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60 Series Service Manual.rev.1.2012 - Kold

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1. M3HShH2 HOLIMS yg 1VISOWH3HL OLOW 1915 IOO QN NIB HOLIMS zi 395 GaHSNYO ya Olo lt vg 8 ONG A HS i 1VISONWS3HI sg oo ci dts we OO TOO us T 8 1409 YOLOW na yg Alddns 8 NOION YSHSNYO na SIndlno Ov LZ 39 HOLIMS d YOO IM3INI M38no IVNOIS FATWA M E SHOSN3SS 8 Su 3 AUNIVYACNAL 8 Vell 5 SXOSNIS 8 3 TJA31 9 9 Sindino OV 440 8 SVO 10 SHOSN3S 8 8 8 B 4 SMOSN3S 8 13431 9 cf M38no9 LZ M38no HOLIMS HOLIMS OO IM3INI OO IH3INI Magno 1 Oma ne M8 9
2. ALARM Machine Status CLEAN E S Water LevelSensor Sequence ER Ed e Evaporator Temperature HI WATE ar ATE UE Reset Button InputStatus E A PLAT Temperature Sensor Port amp Bin Full Adjustment Fault Codes 6 Bst Switch Input Port Water Rinse Jumper Left Dual Evaporator Factory Use Only Jumper Right AC Outputs Machine Status Displays the position of the Ice Clean switch or an Alarm Sequence Displays the current stage of the ice making process See Page 26 for more information Input Status Displays the status of the individual sensors for the ice making process Fault Codes The electronic control will monitor for the following conditions and shut down the ice machine as required to prevent damage to the equipment gt 10 Rev 1 1 1 2 1 3 1 4 1 5 If at any time the evaporator temperature exceeds 120F the controller will shut down the ice maker and provide LED fault indicators gt 20 Rev 1 1 1 2 1 3 1 4 1 5 the water tray automatically cycles 3 times in a row due to a water plate obstruction the controller will shut down the
3. APORATOR EFEI HIGH 31 GB106XR WIRING DIAGRAM RE GLEDE FAI PRESS DEN FLATE PLATE PPE F E ATE REFERENC IT IT H IT IT WIT CI IT E AL KELAY LEAI HERM B LATE LATE BIN DEFI ITEM jz ALARM CLEAN MAKE E ATE REEZE ERF RM RE TEMPERATI
4. Compressor Wiring GT361 Models Only Ll 30 HERMOST EFERENCE HIGH 3ENSOR LO GT36x GT56x GB56x LZ GB1064 A amp L WIRING DIAGRAM 60 Series Service Manual rev 1 2012 ALARM L LEAN MAKE ATER ENSO B L HARVEST WATE 1 ATE ERF RMS UI TEMPERATURE SENSOI E T2 PLATE UI RMS DOWN 7 p at SIGNAL INPUT m ap JTPUT l H x 2 BK BK 3 ys M2 Note A wiring diagram for remote condenser models GB106xR is on the following page ESCRIPTION NTACT HIGH OFF FASTBL FAN ATER PUMP MOTOR L
5. INLET Dp 56 DIA e E MOUNTING HOLE PARTS FOR CONDENSER 102140601 FAN MOTOR RC214APV 230V GBR01890 1 2 MALE SELF SEAL COUPLING FOR CONDENSER ICE MAKER GBR01889 3 8 MALE SELF SEALING COUPLING FOR CONDENSER ICE MAKER PARTS FOR LINE SET GBR02218 1 2 FEMALE SELF SEAL COUPLING FOR LINE SET GBR02219 3 8 FEMALE SELF SEALING COUPLING FOR LINE SET 60 Series Service Manual rev 1 2012 77 KOLD DRAFT PRE CHARGED REMOTE AIR COOLED CONDENSER INSTALLATION Note e Check for freight damage before proceeding with the equipment installation Be sure to inspect the equipment carefully for any damage that may not have been evident on the outside of the carton Contact the freight carrier immediately to report any damage and file a claim e To ensure optimal efficiency and productivity these installation instructions should be followed accurately e All machines have been tested and adjusted for correct performance at the factory e This equipment must be installed in compliance with the applicable federal state province and or local plumbing electrical and health sanitation codes and requirements Warning Do not operate equipment that has been damaged Refer all maintenance to qualified personnel Instruct all personnel in the proper use of the equipment Clean up any liquid
6. uo 2 21246161262 2 Dao de NUDO 3 CUBE FANS 211 cub fn uuu 4 WV ALS NI ANC OO X u u 222 A t 4 Reduced TOOS u 4 5 Additional Pre install Information for Cooling Tower Applications models 7 PSOE mM 8 WIN 8 PASS CIID IY 8 erate ener neem ca 10 ICE CEEANING PROGEDUTRE Xu u UR Ud M odds ce 11 SPECIFICATION lc 12 Machine Capace Soire oom 12 Electrical Use and Machine 13 Water Fill Levels Cycle Times and Harvest 14 GUDE DD 14 Typical Refrigerant Operating 14 uuu e PE 15 GOMPOMC TE 15 GB106x Series Unique Components 18 19 ERROR CODE TROUBLESHOOTING et ede i 22 SEQUENCE OF OPERA
7. 68 neve t 69 Inilial Surt 0 73 ICE CRUSHER OPERATION ___ ________ __ 73 ICE CRUSHER CLEANING uy tend v EP dcc 73 ADJUSTMENT AND 73 WIBING DIAGRERAN S 74 PRE GHARGED REMOTE AIR COOLED CONDENSER 75 PRE CHARGED REMOTE AIR COOLED INSTALLATION 76 uuu u u u aa Da wbb anan 76 ISIS 79 UID 79 Minimum Ee eris M SIDES 78 M aniio UTE 81 81 ICE CUBER SAFETY INFORMATION opecial attention should be given to potential hazard labeling on the equipment and the signal words and symbols that are used throughout this manual They may also be used to alert against unsafe practices Note Note is used to notify personnel of installation operation or maintenance information which is important but not a cause of personal injury or property damage Warning Indicates a potentially hazardous situation that may result in minor or moderate injury The situation may also cause minor damage to the machine Caution Indicates a potentially hazardous situation th
8. 34 Test Procedure for Compressor Electrical Components 35 resting The RUM gt IAIN 35 Testno S EET 35 Additional Service Information 2 020 00 36 WATER PLATE REPLACEMENT e Ehepaar ______________ ___ 36 WATER PEATE ALIGNMENT uu uu 38 WATER PLATE UP DOWN POSITION AND ADJUSTMENT 38 APPLICA TION LIST scende ivive u Q 40 MEME EE LAM 41 INSTRUCTIONS FOR GB1064 WATER FILL ADJUUSTMENT 42 TROUBLEESEOOTINGL iti dits u uu er 44 PARISIDIAQGPANS Sonet 49 1 m T m Un 50 51 53 T T T NM 54 e 2 58 ACTUATOR MOTOR Kit APPLICATION LIS deve vd 61 STACKING ING TRUCTIONS Cic 62 ICE COBE CRUSHERS 65 ICGE CRUSHER u asuy uno ON 66 2 ud tacta 67
9. e 180 82 169629 18062 16 9 429 163429 17479 e 31065 257663 1699 409 meu f e 3055 257663 1699 409 31055 2570653 39708 i 80 1065 17 432 r no EC GB561AHK 42 3 107 4 31 1 79 17 43 2 207 94 GB561LC 42 3 107 4 25 63 65 1 17 43 2 185 84 207 8 1858 Tea se lt r B r B 312 142 231074 557 656 GB1064RC amp RC214APV 42 3 107 4 25 7 65 3 33 7 85 6 335 152 GB1064RHK amp RC214APV 42 3 107 4 25 7 65 3 33 7 85 6 335 152 RC214APV 40 75 103 5 22 75 57 8 30 2 76 6 160 73 60 Series Service Manual rev 1 2012 13 KOLD DRAFT Water Fill Levels Cycle Times and Harvest Weights Water Fill Level inches mm 2 75 70 2 75 70 2 75 70 2 75 70 24 31 24 22 98 44 Approximate Cycle Time Minutes 31 24 31 2 Approximate Harvest Weight lbs kg o a d 2 ips E P Note Rough measurement from top edge of water tank to water level in control tube after water fill is complete Additional fine adjustments may be required Cube Information Cube Type Cube Dimensions in mm Cube Weight oz 0 0295 Full Cube 1 25 x 1 25 x 1 25 31 x 31 x 31 1 15 32 6 HK Half Cube 1
10. INI AL M4 32 COMPRESSOR TEST PROCEDURE Warning Refer all service work to qualified technicians Knowledge of proper installation and service procedures is essential to the safe maintenance of KOLD DRAFT equipment Do not operate equipment that has been damaged Always disconnect the power supply before servicing the equipment Some circuits remain energized when the ice machine is switched off Never operate the ice maker with any covers panels or other parts removed or not properly secured Never modify the circuitry of KOLD DRAFT equipment from the original specifications Use only genuine KOLD DRAFT replacement parts Use of non approved parts when servicing KOLD DRAFT equipment may create a safety hazard or cause equipment and property damage Use of non approved parts when servicing KOLD DRAFT equipment will void the equipment warranty Disconnect all electrical power before removing the protective terminal cover Never energize the system unless the protective terminal cover is securely fastened Never energize the system unless the compressor is properly connected to ground Never reset a circuit breaker or replace a fuse without checking for a short circuit to ground An open fu
11. KOLD DRAFT Test Procedure for a Short Circuit to Ground Ground Fault 1 2 Disconnect all electrical power to the system making sure all power legs are open Remove the protective terminal cover Inspect for evidence of overheating at any connection Overheating is an indication that a compressor motor problem exists Disconnect all leads from the terminal pins Check the compressor for a ground fault using an ohm meter or a high potential ground tester Connect one lead to the copper suction line and connect the other lead to one of the terminal pins Repeat this procedure for the two remaining terminal pins the instrument indicates any resistance less than 2 mega ohms between any pin and the suction line compressor housing a ground fault exists If a ground fault exists replace the compressor Do not reconnect the compressor or re use any leads or terminal connectors that exhibit signs of overheating Test Procedure for Continuity and Proper Resistance 1 If no ground fault has been found determine if there is an open or short circuited motor winding or if the thermal protector is open Allow time for the thermal protector to reset This may take as long as an hour for internal type thermal protectors For single phase compressors test the continuity of the start winding by measuring between terminal pins C and S Test the continuity of the main winding by measuring between terminal pins C and R If there is
12. Note e Abnormal operation of the ice machine is covered in the Fault Condition section of the manual e he sequence of operation for GB106x models is identical to the GB56x and all models utilize the same controller Note GB106x models employ two each of the following electrical components and controls Condenser Fan Motor air cooled models only Actuator Motor Water Pump Defrost Valve Water Plate Switch Arms Up Switch Arms Down Switch Ice Making Sequence Lower Harvest Raise Evaporator Temperature Probe pu pe emm Men High Level Water Level Control Gf rising i j m None Forming Fully Formed Fully Formed Compressor Condenser Fan d On On On On WaerPump On D frgstValva P Closed Open Open Closed De energized De energized Energized De energized Open Closed Open Closed Open Actuator Motor On CCW On CW Rotation Control Stream E to High 26 Ice Bin Full Cleaning Mode Mode Open Note If the water level is low the water valve will open to fill the water tank Description of Each Process The following sequence begins with the cuber as shipped from the factory with the water plate s closed and ready to begin a normal ice making cycle Fill The water solenoid valve will be energized only until the water level reaches the high water level probe and the water pump will run
