of low voltage condition.

Compressor thermal protector open because of defective run capacitor.

Contactor is defective.

Compressor start capacitor or relay defective

Clean condenser and reset high pressure cut-out. Confirm proper operating pressures.

Provide adequate spacing between the ice machine and walls, ceilings or other equipment. See installation instructions for spacing requirements. Confirm proper pressures.

Restore adequate coolant liquid supply and reset high pressure cut out. Confirm proper operating pressures.

Clean or replace condenser.

Remove refrigerant and recharge the system to specifications.

Allow thermal protector to reset. Measure voltage at contactor while compressor is running. Correct power supply problem if voltage is lower than specified on the ice machine electrical plate. See compressor test procedure for more information.

Replace run capacitor. See compressor test procedure for more information.

Check for voltage at coil terminals. Replace contactor if it does not close when the coil is energized.

Test and replace these parts if defective. See compressor test procedure for more information.

Problem Possible Cause Solution

Condenser fan

motor is not

operating on air-

cooled models.

Compressor is

operating

Defrost

performance slow

TROUBLE SHOOTING

Replace compressor. See

Compressor is defective.

compressor test procedure for more information.

Replace motor if it does not run

Fan motor protector open.

when cool or at normal operating conditions.

Fan motor defective Replace motor.

Condenser sub-cooling >11°C at the middle point of the freeze cycle on liquid-cooled models.

Condenser liquid regulating valve not closing fully during defrost on liquidcooled models.

Air cooled ice machine installed in a low ambient temperature location.

Ice frozen into the water plate surface. Thick web between ice cubes.

Ice frozen into the water plate surface. Cubes are fully formed without small dimples.

System is overcharged with refrigerant. Remove refrigerant and recharge the system to specifications.

Adjust, repair or replace liquid regulating valve.

Ambient temperature must be 60°F (15°C) minimum.

Adjust web thickness to specifications.

Reduce the water fill level until ice cubes are produced with small dimples.

Water plate re-

opens immediately

after closing

Water plate closes

but re-opens before

water fill is

completed.

Ice cubes have large dimples or are hollow at the end of the freeze cycle. Batch weight is too light.

Evaporator grids are distorted.

"Water plate up" switch lever is not being pushed up completely.

Water plate is prevented from closing by some obstruction such as ice remaining on the water plate surface.

Water plate springs are stretched or weak and allow the water plate to drop slightly as the water fills the tank. The "water plate up" switch lever is allowed to drop and re-open the water plate.

A water plate spring is broken or disconnected from the cam arm or the water plate.

Increase the water level until ice cubes are produced with small dimples.

Carefully straighten grids or replace evaporator if the damage is severe.

Adjust "water plate up" switch actuator on water plate until it pushes up the switch lever completely.

Eliminate obstruction. Adjust the evaporator temperature probe so all ice is out of the evaporator before the water plate begins to close.

Replace defective springs.

Replace broken spring or reattach disconnected spring.

60 Series Service Manual.rev.1.2012

- 45 –

TROUBLE SHOOTING

Problem Possible Cause Solution

Evaporator temperature probe is

Water plate will not

close after defrost.

Defrost does not

initiate when water

level drops below

low water level

probe.

defective and not sensing warm evaporator temperature.

Actuator motor output shaft is tuning but front cam is not turning.

Actuator motor will not run. No voltage measured at actuator motor.

Actuator motor will not run. No voltage measured at actuator motor and controller output terminal.

Actuator motor will not run. Voltage measured at actuator motor. Actuator motor or capacitor defective.

Actuator motor overheated. Open thermal overload.

Water level probe does not sense that the water level is low.

Water level probes are OK but no voltage measured at the controller output terminals to the actuator motor, water valve or defrost valve.

Test probe and replace if defective.

Cam pin is broken or missing. Inspect operation of arms up and

arms down switches. Adjust or replace if defective.

Test controller and replace if defective.

Replace defective actuator motor or capacitor. See actuator motor test procedure for additional information.

Let motor cool and determine why motor is running continuously.

Be sure there is no continuity path between the probes through water or mineral deposits on the probe cap. Make sure the cap is clean and dry especially after cleaning the ice machine.

Test controller and replace if defective.

Defrost cycle ends

and water plate

closes before all ice

is out of the

evaporator.

Evaporator temperature adjustment is set too cold and terminates defrost too early.

The evaporator temperature probe has poor contact with the evaporator and terminates defrost too early.

Evaporator grids are distorted, slowing the fall of the ice from the evaporator.

Adjust evaporator temperature adjustment counter-clockwise (warmer) to extend defrost time.

Be sure the evaporator temperature probe is fully inserted into the evaporator probe holder.

Carefully straighten grids or replace evaporator if the damage is severe.

Problem Possible Cause Solution

Defrost valve opens

during water fill.

Ice remains attached

to the water plate

surface at the end of

defrost.

Water valve will not

close. Potable water

level continues to

rise after contacting

the tip of the high

water level probe,

during the fill cycle.

TROUBLE SHOOTING

Slow water fill.

Cold potable water supply.

Ice frozen into the water plate surface. Thick web between ice cubes.

Ice frozen into the water plate surface. Cubes are fully formed without small dimples.

Over-freezing

Cold potable water supply.

No voltage measured at water valve coil. Water valve remains open because of water supply problem.

The water supply pressure must be a minimum of 5 PSI (34 kPa) dynamic at the water valve. Be sure that the supply line is of adequate size. This is especially important for liquid cooled models where the potable water and condenser coolant water are supplied by the same water line. Check for restrictions in the water supply line including clogged filters. Check the water line strainer and clean it if needed.

This is normal operation of the unit, if the water supply is too cold. Very cold water will not rinse the ice residue from the water plate, causing it to build up and affect normal operation.

Adjust web thickness to specifications.

Reduce the water level until ice cubes are produced with small dimples.

Be sure that the control stream does not go over the dam for longer than 15 seconds.

Very cold water will not rinse the ice residue from the water plate thoroughly.

60 Series Service Manual.rev.1.2012

- 47 –

TROUBLE SHOOTING

Problem Possible Cause Solution

No voltage measured at water valve coil. Water valve remains open because of dirty or defective water valve.

Line voltage measured at water valve coil.

Disassemble and clean water valve if needed. Make sure the bleed holes in the valve diaphragm are open. Replace water valve if defective.

Test for continuity through the high level probe and the reference probe. Replace the probe if the continuity is broken.

Water valve will not

open. Potable water

level never reaches the high water level

reaches the high

water level probe,

during the fill cycle.

Poorly formed or

cloudy

ice cubes.

Water level probes test OK, but line voltage measured at water valve coil.

No voltage measured at water valve coil because of an abnormal probe continuity path.

