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Rapid Freeze ICE FLAKERS INSTALLATION & SERVICE MANUAL

1. AAOLIVGA ddI ZH09 9t A0 z Ad3ddnS 83 MODEL RLE RLB OPERATING SERVICE MANUAL 31 iring Diagrams Condensing Unit Wiring Diagram Model 3000 RHS 0292896 ON 009 an 005 BEEN 31 ONY Hla X0 ONS 13 PSA 009 009 1 FA LO ELEI EEGEN INSIVAINGOS AG NADHS 3dAi1 Ssnd X 7 9 3 _ 10 01 6 P 41 801129492 NNA J AW 71334 IGaLNOD 2318 NADO S d 010937105 710 sao O HJLIAS 34155344 AQI 541 3A3WA 305 01123 9110913 511 211 45 34055384 HOIH SdH Qnngyg HOLIAS 123 02510 43503 Sa4 jay Nd NIANI 2222 1 3AUH 13NVd N NB oe a HOLIVINOD 19 MOSS3NdWDO ASVIAINVAP uin NY 4 S 13004 D LHSI 5534 MOT LII 4S2 gt AJNO 51 CAGNO SALINN AQGr ALH AA 017314 DNISIA 4401394 A IND 53 012 3dd023 35 ASVLIOA ao 31914 3385 335 MODEL RLE RLB OPERATING SERVICE MANUAL 32 Photo Eye Sensor Connections Photo Eye Control Wiring Exhibit 24 N O Output Wired in series with module on off switch and remote i o LC 1 1 240V xp
2. 7 8 POWER SUPPLY A 2000 RLE 1 2 005 ICE FLAKER LIQUID 1 1 8 UDS INLET SUCTION 3 4 ID 3 8 39 1 4 DRAINCO WATER INLET 1500 ICE BIN 99 1 4 ICE BIN pu di DRAIN 70 1 2 71 174 3 4 PVC DRAIN LINE E F i 60 3 4 ID CART DRAIN ICE BIN BACK VIEW MODEL RLE RLB OPERATING SERVICE MANUAL 5 Introduction Assembly Drawing 3000 RLB 3000 RLE Flaker amp CP2500 Mobile Express Bin Exhibit 4 18 29 1 2 11 7 8 31 5 8 POWER SUPPLY A 3000 RLE e Ds z ICE FLAKER LIQUID 1 1 8 0DS INLET SUCTION 3 4 ID 3 8 39 1 4 DRAINCO WATER INLET CP 2500 CE BIN 132 1 4 103 1 2 ICE BIN 104 1 4 ICE BIN DRAIN 3 4 PVC DRAIN LINE hje 60 x 3 4 ID CE BIN A CART DRAIN BACK VIEVW MODEL RLE RLB 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 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
3. HOWE Rapid Freeze ICE FLAKERS INSTALLATION amp SERVICE MANUAL and parts catalog General Purpose Flake Ice Machines 1000 2000 amp 3000 e Remote Low side Series RLE e Remote High Side Condensing units RHS e Mobile Express Storage bins CP Howe Corporation 1650 North Elston Ave Chicago IL 60622 TECHNICAL ASSISTANCE LINE 1 773 235 0200 www howecorp com email howeinfo howecorp com Rev 02 07 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 connection with the furnishing performance or use of this manual The information contained herein 1s 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 15 cautioned that use of this manual with older equipment 15 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 2006 All rig
4. Head pressure controls defective head defective pressure control Headmaster Control Condensing unit Replace unit with properly undersized _sized condensing unit alla too low Adjust EPR for because condensing unit is temperature to O F For 1000 oversized RLE 16 5 F For 2000 amp 3000 RLE Excessive ice blade Inspect and adjust ice blade clearance clearances See section 11 service amp adjustment Worn main bearings Replace bearings and or shaft amp adjustment Ice deflector not properly pma ice deflector see positioned section 11 service amp adjustment Ambient temperature too Ice must be moved to cold warmer area where ambient temperatures above 50 F SRR RE REE E REET EERE EERE EERE EE EERE EERE EERE EERE r1 Water temperature too Water temperature must be cold above 40 F Install water mixing valve to supply 60 F ideally water to ice flaker XII i Ice in storage bin too 1 wet water dripping Water level in sump set too Adjust water float valve to high maintain water level 2 fullin MODEL RLE RLB OPERATING SERVICE MANUAL 44 TroubleShooting Chart PROBLEM PROBABLE CAUSE REMEDY 3 into bin with ice Water sump overflow plugged sump amp water return water overflowing trough collecting trough Clear overflow drain line 2 Water overflowing top water distribution
5. adjustment stem should be set at 18 PSIG for R 404A 11 PSIG for R 22 A NET lu FAN CYCLING SES The 1000 amp 2000 RHS Condensing units have two condenser fans the lead fan is always on when the compressor is running the second fan is controlled by an ambient switch to be set at 50F second fan is off when ambient temp is under 50F The 3000 RHS condensing unit has a single condenser fan which is always on when the compressor is running MODEL RLE RLB OPERATING SERVICE MANUAL 22 Installing the Rapid Freeze Condensing unit IMPORTANT NOTICE DO NOT ATTEMT TO ADJUST ICE FLAKER SPLIT SYSTEM FOR EVAPORATOR SUPERHEAT REFER TO START amp ADJUST SECTION OF THIS MANUAL FOR PROPER ADJUSTMENT OF EPR AND TXV VALVE ON ALL HOWE ICE FLAKERS IMPORTANT NOTICE Lig uin DICATOER 1 1 raa _ 1 a ERR f EXCH ANGER 1 1 T 9 i 1 1 COOLED CONDENSER ICE FLAKER TEV VALVE COHFPRESSOR DISCHARGE E SUCTIQH ACCUMULATOR i IH u ID Flaker suction Accumulator amp Heat Exchanger A Field Installed FEC EIVER FILTER Condensing Unit Suction accumulator and heat exchanger to be field mounted The Suction accumulator should be mounted near the condensing unit the heat exchanger when required should be near the flaker The heat exchanger 15 typically needed only w
6. 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 rest overload and check for operation If red LED 1s illuminated and motor amps 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 1f necessary MODEL RLE RLB OPERATING SERVICE MANUAL 39 TroubleShooting Chart PROBLEM PROBABLE CAUSE REMEDY x Solid State Control Board 1 Ice flaker is not running 1 No control power from Using a digital voltmeter set x A control transformer AC Voltage check voltage Secondary 24 VAC between 1 amp 2 on Solid State Control Board voltage reading should be 24 VAC If 24 VAC is not present control x tra
7. twice a year may be sufficient When cleaning 15 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 l Turn off refrigeration compressor If flaker 1s 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 2 Remove all ice in storage bin Close water supply shut off valve 4 Drain water from drain connection water sump Some models are equipped with a drain valve others have a drain plug located below the water float valve connection 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 1 may overflow into bin MODEL RLE RLB OPERATING SERVICE MANUAL 34 Maintenance I Start the ice flaker d
8. 31ES 31ESS Part No And Suggested List Price EACH E20H39 P N A E30H9 10 51 10 17 E20H38 P E10H31 E10H60 E10H20 F5H25 2 E10H21 E20H10 F5H25 3 E20J2 E20J6 E10H29 E50H18 E20P1 CNB BR02 06 CNBHF SG BR08 E10H7 E30H3 E10H9 20 14 E30H4 E20H19 ELM CT NY 10 08 E20H24 E20H12 20 13 E3001 E3001 E1001 E10H32 68 Replacement Parts Catalog 2000 10E 3000 15E 16E 4000 20E 21E 6000 30E 31E TABLE 4 Replacement Parts for Models Listed to Right 10EA 10EAR I5EA 15 20EA 20 30EA 30EAR 31ES 31ESS 11 5 IIESS 16 5 16 55 2IES 21ESS Part No And Suggested List Price EACH i NA E10H31 E30H7 Item No Part Description Water pump 230 1 60 see p 70 Water pump retrofit kit Replaces old style side mounted 230 1 60 62a 62b Water pump seawater 115 230 1 50 60 Gearmotor 230 1 60 1 45 HP Used on RLE models 95 7 5 2 Gearmotor 220 240 1 50 1 45 HP Used RLE F5M3 models Old Gearmotor 115 230 1 50 60 1 20 HP Used on RLE F5M10 models New E10M2 Gearmotor shaft 1 20HP Drive motor 115 230 1 60 1 3HP 1 2HP Drive motor 110 220 1 50 1 3HP 1 2HP Drive motor 208 230 460 3 50 60 1 2HP Drive motor 230 1 60 1 2HP TEFC For seawater Drive motor 380 3 50 1 3HP TEFC For seawater ON 3a Drive motor key 65 66 67 coupling complete For speed reduc
9. 36 37 37 38 38 40 40 40 44 44 45 46 47 48 49 49 49 51 52 52 53 53 54 54 55 55 55 56 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 equipment 15 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
10. 50 F 10 C If installed in cold ambient conditions it is advisable to supply the ice Flaker with warmer water through a water mixing valve around 60 F 15 C When a combination of cold water and cold air temperature exists the water mixing valve must be used Failure to do so will cause the lower water collecting trough and sump to plug up with ice to the extent that the water may overflow into the ice storage bin in addition to blocking the water inlet to the pump CAUTION NEVER install an ice flaker in a COLD room 50 F 10 C or lower The ice warranty is void if the ice flaker is installed in a cold room or outside where the ambient temperature may drop below freezing CAUTION Optimum surrounding air temperature range 60 F 15 C to 95 F 35 C Minimum air temperature 50 F 10 C 2025982 100 F 38 C Optimum water temperature ranee 60 F 10 C to 80 F 25 C Minimum water temperature without water mixing valve 45 F 8 C Minimum water temperature water mixing valve must be used 36 F 4 C Maximum water temperature 90 F 32 C Refrigeration Requirements Flaker Model
11. PSIG water filters clogged Replace filters every 6 months u or sooner if necessary Back flushing filter may temporarily work until replacement filters arrive Ice flakes too thin 1 Evaporating Temp too high because overfeeding Pinch down TXV close 2 turn compressor frosted at a time m n e m EPR set too high Adjust EPR for evaporating temp 0 F Model 1000 5 F for model 2000 amp 3000 2 Condensing unit not producing rated capacity because a Compression valves Repair service broken compressor condensing unit Bera L R amp MODEL RLE RLB OPERATING SERVICE MANUAL 43 PROBLEM IX XI i T EE Chart PROBABLE CAUSE REMEDY x b M Ice flakes too small 1 and too powdery Ice chatters 1 excessively does not run smoothly 2 and or shaft if worn see section 11 service Too much ice accumulation in bottom water collecting trough Too much ice 1 accumulation in bottom water collecting trough and in water sump and excessive ice build up on bottom 3 ribs Condenser dirty head Clean fin coil air cooled unit press too high Clean tubes water cooled units