13. INVA ODA SVO OH Sv9 LOH zi zi AV 13M AV Es O N ON O N INOS ng M u8 25184 NOLOW 9 on 9 ow 9 4 YOLOW A M 4 10275 SOLON HOLIMS no A da ns CD MOI2313S ad 9 9 m 8 mee 1915 1VISOWS3H m Imi YSIHSNYO M NIB NIB SMOSN3S 3415 38 0 8 A AV TM ui MOLON 2 16 1 M3HShHO M M 1VISOWM3H 7102313 10313 NIB z N38no9 1 39 3415 03 VYLASN Y ng 4 1 na na na 75 60 Series Service Manual rev 1 2012 102122601 SWITCH GBR00856 ACTUATOR LINK CRUSHER amp CUBE 506102601 SIDE BIN 102121704 SELECTOR SHAFT THERMOSTAT SELECTOR SWITCH T260 amp T270 102103701 102113302 CRUSHER 1 MOTOR T260 amp TT270 102125801 DRIVEN 102103801 RELAY PLUG IN 230V PULLEY 36 TOOTH 1260 amp T270 102125701 DRIVE PULLEY 13 TOOTH 1260 amp 1270 102125901 102121703 INTERLOCK SWITCH DRIVE BELT 1260 amp T270 76 PRE CHARGED REMOTE AIR COOLED CONDENSER RC214APV Installation Operation Technical Service and Replacement Parts D TN LIFTING HOLE AIR FL
14. Installation Operation Technical Service and Replacement Parts Manual Ice Cube Makers GT36x GT56x GB56x GB106x Stacking Instructions Multiple GB56x or GB106x Ice Cube Crushers T27x Pre charged Remote Air Cooled Condenser RC214APV TII TIAM am A GT36x GT56x GB56x GB106x J KDindustries Inc 1525 East Lake Erie PA 16511 1088 U S A 800 840 9577 FAX 800 548 9392 www kold draft com N SF UNE E Us April 2013 Intertek This manual is updated periodically Visit http www kold draft com resources literature php S DRAFT KOLD DRAFT Installation Operation Technical Service Specifications and Replacement Parts Manual Ice Cube Makers GT36x GT56x GB56x GB106x Stacking Instructions Multiple GB56x or Multiple GB106x Ice Cube Crushers T27x Pre charged Remote Air Cooled Condenser RC214APV For GB106xR Copyright 2010 KDIndusiries Unauthorized reproduction of this manual is freely permitted for all purposes except for monetary gain It is not guaranteed that this service manual is up to date technically correct complete or free from writing problems or that the product is free from minor flaws or that it meets the needs of the customer April 2013 Table of Contents SAFETY INFORMA TION 4 IOE 2
15. Knowledge of proper installation and service procedures is essential to the safe operation and maintenance of KOLD DRAFT equipment Refer all installation and service work to qualified technicians Always disconnect the power supply before servicing the equipment or when the equipment will not be used for a period of time Some circuits remain energized when the ice machine is switched off Never operate equipment that has been damaged or does not have all the protective covers in place Never operate equipment that has been altered from the original KOLD DRAFT specifications opecial attention should be given to potential hazard labeling on the equipment and the signal words and symbols that are used throughout this manual Instruct all personnel in the proper use of the equipment Clean up any spillage immediately Failure to comply with all KOLD DRAFT installation guidelines may cause personal injury equipment or property damage and may void the product warranty For stacking 2 or more KOLD DRAFT 6 series energy efficient ice making machines 1 2 3 LOWER FRAME Hemove the cabinet panels from the upper and lower ice machines Mount the frame spacers on the top side panel flanges of the lower ice machine frame Position so the spacer holes are aligned with the holes in the frame Position the front panel hanger on the top front rail as shown _ Z FRONT PANEL HANGER VIEW FRAM
16. 15 of gt O D discharge 6 0 line at gt 70 F 3 5 Ib flooded condenser at 20 F 121 25 oz 7 6 Ib The factory charge for GB1060R models is 10 5 Ib Caution e Do not exceed the specified maximum total system charge nterconnecting lines over 50 are not recommended e Lines must be pitched upward toward the condenser with no droops or traps Note The compressor will start immediately when power is applied regardless of the On Off or the Make Ice Clean switch positions if the low side pressure is at or above the pump down controller cut in setting and the high pressure cutout is not open Be sure that the compressor stops when the low side pressure is between 5 and 15 psig 80 Electrical Information NDOENSCEI MACHINE Removing From Service When the ice maker is determined to be no longer useable please be sure that it is rendered safe for storage or disposal All applicable recycling measures should be exercised to avoid injury and harm to the environment The manufacturer and or seller is not responsible for any harm to people animals property and the environment caused by incorrect installation and or disposal END OF DOCUMENT 60 Series Service Manual rev 1 2012 81
17. See the remote air cooled section of the manual for information on these models Condenser Fan and Motor Provided with all air cooled models to draw air through the condenser Liquid Regulator Valve Provided with all liquid cooled L models to regulate the flow of coolant through the condenser and maintain a specified refrigerant discharge pressure Heat Exchanger Provided to sub cool the refrigerant ensuring that the refrigerant is liquid at the inlet of the expansion valve Filter Drier Provided as insurance that all moisture and impurities are removed from the refrigeration system Thermostatic Expansion Valve Maintains the proper flow of refrigerant through the system as the load changes during the ice making cycle Evaporator A plated copper evaporator is found in all models The evaporator provides the five freezing surfaces for ice cube formation Defrost Valve Directs compressor discharge gas to the evaporator warming it to release the ice cubes during the harvest cycle Water Tank Provided as a sump to hold the water required to make one batch of ice cubes Water Solenoid Valve Opens to allow potable water to enter the ice machine and closes when the water tank is filled to the correct level Note There is a strainer in the water valve inlet which protects the water valve from particles in the water supply If the need for cleaning this strainer is frequent an external water filter should be pr
18. new relay does not correct the operation the compressor may have a mechanical problem Note Excessive short cycling may be caused by a faulty thermal protector but it also may be caused by other malfunctioning system components such as the bin thermostat Ice Off Wash switch and contactor or high pressure cut out 36 WATER PLATE REPLACEMENT Turn off water and open plate until cams are in the 9 00 position then turn off the power 2 Remove the control stream drain hose 3 Remove water level probe assembly by sliding it to the right beyond the control stream box and lift Disconnect tube assembly from main tank 4 Remove the pump mounting screw holding the water plate brace the inlet and outlet hoses from the pump 5 Pry plastic hinge brackets away from the plate 6 Unhook the main springs from the water plate 7 Remove the screws that mount the control module box Pull the module forward to disconnect front cam 8 Slide the water plate and tank to the right without turning and slide it forward out of the machine 9 Remove the spring bosses water plate brace water Ps ss deflector pressure pads and the four screws Fe C C y holding the tank to the water plate Remove plastic bolt from shoulder on water plate and place in new 1594 m plate 10 Attach the tank to new water plate with two 6 mach screws on the left side and two 10 sheet metal screws on the front and back Note The speed nuts on the fro
19. 25 x 1 25 x 62 31 x 31 x 15 53 15 0 Typical Refrigerant Operating Pressures High Side Approximate Low Side Discharge Pressure R 404a Suction Pressure Approximate Approximate Air Cooled Liquid Cooled 50 PSI 1650 kPa Beginning of Freeze Cycle 845 kPa oee Note 1 See Note 3 12 to 20 PSI 1650 kPa Just Before Defrost Cycle Begins 80 to 140 kPa oee Note 2 See Note 3 Measurement Point Durina Defrost 70 to 150 PSI 150 PSI 150 PSI 9 y 480 to 1030 kPa 1030 kPa 1030 kPa Note 1 High side pressure in air cooled models at the beginning of the freeze cycle is likely to be higher than 250 PSI 1720 kPa Note 2 High side pressure in air cooled models at the end of the freeze cycle is likely to be lower than 250 PSI 1720 kPa Note 3 240 PSI 1650 kPa is equivalent to 101 380 condensing temperature 14 COMPONENTS Mechanical Components Refrigerant Compressor Provided to pump refrigerant through the refrigeration system See the serial number plate for refrigerant specification and electrical characteristics Condenser All air cooled and liquid cooled models are provided with a self contained refrigerant condenser to remove heat from the refrigeration system These condensers are designated in the model number as air cooled and L liquid cooled Remote air cooled condensers also available for some models These are designated as R in the model number
20. 3 Evap Bin Temp Sensor Assembly 4 Plate Cam Switch 3x mater v 6 High Pressure Cut Out 20 Filter Drier gt j 28 4 3 EDT i ay 7 Defrost Valve Coil A V b 19 Expansion Valve gt Py 12 Front Cam w Springs 17 Drain Pan 15 Spring 2x 10 Fuse Holder with 4A fuse 13 Rear Cam w Springs 14 Water Deflector 11 On Off Switch 21 Probe Tube Assembly 8 Ice Clean Switch 18 Water Pump 9 Controller 16 Water Tank GB56x GBR00200 Controller 102138201 Water Plate HO Plate HK GB56x GBR00270 e SS em mme 4 Plate Cam Switch 2 Switch 2 102138001 38001 17 DrinPan Pan GB56x 102137801 Actuator Motor 0 Motor X 102123801 18 TransformerAl230V 8564 10214540 GBR02750 8 lce CleanSwich 102138501 54 GB56x Air Cooled 1 Defrost Valve Coil 4 Water Valve 5 Fan Blade 6 Fan Motor 2 Defrost Valve Body 3 Compressor 7A Condenser Air Cooled GB56x Liquid Cooled Description Mode s PartNo 8 Regulator Valve 4 Water Valve 2 Defrost Body GB56x 102101001 GBS64 102119131 NP tone smn F wam Fan Blade GB56x 102101602 GB561 102139201 Fan Motor GB564 102139301 Condenser Air Cooled