Test controller and replace if defective. No voltage measured at water valve coil and controller output terminal because of defective controller.

Water valve closes when water contacts the tip of the low water level probe, because the low and high water level probes are reversed in the water level probe terminal plug.

Water plate pressure is low. Pump operating improperly because of low supply voltage.

Water plate pressure is low. Improper pump installed in ice machine.

Water plate pressure is low. Water plate is cracked or leaking

Ice cubes have large dimples or are hollow at the end of the freeze cycle.

Water plate is out of alignment with evaporator.

Test controller and replace if defective.

Be sure there is no continuity path between the probes through water or mineral deposits on probes through water or mineral deposits on probes through water or mineral deposits on the probe cap. Make sure the cap is clean and dry especially after cleaning the ice machine.

Test controller and replace if defective.

Relocate and reinstall the probe wires, in the probe terminal plug or replace the water level probe set.

Measure the supply voltage with the ice machine running. Be sure voltage is within the specified tolerances.

Be sure the pump being used is proper for the ice machine model.

Repair or replace water plate. Increase the water level until ice

cubes are produced with small dimples.

Re-align water plate. See the water plate alignment illustration for more information

Problem Possible Cause Solution

Ice cubes do not break apart after defrost because of thick web between cubes.

Ice cubes have uneven dimples. Dimples are larger on right side of evaporator because of low refrigerant charge.

Ice cubes have uneven dimples. Dimples are larger on right side of evaporator because of high evaporator superheat.

Ice cubes have uneven dimples. Dimples are larger on left side of evaporator and ice may freeze into the right side surface of the water plate because of low evaporator superheat.

Arms up and arms down switches are

Actuator motor turns

clockwise at start of

defrost.

defective, or the relationship between the switches and switch operators is improper.

Arms up and arms down switch wiring is incorrect.

Cam arms are

improperly

positioned when the

water plate is fully

opened and/or

The relationship between the switches and switch operators is improper.

closed.

TROUBLE SHOOTING

Adjust spacing between evaporator and water plate. See the web thickness adjustment illustration for more information.

Remove refrigerant and recharge the system to specifications.

Adjust the expansion valve to decrease the evaporator superheat.

Adjust the expansion valve to increase the evaporator superheat.

Confirm proper operation of the arms up and arms down switches and replace if needed. Confirm proper settings of the switch operators and adjust as required.

Correct switch wiring. Adjust switch operators so the cam

arms are at the 12 o'clock position when the water plate is fully closed and at the 7 o'clock position when the water plate is fully open. See the cam arm, switch and switch operator relationship illustration for more information.

60 Series Service Manual.rev.1.2012

- 49 –

Evap/Bin Temperature Probe Assy

GT36x Parts – Left Side

2-Evaporator

1-Water Plate

20-Filter Drier

19-Expansion Valve

18-Probe Tube Assy

17-Water Pump

PARTS DIAGRAMS

5-Spring (2x)

4-Evap/Bin Temp Sensor Assembly

3-Plate/Cam Switch (3x)

6-Front Cam w/Springs 7-Rear Cam w/Springs

8-Actuator Motor

9-High Pressure Cut-Out

10-Ice/Clean Switch

11-Controller

12-Water Deflector

16-Drain Pan

No. Part Description Model Part No.

Water Plate "C" GT36x 102141501 10 Ice-Clean Switch All 102138501

Water Plate "HK” GT36x 102141601 11 Controller All 102138201 Evaporator "C" GT36x 102142101 12 Water Deflector GT36x 102141001

Evaporator "HK" GT36x 102142001

3 Plate/Cam Switch 3Req’d All 102138001 14 On-Off Switch All 102138601

4 Evap/Bin Temperature Probe Assy GT36x 102143901 4

For HK Evap After SN/610899

5 Spring 2Req’d All GBR00909 16 Drain Pan GT36x 102142201 6 Cam (Front) with Spring All GBR00969 7 Cam (Rear) with Spring All GBR00949 Transformer All 230V GT364 102145401

Actuator Motor GT361 102140901 18 Probe Tube Assembly GT36x 102140401

Actuator Motor GT364 102123802 19 Expansion Valve GT36x 102118802 High Pressure Cut-Out

(Manual Reset)

15-Water Tank

GT36x 102144201

All 102105501 20 Filter Drier All GBR02750

14-On/Off Switch

No. Part Description Model Part No.

13 Fuse Holder With Fuse 4amp All 102144901

Fuse Only All 102136301

15 Water Tank GT36x 102142301

Water Pump All GT3,GT5,GB ALL IM 102145501

13-Fuse Holder w/ 4A fuse

GT36x Parts – Right Side-Air Cooled

5-Fan Blade 6-Fan Motor

7-Condenser (Air Coole )

GT36x Parts – Right Side-Liquid Cooled

2-Defrost Valve Body

1-Defrost Valve Coil

4-Water Valve

3-Compressor

8- Condenser (Liquid Cooled)

No. Description Model Part No.

2 Defrost Valve Body GT36x 102100801 3

5 Fan Blade GT36x 102101602 7 Condenser (Air Cooled) GT36xA 102141901

8 Condenser (Liquid Cooled) GT36xL 102102101 9 Liquid Regulator Valve GT36xL GAR00701D

10 Relay Box Assembly GT361 102142401

9-Liquid Regulator Valve

Defrost Valve Coil GT361 102101101 Defrost Valve Coil GT364 102101201

Compressor GT361 102140701 Compressor GT364 102141701 Water Valve-Before S/N 607945 GT361 102138301 Water Valve-Before S/N 607945 GT364 102138401 Water Valve-After S/N 607945 GT361 102141201 Water Valve-After S/N 607945 GT364 102141101 Fan Motor GT361 102139201 Fan Motor GT364 102139301

Relay Box – Components Relay Potential

Start Capacitor 102119502

GT364

Run Capacitor 102104401

102145101

60 Series Service Manual.rev.1.2012

- 51 –

GT56x Parts – Left Side

1-Water Plate

24-Filter Drier

23-Expansion Valve

22-Probe Tube Assembly

20-Water Pump

21-Water Tank

19-Drain Pan 18-Fan Blade

17-Fan Motor

16-Compressor

4-Evap/Bin Temp Sensor Assembly

3-Plate/Cam Switch (3x)

2-Evaporator

5-Front Cam w/Springs 6-Rear Cam w/Springs

7-Spring (2x)

8-Actuator Motor

9-High Pressure Cut-Out

10-Water Deflector

11-Defrost Valve Coil

12-Ice/Clean Switch

13-Controller

14-Fuse Holder with 4A Fuse

15-On/Off Switch

No. Part Description Model # Part No.

