Manitowoc KY0350A, KD0250A, KY0250A, KD0350A, KD0350W Installation, Operation And Maintenance Manual
...
Ice Machines
K Series
Installation, Operation and Maintenance Manual
Part Number 000012545 Rev 02 11/16
Safety Notices
Safety Notices
Read these precautions to prevent personal injury:
• Read this manual thoroughly before operating,
installing or performing maintenance on the
equipment. Failure to follow instructions in this
manual can cause property damage, injury or death.
• Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
• Proper installation, care and maintenance are essential
for maximum performance and trouble-free operation
of your equipment.
Visit our website www.kool-aire.com for manual
updates, translations, or contact information for
service agents in your area.
• This equipment contains high voltage electricity and
refrigerant charge. Installation and repairs are to be
performed by properly trained technicians aware of
the dangers of dealing with high voltage electricity
and refrigerant under pressure. The technician must
also be certified in proper refrigerant handling
and servicing procedures. All lockout and tag out
procedures must be followed when working on this
equipment.
• This equipment is intended for indoor use only. Do
not install or operate this equipment in outdoor areas.
Warning
n
Follow these electrical requirements during
installation of this equipment.
• All field wiring must conform to all applicable
codes of the authority having jurisdiction. It is
the responsibility of the end user to provide the
disconnect means to satisfy local codes. Refer to rating
plate for proper voltage.
• This appliance must be grounded.
• This equipment must be positioned so that the plug is
accessible unless other means for disconnection from
the power supply (e.g., circuit breaker or disconnect
switch) is provided.
• Check all wiring connections, including factory
terminals, before operation. Connections can become
loose during shipment and installation.
Warning
n
Follow these precautions to prevent personal injury
during installation of this equipment:
• Installation must comply with all applicable
equipment fire and health codes with the authority
having jurisdiction.
• To avoid instability the installation area must be
capable of supporting the combined weight of the
equipment and product. Additionally the equipment
must be level side to side and front to back.
• Ice machines require a deflector when installed on
an ice storage bin. Prior to using a non-OEM ice
storage system with this ice machine, contact the
bin manufacturer to assure their ice deflector is
compatible.
• Remove all removable panels before lifting and
installing and use appropriate safety equipment
during installation and servicing. Two or more people
are required to lift or move this appliance to prevent
tipping and/or injury.
• Do not damage the refrigeration circuit when
installing, maintaining or servicing the unit.
• Connect to a potable water supply only.
• This equipment contains refrigerant charge.
Installation of the line sets must be performed by
a properly trained and EPA certified refrigeration
technician aware of the dangers of dealing with
refrigerant charged equipment.
• Legs or casters must be installed and the legs/casters
must be screwed in completely. When casters are
installed the mass of this unit will allow it to move
uncontrolled on an inclined surface. These units must
be tethered/secured to comply with all applicable
codes. Swivel casters must be mounted on the front
and rigid casters must be mounted on the rear. Lock
the front casters after installation is complete.
• Some 50 Hz models may contain up to 150 grams
of R290 (propane) refrigerant. R290 (propane)
is flammable in concentrations of air between
approximately 2.1% and 9.5% by volume (LEL lower
explosion limit and UEL upper explosion limit). An
ignition source at a temperature higher than 470°C is
needed for a combustion to occur. Refer to nameplate
to identify the type of refrigerant in your equipment.
Only trained and qualified personnel aware of the
dangers are allowed to work on the equipment.
Warning
n
Follow these precautions to prevent personal injury
while operating or maintaining this equipment:
• Read this manual thoroughly before operating,
installing or performing maintenance on the
equipment. Failure to follow instructions in this
manual can cause property damage, injury or death.
• Crush/Pinch Hazard. Keep hands clear of moving
components. Components can move without warning
unless power is disconnected and all potential energy
is removed.
• Moisture collecting on the floor will create a slippery
surface. Clean up any water on the floor immediately
to prevent a slip hazard.
• Objects placed or dropped in the bin can affect
human health and safety. Locate and remove any
objects immediately.
• Never use sharp objects or tools to remove ice or frost.
Do not use mechanical devices or other means to
accelerate the defrosting process.
• When using cleaning fluids or chemicals, rubber
gloves and eye protection (and/or face shield) must
be worn.
DANGER
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications. This
appliance is not intended for use by persons (including
children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge, unless
they have been given supervision concerning use of the
appliance by a person responsible for their safety. Do
not allow children to play with, clean or maintain this
appliance without proper supervision.