21. 500 226 89 580 263 08 380 172 19 471 213 64 433 196 49 550 249 47 GT564LHK 573 259 90 446 202 30 544 246 75 479 217 27 580 263 08 443 200 94 538 244 03 524 237 68 534 242 21 906 411 1045 474 r 9 1 91 1 1 8 6 1 97 2 1 94 1 39 4 1 7 2 1 1 1 452 858 20407 26 4 43 351 13 2 1 137 4 11 47 03 83 3 97 315 3 144 2 12 03 EN 05 5 40 428 4 82 382 4 73 375 4 20 33 5 47 4 75 4 47 4 37 4 58 4 09 32 L6 3 G w 434 8 N f lt 703 45 4 4 46 354 952 432 3 84 304 GB1064LHK 900 408 1044 473 3 86 306 4 2 0 163 13 6 5 2 1 5 2 1 1 4 6 365 24 2 0 760 345 5 9 468 950 431 4 43 351 25 2 1 GB1064RHK amp 214 850 386 5 6 444 1080 490 4 09 324 25 2 1 432 26 5 2 16 1 1 34 141 8 11 83 12 Electrical Use and Machine Dimensions Weight Amps Am Dimensions inches cm Ship Weight CA Power Tier Max Min Circuit GT361AC 15 30 1 76 5 25 7 65 3 16 9 42 9 Model Number 307 78 155 228 105
22. 6 HK models squeeze the restrictor clamp to reduce the bottom tank fill rate If the top tank level is more than inch 3 mm for C models inch 6 mm for HK models 1 8 higher than the lower tank level open the restrictor clamp to increase the lower tank fill rate Small adjustments are recommended When the adjustment appears to be correct dump the water by pulling down on a water plate as above allow the water tanks to fill again and re check the levels 42 60 Series Service Manual rev 1 2012 43 KOLD DRAFT TROUBLE SHOOTING Possible Cause in Off position Move switch to On position fuse or reset breaker protector open Check circuit for overload condition Ice machine off because bin is full of ice or move ice away from bin level probe Ice machine off because bin level probe is defective Ice machine off as if bin is full Ambient temperature must be 60 Ambient temp below 50 T 106 15 C minimum T o 5 5 Z 3 D O 2 22 O Ice machine is operating Replace bin level probe Ice Clean switch in Clean position Move switch to Ice position Clean condenser and reset high pressure cut out Confirm proper operating pressures Provide adequate spacing between High pressure cut out open on air the ice machine and walls ceilings cooled
23. Before testing the relay be sure it is the one specified for use with the ice machine compressor and the mounting position of the relay is correct Measure for continuity between terminals 5 and 2 1 there is no continuity replace the relay Measure for continuity between terminals 2 and 1 1 there is no continuity the contacts open and the relay must be replaced The relay may also malfunction if the supply voltage is 1096 higher or lower than the rated voltage or if the relay is loosely mounted allowing it to vibrate or if it is used in conjunction with an incorrect start capacitor Testing the Run Capacitor 1 Before testing the run capacitor be sure it is the one specified for use with the ice machine compressor After making sure the capacitor is discharged disconnect it and test the value with a capacitance meter If the measured value is more than 10 higher or lower than the rated value replace the run capacitor The capacitor may also malfunction if the supply voltage is more than 10 higher than the rated voltage Testing the Start Capacitor 1 Before testing the start capacitor be sure it is the one specified for use with the ice machine compressor After making sure the capacitor is discharged disconnect it and test the value with a capacitance meter If the measured value less than the rated value or more than 20 higher than the rated value replace the start capacitor As an alternat
24. C and 90 32 e water supply must be potable not laden with sediment and have free chlorine levels no greater than 0 2 e A minimum 5 psig 0 034 MPa dynamic water supply pressure is required for proper operation of the ice maker water valve Please note that on liquid cooled ice machines where the same water supply is used for both condenser cooling and the potable water supply the demand for condenser coolant may cause the supply pressure to drop This is most notable at the time of peak load at the beginning of the freeze cycle The maximum water supply pressure is 100 psig 0 6 MPa All water lines have been purged before connection All KOLD DRAFT models are intended to be installed with a permanent connection to the field electrical supply Drop cord connections are not to be used with this equipment Always be sure the power supply is the same as the ice machine s electrical specification which is listed on the serial number tag on the front of the top frame cross member e Each ice maker must be connected to the grid through its own dedicated fuse or HACR type circuit breaker Each ice maker must be connected to a separate protected circuit with no other loads e Fused disconnects installed adjacent to each ice maker are recommended and may be required by local codes These components must be supplied by the installer 60 Series Service Manual rev 1 2012 5 KOLD DRAFT e Electrical service must fall
25. GB56x 102101802 7 Condenser Liquid Cooled GB56x 102102101 Liquid Cooled eiquidiReauiater valve GAR00701D 7B Condenser 60 Series Service Manual rev 1 2012 55 KOLD DRAFT GB1064X Parts 3 Plate Cam Switch 2 Evaporator 4 Actuator Motor 1 Water Plate 5 Defrost Valve Coil 26 Filter Drier 6 Defrost Valve Body 25 Expansion Valve 7 Defrost Valve Coil 19 Water Pump 23 Drain Pan 8 High Pressure Cut Out 22 Probe Tube Assembly 9 Defrost Valve Body 21 Filter Drier 10 Ice Clean Switch 20 Expansion Valve 11 Controller 12 Fuse Holder 19 Water Pump with 4A fuse 13 On Off Switch 18 Drain Pan 16 Evap Bin Temp Sensor Assembly 15 Spring 4x 14 Water Deflector 17 Water Tank m Part Description Model Part Part Description ELM GB106x EM Water Plate C Water Plate GB106x GBR00270 On Off Switch 102138601 Evaporator GB106xC GBR00148 Water Deflector 06x GBR00202 Before S N 608888 Evaporator GB106xC 102144501 Spring 2 PER PK 4 e ow GBR00909 After S N 608888 Evaporator GB106xHK 68900167 Before S N 608888 Evaporator GB106xHK 102144601 After S N 608888 Plate Cam Switch 2 EENEE UN 102138001 Tank GB106xHK GAR00203 4 Actuator Motor GB1064 102123802 PEL Tank GB106xC 102143301 Defrost Valve Coil GB1064 102101201 GB106x 102137801 Defrost Valve Body GB106xA L 102101001 wameoa m Defrost Valve Body GB106xH 10
26. GT364 102123802 19 Expansion Valve Valve GT36x 102118802 High Pressure Cut Out EN Manual Reset EN 102105501 EI Filter Drier EM GBRO02750 90 GT36x Parts Right Side Air Cooled 5 Fan Blade 6 Fan Motor 7 Air Coole Description PartNo 1 Defrost Valve Coil GT361 102101101 Defrost Valve Coil GT364 102101201 2 Defrost Valve Body GT36x 102100801 GT36x Parts Right Side Liquid Cooled GT364 102141701 2 Defrost Valve Body 1 Defrost Valve Coil 4 Water Valve Fan Blade GT36x 102101602 Condenser Air Cooled GT36xA 102141901 l Condenser Liquid Cooled GT36xL 102102101 8 Liquid Regulator Valve GT36xL GARO0701D Relay Box Assembly GT361 102142401 Relay Box Components Ps JM Relay Potential 102145101 Start Capacitor GT364 102119502 3 Compressor 8 Condenser Liquid Cooled 102104401 Run Capacitor 9 Liquid Regulator Valve 60 Series Service Manual rev 1 2012 51 GT56x Parts Left Side 4 Evap Bin Temp Sensor Assembly 5 Front Cam w Springs 8 Actuator Motor 2 Evaporator 7 Spring 2x 24 Filter Drier 23 Expansion Valve 10 Water Deflector 22 Probe Tube Assembly 21 Water Tank 20 Water Pump 11 Defrost Valve Coil r 19 Drain Pan 18 Fan Blade 12 Ice Clean Switch 13 Controller 17 Fan Motor 14 Fuse Holder with 4A Fuse 1
27. dimples defrost Be sure that the control stream does not go over the dam for longer than 15 seconds Very cold water will not rinse the ice Cold potable water supply residue from the water plate thoroughly The water supply pressure must be a minimum of 5 PSI 34 kPa dynamic at the water valve Be Water valve will not sure that the supply line is of close Potable water adequate size his is especially level continues to voltage measured at water valve important for liquid cooled models rise after contacting coil Water valve remains open where the potable water and the tip of the high because of water supply problem condenser coolant water are water level probe supplied by the same water line during the fill cycle Check for restrictions in the water supply line including clogged filters Check the water line strainer and clean it if needed 60 Series Service Manual rev 1 2012 47 KOLD DRAFT 0 TROUBLE SHOOTING o O3 O PQp amp RA A Se A f f la SHOOTING Possible Cause Disassemble and clean water valve if needed Make sure the bleed holes in the valve diaphragm are open Replace water valve if No voltage measured at water valve coil Water valve remains open because of dirty or defective water valve defective Test for continuity through the high Line voltage measured at water valve level probe and the reference probe Replace the probe if the continuity is broken
28. ice maker and provide LED fault indicators gt 30 Rev 1 1 1 2 If the Freeze cycle exceeds 60 minutes the controller will shut down the ice maker and provide LED fault indicators REV 1 3 1 4 1 5 1 6 If the Freeze cycle exceeds 45 minutes three times in a row the controller will shut down the ice maker and provide LED fault indicators 60 Series Service Manual rev 1 2012 19 gt 40 gt 50 gt 60 gt 70 gt 80 gt 90 Rev 1 1 1 2 1 3 1 4 1 5 If the Freeze cycle lasts less than 5 minutes 3 times in a row before automatic harvest the controller will shut down the ice maker and provide LED fault indicators Rev 1 6 and higher After 3 consecutive occuerences of fault 40 the machine will attempt to remove any blockages by defrosting and cycling water LED40 will be flashing 5Hz during this defrost and water cycle defrost will last for 5 minutes Water will cycle for 10 minutes if the machine has 3 more consecutive short freeze cycles LEDAO will be solid and the machine will shut down Rev 1 1 1 2 1 3 1 4 1 5 the Harvest cycle exceeds 20 minutes the controller will shut down the ice maker and provide LED fault indicators Rev 1 6 and higher Fault 50 Removed Ice Mode Added a Max defrost time 5 minutes Ice maker will attempt to begin a new cycle after 5 minutes of defrost or when the Evaporator Temp Probe reaches the set tenpeature Rev 1 1 1 2 If the Fill cycle exceeds 5 minutes the controller will
