Home

Rapid Freeze ICE FLAKERS - Catalog

image

Contents

1. WATER 1 2 DRAIN PUMP NOTES DASHED LINES INDICATE FIELD PIPING X WHERE REQUIRED Models Suction Line Suction Line Liquid Line Float Valve Dual Pressure Stop Valves Valves Orifice Regulator 50 RLA 1 Port 1 1 2 FPT 7 64 1 1 4 Flanges 75 RLA 1 1 4 Port 2 SW 1 8 1 1 2 Flanges 100 RLA 1 1 4 Port 2 SW 9 64 1 1 2 Flanges 61 8 Ice Flaker Unit Drawings Piping Schematic 2000 RLR 3000 RLR 4000 RLR amp 6000 RLR DUAL PRESSURE REGULATOR SET 8 128 amp 75 SUCTION FLANGES 1 2 RELIEF VALVE 150 STOP VALVE SUCTION LINE REDUCERS REDUCING BUSHING SDLENDID VALVE FLANGED LIQUID LINE REDUCING STOP 1 2 DRAIN BUSHING VALVE HAND STRAINER NOTES WHERE REQUIRED Models Pee Suction Line Liquid Line TEE Suction Stop Valves Valves Flanges Regulator 34 Port 50 Plug x iz 2000 RLR 34 FPT Flanges 1 FPT 2 1 1 4 FPT 1 1 2 FPT 34 Port 50 Plug 53 T 300 RLR 34 Flanges 1 FPT 2 1 1 4 FPT 1 1 2 FPT 34 Port 14 4000 RLR 1 EPT Flanges 1 1 4 FPT 2 1 1 2 FPT 2 FPT 34 Port 5 6000 RLR 1 FPT Flanges 1 1 4 FPT V 1 1 2 FPT 2 FPT 62 8 Ice Flaker Unit Drawings Piping Schema
2. p 21 1 Ine zit NOU ERAS ID ide 11 ms 67 9 Wiring Diagrams Figure 15 Photoeye Ice Level Controls N O Output 28 Wired in series with module on off switch and remote i o 29 ss 240V AC A 1 76 k 24 7 Input Os 3 10 Terminals 10 amp 1 24V AC Output o Direct Plug In Banner Replacement Terminal 11 Trigger Delay Timer Step Down Power Supply No Connectior for use with Honeywell MicroSwitch Photo Controls Honeywell Microswitch No Connection Receiver 68 9 Wiring Diagrams 69 10 Parts List I0 Appendix C Parts List Number in parentheses indicates quantities if more than one is required 70 10 Parts List Cc HOWE Replacement Parts for Rapid Freeze Ice Flakers Effective January 1 2002 Number in parentheses indicates quantities if more than one is required 71 10 Parts List Figure 16 Ice Flaker Cross Section Models 4000 RL 6000 RL O O O 11 4 61 EM 3 E gt pa 1 74 N N q SHAFT ROTATION 42 CIL 48 15 4 44 46 18 68 65 22 66 8r 20 63 5 22 80 53 54 3 12 1 36 56 57 56 62 45 gt 6 Lg 38 7 4 7 15 3 5
3. 3 Ice Flaker run input signal all ON OFF switches ice level controls and any special controls must be in this circuit 4 Overload reset input normally open momentary contact Motor overload output for overload indicating light Energized upon overload condition stays on until overload is manually reset Red LED on control module indicates overload condition This LED will glow prior to actual shutdown of drive contactor 6 Ice flaker contactor output output is energized when input signal is present and control is not in overload condition When input signal is removed switch or ice level control open timer circuit is started Output will stay energized until timing circuit releases output Output is de energized immediately upon overload condition 7 8 Isolated output contacts for liquid solenoid valve normally open Contacts close immediately upon input signal 3 stay closed until input signal is removed Contacts open when input signal is removed or when overload condition exists 28 5 Maintenance 5 Maintenance 5 Maintenance Evaporator To keep the evaporator in peak performance the ice flaker should be cleaned with an approved ice machine cleaner at least twice a year more often if water conditions cause mineral build up using an approved food grade ice machine cleaner The water pump is used to circulate ice machine cleaner through the system Refer to cleaning instructio
4. MINIMUM WATER PRESSURE OF 30 PSIG IS REQUIRED AT THE ICE FLAKER FOAT VALVE TO INSURE ADEQUATE WATER FLOW MAXIMUM ALLLOWABLE WATER PRESSURE TO THE FLOAT VALVE IS 60 PSIG CAUTION Figure 3 Water Supply amp Filter Connections PREALTER WATER FILTER CARTRIDGES a TO WATER DISTRIBUTION PAN WATER p YER PUMP VAL OVERFLOW FITTING ORAN WATER SUMP FITTING kakak WARNING NEVER OPEN CHARGING VALVE ALLOWING REFRIGERANT TO VENT DIRECTLY TO THE ATMOSPHERE REFRIGERANT MUST BE RECLAIMED THROUGH A RECOVERY SYSTEM ee WARNING es 4 Accessories CAUTION SERVICE INSTALLATION PERSONNEL MUST HAVE KNOWLEDGE OF REFRIGERATION SYSTEMS TO PROPERLY CHARGE THIS FLAKER CAUTION ve WARNING ALL RAPID FREEZE REMOTE MODEL ICE FLAKERS SHIPPED WITH SMALL HOLDING CHARGE OF DRY NITROGEN SYSTEM MUST BE EVACUATED PRIOR TO CONNECTING TO THE AMMONIA SYSTEM LII WARNING Follow good accepted practice and procedure to charge refrigerant into the system briefly outlined as follows 1 Pressurize and test the system checking for leaks 2 Usea good quality vacuum pump to evacuate the system Make sure all shut off valves are OPEN so that the entire system is evacuated Allow vacuum pump to run for several hours 3 Break vacuum with refrigerant and evacuate again 4 Repeat step 3 This is called triple evacuation I
5. Y LOL ZLL S 21 16 iz 3215 391 09 0 2 802 n VOLON 66 208 230V 1 60 shown other voltages available ing Diagrams Ut 9 Wi iagram D iring Ice Flaker W 230 3 60 for 20 Ton Ice flakers 00121022 602 JAYA 09 51052 805 43 404 09 21052 202 IN 3H TANY d 1031N09 H3MY 1H 310 334 OEZ MLIW L0 020 NOIL VHOdHOO 418 002 V13 00Z S1300MW 303 18012 SI DINNGG SIN NG 1G 4 FEQIQOS ANINO BIZ V1HDO dF LA 8310H Y 3029091 13334 s IATA Aina EF 13634 HIST L IAUN HINL AVI KE EIST 93153 NG1G T mE 33914 lv 4 EDS ANA 39 atem on HI wA udi av ure AUN Hows Vu Ka NG Lae MAL S3Iv3H diu YOLYINETY TYY j mawa 7710 OICHTIDE 3H1 lneci inm Fila ww 4 1302171 lt n ane Y 4 2 C fa T pie 3 T tL zs HG 4 NA 4 P TI pa a U un jb rige
6. 9 Ice flaker chatters and does not run Ice blade clearance is too high Check clearance and adjust as necessary smoothly Main bearings are Worn Replace worn bearings Repair or replace main shaft is excessive wear is detected 10 Ice accumulates in the water return trough Ice deflector is not positioned properly Adjust ice deflector position as specified on page 43 11 Ice accumulates in the water return trough sump and on the ribs in the bottom casting Ambient temperature is too low e If ambient temperature is between 45 F and 50 F install rib heaters e If ambient temperature is below 45 F relocate the flaker to a warmer area See Installation conditions on page 8 Ice Storage and Removal 1 Ice flakes are frozen together in a hard block Ice has been left in the storage bin too long e Remove ice from the storage bin daily e Install a clock timer to limit the ice flaker production Water level in the sump is too high causing water to overflow the return trough Adjust the water float valve to maintain water level approximately 4 below the return trough Water is overflowing the distribution pan One or more water distribution tubes is missing or broken e Distribution tubes may be plugged Clean or replace tubes as necessary e Level in distribution pan may be too high Adjust the water
7. HOWE Rapid Preege ICE FLAKERS INSTALLATION amp SERVICE MANUAL and parts catalog Selective Purpose Flake Ice Machines 2 000 40 000 Ib day capacity e Flooded Ammonia series RLA e Recirculated Ammonia series RLR TECHNICAL ASSISTANCE LINE 1 773 235 0200 Howe Corporation 1650 North Elston Avenue www howecorp com Chicago IL 60622 e mail howeinfo O howecorp com Notice This manual and all information contained herein are provided as is and are subject to change without notice Howe Corporation makes no warranty of any kind with regard to this manual including but not limited to the implied warranties of merchantability and fitness for a particular purpose Howe Corporation shall not be liable for any errors or for incidental or consequential damages in connection with the furnishing performance or use of this manual The information contained herein is applicable to the specified models current at the time of publication Some information in this manual will be of use to owners of older model machines The reader is cautioned that use of this manual with older equipment is at the user s risk Howe Corporation makes no warranty or guarantee explicit or implicit with regard to the use of this manual with equipment models outside the scope of this manual If in doubt of the scope of this manual contact Howe Corporation Howe Corporation 2005 All rights reserved Reproduction adaptation or translation o
8. 18 5 Maintenance 5 Start amp Adjust 5 Maintenance Once installation has been completed the ice flaker has been properly evacuated and charged with the Freon identified on the ice flaker label you may proceed with the check and adjust section Checklist 2 3 4 5 6 7 Before power is turned on open inlet water valve field supplied amp installed near the back of the ice flaker and check water level in sump The water level in the sump is the same as the return trough it should be about half full see Figure 6 below Figure 6 Sump Water Level WATER LEVEL Make sure the ON OFF switch is in the OFF position then turn on the main disconnect Check voltage between line 1 and line 2 and verify that it is within nameplate ratings Turn the ON OFF switch ON Verify that the solenoid valve has opened the valve will click loudly Verify that the drive motor and water pump start Verify that water is delivered to the distribution pan located inside the evaporator 20 8 9 10 11 12 13 14 15 16 5 Maintenance Verify that the distribution pan water level is maintained at the half full point Open or close the water adjustment valve until the water level is maintained at the proper level see Figure 7 below 20 ton model ice flakers have a distribution ring Figure 7 Water Distribution Pan Water Level Allow 10 15 minutes to let the ice
9. 4 Using a 13 16 socket a spark plug wrench works well remove the locking nut from the valve body you may need to hold the valve body to keep it from turning 5 Remove the old valve and fiber washer Install new valve with fiber washer on the inside of the water sump and tighten the locking nut with the socket The valve body should be held in place with the discharge port facing straight down 6 Re install the float valve fitting and reattach the water supply line 7 Turn on water shut off valve and check for leaks at the compression fitting and at the float valve fitting The water level should be maintained to the point just below the lower edge of the water return trough while the flaker is operating To adjust the operating level hold the float in one hand and push or pull on the brass shaft depending on whether the water 47 7 Service amp Adjustment level is too high or too low Watch the operation for a while to verify the water level If the water level is still not where it should be re adjust the float Replacement of Solenoid Valve ON ICE FLAKERS THAT ARE CONNECTED TO A CENTRAL REFRIGERATION RACK A JUMPER WIRE MUST BE PLACED BETWEEN TERMINAL A AND TERMINAL B ON THE TERMINAL STRIP AT THE BOTTOM OF THE CONTROL PANEL THIS JUMPER WILL ALLOW THE SOLENOID VALVE TO ENERGIZE WHEN THE OPERATING CIRCUIT IS ENERGIZED CAUTION 1 Pump down the ice flaker and evacuate
10. 8 Check to ensure that the control panel ON OFF switch is in the Off position Turn on the main power disconnect 9 Align the photoeye receiver This alignment is critical to the proper operation of the level controls a Check the LED on the emitter With the disconnect switch ON the red LED on the emitter should be glowing If the light does not come on check the Molex plug and the connections on the base until the LED lights b Move the receiver until the LED on the receiver lights When proper alignment has been achieved secure the receiver c Check once more that the LEDs on both the emitter and receiver are lit Realign or tighten loose connections as necessary to keep both LEDs lit 10 Reroute and fasten cables as necessary If the photoeye elements are installed in the ice bin as opposed to in recessed housings in the bin tops leave enough slack in the cables to provide for drip loops in the cables so that condensation will travel down the cables and drip into the bin and not onto the emitter or receiver DO NOT run the photoeye cables close to high voltage wires High voltage wires will interfere with the low voltage control signals and may cause the ice flaker to shut down 11 Turn on the control panel ON OFF switch The flaker should begin making ice within minutes Ice Bin Thermostats The use of a bin thermostat is not recommended and is not permitted The Rapid Freeze ice flaker is designed so that the fr
