Multiplex G2-W Installation Manual

G SERIES CUBER

INSTALLATION & SERVICE GUIDE

Part Number 5006772

Manitowoc Beverage Equipment

2100 Future Drive Sellersburg, IN 47172-1868
Tel: [phone] Fax: [phone]
www.manitowocbeverage.com

In accordance with our policy of continuous product development and
improvement, this information is subject to change at any time without notice.

Printed in The United States of America

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Installation and Service Manual

WARRANTY POLICY

SerVend retains the right to refuse payment for the following conditions. Premium labor rates, holidays, overtime,
travel time, flat service call charge, mileage or material charges.

SerVend will not pay for:

Corrections to your installation, to instruct you how to care for your equipment, maintenance, leveling, or cleaning.
Replacement of fuses, circuit breakers, building wiring or plumbing to accommodate installation of this equipment.
Repairs to this equipment when used in a non-approved installation, or removal of equipment for repairs. Repairs
due to improper installation or correcting original installation. Repairs due to transportation or mishandling.

Adjustments to SerVend equipment.

Repairs when accessibility of equipment is hindered by ambient conditions. Repairs to parts or systems caused by
unauthorized modifications. Return service calls for the same problem. Any claim submitted with improper, inaccu­rate or illegible labor forms.

Damage due to failure of electrical supply, water supply, or improper ventilation around the product. Damages due
to fire, flooding or freezing. Damage and/or defects attributed to the use of any non factory accessory or compo­nents, including but not limited to filters, reclaimers, remote condensers, or any other devices attached to SerVend
equipment. Labor or part claim for components proven at our facilities not to be defective. Repairs or replacement
of damaged components. Labor claims (including diagnostic) submitted over the times allowed in our current labor
time chart.

The other of the warranted equipment is responsible for any transportation costs for replacement components.

SerVend will pay for:

Replacement parts and designated labor hours to repair defects in material and workmanship during the warranty
period. Service provided by an authorized SerVend service company.

Please see your dealer for a copy of the detailed SerVend warranty for your equipment.

PURCHASED PARTS WARRANTY

Following the expiration of SerVend’s standard cuber and dispenser warranty, replacement purchased (from SerVend)
parts are covered by the parts warranty. Any replacement part purchased by the owner of the SerVend equipment
shall be warranted for a period of ninety (90) days from date of purchase, or proof of installation of said purchased
part(s)

Following the expiration of SerVend extended parts warranties (compressor or evaporator), any purchased (from
SerVend) part is covered by the parts warranty. These components (compressor or evaporator) are covered for a
period of one (1) year from date of purchase or proof of installation of said purchased part(s).

The owner of the equipment will be required to pay for any labor to replace these defective parts. The owner shall
also be responsible for transportation costs to obtain and return any defective parts.

The purchased parts policy shall cover any part or component supplied as a standard original equipment part is
covered under this warranty.

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FREIGHT CLAIM LOSS OR DAMAGE

The delivery freight company, distributor or dealer is responsible for loss or damage to your merchandise. All claims
must be filed with the party that delivers your merchandise.

Check the number of containers delivered against the number shown on your receipt. If the total is not correct, have
the driver note the shortage on your receipt. Check all cartons for visible damage, open and check the contents of any
carton in question before the driver leaves. Be sure the driver notes the type and degree of damage on your receipt.
All damaged merchandise must be inspected within 15 days of delivery. Please notify your carrier immediately.

If concealed damage is found when merchandise is unpacked, place the packing material with the merchandise and
request an inspection from the delivering carrier. File your claim for loss or damage at once. Delays in filing will only
hinder achieving a satisfactory resolution to your claim.

SAFETY INSTRUCTIONS

Installation and start-up of this equipment should be done by a qualified service technician. Operation, mainte­nance, and cleaning information in this manual are provided for the user/operator of the equipment.

REFRIGERANT LEAK AND REPLACEMENT POLICY

In any instance where there is a partial charge of R-404A refrigerant in a SerVend ice maker or a compressor
electrical burn out, SerVend requires the following:

Recover and properly dispose of any remaining refrigerant charge in the machine. After all repairs are made to the system,
replace the refrigerant with a weighed in charge (listed on the serial name plate) of new virgin refrigerant. This policy also
applies to any machine having a compressor replacement with an electrical burn out.

RE-USE OF CURRENT REFRIGERANT

In any instance where a component in a SerVend ice maker is replaced, the following is policy.

Properly recover the refrigerant charge from the system. Replace the component in question. Check the system
for refrigerant leaks using dry nitrogen. Replace the original refrigerant back to the machine. This will apply with all
component changes EXCEPT a compressor electrical burn out. In the event of a compressor burn out refer to the
refrigerant leak policy above.

REPLACEMENT OF FILTER DRIERS

In regards to filter driers on SerVend R-404A equipment, the following is SerVend policy.

Whenever entering a refrigerant system on a SerVend ice maker always replace the filter drier. The replacement
filter drier must be of one size larger than the original equipment filter drier, according to the replacement chart
found in the specification section of this manual. When making any repair to the sealed system under warranty, the
filter drier is considered a part of the repair to the system, and SerVend driers MUST be used.

If the filter drier is not replaced or SerVend parts are not used in the repair, all warranties are voided.

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TABLE OF CONTENTS

WARRANTY POLICY .......................................................................................... 3

PURCHASED PARTS WARRANTY ...................................................................................... 3

FREIGHT CLAIM LOSS OR DAMAGE .................................................................................. 4

SAFETY INSTRUCTIONS .....................................................................................................4

REFRIGERANT LEAK AND REPLACEMENT POLICY ......................................................... 4

RE-USE OF CURRENT REFRIGERANT ............................................................................... 4

REPLACEMENT OF FILTER DRIERS ...................................................................................4

SERVEND CUBER MODEL NUMBERING SYSTEM.......................................... 8

SERVEND SERIAL NUMBER SYSTEM ............................................................. 9

ICE MACHINE INSTALLATION INSTRUCTIONS ............................................. 10

STORAGE BIN .................................................................................................................... 10

ICE DROP ZONE................................................................................................................. 10

CUBER WITH ICE DISPENSER .......................................................................................... 11

LOCATION OF REMOTE CONDENSER ............................................................................. 11

ASSEMBLY OF THE REMOTE CONDENSER .................................................................... 11

INSTALLATION OF THE REMOTE TUBING ....................................................................... 11

PLUMBING LINES AND CONNECTIONS ........................................................................... 12

DRAINS .............................................................................................................................. 12

ELECTRICAL CONNECTIONS SELF CONTAINED ............................................................ 12

ELECTRICAL CONNECTIONS REMOTE CONDENSER: ................................................... 13

ADJUSTMENT OF THE WATER LEVEL ............................................................................. 13

ADJUSTMENT OF THE WATER CURTAIN ......................................................................... 13

STACKING KITS ................................................................................................ 14

INSTALLATION INSTRUCTIONS ........................................................................................ 14

INSTALLATION CHECK LIST ............................................................................................. 14

START UP PROCEDURE SELF CONTAINED.....................................................................15

REMOTE START UP PROCEDURE .................................................................................... 15

ICE MAKER CLEANING PROCEDURE: .......................................................... 16

SANITIZE CYCLE: .............................................................................................................. 16