Warning
n
This product is hermetically sealed and contains
fluorinated greenhouse gas R410A.
DANGER
Follow these precautions to prevent personal injury
during use and maintenance of this equipment:
• It is the responsibility of the equipment owner to
perform a Personal Protective Equipment Hazard
Assessment to ensure adequate protection during
maintenance procedures.
• Do Not Store Or Use Gasoline Or Other Flammable
Vapors Or Liquids In The Vicinity Of This Or Any Other
Appliance. Never use flammable oil soaked cloths or
combustible cleaning solutions for cleaning.
• All covers and access panels must be in place and
properly secured when operating this equipment.
• Risk of fire/shock. All minimum clearances must be
maintained. Do not obstruct vents or openings.
• Failure to disconnect power at the main power supply
disconnect could result in serious injury or death.
The power switch DOES NOT disconnect all incoming
power.
• All utility connections and fixtures must be
maintained in accordance with the authority having
jurisdiction.
• Turn off and lockout all utilities (gas, electric, water)
according to approved practices during maintenance
or servicing.
• Units with two power cords must be plugged into
individual branch circuits. During movement, cleaning
or repair it is necessary to unplug both power cords.
• Never use a high-pressure water jet for cleaning on
the interior or exterior of this unit. Do not use power
cleaning equipment, steel wool, scrapers or wire
brushes on stainless steel or painted surfaces.
• Two or more people are required to move this
equipment to prevent tipping.
• Locking the front casters after moving is the owner’s
and operator’s responsibility. When casters are
installed, the mass of this unit will allow it to move
uncontrolled on an inclined surface. These units must
be tethered/secured to comply with all applicable
codes.
• The on-site supervisor is responsible for ensuring that
operators are made aware of the inherent dangers of
operating this equipment.
• Do not operate any appliance with a damaged cord
or plug. All repairs must be performed by a qualified
service company.
Safety Notices
Section 1
General Information
Section 2
Installation
Table of Contents
Safety Notices ..................................................................................................................... 3
Model Numbers .................................................................................................................. 7
Ice Deflector ........................................................................................................................7
Bin Installation .........................................................................................................................................7
Air Baffle .............................................................................................................................7
Warranty Information ........................................................................................................ 7
Model Nomenclature ............................................................................................................................8
Location of Ice Machine ..................................................................................................... 9
Clearance Requirements ....................................................................................................9
Ice Machine Heat of Rejection .........................................................................................10
Removing Drain Plug and Leveling the Ice Storage Bin ................................................10
Air Baffle ...........................................................................................................................10
Electrical Service ..............................................................................................................11
Minimum Circuit Ampacity .............................................................................................................. 11
Electrical Requirements .................................................................................................................... 11
Ground Fault Circuit Interrupter .................................................................................................... 11
Minimum Power Cord Specifications ........................................................................................... 11
For United Kingdom Only ................................................................................................................ 11
Maximum Breaker Size & Minimum Circuit Amperage Chart .......................................12
Water Supply and Drain Requirements .......................................................................... 13
Water Supply ......................................................................................................................................... 13
Water Inlet Lines .................................................................................................................................. 13
Drain Connections .............................................................................................................................. 13
Water Supply and Drain Line Sizing/Connections ......................................................... 14
Water-Cooled Condenser Water Pressure ..................................................................................14
Cooling Tower Applications (Water-Cooled Models) ............................................................. 14
Remote Condenser/Line Set Installation ........................................................................15
Remote Ice Machine Refrigerant Charge ....................................................................................15
General ....................................................................................................................................................16
Wiring ...................................................................................................................................................... 16
Guidelines for Routing Line Sets ....................................................................................................16
Calculating Remote Condenser Installation Distances ..........................................................17
Route the Line Set ............................................................................................................................... 18
Connect the Line Set .......................................................................................................................... 18