11. 391 S JAWA QION3TOS ANIT Sv STYNINYAL IWYS OL 305534 IAIM uva AINO 583914 IDI VINOWWIV 01 SINddV YOLVINDIY 3unssaud P SNLVAS YOSSIYAWO YOLINOW OL SLHOM ONLLVOIGNI St T3NVd TVNOLLdO NVHL LINN DNISNJONO AHOLOV V OL HOVE 01 G3193NNOO LON SI VINVIS VINOWWV SYINV13 310N3H NO333 SYIAVIS 31038 2 039 YOLOM NIJYIINNY YINV14 32 SLHOIN 9NLLVOIONI SVH 13Nvd 1 310N NOLLO3NNOO O aouao V7 m 9 10 e sut zn 16 loe ze en wa aha MOLON 391 1 NY YINN14 391 W JQVOTH3AO YOLOW 5 1YOHS LON 00 1031931039 ATIVNYSLN 0437 AYVONOD3S YOLVINDAY 340 334 3ATVAGION3TOS 4 anon W13 1948 995 09 1 0 2 802 GIOYOL GVOTH3AO YOLOW Mo I i A 4 9 ff NOILI3LOYd 103NNOOSIONVW 09 062 802 ano 208 230V 1 60 shown other voltages available 65 ring Diagrams Figure 14 Ice Flaker Electrical Schematic 230 1 60 Remote
12. 6 0 5 0 Bottom blade E30E3 E30E5 pa Oa Nuts Bolts amp washers bottom ice blade Ice Blade Adjustment Gauge kit Set of five feeler gauges for ice blade adjustment EIOTI5 E50G5 1 Ice deflector blade 1 E50G8 Nuts Bolts amp washers deflector E50J1 2 Insulating ring 2 12a Insulating ring adhesive 2 pint 7V033 13 Ice deflector bracket 2 E50G9 14or15 amp Bottom auxiliary ice scraper 2 E20E4 E20E7 E30F3 E100F3 E30F8 E100F4 E30F22 E100F8 ESOF1 ESOFI Bottom bearing thrust plate Main bearing grease seal 3 2 Top main bearing retainer Top bearing replacement kit includes bearing 2 seals shaft ESOK10 25a sleeve 26 Bottom main bearing retainer E50K4 F 42 replacement kit includes bearing 1 seal Main bearing pull out washer 2 Water distribution side spout amp fitting 11 Number in parentheses indicates quantities if more than one is required 76 15a Nuts Bolts amp washers aux Ice scraper 16 Squeegee 17 Squeegee wrapper 17a Nuts Bolts amp washers squeegee wrapper 18 Top squeegee bracket 9 Bottom squeegee bracket 2 N 1 22 amp 23 NI 28 35 amp 36 10 Parts List 100E 101E TABLE 4 Replacement Parts for Models Listed to Right 50EA 50EAR 75EA 75EAR 100 100EAR Water sump bolt down cover Water sump removable cover Water float valve fitting W
13. Connect the new sensors wires to the terminal strip Install the sensor in the mounting bracket and tighten the locknuts taking care not to over tighten as this could damage the sensor use a maximum torque of 13 Ibs in Re install the power module into the base Turn on main power Check alignment of the sensors When proper alignment is achieved the LED on the receiver will light Adjust the mounting brackets as necessary to ensure that the sensors are properly aligned 10 Reinstall the sensor housing covers Replacement and Adjustment of Ice Deflector To properly install the upper edge of the deflector should be positioned approximately 1 8 BELOW the aluminum lip under the evaporator The ice deflector should be centered beneath the ice cutter blade so that as the ice is removed from the evaporator it will be deflected into the ice bin opening away from the water collecting trough The ice deflector prevents ice from dropping into the water collecting trough TO REPLACE ICE DEFLECTOR PROCEED AS FOLLOWS 1 Are 9 Shut off ice flaker and allow machine to pump down de ice Once the machine is clear of ice disconnect the main power to the ice flaker and LOCK THE DISCONNECT SWITCH IN THE OFF POSITION to prevent accidental start up larger capacity models may be better serviced form below Remove the service access cover on the top casting Remove 2 or 3 water distribution tubes if necessary Reaching
14. aligned with the key When the motor is in place rotate it until the mounting lugs are aligned with the 4 mounting holes on the motor mounting plate on the speed reducer Insert a bolt in each hole and tighten 4 Reattach the flexible power cable to the motor connect the power leads to terminals marked and L check to insure the motor is wired for the correct power 115V or 230V and for the correct rotation CCW Refer to wiring connections on the motor nameplate for the correct connections 5 When the motor is reattached and connected turn on power and check operation Place an ammeter on the power line and check to insure the motor is drawing within the nameplate FLA Replacement Of Speed Reducer and Flexible Coupling 1 Disconnect main power to the ice flaker 2 Remove the drive motor as described above 3 Remove the 4 mounting bolts attaching the gearbox to the top aluminum casting The gearbox can then be lifted straight up The top part of the flexible coupling will lift off with the gearbox the bronze star and bottom part of the coupling will stay attached to the main shaft 4 Loosen the setscrew on the top part of the coupling to remove it from the gearbox Care should be taken to avoid oil from seeping out of the relief vent located on the top of the gearbox in a set screw if the gearbox is turned on its side or up side down 5 The bottom part of the flexible coupling is attached to the shaft with a setscrew
15. Check LED on emitter If LED is lit emitter is functioning properly If LED is not lit check to see that power is turned on and that all connections between the emitter and control panel are secure If LED still is not lit replace emitter Photoeye receiver is defective Check LED on receiver If LED is lit receiver is functioning properly If LED is not lit check to see that power is turned on and that all connections between the emitter and control panel are secure Check alignment of sensors If possible remove sensors form their housings and hold them a few inches apart If LED still is not lit replace receiver Photoeye control module is defective If both sensors are operating properly see d and e above replace control module 2 Solenoid valve energizes drive motor contactor does not energize Control module is defective Check voltage between terminals 2 and 6 on control module If voltage reads 24V AC replace the control module Contactor coil is defective Check voltage between terminals 2 and 6 on control module If voltage reads OVAC check wiring and contactor coil for defects 3 Solenoid valve does not energize drive motor contactor energizes Control module is defective Close all switches remove wires from terminals 7 and 8 on the control module With voltmeter set to ohms check for continuity between terminals 7 and 8 If
16. Loosen the setscrew and then lift the coupling off the shaft The use of a gear puller may be required to assist in removing either part of the coupling 6 Install the new or existing if it is not damaged flexible coupling to the shaft and speed reducer lining up the keyways with the key Re tighten the setscrews in both parts 7 Place the bronze star on the bottom part of the coupling 8 Install the gearbox with top coupling attached onto the top casting over the bottom part of the flexible coupling If the gearbox does not sit on the top casting properly you may need to loosen one or both of the setscrews on the flexible coupling to allow the gearbox to seat on the machined surface of the casting There should be a 1 16 gap between the top coupling half and the bronze star 9 Rotate the gearbox COUNTERCLOCKWISE ONLY until the mounting holes line up Once aligned re install the mounting bolts Re position the coupling halves with required clearance and re tighten 46 7 Service amp Adjustment Figure 11 Drive Motor and Speed Reducer Disassembly Drive Motor Speed Reducer Flexible Coupling Replacement and Adjustment Of Water Float Valve 1 Shut off the water supply to the ice flaker and drain the supply line 2 Loosen and remove the compression fitting at the float valve While holding the float valve body with pliers or a crescent wrench remove the water float valve fitting from the valve body
17. Model 200 RLR le MINIMUM FOR SERVICE 1 FLANGE LIQUID 2 e 1 e sw FLANGE SUCTION 13 16 MOUNTING HOLES 25 7 8 25 7 8 TOP VIEW 59 8 Ice Flaker Unit Drawings Piping Schematic Models 2000 RLA 3000 RLA 4000 RLA amp 6000 RLA DUAL PRESSURE REGULATDR SET 128 758 SUCTION LINE E E E A STOP VALVE STOP VALVE REDUCERS E LIQUID LINE Ve RELIEF VALVE STOP VALVE FLDAT VALVE WITH 3 FPT FLANGE 1 2 FPT STRAINER STDP VALVE SOLENDID VALVE WATER 1 2 DRAIN PUMP NOTES DASHED LINES INDICATE FIELD PIPING WHERE REQUIRED Models ni Suction Line Liquid Line Float Valve Stop Valves Stop valves Orifice Regulator 34 Port 50 Plug 5 iL 2000 RLA 34 FPT Flanges 1 2 3 32 34 Port 50 Plug 5 129 3000 RLA 34 Flanges 1 2 3 32 34 Port 1 dd 4000 RLA 1 FPT Flanges 1 1 4 FPT 2 3 32 Ja Port 99 1 2 99 6000 RLA 1 FPT Flanges 1 1 4 FPT 2 3 32 60 8 Ice Flaker Unit Drawings SUCTION LINE SET ri amp 75 eee bI STOP VALVE LIQUID LINE VALVE REDUCERS ES 1 2 RELIEF VAL VE STOP VALVE dl FLOAT VALVE VITH 3 FPT FLANGE SURGE DRUM 1 2 FPT STRAINER STOP VALVE GE a 94 paese Y SOLENOID VALVE
18. flaker come down to temperature and balance out Verify that ice is being frozen and harvested over the entire surface of the evaporator If it is skip to step 14 below If it is not continue to the next step Check the suction pressure at the ice machine Suction temperature must be maintained between 5 F amp 20 F depending on model flaker at all times Adjust Dual Pressure Regulator Low range operating to 9 12PSIG 5 to 10 F 3 6 PSIG 20 F for 20 ton High Range relief to 65 75 PSIG Recirculated ammonia suction temperature is 5 F Adjust the hand expansion valve s Adjust the hand expansion valves to meter the correct amount of Liquid to fill each circuit Adjust the adjustment stem 1 8 to 1 4 turn at a time counterclockwise to open the valve if the evaporator was not freezing ice on its entire length Wait 10 15 minutes between each adjustment to allow the valve and machine balance out Repeat this step until ice is produced and harvested all the way down to the bottom of the evaporator When the ice maker is adjusted and operating properly turn ON OFF switch OFF and verify that the solenoid valve closes the valve will click loudly Verify that the off delay is set correctly After the ice flaker is turned OFF the drive motor and water pump will continue to operate for a period of time This should be adjusted to allow the drum to be cleared of residual ice after the solenoid valve is de energized This en
19. from the freezing surface The material and method of fabrication mean that the blade will never need re sharpening Squeegee Made of USDA approved material the squeegee removes excess water from the surface of the ice guaranteeing that the ice produced by the flaker is dry and sub cooled Ice Deflector Mounted underneath the ice blade the deflector directs the harvested ice toward the center of the drop zone Water Distribution Pan The water distribution pan and tubes provide a continuous flow of water over the evaporator surface Ice production is rapid and continuous with no interruption in production Water Sump Collects water that was not frozen on the evaporator and re circulates it to the water distribution pan The incoming water supply is connected here through a float valve that maintains a constant water level in the sump Bearings Oversized bronze bearings ensure a long service life Control Panel The brains of the ice flaker the control panel governs all of the functions of the ice flaker Available in a NEMA4 weatherproof enclosure for harsh environments or frequent washdown applications Drive Motor Open drip proof drive motor Totally enclosed fan cooled motor available for harsh environments or frequent washdown applications 2 Introduction Figure 1 Howe Rapid Freeze Ice Flaker Major Components Drive Motor Speed Reducer a x iZ Water Distribution Pan Main Shaft Eva