Water Plate "C" GT56x GBR00200 12 Ice/Clean Switch All 102138501

Water Plate "HK” GT56x GBR00167 13 Controller All 102138201

Evaporator-"C" Before S/N 608887

Evaporator-"C" After S/N 608887

Evaporator-"HK” Before S/N 608887

Evaporator-"HK” After S/N 608887

3 Plate/Cam Switch (2) All 102138001

Evap/Bin Temp Sensor-Before S/N 608888 GT56x 102144001 Fan Motor GT564 102139301

Evap/Bin Temp Sensor-After S/N 608888 GT56x 102144201 18 Fan Blade All 102101601 5 Front Cam w/Springs All GBR00969 19 Drain Pan GT56x 102137801 6 Rear Cam w/Springs All GBR00949 7 Spring (2 per pk ) All GBR00909 Transformer All 230V GT564 102145401

Actuator Motor GT561 102123801 21 Water Tank GT56x 102143301 8

Actuator Motor Serial No. After 611032 GT561 102144403

Actuator Motor GT564 102123802 22 Probe Tube Assy GT56x 102140501 9 High Pressure Cut-Out All 102105501 23 Expansion Valve GT56x GBR02359

10 Water Deflector GT561 GBR00202 24 Filter Drier All GBR02750

Defrost Valve Coil GT561 102101101

Defrost Valve Coil GT564 102101201

GT56x GBR00148 14

GT56x 102144501 15 On/Off Switch All 102138601

GT56x GBR00167

GT56x 102144601 Compressor GT564 102119131

No. Part Description Model # Part No.

Fuse Holder With 4A Fuse FUSE ONLY

Compressor GT561 102119128

Fan Motor GT561 102139201

Water Pump All GT3,GT5,GB ALL IM 102145501

All

102144901 102136301

Left Side

Liquid Regulator Valve

No. Description

Model(s)

Part No.

GT56x Parts

Right Side

Water valve in same location on “A” and “L” models.

1-Water Valve

2-Defrost Valve Coil

Liquid Cooled

3-Defrost Valve Body

5-Condenser (Liquid Cooled)

6-Condenser (Air Cooled)

Water Valve-115V Before S/N 607945

GT561 102138301

Water Valve-115V After S/N 607945

Water Valve-230V Before S/N 607945

Water Valve-230V After S/N 607945

Defrost Valve Coil GT561 102101101

Defrost Valve Coil GT564 102101201 3 Defrost Valve Body GT56x 102101001 4 Liquid Regulator Valve GT56xL GAR00701D 5 Condenser-Liquid Cooled GT56xL 102102101 6 Condenser-Air Cooled GT56xA 102101803

GT561 102141201

GT564 102138401

GT564 102141101

60 Series Service Manual.rev.1.2012

- 53 –

2-Evaporator

No. Part Description

Model #

Part No.

No. Part Description

Model #

Part No.

GB56x

21-Probe Tube Assembly

20-Filter Drier

19-Expansion Valve

18-Water Pump

17-Drain Pan

16-Water Tank

1-Water Plate

15-Spring (2x)

3-Evap/Bin Temp Sensor Assembly

4-Plate/Cam Switch (3x)

12-Front Cam w/Springs

13-Rear Cam w/Springs

14-Water Deflector

5-Actuator Motor

6-High Pressure Cut-Out

7-Defrost Valve Coil

8-Ice/Clean Switch

9-Controller

10-Fuse Holder with 4A fuse

11-On/Off Switch

Water Plate "C"

Water Plate "HK”

2 Evaporator-"C"

Before S/N 608888 Evaporator-"C"

After S/N 608888 Evaporator-"HK”

Before S/N 608888 Evaporator-"HK”

After S/N 608888

3 Evap/Bin Temp Sensor-

Before 608888 Evap/Bin Temp Sensor-

After 608888 4 Plate/Cam Switch (2) All 102138001 17 Drain Pan GB56x 102137801 5 Actuator Motor GB561x 102123801 18

Actuator Motor GB564x 102123802 6 High Pressure Cut-Out All 102105501 19 Expansion Valve GB56x GBR02359 7 Defrost Valve Coil GB561x 102101101 20 Filter Drier All GBR02750

Defrost Valve Coil GB564x 102101201 21 Probe Tube Assy GB56x 102140401 8 Ice/Clean Switch All 102138501

GB56x GBR00200 9 Controller All 102138201 GB56x GBR00270 10

GB56x GBR00148 11 On/Off Switch All 102138601

GB56x 102144501 12 Front Cam w/Springs All GBR00969

GB56x GBR00167 13 Rear Cam wSprings All GBR00949

GB56x 102144601 14 Water Deflector GB561x GBR00202

GB56x 102143901 15 Spring (2 per PK ) All GBR00909

GB56x 102144201 16 Water Tank GB56x 102143301

Fuse Holder with 4A Fuse FUSE ONLY

Water Pump All GT3,GT5,GB

Transformer All 230V GB564 102145401

All 102144901

102136301

ALL IM 102145501

5-Fan Blade

No. Description

Model(s)

Part No.

GB56x-Air Cooled

1-Defrost Valve Coil

2-Defrost Valve Body

3-Compressor

4-Water Valve

6-Fan Motor

7A-Condenser (Air Cooled)

GB56x-Liquid Cooled

3-Compressor

8-Liquid Regulator Valve

7B-Condenser (Liquid Cooled)

4-Water Valve

Defrost Valve Coil GB561 102101101

Defrost Valve Coil GB564 102101201

Defrost Valve Body GB56x 102101001 Compressor GB561 102119128

Compressor GB564 102119131 Water Valve

S/N Before 607945 GB561 102138301 Water Valve

S/N After 607945 GB561 102141201

Water Valve S/N Before 607945 GB564 102138401

Water Valve S/N After 607945 GB564 102141101

Fan Blade GB56x 102101602 Fan Motor GB561 102139201

Fan Motor GB564 102139301 Condenser-Air Cooled GB56x 102101802

7A 7B

Condenser-Liquid Cooled GB56x 102102101

8 Liquid Regulator Valve All GAR00701D

60 Series Service Manual.rev.1.2012

- 55 –

Part Description

Model #

Part No.

No. Part Description

Model #

Part No.

Evap/Bin Temp

GB1064X Parts

1-Water Plate

26-Filter Drier

25-Expansion Valve

19-Water Pump

23-Drain Pan

22-Probe Tube Assembly

21- Filter Drier

20-Expansion Valve

19-Water Pump

2-Evaporator

3-Plate/Cam Switch

4-Actuator Motor

5-Defrost Valve Coil

6-Defrost Valve Body

7-Defrost Valve Coil

8-High Pressure Cut-Out

9-Defrost Valve Body

10-Ice/Clean Switch

11-Controller

12-Fuse Holder with 4A fuse

13-On/Off Switch

18-Drain Pan

17-Water Tank

16-

Sensor Assembly

15-Spring (4x)

14-Water Deflector

No.