Pressure Test and Evacuate Line Set and Condenser ............................................................. 18
Open Line Set Valves .......................................................................................................................... 18
Installation Check List ......................................................................................................19
Additional Checks for Remote Models ...........................................................................19
Before Starting the Ice Machine ......................................................................................19
Part Number 000012545 Rev 02 11/16 5
Section 3
Operation
Section 4
Maintenance
Section 5
Troubleshooting
Table of Contents (continued)
Ice Making Sequence of Operation .................................................................................21
Control Board Timers ......................................................................................................................... 21
Safety Limits .......................................................................................................................................... 21
Operational Checks ..........................................................................................................22
General ....................................................................................................................................................22
Minimum/Maximum Slab Weights ............................................................................................... 22
Ice Thickness Check ............................................................................................................................ 22
Cleaning and Sanitizing ................................................................................................... 23
General ....................................................................................................................................................23
Cleaning/Sanitizing Procedure.......................................................................................................23
Preventative Maintenance Cleaning Procedure .......................................................................23
Exterior Cleaning ................................................................................................................................. 23
Cleaning/Sanitizing Procedure .......................................................................................24
Sanitizing Procedure .......................................................................................................................... 25
Parts Removal for Cleaning/Sanitizing ..........................................................................26
Preventative Maintenance Cleaning Procedure ............................................................27
Door Removal ...................................................................................................................27
Cleaning the Condenser Filter .........................................................................................27
Cleaning the Condenser ..................................................................................................27
Removal from Service/Winterization .............................................................................28
Water-Cooled Ice Machines ............................................................................................................. 28
Checklist ............................................................................................................................ 29
Safety Limit Feature .........................................................................................................30
6 Part Number 000012545 Rev 02 11/16
Section 1
General Information
Model Numbers
This manual covers the following models:
Self-Contained
Air-Cooled
KD0250A
KY0250A
KD0350A
KY0350A
KD0420A
KY0420A
KD0500A
KY0500A
KD0600A
KY0600A
KD1000A
KY1000A
KD1350A
KY1350A
KD1800A
KY1800A
Self-Contained
Water-Cooled
----
---KD0350W
KY0350W
KD0420W
KY0420W
KD0500W
KY0500W
KD0600W
KY0600W
KD1000W
KY1000W
KD1350W
KY1350W
Remote
----
----
----
----
----
----
----
----
----
---KY1000N
KD1000N
KY1350N
KD1350N
KY1800N
KD1800N
Ice Deflector
An ice deflector is required when the ice machine is
installed on a bin. An ice deflector is not required when the
ice machine is installed on a dispenser.
BIN INSTALLATION
• All ice machines installed on a bin require an ice
deflector.
• Koolaire bins have a deflector installed and require
no modifications when used with a forward facing
evaporator.
• Align sides and back of ice machine with sides and back
of bin, when placing ice machine on bin.
Air Baffle
Self-Contained Air-Cooled Only
The air-cooled baffle prevents condenser air from
recirculating.
Warranty Information
Visit www.kool-aire.com for:
• Warranty Verification
• Warranty Registration
• View and download a copy of your warranty
Part Number 000012545 Rev 02 11/16 7
General Information Section 1
MODEL NOMENCLATURE
CONDENSER TYPE
A -Self-Contained Air-Cooled
W -Self-Contained Water-Cooled
N -Remote Air-Cooled
3 -Three Phase
NO INDICATOR -1 Phase
ICE CUBE SIZE
D -Dice
Y -Half-Dice
ICE MACHINE MODEL
Ice Machine Series
# HERTZ
5 -50HZ
6 -60HZ
KD 1350 A3 – 263
VOLTAGE
161 -115/60/1
261 -208-230 /60/1
251 -230/50/1
263 -208-230 /60/3
8 Part Number 000012545 Rev 02 11/16
Section 2
Installation
Location of Ice Machine
The location selected for the ice machine must meet the
following criteria. If any of these criteria are not met, select
another location.
• The location must be free of airborne and other
contaminants.
• The air temperature must be at least 35°F (1.6°C), but
must not exceed 110°F (43.4°C).
NOTE: K1350 Minimum air temperature is 40°F (4.4°C).
• Remote air-cooled - The air temperature must be at least
-20°F (-29°C), but must not exceed 120°F (49°C).
• The location must not be near heat-generating (ovens,
dishwashers, etc.) equipment or in direct sunlight and
must be protected from weather.
• The location must not obstruct airflow through
or around the ice machine. Refer to the clearance
requirements chart.
These ice machines are intended for use in applications
such as:
• Staff kitchen areas in shops, offices and other work
environments
• Clients in hotels, motels, farmhouses, bed and breakfast
and other residential type environments
• Catering and similar non-retail applications
Clearance Requirements
Warning
n
Do not obstruct ice machine vents or openings.