20. is an integral part of the top designed specifically for the Rapid Freeze Ice Flaker model installed on it The ice bin should be designed to support the weight of the flaker and the ice stored inside the bin Most ice storage bins can handle the weight of a 2000 3000 4000 or 6000 pound capacity ice flaker without any additional bracing It is recommended that the bin manufacturer be consulted before any ice flaker is placed on top of a bin The weight of each ice flaker machine along with the diameter of the hole required for ice entry into the bin is given on the specification sheet for that particular model Allow for a MINIMUM OF 6 clearance on top of the ice flaker for removal of the speed reducer and sufficient space around the unit approximately 3 feet for inspection and service Recommended Installation Method on Ice Bin Refer to bin manufacturer s installation instructions for proper assembly and set up procedures Locate and set the bin on a solid level footing Once the bin is set in place and leveled the Rapid Freeze ice flaker can be placed inside the drip pan Exhibit 2 illustrates the forklift and block method of placing the ice flaker on the bin Forklift amp Block Method You will need Y Forklift truck with adequate load and height capacities 8 2 4 wood blocks approximately 6 8 long 2 2 4 5 approximately 36 long Pry Bars Step 1 Position ice flaker on forks Step 2 Stack two wood blocks in
21. occurs first The above chart assumes continuous operation of the ice flaker t Only required on speed reducers equipped with grease fittings at the bearings Use food grade grease such as Chevron FM or equal TT Use industrial feeler gauge If wear is greater than 0 007 bearings may be wearing excessively Contact factory for guidance t Usean industrial feeler gauge Check blade at top and bottom in at least four locations around the evaporator quarter points Clearance should be 0 004 0 006 in all locations If clearance is not within these parameters contact factory for guidance tt Oil pot should not be insulated Frost line on oil pot will indicate oil level When pot is nearly full drain oil 233 5 Maintenance 34 6 Troubleshooting 6 Troubleshooting 6 Troubleshooting Problem Possible Cause Remedy Operation 1 Ice flaker will not start ON OF switch is open Turn all power switches ON Control transformer is defective Control switches are open Check voltage between terminals 1 and 2 on the flaker control module part E20T48 Normal reading is 24 VAC If 24V AC is not present replace the transformer Check voltage between terminals 1 and 3 on the flaker control module With all control switches open normal reading is 0 VAC With all control switches closed normal reading is 24 VAC Photoeye emitter is defective
22. reducer is worn Replace seal 40 7 Service amp Adjustment 7 Service amp Adjustment 7 Service amp Adjustment ee ES THIS INFORMATION IS INTENDED FOR USE BY INDIVIDUALS POSSESSING ADEQUATE BACKGROUND IN ELECTRICAL REFRIGERATION AND MECHANICAL SERVICE ANY ATTEMPT TO REPAIR MAJOR EQUIPMENT MAY RESULT IN PERSONAL INJURY AND OR PROPERTY DAMAGE THE MANUFACTURER OR SELLER IS NOT RESPONSIBLE FOR THE INTERPRETATION OF THIS INFORMATION NOR WILL THEY ASSUME ANY LIABLITY IN CONNECTION WITH ITS USE OP V GN COIN GG DANGER THE CONTROL PANEL ON THIS ICE FLAKER MAY BE POWERED BY TWO SEPARATE POWER SOURCES DISCONNECT BOTH SOURCES PRIOR TO SERVICING THIS PIECE OF EQUIPMENT FAILURE TO DO SO MAY RESULT IN AN ELECTROCULTION HAZARD DANGER EE WARNING ONLY TECHNICALLY QUALIFIED PERSONS EXPERIENCED IN THE HANDLING OF REFRIGERANTS AND THE OPERATION OF REFRIGERATION SYSTEMS SHOULD PERFORM THE OPERATIONS DESCRIBED IN THIS MANUAL WARNING ES 42 7 Service amp Adjustment Replacement of Photoeye Ice Level Controls Turn off the main power and remove the 11 pin power module Locate the sensor to be replaced and remove the sensor housing cover if present Using two open ended wrenches placing one on the back nut and one on the forward nut remove the sensor Disconnect the old sensor wires from the terminal strip
23. refrigerant from the liquid line 2 Turn off main power to ice flaker and disconnect wires leads from the solenoid valve and remove the armored cable Remove the solenoid valve from the liquid line 4 Install the new valve into the liquid line Using a high quality vacuum pump evacuate the liquid line to remove any moisture that may have entered the system while the line was open to the atmosphere 6 Re connect armored cable and solenoid wires 7 Turn on main power turn on ice flaker switch and check operation of the solenoid valve THE ARROW MARKED ON THE SOLENOID VALVE MUST POINT IN THE DIRECTION OF REFRIGERANT FLOW TOWARD THE ICE FLAKER CAUTION Replacement and Adjustment of the Hand Expansion Valve Pump down the ice flaker and evacuate refrigerant from the liquid line Remove the old expansion valve 1 2 3 Install the new valve 4 Re insulate the suction line 5 Using a high quality vacuum pump evacuate the liquid line to remove any moisture that may have entered the system while the line was open to the atmosphere Restart ice flaker and adjust hand expansion valve as necessary 7 To adjust the hand expansion valve turn the adjustment handle 1 8 to 1 4 turn at a time clockwise to close the valve if it was overfeeding counterclockwise to open the valve 48 7 Service amp Adjustment Wait 5 10 minutes to allow the system to s
24. with overload M2 M2 DSC E20T55 10 Amp single pole circuit breaker CB1 E20T56 Red oil tight indicating lamp 2 LP1 LP2 E20T57 Green Oil tight indicating lamp LP3 E20T58 Oil light On Off switch SW1 E20T59 Off delay timer TMR1 E20T61 DPDT Mini Relay R1 E20T62 Relay Socket Base for Timer Relay E20T63 Relay socket base for Mini Relay E20T64 Parts for E20T47 Control Panels 480V 3 60 Drive motor starter with overload E20T54 Water Pump Contactor E20T72 Control Transformer 480v Pri 240v Sec 300VA E20T74 Ice Flaker initiate relay E20T62 Water pump run relay E20T62 Mini relay base E20T46 Off delay timer 5V012 Timer base 5V013 3 amp fuse 600V CCMR 3 2 amp fuse 600 V CCMR 2 2 Amp fuse 250V KLDR 2 Number in parentheses indicates quantities if more than one is required 78 10 Parts List Replacement Neon Indicating Lights Green 230VAC LGX 2 Amber 230VAC LAN 2 Red 230VAC LRN 2 Green 24VAC LGX 24 Amber 24VAC LAN 24 Parts for E20T73 Photoeye Level Controls Power module relay E20T68 Sensor emitter with Molex plug E20T69 Sensor receiver with Molex plug E20T70 Sensor emitter with 15 lead no plug E20T69 15NP Sensor receiver with 15 lead no plug E20T70 15NP 11 pin socket base for photoeye power module 5V013 Photoeye sensor mounting brackets pair E10U44 Table 4 Miscellaneous Accessories and Parts Part Desc
25. 2 2 gt 4 22 AB HEATER O 100 20 e s 21 2 J 47 16 80 49 50 Number in parentheses indicates quantities if more than one is required 72 10 Parts List Table 2 Replacement parts for 4000 6000 pound ice flakers 4000 RL 6000 RL Item No Part Description Part Number 3 Insulated lug spacers 8 E20J4 7 Main shaft E20D2 E30D4 9 Ice blade 12 1 2 L 20 7 L E20E2 E30E3 9a Nuts bolts and washers Ice blade E20E6 E30E5 11 Ice deflector blade E20G2 lla Nuts bolts and washers ice deflector E20G5 12 Insulating ring 2 E20J1 12a Insulating ring adhesive 1 2 pint 7V033 14 15 Auxiliary ice scraper 2 E20E4 15a Nuts bolts and washers auxiliary ice scraper E20E7 16 Ice deflector scraper E20G4 17 Squeegee 12 Y L 20 Y L E20F4 E30F3 18 Squeegee wrapper E20F9 E30F8 18a Nuts bolts and washers squeegee wrapper E20F8 E30F22 19 Squeegee bracket E20F11 E30F7 20 Main shaft bearings 2 E20K1 21 Bottom bearing thrust plate E20K2 22 Main bearing grease seal 3 E20K3 22a Bearing replacement kit includes 2 bearings 1 bearing E20K4 plate and 3 seals 22b Bearing removal replacement tool kit E10T1 27 Bottom bearing cover E20B8 25 46 Water distribution side spout and fitting 6 plastic E20H39 P Water distribution side spout and fitting 6 metal E30H8 Water distribution
26. 68 81 1614 60 24 x 40 9 64 2 1 2 Y 1 2 3 8 180 000 56 8 Ice Flaker Unit Drawings Assembly Drawing 2000 RLR 3000 RLR 4000 RLR amp 6000 RLR 6 MINIMUM FOR SERVICE TO ICE BIN DUNTING HOLE SUCTION MATER PUMP REFRIGERANT LIQUID INLET DETAIL LIQUID INLET x y 1 8 FPT lt lt DIL DRAIN Ice Flaker Information DIMENSIONS Connection Sizes Refrigerant Requiremnt C D H J W Suction Liquid Wagi 5 F Inlet Evap INCHES FPT FPT OD BTU HR 2000 RLR 14 23 34 81 28 Ya 1 Y 3 8 18 000 3000 RLR 14 23 38 Ya 8 28 Ya 1 Y 3 8 27 000 4000 RLR 18 27 1 2 43 10 3215 1 14 Y 3 8 36 000 6000 RLR 18 27 50 10 36 Ya 1 34 3 8 54 000 257 s 8 Ice Flaker Unit Drawings Assembly Drawing 50 RLR 75 RLR amp 100 RLR 10 MINIMUM FOR SERVICE SUCTION MOUNTING HOLE MOUNTING HOLE WATER PUMP MOUNTING HOLE VA USE MENS WATER SUMP REFRIGERANT LIQUID INLET DETAIL LIQUID INLET TE 52 1 8 FPT DIL DRAIN Ice Flaker Information DIMENSIONS Connection Sizes Refrigerant Requiremnt C D H J W Suction Liquid Q 5F Inlet Evap INCHES FPT FPT OD BTU HR 50 RLR 30 42 58 1614 5315 2 3 4 1 2 90 000 75 RLR 30 43 74 1614 53 Y 2 3 4 Y 135 000 100 RER 30 43 81 1614 53 Y 2 1 2 1 Y 180 000 58 8 Ice Flaker Unit Drawings Assembly Drawing
27. Drawings Assembly Drawing 6000 RLA 6 MINIMUM FOR SERVICE AMMDNIA LIQUID FLOAT VALVE FOR DRIFICE SIZE SEE TABLE BELOW Le DIA DPENING TO ICE BIN MOUNTING HOLE gt USE 1 2 SCREWS WATER PUMP AMMONIA LIQUID INLET EITHER SIDE Ice Flaker Information F Connection Sizes 3 Dimensions Surge Float Inches Refrigeration Drum Valve Requirement J w DxL Orifice Suction Liquida meet Water 5 F Drain Inlet INCHES FPT FPT FPT FPT OD BTU HR 6000 RLA 18 47 50 10 35 Ya 10 4 24 3 32 11 4 1 2 Y 1 2 3 8 54 000 255 8 Ice Flaker Unit Drawings Assembly Drawing 50 RLA 75 RLA amp 100 RLA 10 MINIMUM FOR SERVICE AMMONIA LIQUID FLOAT VALVE FOR ORIFICE SIZE SEE TABLE BELOW 4 X4 X9 BLOCK BY OTHERS MQUNTING HOLE USE 1 8 SCREWS TYP y LES WIA 5 nn gt LTT AMMONIA LIQUID INLET EITHER SIDE SUCT ION TO COMPR L Ice Flaker Information Connection Sizes Dimensions Surge Float Inches Refrigeration Drum Valve Requirement C D H J w DxL Orifice Suction Liquid Relief Water 5 F Drain Inlet INCHES FPT FPT FPT FPT OD BTU HR 50 RLA 30 63 58 16 4 60 18x40 7 64 11 2 1 2 Y 1 2 3 8 90 000 75 RLA 30 64 74 16 60 20 x 40 9 64 2 1 2 Y 1 2 3 8 135 000 100 RLA 30
28. E BEARING WEAR KKK CAUTION 10 Loosen the squeegee mounting bolts and push the squeegee away from the evaporator surface 11 Lift the shaft assembly out of the evaporator being careful to avoid scratching the evaporator surface with the ice blade 12 Examine shaft journals for wear If worn repair or replace shaft 13 Remove the old oil seals from the upper casting 14 Drive the upper bearing out of the top casting using a drift pin or properly sized wood block Note to avoid distortion of the top casting it should be supported near the bearing and not along the outer edge 15 Drive the new bearing into place centering it in the retainer 16 Press the new oil seals in place 17 To remove the bottom bearing remove the bottom bearing cover and the bearing plate 18 Repeat steps 12 16 above for the bottom bearing 19 Install the new bottom bearing plate and then replace the bottom bearing cover 20 Install the main shaft assembly 21 Reposition the rubber insulating ring on top of the evaporator using adhesive if possible 22 Reinstall the top casting making sure to reinstall shims in their former locations Make sure that the evaporator lugs are properly seated against the shoulders machined into the top casting When the casting is repositioned correctly tighten the four mounting bolts evenly 23 Rotate the shaft to check for proper clearances before re installing the drive assembly 24 Ch
29. Low Side w rib heaters Ut 9 Wi O9 L Z B O9 L 0 C SYOLOW 9 09 1 0 Z 09 1 062 802 8 T3NVd TOHINOO Y3AV 321 310W3H Y1H 1Y40P1023 NOILLVHOdHOO 3MOH 0350 SI a Sad WNP LON OQ LINN DNISNIONOD NI ONILVTOSI NV SI CHO 9 ONILVM3dO SI 3NIHOVIN N3HM FATWA GION310S INIT YIMOd 1 ONY Va STVNINYAL TTV1SNI LSNW UDV VINOINAV WILSAS NIVE NO333 V OL YANV IDI SIHL SNILOSNNOO N3HM S INIT 3 31 INDIN Sv IWYS OL YOLVINDIY FAIM VI ON 531535 Suiv 14 391 VINOWWV OL S3r1ddV u01v 11939 0 SLIVEA SNAVS 409534409 01 SLHOM ONLLVOIONI SIEVIVAV SI TANYA NV LIN 314405 ANOLOV4 OL LNG NOVY 2 OL 1 LON SI 6 GRO VINO VINOWWV SYDV BLOWS TIV SU3XY14 SLOWS TIV na 2 GION310S _ ANN aon YOLOM 391 SAHONT ONU VOIONI 2 TANYA 1 SILON NOLLO3NNOO amaa