Water Plate "C"

Water Plate "HK” GB106x GBR00270 13 On/Off Switch All 102138601

2 Evaporator-

Before S/N 608888 Evaporator-

After S/N 608888 Evaporator-

Before S/N 608888 Evaporator-

After S/N 608888 3 Plate/Cam Switch (2) All 102138001 17 Water Tank GB106xHK GAR00203 4 Actuator Motor GB1064 102123802 Water Tank GB106xC 102143301 5 Defrost Valve Coil GB1064 102101201 18 Drain Pan GB106x 102137801 6 Defrost Valve Body GB106xA/L 102101001 19 Water Pump All

Transformer All 230V GB1064 102145401

Defrost Valve Body GB106xR 102100801 20 Expansion Valve GB106x GBR02359 7 Defrost Valve Coil GB1064 102101201 21 Filter Drier All GBR02750 8 High Pressure Cut-Out All 102105501 22 Probe Tube Assy GB106x 102140401 9 Defrost Valve Body GB106xA/L 102101001 23 Drain Pan GB106x 102137801

GB106x GBR00200 12 Fuse Holder

with 4A Fuse FUSE ONLY

GB106xC GBR00148 14 Water Deflector GB106x GBR00202

GB106xC 102144501 15 Spring (2 PER PK )4x All GBR00909

GB106xHK GBR00167 16 Evap/Bin Sensor-

Before 608888

GB106xHK 102144601 Evap/Bin Sensor-

After 608888

GT3,GT5,GB

All 102144901

102136301

GB106x 102143901

GB106x 102144201

ALL IM 102145501

Defrost Valve Body GB106xR 102100801

10 Ice/Clean Switch All 102138501 25 Expansion Valve GB106x GBR02359 11 Controller All 102138201 26 Filter Drier All GBR02750

No. Description

Model(s)

Part No.

GB1064R Side

7-Head Pressure Control Valve

6-Compressor

5-Receiver

1-Harvest Regulator Valve

2-Water Valve

3-Liquid Line Solenoid Valve Body

4-Liquid Line Solenoid Valve Coil

1 Harvest Regulator Valve GB106xR 102122001

Water Valve – S/N Before 607945 GB1064 102139101

Water Valve – S/N After 607945 GB1064 102141301 3 Liquid Line Solenoid Valve Body GB106xR 102101001 4 Liquid Line Solenoid Valve Coil GB106xR 102101201 5 Receiver GB106xR 102102301 6 Compressor GB1064 102119126 7 Head Pressure Control Valve GB106xR GBR02351 8 Drier ( Add on 04/12/13 ) GB1064R 102107101

8- Drier

60 Series Service Manual.rev.1.2012

- 57 –

Water Valve

Defrost

4-Fan Blade

No. Description

Model(s)

Part No.

1-Defrost

Valve

Coil

Defrost

GB1064A Side

Valve Body

Valve Coil

Valve Body

Valve Coil

3-Fan Motor

8- Condenser-Air Cooled

GB1064L Side

Valve Coil

Valve Body

6-Compressor

2 3 4

6 7

5-Water Valve

Defrost Valve Coil GB1064A 102101201 Defrost Valve Coil GB1064L 102101101

Defrost Valve Body GB1064 102101001 Fan Motor GB1064A 102139301 Fan Blade GB1064A 102101602

Water Valve – S/N Before 607945 GB1064 102139101

Water Valve – S/N After 607945 GB1064 102141301

Compressor GB1064 102119126 Condenser-Liquid Cooled GB1064L 102102101 Condenser-Air Cooled GB1064A 102101802

6-Compressor

7-Condenser (Liquid Cooled)

Description

Model(s)

Part Number

PARTS LIST

Actuator Motor GT361 102140901 Actuator Motor GT561, GB561 102123801 Actuator Motor GT364, GT564, GB564, GB1064 102123802 Actuator Motor Box Cover GT36x 102143401 Actuator Motor Box Cover GT56x, GB56x, GB106x 102137201 Actuator Motor Capacitor GT361, GT561, GB561 102124101 Actuator Motor Capacitor GT364, GT564, GB564, GB1064 102124102 Cam (Front) All GBR00969 Cam (Rear) All GBR00949 Cam Pin All 102121001 Cam Shaft GT36x 102141801 Cam Shaft GT56x, GB56x, GB106x GBR00942 Cam Shaft Bracket All GBR00937 Cam Shaft Shim Set All GBR00580 Compressor GT361 102140701 Compressor GT364 102141701 Compressor GT561, GB561 102119128 Compressor GT564, GB564 102119131 Compressor GB1064 102119126 Condenser-Air Cooled GT36xA 102141901 Condenser-Air Cooled GT56xA 102101803 Condenser-Air Cooled GB56xA, GB1064A 102101802

Condenser-Liquid Cooled Contactor-Single Pole 120V Coil GT361, GT561, GB561 102103501

Contactor-Single Pole 240V Coil GT364, GT564, GB564, GB1064 102103601 Control Box Cover GT36x 102142501 Control Box Cover GT56x 102142601 Control Box Cover GB56x, GB106x 102137301 Controller All 102138201 Defrost Valve Body GT56x, GB56x, GB106xA/L 102101001 Defrost Valve Body GT36x, GB106xR 102100801 Defrost Valve Coil GT361, GT561, GB561 102101101 Defrost Valve Coil GT364, GT564, GB564, GB1064 102101201 Drain Pan GT36x 102142201 Drain Pan GT56x, GB56x, GB106x 102137801 Drain Tube All 102120101 Drier All GBR02750 Drier ( GB1064R )ADD ON 04/12/13 GB1064R 102107101 Evap/Bin Temperature Probe Assembly GT36x, GB56x, GB106x 102143901 Evap/Bin Temperature Probe Assembly (Up to S/N 608887) Evap/Bin Temperature Probe Assembly (Starting at S/N 608888) Evaporator "C" GT36x 102142101

GT36Xl, GT56xL, GB56xL, GB106xL

102102101

GT56x, GB56x, GB106x 102144001 GT56x, GB56x, GB106x 102144201

60 Series Service Manual.rev.1.2012

- 59 –

Description

Model(s)