29. level surface All models are intended for indoor use only Do not install the equipment in unprotected outdoor areas Always securely attach individual machines together Do not install the equipment in wet areas Do not locate the equipment near any heat source in direct sunlight in high ambient areas or without proper clearance for ventilation Placing equipment in these locations will result in reduced capacities high system pressures and may cause equipment failure Pre Install Checklist All KOLD DRAFT models are intended to be installed with a permanent connection to the field electrical supply Drop cord connections are not to be used with this equipment Always be sure the power supply is the same as the ice machine s electrical specification which is listed on the serial number tag on the front of the top frame cross member Each ice crusher must be connected to the grid through its own dedicated fuse or circuit breaker Each ice crusher must be connected to a separate protected circuit with no other loads Fused disconnects installed adjacent to each ice maker are recommended and may be required by local codes e Electrical service must fall within the voltage tolerances listed below Nominal V No Load Maximum Full Load Minimum 115 1 Series 208 230 4 Series e Breaker or fuse rating must be no greater than the maximum rating as specified on the rating label attached to the back o
30. low Water Repair or replace water plate plate is cracked or leaking Increase the water level until ice cubes are produced with small dimples Ice cubes have large dimples or are hollow at the end of the freeze cycle Re align water plate See the water plate alignment illustration for more information Water plate is out of alignment with evaporator 48 0 TROUBLE SHOOTING SHOOTING Possible Cause ma utnrm cr Actuator motor turns clockwise at start of defrost Cam arms are improperly positioned when the water plate is fully opened and or closed 60 Series Service Manual rev 1 2012 Ice cubes do not break apart after defrost because of thick web between cubes Ice cubes have uneven dimples Dimples are larger on right side of evaporator because of low refrigerant charge Ice cubes have uneven dimples Dimples are larger on right side of evaporator because of high evaporator superheat Ice cubes have uneven dimples Dimples are larger on left side of evaporator and ice may freeze into the right side surface of the water plate because of low evaporator superheat Arms up and arms down switches are defective or the relationship between the switches and switch operators is improper The relationship between the switches and switch operators is improper 49 Adjust spacing between evaporator and water plate See the web thickness adjustment illustration fo
31. models Air circulation through other equipment See installation condenser is insufficient or hot is instructions for spacing recalculating through the condenser requirements Confirm proper pressures Restore adequate coolant liquid supply and reset high pressure cut out Confirm proper operating pressures High pressure cut out open on air cooled models Condenser dirty High pressure cut out open on liquid cooled models Coolant liquid interrupted or insufficient r s High pressure cut out open on liquid cooled models Interior of condenser Clean replace condenser pump and other has a mineral build up components are operating normally High pressure cut out open Remove refrigerant and recharge Refrigeration system is overcharged system to specifications compressor test procedure for more Allow thermal protector to reset informatio Measure voltage at contactor while compressor is running Correct Compressor thermal protector open power supply problem if voltage is because of low voltage condition lower than specified on the ice machine electrical plate See compressor test procedure for more information Replace run capacitor See compressor test procedure for more information Check for voltage at coil terminals Contactor is defective Heplace contactor if it does not close when the coil is energized Test and replace these parts if defective See compressor test pro
32. no continuity in either winding replace the compressor For three phase compressors test the continuity of the windings by measuring between each pair of terminal pins 1 2 2 3 and 1 3 If there is no continuity between any set of terminal pins replace the compressor continuity is found in all motor windings measure the resistance ohms of the windings For single phase compressors measure between each pair of terminal pins C S C R and o H The sum of the resistance measured between C S and should equal the resistance measured between 5 plus or minus small deviation Proper resistance may be confirmed by comparing the measured resistance to the resistance specifications for specific compressor models If the resistance is not correct replace the compressor If the specifications are not found on the ice machine please contact the factory For three phase compressors measure between each pair of terminal pins 1 2 2 3 and 1 3 The resistance measured between each pair of pins should always be greater than zero and within 1096 of one another Proper resistance may be confirmed by comparing the measured resistance to the resistance specifications for specific compressor models If the resistance is not correct replace the compressor If the specifications are not found on the ice machine please contact the factory 34 Test Procedure for Compressor Electrical Components 1 2 Testing The Potential Relay
33. plate is not aligned with the evaporator the cubes may appear cloudy or misshapen RIEN E EE GENER LL Dimension is not adjustable If this dimension is out of tolerance the evaporator or water plate mounting components may be damaged Adjustments to dimension B can be made by sliding the front and rear hinges along the left edge of the water plate Lightly tap the hinges as required to align the water plate with the evaporator Alignment is correct when the space between the evaporator and the water plate is equal in front and in back 21 5 3 32 38 mm 2 5 mm B 5 16 1 16 8 mm 1 5 mm WEB THICKNESS ADJUSTMENT The web thickness between cubes the gap between the bottom of the evaporator and the water plate surface can be adjusted by inserting or removing shims between the support channels and the evaporator support posts or the cam shaft bearing brackets Loosen the actuator motor mounting screws before inserting or removing shims between the channels and cam shaft bearing brackets The web thickness specification for both C and HK models is 1 16 2mm 38 WATER PLATE UP DOWN POSITION AND ADJUSTMENT When the water plate is up closed the spring end of the cam arm must be in the 12 o clock position with the spring on th
34. pouring the water directly onto the evaporator the evaporator is equipped with drain holes for this purpose and to allow melted frost to drain into the water tank In tight spaces a funnel and hose can be used to pour water onto the evaporator Alternatively the water can slowly be poured into the clear control stream box on the front of the water plate or between the evaporator and the top left wall of the water plate Move the on off switch to the on position and observe the water flowing from the distributor tube filling the water tank Also observe that the water pump is circulating water through the system A momentary sucking cavitation sound is normal at the beginning of the process when the water level is low The water fill is complete when the water level in the probe tube reaches the high level probe Observe that the water valve is de energized by ensuring water has stopped flowing through the distributor tube Check that there are no water leaks from the hoses or water tank into the drain pan Note For GB106x models observe that the water fill difference between the upper and lower water tanks measured from the top of the control stream box is less than 7s inch 3 mm for models and 14 inch 6 for HK models Pull down on the right side of the water plate stretching the springs until the water plate switch is disengaged observe that the pump stops and the actuator motor rotates the cam arms counter clockwise Ob
35. shut down the ice maker and provide LED fault indicators REV 1 3 and higher Water fill exceeds 3 minutes then the Valve closes amp waits 10 minutes as LED60 Flashes Valve then opens amp tries again This routine repeats 3X and results in a solid Code 60 if the fill is not completed on the third try Rev 1 1 1 2 f the evaporator temperature during the Fill cycle is less than 31F the controller will energize the Defrost Valve until the evaporator temperature reaches 41F and provide a temporary LED fault indicator REV 1 3 Both Arm Up Arm Down Cam Switches Closed un actuated at the same time not allowed REV 1 3 Only Indicates that the machine is in full rinse mode left jumper pulled REV 1 3 Only Indicates bin full Ice machine will be shut down after current batch is complete REV 1 70 ICE MODE and CLEAN MODE WATER WILL NOW HIT HIGH PROBE THEN TURN ON WATER PUMP WATER VALVE OFF AND THEN REFILL TO HIGH PROBE CHANGED HIGH AND LOW WATER DEBONUNCE 0 5 SECOND DELAY NOW APPLIES WHEN RETURNING TO THE FILL STATE ENTIRE FILL ROUTINE WILL NOT BE REPEATED IF RETURNING TO THE FILL STATE FROM THE HI WATER DEBOUNCE STATE ONLY REFILLING TO THE HI WATER PROBE 0 5 SECOND DELAY NOW APPLIES WHEN RETURNING TO THE FREEZE ICE MODE OR CIRULATE CLEAN MODE STATE Note The controller will need to be reset to clear these error codes Board Revision numbers are found on the sticker placed on a processor chip in the middl