30. achine back to ON Water Distribution Tubes Water distribution tubes should be kept clean and free of any mineral buildup When they do accumulate mineral deposits the flaker must be thoroughly cleaned Remove each tube and clean with cleaning solution and small tubing brush Carefully inspect each distribution tube and fitting for leaks or cracks Replace defective tubes when necessary Water Sump Water sump and pump should be kept clean and free of any mineral buildup When mineral deposits accumulate the machine must be thoroughly cleaned The water sump will be cleaned when you normally clean the equipment by circulating the ice machine cleaner through the water system In extreme cases of mineral or slime buildup shut off the main power and remove the top covers from the sump and using the ice machine cleaner and a scrub brush clean the aluminum sump body until the deposits are removed Water Filter Back Flushing A unique feature of the Howe water filter system is the cartridge back flush capability The unique omni directional cartridge design permits back flushing of the cartridge in the event of a premature plugging before the 6 month life has occurred In most cases this will not be necessary however when there are large accumulations of sediment and dirt caused by line interruptions construction and heavy rain conditions back flushing will permit the cartridges to be used for their rated life To back flush the cartridges p
31. after bearing replacement a Feed water 1s too hard b Freezing surface is coated with hard water deposits Re align and reassemble the top casting Contact factory for assistance Install a water softening system Clean the evaporator surface with ice machine cleaner 5 No ice freezes on the evaporator and compressor short cycles a Loss of refrigerant charge Inspect refrigeration system for leaks Repair as necessary and recharge system 6 Flaker makes ice intermittently and compressor short cycles 7 Ice flakes are too thin a Undersized water line Install properly sized water line b Low water pressure under 20 psi Contact factory for guidance c Water filters are clogged a Evaporator temperature is too high Replace water filters Check and adjust Dual Pressure regulator Gf equipped regulator should be set between 5 F and 10 F 20 for 20 ton during operating cycle e Close the hand expansion valve 14 turn at a time until ice quality is acceptable Wait 10 15 minutes between adjustments to allow the system to balance 8 Ice flakes are too small with an excessive amount of snow a Evaporator temperature is too low e Check and adjust hand expansion valve if equipped valve should be set between 5 F and 10 20 for 20 ton 38 Problem 6 Troubleshooting Possible Cause Remedy
32. ater mixing valve must be used 36 F 2 C Maximum water temperature 90 F 32 C Installation without ice bin Rapid Freeze Ice Flakers may be installed under certain conditions without a typical ice bin When the flaker is installed without a bin it must have a drainable condensate pan located under the machine The flaker must also be mounted high enough off the floor so there is no chance that somebody may reach into the evaporator from below either with a pole or their arm while the flaker is operating Refrigerating the ice storage bin is not normally necessary nor is it recommended However in those cases where ice is to be discharged into an existing freezer room then as a minimum electric heaters should be installed on the bottom casting and the sump regardless of the actual ambient temperature of the air surrounding the ice flaker Air from the freezer room should be directed away from the ice flaker opening otherwise the effectiveness of the heaters will be reduced If the storage area is held at 28 F 8 C or colder it is advisable to install the ice flaker 1 to 2 feet above the freezer and use a duct section to direct the ice into the storage bin 4 Accessories Installation on Ice Storage Bins Rapid Freeze Ice Flakers are designed to run smoothly and without vibration The machines are usually mounted directly on top of an insulated ice storage bin The storage bin must have an insulated top with a drip pan that
33. ater tube 100 1 Water tube insulation E100H2 Water tube valve brass nipple Water tube regulating valve Water pump 230 460 3 50 60 Water pump 220 230 1 50 60 Drive motor 208 230 460 3 50 60 1 HP O D P Drive motor 115 230 1 50 60 HP 1 HP O D P Drive motor 208 230 460 3 50 60 1 HP TEFC Drive motor 220 380 3 50 TEFC Drive Motor 208 230 1 60 1 HP TEFC Drive Motor 110 200 220 1 50 1 HP TEFC Drive motor 220 380 3 50 O D P 65 66 67 Flexible coupling complete PART DESCRIPTION Water distribution bottom spout amp fitting Item No 37 amp 38 40 pl al gt BR S NI 33 5 A 35 57 gt 75 Number in parentheses indicates quantities if more than one is required T 10 Parts List Table 3 Electric Panel Parts Part Description Part Number Parts for E20T40 Control Panels Control transformer 230V AC primary 24V AC secondary E20T31 Solid state control module E20T48 Overload reset button normally open E20T23 ON OFF rocker switch E20T24 4 pole contactor 24V AC coil for drive motor E20T44 230V AC single pole double throw relay E20T45 Relay base socket for E20T45 relay E20T46 Parts for E20T42 Control Panels 380V 3 50 CE mark Disconnect switch DSC1 E20T53 Drive motor starter with overload M1 M1 DSC E20T54 Pump motor starter
34. ausing contacts 21 amp 24 R1 To open which initiates the off delay time period Opening of contacts R1 causes liquid line solenoid valve to de energize and close After set time 20 minutes contacts TR1 open de energizing ice flaker contactor Ice flaker is off and flaker run light green is off 25 5 Maintenance Control Panel Layout Figure 8 E20T40 RL Exterior Panel Layout Remote Low Side Ice Flakers 2 ICE FLAKER ICE MAKER Gua Orem fuse fO BESE FLAAEA HO wie 1 On Off Switch Main On Off switch for the control circuit This switch is wired in series with the optional field installed switch and the photoeye ice level control 2 Ice Flaker Run Light Green light is on whenever the contactor and drive motor are energized 3 Motor Overload Light Amber light is on whenever the electronic overload opens stopping the drive motor and water pump 4 Overload Reset Button Normally open reset button resets overload circuit following overload condition 26 D 2 3 4 5 6 7 8 5 Maintenance Figure 9 Ice flaker Control Panel Interior Layout ARA KG CSC Motor Contactor Provides power to the drive motor and water pump Energized during freezing and pump down cycle then timed off for shut down Auxiliary contact provides power to the liquid solenoid valve when the contactor is energized Control Transformer Provides 24V contr
35. contacts are open replace the control module 36 Problem 6 Troubleshooting Possible Cause Remedy There is a wiring Close all switches remove wires from defect terminals 7 and 8 on the control module With voltmeter set to ohms check for continuity between terminals 7 and 8 If contacts are closed check the line A jumper CR contacts wiring and solenoid coil 4 Drive motor is always a ON OFF switch is Replace ON OFF switch on defective b Photoeye controls Check per 1 d 1 f above 5 Solenoid valve is always energized 6 Ice maker does not shut off when bin is full a Photoeyes are not Control module is are defective defective installed Replace control module Install photoeyes per instructions on page 16 Photoeyes are defective Check per 1 d 1 f above 7 Drive motor cuts out on overload a A speed reducer gear is worn or broken Repair or replace the speed reducer Electronic overload is set too low Check amp draw on drive motor If amps do not exceed the nameplate rating adjust the potentiometer on the control module clockwise until flaker operates properly Turn potentiometer counter clockwise just to the point that the overload trips then turn potentiometer clockwise 1 8 turn e Thermal overloads Ice blade is may be improperly sized dragging on the drum Check ratings and insta
36. d reducer 60 cycle 926MDVD 600 1 E20R4 Speed reducer 50 cycle 926MDVD 450 1 E20R3 75 Handhole cover removable E10A3 75a Handhole cover boltdown E10A5 Thermostatic expansion valve R 502 R 404a SRE 4 C SSE 6 C HIM valve balanced port BFRE C Z BSRE 7 Thermostatic expansion valve R 22 SVE 4 C SVE 5 C Thermostatic expansion valve balanced port R 22 BFVE B Z BFVE C Z Liquid line solenoid valve B6S1 1 2 B14S2 Control panel 230 1 60 2 light E20T40 RL Control panel 230 1 60 6 light E20T40 SCA Replacement rib heater element 3 HT150 240 037 50 Number in parentheses indicates quantities if more than one is required 74 10 Parts List Cross Section Drawing 5 10 ton flaker IL 66 28 SIS 8 4 80 12 N N N 22 N N N o IS 2 5 KIS SG AA rr 0900004 25254 7 SS SIS e KS eS 5 Y 9 PR o 25 Number in parentheses indicates quantities if more than one is required 75 10 Parts List 100E 101E TABLE 4 Replacement Parts for Models Listed to Right 50EA 50EAR 75EA 75EAR 100EA 100EAR PART NUMBER E50J2 PART DESCRIPTION Insulated lug spacers 8 Item No 3 5001 E75D1 E100D1 Main shaft Shaft sleeve E50D2 Top ice blade 2020 L 122 L 202 L E30E3 E20E2 E30E3 Nuts Bolts amp washers top ice blade 0 5 20
37. ducer Some speed reducers are equipped with a grease fitting to lubricate the bearing on the top slow speed gear This bearing must be lubricated greased every six months with standard bearing grease not food grade The oil in a new speed reducer should be changed at the end of 250 hours of operation Under normal conditions after the initial oil change the oil should be changed after every 2 500 hours or every six months whichever occurs first Periodic examination of oil samples taken from the unit will help establish the appropriate interval When operating the ice flaker in low ambient temperatures colder than 50 F synthetic oil should be used in the speed reducer Rotary Ice Harvesting Blade 20 ton models The rotary ice blades must be greased every 3 months The grease fitting is located on the bottom of each blade assembly Use food grade grease add grease until it starts to come out of the vent on the blade near the top Preventative Maintenance The ice flaker should be visually checked daily by a designated employee This inspection should ensure that e Photo eyes and brackets are in proper alignment e Ice quality size of ice flakes appears normal e Ice quantity appears normal e No bubbles are visible in the sight glass e The flaker is clean e No unusual noises are present When these items are checked on a daily basis any change will be easily detected prior to any service call for a malfunction of t
38. e and evaporator surface to between 0 004 and 0 006 at the top and bottom of the blade Tighten the blade mounting bolts and re check clearance Bearing Replacement Small Capacity models 2000 6000 pound 1 Turn the ice flaker off and pump down until all ice is removed from the evaporator 2 Shut off main disconnect and lock out power 3 Remove the speed reducer and drive motor from the machine refer to instructions on page 46 4 Remove the bottom half of the flexible coupling Remove the rivets that retain the outer stainless steel insulation jacket around the ice flaker Remove the stainless steel jacket 6 Cutaway the upper 3 of insulation from the evaporator uncovering 4 cap screws that bolt the upper aluminum casting to the evaporator through four lugs welded to the evaporator 7 Remove the 4 cap screws 8 Using a rubber mallet gently tap the aluminum casting from below upward to free it from the evaporator 9 Liftup the aluminum casting and slide it off the main shaft 49 7 Service amp Adjustment e CAUTION kkk RETAIN ANY SHIMS THAT MAY BE FOUND BETWEEN THE TOP CASTING AND THE BOLTING LUGS THESE SHIMS ENSURE THAT THE TOP CASTING IS PROPERLY ALIGNED ON THE EVAPORATOR WHEN RE ASSEMBLING THE TOP CASTING THESE SHIMS MUST BE PLACED BACK IN THE SAME LOCATION AS WHERE THEY WERE ORIGINALLY INSTALLED FAILURE TO DO SO WILL RESULT IN THE MAIN SHAFT BEING MISALIGNED AND MAY RESULT IN EXCESSIV
