AF 80 AF 100 AF 200 - Cold Control Services
Contents
1. WARNING This Ice Flaker is designed for indoorinstallation only Extended periods of operation at temperature exceeding the following limitations will constitute misuse under the terms ofthe SCOTSMAN Manufacturer s Limited Warranty resulting in LOSS of warranty coverage 1 Position the unit in the selected permanent location Criteria for selection of location include a Minimum room temperature 10 C 50 F and maximum room temperature 40 C 100 F b Water inlet temperatures minimum 5 C 40 F and maximum 40 C 100 F c Wellventilated location for air cooled models Clean the air cooled condenser at frequent intervals d Service access adequate space must be left for all service connections through the rear of the ice maker A minimum clearance of 15 cm 6 must be left at the sides of the unit for routing cooling air drawn into and exhausted out of the compartment to maintain proper condensing operation of air cooled models 2 Levelthe unitin both the left to right and front to rear directions D ELECTRICAL CONNECTIONS See data plate for current requirements to determine wire size to be used for electrical connections All SCOTSMAN icemakers require a solid earth wire All SCOTSMAN ice machines are supplied from the factory completely pre wired and require only electrical power connections to the wire cord provided at the rear of the unit Make sure that the ice machine is connected2. 4 Remove the top panels to gain access to the water reservoir 5 Remove the float reservoir cover and with a piece of copper wire jump the two water level sensors 6 Place a water pan under the freezer water inlet port disconnect the water hose from this port and allow the water from the freezer to flow into the pan previously positioned Then refit the water hose to the freezer water inlet port 7 Prepare the cleaning solution by diluting in a plastic container two or three liters of warm water 45 50 C with a 0 2 0 3 liters of SCOTSMAN Ice Machine Cleaner WARNING The SCOTSMAN Ice Machine Cleaner contains Phosphoric and Hydroxyacetic acids These compounds are corrosive and may cause burns if swallowed DO NOT induce vomiting Give large amounts of water or milk Call Physician immediately In case of external contact flush with water KEEP OUT OF THE REACH OF CHILDREN 8 Switch ONthe Master switchto startthe unit then pour the cleaning solution into the float reservoir 9 Wait for about three minutes for the unit to start operating then continue to slowly pour the cleaning solution into the water reservoir taking care to maintain the level just below the overflow NOTE The ice made with the cleaning solution is slushy and coloured also it may tend to loose fluidity creating some resistence in being elevated and extruded this situation can be heard by the creacking noise made by the ice S
3. GREEN LIGHT Unit under electrical power YELLOW LIGHT Unit shut off at full storage bin YELLOW LIGHT Unit shut off due to a too lo water level into float tank RED LIGHT ON all the time Unit shut off due to a too hi condensing temperature Unit shut off due to a too lo ambient temperature lt 1 C Blinking 3 minutes start up delay time YELLOW LIGHT ON all the time Unit shut off due to the wrong rotation direction of gear motor Unit shut off due to the too lo speed of gear motor Blinking Unit shut off due to a too hi evaporating temp gt 1 C after 10 min of operation Page 22 G P C BOARD DIP SWITCH TheP C Board which controls the entire operaton of the ice maker has a DIP SWITCH with eight switching keys which allow to change the functions and set up of some of the system controls as described in details herebelow The first DIP SWITCH Key if positioned in ON allows the skipping of the 3 minutes delay period at every start up of the Ice Maker NOTE To prevent that the unit be subject to startings and stoppings in rapid sequence it is strongly recommended to keep this key in OFF position The 2nd key allows to make a rapid auto diagnosis of the P C Board outputs to compressor gearmotor and fan motor by energizing them in rapid sequence 2 seconds one at the time to make sure of their operation DURING THE AUTOMATIC OPERATION OF THE ICE MAKER THIS KEY
4. Pitted or stained auger surface Blow charge add new gas 8 drier after evacuating system with vacuum pump Same as above Adjust to approx 20 mm below ice spout Check for leaks amp recharge Clean or replace auger Page 31 SERVICE DIAGNOSIS SYMPTON POSSIBLE CAUSE SUGGESTED CORRECTION Wet ice Ambinet temperature too high High water level in the freezer Faulty compressor Move unit to cooler location Lower to approx 20 mm below ice spout Replace Machine runs but makes no ice Water not entering in the freezer Gear stripped Moisture in the system Air look in feed line to freezer Clogged feed line to freezer Clean it Check and repair Purge replace drier and re charge Water leaks Water seal leaking Water feed line to freezer leaking Float valve not closing Rubber spout gasket leaking Replace water seal Check and fasten hose clamp Check and adjust float valve setting screw Remove spout and replace gasket Excessive noise or chattering Mineral or scale deposit on auger and inner freezer walls Low suction pressure Water feed line to freezer clogged Low water level into freezer Remove and manually polish auger and inner walls of freezer barrel using emery paper Add refrigerant to rise suction pressure Vent and clean it Adjust to approx 20 mm below ice spout Gear motor noise Worn rotor bearings Shortage or poor lubricant i
5. HEIGHT less legs 1006 mm HEIGHT with legs 1126 mm WIDTH 592 mm DEPTH 622 mm WEIGHT 72 Kg AF 200 MACHINE SPECIFICATIONS Model Cond unit Finish Comp HP 1 200 5 Air 100 AF 200 WS Water S Steel 3 8 32 Kg 580 Basic electr Amps Watts 7 Nr of wires Amps fuse 230 50 1 3 5 18 760 12 3 x 1mm 10 A 15 C water temperature Page 9 GENERAL INFORMATION AND INSTALLATION A INTRODUCTION This manual provides the specifications and the step by step procedures forthe installation start up and operation maintenance and cleaning for the SCOTSMAN AF 80 AF 100 and AF 200 icemakers The Electronic Flakers are quality designed engineered and manufactured Their ice making systems are thoroughly tested providing the utmost in flexibility to fit the needs of a particular user NOTE To retain the safety and performance built into this icemaker it is important that installation and maintenance be conducted in the manner outlined in this manual B UNPACKING AND INSPECTION 1 Callyour authorized SCOTSMAN Distributor or Dealer for proper installation 2 Visually inspect the exterior of the packing and skid Any severe damage noted should be reported to the delivering carrier and a concealed damage claim form filled in subjet to inspection of the contents with the carriers representative present 3 Cut and remove the plastic strip securing the carton
6. resume its operation NOTE The ice level control uses devices that sense light therefore they must be kept clean enough so they can see Every month clean wipe the sensing eyes with a clean soft cloth 10 Check for refrigerant leaks and for proper frost line which should frost as far as approx 20 cm 8 from the compressor When doubtful about refrigerant charge install refrigerant gauges on corresponding Schr der valves and checkfor correct refrigerant pressures See Operating pressure at page 19 of this manual 11 Check that fan blades move freely and are not touching any surfaces 12 Removethe retaining ring and the hook and cap from the top of the freezer assembly then inspect the top bearing wipe clean of all grease and apply a coating of food grade water proof grease P N 263612 00 NOTE It is recommended to use only food grade and waterproof grease to lubricate the freezer top bearing 13 Checkthe quality of ice Ice flakes should be wet when formed but will cure rapidily to normal hardness in the bin NOTE It is not abnormal for some water to emerge from the ice spout with the flaker ice C CLEANING INSTRUCTIONS OF WATER SYSTEM 1 Switch OFF the Master disconnect switch on the power line 2 Remove all ice stored in the bin to prevent it from getting contaminated with the cleaning solution Page 33 3 Shutclose the water shutoff valve on water line