Part Number

Evaporator "C" (Up to S/N 608887) GT56x, GB56x, GB106x GBR00148 Evaporator "C" (Starting at S/N 608888) GT56x, GB56x, GB106x 102144501 Evaporator "HK" (Up to S/N 608887) GT56x, GB56x, GB106x GBR00167 Evaporator "HK" (Starting at S/N 608888) GT56x, GB56x, GB106x 102144601 Evaporator Shim Set All GBR00111 Evaporator Spacer Set “ C” “HK” GBR00113 Expansion Valve GT36x 102118802 Expansion Valve GT56x, GB56x, GB106x GBR02359 Fan Blade GT36x, GT56x, GB56x, GB106x 102101602 Fan Motor GT361, GT561, GB561 102139201 Fan Motor GT364, GT564, GB564, GB1064 102139301 Fan Motor Support All 102121404 Front Panel GT36x 102143701 Front Panel GT56x 102143801 Front Panel GB56x 102137901 Front Panel GB106x 102144101

Fuse Holder With Fuse 4amp Harvest Regulator Valve GB106xR 102122001

Head Pressure Control Valve GB106xR GBR02351 High Pressure Cut-Out (Manual Reset) All 102105501 Hose Kit All GBR02087 Ice Deflector Kit GT36x 102143101 Ice Deflector Kit GT56x 102143201 Ice Deflector Kit GB56x, GB106x Lower 102137601 Ice Deflector Kit GB106x Upper 102139701 Ice-Clean Switch All 102138501 Left Side Panel GT36x 102142701 Left Side Panel GT56x 102142801 Left Side Panel GB56x 102137101 Left Side Panel GB106x 102139401 Liquid-Line Solenoid Valve Body GB106x 102101001 Liquid-Line Solenoid Valve Coil GB106x 102101201 Liquid Regulator Valve All GAR00701D On-Off Switch All 102138601 Plate/Cam Switch All 102138001 Probe Tube Assembly GT56x 102140501 Probe Tube Assembly GT36x, GB56x, GB106x 102140401 Pump-Down Control GB106xR 102105202 Receiver GB106xR 102102302 Relay Box Assembly GT361 102142401 Right Side Panel GT36x, GB56x 102137501 Right Side Panel GT56x 102142901 Right Side Panel GB106x 102139501 Run Capacitor GT561, GB561 102119704 Run Capacitor GT564, GB564 102104401 Run Capacitor GB1064 102119702 Spring ( 2 per pk ) All GBR00909

All FUSE ONLY

102144901 102136301

Description

Model(s)

Part Number

Spring Boss All GBR00951 Stacking Chute GB106x 102139601 Start Capacitor GT561, GB561 102119508 Start Capacitor GT564, GB564 102119502 Evaporator "HK" (Starting at S/N 608887) GT56x, GB56x, GB106x 102144601 Evaporator Shim Set All GBR00111 Evaporator Spacer Set All GBR00113 Start Capacitor GB1064 102119509 Start Relay GT561, GB561 102104709 Start Relay GT564, GB564 102104706 Start Relay GB1064 102104713 Top Panel GT36x 102143501 Top Panel GT56x 102143601 Top Panel GB56x, GB106x 102137401 Water Deflector GT36x 102141001 Water Deflector GT56x, GB56x, GB106x GBR00202 Water Distributor Tube GT36x 102143001 Water Distributor Tube GT56x, GB56x, GB106x GBR00403 Water Plate "C" GT36x 102141501 Water Plate "C" GT56x, GB56x, GB106x GBR00200 Water Plate "HK” GT36x 102141601 Water Plate "HK” GT56x, GB56x, GB106x GBR00270 Water Plate Hinge Set All GBR0028206 Water Plate Plug Set All GBR00223 Water Pump All GT360,GT560,GB560,GB1060

ALL IM 102145501

Transformer All 230V ( 1 Transformer can rum the 2 pump on a GB1060 ) The 2 pump on GB1064 must be the same

GT364,GT564,GB564,GB1060 102145401

style Water Supply Tube All 102137001 Water Tank GT36x 102142301 Water Tank GB106xHK GAR00203 Water Tank GT56x,GB56x, GB106xC 102143301 Water Valve (Up to S/N 607944) GT361, GT561, GB561 102138301 Water Valve (Up to S/N 607944) GT364, GT564, GB564, GB1064 102138401 Water Valve (Up to S/N 607944) GB1064 102139101 Water Valve (Starting at S/N 607945) GT361, GT561, GB561 102141201 Water Valve (Starting at S/N 607945) GT364, GT564, GB564 102141101 Water Valve (Starting at S/N 607945) GB1064 102141301

60 Series Service Manual.rev.1.2012

- 61 –

ACTUATOR MOTOR KIT APPLICATION LIST

Energy Efficient

GT361

GB561, GT561

GB564, GT364

GB1064

Required

Classic

GB421, GB431, GB441, GB451,

GT551

GB427,

GB434, GB437, GB444,

GT557

GB1224, GB1225, GB1244,

GB1257, GB1258

GT331, GT341, GT351

GT334, GT337, GT344, GT347,

GT354, GT357,

Electronic

GB401, GB402, GB406, GB503,

GT402, GT406, GT503, GT603,

IS401, IS503

GB903, GB1003, GB1204, GB1205

2-Required

GB407, GB507, GT307, GT407,

GT507, IS507

GB1208

2-Required

Electro

Mechanical

GB1, GB2, GB5, GB7, GS6, GT1,

GT7, GT8, GY3, IS1, IS5, IS7,

MD1, MD5

GB4

2-Required

GB1F, GB7F, GS6F, GT1F, GT7F,

GY3F, IS7F

Other

T175 crusher, TKN2 agitator, AKD

agitator

Model Number

GB447, GB454, GB457, GB624, GB627, GB634, GB637, GB644, GB647, GB654, GB657, GT554,

GB1245, GB1254, GB1255,

GB603, GT301, GT306, GT401,

206121201 115V 60HZ

102129201

115V 60HZ

102129202

208/240V

50/60HZ

102123801

115V 60HZ

102123802

208/240V

50/60HZ

102123901

115V Timer Kit

102123902

208/230V

Timer Kit

2-Required

102124001

Motor Cover Kit

STACKING INSTRUCTION

Caution:

Knowledge of proper installation and service procedures is essential to the safe operation

of KOLD

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 t

Never operate equipment that has been damaged or does not have all the protective

Never operate equipment that has been altered from the original KOLD

Special attention should be given

signal words and symbols that are used throughout this manual.

Instruct all personnel in the proper use of the equipment.

Clean up any spillage immediately.

Failure to comply with all KOLD

equipment or property damage and may void the product warranty.

DRAFT 6 series energy efficient

panels

holes

hanger

DRAFT equipment. Refer all installation and service work to

to potential hazard labeling on the equipment and the

ation guidelines may cause personal injury,

making machines.

ice

•

and maintenance qualified technicians.

•

is switched off.

•

covers in place.

•

specifications.