39. e Bin Thermostats 17 Rib Heating Blements eene ie 17 6 Stare amp 19 Checklist ien 20 7 Electrical Systems A 23 Control Panel Layout it eee sete e e tenete 24 Control Module ui e teet 28 8 MAINTENANCE RR 29 Ice Machine Cleaning Instructions 30 9 Pr oublesh otIne u P EC 35 COCOA 36 Freezing and Refrigeration ess csc idee e 37 Ice Storage and Removal mii a 39 Speed de e be ete Reste ie tete 40 10 Service amp Adjustmerit TRINA 41 Replacement of Photoeye Ice Level eene enne 43 Replacement and Adjustment of Ice Deflector nas 43 Replacement and Adjustment of the Ice Deflector Scraper 44 Replacement and Adjustment Of The Squeegee amp Squeegee Wrapper 44 111 Replacement Of Water Ete e eee 45 Replacement Of Drive Motor esos loci etae de tegit ee 45 Replacement Of Speed Reducer and Flexible Coupling eene 46 Replacement and Adjustment Of Water Float 47 Replacement of Solenoid n detener ette oec ette ete terne talea 48 Replacement and Adjustment
40. each corner of the drip pan on the ice bin Step 3 Lift ice flaker over the wood blocks position ice drop zone over the bin top opening then set the flaker on the blocks Step 4 Remove forklift Step 5 Stack the two 36 long 2 X 4 s on the side of the bin beside the drip pan overlapping the front and back of the bin Step 6 Using a pry bar as a lever on the 2 X 4 s raise the side of the flaker and remove the TOP blocks only Step 7 Repeat steps 5 amp 6 on the other side Step 8 With the flaker sitting on one 1 block under each corner repeat steps 5 6 amp 7 removing the remaining blocks Drip pan flanges MAY bend slightly Step 9 Straighten the drip pan flanges if necessary 4 Accessories Figure 2 Ice Flaker Installation CONTROL PANEL REMOTE LOW SIDE FLAKE ICE MACHINE ELECTRIC JUNCTION BOX WOOD BLOCKS 2 EACH CORNER Water Supply amp Filter Connections WATER LINE Connect a 1 2 galvanized or 1 2 ODS COPPER water pipe from the closest convenient water line to within 2 to 4 feet of the ice flaker water sump Install a water line shutoff valve near the ice flaker Use copper tubing between water valve amp water inlet connection located on water sump Refer to the engineering sheet for the line size connection from the ice flaker sump to the water supply line If water supply has silt or sand in it a coarse water filter is recommended 10 4 Accessories CAUTION
41. eck the clearance on the ice blade see page 49 for details If the ice blade clearances cannot be adjusted to within specifications contact the factory 25 Re install the flexible coupling speed reducer and drive motor 26 Remove power lockout and turn the flaker on Check rotation and amp draw prior to opening the liquid solenoid valve 27 Energize the liquid solenoid valve and allow the machine to begin making ice 28 Discard the first half bin of ice Clean and sanitize the storage bin prior to using ice for consumable products 50 7 Service amp Adjustment Bearing Replacement Large Capacity models 10 000 40 000 pound models Bearing replacement on large capacity machines is accomplished without removing the shaft from the flaker Turnice flaker off and pump down until all ice is removed from the evaporator 2 Shut main disconnect off and lock out power 3 Remove speed reducer and drive motor from machine leave flexible coupling on until later The flexible coupling will help to keep the shaft from dropping when the bottom bearing retainer is removed 4 The bottom bearing retainer and bottom bearing cover are attached to the bottom casting via 4 5 16 bolts Remove the 4 bolts from the cover amp retainer Once the bearing cover is removed you will see the bottom bearing retainer and the end of the shaft There are two threaded holes on the retainer install two of the removed bolts into these threaded hole
42. eezing drum operating at 5 F is located directly over the ice drop opening in the bin This large opening permits cold air to cascade off the evaporator down into the bin Since the air temperature in the bin is equal to or lower than the ice temperature the set point of the thermostat cannot be adjusted with sufficient accuracy to distinguish temperature difference upon contact with the ice Use of a bin thermostat for level control will void the product warranty Rib Heating Elements Rapid Freeze ice flakers are designed to operate in ambient temperatures between 50 F 10 C and 100 F 38 C When operating in ambient temperatures between 50 F 10 and 45 F 7 C rib heaters must be installed on the ice flaker Under no circumstances is the machine to be allowed to operate in ambient conditions below 45 F 7 C 4 Accessories Factory installed rib heaters are available on all sizes and configurations when ordered with the ice machine These heaters are installed in the three ribs on the bottom casting inside the evaporator section of the ice flaker These heaters warm the ribs and water return trough to prevent the accumulation of ice inside the evaporator General Purpose ice flakers 1 000 6 000 Ib day cannot be retrofitted with rib heaters if they were not installed at the factory Carefully consider the installation conditions prior to ordering the ice flaker to ensure that all necessary equipment is furnished
43. er the surge drum through the ammonia lp float valve The dual pressure regulator solenoid mounted on the suction line will also be energized When this solenoid valve is energized the evaporator pressure is regulated 12 9 psig assuming the suction pressure on the system side of the regulator is lower During shut down When the ice flaker is shut down both the liquid line solenoid and the dual pressure regulator solenoid are de energized The liquid line solenoid positively stops liquid from entering the surge drum and evaporator while the dual pressure reg will switch to the higher setting which is 75 psig Pressure in the surge drum and ice flaker will rise as the ice flaker warms up When pressure reaches 75 psig the dual pressure regulator opens relieving pressure into the suction line Even in the event of a power failure the dual pressure regulator will act as an internal relief valve burping into the main suction line whenever the ice flaker surge drum and evaporator pressure builds to 75 psig Dual Pressure Regulator for ammonia ice flakers The dual pressure regulator has two settings for pressure regulation The first setting is for normal operating conditions will be set for approximately 12 9 psig allowing the evaporator to operate at 5 F to 10 F depending on the model of the ice flaker The evaporator will operate at this temperature when the solenoid valve on the dual pressure regulator is energized The sec
44. erform the following functions 1 Close shut off valve on outlet of manifold Close shut off valve on inlet of manifold Release bottom manifold from quick disconnect fittings on filters Reverse direction of filters on manifold system Re attach bottom manifold to filters Open flush valve on bottom manifold and put flush hose into bucket or drain ee qe Open shut off valve on inlet of manifold and accumulated dirt will be flushed out of filter SAT x 5 Maintenance 8 Close shut off valve on flush hose and open outlet valve on manifold The pressure in the system should now be operational for use Note If pressure does not return to normal zone on gauges reverse the filters and re perform functions 5 through 8 When the pre filter element in the clear pre filter housing becomes discolored this is the indication that it needs to be replaced Lubrication Bearings amp Seals Main bearings on the ice flaker should be greased every three months using FDA approved food grade edible grease The grease fittings are easily accessible from the front of the flaker the top bearing is lubricated through a grease fitting accessible through the inspection service opening the bottom bearing is lubricated through a grease fitting on the outer edge of the bottom casting NOTE One pump of a grease gun is normally adequate to grease the bearings Do not over grease as this may damage the grease seals at the bearings Speed re
45. everse the above procedure Use caution when routing the new cables to insure they are secured to avoid accidental damage Replacement Of Drive Motor 1 Disconnect main power to the ice flaker Remove electric wiring cover on the drive motor Remove the power leads attached to terminals marked L and Refer to Figure 11 The drive motor is attached to the gearbox with 4 bolts through the motor mounting plate Remove the 4 bolts The motor may be removed by pulling it away from the gearbox There are no setscrews or couplings the motor shaft fits directly into the hollow high speed input shaft on the speed reducer with a key If the old motor cannot be removed easily then locate two threaded holes on the motor mounting plate They will be on the horizontal centerline one on each side of the input shaft Insert one of the mounting bolts into each threaded hole so they push against the drive motor you may have to rotate the motor housing so the bolts can press against the mounting lugs on the 45 7 Service amp Adjustment motor making sure the bolts do not thread into the mounting lugs Turn both bolts until they are hand tight and then turn each bolt alternately 1 2 turn at a time until the motor is free enough to remove by hand 3 When installing the new motor place the 14 key on the shaft lightly grease the surface of the motor shaft and insert in the hole on the high speed input shaft keeping the keyway
46. f this manual is prohibited without prior written permission of Howe Corporation except as allowed under the copyright laws Howe Corporation 1650 North Elston Avenue Chicago IL 60622 Phone 773 235 0200 Fax 773 235 0269 e mail howeinfo howecorp com web www howecorp com Revision date October 2005 1 TABLE OF CONTENTS PAN NAN TG 2 nn AA AA 1 Introduction to the 2424 Freeze Ice Flaker a aaaannnansssssssssssssssssssssssssssa 2 Important Safety Information J 4 Safety Symbols and What They Mean eene nnne enne 4 3 Receiving and Inspection of Equipment 5 4 Installation of Rapid Freeze Flaker 7 Installation onditions enint aie e e eL be o e e pedea 8 Installation without ice hiiii 8 Installation on Ice Storage 9 Recommended Installation Method on Ice 9 Water Supply amp Filter Connections nseni n a a a e a i E 10 Wiring amp Electrical Connectiossssss 13 Piping Connections uo temen daten ege IN NADA e teens 13 S uu SONICS MT 16 Electric Bye Ice Level Control ie RR geriet e La 16 Installation Instructions for Photoeye Ice Level 16 Ic
47. he machine 5 Maintenance Preventative Maintenance Schedule 3 months 12 months Clean ice machine Check ice harvesting Clean electric eyes amp check alignment Inspect flaker for damaged parts Inspect squeegee Inspect water float valve Inspect deflector scraper Grease top amp bottom bearings Grease bearings on rotary Harvest blade 20 ton models X X X X X X X X X Check and replace speed reducer oil standard oil Check and replace speed reducer oil synthetic oil Grease speed reducer bearings 1 Sanitize ice machine Check bearing wear gt gt gt gt x lt Check cutting blade clearance Check oil level in oil pot and drain ti Check rib heaters for proper operation if furnished Replace squeegee As necessary Replace deflector scraper As necessary Replace water float valve As necessary Clean and sanitize at least annually more frequently if necessary Inspection should include at a minimum the following parts ice deflector deflector scraper squeegee squeegee wrapper water distribution tubes and float valve Speed reducer oil should be changed every 2 500 hours of operation 5 000 hours with synthetic oil or every six months whichever