4 RELAY CIRCUIT BOARD (SERIES 007 MICROCHIP) ................................. 16

SEQUENCE OF OPERATION ............................................................................................. 16

4 RELAY CIRCUIT BOARD (SERIES 008 MICROCHIP) .................................. 17

SEQUENCE OF OPERATION ............................................................................................. 17

4 RELAY CIRCUIT BOARD COMPONENTS ....................................................................... 17

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TABLE OF CONTENTS

4 RELAY CIRCUIT BOARD ............................................................................... 18

CHECKING THE CIRCUIT BOARD ..................................................................................... 18

COMPRESSOR & START COMPONENTS ...................................................... 19

COMPRESSOR CONTACTOR ............................................................................................ 20

CHECKING THE CONTACTOR ........................................................................................... 20

EVAPORATOR .................................................................................................................... 20

FAN CYCLE CONTROL ...................................................................................................... 20

FLOAT VALVE..................................................................................................................... 20

HALL SWITCH .................................................................................................................... 20

HEAD PRESSURE CONTROL VALVE ................................................................................ 21

HIGH PRESSURE CUT OUT ............................................................................................... 21

HOT GAS VALVE ................................................................................................................21

ICE CAPACITY .................................................................................................. 22

ICE CAPACITY CHECK PROCEDURE ............................................................................... 22

ICE THICKNESS CONTROL DIAGNOSIS ........................................................................... 22

CHECK PROCEDURE ........................................................................................................ 22

CHECKING THE THERMISTOR ....................................................................... 23

ICE THICKNESS CONTROL REPLACEMENT .................................................................... 24

ICE THICKNESS CONTROL ADJUSTMENT ...................................................................... 24

SAFETY THERM-O-DISC .................................................................................................... 24

CHECKING THE THERM-O-DISC ....................................................................................... 25

THERMOSTATIC EXPANSION VALVE ................................................................................25

CHECKING THE EXPANSION VALVE ................................................................................ 25

WATER PUMP .................................................................................................................... 25

DISASSEMBLY OF A SERVEND WATER PUMP ................................................................ 26

WATER REGULATING VALVE .......................................................................... 26

SYSTEM EVACUATION .................................................................................... 27

SELF CONTAINED SYSTEM ACCESS POINTS ................................................................. 27

REMOTE REFRIGERATION SYSTEM ACCESS POINTS ................................................... 28

CHARGING THE SYSTEM ................................................................................ 29

CLEANING UP A CONTAMINATION SYSTEM .................................................................... 29

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WIRING DIAGRAMS ......................................................................................... 30

SPECIFICATIONS ............................................................................................. 39

DATA PER ARI STANDARDS & WATER CONSUMPTION ..................................................39

OPERATING LIMITS ........................................................................................................... 39

PRESSURE - TEMPERATURE CHART FOR R-404A ......................................................... 40

G2 SPECIFICATIONS ......................................................................................................... 43

G4 SPECIFICATIONS ......................................................................................................... 44

G5 SPECIFICATIONS ......................................................................................................... 45

G7 SPECIFICATIONS ......................................................................................................... 46

G10 SPECIFICATIONS ........................................................................................................ 47

G12 SPECIFICATIONS ........................................................................................................ 48

"KG" CONDENSER SPECIFICATIONS .............................................................................. 49

COMPRESSOR SPECIFICATIONS ..................................................................................... 50

MODEL G-2 A ..................................................................................................................... 55

MODEL G-2 W .................................................................................................................... 56

MODEL G-4 A ..................................................................................................................... 57

MODEL G-4 W .................................................................................................................... 58

MODEL G-5 A ..................................................................................................................... 59

MODEL G-5 W .................................................................................................................... 60

MODEL G-7 A ..................................................................................................................... 61

MODEL G-7 W .................................................................................................................... 62

MODEL G-7 R ..................................................................................................................... 63

MODEL G-10 A ................................................................................................................... 64

MODEL G-10 W .................................................................................................................. 65

MODEL G-10 R ................................................................................................................... 66

MODEL G-12 A ................................................................................................................... 67

MODEL G-12 W .................................................................................................................. 68

MODEL G-12 R ................................................................................................................... 69

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SERVEND CUBER MODEL NUMBERING SYSTEM

Example:

MODEL - G 7 A M A S - A

(1) (2) (3) (4) (5) (6) (7)

(1) Series of the machine

C = R-502 refrigerant - 30” or 48” wide cuber
S = R-502 refrigerant - 22” wide cuber
B = Ice Storage Bin
G = R-404A ice machines - all widths

(2) Nominal Capacity per 24 hours in 100 pounds

i.e. 7 = 700 pounds

(3) Type of Condenser

A = Air Cooled
W = Water Cooled
R = Remote Cooled

(4) Size of Cuber

M = Mini Cube (3/8” x 7/8” x 7/8”)
F = Full Cuber (7/8” x 7/8” x 7/8”)
J = Jumbo Cube (7/8” x 7/8” x 1 1/2”)

(5) Electric Code

VOLTS CYCLE PHASE
A = 208/230 60 1
B= 115 60 1
C = 208/230;200/220 60/50 1
D = 220/240 50 1
G = 208/230 60 3

(6) S = Stainless Steel Panels (blank) = Painted Panels

(7) Generation Code

A, B, C, etc.

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SERVEND SERIAL NUMBER SYSTEM

Effective August 12, 1991 all SerVend dispensers, cubers and bins manufactured by SerVend International have a
new serial numbering system.

SAMPLE

94 H G 01 0001
Year Month Product Major Change Unit
Manufactured Code Code S/N

The above serial number is defined as:
Hotel dispenser built in August, 1994 - 1st unit built under major code #1

MONTH MANUFACTURED PRODUCT CODE

January A A = K Seried (obsolete)
FebruaryB B = KD Seried (obsolete)
March C C = M Series
April D D = MD Series
May E E = B Series
June F F = H Series
July G G = Cubers
August H H = Bins
September J J = Drop-In
October K 7 = Remote Condensers
November L
December M

Alphabet codes will not use the letter “I” to prevent confusion with the number “1”.

Unit Serial number will roll back to 0001 at the beginning of each new year and/or with each major change code.

MAJOR CHANGE CODE IS AN ENGINEERING TRACKING CODE FOR SERVEND USE. A major change code of
‘XX’ identifies an engineering field test unit.

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ICE MACHINE INSTALLATION

INSTRUCTIONS

To assure maximum efficiency and performance from
your new SerVend equipment, we recommend the in­stallation and start up be performed by SerVend Con­tracted Service Company.

For best performance, select a location away from all
heat sources such as ovens, direct sunlight, etc.. Avoid
placing air cooled models in kitchens whenever possible
as grease, flour or other airborne particles will collect on
the condenser and fan blade. This will require increased
maintenance and will reduce efficiency.

Discuss the best location with your SerVend Contracted
Service Company representative. Always allow 15 cm
(6”) clearance around the ice maker for air circulation.
This includes the top, back, and both sides. Restricted
air circulation will affect the maintenance free life of your
ice maker and its efficiency.