36. spills immediately Always install equipment on a stable and level surface Never operate this equipment with covers panels guards or other parts removed or not properly secured KOLD DRAFT reserves the right to disallow any warranty claims which result from the use of non KOLD DRAFT condensers and or line sets Read the entire manual before installing operating or servicing the machine Pre Install Checklist e All KOLD DRAFT models are intended to be installed with a permanent connection to the field electrical supply Drop cord connections are not to be used with this equipment Always be sure the power supply is the same as the ice machine s electrical specification which is listed on the serial number tag on the front of the top frame cross member Each ice maker must be connected to the grid through its own dedicated fuse or type circuit breaker e Each ice maker must be connected to a separate protected circuit with no other loads Fused disconnects installed adjacent to each ice maker are recommended and may be required by local codes e Breaker or fuse service must be no greater than the maximum rating as specified on the rating label attached to the back of the machine minimum circuit ampacity listed on the back of the machine does not indicate a typical running current value Use the minimum ampacity value for sizing branch circuit conductors up to 8 meters 26 feet in length For a conductor leng
37. the 3 8 line to the lower liquid fitting on the condenser and to the Refrigerant In on the ice maker 1 2 line connects to the upper inlet fitting on the condenser and the Refrigerant Out on the ice maker 6 Each fitting on the line sets condenser and ice maker is self sealing and should be tightened 1 4 turn more than hand tight Always use a backup wrench to prevent tubing twist when tightening these fittings The condenser fan motor requires power supply provisions that comply with all applicable code requirements The Ice Maker is provided with wire connection pigtails that include an L1 red wire for connection to the fan motor circuit along with L2 and Grounding conductors 8 The refrigerant lines should be routed inside the building or otherwise mechanically protected wherever possible Caution multiple circuit installations fan power must be provided separately by a circuit that will not be interrupted so that the fan motor will run continuously Hemote condenser Ice Maker models from the factory are provided with adequate refrigerant charge to accommodate all acceptable condenser ambient temperatures and up to 50 ft refrigerant lines The Ice Maker Nameplate label on the rear of the cabinet indicates the factory charge amount maximum total charge and refrigerant type Ice makers are provided with re sealable refrigerant line connection couplings Specifications MODEL Gross Wt MODEL VO
38. to lower but is staying up 7 Hot Gas Valve won t open 8 During harvest Evaporator Probe out of adjustment reads too cool or defective Ice production may be low 9 Bad Contactor Compressor would be off 24 SOLUTION 1 Insure Expansion Valve TXV is covered with insulating foam Adjust TXV as needed Asa starting point gently turn the TXV in CW direction until it stops then turn it CCW 5 1 2 turns Adjust in 1 4 turn increments as needed 2 Repair wiring to Low Level Probe or replace Probe Assy 3 Inspect hoses water tank water pump water plate and water level probe assembly to locate leak Repair or replace part as needed 4 Adjust colder CW 5 Locate amp repair short circuit 1 On the Controller adjust Evaporator Probe pot CW toa colder setting so that the Water Plate returns to the closed position about 5 sec after ice releases If Evaporator Probe is non responsive and Actuator Motor is confirmed operational then replace the Evaporator Probe 2 Replace Actuator Motor Motor should drive up when Water Plate is down amp Evaporator Probe is gt 38 35 45F 3 Replace Actuator Motor 4 Replace Controller Board When Water Plate is down amp Evap Probe is gt 38F there should be line voltage to the Actuator Motor between Pins 2 amp 8 on the green output connector of the Controller If voltage not present replace the Controller 5 Free up adjust or replace Arms Down Switch
39. verify your software Revision Level Rev 1 1 1 2 or 1 3 POSSIBLE CAUSE 1 Water supply off or major leak in the water tank or water lines 2 External water filter plugged 3 Water solenoid valve inoperative 4 Upper short Probe in the Water Level Probe Assy may have a loose wire connection open 5 Common longest Probe in the Water Level Probe Assy may have a loose connection open 6 Controller is bad Rev 1 1 1 2 1 This is not necessarily a fault condition but could indicate that the incoming water temp is very cold which can slow down ice production as the Hot Gas Valve continually reopens to warm the Evaporator to 38F Rev 1 3 2 Switches are loose 3 Switches are mis wired 4 Switch Bracket bent amp switches not in position 5 Switch Cams loose and or in the wrong position 6 Arms Up Switch stuck closed Plate stays down 7 Arms Down Switch stuck closed Plate stays up 1 This is an optional mode that is not as energy efficient 1 This is a normal condition indicating that the Bin is full Bin Probe is cold 2 If Code 90 is indicated but Bin is not full check for faulty Bin Probe bad wiring to Bin Probe or faulty Controller Board 25 SOLUTION 1 Turn on water supply or check for leaks 2 Replace bypass or eliminate external water filter 3 Place in Wash Mode and pull down on water plate to lower it Onreturn up water valve will energize to fill unti
40. wire assembly as shown below 18 Locate the bin thermostat of the ice machine and cut the probe off of the end of the cable 19 Route the cable through one of the small holes in the bottom of the ice machine and into the back of the crusher control box 20 the cable out through the front of the crusher control box and cut off the cable to manageable length 21 Strip the outer cable jacket back about 3 Then strip the red and black wires back about 77 22 Connect the stripped wires to the left relay as shown Upper Maker Thermostat If Installed Lower Ice Maker Thermostat 72 23 Turn off the breaker or disconnect the fuse that will service the machine 24 Make all electrical connections to the electrical service in a manner that complies with local code Note e f two separate ice making machines for example two GB1064 models stacked are installed the bin thermostats of both ice makers will need to be connected to the crusher e Ensure that the thermostat cable is not routed through the ice chute Do not run the cable through the same hole that the safety switch wire assembly and the motor control wire assembly are run through Initial Start Up 1 Ensure all electrical connections were made properly and turn on the electrical service Note There is no on switch the machine will run when the ice maker tells it to 2 Adjust the bin thermostat to turn off the ice maker before the ice level is
41. 102102101 1 Defrost EN Condenser Air Cooled GB1064A 102101802 Valve Coil 2 Defrost 5 Water Valve Valve Body 6 Compressor 7 Condenser Liquid Cooled 58 PARTS LIST Actuator Motor Cam Shaft C GT36Xl GT56xL GB56xL Condenser Liquid Cooled GB106xL 102102101 Drain Pan 0 o _____ 14 08100 mac 59 60 Series Service Manual rev 1 2012 Model s d _____ _ 14 _ WI _____ 60 m 14 s Water Plate HK ____ i u NENNEN ________________ _ Lo 1 _ 60 Series Service Manual rev 1 2012 61 ACTUATOR MOTOR KIT APPLICATION LIST 102129202 102123802 102123902 aseo REA aww Energy Efficient F i F C fed GT551 GB427 GB434 GB437 GB444 GB457 GB637 GB657 GB1224 GB1225 GB1244 GB1245 GB1254 GB1255 GB1257 GB1258 GT331 GT341 GT351 GT334 GT337 GT344 GT347 GT354 GT357 GB401 GB402 GB406 GB503 GB603 GT301 GT306 GT401 GT402 GT406 GT503 GT603 15401 15503 GT507 15507 GT7 GT8 GY3 151 155 157 MD5 UJ GB7F GS6F 1 GT7F IS7F T175 crusher TKN2 agitator agitator 62 STACKING INSTRUCTIONS Caution
42. 2100801 Expansion Valve GB106x GBR02359 Defrost Valve Coil GB1064 102101201 Filter Drier GBR02750 EN High Pressure Cut Out 102105501 Probe Tube Assy GB106x 102140401 Defrost Valve Bod GB106xA L 102101001 GB106x 102137801 Defrost Valve Bod GB106xR 102100801 L 10 Ice Clean Switch 102138501 GB106x GBR02359 Controller 102138201 26 Filter Drier Al GBRO2750 96 GB1064R Side 1 Harvest Regulator Valve 7 Pressure Control Valve 2 Water Valve 3 Liquid Line Solenoid Valve Body 6 Compressor 4 Liquid Line Solenoid 5 Receiver Valve Coil 8 Drier 22 Models FH Harvest Regulator Valve GB106xR 102122001 Liquid Line Solenoid Valve Body GB106xH 102101001 e commen cune a bie 10107101 60 Series Service Manual rev 1 2012 57 KOLD DRAFT GB1064A Side 1 Defrost Valve Coil 3 Fan Motor 4 Fan Blade 8 Condenser Air Cooled 2 Defrost Valve Body 1 Defrost Valve Coil 2 Defrost Valve Body 6 Compressor 5 Water Valve Description Models __ m Defrost Valve Coil GB1064A 102101201 1 Defrost Valve Coil GB1064L 102101101 Defrost Valve Bod GB1064 102101001 GB1064L Side GB1064A 102139301 Valve Coil Fan Blade GB1064A 102101602 Valve Body S N Before 607945 GB1064 102139101 S N After 607945 GB1064 102141301 Condenser Liquid Cooled GB1064L
43. 6 Compressor 15 On Off Switch Part Description Model PartNo Part Description Model Water Plate C GT56x GBR00200 1 Ice Clean Switch Water Plate HK GT56x GBR00167 Controller All 1 All Evaporator C Before S N 608887 T n 2 e P E Evaporator C On Off Switch 102138601 After S N 608887 GT56x 102144501 15 Before SIN 608 Compressor GT561 102119128 Before S N 608887 ie Evaporator Hk 18 3 Plate Cam Switch 2 E w GT564 102139301 Fan Blade 102101601 Front Cam w Springs GBR00969 Drain Pan GT56x 102137801 Rear Cam w Springs GBR00949 20 Spring 2 per pk 8800909 Transformer an 280v 7564 102145401 All A Actuator Motor Serial No After 611032 102123802 10214050 Water Deflector GT561 GBR00202 Filter Drier GBHR02750 Defrost Valve Coil GT561 102101101 11 Defrost Valve Coil GT564 102101201 Actuator Motor GT561 102123801 Water Tank GT56x 102143301 52 GT56x Parts Right Side Water valve in same location on A and L models 1 Water Valve 2 Defrost Valve Coil Left Side Liquid Cooled 3 Defrost Valve Body x 4 Liquid Regulator Valve 5 Condenser Liquid Cooled 6 Condenser Air Cooled HET w i 6 CondenserAirCooled 102101808 60 Series Service Manual rev 1 2012 53 KOLD DRAFT GB56x 2 Evaporator 1 Water Plate