48. ided that three 3 electric rib heaters available from the factory are installed to heat the bottom casting to prevent ice buildup on the three supporting ribs for the bottom bearing If installed in cold ambient conditions it is advisable to supply the ice flaker with warmer water through a water mixing valve around 60 F 15 C When a combination of cold water and cold air temperature exists the mixing valve and rib heaters must be used Failure to do so will cause the lower water collecting trough and sump to plug up with ice to the extent that the water may overflow into the ice storage bin in addition to blocking the water inlet to the pump Also it is advisable to direct air blowers and fans away from the ice flaker as air velocity over the ice flaker will reduce the effectiveness of the heaters CAUTION ES NEVER INSTALL AN ICE FLAKER IN A COLD ROOM 45 F 7 C OR LOWER THE ICE FLAKER WARRANTY IS VOID IF THE ICE FLAKER IS INSTALLED IN A COLD ROOM OR OUTSIDE WHERE THE AMBIENT TEMPERATURE MAY DROP BELOW FREEZING CAUTION Optimum surrounding air temperature range 60 F 15 C to 95 F 35 C Minimum air temperature without heater 50 F 10 C Minimum air temperature with heater 45 F 7 C Maximum air temperature 100 F 38 C Optimum water temperature range 60 F 15 C to 80 F 25 C Minimum water temperature without water mixing valve 45 F 7 C Minimum water temperature w
49. ll properly sized overloads if necessary Readjust the clearance on the ice blade as specified on page 49 8 Drive motor runs but main shaft only turns when there is no ice on the drum a The woodruff key on the slow speed output shaft of the speed reducer has sheared Repair or replace the speed reducer Freezing and Refrigeration 1 Ice freezes along entire length of drum but harvests only on the upper half a System is short of refrigerant Charge system until there are no bubbles in the sight glass Superheat setting is too high Open the hand expansion valve 1 4 turn at a time until ice is harvested over entire evaporator Wait 10 15 minutes between adjustments to allow the system to balance Problem 6 Troubleshooting Possible Cause Remedy d Head pressure is too low Adjust or replace head pressure controls as necessary e The liquid line filter drier is dirty Replace the filter drier 2 Ice freezes and harvests entire height of evaporator but harvests on only one side of the drum 3 Ice freezes and harvests entire height of evaporator but harvests poorly or at random a Main bearings are worn Replace worn bearings Repair or replace main shaft is excessive wear is detected b Ice blade clearance is too high Check and adjust blade clearance as necessary e Top casting was misassembled
50. nd at the main shut off disconnect Cover or remove any ice that may be present in the ice storage bin 2 Open the front cover of the flaker control panel Locate the 11 pin mounting base for the photoeye control module If the control module is installed in the base unplug the control module 3 Mount the photoeye emitter If the storage bin top was supplied by Howe there will be recessed pockets in the bin top for placement of the photoeye elements If pockets are not present mount the emitter securely to the top or side wall of the bin and align the emitter so that it projects its beam directly across the ice drop opening 4 Locate the photoeye receiver Again if the storage bin top was supplied by Howe there will be recessed pockets in the bin top for placement of the photoeye elements If pockets are not 6 4 Accessories present mount the emitter securely to the top or side wall of the bin and align the receiver so that it is directly across the ice drop opening from the emitter DO NOT permanently affix the receiver Leave enough adjustment to ensure proper alignment with the emitter 5 Run the long cables through one of the knockouts furnished on the side of the control panel 6 Connect the wires to the control module base as shown in Figure XX NOTE If a wire jumper is installed between terminals 5 amp 6 it must be removed for the photoeye controls to operate properly 7 Plug the control module into the base
51. ns below for complete cleaning instructions Ice Machine Cleaning Instructions An important part of ice flaker maintenance is to clean it frequently so that the water passages are not clogged and the freezing surface is clear and free of scale caused by calcium and iron deposits Frequency of cleaning depends upon the quality of water In extreme hard water areas it may be necessary to clean the flaker as often as every 2 months whereas in normal or soft water areas twice a year may be sufficient When cleaning is necessary proceed as follows 1 Turn off refrigeration compressor If flaker is connected to a compressor rack close the liquid line shut off valve Turn off the ice flaker switch and adjust the off delay time adjustment fully clockwise Remove all ice in storage bin Close water supply shut off valve Uno e 1937 Drain water from the drain connection in water sump Some models are equipped with a drain valve others have a drain plug located below the water float valve connection 6 Prepare the cleaning solution following the instructions on the bottle KKK CAUTION USE APPROVED ICE MACHINE CLEANERS ONLY MIX SOLUTIONS IN ACCORDANCE WITH THE MANUFACTURER S INSTRUCTIONS ICE MACHINES CLEANERS CONTAIN ACIDS WHICH MAY CAUSE BURNS HANDLE WITH CARE IN CASE OF EXTERNAL CONTACT FOLLOW FIRST AID INSTRUCTIONS ON THE BOTTLE IF SWALLOWED SEEK IMMEDIATE MEDICAL ATTENTION CAUTION ES 7 P
52. nsing unit indicator lights not applicalble for ammonia ice flakers 11 On Off Switch Terminals Terminals for installing a remote On Off switch or auxiliary control such as a 7 day clock timer or remote modem These auxiliary controls must be wired in series with the panel mounted On Off switch and factory wired photoeye ice level control so that all three switches must be closed to start the machine but opening amy switch will shut the machine off 12 Photoeye Terminals Terminals for installing photoeye level control emitter and receiver Control Module The E20T48 control module is the main processor for the ice flaker control panel It incorporates the timer functions control relay functions and overload relay functions Motor Overload Adjustment Adjusts the sensitivity of the motor overload protection device Set at factory Adjust only if the motor shuts off on overload and there is nothing preventing the motor from turning ice collecting in the evaporator very soft ice seized bearings etc Off delay Timer Adjustment Sets the delay between turning the flaker off closing the solenoid valve and shutoff of the motor and water pump Factory set Adjust only if ice is still present in the evaporator when the motor and water pump shut off or if the motor and water pump operate for an excessive period of time after the evaporator stops freezing the feed water Terminal Description Number 1 24 V AC input power
53. nt kit includes bearing 2 25a seals shaft sleeve G200K6 1 seal shaft sleeve G200K7 a 26 26a 27 44 Water float valve fitting G200P2 57 Water tube regulating valve 2 G200P3 62 Water pump 230 460 3 50 60 G200Q1 Number in parentheses indicates quantities if more than one is required 82 10 Parts List Model 200G 201G TABLE 5 Replacement Parts for Models Listed to Right aus Part Description Part No Drive motor 220 380 3 50 TEFC G200M2 63a Drive motor key G200M3 65 66 67 Flexible coupling complete G200N1 6 Flexible coupling key for shaft G200N2 06 Speed reducer 60 cycle G200R1 Number in parentheses indicates quantities if more than one is required 83
54. of the Hand Expansion Valve 48 Replacement and Adjustment of Ice 49 Bearing Replacement norte ate e eet 49 11 Appendix A Ice Flaker Drawinss 53 12 Appendix B Wiring Diagramss 64 13 Appendix Parts 70 IV 2 Introduction 2 Introduction 2 Introduction The Rapid Freeze by Howe ice flaker is backed by over 50 years of proven performance and innovation Long known for durability and reliability our flake ice equipment is unsurpassed in energy efficiency and low maintenance Available in a wide variety of sizes and configurations the rugged Rapid Freeze flaker can be found in diverse applications from supermarkets and food processors to remote fishing villages Introduction to Zagid Ice Flaker Refer to Figure 1 for a guide to the major components of the Howe ice flaker Among the key features are Evaporator The heart of the Howe ice flaker is the carbon steel flooded evaporator The carbon steel construction provides exceptional heat transfer properties while the hard chrome lining provides a clean sanitary corrosion resistant freezing surface Ice Blade An investment cast stainless steel ice blade removes the ice
55. ol power to the control panel components control module motor contactor and indicating lights Control Module Main control processor Incorporates motor overload operating circuit and off delay circuit Controls motor contactor and solenoid valve power Photoeye Power Module Processes signals from electronic eye level control with built in time delay Shuts machine off when ice bin is full to prevent damage to the flaker due to ice backing up into the evaporator L1 L2 L3 Terminals Main power terminals for field wiring electric power to control panel Single phase standard power is wired to L1 and L2 Three phase power is wired to L1 L2 and L3 T1 T2 Motor Pump Terminals Terminals for wiring drive motor and water pump May be factory or field wired Solenoid A1 A2 Terminals Terminals for field wiring liquid solenoid valve wires Heater A1 A2 Terminals terminals for field wiring electric rib heater wires 27 5 Maintenance 9 A B Terminals Terminals for providing Line 2 power to solenoid valve On models with condensing units wired through compressor safety switches high discharge pressure and high oil pressure to assure liquid solenoid valve will de energize if the compressor shuts down on a safety failure When connected to a refrigeration rack or ammonia system a wire jumper is placed between line A and line B in the flaker control panel 10 Terminals 1 8 Terminals for field wiring conde
56. ond setting which actually acts as an internal relief valve is set at 75 psig which will burp excess pressure in the evaporator and surge drum into the suction line so the internal pressure of the evaporator will never exceed 75 psig The safety relief valve set E 150 psig to atmosphere is ultimate safety required by code 24 5 Maintenance Electric Control Panel Operation Ammonia Start Sequenc q e 1 2 3 4 When on off selector switch is manually turned the on position the following events occur to start the ice flaker system provided the optional photo electric eye is calling for ice Relay 1 is energized causing contacts 8 amp 6 R1 to close and contacts 3 amp 1 R1 to close Closing of contacts 21 amp 24 R1 causes off delay timer to reset and will close contacts TRI N O T O Ice flaker contactor is energized and drive motor and water pump start provided overload holding contacts M1 MP M2 MP are closed indicating overload condition does not exist and ice flaker run light green will light When ice flaker contactors are energized auxillary contacts M1 M2 R1 close thereby energizing liquid line solenoid valves Liquid line amp Dual Pressure regulator Stop Sequence 1 2 56 When selector switch is manually turned to off position or if the ice level control is satisfied the following events occur to stop the system Relay R is de energized c