Your ice maker will perform at optimum efficiency in an
approximate 210 C (700 F) room with 100 C (500 F) water.
Increased air or water temperatures will decrease per­formance. Never operate your machine with ambient
temperatures below 100 C (500 F) or above 380 C (100
F). If the ice maker is located in an unheated are, it
must be protected from freezing temperatures or shut
down and winterized.

ICE DROP ZONE

If this installation of a SerVend ice maker is on a differ­ent manufacture bin or other storage device, the open­ing to allow the ice to fall into that device is as indicated
on the following drawings:

0

STORAGE BIN

Remove the sides and top from the ice storage bin. Lay
the flattened carton on the floor. Place the bin on its
back on the corrugated carton to prevent scratching.
Screw the legs into the bin bottom. Set the bin on its
legs. Move the bin to its final location, level the bin by
screwing the feet either up or down. Remove the carton
from the ice maker and place the ice maker on the bin.
Align the machine with the bin back and sides. Remove
the internal packing from the ice maker.

Level the ice maker head. Remove the water curtain
and place a torpedo level on the face of the evaporator.
With the level held against the lower edge of the metal
evaporator, level the unit left to right. Accomplish this
adjustment by the bin legs. Place the level in the verti­cal position on the face of the evaporator. Level the
machine from front to back (evaporator plumb). This is
critical to have the EVAPORATOR level and plumb.

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CUBER WITH ICE DISPENSER

Install the dispenser according to the instructions provided.
Remove the carton from the ice maker and place the ice
maker on the dispenser. Align the machine with the dispenser
front. Secure the unit with earthquake brackets if provided.
Remove the internal packing from the ice maker.

Level the ice maker head. Remove the water curtain and
place a torpedo level on the face of the evaporator. With
the level held against the lower edge of the metal evapo­rator, level the unit left to right. This is done by the utiliza­tion of shims between the ice maker head and the dis­penser. Place the level in the vertical position on the face
of the evaporator. Level the machine from front to back
(evaporator plumb).

IT IS CRITICAL TO HAVE THE EVAPORATOR PLUMB
AND LEVEL.

Install the ice deflector baffle in the evaporator space be­hind the front panel. Remove the front panel from the cu­ber. Remove the bottom screw from the component box
cover. Slide the ice deflector between the left side panel
and enclosure and between the component box cover and
enclosure. Slide slot and notch in ice deflector over the
front channel. Install the screw in the component box
cover. Replace the front panel on the cuber. Refer to the
drawing on previous page.

DO NOT INSTALL A REMOTE MACHINE WITH
LONGER LINES WITHOUT WRITTEN PERMISSION
FROM THE FACTORY. INSTALLATION WITH LONGER
LINES WILL VOID YOUR WARRANTY.

In using longer line lengths, you can starve the com­pressor of oil. Longer lines can also provide a very high
pressure drop in the tubing.

When placing the remote condenser, keep in mind the
maximum height and drop from the ice maker head. The
condenser cannot be placed over 10 m (35 ft.) above
the head. The condenser cannot be placed more than 5
m (15 ft.) below the head.

NOTE: HEIGHT + LENGTH SHOULD NOT
EXCEED 50 FEET.

ASSEMBLY OF THE REMOTE

CONDENSER

Select an area for the condenser that is well ventilated.
The condenser must be located away from the discharge
of other condensers and ventilators.

Unpack the condenser assembly at the final location.
Turn the condenser upside down. This eases further
assembly.

INSTALLATION INSTRUCTION REMOTE CON­DENSER:

Follow the standard installation instructions for the re­mote condenser head. These instructions are listed pre­viously in this section of this manual. Do not power the
ice maker unit before the remote system installation is
complete

INSTALLATION OF A SERVEND REMOTE ICE MAKER
WITH A NON-SERVEND CONDENSER CAN VOID ALL
FACTORY WARRANTIES.

LOCATION OF REMOTE CONDENSER

The placement of the remote condenser is very impor­tant. Place the condenser where the air flow through the
condenser will be unobstructed. The intake to the con­denser must have a minimum clearance of 1 m (3 ft.) to
the closest object. The discharge minimum clearance
must be 3 m (9 ft.). The maximum remote tubing line
length is 15 m (50 ft.).

Assemble the four legs to the base panel. Place the leg
gussets on the legs and attach the support brackets. Use
the diagrams included for additional guidance. Turn con­denser upright and place in proper position.

Using the mounting holes in the base of the leg gussets, se­cure the condenser to the mounting surface. Remember to
properly seal all roof and wall penetrations.

INSTALLATION OF THE REMOTE

TUBING

Unpack the pre-charged tubing from the carton. Care­fully unroll the tubing. BE SURE YOU DO NOT KINK
THE TUBING. Position the tubing in its proper location.
Do not connect any of the tubing ends at this time.

When making a roof penetration, proceed as follows:
Cut a 10 cm (4in.) hole in the roof. Seal around the line
set at the hole with appropriate sealant. Place a roof
flange over the tubing penetration, sealing again.

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INSTALLATION OF THE REMOTE TUBING

Decide if the tubing is of the proper length. A service
loop is advisable behind the ice maker head. If you must
coil the tubing, you need to shorten the length as de­scribed below. Servend has line sets available in 6 m
(20 ft.), 10 m (35 ft.), and 15 m (50 ft.). To ease service,
SerVend has placed access ports on each end of both
tubes.

You may need to lengthen the remote tubing (maximum
total length of 15 m - 50 ft.) Evacuate the charge in the
tubing. Cut the lines and insert the needed length. The
size of the condenser incoming line is 1/2” and the re­mote discharge line is 5/16”. These are O.D. refrigeration
tubing size. Solder the sections together and evacuate
the tubing. You man add one or two ounces of refrigerant
to act as a holding charge.

You may need to shorten the line length. Evacuate the
charge in the tubing. Cut the lines and remove the ex­cess length. Solder the sections together and evacuate
the tubing. You may add one or two ounces of refriger­ant to act as a holding charge.

detrimental to the components of the machine and can
not be ingested by some of your customers. The incom­ing water pressure must not exceed 8.4 kg/cm
and not lower than 1.4 kg/cm2 (20 psi). Water supply lines
to the water cooled condenser should include a standpipe
for the prevention of “water hammer.” Locate shut off
valves in all water supply lines. It is impossible to connect
a water cooled condenser to a recirculation system or
cooling tower. However, you must maintain a minimum of
.7 kg/cm
when operational.

2

(10 psi) pressure drop across the condenser

2

(120 psi)

DRAINS

To ensure trouble free drainage, vent the cuber and bin
drains to the atmosphere at the cabinet. Each of the
drains should have a 25 cm (10”) standing vent pipe to
the atmosphere. This allows oxygen to enter the drain,
slowing the formation of algae in the drain. Venting also
relieves back pressure on the drains allowing faster and
easier water removal. Drain lines require a drop of 6
mm (1/4”) per 30 cm (1”) line length. Lines should end
over an open, trapped, vented drain.