44. 8H 2038 8J 2039 MONTH KEY M JANUARY APRIL U JULY X OCTOBER N FEBRUARY MAY V AUGUST Y NOVEMBER MARCH T JUNE W SEPTEMBER Z DECEMBER EXAMPLE 5 MAY 2008 Model Number Key Note Model numbers mentioned in this manual that look like GB56x are used to refer to general families of machines x could stand for any combination of a machine s electrical characteristics condenser type and cube size GB 5 6 1 A HK Cube Size C Ful Cube HK Half Cube Condenser Type A Air Cooled Condenser Self Contained L Liquid Cooled Condenser Self Contained Remote Air Cooled Condenser Electrical Characteristics 1 115 Volt 60 Hz 1 ph 2 wires ground 208 230 Volt 60 Hz 1 ph 2 wires ground 208 230 Volt 60 Hz 3 ph 3 wires ground 230 Volt 50 Hz 1 ph 2 wires ground 220 380 Volt 50 Hz 3 phase plus neutral 4 wires ground Modification Code 6 R 404a Tecumseh compressor POE lubricant Energy Efficient o Series 3 300 Series 5 500 Series 10 1000 Series Cabinet Width GB 42 Wide GT 30 Wide 60 Series Service Manual rev 1 2012 3 KOLD DRAFT ICE CUBER INSTALLATION Warning Do not operate equipment that has been damaged Refer all maintenance to qualified personnel Instruct all personnel in the proper use of the equipment Clean up any liquid spills immediately Always install equipment on a stable and level surface All models are intended for indoor use only Do not i
45. E SIDE TUBE HOLDER CUBER FRAME LOCKWASHER GASKET CRUSHER FRAME CAP SCREW 9 Install gasketing on top of crusher 10 Remove the ice maker cabinet panels lift and position ice maker on top of gasketed crusher and align the mounting holes Install cap screws lock washers and nuts 11 Mount the ice maker safety switch as shown If not provided locate and drill two 3 16 inch dia holes in the ice maker lower front rail Mount the safety switch support with the 48 32 screws and lock nuts provided 70 SWITCH BRACKET SWITCH BRACKET MAKER SAFETY LOWER SWITCH FRONT RAIL 22 CRUSHER 2 8 32 x 3 8 screws FRONT 2 8 32 LOCK NUTS _ x RAIL 1 1 2 7 1 8 Notes e The crusher is designed to operate in conjunction with one or two KOLD DRAFT ice makers Two motor control relay blocks are provided and a relay coil must be installed for each ice maker used Each relay coil must have a voltage rating matching the voltage of the ice maker regardless of the crusher motor voltage 271 crushers are supplied with 115V relays T274 crushers are supplied with 208 230V relays relay coils are installed through the opening in the control box A third relay is provided for controlling one or two ice makers with the same set of bin thermostats This relay coil voltage rating is matched to the crusher motor voltage and is provided with the crusher dual safety switch system is employed in the crusher design to br
46. E SPACER RAIL 60 Series Service Manual rev 1 2012 63 KOLD DRAFT 5 Apply the gasket provided to the top of the lower ice machine frame as shown Place the gasket over the frame spacers to secure them in position GASKET VIEW FRAME SPACER 6 Position the stacking chute in the lower machine as shown Locate on the support channels against the partition wall 7 Carefully lift the upper machine and place it on top of the lower machine and align frames Fasten the frames together using the screws washers and lock nuts provided 64 LOWE AM AME VU D N AME SPAC CA See L 8 Replace the front and back deflectors of the top ice machine with the deflectors provided in the stacking kit Install the deflectors into the slots in the back wall and front rail Push down on the deflectors until they engage beside the stacking chute and snap in place 9 Feed the bin probe from the upper machine through one of the holes in the upper machine condensing unit pan and position in one of the holes in the lower ice machine condensing unit pan and adjust as required 60 Series Service Manual rev 1 2012 65 ICE CUBE C
47. LTAGE DESCRIPTION T 208 230 60 1 1 Circuit 2 Ton R 404a 20 1 8 x 34 3 4 x 30 0 7 FLA Precharged Remote Condenser w legs amp guard Caution Refrigerant charges must be accurately weighed 60 Series Service Manual rev 1 2012 79 KOLD DRAFT Minimum Total Charge Required Note The factory charge in dual evaporator models is 168 oz 10 5 Ib 404 e The maximum total system charge for dual evaporators is 208 oz 13 16 404 e The basic charge for a dual evaporator model is 3 R 404a To determine the total charge add the following to the basic charge below 1 For each 10 feet of 3 8 O D liquid return tubing add 6 oz of R 404a 0 For each 10 feet of 1 2 O D compressor discharge line gt 70 F add 12 oz R 404a 3 For each 10 feet of 1 2 O D compressor discharge line lt 70 F add 11 oz R 404a assume 0 that at least 15 will be lt 70 F if not certain 4 Use the following amounts of R 404a according to the condenser model and the MINIMUM ambient temperature expected at the condenser RC214APV 2 3 lb 2 9 lb 3 3 Ib 3 5 Ib EXAMPLE Calculate the minimum total system charge for GB1060R Ice Maker with RC214APV single circuit 2 ton condenser and 30 feet of interconnecting tubing with 20 minimum condenser ambient temperature The calculation would be as follows 3 Ib basic 6 charge 16 5 oz 15 of 1 2 O D discharge line at 70 F 0 75 oz
48. MPa minimum is required to ensure consistent water fill performance Before adjusting the water fill levels be sure that the Water Level Probes are properly adjusted and no hoses are kinked Refer to the Service Manual for the adjustment specifications according to cube size To Adjust For Equal Fill 1 Place the selector in the CLEAN mode switch the Power Switch to ON 2 Pull down on the right side of either water plate stretching the springs until the actuator motors rotate the cam arms counter clockwise Observe that the cam arms continue to turn opening the water plates fully dumping the water in the tanks It may be necessary to turn the power off with the water plates fully open in order to completely drain the water tanks At this point the cam arm rotation will reverse and close the water plates The cam arm rotation will stop when the water plates are fully closed and the water fill will occur When the fill water reaches the high level probe the water fill valve is de energized and the water fill stops A small amount of water will drain back from the water fill tubing to the lower water tank 3 Compare the water levels in the probe tube and the upper section control stream overflow as seen on the next page to determine if the upper and lower water tanks are filling within the specified maximum difference 4 f the top tank level is lower than the bottom tank level by more than inch 3 mm for models and inch
49. ROCEDURE Water Level Probes Water level probes can be tested at any temperature and are good if they exhibit continuity 0 ohms resistance along the length between the probe wire and the connector at the controller It is advisable to flex the probe at the two connections while testing for continuity to eliminate the possibility of an intermittent failure Evaporator Temperature and Level Probes The evaporator temperature probe and the ice level probe are designed to have a nominal resistance of 5650 ohms at 32 F 06 To test the se probes they must be placed in ice water 32 06 for a minute and then checked for resist ance while the tube is still in the ice water probe is considered good if it exhibits a resistance value between 5400 and 5900 ohms at 32 F 00 Probes with values outside this range should be replaced 60 Series Service Manual rev 1 2012 41 KOLD DRAFT FOR GB1064 MACHINES BUILT BEFORE 607945 WATER FILL ADJUSTMENT INSTRUCTIONS Note This applies only for GB1064 machines with serial numbers before 607945 Machines built after 607945 have an upgraded water valve which equalizes the amount of water in each tank per load Since supply pressures vary between the factory and install locations water fill levels between the top and bottom water tanks will also vary The water fill difference between the upper and lower water tanks should be less than 1 8 in 8 mm A dynamic water pressure of 30 psig 0 2
50. RUSHERS T27X For KOLD DRAFT GB series Ice Makers Installation Operation Technical Service and Replacement Parts KOLD DRAFT 66 ICE CRUSHER SAFETY INFORMATION opecial attention should be given to potential hazard labeling on the equipment and the signal words and symbols that are used throughout this manual They may also be used to alert against unsafe practices Note Note is used to notify personnel of installation operation or maintenance information which is important but not a cause of personal injury or property damage Warning Indicates a potentially hazardous situation that may result in minor or moderate injury The situation may also cause minor damage to the machine Caution Indicates a potentially hazardous situation that could cause serious injury or death The situation may also critically damage the machine DANGER Indicates a potentially hazardous situation that could cause serious injury or death The situation may also critically damage the machine Check for freight damage before proceeding even though damage to the carton may not have been evident check for hidden damage and contact freight carrier immediately if necessary to file a claim This equipment must be installed in compliance with the applicable federal state province and or local plumbing electrical and health sanitation codes and requirements Caution Hisk of personal injury property damage equipment failure or