57. our solution of ice machine cleaner into sump to normal operating level Do not overfill as the water may overflow into the ice storage bin 8 Start the ice flaker drive motor and water pump by turning the switch on then immediately off This will allow the gear motor amp water pump to run for approximately 30 minutes with out refrigeration to circulate cleaning solution over the freezing surface and all water passages Operate until all scale is removed This may require from half hour up to 2 hours if scale build up is heavy 9 When system is clean drain cleaning solution and rinse with 2 or more complete rinses to insure that cleaning solution is flushed away thoroughly At each rinse fill sump with fresh water and run drive motor and water pump for 10 minutes then drain 30 5 Maintenance TO SANITIZE 10 Mix a solution of approved sanitizer or mix 16 oz of household bleach with 2 gallons of warm water 90 115 F 11 Pour solution into sump to normal operating level as in 7 above then re circulate sanitizing solution for approximately 20 minutes by turning on drive motor amp water pump 12 Drain solution and rinse thoroughly with fresh water at least twice following procedure described in 9 above 13 After ice flaker is thoroughly rinsed return machine to normal operation by opening water supply valve readjusting off delay timer setting to previous set point restoring refrigeration and turning the m
58. pan assembly includes distribution E20H40 _ tubes and fittings plastic 36a Water distribution pan assembly includes distribution E30H9 tubes and fittings metal Water distribution bottom spout and fitting for plastic E20H38 P _ 37 38 Water distribution bottom spout and fitting for aluminum E20H38 pan 39a Water sump assembly includes water pump E10H31 E30H7 Water sump gasket E202 42 Water sump silicone adhesive E20J6 Number in parentheses indicates quantities if more than one is required 299 10 Parts List 4000 RL 6000 RL Item No Part Description Part Number 43 Water float valve E10H29 E50H18 44 Water float valve fitting CNB BR02 06 CNBHF SG BR08 53 Water tube E20H30 E30H3 54 Water tube insulation E20H14 E30H4 55 Water tube grommet E20H19 56 Water tube fitting 2 ELM CT NY 10 08 57 Water tube regulating valve E20H24 60 Water tube sleeve E20H12 61 Water sump screen E20H13 Water pump 230 1 60 E10H32 Water pump 115 230 1 60 E30Q1 Drive motor 115 230 1 60 1 3HP 1 2HP ODP E20M1 E30MI Drive motor 110 220 1 50 1 2HP ODP E30M3 63 Drive motor 208 230 460 3 50 60 1 2HP E20M2 Drive motor 230 1 60 1 2HP TEFC E30M2 Drive motor 380 3 50 1 3HP TEFC E20M5 63A Drive motor key E20M8 65 66 67 Flexible coupling complete E20N9 67A Flexible coupling key for shaft E20N10 Spee
59. porator Water Regulating Valve p Water Pump Water Return Trough Bearing Bottom 2 Introduction Important Safety Information The information found in this manual is intended for use by individuals possessing adequate backgrounds of electrical refrigeration and mechanical experience Any attempt to repair or make alterations to this equipment may result in personal injury or property damage The manufacturer or seller cannot be responsible for the interpretation of this information nor can it assume any liability in connection with its use Safety Symbols and What They Mean Please read and understand this manual prior to installing or operating this Rapid Freeze ice flaker You must be completely familiar with the start up operation and service of this flaker before you attempt to start operate or adjust this piece of equipment The following safety symbols will alert you to any special precautions throughout this manual DANGER BEWARE OF HAZARDS THAT CAN RESULT IN PERSONAL INJURY DANGER WARNING DO IT RIGHT OR RISK SEVERE PERSONAL INJURY FOLLOW INSTRUCTIONS CAREFULLY WARNING CAUTION RISK OF PERSONAL INJURY OR DAMAGE TO EQUIPMENT FOLLOW INSTRUCTIONS CAREFULLY CAUTION 3 Receiving and Inspection of Equipment J Receiving and Inspection of Equipment 3 Receiving and Inspection of Equipment Upon receipt of your Rapid Freeze ice flaker you should fir
60. r clearance before re installing the drive assembly 13 Re install the flexible coupling gearbox and drive motor 14 Remove power lockout and turn flaker on Check rotation and amp draw prior to opening the liquid solenoid valve 15 If all seems to be in order open energize the liquid solenoid valve and allow the machine to start making ice 16 Discard the first bin 2 bin of ice and clean amp sanitize the bin prior to using ice for consumable products aT 7 Service amp Adjustment 289 2 8 Ice Flaker Unit Drawings 8 Appendix A Ice Flaker Drawings 8 Ice Flaker Unit Drawings Assembly Drawing 2000 3000 amp 4000 RLA AMMONIA LIQUID FLOAT VALVE ICE SIZE FOR ORIF SEE TABLE BELOW Figure 12 C DIA DPENING TO ICE BIN MOUNTING HOLE USE 172 TYP SCREWS 6 MINIMUM FOR SERVICE WATER PUMP AMMONIA LIQUID INLET EITHER SIDE TO COMPR L Ice Flaker Information Connection Sizes Dimensions Surge Float Inches Refrigeration Drum Valve Requirement p H J w DxL Orifice suction Liquid Retier Water Q 5F Drain Inlet INCHES FPT FPT FPT FPT OD BTU HR 2000 RLA 14 41 34 8 Y 29 Ya 8 5 8 x 24 3 32 1 1 2 Y 1 2 3 8 18 000 3000 RLA 14 41 38 Ya 8 29 Ya 8 5 8x 24 3 32 1 Y Y Y 3 8 27 000 4000 RLA 18 45 43 10 31 8 5 8 x 24 3 32 11 4 Y 1 2 Y 3 8 36 000 54 8 Ice Flaker Unit
61. refrigerant loss Line Insulation After the final leak test refrigerant lines should be insulated to reduce heat pick up and prevent the formation of flash gas in the liquid lines Suction lines should insulated with 24 wall Armstrong Armaflex or equal Liquid lines should be insulated with 42 wall insulation or better Insulation located in outdoor environments should be protected from UV exposure to prevent deterioration of the insulation 15 4 Accessories 4 Accessories Electric Eye Ice Level Control The use of a suitable ice level control to shut off the ice flaker when the storage bin fills is mandatory Failure to use the proper ice level control will cause the ice to build within the ice flaker evaporator after the bin is full to capacity Operating the flaker with a full bin will cause the ice deflector to bend or break as it churns the ice In extreme cases it may result in damage to the speed reducer and or the electric drive motor and flexible coupling The proper and approved bin level control is the photoelectric eye When ordered with the machine the eyes are mounted on brackets that will attach to the bin top or wall The cables are routed through the bottom casting of the ice flaker The power module is mounted inside the ice flaker control panel Figure 5 Electric Eye Ice Level Control Installation Instructions for Photoeye Ice Level Controls 1 Turn off the ice flaker at the control panel a
62. regulating valve to set level in the distribution pan to half full Replace as necessary The lead water tube may be splashing water into the bin Adjust lead water tube as necessary Condensate drip pan is leaking into the storage bin Repair or replace drip pan Humidity level in storage bin is too high e Check and repair bin insulation as necessary e Check and repair seals on the bin e Bin door has been left open too long Close door when not removing ice 39 Problem 6 Troubleshooting Possible Cause Remedy 2 Ice in storage bin is too wet Speed Reducer Water level in the sump is too high causing water to overflow the return trough Adjust the water float valve to maintain water level approximately 4 below the return trough Water is overflowing the distribution pan One or more water distribution tubes is missing or broken e Distribution tubes may be plugged Clean or replace tubes as necessary e Level in distribution pan may be too high Adjust the water regulating valve to set level in the distribution pan to half full Replace as necessary 1 Oil is leaking between the front of the motor and the motor mounting flange High speed oil seal in the speed reducer is worn Replace seal 2 Oil leaking is evident on the top of the flexible coupling Slow speed oil seal in the speed
63. ription Part Number USDA approved bearing grease E20K6 Speed reducer oil natural SR OIL Speed reducer oil synthetic SR OIL SYN Replacement 20 micron water filter cartridge E10H43 Replacement 20 water filter pre filter core E10H46 Replacement 20 water filter pre filter housing cover blue E10H45 Ice machine cleaner E10V1 Number in parentheses indicates quantities if more than one is required 79 10 Parts List Rotary Blade Cross Section for 20 Ton Flaker TOP HEX HEAD BOLT BLADE CARRIER N TOP CAP CE 5 SEAL Ties ee EN BEARING ROTARY BLADE POLYETHYLENE ROD NA LITA BEARING Nal 2 N NY AN 2 ES 51 BOTTOM SS AGAR Number in parentheses indicates quantities if more than one is required 80 10 Parts List Cross Section Drawing for 20 ton ice flaker E EUA 1 3 oz le PATA y ESSI UA LZ 4 LI Number in parentheses indicates quantities if more than one is required 81 10 Parts List Model 200G 201G TABLE 5 Replacement Parts for Models Listed to Right Item No Part Description 11 12 12a 20 Main shaft bearings 2 G200K1 21 Bottom bearing thrust plate G200K2 22 amp 23 Main bearing grease seal 3 G200K4 25 Top main bearing retainer G200K3 Top bearing replaceme
64. s turning each one an equal amount to Ajacke the retainer out of its normal position on the bottom casting 5 When the retainer is removed the old bearing can be pressed out of the aluminum retainer 6 There is a stainless steel shaft sleeve between the shaft and the bearing the shaft sleeve will probably come off the shaft with the bearing and retainer If it did not then remove the sleeve from the shaft it is kept in place with only a keyway there is no set screw It will slide freely but rotate with the shaft 7 Press the new bearing into place it should be centered in the retainer 8 The new seals can then be pressed into place the auxiliary seal is placed inside the main seal 9 Place the new shaft sleeve on the shaft and install the bearing retainer with new bearing amp oil seals installed and bottom bearing cover Align the bolt holes with the threaded hole in the casting and re install the 4 mounting bolts taking care to tighten them equally so the retainer goes in straight 10 Remove the flexible coupling from the flaker shaft then remove the 4 5 16 bolts holding the top bearing retainer in place 11 Repeat steps 4 9 for the top bearing amp retainer removal the only difference is there is no bearing plate on the top bearing instead there are seals on the top and on the bottom of the bearing all seal are to be installed with the seals positioned to keep the grease ibn the bearing area 12 Rotate the shaft to check fo
65. se to the evaporator that the squeegee bends excessively This may cause premature squeegee wear and increase load on the gearbox and drive motor Tighten the nuts and bolts only till the lock washers lock Do not over tighten bolts as this may cause distortion of the squeegee wrapper and possibly cause premature squeegee wear Re install the water distribution tubes Remove all tools from inside the machine and re attach the service access cover Remove lockout device from the main power disconnect and turn on the main power Turn on the ice flaker switch you may need to press the overload reset button and check the squeegee to insure that it touches the evaporator on the entire circumference of the freezing chamber If the squeegee looses contact with the evaporator surface at any point then shut down the machine repeating the above steps to readjust the squeegee a little closer Replacement Of Water Pump Turn off the main power to the flaker Remove the screws securing the stationary sump cover Loosen and remove water tube fitting Nylon compression fitting Remove the cover from the electrical junction box ad disconnect the water pump wires from the terminal strip Lift the water pump with cover attached off the sump Remove the water tube hose and clamp Loosen and remove the four nuts holding the water pump onto the sump cover Remove the pump from the cover To install the new pump simply r