K0250 Self-Contained
Air-Cooled
Top/Sides 12" (30.5 cm) N/A
Back 5" (12.7 cm) N/A
K0350/K0420
K0500/K0600/
K1000/K1350/
K1800
Top/Sides 8" (20.3 cm) 8" (20.3 cm)
Back 5" (12.7 cm) 5" (12.7 cm)
K0420
Tropical Rating
50 Hz Only
Top 24" (61.0 cm) 8" (20.3 cm)
Sides 12" (30.5 cm) 8" (20.3 cm)
Back 5" (12.7 cm) 5" (12.7 cm)
K1000
Tropical Rating
50 Hz Only
Top 12" (30.5 cm) 8" (20.3 cm)
Sides 8" (20.3 cm) 8" (20.3 cm)
Back 5" (12.7 cm) 5" (12.7 cm)
Self-Contained
Air-Cooled
Self-Contained
Air-Cooled
Self-Contained
Air-Cooled
Self-Contained
Water-Cooled
Water-Cooled
and Remote*
Water-Cooled
Water-Cooled
and Remote
Warning
n
Two or more people or a lifting device are required to lift
this appliance.
The ice machine must be protected if it will be subjected
to temperatures below 32°F (0°C). Failure caused by
Caution
,
exposure to freezing temperatures is not covered by the
warranty.
Part Number 000012545 Rev 02 11/16 9
Installation Section 2
Ice Machine Heat of Rejection
Series
Ice Machine
K0250 4600 5450
K0350 3800 6000
K0420 5400 6300
K0500 5300 6100
K0600 9000 13900
K1000 17000 20700
K1350 23900 29000
K1800 29800 34700
1 B.T.U./Hour
2 Because the heat of rejection varies during the ice making cycle, the
figure shown is an average.
Air Conditioning
Heat of Rejection
2
Ice machines, like other refrigeration equipment, reject
heat through the condenser. It is helpful to know the
amount of heat rejected by the ice machine when sizing air
conditioning equipment where self-contained air-cooled
ice machines are installed.
This information is also necessary when evaluating the
benefits of using water-cooled or remote condensers to
reduce air conditioning loads. The amount of heat added to
an air conditioned environment by an ice machine using a
water-cooled or remote condenser is negligible.
Knowing the amount of heat rejected is also important
when sizing a cooling tower for a water-cooled condenser.
Use the peak figure for sizing the cooling tower.
1
Peak
Removing Drain Plug and Leveling the Ice
Storage Bin
Warning
n
To avoid instability, the bin/dispenser must be installed
in an area capable of supporting the weight of the bin/
dispenser, ice machine and a full bin of ice (48" models
1000 lbs [454 kg], 30" models 750 lbs [340 kg]). The bin/
dispenser must be level side-to-side and front-to-back
before installing the ice machine.
1. Remove threaded plug from drain fitting.
2. Screw the leveling legs onto the bottom of the bin.
3. Screw the foot of each leg in as far as possible.
Caution
,
The legs must be screwed in tightly to prevent them
from bending.
4. Move the bin into its final position.
5. Level the bin to assure that the bin door closes and
seals and the ice machine operates properly. Use a
level on top of the bin. Turn the base of each foot as
necessary to level the bin.
6. Inspect bin gasket prior to ice machine installation.
(Our bins come with a closed cell foam gasket installed
along the top surface of the bin.)
7. Remove all panels from ice machine before lifting and
installing on bin. Remove front panel, top cover, left
and right side panels.
Air Baffle
Self-Contained Air-Cooled Only
To install:
1. Loosen the back panel screws next to the condenser.
2. Align the keyhole slots in the air baffle with the screw
holes and slide the baffle down to lock in place.
Air Baffle
10 Part Number 000012545 Rev 02 11/16
Section 2 Installation
Electrical Service
Warning
n
All electrical work, including wire routing and grounding
must conform to all applicable national and local
electrical codes.
MINIMUM CIRCUIT AMPACITY
The minimum circuit ampacity is used to help select the
wire size of the electrical supply. (Minimum circuit ampacity
is not the ice machine’s running amp load.)
ELECTRICAL REQUIREMENTS
Refer to Ice Machine Model/Serial Plate for voltage/
amperage specifications.
• A separate fuse/circuit breaker must be provided for
each ice machine.
• The wire size (or gauge) is dependent upon location,
materials used, length of run, etc., so it must be
determined by a qualified electrician.
• The ice machine must be grounded. Check all green
ground screws in the control box and verify they are
tight before starting the ice machine.
• The maximum allowable voltage variation is ±10% of
the rated voltage at ice machine start-up (when the
electrical load is highest).
Caution
,
Observe correct polarity of incoming line voltage.
Incorrect polarity can lead to erratic ice machine
operation. Operate equipment only on the type of
electricity indicated on the specification plate.