7. 6 Toinstall the replacement condenser follow the above steps in reverse NOTE Thoroughly evacuate the system to remove moisture and non condensables after condenser replacement O REPLACEMENT OF WATER COOLED CONDENSER 1 Remove front and left side panels 2 Removethe condenser temperature sensor probes from condenser 3 Remove bolts which secure the condenser to the unit base 4 Remove the corbin clamps and disconnect the plastic hoses from the water cooled condenser 5 Recover the refrigerant from the system and transfer it in a container so to reclaim or recycle it 6 Unsolder the refrigerant lines from the condenser and remove it from the unit NOTE It is imperative to install a replace ment drier whenever the sealed refrigeration system is open Do not replace the drier until all other repairs or replacements have been completed 7 Toinstall the replacement condenser follow the above steps in reverse NOTE Thoroughly evacuate the system to remove moisture and non condensables after condenser replacement P REPLACEMENT OF WATER REGULATING VALVE WATER COOLED MODELS 1 Remove front and left side panels 2 Close the shut off valve on the water supply line and disconnect it at the rear of the flaker 3 Remove corbin clamp and disconnect the water hose from the outlet of water regulating valve 4 Unloosethenutsecuringthe water regulating valve to the unit
8. LINE CONDENSER FAN MOTOR limit the temperature sensor changes again its electrical resistance reducing therefore the current flow to the P C Board to cause a temporary stop ofthe Fan Motor On the water cooled versions the refrigerant head pressure is kept at the constant value of 9 5 bars 138 psig by the metered amount of water passing through the condenser which is regulated by the action ofthe Water Regulating Valve that has its capillary tube connected to the liquid refrigerant line As pressure increases the water regulating valve opens to increase the flow of cooling water to the condenser Page 18 NOTE In case the condenser temperature probe senses that the condenser temperatu re has rised to 70 C 160 F on air cooled versions or 62 C 145 F on water cooled versions for one of the following abnormal reasons CLOGGED CONDENSER Air cooled version INSUFFICIENT FLOW OF COOLING WATER Water cooled version FAN MOTOR OUT OF OPERATION Air cooled version AMBIENTTEMPERATURE HIGHER THEN 43 C 110 F itcauses the total and immediate SHUT OFF of the machine in order to prevent the unit from operating in abnormal and dangerous conditions When the ice maker stops on account of this protective device there is a simultaneous glowing of the RED LED warning the user of the Hi Temperature situation After having eliminated the source of the excessive condenser temperature to res
9. MUST BE SET IN OFF POSITION WARNING This auto diagnosis must be performed inthe shortest possible time in order to avoid frequent startings and stoppings of the electrical components which may cause demages to their windings and controls The 3rd key is no longer used and can be set to ON or OFF position The 4th key allows the switching of the unit re set from manual OFF setting to automatic ON setting when the machine operation has been cut out by any of the safety control devices The keys 5 6 and 7 may be used to vary the temperature differential determined by the condenser temperature sensor for the cut in and cut out of the fan motor as indicated in the following table DIP SWITCH FACTORY SETTING COMBINATIONS pipswittH 1 2 3 4 5 6 7 8 Aircooled OFF OFF ON OFF ON ON ON ON Water cooled OFF OFF ON OFF ON ON ON OFF DIFFERENTIAL VARIATIONS OF CONDENSER TEMPARATURE SENSOR ACCORDING TO THE DIP SWITCH KEY SETTING COMBINATIONS 5 6 7 DELTA T C ON ON ON 0 5 OFF ON 1 0 ON OFF 1 5 OFF OFF ON 2 0 ON ON OFF 2 5 OFF OFF 3 0 ON OFF OFF 3 5 OFF OFF OFF 40 Page 23 The ideal combination which assure the best performance of the ice maker is the first one on the table that gives a differential equal to 0 5 C from cut in and cut out of the fan motor to keep the condensing temperature and pressure as stright as possible The 8th key is used to m
10. at high voltage to the fan motor so that it can cool the condenser and reduce its tempera ture In the event the condenser temperature rises and reaches 70 C or 62 C the current arriving to the micro processor is such to cause an imme diate and total stop of the machine operation NOTE To restart the unit after the shutoff caused by the hi condenser temperature it is necessary to push the RE SET button after having remedied to the causes of unit stoppage or to switch OFF and ON the power line main disconnect Switch NOTE In the event of shortage of walter in the reservoir or in case the water used is too soft de mineralized to cause greater resistence to the current flow conductivity lower than 30uS this sensor system causes the shutoff of the machine to protect it from running with an interrupted or inadequate water supply In this situation the YELLOW LED will glow n ofthe machine shutoff and the reason why D GEAR MOTOR ROTATION AND SPEED SENSOR This safety device is housed on top of the Drive Motor and detects based on Hall Effect principle the rotating speed and rotating direction of the drive Motor Should the rotating speed drop below 1300 r p m the magnitude measured by this device is such to signal to the microprocessor to stop the unit and light up the YELLOW LED About the same reaction occures when the drive motor will tend to rotate in the wrong direction counterclockwise situa
11. between them signalling in this way to the P C Board the presence of the water in the reservoir In case the water used is very soft de mineralized or the float reservoir gets empty the current flow between the sensors become so weak or is no longer maintained that as consequence the P C Board shutoff the flaker operation with the simultaneous glowing of the YELLOW LED signalling Shortage of water The float reservoir is positioned the side of the freezing cylinder at such an height to be able to maintain a constant water level around the freezer auger In fact the water flows from the reservoir into the bottom inlet of the freezing cylinder to sorround the stainless steel auger which is vertically fitted in the center of the freezer In the freezer the incoming water gets chilled into soft slush ice which is moved upward by the rotating action of the auger The stainless steel auger that rotates counter clockwise within the freezer is powered by a direct drive gear motor and carries the ice upward along the refrigerated freezer inner walls and by doing so the ice gets progressively thicker and harder ICE SPOUT FLOAT TANK FLOAT VALVE FREEZER FREEZER i FEED LINE WATER INLET LINE L Theice being costantly lifted up meet the toothed point of the ice breaker which is fitted on the top end of the auger where it gets compacted cracked and forced to change
12. box to the skid b Remove the packing nails securing the carton box to the skid c Cut open the top of the carton and remove the polystyre protection sheet d Pull out the polystyre posts from the corners and then remove the carton 4 Remove the frontand if any the rear panels ofthe unit and inspect for any concealed damage Notify carrier of your claim for the concealed damage as stated in step 2 above 5 Remove all internal support packing and masking tape Leg package is located in the storage bin compartment 6 Checkthatrefrigerantlines do notrub against or touch other lines or surfaces and that the fan blades move freely 7 Check that the compressor fits snugly onto all its mounting pads 8 Use clean damp cloth to wipe the surfaces inside the storage bin and the outside of the cabinet 9 See data plate on the rear side of the unit and check that local main voltage corresponds with the voltage specified on it CAUTION Incorrect voltage supplied to the icemaker will void your parts replacement program 10 Remove the manufacturer s registration card from the inside of the User Manual and fill in all parts including Model and Serial Number taken from the data plate Forward the completed self addressed registration card to SCOTSMAN EUROPE factory 11 If necessary fit the four legs into their seats on the machine base and adjust them to the desired level C LOCATION AND LEVELLING