12. Style Gearmotor Reattach the power plug to motor connections check to insure the motor 15 wired for the correct power 115V or 230V and for correct rotation CCW Refer to wiring connections on the motor Figure 2 Offset Style Gearmotor MODEL RLE RLB OPERATING SERVICE MANUAL 50 Service amp Adjustment nameplate for the correct connections Motors come wired standard 230V from the factory 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 Reset the motor overload per instructions in Start amp Adjust section of this manual 5 7 N E e Y S lt js 205 b x b 4 u ER 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 and The drive motor 15 attached to the gearbox with 4 d 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 horizont
13. 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 should perform the operations described in this manual If a refrigeration system is being charged from refrigerant cylinders disconnect each cylinder when empty or when system is fully charged A gauge should be installed in the charging line to indicate the refrigerant cylinder pressure The cylinder may be considered empty of liquid R 22 refrigerant when the gauge pressure is 25 pounds or less and there is no frost on the cylinder Close the refrigerant charging valve and cylinder valve before disconnecting the cylinder Loosen the union in the refrigerant line SLOWLY and CAREFULLY to relieve refrigerant pressure in the charging hose MODEL RLE RLB OPERATING SERVICE MANUAL 1 Introduction WARNING Never open charging valve allowing refrigerant to vent directly to atmosphere Refrigerant must be reclaimed through a recovery system WARNING Always store cylinders containing refrigerant in a cool place They should never be exposed to temperatures higher than 125NF and should be stored and secured in a manor to prevent abnormal mechanical shocks Safety Symbols
14. amp What They Mean Please read and understand this manual prior to installing or operating this Rapid Freeze7 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 DANGER BEWARE OF HAZARDS WHICH CAN RESULT IN PERSONAL INJURY DANGER WARNING DO IT RIGHT OR RISK SEVERE PERSONAL INJURY FOLLOW INSTRUCTIONS WARNING CAUTION BE CAREFUL NOT TO HURT YOURSELF OR TO DAMAGE THE EQUIPMENT FOLLOW INSTRUCTIONS CAUTION MODEL RLE RLB OPERATING SERVICE MANUAL 2 Introduction TYPICAL INSTALLATION DRAWING Exhibit 1 1 MODEL RLE RLB OPERATING SERVICE MANUAL 3 Introduction ASSEMBLY DRAWING 1000RLB 1000 RLE Flaker amp CP750 Mobile Express Bin EXHIBIT 2 85 1 4 UN N PDWER 000 RL SUPPLY 7 B DDS l T x ICE FLAKER SUCTION 30 1 4 3 8 005 90 1 16 ICE BIN 71 1 4 DRAIN 3 4 PVC DRAIN LINE 3 4 CART DRAIN BACK VIEW 750 SINGLE CART ICE BIN 30 OPENING TOP VIEW MODEL RLE RLB OPERATING SERVICE MANUAL 4 Introduction Assembly Drawing 2000RLB 2000 RLE Flaker amp CP1500 Mobile Express Bin Exhibit 3 18 29 1 2 11
15. amp refrigerant locate and install condensing unit in a location accessible for service Rigging holes have been provided on all condensing units Caution should be exercised when moving these units To prevent damage to the unit housing during rigging cables and chains used must be held apart by spacer bars The mounting platform or base should be level and located so as to permit free access of supply air GROUND MOUNTING Concrete slab raised six inches above ground level provides a suitable base Raising the base above ground level provides some protection from ground water and wind blown matter Before tightening mounting bolts recheck level of unit The unit should in all cases be located with a clear space in all directions that is at a minimum equal to the height of the unit above the mounting surface A condensing unit mounted in a corner formed by two walls may result in discharge air recirculation with resulting loss of capacity ROOF MOUNTING Due to the weight of the units a structural analysis by a qualified engineer may be required before mounting Roof mounted units should be installed level on steel channels or an I beam frame capable of supporting the weight of the unit Vibration absorbing pads or springs should be installed between the condensing unit legs or frame and the roof mounting assembly ACCESS Provide adequate space at the compressor end of the unit for servicing Provide adequate space on the connection side to
16. de energize the solenoid valve and start the off delay cycle for the drive motor amp water pump Ice flaker 1s 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 Electronic overload set point 1s factory set to trip within seconds when the motor reaches an overloaded condition Ice maker is adjusted and producing dry flakes of ice Water is NOT dripping into the bin If it is locate the dripping point and correct it 1 e distribution pan overflowing water recovery trough overflowing or distribution tubes broken or misaligned MODEL RLE RLB OPERATING SERVICE MANUAL 26 Start amp Adjust SUPERHEAT SETTING DO NOT USE SUPERHEAT to adjust ice evaporator pressure settings EPR valve should be adjusted to obtain evaporator temperature of 5F 2000 amp 3000 models 3 F for 1000 models OPTIMUM EVAPORATOR PRESSURE SETTINGS 1000 models R 404A 36PSI 2000 amp 3000 R 404A 28 PSI 5 F 1000 models R 22 26 5 PSI 3 F 2000 amp 3000 R 22 20 PSI 5 EPR set too low ADJUSTING TXV IMPROPERLY ADJUSTED TXV PROPERLY ADJUSTED TXV Once the EPR is set so the evaporator is at 5 F 2000 4 3000 models 3 F for 1000 models then the TXV valve may be adjusted for optimum ice production If ice freezes on entire length of evaporator top to bo
17. k 1 76 gt k 2 4 gt Input O O E20T68 Os ICE LEVEL CONTROL 10 Terminals 10 amp 1 24V AC Output 11 1 Terminal 11 Trigger ia No Connection Honeywell Microswitch Blue OR Red with White Trace Blue OR Red with White Trace Brown OR Red with Black Trace No f Connection EMITTER PART E20T69 RECEIVER PART E20T70 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 peak 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 15 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 1s 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
18. 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 MODEL RLE RLB OPERATING SERVICE MANUAL 57 Service amp Adjustment 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 evaporator surface 7 Lift shaft assembly out of evaporator Be careful to avoid scratching evaporator freezing surface with the ice blade 8 Examine shaft journals for wear 1f worn repair or replace shaft 9 Remove old oil seals in upper casting 10 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 11 Press new bearing into position Then press the new oil seals into position 12 To remove the bottom bearing first remove the bottom bearing cov
19. on the suction line and remove the remote bulb The bulb is secured to the suction line with two straps Remove insulation from liquid line and expansion valve cut out or de solder expansion valve from liquid line and remove the old valve Install and solder the new valve into the liquid line Pressure test your connections for leaks Re attach the bulb to the suction line at approximately 5 O Clock position Secure the bulb using two straps Re insulate the suction amp liquid lines 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 ADJUSTMENT OF EXPANSION VALVE Note When the ice flaker is in a cold ambient location and or the machine is supplied with cold water the standard TXV valves may appear to overfeed however when properly adjusted they should feed properly In extreme cases of cold ambient and or cold water temperature the next smaller sized expansion valve may need to be installed Always adjust EPR valve prior to attempting to adjust TXV valve If ice freezes on entire length of evaporator top to bottom but harvests only the upper portion with each revolution of the shaft and there are no bubbles in the sight glass then the expansion valve must be adjusted Opened to feed more refrigerant On the other hand frost on the compressor body indicates that the valve 1s overfeeding Remove the adjustment stem cover and turn
20. permit service of components SPRING MOUNTED COMPRESSOR Compressors are secured to make sure there 1s no transit damage Before operating the unit it 1s necessary to follow these steps a Remove upper nuts amp washers b Discard the shipping spacers Install the neoprene spacers Spacers located the electrical panel or tied to compressor d Replace the upper mounting nuts and washers e Allow 1 16 inch space between the mounting nut washer and the neoprene spacer MODEL RLE RLB OPERATING SERVICE MANUAL 20 Installing the Rapid Freeze Condensing unit RIGID MOUNTED COMPRESSOR Some condensing units use rigid mounted compressors Check the compressor mounting bolts to insure they have not vibrated loose during shipment Spring Mount A AS 2 2 5 Es P ak a z L7 qu gt Gane Compressor Mounting Shipping Spacer Mounting Stud _ Mounting Nut Upper Rubber Spacer Mounting Spring Mounting Nut Lower Mounting ase Lockwasher Solid Mount for Mobile or Deep Sump Application i ii e Compressor Mounting Foot Mounting Stud Mounting Nut a Upper Compressor Mounting Foot Rubber Spacer x w Mountin Rubber Spacer tts Song Lower Lockwasher Locking Device s 9 Mounting Nut Lower Mount is shown in properly adjusted posi