GROUND FAULT CIRCUIT INTERRUPTER
Ground Fault Circuit Interrupter (GFCI/GFI) protection is a
system that shuts down the electric circuit (opens it) when
it senses an unexpected loss of power, presumably to
ground. GFCI/GFI circuit protection is not recommended
with our equipment. If code requires the use of a GFCI/GFI,
then you must follow the local code. The circuit must be
dedicated, sized properly and there must be a panel GFCI/
GFI breaker. We do not recommend GFCI/GFI outlets as they
are known for more intermittent nuisance trips than panel
breakers.
MINIMUM POWER CORD SPECIFICATIONS
Maximum Breaker
Size
15 amp 14 gauge 6 feet (1.83 m)
20 amp 12 gauge 6 feet (1.83 m)
30 amp 10 gauge 6 feet (1.83 m)
40 amp 8 gauge 6 feet (1.83 m)
Minimum Wire
Size
Maximum Length
of Power Cord
If a power cord is used, the wire size to the receptacle is
dependent upon location, materials used, length of run,
etc., so it must be determined by a qualified electrician.
Local, state or national requirements will supersede our
minimum requirements.
FOR UNITED KINGDOM ONLY
As the colors of the wires in the mains lead of the
appliance may not correspond with the colored markings
identifying the terminals in your plug, proceed as follows:
• The wire which is colored green and yellow must be
connected to the terminal in the plug which is marked
with the letter E or by the earth ground symbol or
colored green or green and yellow.
• The wire colored blue must be connected to the
terminal which is marked with the letter N or colored
black.
• The wire colored brown must be connected to the
terminal which is marked with the letter L or colored
red.
Part Number 000012545 Rev 02 11/16 11
Installation Section 2
Maximum Breaker Size & Minimum Circuit Amperage Chart
Important
Due to continuous improvements, this information is for reference only. Please refer to the ice machine serial number tag
to verify electrical data. Serial tag information overrides information listed on this page.
Air-Cooled Water-Cooled Remote
Ice Machine
K0250
K0350
K0420
K0500
K0600
K1000
K1350
K1800
Voltage/
Phase/Cycle
115/1/60 15 9.44 N/A N/A N/A N/A
230/1/50 15 4.5 N/A N/A N/A N/A
230/1/60 15 4.7 N/A N/A N/A N/A
115/1/60 15 12.1 15 11.4 N/A N/A
230/1/50 15 6.3 15 5.9 N/A N/A
230/1/60 15 6.2 15 5.8 N/A N/A
115/1/60 15 11.3 15 10.6 N/A N/A
230/1/50 15 6.2 15 5.8 N/A N/A
230/1/60 15 6.2 15 5.8 N/A N/A
115/1/60 20 12.7 20 12.0 N/A N/A
230/1/50 15 6.3 15 5.9 N/A N/A
208-230/1/60 20 9.2 20 8.8 N/A N/A
230/1/50 20 8.6 20 8.2 N/A N/A
208-230/1/60 20 13.9 20 13.2 20 12.8
230/1/50 20 13.8 20 13.1 20 14.1
208-230/1/60 30 18.2 30 16.8 30 17.8
208-230/3/60 20 13.6 20 12.2 20 13.2
230/1/50 30 18.2 30 16.8 30 17.8
208-230/1/60 30 19.6 N/A N/A 30 19.6
208-230/3/60 20 13.3 N/A N/A 20 12.9
230/1/50 30 19.6 N/A N/A 30 19.6
Maximum
Fuse/Circuit
Breaker
Minimum
Circuit Amps
Maximum
Fuse/Circuit
Breaker
Minimum
Circuit Amps
Maximum
Fuse/Circuit
Breaker
Minimum
Circuit Amps
12 Part Number 000012545 Rev 02 11/16
Section 2 Installation
Water Supply and Drain Requirements
WATER SUPPLY
Local water conditions may require treatment of the water
to inhibit scale formation, filter sediment, and remove
chlorine odor and taste.
Warning
n
Connect to a potable water supply only. Plumbing must
conform to state, local and national codes.
WATER INLET LINES
Follow these guidelines to install water inlet lines:
• If you are installing a water filter system, refer to the
installation instructions supplied with the filter system
for ice making water inlet connections.
• Do not connect the ice machine to a hot water supply.
Be sure all hot water restrictors installed for other
equipment are working. (Check valves on sink faucets,
dishwashers, etc.)
• If water pressure exceeds the maximum recommended
pressure of 80 psi (552 kPa), obtain a water pressure
regulator from your local distributor.
• Install a water shut-off valve for both the ice making and
condenser water lines.