51. TION ier ttes sued tun eate 26 Ice WAKING Sedieli66 sscunsdii dedo iae tem EM 26 Ice Bir Full Cle eran OCS tut 27 DESCHDUON OF ACM mdi e PES TETTE 27 T 27 27 28 HAVES ieee te a a nn er 28 acm 28 OD LLL 28 EEE 28 Water Plate Closure 28 MON uuu bet d de RU 28 Dc RT ________ 29 e IWIN Mode otar ___ __________ ____ __ _ 29 cleaning Mode Slat trao ici d 29 aL36X GI56X GB5OX WIRING DIAGRAM dam ir deas 30 amp L WIRING DIAGRAM uu uuu lll uu unus 2 222 nu 31 mu 32 COMPRESSOR TEST TROOGEDURME ee an u eee 33 Test Procedure for a Short Circuit to Ground Ground 34 Test Procedure for Continuity And Proper Resistance
52. Water level probes test OK but Test controller and replace if voltage measured at water valve coil defective Be sure there is no continuity path between the probes through water or mineral deposits on probes No voltage measured at water valve through water or mineral deposits coil because of an abnormal probe on probes through water or mineral continuity path deposits on the probe cap Make Water valve will not sure the cap is clean and dry open Potable water especially after cleaning the ice level never reaches machine the high water level Test controller and replace if reaches the high defective No voltage measured at water level probe water valve coil and controller output during the fill cycle terminal because of defective controller Water valve closes when water contacts the tip of the low water level Relocate and reinstall the probe probe because the low and high wires in the probe terminal plug or water level probes are reversed in the replace the water level probe set water level probe terminal plug Test controller and replace if defective Measure the supply voltage with the ice machine running Be sure voltage is within the specified tolerances Water plate pressure is low Pump operating improperly because of low supply voltage E Be sure the pump being used is Improper pump installed in ice Poorly formed or RER ESIN proper for the ice machine model cloud y Water plate pressure IS
53. a minimum twice per year Note Use a clean plastic bottle fitted with a stopper or cap that has a pouring tube and a vent to facilitate mixing and pouring of the specified solutions Mix 3 oz 500023 KD Nickel Safe Ice Machine Cleaner per gallon of warm water If the ice machine is operating wait until the ice falls out of the evaporator then move the Ice Clean Switch to the Clean position Empty the storage bin and turn off any other ice machines on the same bin After the water fill is complete turn off the ice machine While pinching the water level control tube remove it from the probe cap Hold the water level control tube high enough so that the water does not overflow release the control tube and pour about half the cleaning solution into the top of the probe tube Pinch the control tube again and reassemble the probe tube to the cap Pour the remaining cleaning solution into the control stream box Turn on the ice machine and allow the solution to circulate for 15 minutes then pull down on the right side of the water plate This will cause it to open and dump the cleaning solution and then refill with water Repeat the dump process three times to be sure all the cleaning solution is rinsed out of the machine Mix a sanitizing solution containing 0 5 ounce 15 mL 5 1 4 sodium hypochlorite household bleach or equivalent and 1 quart 3 8 Liter clean water Using the same process as in step 4 pour half of the sanitiz
54. above the guard Screen 3 Adjust the thermostats to shut off the ice maker approximately 1 minute after the ice contacts the capillary tubes Note e is allowed to collect above the screen it will not clear when the ice below is removed This condition will cause ice to pile up in the chute of the crusher and ultimately damage the ice maker The use of the bottom guard will reduce the effective volume of the bin ICE CRUSHER OPERATION With the crusher knob in the crushed position ice falling from the ice maker will be directed by the selector plate through the crusher mechanism and deposited into the left side of the bin The crusher motor is powered through a relay which is energized by the hot gas valve circuit of the ice maker The selector knob must be in the crushed position to close a switch and complete the circuit to the motor Additionally the front panel safety switches must be depressed covers on for motor operation With the crusher knob in the CUBE position ice falling from the ice maker will bypass the crusher mechanism and be dumped into the right side of the bin The crusher motor will not be energized 60 Series Service Manual rev 1 2012 73 KOLD DRAFT ICE CRUSHER CLEANING PROCEDURE DANGER Disconnect or turn off all ice machine and crusher fuses or breakers before cleaning either machine e Do not use ammonia solutions or strong detergents in cleaning the crusher e Never use applia
55. and informs the controller about the position of the plate fully up or not fully up this switch is not actuated when the water plate closes because ice is remaining on the water plate surface the actuator motor will reverse and reopen the water plate This will continue until the surface is clear Adjustment The switch should be actuated when the front cam arm is between the 10 o clock and 11 o clock positions The switch is closed when the plate up LED is lit Adjust the actuation point by adjusting the height of the white actuation screw on the water plate Note Do not bend the switch lever to make this adjustment Arms Up Switch This switch acts to limit the clockwise rotation of the actuator motor It informs the controller when the cam arms are in the 12 o clock position water plate up so the actuator motor can be de energized Adjustment The switch operator which is attached to the output shaft of the actuator motor can be rotated on the shaft and fixed in place with a set screw When adjusted properly the cam arm will stop in the 12 o clock position The motor stops when the flat spot on the switch operator allows the switch lever to drop down Note front water plate spring must be on the left side of the cam hub when the water plate is fully closed cam arm in the 12 o clock position Arms Down Switch This switch acts to limit the counter clockwise rotation of the actuator motor It informs the controll
56. at could cause serious injury or death The situation may also critically damage the machine DANGER Indicates a potentially hazardous situation that could cause serious injury or death The situation may also critically damage the machine Note Check for freight damage before proceeding with the equipment installation Be sure to inspect the equipment carefully for any damage that may not have been evident on the outside of the carton Contact the freight carrier immediately to report any damage and file a claim Read the entire manual before installing operating or servicing the machine To ensure optimal efficiency and productivity follow these installation instructions exactly All machines have been tested and adjusted for correct performance at the factory Knowledge of proper installation and service procedures is essential for the safe operation and maintenance of KOLD DRAFT equipment Refer all installation and service work to qualified technicians e This equipment must be installed in compliance with the applicable federal state province and or local plumbing electrical and health sanitation codes and requirements Always disconnect the power supply before servicing the equipment or when the equipment will not be used for a period of time Some circuits remain energized when the machine is switched off e Never operate equipment that has been damaged or does not have all the protective covers in place e Never op
57. back switch operator clockwise to stop the arm s rotation later e f the cam arm in the down position is too far counterclockwise from 7 o clock rotate the back operator counterclockwise to stop the arm s rotation earlier Note Component relationships and or operation other than described indicate component failure maladjustment or improper reassembly when servicing the ice machine 5 m 12 ARMS N RMS 4 lt A mmm ATERPLATE ITCH ITCH PERATORS P ROTATION ARMS SWITCH FORWARI ARMS N BEHINI m cD WN 60 Series Service Manual rev 1 2012 39 KOLD DRAFT ACTUATOR MOTOR ELECTRICAL TESTS The following tests are for troubleshooting the actuator motor and related circuits Use an AC voltmeter set for the proper range Voltages in the tables are measure across the motor reversing capacitor between the colored motor lead wires If there is no ice in the evaporator s and the water plate s is are not fully closed with the water plate switch es pushed up and the ARMS UP LED on the actuator motor s and pump s should be running If not be sure there is power to the motor s and also that the motor s is are not over
58. ce Contactor 6 Replace Water Valve 7 Replace Controller 8 Replace Hot Gas Valve ERROR CODE TROUBLESHOOTING CODE FAULT CODE INDICATES Rev 1 1 1 2 1 3 Freeze time less than 5 min for 3 consecutive times Water level in the glass Probe Tube is prematurely falling below the low level probe during the first 5 minutes of the freeze cycle or the Low level probe circuit is open 40 Rev 1 1 1 2 1 3 Harvest cycle exceeds 20 min 50 Before troubleshooting first check the Control Board and verify your software Revision Level Rev 1 1 1 2 or 1 3 POSSIBLE CAUSE 1 Slushing in Pump water lines or Water Tank due to Expansion Valve mis adjustment or not being wrapped in insulating foam or failure 2 Low level Probe circuit is open or the Water Level Probe Assy is bad 3 Water is being lost somewhere leaking causing premature harvest to occur 4 During harvest Evaporator Probe out of adjustment too warm 5 High level Probe possibly short circuiting during fill causing short fill and hollow cubes 1 Evaporator Temperature Probe out of adjustment reads too warm or is defective open 2 Actuator Motor won t raise Water Plate 3 Actuator Motor won t lower Water Plate 4 Controller Board is defective 5 Arms Down Switch stuck open Lowering Cam rotates CCW amp wraps spring around cam shaft causing Cam or Spring damage 6 Arms Down Switch stuck closed Plate supposed