21. suction strainer is recommended for your Rapid Freeze ice flaker Flaker Model Suction Strainer Model 1000 RLE F5C22 7 8 ODS 2000 RLE E10C24 1 1 8 ODS 3000 RLE 15 5 1 3 8 ODS Install the strainer with flow in direction of the arrow on the top of the strainer By pass feature will be operational and pressure port 15 at outlet Install strainer in horizontal lines only Suction strainers are available shipped loose as an option with Howe flakers See Price list for pricing Suction Strainer CHBCHEL HS NR Se ee CEU Kwa a a ea a ne BRET Ei This drawing illustrates the refrigerant flow pattern with the filter in the normally closed position a phere a A ee A A A a T 5524 This drawing illustrates the refrigerant flow with the bypass in the open position 1 rr Tam EI NL PUE Mum Nd Bypass Open kx Bi directional means the Suction Filter can be installed in either one flow direction or the other it does not mean the Suction Filter is suitable for reversible flow LINE INSULATION After the final leak test refrigerant lines should be insulated to reduce heat pick up and prevent the formation of flash gas in the liquid lines Suction lines should insulated with wall Armstrong Armaflex or equal Liquid lines should be insulated with gt wall
22. through the hand hole cover the bottom bearing 15 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 15 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 seal 1s damaged dew to over greasing the seal may need to be replaced 1000 series SERVICE OPENING TOP BEARING LUBRICATION FITTING BOTTOM BEARING LUBRICATION FITTING ACCESS FROM ICE BIN Gear motor Lubrication The motor ball bearings are grease lubricated and do not normally require re lubrication or replacement Gearmotor gearing and bearings are supplied with sufficient grease to last the A design life of the gearmotors MODEL RLE RLB OPERATING SERVICE MANUAL 36 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 No
23. will be operational refrigeration must be piped and charged for flaker to make ice EXHIBIT 7 6 Re install side panels if removed and top cover 7 Install lower drain rear cross member of bin stand This is behind mobile ice cart 8 Install drain line from upper horizontal slide door and lower mobile ice cart drain pans BACK OF 1000 RL ICE FLAKER SUMP DRAIN 9 Install drain line from flaker condensate and DRAIN overflow connections located on rear panel of ice machine Be sure to follow local plumbing codes to prevent back flow ICE BIN DRAIN 10 Run all drain lines in rear of ice bin to floor drain FLOOR DRAIN MODEL RLE RLB OPERATING SERVICE MANUAI Installing the Rapid Freeze Flaker E20T69 and E20T70 Photo Eye Moisture Prevention Instructions Pack Molex plug s with dielectric grease prior to installation Re pack any time Photo Eye 15 unplugged to maintain moisture resistance Use dielectric grease only Hold connectors to connect disconnect DO NOT PULL BY CABLE REMOTE LOW SIDE RLE MODEL INSTALLATION CAUTION Electrical wiring should be performed by qualified technicians following Local Electrical codes CAUTION WIRING amp ELECTRICAL CONNECTIONS The electric controls are mounted inside the enclosure under the metal cover for easy access to controls 1 Install disconnect not supplied by factory and connect power
24. 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 15 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 wrapper 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 s
25. 1E 6000 31E TABLE 4 Replacement Parts for Models Listed to Right 1 10 15 15 20EA 20EAR 30EA 30EAR 11ES 11 55 16ES I6ESS 21ES 21ESS 3IES 31ESS Part Description Part No And Suggested List Price EACH Insulated lug spacers 8 E10D2 Main shaft 10 2 Ice blade 8 L 12 L 207 L E30E3 10 5 0 5 Nuts bolts amp washers Ice blade Ice blade adjustment gauge kit Set of 5 feeler gauges for ice blade adjustment 10 15 10 1 1 Ice deflector 1 E10G6 KT lla Ice deflector scraper amp backer plate kit Nuts bolts amp washers Ice deflector E10J1 12 Insulating ring 2 isis ______ 14 amp 15 amp bottom auxiliary ice scraper gm Irs Amicessmpey o 15a Nuts bolts amp washers Aux ice scraper og 16 Ice deflector scraper Only gg er 16a Ice deflector scraper backer plate Only Nx 17 Squeegee 8971 1271 2012 1 a 18 Squeegee wrapper am usto washes Squeegee wrappe 18a Nuts bolts amp washers Squeegee wrapper ENTE 19 Squeegee bracket gms 19a Squeegee bracket Seawater om 20 Main shaft bearings 2 oo o 21 Bottom bearing thrust plate esse l S 22 Main bearing grease seals 3 ma aic 22a seals 35 amp 36 Water distribution side
26. 1s not slugged into the compressor WHY ICE BIN THERMOSTATS ARE NOT USED The use of a bin thermostat 1s not recommended and not permitted The Rapid freeze ice flaker 1s designed so that the freezing drum operating 0 F B5 F is located directly over 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 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 OPERATING SERVICE MANUAL 24 Start amp Adjust Once installation has been completed and the ice Flaker has been properly evacuated and charged with the Freon identified on the ice flaker label you may proceed with the check and adjust section 2 3 4 5 6 7 Checklist Before power 15 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 19 L WATER LEVEL Make sure the On
27. NG MODEL RLE RLB OPERATING SERVICE MANUAL 47 Service amp Adjustment REPLACEMENT amp ADJUSTMENT OF ICE DEFLECTOR To properly install the upper edge of the deflector should be positioned approximately 1 8 BELOW the aluminum lip under the evaporator The ice deflector should be centered beneath the ice cutter blade so that as the ice is removed from the evaporator it will be deflected into the ice bin opening away from the water collecting trough The ice deflector prevents ice from dropping into the water collecting trough TO REPLACE ICE DEFLECTOR PROCEED AS FOLLOWS Shut off ice flaker and allow machine to pump down de 1ce 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 1ce 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 sw
28. OR MOISTURE IN MOLEX PLUG If the Molex plug for either the emitter or receiver 1s 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 1 may cause the female pin to open slightly Check the Female pins 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 wiring harness 1f 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 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 1n the Molex plug the b
29. Off switch 1s 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 15 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 15 maintained at the proper level see below EXHIBIT 20 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 OPERATING SERVICE MANUAL 25 9 10 11 12 13 14 15 16 17 Start amp Adjust Looking down into the evaporator through the hand hole cover check to make sure the ice 15 being frozen and harvested over the entire surface of the evaporator If it 1s not check for bubbles in sight glass located on rear of flaker 9b check the suction pressure the ice machine C
30. Refrigeration Requirements Optimum Evaporator Temp 1000 RLE 9S0 BTU 2000 RLE 18 000 BTU hr 3000 RLE 27 000 BTU hr 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 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 OPERATING SERVICE MANUAL 8 Installing the Rapid Freeze Flaker Installation on Ice Storage Bins Rapid Freeze7 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 pla
31. T N O CM Solid State Control Board Level Control R1 Drive motor amp Water pump Relay contactor CR3 Isolating relay when used in remote condensing unit 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 MODEL RLE RLB OPERATING SERVICE MANUAL 30 iring Diagrams 7 3 d Condensing Unit Wiring Diagram Model 1000 RHS Model 2000 RHS 4 905 alH 3A J32 JSVOANVA 7 3 N N 0 3 aa M o 1 5 TIN A3N V cu l xL H I luis su v3 _ 009 0 0041 51 Juin 002 30 cog 7 Podi an ONH od s S D A ELLA CECE ODER NAOHS AdAL SSN 130 NBIL231U03d JINDYLNAS 405 T0Oa1N09 H31IAS NAUG S d WA 105 N30134 110 Sun JIMAS 33nSS3 d U 541 LIAS 38055344 SdH AS 123 03510 083543 543 7777 E Ten Sak 1V1SOWN3H1 iv 55344 05 co yOLOW NV 3 NV 3 gt 312 2 Ld NV 3 19 55384 ENS LL cao Li LI L sai T 01314
32. 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 beginning 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 it s refrigerant charge 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 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 Do not install ice Flaker s in refrigerated cold rooms or in areas where the ambient temperature is lower than