Working at one end, apply refrigeration oil to the threads
of the connectors (both male and female).

Hand thread the fittings onto the machine. Using two
wrenches, tighten the fitting an additional 1/8 turn. DO

NOT TURN MORE THAN 1/4 TURN.

Working at the other end, apply refrigeration oil to the
threads of the connectors (both male and female). Hand
thread the fittings onto the machine. Using two wrenches,
tighten the fitting an additional 1/8 turn. DO NOT TURN

MORE THAN 1/4 TURN.

When the fittings are attached to the machines, the line
seals are broken. Removal of the tubing will discharge
the operating charge of the machine.

PLUMBING LINES AND CONNECTIONS

All plumbing (water and drain) connections must conform
to local and national codes. Please refer to diagrams
concerning the locations of all connections.

To prevent water condensation, insulate all water and drain
lines.

It may be necessary to connect the potable water supply
to a water treatment system. Contact your local SerVend
Contracted Service Company for the proper size required.
DO NOT connect this or any commercial ice maker to a
water softener using salt. The salt can precipitate out of
the water during the freeze cycle. The salt water can be

ELECTRICAL CONNECTIONS SELF

CONTAINED

All supply wiring and connections must conform to na­tional and local codes. Properly size wiring and electri­cal protection devices to the nameplate specifications.
Connect the cuber to a separate location between the
cuber and the protection device. You must ground the
cuber by the control box ground screw provided or a
proper conduit connection. See wiring connection dia­gram on this page.

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ELECTRICAL CONNECTIONS

REMOTE CONDENSER:

Connection of the remote ice making head is accom­plished similar to that found in the installation section of
this manual. Please refer to the self contained installa­tion instructions previously established in this manual.

The power supply for the remote condenser is routed to
the condenser separately, not through the ice maker
head. Obtain the proper voltage from the vicinity of the
condenser. A manual disconnect should be installed in
the electric line. You may connect electric from the power
distribution panel direct to the condenser.

DO NOT RUN THE POWER WIRES FROM THE
ICE MAKER HEAD TO THE REMOTE
CONDENSER.

Route the power supply wires to the condenser junction
box. Connect the wires to the proper wires. Properly
ground the condenser.

The fan motor of a remote condenser is independently
controlled. This is accomplished through the use of a
fan cycle switch inside the condenser. The fan will ener­gize at approximately 17.5 kg/cm2 (250 PSI) and will turn
off at 13 kg/cm2 (185 PSI).

EXAMPLE OF WATER LEVEL MARK:

With the water level set, turn only the water pump
on. This will circulate the water throughout the sys­tem. Check to assure the float returns the water
level to the proper water level mark and shuts off.

ADJUSTMENT OF THE WATER

CURTAIN

The water curtain acts as a shield to prevent the
water being circulated across the evaporator from
going into the ice bin. With the water curtain miss­ing the float must allow additional make up water to
the machine.

Before making any adjustments be sure the ice
maker evaporator is level and plumb.

The water pan should rest on the plastic holding
blocks. See drawing on previous page.

Please follow all local codes when installing any equipment.

ADJUSTMENT OF THE WATER

LEVEL

Each water pan has a water level mark molded into it.
The water mark is the crease in the water pan about one
half way up the front of the water pan. The proper water
level is achieved when the water in the water pan is at
this water level mark on the pan. This should be checked
when the float has just filled the pan and closed off the
supply of water to the pan.

Adjust the float by loosening the screw on the float bracket.
This will allow you to rise or lower the float assembly.

Adjust the water curtain to a maximum clearance of
3 mm (1/8”) above the water pan. Adjust the curtain
as close to the evaporator as possible. Adjustments
to the curtain are attainable through the plates hold­ing the curtain pins. Loosen the two screws on each
of the curtain plates. This will allow the plate to ad­just up and down, forward and back.

The water curtain should not touch and yet clear the
Hall switch by a maximum of 1.5 mm (1/16”). This
adjustment is accomplished in two ways. First the
curtain should have little lateral (left to right) move­ment. If the curtain moves laterally more than 1.5
mm (1/16”) the addition of a curtain shim behind the
curtain plate is necessary. If the curtain moves less
than 1.5 mm (1/16”) with more than 1/5 mm (1/16”)
clearance or touching the Hall switch you must ad­just the position of the switch. To adjust the Hall
switch, loosen the lock nuts on the body of the switch,
allowing proper placement of the switch.

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STACKING KITS

Stacking allows more ice production in the same foot print
size. All G5 and larger SerVend ice makers are stackable
with the same physical size ice maker. When ordering a
stacking kit for your machine, always order by using the
model number of the bottom ice maker.

EXAMPLE You have a G-7 ice maker installed and wish to

add additional capacity. You can then order a
K7-SK stacking kit for the lower machine. Then
you could place either another G-7 on top, or
install a G-9 machine on top.

INSTALLATION INSTRUCTIONS

Install the bottom ice maker on the bin according to the
ice maker installation instructions.

Remove front panel, top cover, component box cover
and left side cover of the bottom ice maker.

On air cooled units ONLY:

Remove the right side and back panels.

Install support bracket (item #3) as shown in Figure
1of the instructional diagram. Replace the back
panel at this time.

Replace left side panel, inserting a gasket between panel
and bottom flange as shown in Figure 1 of the instructional
diagram.

After start up procedures have been completed, replace any
panels removed.

INSTALLATION CHECK LIST

• Is the cuber evaporator level and plumb?

• Are electric connections complete?

• Is the proper voltage supply provided? Check the
nameplate and verify before turning power on to the
machine.

• Turn power on to the machine.

• Has the water inlet pressure been checked? Is it
within guidelines?

• Are water filters installed?

• Are water shut off valves open?

• Are the drain connections made properly? Is the bin
drain separate from the ice maker drain?

• When used, is the water cooled condenser drained
separately?

• Are the cuber and bin drains vented at the rear of the
equipment with an open stand pipe?

• Are all drain lines vented at the floor?

• Are the drain lines insulated and sloped to the open
floor drains?

On air cooled units, place the air condenser baffle on
bottom unit as shown in Figure 2 of the instructional dia­gram.

Install stacking kit top panel (item #1) as shown in Fig­ure 2 of the instructional diagram.

Before installing the second unit and inserting stacking
kit ice chute, start the bottom unit per start up proce­dures. Allow at least four complete cycles of the bottom
unit.

Replace front panel and component box cover.

Install second unit on top of bottom unit following the
instructional diagram.

Make sure each unit is connected to a separate fused circuit.

Install the ice chute (item #2) in the bottom unit as shown in
Figure 3 of the instructional diagram. Hook the down-turned
flange on top of ice chute into the upturned flange on stacking
kit top panel.

Use two #8-32 x 1 inch SS screws and ESNA nuts to attach the
ice chute to the bottom of the bottom unit and to attached the
bottom unit to the top unit.

Start the top unit per start up procedures. Allow the top unit
to complete at least four cycles.

• Is there 15 cm (6”) clearance around the cuber for
ventilation?

• Is the cuber installed in ambient temperatures with a mini­mum of 100 C (500 F) or above 380 C (1000 F)?