•

For stacking 2 or more KOLD-

1. Remove the cabinet

2. Mount the frame spacers

3. Position so the spacer

4. Position the front panel

-DRAFT install

ice-

from the upper and lower ice machines.

the top side panel flanges of the lower

are aligned with the holes in the frame.

on the top front rail as shown

he ice machine

-DRAFT

machine frame.

60 Series Service Manual.rev.1.2012

- 63 –

provided

spacers

chute

partition

machine

frames

ANGER

: It is highly recommended that 2 or more people perform this job, if the

could cause serious injury or death.

Locate

machine

lock

5. Apply the gasket gasket over the frame

to the top of the lower ice machine frame

to secure them in position.

as shown. Place the

6. Position the stacking channels, against the

7. Carefully lift the upper frames. Fasten the

in the lower machine as shown.

wall.

and place it on top of the lower

together using the screws, washers and

on the support

and align the

nuts provided

machine falls it

back

the

until

the

position

required.

wall

and

machine

8. Replace the front and the stacking kit. Install down on the deflectors

9. Feed the bin probe from condensing unit pan and unit pan and adjust as

deflectors of the top ice machine with the

deflectors into the slots in the back

they engage beside the stacking chute

upper machine, through one of the holes

in one of the holes in the lower ice

deflectors provided in

and front rail. Push

snap in place.

in the upper machine

condensing

60 Series Service Manual.rev.1.2012

- 65 –

ICE CUBE CRUSHERS - T27X

(For KOLD-DRAFT GB series Ice Makers)

Installation, Operation, Technical Service and Replacement Parts

D-D

DRAF

Caution:

DANGER:

Caution:

ICE CRUSHER-SAFETY INFORMATION

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

Check for freight damage before proceeding, even though damage to the carton may not have been evident, check for hidden damage and contact freight carrier immediately if necessary to file a claim.

This equipment must be installed in compliance with the applicable federal, state/province and/or local plumbing, electrical and health/sanitation codes and requirements.

•

Risk of personal injury, property damage, equipment failure or fire.

•

Refer all maintenance to qualified personnel.

•

Risk of personal injury, property damage, equipment failure or fire.

•

Never operate this equipment with covers, panels or other parts removed or not properly

secured.

•

Warn all users to clean up spillage immediately, keep storage bin doors closed, and report any

apparent leakage or unusual sounds to maintenance personnel.

•

Proper installation must include KOLD-DRAFT® GB Series Ice maker mounted above Crusher.

60 Series Service Manual.rev.1.2012

- 67 –

ICE CRUSHER INSTALLATION

Notes:

•

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.

•

To ensure optimal efficiency and productivity these installation instructions should be followed

accurately.

•

All machines have been tested and adjusted for correct performance at the factory.

•

This equipment must be installed in compliance with the applicable federal, state/province,

and/or local plumbing, electrical, and health/sanitation codes and requirements.

Warning:

•

Do not operate equipment that has been damaged.

•

Refer all maintenance to qualified personnel.

•

Instruct all personnel in the proper use of the equipment.

•

Clean up any liquid spills immediately.

•

Always install equipment on a stable and level surface.

•

All models are intended for indoor use only. Do not install the equipment in unprotected

outdoor areas.

•

Always securely attach individual machines together.

•

Do not install the equipment in wet areas.

•

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.

Pre-Install Checklist

•

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 crusher must be connected to the grid through its own dedicated fuse or HACR type

circuit breaker.

•

Each ice crusher 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.

•

Electrical service must fall within the voltage tolerances listed below

Nominal (V) No-Load Maximum

115 (1 Series) 126 104

208/230 (4 Series) 250 210

Full-Load Minimum

•

Breaker or fuse rating 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 8 meters (26 feet) in length. For a conductor length over 8 meters, increase the wire gauge as required by code.

DANGER:

Failure to comply with these regulations may cause serious injury or death

and cause damage to the machine and its surroundings.

Position the ice storage bin maintaining the minimum cleara

Level the bin with adjusters on its legs, or by shimming if the bin is to be sealed to the floor. If

there are gaps between the bin and the floor greater than 1/8 inch, install a cove molding

tom. Seal the bin (and molding) to the floor with NSF Certified RTV sealant

Corning RTV 732 or equivalent).

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 peri

crusher is in place. To apply the gasket

Place the crusher on a flat surface. If the floor is a rough or marring surface place a large rag or

mat on the floor to the left of the crusher and stand the crusher on its left side.

Position the bottom guard so that the right side flange is hung over the ice breaker bar.

Install the left side flange over the mounting studs and secure in place with

Use care when positioning the ice crusher on the bin so that the guard is not damaged.

Be sure to check for internal bin components such as deflectors, dividers etc., which may

interfere with the guard during

Carefully lift the crusher and place onto the gasketed bin. Remove the front cover and note

the alignment of the mounting holes in the chassis if mounting means are provided on the bin.

Follow the bin installation instructions for securing t

nces specified in the ice maker

meter of the ice crusher chassis when the ice

peel away the white backing strip and press firmly in

he crusher to the bin.

Assembly/Installation

1. instructions.

2. around the bin bot

(Dow-

place.

4. rubber

the supplied 1/4-

20 lock nuts. Note:

installation.

60 Series Service Manual.rev.1.2012

- 69 –

Note: The plastic selector knob must be removed before the front cover can be removed on older machines.

8. Insert the straight thermostat holder tube into the rubber grommet located directly behind the crusher motor. Route the crushed ice thermostat capillary tube through the straight thermostat tube holder. Ensure that the capillary tube is slightly protruding from the bottom of the tube holder.

Place the cube ice thermostat capillary tube into the bent thermostat tube holder. Ensure that the capillary tube is slightly protruding from the bottom of the tube holder. Mount the tube holder as shown using the supplied hardware. Tighten the clamp screws. The picture below is a view of the right side of the crusher assembly from within the crusher frame. This portion will be above the un-crushed cube side of the bin.

9. Install gasketing on top of crusher.

10. Remove the ice maker cabinet panels, lift and position ice maker on top of gasketed crusher and align the mounting holes. Install cap screws, lock washers and nuts.

11. Mount the ice maker safety switch as shown. If not provided, locate and drill two 3/16 inch dia. holes in the ice maker lower front rail. Mount the safety switch support with the #8-32 screws and lock nuts provided.

Notes:

•

The crusher is designed to operate in conjunction with one or two KOLD-DRAFT® ice

makers. Two motor control relay blocks are provided and a relay coil must be installed for each ice maker used. Each relay coil must have a voltage rating matching the voltage of the ice maker, regardless of the crusher motor voltage. T271 crushers are supplied with 115V relays. T274 crushers are supplied with 208-230V relays. The relay coils are installed through the opening in the control box. A third relay is provided for controlling one or two ice makers with the same set of bin thermostats. This relay coil voltage rating is matched to the crusher motor voltage and is provided with the crusher.