33. aft if worn 3 Mis assembled top casting See section 11 Service amp after bearing replacement adjustments bearing replacement procedure and align assemble top casting III Ice freezes soft on Almost entire refrigerant Pump out accumulator restart entire length of drum ice charge in accumulator little or system Adjust TX V if flaker drive motor cuts out liquid in receiver necessary on overload a few minutes after start up IV Ice freezing hard on D Water auditus not suitable Install Howe Phosphate F Filters entire length of i hard water drum but EEE EEE EEE EEE eee harvesting poorly topes 2 Freezing surface coated Clean evaporator with ice and at random with AN no specific pattern with hard water deposits machine cleaner to remove MODEL RLE RLB OPERATING SERVICE MANUAL 42 TroubleShooting Chart Leaves strips of ice deposits at upper end of drum some at lower end etc ttt nn tremite rr rrr rrr V No ice freezing on 1 Loss of refrigerant charge Inspect for and repair leaks drum and charge to proper refrigerant compressor short levels cycles TXV VI Ice flaker makes ice Insufficient water supply to ice x intermittently and flaker because compressor short cycles a Water supply line Install water supply line of undersized proper size b Water supply less than 30 Consult factory
34. ain shaft Ice harvesting blade 18 water sump Old see p 64 water sump New see p 64 1000 RLE SCA SCW PART No LIST PRICE EA F5A6 F5D2 F5EI 5 5 515 5 F5G2 5 4 5 5 2 F5K3 5 4 5 5 5 6 F5K7 5 5 5 6 5 7 F5H8 F5H16 F5H26 ESHI8 F5H24 504 E20H24 10 59 63 Service amp Adjustment TABLE 1 REPLACEMENT PARTS 1000 RLE SCA SCW PART DESCRIPTION PART No LIST PRICE EA Water pump discharge tube Old F5H11 Water pump discharge tube New NENNEN Water pump discharge elbow fitting Old 5 1 Water float valve Old E10H29 Water float valve New CNB BR02 06 F5H10 F5H14 CNM NY 08 08 Water tube fitting Drive Motor 115 230 1 60 1 12 HP Gearmotor 230 1 60 1 45 HP F5M3 Gearmotor 220 240 1 50 1 45 HP 5 10 Gearmotor 230 1 60 1 20 HP rexiblecoupingtcomplse 20 Flexible coupling complete F512 22 Handhole cover removable F5A7 2 Gearmotor mounting plate 1 20 HP Motor TABLE 2 ACCESSORIES 100 RLE SCA SCW PART DESCRIPTION PART No LIST PRICE EA F5V18 Thermostatic expansion valve R 404A RC SCA amp SCW units 502 5 17 Thermostatic expansion valve 22 RC SCA 6 SCW units F5V20 Balanced port expansion valve R 404A RL units 19 5 19 Balanced port expansion valve R 22 RL units E6S130 S Liquid line so
35. al center line one on each side of the input shaft Insert one of the mounting bolts into each threaded hole so they push against the drive motor you may have to rotate the motor housing so the bolts can press against the mounting lugs on the motor making sure the bolts do not thread into the mounting lugs Turn in both bolts until they are hand tight then turn 1n 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 3 key on the shaft lightly grease the surface of the motor shaft and insert 1n 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 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 MODEL RLE RLB OPERATING SERVICE MANUAL 51 Service amp Adjustment REPLACEMENT OF SPEED REDUCER amp FLEXIBLE COUPLING Disc
36. ce 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 the bin MODEL RLE RLB OPERATING 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 by lifting straight up and set aside with front cover 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 and not on cables for ice level controls 4 Locate cables for ice level controls one on the left and right side of ice machine and route under protrusions on sides of flaker enclosure Reach into the front of flaker and pull cables to front of unit 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 cable together See note on next page regarding Di electric grease When power is provided and flaker is turned on ice machine and ice level control
37. cement water pumps for Freshwater ice flakers Start End Date 2000 Pound Models 3000 Pound Models 4000 Pound Models 6000 Pound Models Date 0 07 6 EIOH3I EIOH3I EIOH3I EIOH3I 2000 RLE amp 3000 RLE use replacement pump part E10H32 P Pump with Molex plug installed Replacement sump assembly Replacement water float valves Freshwater flakers 2000 Pound Models 3000 Pound Models 4000 Pound Models 6000 Pound Models Date 0 07 86 E20P1 E20P1 E20P1 E20P1 07 86 01 91 E50H18 E50H18 E50H18 E50H18 01 91 E10H29 E10H29 E10H29 50 18 For more detailed information contact Howe customer service department with flaker serial number Speed reducer field replacement parts are no longer available Speed reducers can be sent to factory to be rebuilt See our website http www howecorp com speed reducer htm or contact Howe for information on rebuilding reducers 70
38. ches are continuity between terminals 7 closed or two red wires in amp 8 while module is junction box on rear of flaker energized all switches in the on are not wired together or closed position solenoid coil defective Contacts open output MODEL RLE RLB OPERATING SERVICE MANUAL 40 TroubleShooting Chart PROBLEM PROBABLE CAUSE REMEDY defective replace module Contacts closed Module output OK Check jumper or CR contacts wired between two red wires in junction box on rear of flaker see wiring diagram Check wiring or solenoid coil terre rem rrr rmn 4 Drive motor always stays Power is maintained to input Check on off switch s and ice ams 3 level control for proper on off switch s and or ice level operation control is are not shutting off replace if defective 5 Liquid line solenoid valve Solid State Control Board Replace defective Solid State energized always isolated contacts will not open Control Board assuming no power to terminal 3 Ice Flakes Frozen together 1 Lead tube splashing water Adjust lead tube so that it into a hard block of ice in off the ice deflector into doesn t splash water over the storage bin the storage bin ice deflector 2 Drip pan leaking into Repair or replace drip pan storage bin 3 Humidity level in bin too high because b Bin door left open Keep bin door closed when not removing ice 4 Ice left in st
39. cial controls installed must be in this circuit Terminal 4 Overload reset input Normally Open momentary contact Terminal 5 Motor overload output for overload indicating light energized upon overload condition stays on until overload 1s manually reset Terminal 6 Ice Flaker contactor output Output is energized when input signal 1s present amp control is not in overload condition When input signal 1s removed switch or 1ce level control open timer circuit 1s started output will stay energized until timing circuit releases output Output 1s 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 1s removed Contacts open when input signal 3 1s removed or when overload condition exists MODEL RLE RLB OPERATING SERVICE MANUAL 29 Wiring Diagrams Wiring Schematic WS 140 Exhibit 23 208 230 1 60 L1 112 MAIN DISCONNECT amp BRANCH CIRCUIT PROTECTION 4 SUPPLIED BY OTHERS gt lt DRIVE MOTOR 230 1 60 1 45 HP 59FLA 0 sb 3 230 1 60 T8FLA LIQUID LINE 7 SOLENOID VALVE T LEVEL CONTROL 230V LC1 PRI SECONDARY LEADS INTERNALLY PROTECTED anya DO NOT SHORT 12 MOTOR OVERLOAD ICE FLAKER RUN OVERLOAD RESE
40. e Manual Information Condensing Unit Installation HOW THE RAPID FREEZE FLAKER OPERATES Why Ice Bin Thermostats Are Not Used START and ADJUST Checklist Sump Assembly Water Level Distribution Pan Water Level Expansion Valve Off Delay Timer Drive Motor Overload Suction Pressure ELECTRIC CONTROL PANEL Components amp Functions E20T48 Solid State Control Board WIRING DIAGRAMS 1 3000RLE 1 2000 RHS Condensing Units 3000 RHS Condensing Units Photo Eye Sensor Connection MAINTENANCE Evaporator Cleaning Procedure Water Distribution Tubes Water Sump Ice Machine Condensate Drip Pan Water Filter Back flush Instructions Lubrication Bearing amp Seal Exhibit 19 Exhibit 20 Exhibit 21 Exhibit 22 Exhibit 23 Exhibit 24 20 23 24 25 25 25 26 26 26 26 27 28 29 30 31 32 33 33 34 34 34 34 35 36 36 9 10 11 Rapid Freeze Manual Information Gear Motor Preventative Maintenance PM Maintenance Schedule TROUBLESHOOTING CHART Photo Eye Solid State Control Board Ice Storage Freezing Gear Motor SERVICE and ADJUSTMENT Warnings amp Safety Information Ice Deflector Exhibit 26 Squeegee Water Distribution Tubes Gear Motor Drive Motor Gear Box Ice Level Control Water Pump Float Valve Expansion Valve Solenoid Valve Adjustment of EPR Valve Adjustment of Ice Blade Main Bearing Replacement GENUINE REPLACEMENT PARTS CATALOG
41. ear the sensor so any moisture accumulating on 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 1s 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 Asees 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 1f removed top cover and front panel REPLACEMENT OF WATER PUMP l 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 OPERATING SERVICE MANUAL 54 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 cov
42. earbox COUNTERCLOCKWISE ONLY until 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 OPERATING SERVICE MANUAL 52 Service amp Adjustment Drive Motor amp Speed Reducer 3000 RLE only Drive Motor Speed Reducer n Flexible Coupling MODEL RLE RLB OPERATING SERVICE MANUAL 53 Service amp Adjustment REPLACEMENT OF ELECTRIC EYE SENSOR s T 2 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 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 15 a Drip loop on the cable n