13. or dirty ice level control Shortage or too soft water High head pressure Ambient temperature too low Too hi evap temperature Shortage or lack of refrigerant Gear motor tends to run on reverse Too low gear motor rotating speed No rotation of gear motor Gear motor starts and stop after a while Replace fuse amp check for cause of blown fuse Turn switch to ON position Replace P C Board Check wiring Replace or clean ice level control See remedies for shortage of water or install a mineral salt metering device Dirty condenser Clean Inoperative fan motor Replace Move unit in warmer location Checkand charge refrigerant system Check gear motor capacitor Check rotor bearings freezer bearings and interior of freezer for Scores Replace whatever worn or damaged Check for power to drive motor 16 A fuses Check for stator winding Check for correct operation of drive motor magnetic sensor Check for correct magnetic capacity of magnetic cylinder Compressor cycles intermittently Low voltage Non condensable gas in system Compressor starting device with Check circuit for overloading Check voltage at the supply to the building If low contact the power company Purge the system Check for loose wires in starting loose wires device Low ice production Capillary tube partially restricted Moisture in the system Low water level in the freezer Shortage of refrigerant
14. suction line assy from the outlet line of the freezing cylinder 6 Remove the three bolts and washers securing the gear reducer base to the unit chassis then remove bolts andlockwashers which attach the bottom of the aluminium adaptor to the gear reducer case cover 7 Lift the freezer up and off the gear motor assembly then if necessary remove the aluminium adaptor by removing the three mounting screws and lockwashers NOTE It is imperative to install a replace ment drier whenever the sealed refrigeration system is open Do not replace the drier until all other repairs or replacements have been completed 8 Toinstallthe replacement evaporator follow the above steps in reverse NOTE Thoroughly evacuate the system to remove moisture and non condensables after evaporator replacement N REPLACEMENT OF AIR COOLED CONDENSER 1 Remove front and back panel on model 2 Remove from the condenser fins the condenser ambient temperature sensor probes 3 Remove the two bolts attaching the condenser to the base 4 Recover the refrigerant from the system and transfer itin a container so to reclaim or recycle it 5 Unsolder the refrigerant lines from the condenser and remove it from the unit NOTE It is imperative to install a replace ment drier whenever the sealed refrigeration system is open Do not replace the drier until all other repairs or replacements have been completed
15. to its own circuit and individually fused see data plate for fuse size Themaximum allowable voltage variation should not exceed 10 and 10 of the data plate rating Low voltage can cause faulty functioning and may be responsible for serious damage to the overload switch and motor windings NOTE All external wiring should conform to national state and local standards and regulations Check voltage on the line and the ice maker s data plate before connecting the unit E WATER SUPPLY AND DRAIN CONNECTIONS GENERAL When choosing the water supply forthe ice flaker consideration should be given to a Length of run b Water clarity and purity C Adequate water supply pressure Since water isthe mostimportant single ingredient in producting ice you cannot emphasize too much the three items listed above Low water pressure below 1 bar may cause malfunction of the ice maker unit Water containing excessive minerals will tend to produce scale build up on the interior parts of the water system while too soft water with too lo contents of mineral salts will produce a very hard flaker ice WATER SUPPLY Connect the 3 4 GAS male of the water inlet fitting using the flexible tube supplied to the cold water supply line with regular plumbing fitting and a shut off valve installed in an accessible position between the water supply line and the unit If water contains a high level of impurities it is advisabl
16. where being cooled down condenses into liquid Flowing into the liquid line it passes through the drier filter then it goes all the way through the capillary tube where it looses some ofits pressure sothatits pressure andtemperature are lowered Next the refrigerant enters into the evaporator coil wrapped around the freezer inner tube The water being constantly fed at the interior of the freezer inner tube exchange heat with the refrigerant circulating into the evaporator coil this cause the refrigerant to boil off and evapora te thereby it changes from liquid into vapor The vapor refrigerant then passes through the suction accumulator and through the suction line where the refrigerant exchanges heat with the one flowing into the capillary tube warmer before being sucked into the compressor to be recirculated The refrigerant heat pressure is kept between two pre set values 8 5 10 bar 120 140 psig by the condenser temperature sensor which has its probe located within the condenser fins in air cooled versions This condenser temperature sensor when senses a rising of the condenser temperature beyond the pre fixed limit changes its electrical resistance and send a low voltage power flow to the MICRO PROCESSOR of the P C Board which energizes through a TRIAC the Fan Motor in ON OFF mode When the opposite situation occures i e the condenser temperature gets below the pre fixed EVAPORATOR SUCTION
17. 00 F WARNING This icemaker is not designed for outdoor installation and will not function in ambient temperatures below 10 C 50 F or above 40 C 100 F This icemaker will malfunction with water temperatures below 5 C 40 F or above 40 C Page 12 OPERATING INSTRUCTIONS START UP After having correctly installed the ice maker and completed the plumbing and electrical connections perform the following Start up procedure A Openthe watersupply line shutoff valve and putthe unit under electrical power by moving the main switch on the power supply line to the ON position The first LED GREEN will glow to signal that unit is under power NOTE Every time the unit is put under power after being kept for sometime in shut off conditions electrically disconnected the RED LED will blink for 3 minutes after which the unit will start up with the immediate operation of the gear motor assembly and after 5 seconds of the compressor assy Fig 1 B Elapsedthe 3 minutes stand by period the unit starts operating with the activation in sequence of the following assemblies GEAR MOTOR COMPRESSOR FAN MOTOR if unit is an air cooled version kept under control by the condenser temperatu re sensor which has its probe within the condenser fins Fig 2 C Elapsed2or3 minutes from the compressor start up observe that flaker ice begins dropping off the ice spout t
18. 123 145 psig Water cooled version 9 5 bar 138 psig Suction pressure 0 4 0 8 bar 6 12 psig Page 21 COMPONENT DESCRIPTION A EVAPORATOR TEMPERATURE SENSOR The evaporator sensor probe is inserted into its tube well which is welded on the evaporator outlet line it detects the temperature of the refrigerant on the way out from the evaporator and signals it by suppying a low voltage current flow to the P C Board Micro Processor According to the current received the micro processor let the ice maker to continue its operations In case the evaporating temperatu re after 10 minutes from the unit start up does not go below 1 C 30 F due to shortage of refrigerant in the system or due to the excessive condensing temperature the evaporator sensor signal reaching the microprocessor is such to stop immediately the unit operation with the 5th Warning YELLOW LED that blinks B WATER LEVEL SENSOR This sensor system consist of two small stainless steel rods vertically fitted on the inner face of the reservoir cover and electrically connected to the low voltage circuit of the P C Board When the cover of the reservoir is positioned inits place the tips of both the rods dip into the reservoir water and detects and signals its presence by making use of its electrical resistance In the air cooled versions in relation to the different current received the micro processor of the P C BOARD supplies through a TRIAC the power
19. D SENSOR 1 Remove the front and top panel 2 Unloosethethree screws securingthe plastic cover to the gear motor speed sensor housing and remove it 3 Unloosethetwo screws securing the sensor to the plastic housing and withdraw it from its seat 4 Trace the gear motor speed sensor terminal plug on the rear side of the control box and draw it out from its socket by carefully slackening the fastening tie 5 Toinstallthe replacementgear motor rotation and speed sensor follow the above steps in reverse F REPLACEMENT OF THE RESERVOIR WATER LEVEL SENSOR 1 Remove the front and top panel 2 Unloose the two nuts securing the wire leads to the two water level sensor rods located on the water reservoir plastic cover 3 Trace the water level sensor terminal plug onthe rear side of the control box and draw it out from its socket by carefully slackening the fastening tie 4 Toinstallthe replacement water level sensor follow the above steps in reverse G REPLACEMENT OF P C BOARD 1 Remove front panel 2 Remove all sensor terminal plugs located on the rear side of P C Board by carefully releasing them out from their sockets clips 3 Disconnect the terminal board connection plug from the rear side of P C BOARD then unloose the four screws holding the same to the plastic control box and remove it 4 To install the replacement P C BOARD follow the above steps on reverse H REPLACEMENT OF THE ICE SPOUT 1 R
20. Itis good practice to replace the water seal assy and both the top and the bottom bearings any time the auger is removed To facilitate this SCOTSMAN EUROPE Service makes available a service Kit which includes besides the above mentioned parts the ice breaker O ring and acan of food grade waterproof grease 12 Reach through the adaptor and remove the coupling parts 13 Check both the coupling halves for chipping and wear and do not hesitate to replace them 14 To install the ratched coupling the water seal the bearings and auger follow previous steps in reverse 4 REPLACEMENT OF THE GEAR MOTOR ASSY 1 Remove the rear and top panel 2 Remove the three bolts and washers securing the gear reducer base to the unit chassis then remove bolts and lockwashers which attach the bottom of the aluminium adaptor to the gear reducer case cover 3 Disconnect the electrical leads from the electromagnetic safety device located on top of drive motor 4 Traceand disconnect the electric wires leads of the drive motor Lift and remove the entire gear motor assembly 5 install the replacement gear motor assy follow the above steps in reverse Page 26 K REPLACEMENT OF FAN MOTOR 1 Remove front and back panel 2 Remove screws and yellow green ground wire Trace the electrical leads of fan motor and disconnect them 3 Remove the bolts securing the fan motor bracket to the cabinet base and then remove the a
21. SCOTSMAN SERVICE MANUAL AF 50 AF 100 AF 200 R 134 A VERSION Electronic flakers with storage TABLE OF CONTENTS Table of contents page Specifications AF 80 Specifications AF 100 Specifications AF 200 GENERAL INFORMATION AND INSTALLATION Introduction Unpacking and Inspection Location and levelling Electrical connections Water supply and drain connections Final check list Installation practice OPERATING INSTRUCTIONS Start up Operational checks PRINCIPLE OF OPERATION How it works Water circuit Refrigerant circuit Mechanical system Operating pressures Components description ADJUSTMENT REMOVAL AND REPLACEMENT PROCEDURES Adjustment of the evaporator water level Replacement of evaporator temperature sensor Replacement of condenser temperature sensor Replacement of ice level light control Replacement of the gear motor rotation and speed sensor Replacement of the reservoir water level sensor Replacement of P C Board Replacement of the ice spout Replacement of the auger water seal bearings and coupling Replacement of the gear motor assy Replacement of fan motor Replacement of drier Replacement of the freezing cylinder Replacement of air cooled condenser Replacement of water cooled condenser Replacement of water regulating valve water cooled models Replacement of compressor Wiring diagram Service diagnosis MAINTENANCE AND CLEANING INSTRUCTIONS General Icemaker Cleaning i
22. are within a minimum of 10 C 50 F even in winter months 2 Is there at least a 15 cm 6 clearance around the unit for proper air circulation 3 15 the unit level IMPORTANT 4 Have all the electrical and plumbing connections been made and is the water supply shut off valve open 5 Has the voltage been tested and checked against the data plate rating 6 Hasthe watersupply pressure been checked to ensure a water pressure of at least 1 bar 14 psi 7 Havethebolts holdingthe compressor down been checked to ensure that the compressor is snugly fitted onto the mounting pads Page 11 8 Check all refrigerant lines and conduit lines to guard against vibrations and possible failure 9 Have the bin liner and cabinet been wiped clean 10 Has the owner user been given the User Manual and been instructed on the importance of periodic maintenance checks 11 Has the Manufacturers registration card been filled in properly Check for correct model and serial number against the serial plate and mail the registration card to the factory 12 Hasthe owner been given the name and the phone number of the authorized SCOTSMAN Service Agency serving him G INSTALLATION PRACTICE 1 Hand shut off valve Water filter Water supply line flexible hose 9 4 GAS male fitting Power line Main switch Drain fitting Vented drain Open trapped vented drain nm ON DO 1
23. cylinder is about 25 mm 1 below the ice discharge opening Low water level causes excessive strain inside the freezer assembly due to a faster freezing rate When the water level is above or below the correct one adjustment can be performed to Raise or Lower the water level by raising or lowering at the measure required the water reservoir and its mounting bracket 1 To Raise the water level a Loosen and remove the screw securing the mounting bracket of the water reservoir to the unit cabinet and raise the water reservoir to the correct level b Thread the mounting screw in the corresponding hole and tighten it 2 To Lower the water level follow the above indications to lower to the correct level the water reservoir assembly WARNING Be sure the electrical power supply circuit breaker and the inlet water supply are OFF before starting any of the following Removal and Replacement procedures as a precaution to prevent possible personal injury or damage to the equipments B REPLACEMENT OF EVAPORATOR TEMPERATURE SENSOR 1 Remove the front and top panels 2 Remove the insulation from the refrigerant tubing connecting the freezer to the accumulator to gain access to the sensor probe well and be able to pull out from this well the sensor probe 3 Trace the condenser sensor terminal plug on the rear side of the control box and remove it from its socket by carefully pulling out the term
24. e sealed refrigeration system is open Do not replace the drier until all other repairs or replacements have been completed 7 Toinstallthe replacement compressor follow the above steps in reverse NOTE Thoroughly evacuate the system to remove moisture and non condensables after compressor replacement Page 29 WIRING DIAGRAM AIR AND WATER COOLED TERMINAL BOARD GV YELLOW GREEN 230 50 1 B WHITE G GREY N BLACK A BLUE M BROWN V GREEN PRINTED CIRCUIT BOARD POWER ON T 100mA a NO WATER u FUSE 816 TOO Hi COND 3 STAND BY 7 WRONG ROTATION E VAP TEMP F16A RESET TOO Hi TEMP use Holts fel IHT gt d iRise meee igigigigigig gig alm D Lil va gt 1 WATER LEVEL GEAR MOTOR ROTATION CONDENSER TEMP EVAPORATOR TEMP iu gt P ul E 4 lt CAPACITOR FAN MOTOR x Iv 2 a w a x E x a lt ul a SENSORS JUST FOR AIR COOLED UNIT amp SERVICE DIAGNOSIS Page 30 SYMPTON POSSIBLE CAUSE SUGGESTED CORRECTION Unit will not run No LED lighted up Bin full yellow LED glows Shortage of water yellow LED glows Red alarm LED glows Reverse rotation yellow LED blinks Reverse rotation yellow LED glows Blown fuse in P C Board Master switch in OFF position Inoperative P C Board Loose electrical connections Inoperative
25. e to consider the installation of an appropriate water filter or conditioner WATER SUPPLY WATER COOLED MODELS The water cooled versions of SCOTSMAN Ice Makers require two separate inlet water supplies one for the water making the flaker ice and the other for the water cooled condenser Page 10 Connect the 3 4 GAS male fitting of the water inlet using the flexible tube supplied to the cold water supply line with regular plumbing fitting and a shut off valve installed in an accessible position between the water supply line and the unit WATER DRAIN The recommended drain tube is a plastic or flexible tube with 18 mm 3 4 1 0 which runs to an open trapped and vented drain When the drain is a long run allow 3 cm pitch per meter 1 4 pitch per foot Install a vertical open vent on drain line high point at the unit drain connection to ensure good draining The ideal drain receptacle is a trapped and vented floor drain WATER DRAIN WATER COOLED MODELS Connect the 3 4 GAS male fitting of the condenser water drain utilizing a second flexible tubing to the open trapped and vented drain This additional drain line must notinterconnect to any other of the units drains NOTE The water supply and the water drain must be installed to conform with the local code In some case a licensed plumber and or a plumbing permit is required F FINAL CHECK LIST 1 Is the unit in a room where ambient temperatures
26. emove the top panel 2 Slacken and remove the two metal straps that hold tight the polystyre insulations against the freezer upper part 3 Remove the optical ice level control 4 Pullloose the stainless steel spout from its rubber gasket grommet 5 Unloose and remove the two screws and separate the spout casting from the freezer cylinder NOTE At this time inspect the spout gasket and replace it if torn cut or worn otherwise retain it to be used again 6 To install the replacement spout follow previous steps in reverse l REPLACEMENT OF THE AUGER WATER SEAL BEARINGS AND COUPLING 1 Remove the front rear and top panel 2 Follow the steps at item to remove the ice spout 3 Unloose and remove two screws and washers holding tight the spout plate to the freezing cylinder 4 Grasp the wire cap hook at the top of the freezer and pull out the auger and attached cap ice breaker bearings and O rings at the top of the auger and the top half ofthe water seal atthe auger bottom NOTE If the auger cannot be pulled out proceed to steps 10 and 11 ofthis paragraph lo gain access to the auger bottom Then with a rowhide mallet or placing a piece of wood on the bottom end of the auger tap this bottom to break loose the auger and be able then to pull it out as in step 4 above 5 With a circlip plier remove the retaining ring and cap hook from the ice breaker 6 Unloose andremove ca
27. ff valve on the water supply line D Removefrontservice panel andif necessary install the refrigerant service gauges on the corresponding Service valves to check both the HI and LO refrigerant pressures Nu e GEAR tc lt Pp ON CONDENSER TEMP y T gt 75 C EVAPORATOR TEMP SENSO DATA PROCESSOR ICE LEVEL CONTROL O FAN MOTOR COMPRESSOR ELECTRONIC CARD Page 15 This will cause a gradual decrease of the water levelinthe float reservoir and as soon the level gets below the sensors the flaker stops to ope rate and the YELLOW warning LED will glow to signal the shortage of water Fig 5 NOTE The water level sensor detects the presence of sufficient water in the float reservoir and confirms it to the micro processor by maintaining a low voltage current flow between the two sensors using the water as conductor WARNING The use of de mineralized water water with no salt content having an electrical conductivity lower than 30 uS will cause the ability of the water sensors to vanish with the consequent CUT OUT of the flaker operations and the glowing of the YELLOW LED of shortage of water even though that water is indeed in the reservoir After this open the water supply line shutoff valve to fill up again the float reservoir the YELLOW LED goes off while the RED LED s
28. frame 5 Recovertherefrigerantfrom the system and transfer it in a container so to reclaim or recycle it 6 Trace the water regulating valve capillary tube and unsolder its end from the refrigerantline then remove it from the unit NOTE It is imperative to install a replace ment drier whenever the sealed refrigeration system is open Do not replace the drier until all other repairs or replacements have been completed 7 Toinstall the replacement water regulating valve follow the above steps in reverse NOTE Thoroughly evacuate the system to remove moisture and non condensables after water regulating valve replacement NOTE The water flow that passes through the valve can be adjusted by means of the valve setting stem in order to have a condensing pressure of 9 5 bars 138 psig Q REPLACEMENT OF COMPRESSOR 1 Remove back and front panels 2 Remove the cover and disconnect the electrical leads from the compressor junction box 3 Recover the refrigerant from the system and transfer it in a container so to reclaim or recycle it Page 28 4 Unsolder and disconnect both the suction line and the discharge line from the compressor 5 Removethefour compressor mounting bolts and the compressor from the unit base 6 Unsolder suction and process header from compressor and retain it to be used on new compressor NOTE It is imperative to install a replace ment drier whenever th
29. from vertical into horizontal motion to be discharged out through the ice spout into the storage bin By running the ice maker i e by putting the unit under power starts the automatic andcontinuous icemaking process which would not stop until the ice storage bin gets filled up to the level of the control eyes located on the sides of the ice spout As the ice level raises to interrupt the light beam running between the two infrared lamps the unit stops after ten seconds with the simulteneous glowing of the YELLOW LED signalling the Full Bin situation NOTE The interruption of the light beam between the two light sensors is immediately signalled by the extinguishing of the RED LED located on the front of the P C Board After about 6 of steady interruption of the light beam the unit stops and the Full YELLOW LED glows The six seconds of delay prevent the unit from stopping for any undue reason like the momentarily interruption of the light beam caused by the flakes that slides along the ice spout before dropping into the bin As some ice gets scooped out from the storage bin the light beam between the two sensors resumes and immediately the RED LED in the front center of the P C Board lights up ten seconds later the ice machine restarts the ice making process and the YELLOW LED goes off REFRIGERANT CIRCUIT The hot gas refrigerant discharged out from the compressor reaches the condenser
30. hould this occure it is recommended to stop for few minutes the ice machine in order to allow the ice in the freezer to partially melt 10 When all the cleaning solution has been used up open the water shutoff valve to allow new fresh water to flow into the reservoir Let the unit to continue to run until the ice resumes the normal colour and hardness 11 Stop the icemaker and pour warm water on the ice deposited into the storage bin to melt it up NOTE DO NOT use ice produced with the cleaning solution Be sure none remains in the bin 12 Pour into the water reservoir 1 cc approx 20 drops of Scotsman Sanitiser Antialgae P N 264000 00 then switch the unit ON 13 Left the unit running for approx 10 minutes then remove the copper wire used to jump the two sensors for the water level and place back correctly the cover on the float reservoir NOTE DO NOT use ice produced with the sanitising solution 14 With a sponge moisted with a sanitising solution wipe clean all the bin interior surfaces REMEMBER To prevent the accumulation of undesirable bacteria it is necessary to sanitise the interior of the storage bin with an anti algae disinfectant solution every week
31. ightbeam gets interrupted for as long as 6 seconds the ice machine stops with the glowing up of the 2nd YELLOW LED to monitor the full ice bin situation The 6 seconds of delay prevents that any minimum interruption ofthe light beam due to the regular ice chuting through the ice spout may stop the operation of the unit As soon as the ice is scooped out with the resumption of the light beam between the two infrared sensor of ice level control the RED LED lights up and after 6 seconds the ice machine resume its operation with the simultaneous extinguishing the 2nd YELLOW LED F P C BOARD Data processor The P C BOARD fitted in its plastic box located in the front of the unit consists of two separated printed circuits one at high and the other at low voltage protected by three fuses integrated with a RE SET button Also it consists of five aligned LEDS monitoring the operation of the machine of one extra monitoring RED LED of a 8 keys DIP SWITCH and of inputterminals for the leads of the sensor probes as well as inputand outputterminals for the leads of the ice maker electrical wires The P C BOARD is the brain of the system and it elaborates through its micro processor the signals received from the sensors in order to control the operation of the different electrical components of the ice maker compressor gear motor etc The five LEDS placed in a row in the front of the P C BOARD monitor the following situations
32. inal plug securing clip 4 Toinstallthe replacement evaporator sensor follow the above steps in reverse C REPLACEMENT OF CONDENSER TEMPERATURE SENSOR 1 Remove the front panel 2 Trace the condenser sensor probe located within the condenser fins on air cooled version and withtrow it On water cooled version remove it by opening the plastic strap reusable securing the probe to the refrigerant liquid line 3 Trace the condenser sensor terminal plug on the rear side of the control box and remove it fromits socket by carefully pulling outthe terminal plug securing clip 4 Toinstallthe replacement condenser sensor follow the above steps in reverse NOTE Both the condenser and the water level sensors have the same terminal plug and socket To avoid confusion when performing their replacement pay attention to the different colour of their terminal plug and socket D REPLACEMENT OF THE ICE LEVEL LIGHT CONTROL 1 Remove the front and top panels 2 Trace the level light control terminal plug black and with four terminal pins on the rear side of the control box and draw it out from its socket by carefully slackening the fastening tie 3 Unloose the two screws holding the optical ice level control to the upper side of the spout and remove it 4 To install the replacement ice level light control follow the above steps in reverse Page 25 E REPLACEMENT OF THE GEAR MOTOR ROTATION AND SPEE
33. m housing the setting screw is perpendicular to the water nozzle 5 Clean the water system water reservoir and the interior of freezing cylinder using a solution of SCOTSMAN Ice Machine Cleaner Refer to procedure C cleaning instructions and after cleaning will indicate frequency and proce dure to be followed in local areas NOTE Cleaning requirements vary according to the local water conditions and individual user operation 6 If required polish the two sensor rods secured to the float reservoir cover heavy scale sediment on them can be removed with the help of a bit of SCOTSMAN Cleaner plain 7 With the ice machine and fan motor OFF air cooled models clean condenser using vacuum cleaner whiskbroom or non metallic brush taking care to do not damage the condenser ambient temperature sensor 8 Checkfor water leaks and tighten drain line connections Pour water down bin drain line to be sure that drain line is open and clear 9 Check the ice level control sensor to test shut off Put your hand between the light source and the receiver so to cut off the light beam for at least 6 seconds This should cause the immediate extinguishing of the RED LED located in the front face of P C Board and 6 seconds later the total stopping of the ice maker with the simultaneous light up of the Full Bin Yellow LED Within few seconds from the removal of the hand from between the sensor lights the ice maker
34. n gear case Gear case bearings and gear racers worn out Check and replace Check for proper lubricant opening gear case Top of gears must be covered with lubricant Check and replace worn parts Shortage of water Strainer at water inlet fitting clogged Float reservoir water nozzle clogged up Remove strainer and clean Remove float valve and clean nozzle Page 32 MAINTENANCE AND CLEANING INSTRUCTION A GENERAL Theperiods andthe procedures for maintenance and cleaning are given as guides and are not to be construed as absolute or invariable Cleaning especially will vary depending upon local water and ambient conditions and the ice volume produced and each icemaker must be maintened individually in accordance with its particular location requirements B ICEMAKER Thefollowing maintenance should be scheduled at least two times per year on these icemakers 1 Check and clean the water line strainer 2 Remove the cover from the float reservoir care to do not damage the two water sensors and depress the float to make sure that a full stream of water enters into the reservoir 3 Checkthatthe icemaker is levelled in side to side and in front to rear directions 4 Check that the water level in the water reservoir is below the overflow but high enough that it does not run out of the spout opening NOTE The float must close positively the incoming waterflow when its fulcru
35. nstructions of water system Page 2 10 11 12 14 17 17 19 20 21 24 24 24 24 25 25 25 25 25 26 26 26 26 27 27 27 28 29 30 32 32 32 Page 3 SPECIFICATIONS ELECTRONIC FLAKER MODEL AF 80 Important operating requirements MIN MAX Water temperature 5 C Electr voltage variations fromvoltage rating specified on nameplate 10 10 ice making capacity ICE PRODUCED PER 24 HRS AIR COOLED MODELS WATER COOLED MODELS Kg oc 75 75 10 70 21 65 60 32 38 55 50 50 zu 45 45 32 1 15 C 32 21 15 96 70 10 21 o o AMBIENT TEMPERATURE ICE PRODUCED PER 24 HRS WATER TEMPERATURE WATER TEMPERATURE Air temperature 10 C 50 F 40 C 100 F 40 F 40 C 100 F Water pressure 1bar 14 psi 5bars 70 psi AMBIENT TEMPERATURE NOTE With the unit in built in conditions the ice production is gradually reduced in respect to the levels shown in the graph up to a maximum of 10 at room temperatures higher than 32 C The daily ice making capacity is directly related to the condenser air inlet temperature water temperature and age of the machine To keep your SCOTSMAN FLAKER at peak performance levels periodic maintenance checks must be carried out as indicated on page 32 of this manual Page 8 SPECIFICATIONS Dimensions
36. o fall into the storage bin NOTE The first ice bits that drop into the ice storage bin are notso hard as the evaporating temperature has not yet reached the correct operating value It is necessary to allow the ice just made to cure itself and wait for about ten minutes for the evaporating tem perature to reach the correct value so to make more hard bits of ice ROTATION GEAR MOTOR gt CONDENSER TEMP T gt 1 C EVAPORATOR TEMP SENSORS ICE LEVEL CONTROL NM NM RESET DATA PROCESSOR FAN MOTOR 4 ELECTRONIC CARD Page 13 NM e ooooe RESET GEAR M SENSORS 8 5 A 5 3 EVAPORATOR TEMP ICE LEVEL CONTROL O gt 2 FAN MOTOR COMPRESSOR ELECTRONIC CARD NL NL 00060 ROTATION GEAR MOTOR O 2 CONDENSER TEMP EVAPORATOR TEMP y T gt 1 C SENSORS ICE LEVEL CONTROL E FAN MOTOR 5 N o o cc 8 4 ELECTRONIC CARD Page 14 NOTE If after ten minutes from the compressor start up the evaporating tem perature has not dropped down to a value lower than 1 C 30 F due to an insufficient quantity of refrigerant in the system the evaporating temperature sensor detects such anabnormal situation and stops consequently the unit opera
37. odify the CUT OUT condensing temperature from 62 C 145 F for the water cooled versions ON position to 70 160 F OFF position for the air cooled versions H FLOAT RESERVOIR Thefloat reservoir consists of a plastic water pan on which is fitted a float valve with its setting screw The float valve modulate the incoming water flow to maintain a constant water level in the reservoir level that corresponds to the one in the freezing cylinder to ensure proper ice formation and fluidity Onthe inner side of the reservoir cover are fitted the two water level sensors which detects the presence orthe shortage of water in the reservoir NOTE Itis very importantto make sure ofthe correct fitting of the cover on the reservoir in ordertoenable the sensor to efficiently control the water situation avoiding undue shutoff interventions I FREEZING CYLINDER EVAPORATOR The freezing cylinder is made of a stainless steel vertical tube on which exterior is wrapped around the cooling coil with the evaporating chamber and in its interior is located the auger which rotates on its vertical axis and it is maintained aligned by the top and bottom bearings A water seal system is located in the bottom part of the freezer while at the top end is fitted the ice breaker The water constantly flowing into the cylinder bottom part freezes into ice when in contact with the cylinder inner walls The ice is then lifted up by the ro
38. onnected to the freezer auger by a ratched coupling which is made of two toothed halves that engages themselves only if turned in the correct direction namely conterclockwise L FAN MOTOR Air cooled version The fan motor is controlled through the P C BOARD and the TRIAC by the condensertempe rature sensor Normally itoperatesto draw cooling air through the condenser fins In cold ambient situation the fan motor can run at intermittance as the condenser pressure mustbe kept between two corresponding head pressure values 8 5 9 5 bars 120 135 psig M WATER REGULATING VALVE Water cooled version This valve controls the head pressure in the refrigerant system by regulating the flow of water going to the condenser As pressure increases the water regulating val ve opens to increase the flow of cooling water N COMPRESSOR The hermetic compressor is the heart of the refrigerant system and it is used to circulate and retrieve the refrigerant throughout the entire system Itcompresses the low pressure refrigerant vapor causing its temperature to rise and become high pressure hot vapor which is then released through the discharge valve Page 24 ADJUSTMENT REMOVAL AND REPLACEMENT PROCEDURES NOTE Head the instructions thoroughly before performing any of the following adjustment or removal and replacement pro cedure A ADJUSTEMENT OF THE EVAPORATOR WATER LEVEL The correct water level in the freezing
39. p screw and remove the ice breaker from the auger 7 Clean away the old grease from the interior of the ice breaker and inspect the conditions of the O ring if torn or worn replace it 8 Inspect the bearing pressed into the top of the ice breaker and if worn do not hesitate to replace it WARNING Thetop bearing assembly works in critical conditions for what concern its lubrication status as it is haused inthe breaker where the formation of a great rate of condensation is usual Therefore it is important to apply on it an ample coa ting of Food grade Waterproof Grease P N 263612 00 before installing the breaker and cap hook in place 9 Slide off from the auger bottom the upper half of the water seal NOTE Any time the auger is removed for replacement or inspection use extra care in handling the water seal parts so no dirt or foreign matters are deposited on the surfaces of the seal If there is any doubt about the effectiveness of the water seal or O ring do not hesitate to REPLACE THEM 10 Unloose and remove the three bolts and lockwashers which attach the freezer assy to the aluminium adaptor 11 Raisethe freezer assy offthe adaptor secure it out of the way to allow room to work Using a suitable lenght and size wooden dowel or stick inserted through the top of the open freezer tap the lower half of the water seal and the lower bearing out the bottom of the freezer NOTE
40. r results to be higher than 1 C 30 F the ice maker stops and the 5TH WARNING YELLOW LED blinks MECHANICAL SYSTEM The mechanical system of the SCOTSMAN Flaker machines consists basically of a gear motor assembly which drives through a ratched coupling a worn shaft or auger placed on its vertical axis within the freezing cylinder The gear motor is made of a single phase electric motor with a permanent capacitor This motor is directly fitted in the gear case through which it drives in counter clockwise rotation at a speed of 9 5 r p m the freezer auger being linked to it by the ratched coupling NOTE In the event the gear motor will tend to rotate in the wrong direction counter clockwise or not rotating at all the unit will stop immediately with the glowing of the WARNING YELLOW LED on account of the intervention of the Electromagnetic Safety Device based on Hall Effect principle After having diagnosed and eliminated the source of the failure to restart the unit it is necessary to press the RE SET push button or switch OFF and ON the power line main disconnnect switch Fig 8 The RED LED will start blinking and after 3 minutes the ice maker will resume its total operations by running first the gear motor and then the compressor When the gear motor rotating speed is slowed below 1300 r p m from the normal speed of 1400 r p m the Electromagnetic Safety Device transmits an electrical signal
41. ssembly 4 Toinstall the replacement fan motor follow the above steps in reverse NOTE When installing a new fan motor check that the fan blades do not touch any surface and move freely L REPLACEMENT OF DRIER 1 Remove front and back panel 2 Recovertherefrigerantfrom the system and transfer it in a container so to reclaim or recycle it 3 Unsolderthe capillary tube andthe refrigerant line from the two ends of the drier 4 To install the replacement drier remove factory seals and solder the refrigerant lines and the capillary tube taking precautions to NOT OVERHEAT the drier body 5 Thoroughly evacuate the system to remove moisture and non condensable after drier replacement 6 Chargethe system with refrigerant 134 A by weight see data plate of machine and check for leaks 7 Replace panels previously removed M REPLACEMENT OF THE FREEZING CYLINDER 1 Follow the steps at item H to remove the ice spout 2 Remove the clamp fastening the water hose to the water inlet port of the freezer assy Place a water pan under this water inlet port then disconnect the water hose and collect all water flowing from freezer and from water hose 3 Withdraw the evaporator sensor probe from the its holder as stated in item B Page 27 4 Recover the refrigerant from the system and transfer itin a container so to reclaim or recycle it 5 Unsolder and disconnect the capillary tube and the accumulator
42. tart the ice machine it is necessary to push the RE SET button that protrudes through the control box cover The RED LED starts blinking and three minutes later the flaker unit resume its normal operating mode The condenser temperatu re sensor has a further safety function which consist in preventing the unit from operating in Lo ambient conditions i e when the condenser body temperature equivalent to the ambient temperature is lower then 1 C 34 F Fig 7 As soon as the ambient tempe rature rises up to 5 C 40 F or more the PC Board will automatically restarts the machine through the three minutes delay time HLL e en GEAR MOTOR yROTATION DO e o 52 CONDENSER TEMP y T lt 1 C i 24 O O o a EVAPORATOR TEMP 7 O E E 7 To a ICE LEVEL CONTROL 2 Bil COMPRESSOR NM u Nu CONTACTOR COIL Lo GEAR MOTOR FAN MOTOR ELECTRONIC CARD Page 19 The refrigerant suction or Lo pressure sets in normal ambient conditions 21 C on the value of 0 4 0 5 bar 6 7 psig after few minutes from the unit start up This value can vary of 0 1 or 0 2 bar 1 5 3 psig in relation to the water temperture variations influencing the freezer cylinder NOTE If after ten minutes from the unit start up no ice is made and the evaporating temperature detected by the evaporator senso