•

A dual safety switch system is employed in the crusher design to break the circuit to the

motor. If either the front panel of the crusher or the front panel of the bottom ice maker is removed, a switch will open the motor circuit. The crusher safety switch is mounted in the crusher control box.

12. Install a grommet in the pre-cut hole in the floor of the ice maker’s compressor compartment directly behind the controller box.

13. Push the safety switch wire assembly (wires with insulated 90 ° flag terminals) and the motor control wire assembly (wires with piggyback terminals) through the grommet into the ice maker

14. Connect the safety switch wires from the crusher to the "Common" and "Normally Open" terminals of the ice maker safety switch (the two outer terminals). (See Wiring Diagram) Note: There are two motor control wire assemblies of different lengths. When using a stacked machine the shorter wire assembly gets connected to the lower ice maker and the longer wire gets connected to the upper ice maker. If the ice maker is not a stacked unit the longer wire is unused

Warning:

The safety switches do not de-energize all circuits in the crusher or circuits in the ice maker. Before cleaning or servicing this equipment disconnect all power supplies.

15. Disconnect the white plug assembly from the ice maker hot gas valve. (If installing a GB1064 ice maker there are two hot gas valves. Use the lower of the two to connect the crusher).

60 Series Service Manual.rev.1.2012

- 71 –

16.

Connect piggyback terminals of the motor control wire assembly to the tabs of the hot gas

Reconnect the white plug assembly to

Locate the bin thermostat of the ice machine and cut the probe off of the end of the cable

Route the cable through one of the small holes in the bottom of the ice machine and into

the back of the crusher control box

Pull the cable out through the front of the crusher control box and cut off the cable to a

Strip the outer cable jacket back about 3”. Then strip the red and black wires back about ¼”.

stripped wires to the left relay as shown.

Lower Ice Maker Thermostat

the piggyback terminals of the motor control wire

Upper Ice Maker Thermostat (If Installed)

valve on the ice maker.

17. assembly as shown below.

18.

19.

20.

manageable length.

21.

22. Connect the

23. Turn off the breaker or disconnect the fuse that will service the machine.

24. Make all electrical connections to the electrical service in a manner that complies with

local code

Note:

•

If two separate ice making machines (for example two GB1064 models stacked) are

installed the bin thermostats of both ice makers will need to be connected to the crusher.

•

Ensure that the thermostat cable is not routed through the ice chute. Do not run the cable

through the same hole that the safety switch wire assembly and the motor control wire assembly are run through.

Initial Start-Up

1. Ensure all electrical connections were made properly and turn on the electrical service.

Note: There is no on-switch, the machine will run when the ice-maker tells it to.

2. Adjust the bin thermostat to turn off the ice maker before the ice level is above the guard

screen.

3. Adjust the thermostats to shut off the ice maker approximately 1 minute after the ice contacts

the capillary tubes.

Note:

•

If ice is allowed to collect above the screen it will not clear when the ice below is removed.

This condition will cause ice to pile up in the chute of the crusher and ultimately, damage the ice maker

•

The use of the bottom guard will reduce the effective volume of the bin

ICE CRUSHER OPERATION

With the crusher knob in the crushed position, ice falling from the ice maker will be directed by the selector plate through the crusher mechanism and deposited into the left side of the bin.

The crusher motor is powered through a relay which is energized by the hot gas valve circuit of the ice maker. The selector knob must be in the crushed position to close a switch and complete the circuit to the motor. Additionally, the front panel safety switches must be depressed (covers on) for motor operation.

With the crusher knob in the "CUBE" position, ice falling from the ice maker will bypass the crusher mechanism and be dumped into the right side of the bin. The crusher motor will not be energized.

60 Series Service Manual.rev.1.2012

- 73 –

DANGER:

ICE CRUSHER CLEANING PROCEDURE

•

Disconnect or turn off all ice machine and crusher fuses or breakers before cleaning either

machine.

•

Do not use ammonia solutions or strong detergents in cleaning the crusher.

•

Never use appliance polishes, finish preservatives or cleaners in areas that could contact ice.

Warning:

•

Always clean the ice maker first, following the ice maker cleaning instructions.

•

Remove all ice from the bin before starting the cleaning procedure.

•

Clean and sanitize storage bin last.

1. Remove ice maker panels, ice chute, deflectors, drain pan, crusher front panel and belt guard.

2. Wash interior with a solution of 2 tablespoons of baking soda per quart of clean warm water, 140°F (60°C) max. The crusher ice hopper can be acc essed from the front and left side of the ice maker. Use a long handled brush to clean inside the hopper, as crusher teeth are sharp and can cause injury.

3. The bottom area of the crusher ice hopper can be accessed from inside the ice bin. Use a long handled brush.

4. Wipe down internal cabinet walls with a cloth soaked in cleaning solution.

5. Rinse with clean tap water.

6. Sanitize all ice contact surfaces with a solution of 1/2 teaspoon 5-1/4% sodium hypochlorite (chlorine bleach) per quart of clean tap water (minimum 100 PPM free chlorine). A spray bottle will facilitate this process.

7. Pour the remaining solution into the crusher chute, slowly, while rotating the cutter wheel by hand turning the pulley.

8. After adjusting and lubricating crusher (See following section), replace all enclosure panels and connect the electrical supply.

9. Exterior surfaces may be cleaned by standard methods suitable to the stainless steel finish.

ADJUSTMENT AND LUBRICATION

1. Oil the crusher motor (if ports are provided) and grease the shaft bearings. (Do not over-lubricate)

2. Check the belt and pulleys for excessive wear. Adjust the belt tension to deflect 5/32 inch with two pounds applied to the center of the span.

3. Tighten any loose set screws, machine screws, nuts and electrical connections.

WIRING DIAGRAM

60 Series Service Manual.rev.1.2012

- 75 –

GBR00856

T260 & T270

SELECTOR SHAFT

CRUSHER & CUBE

SIDE BIN

THERMOSTAT

102113302 CRUSHER

MOTOR T260 &TT270

102125701 DRIVE

PULLEY-13 TOOTH

102121704

SELECTOR

SWITCH

T260 & T270

102125801 DRIVEN

PULLEY-36 TOOTH

T260 & T270

102122601 SWITCH

ACTUATOR LINK

506102601

102103701

RELAY-PLUG IN 115V

102103801

RELAY- PLUG IN 230V

102125901

DRIVE BELT

T260 & T270

102121703 INTERLOCK SWITCH

PRE-CHARGED REMOTE AIR-COOLED CONDENSER - RC214APV

Installation, Operation, Technical Service and Replacement Parts

PARTS FOR CONDENSER

102140601 FAN MOTOR-RC214APV-230V

GBR01890 1/2 MALE SELF SEAL COUPLING FOR CONDENSER / ICE MAKER

GBR01889 3/8 MALE SELF-SEALING COUPLING FOR CONDENSER / ICE MAKER

PARTS FOR LINE SET

GBR02218 1/2 FEMALE SELF SEAL COUPLING FOR LINE SET

GBR02219 3/8 FEMALE SELF-SEALING COUPLING FOR LINE SET

60 Series Service Manual.rev.1.2012

- 77 –

PRE-CHARGED REMOTE AIR COOLED CONDENSER - INSTALLATION

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.