43. er 65a 66a 67a Flexible coupling For gearmotor Adaptor plate for gearmotor Old Adaptor plate for gearmotor New E20N10 67a Flexible coupling key for shaft E10R6 Speed reducer for 60cy 920 MDVD 750 1 E10R5 Speed reducer for 50cy 920 MDVD 600 1 Speed reducer for 60cy 926MDVD 600 1 e Speed reducer for 50cy 926MDVD 450 1 1 gt o 75 Handhole cover Removable 75a Handhole cover Bolt down Thermostatic exp valve R 502 R 404A Soldered exp vate 22 fn Thermostatic exp valve R 22 Soldered Liquid line solenoid valve Soldered B6S1 1 2 1452 69 Replacement Parts Catalog 2000 10E 3000 15E 16E 4000 20 21E 6000 31E TABLE 4 Replacement Parts for Models Listed to Right 10EA 10EAR I5EA 15 20EA 20EAR 30EA 30EAR JES 11 58 16 5 16ESS 21 5 21 55 31ES 3IESS Part Description Part No And Suggested List Price EACH E10V24 Balanced port expansion valve R 22 E10V25 15 7 Balanced expansion valve R 502 404 E20T40 RL Electric control panel 230 1 60 2 light for RL Electric control panel 230 1 60 6 light for RC E20T40 SCA SCA SCW HT150 240 037 50 Replacement rib heater element 3 110 00 SR OIL Speed reducer oil Natural SR OIL SYN Speed reducer oil Synthetic To help determine which ice flaker water pump amp float valve you need use the following tables Repla
44. er and the old bearing plate 13 Now follow the same steps as were done for the top bearing steps 10 12 14 Install new bottom bearing plate replace bottom bearing cover 15 Insert the new or repaired shaft Running clearance between shaft and new bearing must be about 001 Shaft must rotate freely in bearing 16 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 17 Shaft must rotate freely by hand If shaft 15 tight 1t indicates that the top casting 15 off center 18 Install ice blade and adjust clearance to approximately 003 at closest point Refer to blade adjustment instructions MODEL RLE RLB OPERATING SERVICE MANUAL 58 Service amp Adjustment 19 Re install bottom half of the flexible coupling 20 Re install gearmotor 21 Re install insulation and plastic jacket MODEL RLE RLB OPERATING SERVICE MANUAL 59 Service amp Adjustment Replacement Parts Listing MODEL RLE RLB OPERATING SERVICE MANUAL 60 Service amp Adjustment D HOW E Replacement parts for Rapid Freeze Ice Flakers Effective June 2006 Description Cross Section Drawing for 1000 series ice machines Replacement parts for 1000 pound ice machines Replacement Accessories for 1000 pound ice machines Replacement parts for 1000 series elec
45. er as described above 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 flaker 15 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 EXPANSION VALVE Pump down the ice flaker and evacuate refrigerant from the liquid line Carefully cut back the insulation
46. he machine works as described above it is likely the switch has failed to operate proper and the RECEIVER must be replaced If the machine does NOT work as described above it 15 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 1s illuminated whenever the ice machine has power The RECEIVER LED 1s illuminated when it sees the infrared signal from the EMITTER 1 when ice blocks the signal The signal to the RECEIVER must to be blocked for 15 seconds in order for the POWER 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 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
47. hen the condensing unit is mounted close to the ice flaker The Howe Rapid Freeze ice flakers operate on a continuous pump down refrigeration system MODEL RLE RLB OPERATING SERVICE MANUAL 23 How the Rapid Freeze Flaker operates When set up as a split system remote low side ice flaker amp remote high side condensing unit the system 1s 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 1ce level 1n the storage bin raises amp blocks the signal from the emitter to the receiver the solenoid 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 1s typically adjusted to approximately 1 2 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 1s still on the evaporator With a continuous pump down system it is normal for the compressor to cycle periodically while the ice machine is not making ice turned off This ensures the liquid cannot migrate to the suction valves of the compressor so when the ice machine 15 stared liquid
48. hts reserved Reproduction adaptation or translation of this manual 15 prohibited without prior written permission of Howe Corporation except as allowed under the copyright laws Howe Corporation 1650 North Elston Avenue Chicago IL 60622 Phone 773 235 0200 Fax 773 235 0269 e mail howeinfo howecorp com web www howecorp com Revision date EBRUARY 2007 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 1000RLB Exhibit 2 Assembly Drawing 2000RLB Exhibit 3 Assembly Drawing 3000 RLB Exhibit 4 RECEIVING AND INSPECTION OF EQUIPMENT Inspection General Purpose RLE INSTALLING THE RAPID FREEZE FLAKER Installation Conditions Refrigeration Requirements Installation On Ice Bin Exhibit 6 Recommended Installation Method On Ice Bin Exhibit 7 REMOTE LOW SIDE RL MODEL INSTALLATION Wiring amp Electrical Connections Electrical Junction Box General Piping Guideline Freon Piping Line Sizes Table 1 Freon Piping EPR Valve Suction Strainer Line insulation RL Piping Schematic Exhibit 8 Water Supply amp Filter Connections Exhibit 9 Refrigerant Charging Location Drawing for RL Models Exhibit 10 Page Un amp 92 N E E 10 11 11 11 12 12 12 14 14 14 15 15 16 17 18 19 4 5 6 7 8 Rapid Freez
49. igeration system components In accordance with applicable local and national codes in conformance with good practice required for the proper operation of the system The following procedures should be followed a Do not leave dehydrated equipment or lines open to atmosphere any longer that 1s absolutely necessary b Useonly clean new refrigeration grade copper tubing Suction lines should be sloped per 10 feet towards the compressor d Suitable P types oil traps should be located at 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 15 preferred f Useonly 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 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 SUCTION LINE LIQUID LINE MODEL RLE RLB OPERATING SERVICE MANUAL 12 Installing the Rapid Freeze Flaker REFRIGERANT PIPING SUPPORT Example of Pipe Support l Nor
50. insulation or better The insulation located in outdoor environments should be protected from UV exposure to prevent deterioration of insulating value MODEL RLE RLB OPERATING SERVICE MANUAL 15 Installing the Rapid Freeze Flaker CONDENSER FROM RLE PIPING SCHEMATIC EXHIBIT 8 RL FIP ING SCHEMATIC LOW TEMPERATURE EvAPORATOGRE Lote TEMP LOW TEMPERATURE COMPRESSORS 1 IGE FLARER SHAJLO GONNECTED Low TEMPERATURE COMPRES SRS OOHMMECT LINE HEADER STUB FLAKER MUST EE ON RECENVEF SIDE OF LIQUIO CONTROL Vale 45 ILLUSTRATED INSURE CONTINUOUS UNINTERRUPTED LIQUIO SUPFLY TCI FLAKER PL IGE FLAKER IHLET TO L T S2JC TION HEADER VALE MUST BE USED ICE FLAKER TU APPROX S F MODEL RLE RLB OPERATING SERVICE MANUAL 16 LIS Th HEADER HEADER TYRICAL RACE Installing the Rapid Freeze Flaker WATER LINE Connect a 2 galvanized or 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 d OD copper tubing between the field supplied water valve amp water inlet connection located on the rear of the flaker This line
51. itch 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 REPLACEMENT amp ADJUSTMENT OF ICE DEFLECTOR SCRAPER 2 amp 3000 RLE The ice deflector scraper 1s mounted on one of the three bottom ribs using two 3 20 stainless bolts MODEL RLE RLB OPERATING SERVICE MANUAL 48 Service amp Adjustment and nuts The scraper s primary purpose 15 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 15 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
52. lack 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 1s 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 Step 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 control panel The POWER SUPPLY RELAY should open the solenoid valve turn the machine on and begin making ice When the wire jumper 15 removed the solenoid should close MODEL RLE RLB OPERATING SERVICE MANUAL 38 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 t
53. lenoid valve d ODS TABLE 3 ELECTRIC PANEL amp PARTS 1000 RLE SCA SCW 64 Service amp Adjustment PART DESCRIPTION PART No LIST PRICE EA E20T48 Control board 24VAC SSAC E20T23 Overload reset button N O E20T24 Snap in On off rocker switch E20T31 24 Volt control transformer F5T2 3 Pole relay for motor contactor 24 volt coil 5V013 3 Pole relay mounting base Power module for infrared ice level control _ Infrared ice level control emitter Infrared ice level control receiver To help determine which ice flaker water sump amp pump you need use the following tables Items labeled Old represent parts used prior to 07 06 Items labeled New represent parts used from 07 06 until the present For more detailed information contact Howe customer service department with ice flaker serial number 65 Service amp Adjustment Models 2000 IOEAR 11ES 11ESS 3000 15 ISEAR I6ES 16 55 4000 20EA 20EAR 21ES 21ESS 6000 30EA 30EAR 31ES 31ESS ICE FLAKERS CROSS SECTION hs Em s Ss SR A E a E 5 M eA 5 A M grata a t 5 SEIEN atur WK ES ERRA 66 Replacement Parts Catalog 2000 10E 3000 15E 16E 4000 20 2