• Insulate water inlet lines to prevent condensation.
DRAIN CONNECTIONS
Follow these guidelines when installing drain lines to
prevent drain water from flowing back into the ice machine
and storage bin:
• Drain lines must have a 1.5 inch drop per 5 feet of run
(2.5 cm per meter), and must not create traps.
• The floor drain must be large enough to accommodate
drainage from all drains.
• Run separate bin and ice machine drain lines. Insulate
them to prevent condensation.
• Vent the bin and ice machine drain to the atmosphere.
Do not vent the condenser drain on water-cooled
models.
• A separate auxiliary drain is located in the ice machine
base to remove moisture in high humidity areas. The
drain fitting is a female socket for 1/2" CPVC pipe. The
drain is sealed and the seal must be removed before
attaching the drain fitting/tubing. Tap the seal out with
a wooden dowel or similar tool. Seal the CPVC pipe to
the ice machine socket with silicone sealant to allow
future removal.
Caution
,
Do not apply heat to water valve inlet fitting. This will
damage plastic water inlet connection.
Part Number 000012545 Rev 02 11/16 13
Installation Section 2
Water Supply and Drain Line Sizing/Connections
Location Water Temperature Water Pressure Ice Machine Fitting
Ice Making Water
Inlet
Ice Making Water
Drain
Condenser Water
Inlet
Condenser Water
Drain
Bin Drain
Large Capacity
Bin Drain
WATERCOOLED CONDENSER WATER PRESSURE
Water pressure at the condenser cannot exceed 150 psig
(1034 kPa) with the standard water-regulating valve.
Contact your distributor if your water pressure is greater
than 150 psig (1034 kPa). A special order condenser/waterregulating valve is available that allows water pressure up
to 350 psig (2413 kPa).
The Commonwealth of Massachusetts requires that
all water-cooled models must be connected only to a
closed loop, cooling tower system.
35°F (2°C) Min.
90°F (32°C) Max.
– – 1/2" (1.27 cm) Female Pipe Thread 1/2" (1.27 cm) min. inside
90°F (32°C) Max. Standard
– – 1/2" (1.27 cm) Female Pipe Thread 1/2" (1.27 cm) min. inside
– – 3/4" (1.91 cm) Female Pipe Thread 3/4" (1.91 cm) min. inside
– – 1" (2.54 cm) Male Pipe Thread 1" (2.54 cm) min. inside diameter
20 psi (140 kPa) Min.
80 psi (552 kPa) Max.
20 psi (140 kPa) Min.
150 psi (1034 kPa) Max.
High Pressure Option
20 psi (140 kPa) Min.
350 psi (2410 kPa) Max.
3/8" (.95 cm) Female Pipe Thread 3/8" (.95 cm) min. inside
COOLING TOWER APPLICATIONS WATERCOOLED
MODELS
A water cooling tower installation does not require
modification of the ice machine. The water regulator valve
for the condenser continues to control the refrigeration
discharge pressure.
It is necessary to know the amount of heat rejection and
Important
the pressure drop through the condenser and water valves
(inlet and outlet) when using a cooling tower on an ice
machine.
• Water entering the condenser must not exceed 90°F
(32°C).
• Water flow through the condenser must not exceed 5
gallons (19 liters) per minute.
• Allow for a pressure drop of 7 psi (50 kPa) between the
condenser water inlet and the outlet of the ice machine.
• Water exiting the condenser must not exceed 110°F
(43°C).
Tubing Size Up to Ice Machine
Fitting
diameter
diameter
3/8" Female Pipe Thread
diameter
diameter
14 Part Number 000012545 Rev 02 11/16
Section 2 Installation
Remote Condenser/Line Set Installation
Ice Machine
K1000 KC1000
K1350 KC1350
K1800 KC1350
*Line Set Discharge Line Liquid Line
RTK 1/2" (1.27 cm) 5/16" (.79 cm)
RLK 1/2" (1.27 cm) 3/8" (.95 cm)
Air Temperature Around the Condenser
Minimum Maximum
-20°F (-29°C) 120°F (49°C)
Remote systems are only approved and warranted as a
complete new package. Warranty on the refrigeration
system will be void if a new ice machine head section
is connected to pre-existing (used) tubing or remote
condensers.