WARNING! If the air temperature drops below 100 C
(500 F) the unit must be shut down.

• Is the water temperature maintained between 70 C
(450 F) and 320 C (900 F)?

WARNING! If the water temperature drops below 5
C (400 F) the unit must be shut down.

• Does the water curtain move freely?

• Is the water level set properly in the water pan?

• Is the water pan seated properly on the plastic sup­port blocks?

• Is the ice maker and the bin sanitized?

• Is the air cooled baffle installed, if necessary, to pre­vent condenser air recirculation?

• If the ice maker is being installed with an ice dis­penser, is the ice deflector installed?

0

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START UP PROCEDURE SELF

CONTAINED

Open the potable water valve to the machine. Allow water
to fill the water pan. Check the water level in the pan.
The water level should be up to the water level mark in
the water pan with the float “at rest”. Adjust the water
level if necessary.

Apply power to the machine. Turn the toggle switch to
the pump position. Check the water flow across the top
evaporator extrusion. The water flow should be even
across the top. If the water “creeks” across the top with
streams and dry spots, clean the top extrusion with a
SCOTCH BRITE
rough up the extrusion with any abrasion material.

With the water pump on in the pump position, check the
dump valve. Depress the manual dump switch and hold.
This should clean out most of the water in the water pan
while allowing the float to refill the pan. When releasing
the purge switch, the flow of water through the purge
valve should cease.

Place the toggle switch in the off position to allow the
water to refill the water pan.

TM

pad or CLEAN shop cloth. Do not

wedge above the switch case for thicker or thinner bridge.
The switch is on if the top is pushed in.

For future service on this equipment, place your phone
number on the front or side panel of the machine.

Before leaving, be sure the owner understands the ice
maker operation and the value of preventative mainte­nance.

REMOTE START UP PROCEDURE

Remove the left side panel from the ice maker.

Locate the receiver tank. Remove the service valve stem
cap from both receiver tank valves. Open the receiver
valves fully (backseat) to allow the refrigerant to flow
throughout the system.

Leak check the remote tubing connections. This would in­clude both fittings at the ice maker and the condenser.

Replace the side panels of the ice maker.

Follow the start up procedure as outlined at the top of
this page.

Place the toggle switch in the ice position. The com­pressor, condenser fan (if air cooled), and water pump
will operate. Depress the manual harvest switch. The
water pump and fan motor will stop. The harvest sole­noid will open. Swing the water curtain open and hold
for a maximum of thirty (30) seconds. The compressor
will stop. Release the water curtain. The machine will
restart in the ice making mode.

There is a minimum freeze time built into the circuit board.
This minimum time is not in effect on an initial freeze
cycle of the machine.

For optimum life and performance of the ice maker, the
bridge should be a minimum of 3 mm ( 1/8”) to a recom­mended thickness of 5 mm (3/16”) in the center of the
sheet of ice.

Allow the ice maker to make two (2) complete sheets of
ice before making any bridge thickness adjustments.
Make these adjustments with the machine in the off po­sition.

Adjustment to the bridge thickness is done at the circuit
board. On the bottom (front) of the board in the control
box is a set of 8 DIP switches. To have a thicker bridge,
turn the next (right) switch “on”. To have a thinner bridge,
turn the next (left) switch “off”. It is acceptable to have
all of the switches either on or off. Follow the indicator

When power is applied to the remote machine, the com­pressor may operate for a short time. This is the normal pump
down cycle. The unit may do this periodically.

DOES THE OWNER/OPERATOR KNOW?

• The location of the electrical disconnect switch and
water shut off valves?

• How to start, clean, sanitize, and shut down the ice
machine?

• How the bin full operation works?

• Proper method for cleaning the air cooled condenser
and fan blade?

• Use and location of the high pressure reset, if
equipped?

• How to inspect the distributor tube and water sys­tem for mineral deposits?

• How to identify when the water filter needs to be
changed?

Who to contact for service?

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ICE MAKER CLEANING

PROCEDURE:

The use of non approved ice machine cleaners is ex­pressly forbidden and will void your warranty. The ap­proved ice machine cleaners are:

Calgon (Green) Nickel Safe Cleaner
Lime-A-Way Ice Machine Cleaner

WARNING: When using any cleaning fluids or chemicals,
always wear rubber gloves and eye protection.

Turn the selector switch to the off position. Remove all
ice from the storage bin.

SANITIZE CYCLE:

Turn the toggle switch to the pump position. Push the purge
switch allowing the water in the water pan to drain out.
Allow the water to refill the pan and check the water level.
Adjust the water level if required.

Add 7cl. (1/4 oz.) unscented laundry bleach (5.25% Cl
Na O concentration) mixed to yield 200 PPM of avail­able chlorine to the water pan. Allow the pump to circu­late the solution for five (5) minutes.

ALTERNATE: You may use the commercial ice ma-

chine sanitizer following the directions on the con­tainer.

Push the purge switch to remove this solution from the
machine.

Wipe all surface areas of the bin and ice contact areas
with a solution of 28 ml (1 oz.) liquid laundry bleach per
gallon water. You may use a commercial sanitizer mixed
according to package directions.

Turn the toggle switch to the ice position. Discard the
first batch of ice.

4 RELAY CIRCUIT BOARD

(SERIES 007 MICROCHIP)

Pour 4 oz. of approved cleaner in the water pan. Turn the
toggle switch to the pump position. Allow this solution to
circulate over the evaporator for 10 minutes.

While the solution is running in the machine, take some
of the solution on a rag to wipe the inside of the machine
and the water curtain.

Clean the air cooled condenser and fan blade of all dirt.

Push the purge switch and hold. When the solution in
the water pan has been flushed out release the purge
switch. Allow the water to refill the pan.

Circulate this refill water over the evaporator for three
(3) minutes. Then repeat pushing of the purge switch
and hold. When the solution in the water pan has been
flushed out release the purge switch. Allow the water to
refill the pan.

Turn the toggle switch to the ice position. Discard the
first batch of ice.

SEQUENCE OF OPERATION

Place the toggle switch in the ice making mode. The power
LED and the LED(s) by the curtain terminal connections will be
illuminated. You will also energize 3 of the 4 relays on the board.
These are indicated by the illumination of green LED lights along
the side of each rely. Activated will be the dump solenoid, com­pressor contactor, water pump and fan motor, or water pump
and pump down solenoid on remote units. The dump solenoid
relay will be energized for six (6) seconds at the beginning of
the freeze cycle. At the end of the dump cycle the water pump
and dump valve will stop for eight (8) seconds. At the end of this
time period the water pump will resume.

As the ice builds on the evaporator a bridge is built from one
cube to the next. At the bottom of the evaporator this bridge
begins to roll over the lower extrusion. As the thickness of
the ice builds, the temperature of the ice decreases. On this
lower extrusion is located the SerVend ice thickness control.
This control senses the temperature of the ice. When the ice
temperature reaches a specific point as determined by ad­justments on the circuit board, the control indicates the
machine should enter the harvest mode. This harvest mode
is initiated at any time after the first eight (8) minutes of op­eration. This delay prevents premature harvest.