54. 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 EVAPORATOR PRESSURE REGULATOR EPR ADJUSTMENT From evap Model 1000 RLE EPR valve is located inside the enclosure behind the flaker to facilitate ease of adjustment of the valve EPR valves should be adjusted to maintain between 0 F and 5 F depending on ambient amp water conditions suction temperature To C omp at the ice flaker suction line EPR valves on 2 amp 3000 RLE are available as an option When supplied they are shipped loose to be installed on the suction line behind the flaker secured to the building wall The manufacturers setting for the ORIT EPR valve is 30 PSIG Howe doesn t re adjust valve to suit application It must be field adjusted to a pressure equivalent to 0 F for 1000 RLE 5 F for 2 amp 3000 RLE This pressure setting will vary depending on the refrigerant used in your system e g For R 404A the setting is 28 PSIG To adjust the ORIT EPR valve remove the cap and turn the adjustment screw using a 1 4 hex wrench A clockwise rotation increases the valve setting while a counter clockwise rotation decreases the setting To obtain the desired setting a pressure gauge should be utilized on the inlet side of the valve so the effects of any adjustments can be observed The ORIT val
55. lines 230 1 60 to the two black wires marked L1 and L2 m the electric junction box on the rear of the flaker 2 In the electric wiring junction box on the rear of the flaker there are two red wires which are wire nutted together This will enable the liquid line solenoid on the ice flaker to operate properly When connecting to a dedicated condensing unit an interlocking relay may be used Remove the wirenut Jumper and connect the normally open isolating contacts from a relay mounted in the condensing unit to these two wires The coil of the 1solating relay should be wired to the load side of the high pressure switch and line 1 side of the compressor contactor coil MODEL RLE RLB OPERATING SERVICE MANUAL 11 Installing the Rapid Freeze Flaker When connecting to a rack system leave these wires tied together 3 When connecting to nominal 208 1 60 power it may be necessary to install a buck boost transformer to boost the power to 230 1 60 for proper operation This may be necessary if the power drops below 200 VAC 4 If not connected in previous section locate amp connect the photo eye sensors to the matching plug in the ice 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 refr
56. mally 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 and 1 3 8 every 7 feet 1 5 8 and 2 1 8 every 9 10 feet 2 When changing directions in a run of tubing no corner should be left unsupported Supports should be placed a maximum of 2 feet each direction from the corner 3 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 4 not use short radius ells Short radius elbows have points of excessive stress concentration and are subject to breakage at these points 5 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 IMPORTANT NOTICE When piping ice flaker to a central refrigeration rack liquid line must be connected to the receiver side of any defrost solenoid control valve to insure uninterrupted liquid feed supply during normal defrost cycles of the rack IMPORTANT NOTICE Liquid Line For longer runs good refrigeration practice dictate
57. ng plate Remove the 4 bolts The gear motor may be removed by pulling it straight up from the mounting hub The flexible coupling will separate half stays on the flaker shaft with the bronze star the other half is attached to the gear motor The motor shaft fits directly into the top half of the flexible coupling with a 4 key When installing the new offset style gear motor Figure 2 attach the motor to the adapter plate using the 6 4 screws through the bottom of the plate Place the 4 key on the shaft lightly grease the surface of the motor shaft and insert in the hole on the flexible coupling keeping the keyway aligned with the key When the motor is in place rotate it CCW ONLY until the 4 holes on the adapter plate are aligned with the 4 mounting holes on the mounting hub on the flaker Insert a bolt in each hole and tighten You may need to loosen and readjust the flexible coupling to ensure the gear motor seats firmly to the mounting hub Motor Overload Wiring To ensure proper motor overload circuit performance when replacing a vertical style motor with an offset style the motor power lead needs to be looped through the current sensing module located on the control board E20T48 To do this disconnect the wire from the motor contactor mounted in the control panel and loop the loose end through the current sensor a total of 3 times Reattach loose end of the lead to the motor contactor Figure 1 Vertical
58. nsformer may be defective check amp replace 2 Control switch s open Check switches and ice level Check voltage between control for proper operation terminals 1 amp 3 Close switch es or replace To test Place a jumper switch if defective between Terminal 2 amp 3 this will simulate ice level switch amp a Switch es open voltage on off switch are closed ice should be 0 VAC machine should run normally b Switches closed voltage NOTE Unit will NOT shut off should be 24 VAC while jumper is in place 2 Drive motor contactor Solid State Control Board Check voltage between 1 amp 6 not energized output is defective or E NOTE there must be contactor coil burnt or open 0 VAC present output power to terminal 3 for wire in circuit defective replace module the out put 6 to energize input signal p musi be Ensure the input signal is present terminal 3 for out present before condemning put terminal 6 to be Solid State control board energized U as defective the easiest 24 VAC present module way to check this is place 4 output 6 OK check wiring jumper between terminal 2 nr contactor coil amp 3 all wires need to remain connected with jumper in place 3 Solenoid valve not Solid State Control Board Remove wires from 7 amp 8 set energized Drive motor isolated contacts will not close meter to Ohms check for contactor is energized provided all swit
59. onnect low pressure gauge to the charging valve located on the suction line the rear of the ice flaker Suction temperature must be maintained 5 0 F depending in model amp water conditions at all times 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 If suction temperature is 0 F for 1000RLE 5 for 2 amp 3000 RLE and there are no bubbles in the sight glass and ice is not being frozen and harvested on the entire surface of the evaporator then the expansion valve must be adjusted DO NOT ADJUST EPR or TXV for EVAPORTATOR SUPERHEAT Remove the adjustment stem cover and turn the adjustment stem 1 8 to 1 4 turn at a time clockwise to close the valve if it was overfeeding counterclockwise to open the valve 1f the evaporator was not freezing ice on its entire length Wait 10 15 minutes between each adjustment to allow the valve and machine balance out Repeat this step until ice is produced and harvested all the way down to the bottom of the evaporator When the ice maker is adjusted and operating properly turn 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 15 initiated
60. onnect main power to the ice flaker 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 1s 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 1n removing either part of the coupling Install the new or existing 1f 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 g
61. orage bin Too Remove All ice out of bin daily x long because ice usage too small Install clock timer to limit the time flaker produces Match daily ice production with daily ice consumption FREEZING I Ice freezes on the 1 System short of Charge with refrigerant until MODEL RLE RLB OPERATING SERVICE MANUAL 41 T AERE Chart PROBLEM PROBABLE CAUSE REMEDY entire length of the freezing refrigerant Bubbles in bubbles i in sight glass drum but harvests only on sight glass disappear Suction the upper half Ice remains accumulator must be empty of on the lower half of the liquid drum Ice blade teeth cut grooves in the soft ice but cannot remove it superheat setting is Decrease superheat setting too high open valve 2 turn at a time until ice is harvested down to bottom of drum 3 Improper location of TXV Relocate bulb approximately bulb located at ice flaker 6 from inlet side of suction suction outlet line heat exchanger if equipped or on the horizontal section of the suction line at approximately 5 O clock position Clamp securely and insulate Ice freezes and harvests top 1 Ice blade clearance too Adjust ice blade clearance see to bottom of drum but on high instructions in Section 11 one side only Opposite Service amp Adjustment side does not harvest 2 Main bearings worn Replace worn bearings inspect and repair replace sh
62. ove 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 MODEL RLE RLB OPERATING SERVICE MANUAL 35 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