Remote Single
Circuit Condenser
Important
Line Set*
RTK-20-R410A
RTK-35-R410A
RTK-50-R410A
RLK-20-R410A
RLK-35-R410A
RLK-50-R410A
RLK-20-R410A
RLK-35-R410A
RLK-50-R410A
REMOTE ICE MACHINE REFRIGERANT CHARGE
Each remote ice machine ships from the factory with a
refrigerant charge appropriate for installation with line
sets of up to 50' (15 m). The serial tag on the ice machine
indicates the refrigerant charge.
Additional refrigerant may be required for installations
using line sets between 50' and 100' (15-30 m) long. If
additional refrigerant is required, refer to the chart below
for the correct amount to be added.
Ice Machine
K1000 2 lbs (907g)
K1350 2 lbs (907g)
K1800 2 lbs (907g)
Refrigerant to be added for
50'-100' Line Sets
Important
EPA CERTIFIED TECHNICIANS
If remote line set length is between 50' and 100'
(15 and 30 m), add additional refrigerant to the
nameplate charge. Refer to the table below for the
model being worked on.
Tubing length: _________________________________
Refrigerant added to nameplate: __________________
New total refrigerant charge: _____________________
Warning
n
Potential Personal Injury Situation
The ice machine contains refrigerant charge. Installation
of the line sets must be performed by a properly trained
and EPA certified refrigeration technician aware of
the dangers of dealing with refrigerant charged
equipment.
Part Number 000012545 Rev 02 11/16 15
Installation Section 2
GENERAL
Condensers must be mounted horizontally with the fan
motor on top with nothing obstructing it. There must be at
least a 16" (41 cm) clearance from the bottom for air intake.
The front coupling panel and one other panel (back or side)
must also be unobstructed.
Remote condenser installations consist of vertical and
horizontal line sets between the ice machine and the
condenser. When combined, they must fit within approved
specifications. The following guidelines, drawings and
calculation methods must be followed to verify a proper
remote condenser installation.
Caution
,
The compressor warranty (including the labor
replacement warranty) will not apply if the remote ice
machine is not installed according to specifications.
The warranty also will not apply if the refrigeration
system is modified with a condenser, heat reclaim
device, or other parts or assemblies not manufactured
by us unless we specifically approved the component in
writing.
3
2
1
DOWNWARD
DOWNWARD
HORIZONTAL
HORIZONTAL
SPIRAL
SPIRAL
1
2
3
WIRING
Interconnecting line voltage wiring is used to energize and
de-energize the condenser fan motor.
• The remote condenser voltage matches the ice machine
head section voltage.
Interconnecting Wire Connections
Ice Machine Head Section Remote Condenser
F1 L1
F2 L2
GUIDELINES FOR ROUTING LINE SETS
First, cut a 2.5" (6.35 cm) circular hole in the wall or roof
for tubing routing. The line set end with the 90° bend will
connect to the ice machine. The straight end will connect to
the remote condenser.
Follow these guidelines when routing the refrigerant lines.
This will help ensure proper performance and service
accessibility.
1. Optional - Make the service loop in the line sets (as
shown in Routing Line Sets graphic). This permits easy
access to the ice machine for cleaning and service. Do
not use hard rigid copper at this location.
2. Required - Do not form traps in the refrigeration lines
(except the service loop). Refrigerant oil must be free to
drain toward the ice machine or the condenser. Route
excess tubing in a supported downward horizontal
spiral (as shown below). Do not coil tubing vertically.
3. Required - Keep outdoor refrigerant line runs as short
as possible.
Routing Line Sets
16 Part Number 000012545 Rev 02 11/16
Section 2 Installation
H
H
H
CALCULATING REMOTE CONDENSER INSTALLATION
DISTANCES
Line Set Length
The maximum length is 100' (30 m).
The ice machine compressor must have the proper oil
return. The receiver is designed to hold a charge sufficient
to operate the ice machine in ambient temperatures
between -20°F (-29°C) and 120°F (49°C), with line set
lengths of up to 100' (30 m).
Line Set Rise/Drop
The maximum rise is 35' (10.7 m).
The maximum drop is 15' (4.5 m).
Caution
,
If a line set has a rise followed by a drop, another
rise cannot be made. Likewise, if a line set has a drop
followed by a rise, another drop cannot be made.
Calculated Line Set Distance
The maximum calculated distance is 150' (45 m).
Line set rises, drops, horizontal runs (or combinations
of these) in excess of the stated maximums will exceed
compressor start-up and design limits. This will cause poor
oil return to the compressor.
Make the following calculations to make sure the line set
layout is within specifications.
1. Insert the measured rise into the formula below.
Multiply by 1.7 to get the calculated rise.
(Example: A condenser located 10 feet above the ice
machine has a calculated rise of 17 feet.)