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SEQUENCE OF OPERATION

During the harvest mode of operation two relays should
be energized. These relays control the compressor
(green LED) and the hot gas solenoid (red LED). This
mode allows the hot gas to flow directly from the com­pressor tot the evaporator. This will warm up the evapo­rator allowing the sheet of ice to slide off.

As each falls from the evaporator it will push the curtain
away from the evaporator. As the curtain moves, the
target on the curtain will move out of range of the elec­tronic sensing Hall switch. If the ice holds the curtain
target out of the range of the Hall switch, the machine
will shut down. This acts as a bin full indicator. When
the curtain returns to the closed position, the machine
will return to the freeze mode. As the curtain moves
away from the evaporator the machine will remain in the
harvest mode for 30 seconds or until the curtain resets
against the evaporator, whichever is first. If the machine
remains in the harvest mode, the circuit board will re­start the unit in freeze at the end of nine (9) minutes.
Removal of the water curtain(s) can cause the machine
to not operate. If the machine is in the freeze mode, and
the water curtain is taken off, when the machine is to
enter the harvest mode the machine will stop operation.

The cuber can be placed in the harvest mode at any­time. Be sure the water curtain is in place. With the
toggle switch in the ICE mode, gently press the harvest
switch located on the circuit board. This will immedi­ately enter the machine in the harvest mode. If the ma­chine is manually placed in the harvest mode, the mini­mum freeze time for the next cycle only, is not appli­cable.

4 RELAY CIRCUIT BOARD

(SERIES 008 MICROCHIP)

SEQUENCE OF OPERATION

This programing version is the same as the 007 chip
except for the following:

The water dump cycle is moved to the end of the freeze
cycle. This chip energizes the valve for 30 seconds. This
will also allow the water to refill the water pan while a
harvest cycle is in progress.

4 RELAY CIRCUIT BOARD

COMPONENTS

The top relay (with green LED) controls the water pump
on all machines. This relay also controls the condenser
fan motors on an air cooled self contained ice maker.

The second relay (with green LED) from the top controls
the compressor contactor on self contained machines.
On a remote cooled machine, this contactor controls the
pump down solenoid.

The third relay (with red LED) from the top controls the
operation of the hot gas solenoid valve.

The fourth (bottom) relay (with green LED) controls the
operation of the water dump solenoid valve.

The EV terminals on the circuit board just below the fourth
relay are for the ice thickness control. This controls the
thickness of the ice on all machines. On all equipment
this works as a high temperature safety. On a dual evapo­rator machine, the control is connected to the left (facing
the machine) evaporator.

The terminals marked HI TEMP in the lower left corner
are used on a dual evaporator machine only. The ice
thickness control from the right evaporator connects to
this terminal. This controls the high temperature safety
of this evaporator only. This has nothing to do with the
thickness of the ice.

Approximately one half way up the right side of the circuit
board is a bank of three DIP switches. The left and center
switch control how often the water dump valve operates.
With both of the switches in the down (1) position the dump
valve operates at the beginning of each freeze cycle. With
the left switch in the up (3) position and the center switch
down (1) the machine will dump water at the beginning of
every 3rd freeze cycle. With the left switch down (1) and
the center switch up (5) the dump solenoid will operate at
the beginning of every 5th freeze cycle.

Please remember, the less the water is dumped, the more
mineral build up on the evaporators.

The right switch of this three switch bank tells the board
how many evaporators are in this machine. The switch
should be placed at the one (1) or two (2) position corre­sponding to the number of evaporators in your machine.

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4 RELAY CIRCUIT BOARD

COMPONENTS

Just below the 3 DIP switch case is a yellow LED. This is
the POWER light. Whenever power is applied to the
machine with the toggle switch to the ICE position, this
light will be on. If the machine is off due to a bin full situ­ation, this light will still be illuminated.

If the power light is flashing, this is giving you a warning.
A flashing light indicates that any of the following condi­tions may apply:

• High temperature cut out

• Curtain switch set incorrectly one curtain with two
thermistors attached or two curtains with one ther­mistor attached

• Missing ice thickness control

• Mis-wired ice thickness control

• Shorted ice thickness control

• Open ice thickness control

To restart the machine, investigate the reason for the flash­ing light and subsequent shut down. Correct the cause of
the shut down. Turn the toggle switch to the off position
for 5 seconds. Turn the toggle switch to the ICE position.
The machine should restart.

In the lower right corner of the board are two sets of three
spade terminals. The curtain/Hall switch(s) attach to these
terminals. If you are working on a machine with a single
evaporator, your Hall switch connects to the bottom set of
terminals marked “CURTAIN ONE”. If you are working on
a dual evaporator machine, the left Hall switch connects to
the terminals marked “CURTAIN ONE”. The right Hall switch
will then connect to the terminals marked “CURTAIN TWO”.

Between the sets of curtain terminals is a set of three
prongs with a sleeve jumper. Be sure this jumper is cov­ering the top and middle prongs. This is the setting for
the Hall switch used on your equipment. If the jumper is
missing or on the bottom and middle terminals, the ma­chine will not work or may work in harvest cycle when it
should be freezing and freezing when it should be har­vesting.

At the bottom of the circuit board in the center is a bank
of 8 DIP switches. These switches control the thickness
of the ice. Above the switch bank is a wedge giving a
visual indicator of the direction to move the switches.
The top of the switch pushed down indicates that switch
is energized. Turn switches on or off in succession from
left to right. Do not skip switches in this bank.

Slightly to the left of the ice thickness DIP switches is a
small potentiometer. This is a very coarse thickness ad­justment. Do not move this adjustment more than one (1)
graduation at a time. To increase thickness with this poten­tiometer, turn the control clockwise. To decrease thickness,
turn this control counterclockwise.

4 RELAY CIRCUIT BOARD

CHECKING THE CIRCUIT BOARD

There are only two checks you must make in the field on
this board.

1. If the LED along side the relay is energized the relay
should be energized. With your meter in parallel to the
component you are testing you should observe voltage.
If there is no voltage, the relay (board) is defective.

2. If you are experiencing bin control problems and have
tested the Hall switch to be good, take a voltage test.
Remove the Hall switch leads from the + (positive) and
the - (negative) terminals. With the toggle switch in the
ICE position and your meter set to D.C. volts, place the
leads on the corresponding terminals. Your voltage read­ing should be from 12 to 24 volts D.C.. If you have any
other voltage reading check the transformer load side. If
the voltage is the same as found at the circuit board,
verify the incoming voltage to the transformer is correct.
If the transformer is putting out the correct voltage,
change the circuit board. If the transformer is putting out
the wrong voltage with correct line voltage, change the
transformer. Transformer actual voltage should read AC
voltage.

To the left of the jumper mentioned above is a manual har­vest switch. By depressing this switch one time the ma­chine can go immediately into harvest. This will happen if
the toggle switch is to the ICE position, the curtain is in
place and the power light is steady on.

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COMPRESSOR & START

COMPONENTS

When compressors fail to start or run properly, normally it is
a result of an external failure. You should not rule out electric
voltage, start, or run component failure.