63. pan because a Water distributing tubes Unplug all distribution tubes plugged b Water pump delivering too Adjust water regulating valve much water to pan ball valve located near water pump 3 One or more water Replace all defective water distribution tubes broken distribution tubes 4 Ice not harvesting See problem I down to bottom of freezing drum DRIVE MOTOR I Motor amps too high 1 Broken gear tooth in speed Repair or replace speed reach a peak reading reducer reducer at a certain position on the drum 2 Ice blade adjusted closer Readjust ice blade clearance than 003 clearance at that see section 11 Service amp position adjustment II Motor does not start Defective off delay timer Replace Solid State Control when system is circuit Board turned on Defective Bin level control See Photo Eye problems page 61 Motor does not shut Defective off delay timer Replace Solid State Control off when system is circuit Board turned off after normal time delay period MODEL RLE RLB OPERATING SERVICE MANUAL 45 TroubleShooting Chart PROBLEM PROBABLE CAUSE REMEDY IV Motor cuts out on 1 Electronic overload set too Consult factory overload but amps low do not exceed nameplate F L A VI Motor burnt out 1 Electronic overload Consult factory speed reducer output setting too high shaft broken VII Motor burnt out or Ice storage bin wa
64. queegee 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 MODEL RLE RLB OPERATING SERVICE MANUAL 49 Service amp Adjustment REPLACEMENT amp ADJUSTMENT of the WATER DISTRIBUTION TUBES Adjust lead tube bottom spout with 90 Elbow so that the water is dispersed over the evaporator and it doesn t splash water over the ice deflector If it 15 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 VERTICAL STYLE GEAR MOTOR WITH OFFSET STYLE GEARMOTOR Disconnect main power to the ice flaker Remove electric wiring cover on the drive motor Unplug the power leads from machine The gear motor Figure 1 15 attached to the mounting hub with 4 4 bolts through the motor mounti
65. rive 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 1f scale build up is heavy 8 When system 15 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 TO SANITIZE 9 Mix a solution of approved sanitizer or mix 16 oz of household bleach with 2 gallons of warm water 90 115 F 10 Pour solution into sump to normal operating level as in 6 then recirculate sanitizing solution for approximately 20 minutes by turning on drive motor amp pump 11 Drain solution and rinse thoroughly with fresh water at least twice following procedure described in No 8 12 After ice flaker 15 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 Water Distribution Tubes Water distribution tubes should be kept clean and free of any mineral buildup When they do accumulate mineral deposits the flaker must be thoroughly cleaned Rem
66. rmal 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 Month Month Month Month Month Uu eee Clean amp sanitize ice machine as required Check if flaker 15 harvesting properly Clean electric eyes check alignment Inspect flaker for damaged parts check bearing wear check cutter blade clearances Check for bubbles sight glass EN Replace water filter every 6 months m Use Caution to not over grease which may pop the grease seal Tm Typically every 12 months in areas with poor water quality possibly as often as every few months With good quality water cleaning may be required only once a year QUEE Parts to check for damage are ice deflector ice deflector scraper squeegee amp wrapper water distribution tubes and float valve MODEL RLE RLB OPERATING SERVICE MANUAL 37 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
67. s full of Install suitable ice level control off on overload ice ice and flaker continued to Photo Electric Eye deflector broken or operate No ice level bent out of shape control or defective ice level control VIII Gearmotor stops Ice flaker voltage dropped Install Buck Boost turning during below 200 VAC transformer to boost voltage to normal operation ice flaker so it doesn t drop below 200 VAC 220 230 optimum voltage MODEL RLE RLB OPERATING SERVICE MANUAL 46 Service amp Adjustment IMPORTANT SAFETY NOTICE The information in this manual 1s 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 DANGER The control panel on this ice flaker may be powered by TWO SEPARATE power sources Disconnect BOTH SOURCES prior to servicing this piece of equipment Failure to do this may potentially cause a electrocution hazard DANGER 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 WARNI
68. s that the liquid line be sized one size larger to prevent flashing due to excessive pressure drop If system is fully charged the presence of bubbles in the sight glass at the ice flaker is a visible indication that flashing 1s occurring Using sub cooled liquid or a low pressure floating head rack system may MODEL RLE RLB OPERATING SERVICE MANUAL 13 Installing the Rapid Freeze Flaker effect the refrigeration capacity of the standard TXV valves selected If connecting to a floating head rack system contact Howe Corporation regarding possibility of needing to change the valve for proper operation of the ice flaker It may not be possible to adjust the thermostatic expansion valve properly when these conditions exist Note Flashing may also occur if the liquid line is run through hot areas of the building such as boiler rooms or smoke rooms If this is the case the liquid line should be insulated IMPORTANT NOTICE When connecting to a low temperature rack below 10 F you must provide and install a suction pressure regulator EPR Valve to control suction pressure at the ice flaker at approximately 5 F 28 PSIG R 404A 20 PSIG R 22 1000 RLE should be operated at 0 F 33 PSIG R 404A 24 PSIG R 22 IMPORTANT NOTICE Suction Line For longer than 150 foot run the next size suction line may be used for horizontal runs and slightly pitched per 10 towards the compres
69. sformer Provides 24 Volt control power to control panel components Solid State Control Board motor contactor and indicating lights 3 Solid State Control Board E20T48 Main control processor incorporates motor overload operating circuit off delay circuit Controls motor contactor and solenoid valve power 4 Photo Eye control relay processes signals from electronic eye level control 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 Located on Rear of Ice Flaker Normally open reset button resets overload circuit following overload condition MODEL RLE RLB OPERATING SERVICE MANUAL 28 Electrical Controls 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 15 the main processor for ice Flaker control panel It incorporates the timer functions control relay functions and overload relay functions Terminals 1 amp 2 24 VAC input power Terminal 3 Ice Flaker Run input signal all on off switches 1ce level controls and any spe
70. should be as short as possible to avoid pressure drop If water supply has silt or sand it a coarse water filter 15 recommended IMPORTANT NOTICE A MINIMUM WATER PRESSURE OF 30 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 9 WATER FROW SUFF Er TD WATER CIS RIEUTIOH WATER NN WATER FUL RE CULATIHE un LYE Ce ERF FITTING FLOAT WATER SUF MODEL RLE RLB OPERATING SERVICE MANUAL 17 Installing the Rapid Freeze Flaker REFRIGERANT CHARGING CAUTION Service Installation personnel MUST have knowledge of refrigeration systems to properly charge this ice flaker CAUTION Verify that thermostatic expansion valve supplied and installed on ice flaker matches the refrigerant for the rack system or condensing unit 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 briefly outlined as follows 1 Pressurize and test the system checking all refrigerant connections amp fittings ice flaker amp condensing units for leaks 2 Use a large di
71. sor Vertical risers should be the same size as the ice flaker connection size to maintain proper velocity for oil return If the vertical riser is more than 4 feet it is necessary to install a P trap at the bottom of the riser Install an additional trap for each 15ft of riser to facilitate lift suction line should always be insulated Suction P Traps REDUCE HERE Slope 1 4 per 10 ft toward compressor INCORRECT CORRECT EPR VALVE When connecting to a refrigeration rack system the 1ce flaker should be connected to a low temp rack An EPR evaporator pressure regulator valve must also be installed on the suction line preferably near the ice flaker EPR Valves are included with shipped loose all split systems supplied by Howe EPR valves are available shipped loose as an option with Howe remote low side flakers See pricelist for pricing Flaker Model R 404A EPR Model R 22 EPR Model 1000 RLE F5C21 F5C21 7 8 ODS 2000 RLE E10V9 E10V9 1 1 8 ODS 3000 RLE E20V9 1 1 8 ODS MODEL RLE RLB OPERATING SERVICE MANUAL 14 Installing the Rapid Freeze Flaker SUCTION STRAINER Howe strongly recommends installing a suction strainer between the ice flaker evaporator amp the EPR valve when connecting to a rack system Suction strainers offer the following benefits Protects the compressor from dirt a relief device opens if the filter plugs full flow design for low pressure drop The following