66. st inspect the carton very carefully to determine if any damage might have occurred during shipment If you suspect any damage has occurred it should be noted immediately on the freight bill In addition a written notice must be sent to the agent representing the freight carrier The written notice should request an inspection by the agent to verify damage during shipment If the damage was noticed after un crating of the carton it is necessary to keep the original shipping container so that the carrier s agent can investigate the damage claim thoroughly If a repair is necessary for the Rapid Freeze machine you must first obtain written permission from the factory before beginning any repairs Unauthorized work on your Rapid Freeze ice flaker could result in voiding the machine s warranty Immediately upon receipt of equipment before placement or installation of equipment verify the electrical and refrigerant configuration are correct as ordered If any discrepancies are found notify Howe Corporation immediately prior to any installation 4 Accessories 4 Installation of the Rapid Freeze Flaker 4 Accessories Installation Conditions Rapid Freeze Ice Flakers are designed to operate in ambient temperatures warmer than 50 F Do not install ice flaker s in refrigerated cold rooms or in areas where the ambient temperature is lower than 50 F 10 If it is unavoidable ice flakers may be installed in areas down to 45 F 7 C prov
67. sures that when the drive motor and water pump stop the evaporator will be free of ice If necessary adjust the off delay see page 28 for location Turn the ON OFF switch ON 17 18 19 20 21 5 Maintenance Verify operation of the photoeye level controls Block the path of the infrared beam After a built in 15 second delay the shutdown cycle will begin If the ice flaker does not begin shutdown adjust the photoeyes per instructions of page 16 Unblock the photoeye beam and verify that the ice flaker re starts immediately Adjust the electronic overload setting see page 28 for location Slowly turn the overload setting counterclockwise just to the point that the flaker shuts down on overload Turn the overload adjustment turn clockwise reset the overload device and re start the flaker This will insure that the drive motor is adequately protected but will not cause nuisance shutdowns Verify that the ice flaker is adjusted and producing dry flake of ice Verify that water is NOT dripping into the bin If it is locate the dripping point and correct it 1 distribution pan overflowing water recovery trough overflowing or distribution tubes broken or misaligned 22222 5 Maintenance 5 Electrical Systems 5 Maintenance Controls for Ammonia Ice Flaker During operation While the ice flaker is in operation the liquid line solenoid valve will be energized allowing liquid to ent
68. t ensures that all air and moisture has been removed from the system Failure to do so may result in compressor burnout 219 4 Accessories Wiring amp Electrical Connections CAUTION ELECTRICAL WIRING SHOULD BE PERFORMED BY QUALIFIED TECHNICIANS FOLLOWING LOCAL ELECTRICAL CODES CAUTION 5 The electrical control panel is supplied with remote low side RLA or RLR machines but is shipped loose to be mounted on the wall near the bin for easy access to controls To install control panel 1 Install disconnect not supplied by factory and connect main power to terminals marked L1 and L2 in the ice flaker control panel 2 Install optional on off switch to the two terminals designated On Off switch Remove wire jumper on these terminals if you are installing a remote switch 3 A jumper is installed between terminal marked Line A and terminal marked Line B This will enable the liquid line solenoid on the ice flaker to operate properly 4 Following local applicable electric codes wire the remote panel to the components drive motor water pump and solenoid valve on the flaker The drive motor and water pump should be wired to terminals T and respectively in the control panel The solenoid valve and dual pressure regulator are wired to terminals marked solenoid valve in the flaker control panel 5 Ifthe flaker has factory installed supplied photo eye ice level controls connec
69. t the long cables from the ice flaker to the relay base or terminal strip in the control panel The wires are color coded and must be connected to the proper terminals The BLUE leads from both the emitter and receiver cables connect to terminal 10 Blue terminal the BLACK lead from the receiver only connects to terminal 11 Black Terminal and the BROWN leads from both the emitter amp receiver connect to terminal 1 Brown Terminal Refer to Figure 15 on page 68 for electric eye wiring diagram WARNING LES THE SENSOR LEADS FOR THE ICE LEVEL CONTROLS MUST NOT BE RUN IN THE SAME CONDUIT AS THE MOTOR AND SOLENOID WIRES SENSOR WIRES MUST BE RUN IN SEPARATE CONDUIT 2 WA RNING Piping Connections When installing the ice flaker it is important that the flaker is properly piped as indicated below When connecting toa AMMONIA refrigeration system a dual pressure regulator valve must also be provided and installed on the suction line to regulate the evaporator suction temperature to between 5 F and 10 F 20 4 C to 23 2 C eda 4 Accessories Table 1 Flooded Ammonia Piping Connection Sizes Approximate 2000 RLA 3000 RLA 18 400 RLA 2 MET IE L 9 2 I0 RLA 24 EA Approximate MODEL Ammonia Liquid Suction Charge Ibs The ice flaker as supplied by Howe Corporation was thoroughly cleaned and dehydrated at the factory Foreign matter may enter
70. tabilize Repeat this step until ice is produced and harvested all the way to the bottom of the evaporator Replacement and Adjustment of Ice Blade Ice blade adjustment is not normally required except after bearing replacement If you suspect the blade needs adjustment because of excessive clearance it is more likely that the bearings have worn Do not try to adjust the blade clearance without checking for and correcting worn bearings When checking tolerances do NOT use automotive type feeler gauges Automotive types are too short and not flexible enough to give a true reading You MUST use industrial machine tool feeler gauges these are about 2 wide by 12 long These machine tool feeler gauges are available from the factory if you cannot locate them locally Clearance between the ice blade and the evaporator freezing surface must be between 0 004 and 0 006 with the evaporator at room temperature If it is determined that the ice blade clearance must be adjusted 1 Locate the exact position on the evaporator freezing surface where the clearance between the tip of the ice blade and freezing surface is the least Check clearance at the top and bottom of the blade s rotate the blade 60 degrees and check clearance again Repeat this operation at a minimum of six points around the evaporator to accurately determine the point of least clearance 2 With the ice blade rotated to the point of least clearance set the gap between the ice blad
71. the system by way of the field piping Therefore care must be used during installation of the piping to prevent entrance of foreign matter Install all refrigeration system components in accordance with applicable local and national codes in conformance with good practice required for the proper operation of the system The following procedures should be followed a Do not leave dehydrated equipment or lines open to atmosphere any longer that is absolutely necessary b Suction lines should be sloped 14 per 10 feet towards the compressor Pipes sized for normal runs up to 100 FT d Avoid excessive number of elbows bends in all refrigerant lines especially suction lines e Use SCH 80 steel pipe for all ammonia lines except suction lines 1 1 4 and larger may be SCH 40 14 4 Accessories Figure 4 Refrigerant Piping Support 1 Ensure that refrigerant lines are supported and fastened properly See Figure 4 for an example 2 When changing directions in a run of tubing no corner should be left unsupported Supports should be placed a maximum of 2 feet in each direction from the corner 3 Do not use short radius ells Short radius elbows have points of excessive stress concentration and are subject to breakage at these points 4 Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is significant Extra supports are relatively inexpensive as compared to
72. tic Model 200 RLR HA4AD 2 PDRT 2 SW FLGS 2 1 2 SW DUAL PRESS REGULATOR E DUAL RELIEF vith STERNER 230760 2 SET 368 amp 754 1 2 3 WAY VALVE HB021 3 HEADER de da 3 GLOBE S 3 GLOBE N A VALVE VALVE Q ry hh gt E XI gt SUCTION LINE A im 9 X2 REDUCERS cone VALVE 77 c LIQUID LINE 200 RLR N HS7 3 4 PURT 1 SWCorFPTFLGS ICE FLAKER SOLENOID VALVE WITH STRAINER 230 60 GLOBE VALVE gt V A 1 X1 2 HEX REDUCER 2 V TEE 1 2 FPT VALVE DRAIN 2 Notes 1 Required Refrigeration Capacity 30 TR 20 F Evap Temp 3 1 Ratio 4 1 Max 2 All pipe fittings valves amp controls beyond suction amp liquid flanges to be supplied by others for field piping 63 9 Wiring Diagrams 9 Appendix B Wiring Diagrams ing Diagrams Ut 9 Wi Figure 13 Ice Flaker Electrical Schematic 230 1 60 TOYINOD 09 t vz 9 09 1 0 Z SYOLOW 9 IANYA 09 1 02 HIMOd 09 022 802 10S1NOO Y3NV14 321 SLOWSY 72 07023 NOLLVHOdHOO 3MOH aasn SI CHO 31 Va LON LINN DNISNIONO NI AV T3H ONILVTOSI NV SI O 9 ONILV43dO Si 3NIHOVIN N3HM SATVA QION310S INIT ONON H3AAOd TIM 5 1 8 STVNINUZL N33AALJB IAM TIV1SNI NOA VINOWAV W3 LSAS NIYA 03143914434 TVULNZO Y OL
73. up from the bin into the freezing chamber or down from the top loosen and remove the two bolts holding the existing ice deflector in place Remove the damaged ice deflector through the bottom opening Position and bolt the new ice deflector to the shaft Tighten the bolts with the deflector adjusted to within 1 8 but NOT touching the evaporator surface or aluminum casting see Figure 10 below Re install the water distribution tubes if necessary Remove all tools from inside the machine and re attach the service access cover 43 7 Service amp Adjustment 10 Remove lockout device from the main power disconnect and turn on the main power 11 Turn on the ice flaker switch you may need to press the overload reset button and check the deflector to insure that it does not touch the evaporator or aluminum casting 12 If the deflector makes contact with the evaporator surface or aluminum casting at any point then shut down the machine and repeat the above steps to readjust the deflector Figure 10 Ice Deflector and Scraper Adjustment Replacement and Adjustment of the Ice Deflector Scraper The ice deflector scraper is mounted on one of the three bottom ribs using two stainless steel bolts and nuts The scraper s purpose is to clear any buildup of ice from the ice deflector as the deflector passes the scraper When properly positioned the scraper will be approximately 1 8 above the deflector blade see Figure 10 abo
74. ve When replacing the scraper it may be necessary to cut the angled edge to the proper size and angle This may be accomplished with either aviation snips or a razor knife Replacement and Adjustment Of The Squeegee amp Squeegee Wrapper 20 ton model does NOT have squeegee installed Shut off ice flaker and allow machine to pump down de ice Once the machine is clear of ice disconnect the main power to the ice flaker and LOCK THE DISCONNECT SWITCH IN THE OFF POSITION to prevent accidental start up 1 Remove the service access cover on the top casting 2 Remove 2 or 3 water distribution tubes for easier access 3 Reaching into the freezing chamber loosen and remove the two bolts holding the existing squeegee and squeegee wrapper in place 4 Remove the squeegee and wrapper assembly through the service opening If the squeegee wrapper is not bent out of shape or pitted with rust then you can remove the rubber squeegee from the wrapper and install a new squeegee in the existing wrapper 5 Reinstall the squeegee and wrapper assembly onto the mounting bracket in the freezing chamber hand tighten the nuts with the squeegee touching the evaporator surface then 44 10 11 12 7 Service amp Adjustment move the squeegee assembly approximately 1 16 to 1 8 closer to put pressure on the squeegee causing it to bend slightly so that it will drag on the evaporator surface Do not install the squeegee assembly so clo

Download Pdf Manuals

image

Related Search

Related Contents

CANflight User`s Manual V 1.1  

Copyright © All rights reserved.
Failed to retrieve file