•

To ensure optimal efficiency and productivity these installation instructions should be

followed accurately.

•

All machines have been tested and adjusted for correct performance at the factory.

•

This equipment must be installed in compliance with the applicable federal, state/province,

and/or local plumbing, electrical, and health/sanitation codes and requirements.

Warning:

•

Do not operate equipment that has been damaged.

•

Refer all maintenance to qualified personnel.

•

Instruct all personnel in the proper use of the equipment.

•

Clean up any liquid spills immediately.

•

Always install equipment on a stable and level surface.

•

Never operate this equipment with covers, panels, guards or other parts removed or not

properly secured.

•

KOLD-DRAFT reserves the right to disallow any warranty claims which result from the use of

non KOLD-DRAFT condensers and/or line sets.

•

Read the entire manual before installing, operating or servicing the machine.

Pre-Install Checklist

•

All KOLD-DRAFT models are intended to be installed with a permanent connection to the field

•

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.

•

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

•

Remote condenser ambient air temperature: 110°F (43°C) maximum

•

Try to keep the compressor warmer than the condenser. In most installations, the ice maker

runs enough so that residual motor heat minimizes liquid migration to the crankcase. If the ice maker is in a cool location, or if it will be OFF for extended periods, a crankcase heater should be installed.

•

Avoid placing the condenser in the exhaust air stream of other equipment or within a distance

Caution:

MODEL

Gross Wt

Caution:

equal to the width of the condenser from a wall or another piece of equipment. Stay away from kitchen exhaust fans to prevent grease accumulation on the fins. Use a curb, which extends above the deepest expected pond in the condenser area of the roof.

Installation

1. Unpack the condenser and install the mounting legs.

2. Fasten the condenser to its mounting surface using methods that will satisfy the building codes in your area. The condenser must not be lower than the receiver.

3. The line sets are packed separately, with the quantity and length marked on the carton. Make sure that the lines are correct for your installation.

4. A single circuit condenser installation, which uses one line set, will require a 1-3/4" dia. hole to pass the lines through a ceiling or wall. The lines for a 2 circuit condenser require a 2" dia. hole.

5. Each line set consists of a 3/8" liquid line, and a 1/2" insulated discharge line. Connect the 3/8" line to the lower (liquid) fitting on the condenser, and to the "Refrigerant In" on the ice maker. The 1/2" line connects to the upper (inlet) fitting on the condenser, and the "Refrigerant Out" on the ice maker.

6. Each fitting on the line sets, condenser and ice maker is self-sealing, and should be tightened 1/4 turn more than hand tight. Always use a backup wrench to prevent tubing twist when tightening these fittings.

7. The condenser fan motor requires power supply provisions that comply with all applicable code requirements. The Ice Maker is provided with wire connection pigtails that include an L1 red wire for connection to the fan motor circuit along with L2 and Grounding conductors.

8. The refrigerant lines should be routed inside the building or otherwise mechanically protected wherever possible.

For multiple-circuit installations fan power must be provided separately by a circuit that will not be interrupted so that the fan motor will run continuously.

Remote condenser Ice Maker models from the factory are provided with adequate refrigerant charge to accommodate all acceptable condenser ambient temperatures and up to 50 ft. refrigerant lines. The Ice Maker Nameplate label on the rear of the cabinet indicates the factory charge amount, maximum total charge, and refrigerant type. Ice makers are provided with resealable refrigerant line connection couplings.

Specifications

NUMBER

RC214APV

VOLTAGE DESCRIPTION W" x D" x H"

208-230/60/1

0.7 FLA

Refrigerant charges must be accurately weighed.

60 Series Service Manual.rev.1.2012

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1 Circuit - 2 Ton - R/404a

Precharged Remote Condenser

20-1/8 x 34-3/4 x 30

w/legs & guard

(Lbs)

160

Caution:

Minimum Total Charge Required

Note:

•

The factory charge in dual-evaporator models is 168 oz (10.5 lb) R-404a.

•

The maximum total system charge for dual-evaporators is 208 oz (13 lb) R-404a.

•

The basic charge for a dual-evaporator model is 3 lb R-404a.

To determine the total charge, add the following to the basic charge below:

1. For each 10 feet of 3/8” O.D. liquid return tubing add 6 oz of R-404a.

2. For each 10 feet of ½” O.D. compressor discharge line >70o F add ½ oz R-404a.

3. For each 10 feet of ½” O.D. compressor discharge line <70o F add 11 oz R-404a (assume that at least 15’ will be <70o F if not certain).

4. Use the following amounts of R-404a according to the condenser model and the MINIMUM ambient temperature expected at the condenser:

RC214APV

+60o F +40

+20

-20 o F 3.5 lb

EXAMPLE: Calculate the minimum total system charge for a GB1060R Ice Maker with an RC214APV (single-circuit, 2-ton) condenser and 30 feet of interconnecting tubing with -20

minimum condenser ambient temperature. The calculation would be as follows: 3 lb (basic

2.3 lb

2.9 lb

3.2 lb

3.3 lb

charge) + 16.5 oz (15’ of ½” O.D. discharge line at <70o F) + 0.75 oz (15’ of ½” O.D. discharge line at >70o F) + 3.5 lb (flooded condenser at -20 o F) = 121.25 oz (7.6 lb). The factory charge for

GB1060R models is 10.5 lb.

•

Do not exceed the specified maximum total system charge.

•

Interconnecting lines over 50’ are not recommended.

•

Lines must be pitched upward toward the condenser with no “droops” or traps.

Note: The compressor will start immediately when power is applied, regardless of the “On/Off” or

the "Make Ice/Clean" switch positions, if the low-side pressure is at or above the pump-down controller cut-in setting and the high-pressure cutout is not open. Be sure that the compressor stops when the low-side pressure is between 5 and 15 psig.

Electrical Information

Removing From Service

When the ice maker is determined to be no longer useable please be sure that it is rendered safe for storage or disposal. All applicable recycling measures should be exercised to avoid injury and harm to the environment.

The manufacturer and/or seller is not responsible for any harm to people, animals, property, and the environment caused by incorrect installation and/or disposal.

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60 Series Service Manual.rev.1.2012

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Kold-Draft GB561AK Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual