Rapid Freeze ICE FLAKERS INSTALLATION & SERVICE
Contents
1. Re install insulation and plastic jacket MODEL RLE RLB CO OPERATING SERVICE MANUAL 44 Service amp Adjustment Replacement Parts Listing MODEL RLE RLB CO OPERATING SERVICE MANUAL 45 Service amp Adjustment D HOWE Replacement parts for Rapid Freeze Ice Flakers Effective January 2011 Table Description Page Cross Section Drawing 47 Replacement Parts for 2000 6000 pound ice machines 48 49 2 Electrical Panel Parts 49 Miscellaneous Parts 50 Howe Corporation 1650 N Elston Ave Chicago IL 60642 Tel 773 235 0200 Fax 773 235 0269 www howecorp com email howeinfo howecorp com MODEL RLE RLB CO OPERATING SERVICE MANUAL 46 Service amp Adjustment Models 2000 3000 4000 6000 ICE FLAKERS 58 40 O O O 11 4 61 14 Lil f 9 f m t i 05 I i 43 74 N N R O o SHAFT ROTATION o 42 oy s 48 19 45 41 44 46 18 68 65 22 66 A 20 63 5 22 80 53 54 3 12 1 36 56 57 56 62 o TAs 45 T7 6 9 38 37 35 7 4 OHb 1 7 2 15 Q 3 A 2 To el 2 ee 20 21 27 47 CROSS SECTION 49 50 MODEL RLE RLB CO OPERATING SERVICE MANUAL 47 Service amp Adjustment TABLE 1 Replacement Faris for Models Listed 2000 3000 6000 to Right 9a Nuns bolts amp washers Gee biaa mies2. Eor 3065 Fe of nm a naa feeler gauges for ice blade adjustment u Ice Ice deflector 00000 Nuts bolts amp washers Ice deflector Insulating ring 2 E10J1 1 Squeegee 81 7L 121 L 20 7L eh replacement kit 2 bearings 1 plate amp 3 E20K4 E Bearing removal replacement tool kit E10T1 Insulating Ring Tool used to pull out flush to evaporator 35 amp 36 Water pom side spout amp fitting E10H73 6 E20H45 7 E30H8 7 L 3 fr an nce Tubes fittings Aluminum pan copper tubes a mmm sen r Boner e vas o pap side 000000 CO Water sump gasket E20J2 Water float valve E10H29 Round float 6 arm E50H18 Rectangular float 11 arm see p 70 PENH Eons CNBHF Water float valve fitting CNB BRO2X06 SG BRO8 Water tube kit with regulating valve E10H67 KT MODEL RLE RLB CO OPERATING SERVICE MANUAL 48 Service amp Adjustment TA i BLE 1 Replacement Pai for Models Listed 2000 3000 4000 to Right Item No Part Description Part Number FON 65 66 67 Flexible coupling complete For speed reducer PINYA ENSE 68 speed reducer r dy mos O speed reducer or sooy mos mo TABLE 2 Electrical Panel Parts 2000 3000 4000 6000 Item No Part Description Part Number E20T40 RL HTR Control Panel Overload reset button normally open Control transformer 230V AC primary 24V AC secondary 3 pole relay for motor contactor 24V AC F5T2 3 pole relay base 5V
3. Remove the drive motor as described above remove 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 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 the relief vent located on the top if the gearbox in a set screw if the gearbox is turned on its side or up side down The bottom part of the flex coupling is attached to the shaft with a setscrew Loosen the setscrew 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 Install the new or existing if it is not damaged flex coupling to the shaft and speed reducer lining up the keyways with the key Re tighten the setscrews in both parts Place the bronze star on the bottom part of the coupling Install the gearbox with top coupling attached onto the top casting over the bottom part of the flex coupling Ifthe gearbox does not sit on the top casting properly you may need to loosen one or both of the setscrews on the flex coupling to allow the gearbox to seat on the machined surface of the casting There should also be a 1 16 gap between the top coupling half and the bronze star Rotate the gearbox COUNTERCLOCKWISE ONLY until
4. should perform the operations described in this manual MODEL RLE RLB CO OPERATING SERVICE MANUAL 1 Introduction Safety Symbols amp 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 These safety symbols will alert you to any special precautions throughout this manual BEWARE OF HAZARDS WHICH CAN RESULT IN PERSONAL INJURY st WARNING DO IT RIGHT OR RISK SEVERE PERSONAL INJURY FOLLOW INSTRUCTIONS st WARNING st CAUTION BE CAREFUL NOT TO HURT YOURSELF OR TO DAMAGE THE EQUIPMENT FOLLOW INSTRUCTIONS st CAUTION MODEL RLE RLB CO OPERATING SERVICE MANUAL 2 Introduction Installation Drawings MODEL RLE RLB CO OPERATING SERVICE MANUAL 3 Introduction TYPICAL INSTALLATION DRAWING Exhibit 1 MODEL RLE RLB CO OPERATING SERVICE MANUAL 4 Introduction ASSEMBLY DRAWING 2000RLB 2000 RLE CO Flaker amp CP1500 Mobile Express Bin Other models similar EXHIBIT 2 29 1 0 on 2000 RLE CO2 ICE FLAKER CP1500 ICE BIN MODEL RLE RLB CO OPERATING SERVICE MANUAL 5 3 4 1D DRAIN 2 70 BACK VIEW 16 172 86 1 8 ICE BIN DRAIN 3 4 ID CART DRAIN Introduction
5. wiring harness if the plug on the emitter has three pins then do the following Check wiring of the EMITTER cable E20T69 about 3 long in the control panel This should have only the Blue amp Brown wires connected to the RELAY BASE 5V013 in the control panel Blue is connected to terminal 10 and Brown is connected to terminal 1 If the Black wire is connected to terminal 11 lightly marked the side terminal tab of the RELAY BASE this wire should be removed and isolated so it does not come into contact with any other terminal If the emitter has only two pins in the Molex plug the black wire does not need to be removed provided the Molex plug is packed with Di electric grease Next check wiring of the RECEIVER cable E20T70 about 3 3 4 long in the control panel This should have the Blue Brown amp Black wires connected to the RELAY BASE in the control panel Blue is connected to terminal 10 and Brown is connected to terminal 1 Black is connected to terminal 11 If not connect as described Step 4 CHECK FOR CORRECT VOLTAGE With POWER SUPPLY RELAY E20T68 plugged in and power to Flaker on check with volt meter to verify there is 24 volts across Molex spade connectors attached to Blue amp Brown wire for both the EMITTER and RECEIVER Alternatively you can check terminals 1 and 10 on the RELAY BASE If you don t have 24 volts it is likely the POWER SUPPLY RELAY has failed and must be replaced S
6. ASSEMBLY DRAWING 3000 RLB 3000 RLE CO Flaker amp CP2500 Mobile Express Bin Other models similar EXHIBIT 3 29 1 2 7 85 31 5 8 POWER SUPPLY Jaa 3 4 1 H 7 8 0DS SUCTION 3000 RLE CO2 ICE FLAKER 1 2 00S LIQUID INLET 3 4 1D d b DRAIN 2 20 1 4 CP2500 ICE BIN 110 1 8 70 ICE BIN ICE BIN DRAIN 3 4 ID CART DRAIN BACK VIEW MODEL RLE RLB CO OPERATING SERVICE MANUAL 6 Receiving amp Inspection of Equipment CAUTION Only service personnel experienced in refrigeration and qualified to work with high voltage electrical equipment should be allowed to install or service this Rapid Freeze Ice Flaker ea CAUTION Upon receipt of your Rapid Freeze Ice Flaker you should first inspect the carton very carefully to determine if any damage may have occurred during shipment If you suspect any damage has occurred it should be noted immediately on the freight bill In addition a separate 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 uncrating of the carton it is necessary to keep the original shipping container so 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 begin
7. RI MOTOR RELAY R2 HEATER RELAY y ea ee Ca o o OFF ON LCI Swi 4 TA ICE FLAKER RUN sl OVERLOAD RESET N O CM Solid State Control Board LCI Level Control R1 Drive motor amp Water pump Relay contactor CR3 Isolating relay when for remote condensing unit Not applicable for CO gt flakers When connecting to a rack system A amp B wires are to remain wire nutted together A amp B wires are located in the power junction box on the rear of the flaker Remote liquid solenoid leads injunction box Wiring Diagrams PHOTO EYE CONTROL WIRING EXHIBIT 12 N O Output Wired in 28 series with module on off switch and A remote i o LC 1 Ts aes 240V AC O k 1 76 k 2 4 gt Input o E20T68 Os 3 ICE LEVEL CONTROL 10 Terminals 10 amp 1 24V AC Output Terminal 11 Trigger No Connection Honeywell Microswitch Blue OR Red with White Trace Blue OR Red with White Trace Brown OR Red with Black Trace No i Connection EMITTER PART E20T69 RECEIVER PART E20T70 Or EMITTER PART E20T104 RECEIVER PART E20T105 Important It is important to ensure that there is a drip loop on the cables near the rear of the photo eye sensors to allow any moisture to travel to the bottom of the drip loop to drip off thereby not accumulating at the rear of the sensors Maintenance Evaporator To keep the evaporator in p
8. causing water to approximately 1 4 below the return trough overflow the return trough c Water is overflowing the e Distribution tubes may be plugged Clean or distribution pan 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 d One or more water Replace as necessary distribution tubes are missing or broken splashing water into the bin Repair or replace drip pan into the storage bin g Humidity level in storage bin e Check and repair bin insulation as necessary is too high rece e Check and repair seals on the bin e Bin door has been left open too long Close door when not removing ice 2 Ice in storage bin is a Water level in the sump is too Adjust the water float valve to maintain water level too wet high causing water to approximately 1 4 below the return trough overflow the return trough b Water is overflowing the e Distribution tubes may be plugged Clean or distribution pan 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 c One or more water distribution Replace as necessary tubes are missing or broken Speed Reducer 1 Oil is leaking between a High speed oil seal in the Replace seal the front of the motor speed reducer is worn and the motor mounting flange 2 Oi
9. lines should be insulated with Armstrong Armaflex or equivalent Any insulation located in outdoor environments should be protected from UV exposure to prevent deterioration of insulating value Water Line MODEL RLE RLB CO OPERATING SERVICE MANUAL 14 Installing the Rapid Freeze Flaker 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 rear of the ice flaker Install a water line shutoff valve near the ice flaker Use 3 8 OD copper tubing between the field supplied water valve amp water inlet connection located on the rear of the flaker This line should be as short as possible to avoid pressure drop If water supply has silt or sand in it a coarse water filter is recommended IMPORTANT NOTICE A MINIMUM WATER PRESSURE OF 20 PSIG IS REQUIRED AT THE ICE FLAKER FLOAT VALVE TO INSURE ADEQUATE WATER FLOW MAXIMUM WATER PRESSURE TO THE FLOAT VALVE IS 60 PSIG IMPORTANT NOTICE WATER SUPPLY amp FILTER CONNECTIONS EXHIBIT 6 WATER FRDU BUILDING SUPPLY TD WATER CISTRIEUTION PAN WATER RE GULATING WA LYE w WATER PUUP OW ERF LOK FITTING FLOAT VALVE CRAIN FITING WATER SUUP MODEL RLE RLB CO OPERATING SERVICE MANUAL 15 Installing the Rapid Freeze Flaker Refrigerant Charging CAUTION Service Installation personnel MUST have knowledge of refrigeration systems to prope
10. power junction box on the rear of the flaker must be wired together This jumper will allow the solenoid valve to energize when the operating circuit is energized st SPECIAL NOTE Pump down the ice flaker and evacuate refrigerant from the liquid line Turn off main power to ice flaker disconnect wires leads from solenoid valve Cut out or de solder the solenoid valve from the liquid line and remove the old valve Install and solder the new valve into the liquid line pressure test your connections for leaks b li CAUTION ARROW ON SOLENOID VALE MUST POINT IN THE DIRECTION OF FLOW TOWARDS ICE FLAKER t CAUTION 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 atmosphere Re connect solenoid coil wires Turn on main power turn ice flaker switch on and check operation of solenoid valve MODEL RLE RLB CO OPERATING SERVICE MANUAL 41 Service amp Adjustment Electronic Expansion Valve Cascade CO2 Systems feature a motor operated Electronic Expansion Valve EEV which is controlled by a standalone superheat controller contained in a separate panel on the back or the side of the ice flaker The controller comes pre set from the factory to automatically regulate the EEV to the preferred superheat Therefore there should be no need to make any adjustments to the controller However if the setpoints have been changed o
11. the base of each suction riser of four 4 feet or more to enhance oil return to the compressor e When brazing refrigerant lines an inert gas should be passed through the line at low pressure to prevent scaling and oxidation inside the tube Dry nitrogen is preferred f Use only a suitable silver solder alloy on suction and liquid lines g Limit the soldering paste or flux to the minimum required to prevent contamination of the solder joint internally Flux only the male portion of the connection never the female After brazing remove the excess flux The size of the suction and liquid line should be the same as the connection size on the ice flaker provided that the runs are not longer than 150 feet Refer to table below for line sizing TABLE 1 MODEL MIMIMUM SUCTION MINIMUM LIQUID LINE RETURN LINE 2000 RLE CO gt 5 8 ODS 3000 RLE CO 7 8 ODS 1 2 ODS 4000 RL CO gt 1 1 8 ODS z 6000 RL CO gt 1 1 8 ODS REFRIGERANT PIPING SUPPORT MODEL RLE RLB CO OPERATING SERVICE MANUAL 12 Installing the Rapid Freeze Flaker Example of Pipe Support Normally any piping straight run of tubing must be supported in at least two locations near each end of the run Long runs require additional supports The refrigerant lines should be supported and fastened properly As a guide 3 8 to 7 8 should be supported every 5 feet 1 1 8 every 7 feet When changing directions in a run of tubing no corner should b
12. you may proceed with the Start and Adjust section D 2 3 4 5 6 D 8 Checklist 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 below EXHIBIT 8 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 verify that it is within nameplate ratings Turn the On Off switch ON Solenoid valve will click loudly and motor amp pump will start As the drive motor amp water pump are energized water is delivered to the distribution pan located inside the evaporator Looking down inside the evaporator through the hand hole access cover verify that the distribution pan water level is maintained at the half full point If it is too low then the water regulating valve needs to be opened slightly If the water level is too high then the regulating valve must be closed accordingly Continue opening or closing the adjustment valve until the water level is maintained at the proper level see below EXHIBIT 9 After a few minutes the ice maker will begin to freeze the water circulating over the evaporator into ice Allow 10 15 minutes to let the ice flaker come down to temperature and balance out MODEL RLE RLB CO OPERATING SE
13. 013 4 pole contactor for drive motor 24VAC 230VAC single pole double throw relay Relay base socket for E20T45 relay E20T44 E20T45 E20T46 Solid state control module Green 24VAC Indicating Light Amber 24VAC Indicating Light Ice level control power module relay Ice level control power module base Ice level control emitter E20T104 E20T104 NP Ice level control receiver E20T105 E20T105 NP Ice level control sensor bracket set E10U44 MODEL RLE RLB CO OPERATING SERVICE MANUAL 49 Service amp Adjustment TABLE 3 Miscellaneous Parts 2000 3000 Part Description Part Number ee ee care r EE ete oring for ver eho EONS r wrench SCS AE CEV ORCS a III i Expansion van O I rss Tr In A O k kevin Mr MODEL RLE RLB CO OPERATING SERVICE MANUAL 50
14. 1 4 per foot pitch towards the building floor drain The use of a vent at the top of the drain line will ensure that the system will drain properly MODEL RLE RLB CO OPERATING SERVICE MANUAL 8 Installing the Rapid Freeze Flakere Installation on Ice Storage Bins Rapid Freeze Ice Flakers are designed to run smoothly and without vibration Howe Mobile Express ice storage systems are designed to handle the weight of a RLE model ice flaker without any additional bracing It is recommended that the installer contact manufacturer before any other ice flaker is placed on top of a bin 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 Procedure of Ice Machine Ice Level Control and Drain lines Locate and set the bin on a solid surface If the surface is uneven you can level the system by extending the feet until the bin is leveled Once the bin is set in place and leveled the Rapid Freeze ice flaker can be placed on top of the storage bin When location and placement of the ice machine and storage bin are considered a floor drain should be located near or under the units to adequately remove any water from the floor caused by cleaning the equipment or spillage of ice while emptying or transferring ice from bin INSTALLATION ON BIN EXHIBIT 4 MODEL RLE RLB CO OPERAT
15. 16 17 18 19 20 21 evaporator surface Lift the shaft assembly out of the evaporator Be careful to avoid scratching evaporator freezing surface with the ice blade Examine shaft journals for wear if worn repair or replace shaft Remove old oil seals in upper casting Press out bearing in upper casting using a drift pin or properly sized wood block Note To avoid distortion of casting it should be supported near the bearing area and not on the outer edge Press new bearing into position Then press the new oil seals into position To remove the bottom bearing first remove the bottom bearing cover and the old bearing plate Now follow the same steps as were done for the top bearing steps 10 12 Install new bottom bearing plate replace bottom bearing cover Insert the new or repaired shaft Running clearance between shaft and new bearing must be about 001 Shaft must rotate freely in bearing Re position rubber insulating ring use adhesive if possible Re install top casting Make sure that the evaporator lugs are properly seated against shoulders machined in casting Tighten down the four mounting bolts evenly Shaft must rotate freely by hand If shaft is tight it indicates that the top casting is off center Install ice blade and adjust clearance to approximately 003 at closest point Refer to blade adjustment instructions Re install bottom half of the flexible coupling Re install gearmotor
16. ADJUST Checklist Exhibit 8 Distribution Pan Water Level Exhibit 9 Off Delay Timer Drive Motor Overload Suction Temperature ELECTRIC CONTROL PANEL Components amp Functions Exhibit 10 E20T48 Solid State Control Board WIRING DIAGRAMS 2000 amp 3000 RLE CO Exhibit 11 Exhibit 12 MAINTENANCE Evaporator Cleaning Procedure Water Distribution Tubes Water Sump Ice Machine Condensate Drip Pan Lubrication Bearing amp Seal Preventative Maintenance PM Maintenance Schedule TROUBLESHOOTING CHART Photo Eye Solid State Control Board 18 19 19 19 20 20 20 21 22 23 24 25 25 26 26 26 26 27 27 28 28 29 30 Rapid Freeze Manual Information 10 11 Controls and Power Devices Freezing Ice Storage Gear Motor Speed Reducer SERVICE and ADJUSTMENT Warnings amp Safety Information Ice Deflector Squeegee Water Distribution Tubes Drive Motor Gear Box Exhibit 13 Ice Level Control Water Pump Float Valve Solenoid Valve Electronic Expansion Valve Adjustment of Ice Blade Main Bearing Replacement GENUINE REPLACEMENT PARTS CATALOG 31 32 33 33 34 35 36 37 37 39 40 40 41 41 42 43 43 44 45 Introduction Howe Rapid Freeze flakers are available world wide in over 2000 Howe locations The Howe Rapid Freeze Flaker is backed by over 50 years of proven performance and innovation Long known for durability and reliability our flake ice equipm
17. As an alternate method mix a solution of approved sanitizer Howe part E10V31 Follow instructions on bottle 2 Pour solution into sump to normal operating level as in 6 then re circulate sanitizing solution for approximately 20 minutes by turning on drive motor amp pump 3 Drain solution and rinse thoroughly with fresh water at least twice following procedure described in No 8 4 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 and restoring refrigeration by turning the machine back to ON MODEL RLE RLB CO OPERATING SERVICE MANUAL 26 Maintenance Lubrication Bearings amp Seals Main Bearings on the Ice Flaker are oilite and have grease fittings for both top amp bottom bearings The top bearing is accessed through the hand hole cover the bottom bearing is greased via a grease fitting located on the center hub accessed from the ice bin The main bearings should be greased annually using a U S D A approved food grade edible grease Use caution to ensure the bearing is not over greased Typically only one squirt of the grease gun is required or until you feel resistance on the pump to grease the bearing s Over greasing may pop the seal out of its normal position If over greased and the seal is poped out of position the excess grease will need to be removed prior to re installing the seal If
18. D HOWE Rapid Freeze ICE FLAKERS INSTALLATION amp SERVICE MANUAL and parts catalog General Purpose Flake Ice Machines 2000 to 6000 Ib day Capacity e Remote Low side Series RLE e Mobile Express Storage bins CP e For Secondary and Cascade CO Systems TECHNICAL ASSISTANCE LINE 1 773 235 0200 Howe Corporation 1650 North Elston Avenue www howecorp com Chicago IL 60642 e mail howeinfo 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 2011 All rights reserved Reproduc
19. ER SUPPLY RELAY to close the solenoid valve When the solenoid valve de energizes the adjustable off delay timer keeps the drive motor amp water pump running for between 2 30 minutes to clear any residual ice off the evaporator Emitter E20T69 and Receiver E20T70 are interchangeable with newer style Emitter E20T104 and Receiver E20T105 Trouble Shooting Main Control Board Verify 24 VAC 4 VAC between terminal 1 amp 2 If ok proceed if not check transformer in control panel for proper operation Checking Operation Place wire jumper between terminal 2 amp 3 to initiate unit start up Terminal 6 should energize immediately energizing drive motor contactor Terminal 7 amp 8 should close immediately allowing Solenoid Valve to energize Remove Jumper Terminal 6 should be remain energized for off delay time period 1 30 minutes Terminal 7 amp 8 should open immediately de energizing solenoid valve Checking Overload Condition With machine operating in normal condition slowly turn current sensing overload set point down counterclockwise until red LED illuminates continue slowly turning CCW until set point trips Tripping the overload set point does the following De energizes output contact 6 de energizes motor contactor Opens contacts 7 amp 8 de energizing solenoid valve Turn set point CW to point prior to trip point reset overload and check for operation If red LED is illuminated and motor a
20. ING SERVICE MANUAL 9 Installing the Rapid Freeze Flaker 1 Remove front panel of ice flaker by lifting up and away from unit and place aside until all connection and adjustments are made 2 Remove top cover of ice flaker by lifting straight up and set aside with front cover Cover is removed for easy access when installing and connecting refrigeration lines 3 With two people or forklift position ice flaker on to storage bin Be careful to locate bottom frame of flaker over raised portion of ice bin drop zone so ice machine is centered correctly 4 On the bin top remove mounting screws amp eye box covers and set aside with front cover Ice level sensors are mounted in the eye boxes on the bin top one on the left and right side of ice machine Locate cables from ice level sensors and route under protrusions on sides of flaker enclosure Reach into the front of flaker and pull cables to front of unit Leave enough slack to form drip loop on the cable in the eye box Eye boxes should remain dry amp free from moisture to eliminate potential problems 5 Notice that cables have a spaded plug connection Locate similar cables with spaded plug connection which protrude from channel of enclosure frame and attach respective plugs from each sensor to its corresponding plug See note on next page regarding Di electric grease When power is provided and flaker is turned on ice machine and ice level control will be operati
21. N NEVER install an ice flaker in a COLD room below 45 F 7 C 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 t CAUTION Optimum surrounding air temperature rangc 60 F 15 C to 95 F 35 C Minimum air temperature ccccscsssccssssssscccssssssccssssscccsssssesssssssecsccees 50 F 10 C Maximum air temperature scccccssscssssssssssssssscscssssscsescssssscssssscssssssessees 100 F 38 C Optimum water temperature rang e esesssosossooooooooooce 60 F 10 C to 80 F 25 C Minimum water temperature without water mixing valve s ssssssossee 50 F 8 C Minimum water temperature water mixing valve must be used 36 F 4 C Maximum water temperatUre aaaaccnsnccccsnnntnnsnnnannnnannnnnnnnnsnnnntannnnnnnnnnan u 90 F 32 C Refrigeration Requirements Flaker Model Refrigeration Requirements Evaporator Temp Range 2000 RLE CO 18 000 BTU hr 3000 RLE CO 27 000 BTU hr 15 F to 20 F J hr hr 4000 RL CO 34 100 BTU 6000 RL CO 51 150 BTU Refrigeration requirements are based on operating the ice flaker with 70 F supply water and 90 F Ambient air conditions Refrigeration requirements and or capacity may change with temperatures outside these conditions Drain Systems All drains are of the gravity type and must have a minimum of
22. OPERATING SERVICE MANUAL 31 TroubleShooting Chart on overload b Electronic overload is set too Check amp draw on drive motor If amps do not low 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 c Ice blade is dragging on the Readjust the clearance on the ice blade drum 8 Drive motor runs but a The shaft key on the slow Repair or replace the speed reducer main shaft only turns speed output shaft of the when there is no ice on speed reducer has sheared the drum Freezing and Refrigeration 1 Ice freezes along entire a System is short of refrigerant Charge system properly length of drum but b Suction temperature is too Lower suction temperature to 20 F low d The liquid line filter drier is dirty 2 Ice freezes and harvests Replace worn bearings Repair or replace main shaft entire height of is excessive wear is detected harvests on only one high after bearing replacement factory for assistance 3 Ice freezes and harvests a Feed water is too hard Install a water softening system entire height of b Freezing surface is coated Clean the evaporator surface with ice machine evaporator but with hard water deposits cleaner harvests poorly or at random 4 No ice freezes on the a Loss of refrigerant
23. RVICE MANUAL 19 Start and Adjust 9 Looking down into the evaporator through the hand hole cover check to make sure the ice is being frozen and harvested over the entire surface of the evaporator If it is not check the suction temperature at the ice machine Suction temperature must be maintained between 15 F and 20 F 10 Liquid line must have unrestricted flow at all times for proper performance of ice flaker On ice flakers connected to a rack system liquid line should be connected directly to the receiver before any defrost restricting valves 11 If suction temperature is correct and ice is not being frozen and harvested on the entire surface of the evaporator then 12 When the ice maker is adjusted and operating properly turn off the on off switch or block the electric eye beam path The electric eye control has a 15 second delay before it s output opens When the output opens or when the on off switch is opened the shutdown sequence is initiated de energize the solenoid valve and start the off delay cycle for the drive motor amp water pump 13 Ice flaker is pumped down solenoid valve is de energized drive motor amp water pump continue to run until the off delay cycle opens Field adjustable between 1 30 minutes normally set at approximately 5 10 minutes 14 Electronic overload set point is factory set to trip and shut the flaker off when the motor reaches an overloaded condition 15 Ice maker is ad
24. ade 60 degrees and recheck clearance Repeat this operation at a minimum of six points on the circumference of the evaporator in order to determine the point of least clearance accurately With the ice blade rotated to the point of least clearance set gap between ice blade and evaporator freezing surface to between 4 and 6 mil at the top and the bottom of the blade Tighten the blade mounting bolts and recheck clearance Bearing Replacement 1 Remove gearmotor by taking out the 4 cap screws from the top aluminum casting amp Remove the lower half of the flexible coupling 2 Remove rivets which retain the outer jacket around the ice flaker Pull the jacket away from the body of the ice flaker 3 Cut away at the upper 3 inches of insulation uncovering 4 3 8 cap screws which bolt the upper aluminum casting to the evaporator Remove these 4 bolts If spacers are found between evaporator lugs they should be marked and re used in the same position These are required to obtain proper alignment 4 Using a rubber mallet gently tap the aluminum casting from below upwards to free it from the evaporator Adhesive is used to retain the rubber insulating ring in place 5 Lift up on the aluminum casting and slide it off the shaft 6 Loosen rubber squeegee mounting bolts and push squeegee away from the MODEL RLE RLB CO OPERATING SERVICE MANUAL 43 Service amp Adjustment 7 8 9 10 11 12 13 14 15
25. charge Inspect refrigeration system for leaks Repair as evaporator necessary and recharge system 5 Flaker makes ice a Undersized water line Install properly sized water line intermittently b Low water pressure under 20 Contact factory for guidance psi c Water filters are clogged Replace water filters 6 Ice flakes are too thin a Evaporator temperature is too Lower suction temperature to 20 F high 7 Ice flakes are too a Evaporator temperature is too Maintain suction temperature at 20 F small with an excessive low amount of snow 8 Ice flaker chatters and does not run Replace worn bearings Repair or replace main shaft smoothly is excessive wear is detected water return trough properly 11 Ice accumulates in the a Ambient temperature is too e If ambient temperature is between 45 F and 50 F water return trough low install warm water mixing valve sump and on the ribs in the bottom casting e If ambient temperature is below 45 F relocate the flaker to a warmer area Ice Storage and Removal 1 Ice flakes are frozen a Ice has been left in the storage e Remove ice from the storage bin daily MODEL RLE RLB CO OPERATING SERVICE MANUAL 32 TroubleShooting Chart together in a hard bin too long e Install a clock timer to limit the ice flaker block production b Water level in the sump is too Adjust the water float valve to maintain water level high
26. de 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 motor making sure the bolts do not thread into the mounting lugs Turn in both bolts until they are hand tight then turn in each bolt 2 turn at a time alternately until the motor if free enough to remove by hand When installing the new motor place the 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 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 Reattach the flexible power cable to the motor connect the power leads to terminals marked L and L2 and check to insure the motor is wired for the correct power 115 or 230 and for the correct rotation CCW Refer to wiring connections on the motor nameplate for the correct connections 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 amp Flexible Coupling MODEL RLE RLB CO OPERATING SERVICE MANUAL 37 Service amp Adjustment Disconnect main power to the ice flaker
27. e left unsupported Supports should be placed a maximum of 2 feet in each direction from the corner Piping attached to a vibrating object such as a compressor or compressor base must be supported in such a manner that will not restrict the movement of the vibrating object Ridged mounting will fatigue the copper tubing Do not use short radius ells Short radius elbows have points of excessive stress concentration and are subject to breakage at these points Thoroughly inspect all piping after the equipment is in operation and add supports wherever line vibration is significantly greater than most of the other piping Extra supports are relatively inexpensive as compared to refrigerant loss REFRIGERANT PIPING EXHIBIT 5 MODEL RLE RLB CO OPERATING SERVICE MANUAL 13 Installing the Rapid Freeze Flaker CHECK VALVE 0 ICE FLAKER STDP VALVE gE LIQUII L Dr DK A OPTIONAL STRAINER 1 0 RT SOLENOID STO VALVE 1 2 ODS NOTES DASHED LINES INDICATE FIELD PIPING CTION LINE LIQUID LINE S LIQUII MODEL TOP VALVE ALVES Poe ue SOLENOII lt DS ODS lb hr ORIFICE RLE CO PLE CO RLE CO gt RLE CO z SE HIGH PRESSURE RATED VALVES 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 line Refrigerant
28. e water is dispersed over the evaporator and it doesn t splash water over the ice deflector If it is adjusted too far forward the water may cascade down onto the ice deflector and dribble onto the ice in the storage bin If water is running onto the ice deflector turn the lead tube away from the ice blade so water does not run onto the ice deflector The side spouts are positioned so the ends of the tubes are approximately 3 away from the surface along the top edge of the evaporator pointed slightly down towards away from the distribution pan Ensure that the water level is at least 1 2 full in the distribution pan but not overflowing the top Inadequate water level may cause water to dribble out of the distribution tube s down onto the ice in the bin amp not on the evaporator Replacement of Drive Motor 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 L2 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 set screws or couplings the motor shaft fits directly into the hollow high speed input shaft on the speed reducer with a 3 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 center line one on each si
29. eak performance the ice maker 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 instructions 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 CAUTION ICE MACHINE CLEANERS CONTAIN ACIDS AND MAY CAUSE BURNS HANDLE WITH CARE IN CASE OF EXTERNAL CONTACT FLUSH WITH WATER IF SWALLOWED DO NOT INDUCE VOMITING GIVE LARGE AMOUNT OF MILK OR WATER RINSE MOUTH WITH WATER e SEEK IMMEDIATE MEDICAL ATTENTION USE APPROVED ICE MACHINE CLEANER ONLY MIX SOLUTIONS PER MANUFACTURERS INSTRUCTION CAUTION 1 Turn off refrigeration If flaker is connected to a compressor rack close the liquid line shut off valve turn off the ice flaker switch Adjust the off delay time adjustment fully clockwise to allow refrigerant
30. ent 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 Rapid Freeze Energy Efficiency The Rapid Freeze Flaker Ice Machine enjoys a world renowned reputation for having one of the highest energy efficiency rating EER of any ice maker on the market With energy usage of 30 40 below that of many competitors models the Rapid Freeze ice machine offers an outstanding value In addition to high energy efficiency the Rapid Freeze Flaker is extremely dependable with very low maintenance cost Overall the cost of owning and operating a Howe Rapid Freeze Flaker is one of the lowest in the industry 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 Special Precautions To Be Observed When Charging Refrigeration Systems Only technically Qualified persons trained and Certified in the handling of refrigerant and operation of refrigeration systems
31. ent of Ice Deflector Scraper 2000 amp 3000 RLE MODEL RLE RLB CO OPERATING SERVICE MANUAL 35 Service amp Adjustment The ice deflector scraper is mounted on one of the three bottom ribs using two stainless bolts and nuts The scraper s primary purpose is to clear any buildup of ice on the ice deflector as the deflector passes by the scraper When properly positioned the scraper will be approximately c above the deflector blade When replacing the scraper it may be necessary to cut the angled edge down to the proper size This may be cut with either aviation snips or a razor knife Replacement amp Adjustment of the Squeegee amp Squeegee Wrapper 2000 amp 3000 RLE Only Shut off ice flaker and allow machine to pump down de ice Once the machine is clear of ice then disconnect the main power to the ice flaker and LOCK THE DISCONNECT SWITCH IN THE OFF POSITION to prevent accidental start up Remove the service access cover on the top casting Remove 2 or 3 water distribution tubes for easier access Reaching down into the freezing chamber loosen and remove the two 5 16 bolts holding the existing squeegee amp squeegee wrapper in place Remove the squeegee amp 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 your existing wrapper Reinstall the squeegee amp wrappe
32. equired only once a year oe Parts to check for damage are ice deflector ice deflector scraper squeegee amp wrapper water distribution tubes and float valve MODEL RLE RLB CO OPERATING SERVICE MANUAL 28 TroubleShooting Chart Troubleshooting Procedure for Operation of E20T73 Photo Eye Ice Level Control For Photo Eye Level Control sensors supplied with RLE Flaker Models with integral control panels attached with cables using Molex connectors When checking Molex plugs Hold connectors to connect disconnect DO NOT PULL BY CABLE Step 1 CHECK FOR WATER OR MOISTURE IN MOLEX PLUG If the Molex plug for either the emitter or receiver is wet or has moisture in it shake water off plug and dry properly Pack the Molex plug s with Di electric grease re connect amp test unit Note IF Molex plug is unplugged plug must be re packed with Di electric grease each time it is un plugged to maintain water resistance Step 2 CHECK FOR LOOSE OR SLOPPY PIN IN MOLEX PLUG If the Molex plug is connected dis connected multiple times it may cause the female pin to open slightly Check the Female pins in the Molex plug Ice Machine wiring harness to ensure the pins are not opened up too much causing a sloppy or loose connection If pin appears to be opened too much gently close the female pin to ensure a tight fit for the male pin Step 3 CHECK FOR CORRECT WIRING ARRANGEMENT First unplug the emitter from the
33. justed and producing dry flakes of ice 16 Water is NOT flowing into the bin If it is locate source and correct it 1 e distribution pan overflowing water recovery trough overflowing or distribution tubes broken or misaligned MODEL RLE RLB CO OPERATING SERVICE MANUAL 20 Start and Adjust Components amp Functions 1 2 3 4 ELECTRICAL CONTROLS FOR ICE MAKER EXHIBIT 10 MOTOR Solid State LEVEL CONTROL ICE FLAKER A naay Control Board TRANSFORMER ON OFF SUY a ICE FLAKER RUN RIVE MOTO OVERLOAD RESET BUTTON LOCA ON REAR OF ICE FLAI Drive Motor Contactor Relay Provides power to the drive motor amp water pump Energized during freezing and pumpdown cycle then timed off for shut down Auxiliary contact provides power to the liquid solenoid valve when contactor is energized NOTE The red button on the relay is a manual override button when depressed by pressing the red button or raising the lever below it the relay contacts will engage even when the contactor relay coil is NOT energized Control Transformer Provides 24 Volt control power to control panel components Solid State Control Board motor contactor and indicating lights Solid State Control Board E20T48 Main control processor incorporates motor overload operating circuit off delay circuit Controls motor contactor and solenoid valve power Photo Eye control relay processes signals from electronic eye level co
34. l leaking is evident Slow speed oil seal in Replace seal on the top of the the speed reducer is worn kdo flexible coupling MODEL RLE RLB CO OPERATING SERVICE MANUAL 33 Service amp Adjustment IMPORTANT SAFETY NOTICE The information in this manual is intended for use by individuals possessing adequate background in electrical refrigeration and mechanical experience Any attempt to repair major equipment may result in personal injury and 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 IMPORTANT SAFETY NOTICE 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 this may potentially cause a electrocution hazard WARNING Only technically qualified persons experienced and knowledgeable in the handling of refrigerants and operation of refrigeration systems should perform the operations described in this manual WARNING MODEL RLE RLB CO OPERATING SERVICE MANUAL 34 Service amp Adjustment 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 tha
35. moisture accumulating on the cable will travel to the bottom of the drip loop amp drip off rather than running into the rear of the sensor s Turn power on and check alignment of the eyes When the eyes are proper alignment the receiver sensor LED will light up When the signal is blocked the LED will go out then after a 15 second delay the solenoid valve will de energize and the machine will go into pump down When the receiver Sees the signal after the path is cleared of obstructions the solenoid will again energize and the machine will start making ice again Note the LED on the Emitter will be on whenever there is power applied to the emitter Re install side panels if removed top cover and front panel Replacement of Water Pump 1 Turn off the main power to the flaker remove screws holding the stationary sump cover loosen and remove water tube fitting Nylon compression fitting unplug the Nyloc electric plug from the wiring harness Lift the water pump with cover attached off the sump Installing the new pump simply reverse the above procedure Use caution when routing the new cable to insure they are secured to avoid accidental damage MODEL RLE RLB CO OPERATING SERVICE MANUAL 40 Service amp Adjustment Replacement amp Adjustment of Water Float Valve Turn off main power to flaker Shut off the water supply to the ice flaker and drain the supply line Remove water pump amp cover as described abo
36. mps are not above normal load turn slightly CW until LED goes out If control board checks out as described above it is not defective amp does not need to be replaced If any steps above do not operate as described board may be defective contact Howe for further tests if necessary MODEL RLE RLB CO OPERATING SERVICE MANUAL 30 TroubleShooting Chart Possible Cause Operation 1 Ice flaker will not start 2 Solenoid valve energizes drive motor contactor does not energize 3 Solenoid valve does not energize drive motor contactor energizes 4 Drive motor is always on b Control transformer is Check voltage between terminals and 2 on the defective flaker control module part E20T48 Normal reading is 24 VAC If 24VAC is not present replace the transformer c Control switches are open 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 d Photoeye emitter is defective 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 e 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 o
37. n 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 defective above replace control module a Control module is defective Check voltage between terminals 2 and 6 on control module If voltage reads 24VAC replace the control module b 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 a 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 contacts are open replace the control module b There is a wiring defect 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 contacts are closed check the line A jumper CR contacts wiring and solenoid coil b Photoeye controls are Check per 1 d 1 f above defective always energized 6 Ice maker does not a Photoeyes are not installed Install photoeyes per instructions b Photoeyes are defective Check per 1 d 1 f above 7 Drive motor cuts out a A speed reducer gear is worn Repair or replace the speed reducer or broken MODEL RLE RLB CO
38. ning any repairs Unauthorized work on your Rapid Freeze Ice Flaker could result in voiding the machine s warranty Remote low side RLE units are shipped with a holding charge of dry nitrogen to insure the evaporator is kept clean and moisture free They must be pumped down and evacuated after they are connected to the rack system before the entire rack system is charged with refrigerant 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 MODEL RLE RLB CO OPERATING SERVICE MANUAL 7 Installing the Rapid Freeze Flaker Installation Conditions Rapid Freeze Ice Flakers are designed to operate in ambient temperatures warmer than 50 F 10 C Do not install ice Flaker s in refrigerated cold rooms or in areas where the ambient temperature is lower than 45 F If installed in cold ambient conditions it is necessary to supply the ice Flaker with warmer water of at least 60 F 15 C through a water mixing valve When a combination of cold water and cold air temperature exists the water mixing valve must be used Failure to do so will cause the lower water collecting trough and sump to ice up to the extent that the water may overflow into the ice storage bin in addition to blocking the water inlet to the pump bl i CAUTIO
39. noid valve will de energize initiating the pump down sequence The drive motor amp water pump will continue to run until the off delay cycle time expires once the preset time expires the drive motor amp water pump will shut off The time delay period is typically adjusted to approximately 5 10 minutes after the flaker stops making ice This allows the evaporator to warm up so when the blade stops it will not run the risk of freezing to the evaporator if ice is still on the evaporator WHY ICE BIN THERMOSTATS ARE NOT USED The use of a bin thermostat is not recommended and not permitted The Rapid Freeze ice flaker is designed so that the freezing drum operating 20 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 to where it can reliably distinguish temperature difference upon contact with ice In most cases when deflector damage is reported investigation has shown that a thermostat was used as a bin level control device The photo eye ice level control physically sense the presence of ice rather than sensing temperature MODEL RLE RLB CO OPERATING SERVICE MANUAL 18 Start and Adjust Once installation has been completed and the ice Flaker has been properly evacuated and charged with refrigerant
40. ntrol has built in time delays Shuts machine off when ice bin is full to prevent damage to the flaker from ice backing up into the evaporator section Panel Mounted Items 1 Ice Flaker run light Green light is on whenever the contactor and drive motor is energized 2 Motor overload light Amber light is on whenever the electronic overload opens to stop the drive motor amp pump 3 Overload reset button Normally open reset button resets overload circuit following overload condition Located on Rear of Ice Flaker MODEL RLE RLB CO OPERATING SERVICE MANUAL 21 Start and Adjust 4 On Off Switch Main on off switch for control circuit Wired in series with Photo Eye Ice level control E20T48 Solid State Control Board The E20T48 Solid State Control Board is the main processor for the ice Flaker control panel It incorporates the timer functions control relay functions and overload relay functions Terminals 1 amp 2 Terminal 3 Terminal 4 Terminal 5 Terminal 6 24 VAC input power Ice Flaker Run input signal all on off switches ice level controls and any special controls installed must be in this circuit 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 Ice Flaker contactor output Output is energized when input signal is present amp control is not in
41. onal refrigeration must be piped and charged for flaker to make ice 6 Re install side panels if removed and top cover 7 Install lower drain pan on rear cross member of bin stand This is behind mobile ice cart BACK OF 1000 RL ICE FLAKER 8 Install drain line from upper horizontal slide door and N BRAIN lower mobile ice cart drain pans 9 Install drain line from flaker condensate and overflow connections located on rear panel of ice machine Be sure to follow local plumbing codes to prevent back flow If not installed water may migrate into the eye boxes 10 Run all drain lines in rear of ice bin to floor drain FLOOR DRAIN MODEL RLE RLB CO OPERATING SERVICE MANUAL 10 Installing the Rapid Freeze Flaker E20T104 and E20T105 Photo Eye Moisture Prevention Instructions Pack Molex plug s with dielectric grease prior to installation Re pack any time Photo Eye is unplugged to maintain moisture resistance Use dielectric grease only Hold connectors to connect disconnect DO NOT PULL BY CABLE ee dO REMOTE LOW SIDE RLE MODEL INSTALLATION sk CAUTION Electrical wiring should be performed by qualified technicians following Local Electrical codes CAUTION Wiring and Electrical Connections The electric controls are mounted inside the enclosure under the metal cover for easy access to controls 1 Install disconnect not supplied b
42. 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 Terminals 7 amp 8 Isolated output contacts for liquid solenoid valve Normally Open Contacts close immediately upon input signal 3 stay closed until input 3 signal is removed Contacts open when input signal 3 is removed or when overload condition exists MODEL RLE RLB CO OPERATING SERVICE MANUAL 22 Wiring Diagrams WIRING SCHEMATIC WS 140 HTR EXHIBIT 11 208 230 1 60 I I AE te H l MAIN DISCONNECT amp ey s BRANCH CIRCUIT 7 i PROTECTION j f SUPPIED BY OTHERS i I I LI Le 2 Z E l 3 DRIVE MOTOR RI CH 230 1 60 1 TAKI 1 3HP 3 2FLA 1 nx PUMP MOTOR 230 1760 1 11HP 1 3FLA LEAVE A amp B WIRES TOGETHER IN JUNCTION BOX Iim REMOTE LIQUID LINE SOLENDID VALVE CR3 amp 1 4o Ful KLDR 2 5 1L HTR A2 RIB HEATERS l 3x150 WATTS EACH 230V AC 450 WATTS Fui KLDR 2 5 LEVEL CONTROL 230V LCI PRI j SECONDARY LEADS TI INTERNALLY PROTECTED DO NOT SHORT SOMA 24v Le SEC BLUE WIRE LOOP IN JUNCTION BOX CONTROL CUT TO WIRE 1 MODULE 5 MOTOR OVERLOAD CONTROL SWITCH O sm a IN SERIES M O o k
43. pump out 2 Remove all ice in storage bin 3 Close water supply shut off valve 4 Drain water from 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 5 Prepare the cleaning solution Mix 8 oz of Howe ice machine cleaner Howe part E10V1 with 3 quarts of hot water Water should be between 90 115 F If using an alternate ice machine cleaner such as Virginia cat no 418 follow instructions on bottle Mix 8 oz of Virginia ice machine cleaner with 2 gallons of water 6 Pour solution of ice machine cleaner into sump to normal operating level Do not overfill because it may overflow into bin MODEL RLE RLB CO OPERATING SERVICE MANUAL 25 Maintenance T 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 about 2 hours if scale build up is heavy 8 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 Water Distribution Tubes Wate
44. r assembly onto the mounting bracket in the freezing chamber hand tighten the nuts with the squeegee touching the evaporator surface then move the squeegee assembly approximately 1 16 to 1 8 closer to put a little 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 close to the evaporator so that the squeegee bends excessively this may cause premature squeegee wear and increase load on the gearbox and drive motor Tighten down the nuts and bolts only till the lock washers lock do not over tighten bolts this may cause distortion of the squeegee wrapper and possibly cause premature squeegee wear Re install water distribution tubes Remove all tools from inside the machine and re attach the service access cover Remove lock out devise 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 amp Adjustment of the Water Distribution Tubes MODEL RLE RLB CO OPERATING SERVICE MANUAL 36 Service amp Adjustment Adjust lead tube bottom spout with 90 Elbow so that th
45. r 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 crack 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 upon completion of cleaning process open water sump drain valve and flush out the sump assembly After flushing amp Sanitizing close drain valve to resume normal operating conditions In extreme cases of mineral or slime buildup shut off the main power and remove the top covers from the sump using the ice machine cleaner and a scrub brush clean the plastic sump body until the deposits are loosened and flushed out through the sump drain fitting as described above Ice Machine Condensate Drip Pan The ice machine condensate drip pan should be cleaned each time the ice flaker is cleaned The pan should be wiped clean to remove any mineral or slime deposits The drain line should also be flushed to allow condensate to drain freely from the drip pan TO SANITIZE 1 Mix 160z of household bleach with 1 gallon of water la
46. r require resetting the user can set the controller back to the factory settings listed below The user may edit the setpoints by pressing the knob and holding it down for 5 seconds The user is then prompted for a password to verify his credentials 111 should be entered for the password If the password is correct the user may change the setpoints to the value he desires Setpoints are saved to the controller when the user leaves the Setpoint menu by pressing the knob when ESC is shown The setpoint menu has a timeout of 60 seconds for inactivity When the timeout is reached the controller goes back to showing process values and does not save any setpoints that might have been changed Va Description Setpoint ESC Escape and save settings SHSP Superheat Setpoint 5 rEFr Refrigerant R744 d On Delay On 0 dOFF Delay Off 0 d St Delay Percent Open of Valve 0 CtSP Cut out Suction Pressure 0 H_oP Maximum Operating Pressure 150 C in Cut in Temperature 59 Cout Cut out Temperature 60 HiCP Max Valve Capacity 100 SUPS Supermarket Setting OFF P Proportional Coefficient 40 I Integral Coefficient 25 d Derivative Coefficient 5 StEP Valve Type 2500 SPoS Manual Valve Position nEt Network type nbUS Addr Network Master Address 1 un P Pressure Units PSI un T Temperature Units FAHR PtYP Pressure Sensor gAUg CaLP Pressure Sensor calibration value 0 CLtl Tout calib
47. ration value 0 CLt2 Ctp calibration value 0 CLt3 S 3 calibration value 0 CAdr Controller Display Address 0 MODEL RLE RLB CO OPERATING SERVICE MANUAL 42 Service amp Adjustment Ice Blade Adjustment Ice blade adjustment is not normally required typically the only time this is needed is after bearing replacement If you suspect the blade needs adjustment because of excessive clearance it is typically caused by excessive bearing wear not the blade going out of adjustment Do not try to adjust the blade clearance without checking for and correcting worn bearings When checking tolerances do NOT use automotive sparkplug type feeler gauges you MUST use industrial machine tool type feeler gauges these are about 1 2 wide by 12 long The Automotive type are to short and not flexible enough to give a true reading These machine tool type feeler gauges are available from the factory if you cannot locate them locally BLADE SETTING CLEARANCE BETWEEN EXTREME OUTBOARD TIP OF ICE BLADE AND EVAPORATOR FREEZING SURFACE MUST BE 004 TO 006 WITH EVAPORATOR AT ROOM TEMPERATURE Adjustment Procedure With the ice machine turned and locked off and the evaporator at room temperature locate exact position on evaporator freezing surface where the clearance between the tip of ice blade and freezing surface is the least This is accomplished with the use of a feeler gauge Check clearance top and bottom of blade rotate bl
48. rly charge this ice flaker CAUTION WARNING All Rapid Freeze RL model ice flakers are shipped with a small holding charge of dry Nitrogen SYSTEM MUST BE EVACUATED PRIOR TO CHARGING REFRIGERANT WARNING Follow accepted practice and procedures to charge refrigerant into the system Consult the rack or condensing unit manufacturer for full details MODEL RLE RLB CO OPERATING SERVICE MANUAL 16 Installing the Rapid Freeze Flaker LOCATION DRAWING FOR RLB MODEL EXHIBIT 7 ACCESS CLEARANCE 000 RLE ICE FLAKER ICE FLAKER ICE BI ICE BI MODEL RLE RLB CO OPERATING SERVICE MANUAL 17 Installing the Rapid Freeze Flaker HOW THE RAPID FREEZE FLAKER OPERATES The Howe Rapid Freeze ice flakers operate on a continuous pump down refrigeration system When set up as a split system remote low side ice flaker amp remote high side condensing unit the system is set up to operate as follows The main power is to be on at all times for the ice flaker control panel and the condensing unit When the ice level control calls for ice the drive motor water pump and solenoid valve are all energized simultaneously as the ice level in the storage bin raises amp blocks the signal from the emitter to the receiver the sole
49. seal is damaged dew to over greasing the seal may need to be replaced 1000 series SERVICE OPENING TOP BEARING LUBRICATION FITTING BOTTOM BEARING LUBRICATION FITTING CACCESS FROM ICE BIN 2000 amp 3000 series MODEL RLE RLB CO OPERATING SERVICE MANUAL 27 Maintenance Preventative Maintenance Preventative maintenance means that the store or department manager or a delegated employee make a daily visual check of the ice flaker Check for Bin doors are working closing properly Bin doors are kept closed Photo eyes and brackets are in proper alignment Ice Quality Size of flakes Ice Quantity Normal amounts of ice produced Bubbles in sight glass Overall cleanliness of the flaker Any unusual noises When these items are checked on a daily basis any change will be easily detected prior to any service call for a malfunction of the machine Preventative Maintenance Schedule 6 12 24 36 48 60 Month Month Month Month Month Month Replace water filter cartridge EVENTA Clean amp sanitize ice machine as required 1 mee m 1 E AN A re r r dan pase U Trasie l 51 i check cutter blade clearances s Replace water filter every 6 months a Use Caution to not over grease which may pop the grease seal RER Typically every 12 months in areas with poor water quality possibly as often as every few months With good quality water cleaning may be r
50. t 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 Shut off ice flaker and allow machine to pump down de ice once the machine is clear of ice then you should disconnect the main power to the ice flaker and LOCK THE DISCONNECT SWITCH IN THE OFF POSITION to prevent accidental start up Remove the service access cover on the top casting Reaching up from the bin into the freezing chamber loosen and remove the two 10 24 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 Remove all tools from inside the machine and re attach the service access cover Remove lock out devise from the main power disconnect and turn on the main power Turn on the ice flaker switch and check the deflector to insure that it does not touch the evaporator or aluminum casting 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 ICE DEFLECTOR ICE FLAKER BOTTOM CASTING LO Replacement and Adjustm
51. tep 5 CHECK FOR CORRECT OPERATION Place a wire jumper across Blue and Black spades of the Molex plug on RECEIVER cable which is attached at other end directly to POWER SUPPLY RELAY in control panel The POWER SUPPLY RELAY should open the solenoid valve turn the machine on and begin making ice When the wire jumper is removed the solenoid should close MODEL RLE RLB CO OPERATING SERVICE MANUAL 29 TroubleShooting Chart approximately 15 seconds later Depending upon the adjustment of the off delay timer the driver motor and water pump will continue to operate for between 2 30 minutes A If the machine works as described above it is likely the switch has failed to operate properly and the RECEIVER must be replaced B If the machine does NOT work as described above it is likely the POWER SUPPLY RELAY has failed to operate properly and must be replaced C If the machine works as described above and the LED light on the back of the EMITTER is out or dimly illuminated it is likely that the EMITTER has failed to operate properly and must be replaced SEQUENCE OF OPERATION There are LED indicators on the rear of both the EMITTER amp RECEIVER The EMITTER LED is illuminated whenever the ice machine has power The RECEIVER LED is illuminated when it sees the infrared signal from the EMITTER i e when no ice blocks the signal The signal to the RECEIVER must to be blocked for 15 seconds in order for the POW
52. the mounting holes line up Once aligned re install the mounting bolts Re position coupling halves with required clearance and re tighten MODEL RLE RLB CO OPERATING SERVICE MANUAL 38 Service amp Adjustment DRIVE MOTOR amp SPEED REDUCER 2000 amp 3000 RLE EXHIBIT 13 Drive Motor Speed Reducer Flexible Coupling MODEL RLE RLB CO OPERATING SERVICE MANUAL 39 Service amp Adjustment Replacement of Electric Eye Sensor s 1 Z Remove front panel of ice flaker by lifting up and away from unit and place aside until finished Locate cables from ice level sensors one on the left and right side of ice machine and disconnect from wiring harness Remove photo eye mounting bracket from bin carefully pulling cable from flaker enclosure Using two open end wrenches placing one on the back nut one on the forward nut loosen the nut and remove Then attach new eye in place of the old one Tighten the lock nuts taking care not to over tighten as this could damage the sensor Use a maximum torque of 13 Ib in Carefully route the cable s into the ice flaker wiring trough so they are not damaged re attach to the wiring harness packing Molex plug with Di electric grease to prevent moisture from possible temporarily shorting the trigger signal should the plug get wet Secure the cable s so they cannot be damaged by accident Ensure there is a Drip loop on the cable near the sensor so any
53. tion adaptation or translation of 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 60642 Phone 773 235 0200 Fax 773 235 0269 e mail howeinfo howecorp com web www howecorp com Revision date March 2011 Section 1 2 3 Table of Contents INTRODUCTION Rapid Freeze Energy Efficiency Important Safety Information Safety Symbols and Their Meanings Typical Installation Drawing Exhibit 1 Assembly Drawing 2000RLB Exhibit 2 Assembly Drawing 3000 RLB Exhibit 3 RECEIVING AND INSPECTION OF EQUIPMENT Inspection General Purpose RLE INSTALLING THE RAPID FREEZE FLAKER Installation Conditions Refrigeration Requirements Installation on Ice Bin Exhibit 4 Recommended Installation Method on Ice Bin REMOTE LOW SIDE RL MODEL INSTALLATION Wiring amp Electrical Connections Electrical Junction Box General Piping Guideline Piping Line Sizes Table 1 Piping Piping Schematic Exhibit 5 Line insulation Water Line Water Supply amp Filter Connections Exhibit 6 Refrigerant Charging Location Drawing for RL Models Exhibit 7 Page A a we N m 10 11 11 12 12 12 14 14 14 15 15 16 17 Rapid Freeze Manual Information 4 5 6 7 8 9 HOW THE RAPID FREEZE FLAKER OPERATES Why Ice Bin Thermostats Are Not Used START and
54. ve Loosen and remove the compression fitting at the float valve While holding the float valve body with a pliers or crescent wrench remove the water float valve fitting from the valve body Using a 13 16 socket a spark plug wrench works great remove the locking nut from the valve body you will need to hold the valve body from turning Remove the old valve and fibre washer Install new valve with fibre washer on the inside of the water sump tighten the locking nut with the socket The valve body should be held in place with the discharge port facing straight down Re install the float valve fitting Reattach water supply line 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 water return trough from the evaporator while the flaker is operating To adjust the operating level hold the float in one hand and rotate the plastic float clockwise to lower the water level counterclockwise to raise the water level depending on whether the water level is too high or too low Care should be used to avoid unscrewing the float body from the shaft 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 st SPECIAL NOTE On RL flakers that are connected to a central refrigeration rack system the two red wires in the main
55. y factory and connect power lines 208 230 1 60 to the two black wires marked LI and L2 in the electric junction box on the rear of the flaker 2 The yellow wires in the junction box are to be connected to the solenoid valve coil mounted externally to the flaker 3 In the electric wiring junction box on the rear of the flaker there are two red wires tied together with a wire nut When connecting to a rack system leave these wires tied together 4 Ifnot connected in previous section locate amp connect the photo eye sensors to the matching plug in the ice flaker MODEL RLE RLB CO OPERATING SERVICE MANUAL 11 Installing the Rapid Freeze Flaker Piping The ice flaker as supplied by Howe Corporation was thoroughly cleaned and dehydrated at the factory Foreign matter may enter 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 than is absolutely necessary b Use only clean new refrigeration grade copper tubing c Suction lines should be sloped 1 4 per 10 feet towards the compressor d Suitable P types oil traps should be located at
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