2. Insert the measured drop into the formula below.
Multiply by 6.6 to get the calculated drop.
(Example. A condenser located 10 feet below the ice
machine has a calculated drop of 66 feet.)
3. Insert the measured horizontal distance into the
formula below. No calculation is necessary.
4. Add together the calculated rise, calculated drop,
and horizontal distance to get the total calculated
distance. If this total exceeds 150' (45 m), move
the condenser to a new location and perform the
calculations again.
Maximum Line Set Distance Formula
Step 1. Measured Rise (35' [10.7 m] Maximum) ______ x 1.7 = _______ Calculated Rise
Step 2. Measured Drop (15' [4.5 m] Maximum) ______ x 6.6 = _______ Calculated Drop
Step 3. Measured Horizontal Distance (100' [30 m] Maximum) _______ Horizontal Distance
Step 4. Total Calculated Distance 150' (45 m) _______ Total Calculated Distance
D
R
SV1196 SV1195 SV1194
Combination of a Rise and a
HorizontalRun
D
Combination of a Drop and a
HorizontalRun
R
Combination of a Rise, a Drop and a
Horizontal Run
Part Number 000012545 Rev 02 11/16 17
Installation Section 2
ROUTE THE LINE SET
• Route the line set to avoid traps and kinks.
• Minimize the amount of line set exposed on the roof.
CONNECT THE LINE SET
• Cut the line set to the correct length.
• Purge line set with dry nitrogen while brazing.
• Line set shutoff valves on the ice machine must remain
closed and be protected from heat during brazing.
PRESSURE TEST AND EVACUATE LINE SET AND
CONDENSER
• Lineset shutoff valves must remain closed until pressure
testing and evacuation are complete.
• Pressure test @ 150 psi (1000 kPa) for a minimum of 15
minutes.
• Minimum evacuation level is 500 microns.
• Pressure test the line set and condenser with 150 psig of
dry nitrogen. Add nitrogen at the line set shutoff valves
located at the back of the ice machine head section.
Complete the pressure test, verify no leaks are present
and remove the nitrogen from the system before
connecting the vacuum pump.
OPEN LINE SET VALVES
You will not hear refrigerant flow when the valves are
opened. Refrigerant will not flow until the ice machine is
started and the solenoid valve opens.
• All valve caps must be reinstalled, tightened and leakchecked to assure no refrigerant leakage exists.
• Counterclockwise opens all valves.
18 Part Number 000012545 Rev 02 11/16
Section 2 Installation
Installation Check List
Is the Ice Machine level?
Have all of the electrical and water connections
beenmade?
Has the supply voltage been tested and checked
against the rating on the nameplate?
Is there proper clearance around the ice machine forair
circulation?
Is the ice machine grounded and polarity correct?
Has the ice machine been installed where ambient
temperatures will remain in the range of 35° - 110°F
(1.6° - 43.3°C)?
Has the ice machine been installed where the incoming
water temperature will remain in the rangeof 35° - 90°F
(1.6° - 32.2°C)?
Is there a separate drain for the potable water,
binandwater-cooled condenser?
Additional Checks for Remote Models
Does the remote condenser fan operate properly
afterstart-up?
Has the remote condenser been located where
ambient temperatures will remain in the range of -20°120°F (-29 - 49°C).
Is the line set routed properly?
Are both refrigeration lines to remote condenser run so
they do not lay in water and are properly insulated?
Before Starting the Ice Machine
All ice machines are factory-operated and adjusted before
shipment. Normally, new installations do not require any
adjustment.
To ensure proper operation, follow the Operational Checks
in Section 3 of this manual. Starting the ice machine and
completing the Operational Checks are the responsibilities
of the owner/operator.
Adjustments and maintenance procedures outlined in this
manual are not covered by the warranty.
Are the ice machine and bin drains vented?
Are all refrigerant lines free from contact with
othercomponents?
Are all electrical leads free from contact with
refrigeration lines and moving equipment?
Has the owner/operator been instructed
regardingmaintenance and the use of our Cleanerand
Sanitizer?
Has the owner/operator completed the
warrantyregistration card?
Has the ice machine and bin been sanitized?
Is the ice thickness set correctly? (Refer to
OperationalChecks to check/set the correct ice
bridgethickness).
Warning
n
Potential Personal Injury Situation
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified from
that of original manufactured specifications.
Part Number 000012545 Rev 02 11/16 19
Installation Section 2
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20 Part Number 000012545 Rev 02 11/16
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