43. tarts blinking After 3 minutes the unitresumes its total operation with the immediate start up of the gear motor and 2 seconds later of the compressor F Check for the correct operation of the electronic eye for the ice bin level control by placing one hand between the sensing eyes located in the ice spout to interrupt the light beam This interruption will cause an immediate extinguishing of the RED LED located on the front ofthe P C Board and after about 6 seconds causes the shutoff of the unit with the simultaneous lighting of the YELLOW LED signalling the full bin situation Fig 6 Allow the resumption ofthe light beam previously interrupted and after about 6 seconds the flaker will resume through the 3 minutes STAND BY period the ice making process with the extinguishing of the YELLOW LED WATER O Q LEVEL gt GEAR M CONDENSER TEMP EVAPORATOR TEMP LL SENSORS ICE LEVEL CONTROL O 0 COMPRESSOR 00006 DATA PROCESSOR A OTOR FAN MOTOR ELECTRONIC CARD Page 16 M Ifpreviously installed remove the refrigerant NOTE The ICE LEVEL CONTROL INFRA service gauges and re fit the unit service panels RED SYSTEM is independent ofthe tempe previously removed rature however the reliability of its detection can beaffected by external light radiations or by any sort of dirt and scale sediment N Ins
44. tating auger and compacted and forced out by the ice breaker J ICE BREAKER The ice breaker is fitted in the freezer upper part it has two breaker teeth to break the ice and with its slanted shape from the rear tooth to the front one it compacts and forces the ice out in an horizontal way By undergoing this the ice looses its excess of water content so it drops into the bin in hard dry bits of ice In the ice breaker it is housed the top bearing which is made of two rolls bearings positioned to withstand the auger axial and radial loads This bearing is lubricated with a food grade water resistant grease NOTE It is advisable to check the conditions of both the lubricant grease and the bearings every six months K DRIVE GEAR MOTOR This motoreducer is made of a single phase electric motor with permanent capacitor directly fitted on a gear box The drive motor rotor is kept aligned on its vertical axis by two ball bearings permanently lubricated The gear case contains atrain of three spur gears the first one of which is in fiber to limit the noise level All the three gears are encased in case bearings and are covered by lubricant grease MOBILPLEX IP 44 Two seal rings one fitted on the rotor shaft and the other on the output shaft keep the gear case sealed Hovewer the interior can be inspected and serviced by unbolting the two halves of the aluminium gear case housing The gear reducer output shaft is c
45. tion Inthis circustance the5th warning YELLOW LED will blink Fig 3 After having diagnosed and eliminated the cause of the poor evaporating temperature insufficient refrigerant in the system or inoperative evaporator sensor itis necessary to push the RE SET BUTTON that protrudes through the hole of the control box cover Theunit before resuming the total operation will go through the usual 3 minutes STAND BY period NOTE On air cooled models the condenser temperature sensor which is located within the condenser fins keep the head condensing pressure between 8 5 and 9 5 bar 120 135 psig Incase ofcondenser clogging such to prevent the proper flow of the cooling air or in case the fan motor is out of operation or shortage of water in the water cooled condenser the condenser temperature rises and when it reaches 70 C 160 F for air cooled version and 62 C 145 F for water cooled version the condenser temperature sensor shuts off the ice maker with the consequent light up of the RED WARNING LIGHT Fig 4 After having diagnosed the reason of the temperature rise and removed its cause it is necessary to proceed as per the previous NOTE to start up again the operation of the ice maker OPERATION CHECKS UPON THE UNIT START UP E Check for the correct CUT OUT and CUT IN of the float reservoir water level sensors by first shutting closed the water shuto
46. tion that if it occures will greatly affect all the freezer and gear reducer components NOTE To restart the unit after the shutoff caused by this safety device itis necessary firstto eliminate the cause that has generated the intervention of the device and then press the RE SET push button or switch OFF and ON the power line main disconnect switch C CONDENSER TEMPERATURE SENSOR The condenser temperature sensor probe located within the condenser fins air cooled version or in contact with the tube coil water cooled version detects the condenser tempera ture variations and signals them p current at low voltage to the P C B Incasethe condensertemperature a atemperature atthe condenser lower than 1 C 33 F that signify that the ambient temperature is atthe same value therefore it is too low for the correct unit operation the sensor signals to the microprocessor to stop immediately or to do not start the unit operations up to the moment that the ambient temperature will rise to more acceptables terms 5 C E ICE BIN LEVEL LIGHT CONTROL The electronic ice bin level control located into theice spout hasthe functionto stop the operation ofthe ice machine when the light beam between the light source and the sensor gets interrupted by the flake ice which accumulates in the spout When the light beam is interrupted the RED LED located in the front of the P C BOARD goes off incasethel
47. to the MICROPROCESSOR to stop immediately the unit operations like it occures for the wrong rotation with the lighting up of the YELLOW WARNING LED This to relieve from the WO un GEAR MOTOR ROTATION cc GP 5 o O EL CONDENSER TEMP u 6 O EVAPORATOR TEMP IE lt LL O lt o0 a ICE LEVEL CONTROL O O L a e N 2 a o O 000 ELECTRONIC CARD excessive load all the electrical and mechanical components of the entire Drive System and extend their durability Page 20 NOTE After having diagnosed and eliminated the source of the gear motor slow rotation to restart the unit it is necessary to press also in this case the RE SET push button or switch OFF and ON the power line main switch NOTE Before charging the refrigerant system always check the type of refrigerant and quantity as specified on the individual ice machine dataplate Therefrigerantcharges indicatedare relatives to averages operating conditions REFRIGERANT METERING DEVICE capillary tube REFRIGERANT CHARGE R 134 A air cooled water cooled AF 80 310 gr 310 gr AF 100 420 gr gr REFRIGERANT CHARGE R A air cooled water cooled AF 200 420 gr 420 gr OPERATING PRESSURES With 21 C ambient temperature Discharge pressure AF 80 100 200 Air cooled version 8 5 10 bar
48. truct the owner user on the general which may depositdirectly on the light source operation of the ice machine and about the and on the receiver cleaning and care it requires To prevent any possible ice maker malfunction due to negative affection of the light detector it is advisable to locate the unit where it is not reached by any direct light beam or light radiation also it is recommended to keep the bin door constantly closed and to follow the instructions for the periodical cleaning of the light sensor elements as detailed in the MAINTENANCE AND CLEANING PRO CEDURES 00060 O RESET ep GEAR MOTOR ROTATION TO O O e o O o Y CONDENSER TEMP i z man O 9 o EVAPORATOR TEMP ban lt CZ O E Eh Ia ICE LEVEL CONTROL DO O o3 L 1 Km O FAN MOTOR z COMPRESSOR ELECTRONIC CARD Page 17 PRINCIPLE OF OPERATION WATER CIRCUIT The water enter in the machine through the water inlet fitting which incorporates a strainer and it is located at the rear side of the cabinet and then it goes to the water reservoir flowing through a float valve NOTE The presence of the water in the float reservoir is detected by a system of two sensors which operates in conjunction with the P C Board The two sensors use the wateras a conductor to maintain a low voltage current flow
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