Check for the proper voltage. Low or not voltage will re­quire you to trace the electric wiring to determine where
the electric failure has occurred. Correct any discrep­ancy you may find. The lowest voltage should be no
lower than 95% of the ice maker name plate voltage of a
dual voltage machine. A single voltage machine should
be no lower than 90% of the name plate voltage. High
voltage is 10% greater than the name plate voltage.

A defective capacitor or relay may prevent the compres­sor from starting. If the compressor attempts to start or
hums check the start components.

The potential relay contacts are normally closed. These
contacts are opened by the counter electromotive force from
the compressor at approximately 80% of the operating
speed. When the contacts open this removes the start
capacitor from the circuit. The start and run winding with
the run capacitor remain in the circuit. If this relay fails to
open in during operation you should check the holding coil
for continuity.

To check the compressor for ground, use your ohm meter.
Place one lead on a good compressor case ground. The
copper suction line tubing works very well for this. Place
the other lead in sequence on the common, start, and run
terminals. If you obtain any reading of a circuit through the
case, the windings are shorted to ground. The compres­sor must be replaced.

If the overload protector on the compressor trips, you
should check the following items. The voltage at the com­pressor terminals should be no less than 95% of the ice
maker name plate voltage of your particular machine.
Check the ambient operating temperatures, be sure you
have not exceeded the ambient limits of 380 C (1000 F).
Check the condenser for high head pressure conditions.
Tripping can also be caused by defective capacitors or
start relay.

Compressors used in the R-40A machines use polyol es­ter oil (POE). This oil is very susceptible to moisture con­tamination. An open compressor or can of oil can become
saturated with moisture within 15 minutes. Please reduce
the open refrigerant system time. Current accepted POE
oils are:

Mobil # EAL 22 CC-package AK ICI # RL 184

The current relay contacts are normally open. As the com­pressor starts, the high current draw produces a magnetic
field. This magnetic field draws the relay armature in. The
contacts for the start circuit will then close. If the coil on the
relay is open, the relay will not operate.

If a capacitor shows any sign of leaking or damage, re­place it.

When checking capacitors, a capacitor tester must be
used. Remove the resistor (if any) from the terminals.
Attach the tester to the capacitor. If you use an ohm
meter to test capacitors, you can check only of an open,
shorted, or grounded capacitor.

The resistance testing of compressor windings must be
accomplished without wires or components attached. Us­ing an ohm meter, obtain a reading of the compressor wind­ings. Place one lead on the common (C) terminal. Place
the second lead on the start (S) and run (R) terminal in
succession. Compare your readings with those from the
compressor manufacturer.

CAUTION: POE oils are caustic to the skin. Always

wear gloves and goggles when working with the
refrigeration system.

Any defective compressor returned to SerVend must be
stubbed with copper tube and soldered closed.

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COMPRESSOR CONTACTOR

The contactor serves as the power supply switch for the
compressor circuit. Voltage to the coil of the contactor is

supplied by the control board relay on self contained
models.

Caution: On 230 volt models, the contactor breaks only
one power leg. The ice maker is still “live”.

Remote models are wired through controls outside the
control board. The coil receives power through the low
pressure cut out and therm-o-disc(s).

CHECKING THE CONTACTOR

The top terminals of the contactor should always have line
voltage present. The lower two terminals must have the
same line voltage when the contactor is energized. If the
lower terminals have a different voltage when the contactor
is energized, replace the contactor. To check the contactor
coil, you may either ohm check the coil with the coil supply
wires removed or check for power to the coil with your meter
leads in parallel to the coil.

EVAPORATOR

The ice is made on a nickel-coated copper evaporator plate.
This plate has the refrigerant serpentine coil attached to
the back of the plate. As the water cascades over the evapo­rator, check the distribution tube at the top of the evapora­tor. The water must flow from the tube with the holes in the
appropriate direction.

CHECKING THE FAN CYCLE CONTROL

Install a high side gauge to the high side service valve. Do
not attach the gauge to the receiver valve. Operate the sys­tem and observe the pressures with the fan cycling. If the
cycling pressures vary greater than + 10% of the previously
mentioned pressures, replace the contorl. This control is non
adjustable.

FLOAT VALVE

The water level in the water pan is controlled by use of a float
valve. This valve modulates to allow a sufficient volume of
make up water into the pan for production into ice.

Adjustment of the valve is accomplished by the valve bracket.
This bracket has two screws. Loosen the screws to move
the float and bracket up or down to raise or lower the amount
of water in the pan.

Located within the float valve is a flow control washer. This
washer prevents high water pressure from interfering with
the operation of the float valve. At pressures below 1.4 Kg/
cm2 (20 PSI) to 3.9 Kg/cm2 (55 PSI) the flow control washer
is inactive. The flow washer begins to hold back the water
pressure from the float valve from 3.9 Kg/cm2 (55 PSI) to

8.4 Kg/cm2 (120 PSI). At pressures above 8.4 Kg/cm2 (120

PSI) the flow control washer will not control the incoming
water pressure, you must use a water pressure regulating
valve.

HALL SWITCH

The Hall switch operates in conjunction with a magnetic tar­get on the side of the water curtain. This has two functions on
the SerVend machine.

The Hall switch serves as a bin full control. When the bin fills
up the curtain is held away from the face of the evaporator
and out of the range of the Hall switch. As ice is removed from
the bin, the curtain will fall back toward the evaporator. This
will again put the target within range of the Hall switch and the
machine will restart.

FAN CYCLE CONTROL

This is a high slide pressure control that cycles the condenser
fan motor off at approximately 13 kg/cm2 (180 PSI) and will
engage at 17.5 kg/cm2 (250 PSI). It’s purpose is to maintain
a minimum head pressure for operation in low ambient con­ditions.

The fan cycle control is used on all remote condensers. It
is also installed in the left fan of a dual evaporator self con­tained air cooled machine. Also on the G9 air cooled self
contained units.

20

This switch also acts as a harvest termination control. As
the ice falls off the evaporator, the curtain swings out taking
the target out of the switch range. The ice will then fall into
the bin allowing the curtain to immediately fall back against
the evaporator. At that time, the target will return to the Hall
switch range. This will put the machine directly from har­vest into freeze.

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CHECKING THE HALL SWITCH

Turn the toggle switch to the ICE position. With the curtain
in the closed position against the evaporator check the LED
on the circuit board. This is the LED at the curtain switch
terminals on the circuit board. The corresponding curtain
position LED should be on. With the LED on, pull the cur­tain away from the evaporator. The LED should go off.
Release the curtain, allowing it to fall against the evapora­tor. The LED should go on. If the LED operates in this
manner, the switch is good. If the LED does not operate
this way, and voltage is correct according to the section
checking the circuit board on page IV-14, change the switch.

HEAD PRESSURE CONTROL VALVE

The head pressure control used on SerVend remote ice
makers is a modulating control. This control maintains
the proper head pressure in the remote condenser. At
outdoor temperatures above 20o C (70o F) the refrigerant
will flow from the compressor tot the valve. The valve
then moves the flow to the condenser onto the receiver.
At outdoor temperatures below 21o C (70o F) the refrig­erant flow is from the compressor tot the valve. The
valve then mixes the discharge line and the condenser
line. The resultant mixture is sent tot he receiver. This
“by-pass” mode supplements the condenser pressures
and is used to maintain proper operating head pressure.