72. splacement 8scfm vacuum pump capable of at least 500 microns absolute to evacuate the system Make sure all shut off valves are OPEN so that the entire system is evacuated Allow vacuum pump to run for several hours until you reach 1500 microns 3 Allow to stand for 20 minutes 1f system pressure rises re check for leaks Break vacuum with 2 PSIG refrigerant and evacuate again 4 Repeat step 3 this 1s called triple evacuation It insures that all air and moisture has been removed from the system Failure to do so may result in compressor burn out 5 After the third evacuation to 500 microns allow the system to stand for a minimum of six hours if no pressure changes are observed proceed with charging or unit Notice that the eye in the liquid indicator is green indicating that the system 15 clean and dry Then continue to charge the system using gas not liquid Above is a brief outline for charging the system Consult the rack or condensing unit manufacturer for full details MODEL RLE RLB OPERATING SERVICE MANUAL 18 Installing the Rapid Freeze Condensing unit LOCATION DRAWING FOR RLB MODEL EXHIBIT 10 ACCESS CLEARANCE ABOVE UNIT 30 1 4 ICE FLAKER 70 1 2 ICE BIN ACCESS CLEARANCE 6 ACCESS CLEARANCE MODEL RLE RLB OPERATING SERVICE MANUAL 19 Installing the Rapid Freeze Condensing unit CONDENSING UNIT INSTALLATION After inspecting for damage amp correct voltage
73. spout amp fitting 6 E10H18 E20H39 E30H8 E20G8 KT 20 11 20 21 E10B8 67 Replacement Parts Catalog TABLE 4 Replacement Parts for Models Listed to Right Part Description Water distribution side spout amp fitting 6 For use on plastic distribution pan Water distribution pan assembly Includes dist Tubes fittings Aluminum pan copper tubes Water distribution pan assembly Includes dist tubes fittings Water distribution bottom spout fitting Water distribution bottom spout fitting For use on plastic distribution pan Water sump assembly with water pump Old Water sump assembly with water pump New Water sump bolt down cover Old Water sump bolt down cover New Water sump removable cover Old Water sump removable cover New Water sump gasket Water sump silicone adhesive Water float valve E10H29 Round float 6 arm E50H18 Rectangular float 11 arm see p 70 Water float valve circular 5 arm Old see p 70 Water float valve fitting Water tube Water tube insulation Water tube grommet Water tube fitting 2 Water tube regulating valve Water tube sleeve Water sump screen Water pump 115 230 1 60 see p 70 Water pump 230 1 60 see p 70 Water pump 230 1 60 see p 70 E10H18 P 2000 10E 3000 15E 16E 4000 20 21E 6000 30E 31E IOEA IOEAR 15 ISEAR 20EA 20EAR 30EA 30EAR 11 5 IESS 16 5 16ESS 2IES 2IESS
74. t checking for and correcting worn bearings When checking tolerances do NOT use automotive Asparkplug type feeler gauges you MUST use industrial machine tool type feeler gauges these are about 2 wide by 12A 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 1f 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 1s the least This 1s accomplished with the use of a feeler gauge Check clearance top and bottom of blade rotate blade 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
75. the adjustment stem 1 8 to 1 4 turn at a time clockwise to close the valve if it was overfeeding counterclockwise to open the valve 1f the evaporator was not harvesting 1ce on its entire length Wait 10 15 minutes between each adjustment to allow the valve to stabilize Repeat this step until ice is produced and harvested all the way down to the bottom of the evaporator Note Balanced Port Expansion Valves Are more sensitive than normal TXV s so adjustment of the stem should be limited to between 1 16 to c turn at a time MODEL RLE RLB OPERATING SERVICE MANUAL 55 Service amp Adjustment REPLACEMENT OF SOLENOID VALVE SPECIAL NOTE On RL flakers that are connected to a central refrigeration rack system the two red wires in the main 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 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 CAUTION ARROW ON SOLENOID VALE MUST POINT IN THE DIRECTION OF FLOW TOWARDS ICE FLAKER CAUTION Using a high quality vacuum pump evacuate the liquid
76. tion MODEL RLE RLB OPERATING SERVICE MANUAL 21 Installing the Rapid Freeze Condensing unit ELECTRICAL Follow local applicable wiring codes to wire main electrical power from building distribution center to main power terminals condensing unit panel Install wiring race conduit between ice flaker junction box on rear of flaker and condensing unit control panel The two Red wires in the flaker junction box will be connected to terminals marked A amp B in the Howe condensing unit REFRIGERANT PIPING If the ice machine 1s less than 20 running feet from the condensing unit good refrigeration piping practice dictates that you field install a heat exchanger not supplied by factory next to the ice machine Ice flaker model Liquid Line size 1000 RLE 7 8 ODS 2000 RLE ODS 2 ODS Install the suction accumulator near the condensing unit some model condensing units have suction accumulator installed Check all electrical and refrigerant connections Be sure they are tight and leak free ADJUST LOW PRESSURE SWITCH LJ All Rapid Freeze Remote Condensing units have a Low pressure Operating pump down switch To Adjust the Low Pressure switch turn the adjustment IU stem clockwise to raise the cut in setting counterclockwise to lower the cut In setting The cut in right adjustment stem setting should be set at 23 PSIG for R 404A 16 PSIG for R 22 The differential setting cut out left
77. tric control panel Cross section drawing for 2000 6000 pound ice flaker Replacement parts for 2000 6000 pound ice machines Howe Corporation 1650 N Elston Ave Chicago IL 60622 Tel 773 235 0200 Fax 773 235 0269 www howecorp com email howeinfo howecorp com MODEL RLE RLB OPERATING SERVICE MANUAL 61 Service amp Adjustment ce 3 ew MODELS 1000 RL RC SCW amp SCA FRESH WATER ICE FLAKER CROSS SECTION 4 N VX 2 14 4 ZA LL WV z lt i REA X XX XK KKK KKK XXXXXX N Ss a lt lt Gee equa AYS i SAS ASS SSN ANNNNSANS SNARE X k f N s ff y 2 Mw 2 gt NX bJ gt lt XN X VAXXXXXXXXXXXXXX Ves gt MODEL RLE RLB OPERATING SERVICE MANUAL 62 Z f Service amp Adjustment TABLE 1 REPLACEMENT PARTS Item No PART DESCRIPTION Gearmotor Mount M
78. ttom but harvests only the upper portion with each revolution of the shaft and there are no bubbles sight glass then the expansion valve must be adjusted Opened to feed more refrigerant On the other hand frost on the compressor body indicates that the valve 1s overfeeding Remove the adjustment stem cover and turn the adjustment stem 1 8 to 1 4 turn at a time clockwise to close the valve if it was overfeeding counterclockwise to open the valve if the evaporator was not harvesting ice on its entire length Wait 10 15 minutes between each adjustment to allow the valve to stabilize Repeat this step until ice 15 produced and harvested all the way down to the bottom of the evaporator Note Balanced Port Expansion Valves are more sensitive than normal 5 so adjustment of the stem should be limited to between 1 16 to c turn at a time MODEL RLE RLB OPERATING SERVICE MANUAL 27 Electrical Controls Components amp functions Electrical Controls for Ice Maker EXHIBIT 22 LEVEL MOTOR Solid State CONTROL ICE FLAKER CONTROL RELAY Control Board slate Salas ON OFF ICE FLAKER AUN DRIVE MOTOR OVERLOAD RESET BUTTON LOCA ON REAR OF ICE FLAI 1 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 2 Control Tran
79. ve has a access valve on the inlet fitting for this purpose Small adjustments and adequate time between adjustments are recommended to allow the system to balance at the new MODEL RLE RLB OPERATING SERVICE MANUAL 56 Service amp Adjustment setting Average PSI change per rotation of the adjustment screw is 6 psi Service note since these valves are hermetic and cannot be disassembled for inspection and cleaning they usually must be replaced 1f they become inoperative However if an ORIT fails to open close properly or wont adjust it 15 probably due to solder or other foreign materials lodged in the port It is sometimes possible to dislodge these materials by turning the adjustment nut all the way out with the system running If the ORIT develops a refrigerant leak around the spring housing it probably has been overheated during installation or the bellows has failed due to severe compressor pulsations When this occurs the ORIT will close until the inlet pressure becomes greater than the outlet and spring pressures Then the valve will open and close like a pressure differential valve ICE BLADE ADJUSTMENT Ice blade adjustment is not normally required typically the only time this is needed 1s after bearing replacement If you suspect the blade needs adjustment because of excessive clearance it 1s typically caused by excessive bearing wear not the blade going out of adjustment Do not try to adjust the blade clearance withou

Rapid Freeze ICE FLAKERS INSTALLATION & SERVICE MANUAL

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Rapid Freeze ICE FLAKERS INSTALLATION &amp; SERVICE MANUAL

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Rapid Freeze ICE FLAKERS INSTALLATION & SERVICE MANUAL