CHECKING THE HEAD PRESSURE CONTROL

Install a gauge at the receiver tank. With outdoor tempera­tures below 21o C (70o F) receiver pressures will be 13 kg/
cm2 (180 PSI) to 17 kg/cm2 (240 PSI) + 3%.

A head pressure control that stays in by-pass may be the
result of a system that is short of refrigerant. Before re­placing the head pressure control, check the fan cycling
control. If it is not cycling, add refrigerant in 1 kg (2 lb.)
increments up to 2 kg (4 lb.). Allow the machine several
minutes to “balance” between additions. If the addition of
refrigerant corrects the valve problems, locate and repair a
refrigerant leak.

REPLACEMENT OF A HEAD PRESSURE VALVE

Always snap off the stub line at the dome before using a
torch to heat the lines for removal. When installing the
new valve, be sure the dome area is covered with ample
heat sink before applying heat to the valve stubs.

HIGH PRESSURE CUT OUT

Al SerVend water cooled, remote condenser, and G2 air
products contain a high pressure cut out. The function of
this switch is to turn the ice maker off in the event of ex­cessive pressure developing in the high pressure side of
the refrigeration system. This switch will open the power
circuit to the circuit board at 35.2 kg/cm
is a manual reset control located beside the power toggle
seitch. To reset this control, push the red button in.

In the event the high pressure control shuts down the
machine, find the reason for this shut down. Correct any
necessary problems then restart the machine.

2

(500 PSI). This

HOT GAS VALVE

SerVend employs a hot gas defrost method of harvesting
the ice. When the ice reaches the proper temperature,
the ice sensing control initiates the board to open the hot
gas bypass valve. This electrically operated solenoid valve
will allow hot discharge refrigerant gas leaving the com­pressor to return to the inlet of the evaporator. The flow of
liquid refrigerant from the expansion valve will then cease.
The hot refrigerant warms the evaporator therefore allow­ing the ice to melt and slide off the evaporator.

If the hot gas valve fails to open, check the electric power
supply to the coil of the valve. This power supply is supplied
to the coil from the circuit board. The power should be
checked in parallel and should be present when the red LED
is energized. If there is power to the coil without the coil
operating, remove the wire leads from the coil of the valve.
Place your continuity meter on the coil terminals. You should
have continuity at these terminals. If there is no continuity,
replace the coil.

If the coil is energized but the valve still fails to operate, you
may have a sticking valve that needs to be replaced.

A leaking valve can cause excessive freeze times, uneven
bridge thickness, high suction pressures, etc.. A leaking
hot gas valve is difficult to troubleshoot. Several methods
to determine if this valve is leaking in the closed mode are
as follows:

1. The hand temperature method. Place you hand on the
outlet of the valve. The outlet line of the valve should feel
ambient temperature or a little cooler.

2. The use of an electronic sight glass. This can be beneficial
in the detection of a leaking valve. Install the probes on the
outlet line of the valve, several inches apart. If there is a
small leak in the valve, the instrument should detect hot
gas condensing due to the pressure drop and cooler tem­peratures of the evaporator section.

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3. Use of a pinch off tool. By closing the line between the hot
gas valve and the evaporator, you will be able to determine
if the valve is leaking.

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Installation and Service Manual

ICE CAPACITY

The ice manufacturing capacity of any maker is affected by
many operating conditions. These conditions include, but are
not limited to, water and air temperatures, electric and ocation
of equipment, etc.. We have included in the operating speci­fications section typical production capabilities for SerVend
ice makers at specific conditions.

All printed capacity ratings are laboratory readings. If you are
working with a 50 Hz. unit cycle time will increase 12% while
capacity will decrease approximately 12%.

ICE CAPACITY CHECK PROCEDURE

Of paramount importance in checking the ice produciton of
any machine is the collection of accurate data.

Measure the ambient air temperature 5 cm (2”) from the
condenser fins if air cooled. If not air cooled, measure air
temperature 5 cm (2”) from either the right or left side panel
about one half way from the front to the back of the unit.

The incoming water temperature should be measured in the
water stream at the inlet of the float valve. Be sure your
thermometer does not read the water pan temperature.

CHECK PROCEDURE

1. Clear the evaporator of any ice. This can be done with
the use of the manual harvest switch on the circuit baord.

2. Place the machine in the ice mode. Allow the unit to
make one sheet of ice.

3. At the end of a normal freeze time, manually harvest the
ice.

4. Observe the sheet of ice. Is the bridge thickenss even
from top to bottom? Is the bridge thinner at the top of the
sheet than at the bottom?

5. If your sheet of ice is thinner at the top than at the bottom,
your machine is probably suffering from a water loss or a
refrigeration problem. Please refer to the appropriate sec­tions for help.

6. If your ice has an even bridge from top to bottom, proceed
with the OHM meter check.

7. Remove the control wires from the EV terminals on the
circuit board. Do not remove the control from the evapora­tor extrusion. In a dual evaporator machine, only the left
ice thickness control (connected to the EV terminals) de­termines the thickness of the ice.

Allow the machine to make one sheet of ice. Catch this
sheet and weigh it. During produciton, time the complete
cycle. Production time includes the freeze and harvest times
added together.

With this information the calculation can be made.

1440 (number of minutes in a day) + total cycle time X
weight of one sheet of ice X number of evaporators - ice
produciton.

ICE THICKNESS CONTROL

DIAGNOSIS

Before replacing a potential ice thickness control, please
check the following:

1. Are the wire leads to the circuit board secure and tight?

2. Is the tip of the control mounted to the front of the plas­tic extrusion? The tip of the thermistor should not be
recessed into the thermistor hole.

3. Is there a glob of sealant over the tip of the control? A
very slight film is OK. If the tip of the control has an
overabundance of silicone, it can act as an insulator to
the ice.

8. If the ice sensing control is “open” or “shorted”, the power
light on the circuit board will flash. The machine will not
operate, replace the control.

9. Attach your ohm meter to the ends of the wires. Your meter
should be capable of reading 5,000 to 40,000 ohms accu­rately.

10. At room temperature, with no ice on the evaporator,
your control should read ABOUT 10,000 to 15,000 OHM
resistance.

11. Place an ice cube on the tip of the control. You should
obtain a reading about 25,000 to 36,000 ohms. You may
hold in the contactor for the compressor to freeze the evapo­rator rather than hold ice on the tip. Do not hold the contactor
in for more than two minutes. Flood back to the compres­sor may occur with damage to the compressor.

These readings are approximate. Do not be concerned if

your readings are slightly different.

If your control responds comparable to the above readings,

this control is good. If your control does not respond, re­place this ice sensing contorl.

4. After the cachine seats for 24 hours is the first sheet of
ice OK? Does each succeeding sheet of ice get thin­ner? This could be a sealing problem with water in the
sensor well.

22

Revision June 19, 2003

5006772