59. cedure for more information Compressor thermal protector open because of defective run capacitor Compressor start capacitor or relay defective 44 TROUBLE SHOOTING Possible Cause Solution Compressor is defective Condenser fan motor is not operating on air cooled models Compressor is operating Fan motor protector open Condenser sub cooling gt 11 C at the middle point of the freeze cycle on liquid cooled models Condenser liquid regulating valve not closing fully during defrost on liquid cooled models Air cooled ice machine installed in a low ambient temperature location Ice frozen into the water plate surface Thick web between ice cubes Ice frozen into the water plate surface Cubes are fully formed without small dimples Ice cubes have large dimples or are hollow at the end of the freeze cycle Batch weight is too light Evaporator grids are distorted Water plate up switch lever is not being pushed up completely Defrost performance slow Water plate re opens immediately after closing Water plate is prevented from closing by some obstruction such as ice remaining on the water plate surface Water plate springs are stretched or weak and allow the water plate to drop slightly as the water fills the tank The water plate up switch lever is allowed to drop and re open the water plate A water plate spring is broken or disconnected from the cam arm or t
60. condenser fan motor if so equipped This position is useful for cleaning the ice machine and for test procedures where operation of the compressor is not required or desired Ice Level Probe Senses when the ice bin is full Contact between this probe and the ice in the storage bin will signal the controller to shut off the ice machine When ice is removed from the probe the ice machine will restart Adjustment While holding ice against the probe tube turn the adjustment knob on the controller to shut off the ice machine within one minute A warmer CCW Bottom blue knob adjustment will shut off the ice machine sooner A colder CW adjustment will delay shut off 16 Evaporator Temperature Probe Senses the temperature of the evaporator During the defrost cycle the evaporator must warm sufficiently to release the ice This probe signals the controller to terminate the defrost cycle after the ice has fallen out of the evaporator and start the next ice making cycle Note A secondary function of this probe is to signal the controller to shut off the ice machine if the evaporator should overheat Adjustment Turn the adjustment knob on the controller warmer CCW Top blue Knob only if the defrost time is insufficient to drop all the ice from the evaporator before the water plate begins to close defrost time should be increased no more than is required to ensure all the ice has fallen from the evaporator Control Stream This i
61. drop of 7 psi 48 kPa between the liquid coolant inlet and outlet of the condenser The condenser liquid control valve will regulate the flow of coolant through the condenser thereby controlling the high side pressure in the ice machine 60 Series Service Manual rev 1 2012 1 KOLD DRAFT ASSEMBLY Unpacking Unpacking a KOLD DRAFT machine can be done by prying off the boards that are holding the cardboard box to the shipping pallet The box can then be lifted vertically to expose the machine Tools to complete this job would include a claw hammer or some other form of pry bar Assembly Procedure 1 Hemove the ice machine front cover panel top cover panel and side cover panels from the ice machine frame Remove all shipping materials from the ice machine Cut off the water plate shipping strap For proper operation the ice machine and ice bin must be on a level surface If the surface the ice bin will be installed on is not level use shims or the adjusters on the ice bin legs to bring the machine to level If shims were used seal the bin to the floor using a sealant with NSF certification If there are gaps larger than 1 8 8mm install a cove molding around the bottom of the bin to reduce the gap and seal the cove molding to the floor with the approved sealant Confirm that the following holes are installed in the bin top a hole corresponding to the ice drop zone drain pan outlet bin level probe and the threaded mounti
62. e of the control board Example K4B 1 2 indicates a board revision number 1 2 20 Stacked Jumpers Under normal operation all machines will have a jumper across the left pins If this jumper is removed the water valve will stay energized to thoroughly rinse the water plate during the water plate lowering harvest and water plate rising cycles Note The machine will need reset for the controller to acknowledge this change right jumper is used to tell the controller when it is being used on a dual evaporator machine GB1064 models only This is set at the factory and should never be removed Programming Port Used by service technicians to alter or update the controllers software Water Level Sensor Port for water level sensor probes Evaporator Temperature Adjustment increase the temperature of the evaporator at which the water plate closes turn this dial counterclockwise To decrease turn the dial clockwise The operator can the harvest termination temperature between 35 and 60F Note After adjustment the controller must be reset Reset Button Reboots the controller Temperature Sensor Port For evaporator and bin temperature sensor probes 60 Series Service Manual rev 1 2012 21 KOLD DRAFT Bin Full Adjustment increase the temperature at which the ice level probe reacts to contact with ice in the bin turn the dial clockwise To decrease turn the dial counterclockwise The temperature rang
63. e Cam Arm or Cam Pin 2 Reinstall springs or replace as needed 3 Adjust switch actuator or replace as needed Check to insure that the Plate Up Switch actuates before the Arms Up Switch actuates 4 Lower the short water level probe in 1 16 increments until cubes have a pea sized dimple in the center 5 Replace the Water Plate if the factory coating is severely warn and is causing ice to stick to it Use a Foodgrade silicone spray to provide a temporary improved surface until the waterplate can be replaced 6 Adjust Evaporator Probe colder turn CW or replace if adjustment does not help 7 Free up adjust or replace stuck shorted Arms Up Switch or repair wiring 8 Re position or replace Bin Probe 1 Reset high pressure safety if tripped Clean the condenser on air cooled units Check water coolant supply on liquid cooled units 2 Check repair shorted wiring to this probe or gently move probe away from glass surface Make sure probe is not pushed up down out of vertical adjustment when moving it away from glass 3 Unplug the pump and confirm that the impeller is not jammed with foreign material Put machine in Wash Mode amp check voltage at pump cable connector On the Controller Board s AC output buss check wires P5 2 and P5 6 during Wash Mode for line voltage If rated line voltage is present and the pump s impeller is not obstructed replace faulty Water Pump 4 Check for low refrigerant charge 5 Repla
64. e for this adjustment is between 33 and 45F Note After adjustment the controller must be reset Switch Input Port For the on off ice clean and limit switches Factory Use Only Used to display diagnostic codes to a LCD monitor used only by service the factory Output AC output for powering the fan s compressor water pump s actuator motor s Contactor s and valves 22 ERROR CODE TROUBLESHOOTING CODE FAULT CODE INDICATES Rev 1 1 1 2 1 3 Evaporator temp over 120F 10 Rev 1 1 Water Plate failed to close after three consecutive attempts Rev 1 2 1 3 After 3 attempts to close machine goes into a 30 minute shutdown with the Plate open It will repeat this routine w the Plate closing 3 times amp then a 20 30 min wait four times before going out on Code 20 The Code 20 LED will flash as this routine is in process and then light solid after the routine tries 4 times and ends in Code 20 Rev 1 1 1 2 Freeze time exceeds 60 min Rev 1 3 Freeze time exceeds 45 min three times consecutively 30 60 Series Service Manual rev 1 2012 Before troubleshooting first check the Control Board and verify your software Revision Level Rev 1 1 1 2 or 1 3 POSSIBLE CAUSE 1 Bad Evaporator Probe shorted or wiring 2 Hot Gas Valve stuck open Cuber stuck in extended harvest mode 3 Bad Control Board 4 Actuator Motor won t raise Water Plate 1 Cam Arm or Ca
65. e left side of the cam arm hub The arms up switch lever front will be down and the arms down switch lever back will be up When the water plate opens the cam arm turns counter clockwise until the arms down switch operator allows the arms down switch lever to drop When the water plate is fully down open the cam arm should be in the seven o clock position the spring should be aligned with the cam arm When closing again the cam arm will turn clockwise until the arms up switch operator allows the arms up switch lever to drop The positions of the cam arms when the water plate is open and closed may be adjusted by loosening the set screws and rotating the switch operators as required Baseline positions of the switch operators for the front and back are 11 and 4 o clock when the water plate is up When the water plate is down positions for the front and back switch operators are 6 o clock and 11 o clock Note The front operator is for adjusting the arms up switch and the back operator is for adjusting the arms down switch Up Position e f the cam arm in the up position is too far clockwise from 12 o clock rotate the front switch operator clockwise to stop the arm s rotation earlier e f the cam arm in the up position is too far counterclockwise from 12 o clock rotate the front switch operator counterclockwise to stop the arm s rotation later Down Position e f the cam arm in the down position is too far clockwise from 7 o clock rotate the
66. e mounting studs and secure in place with the supplied 1 4 20 lock nuts Note Use care when positioning the ice crusher on the bin so that the guard is not damaged Be sure to check for internal bin components such as deflectors dividers etc which may interfere with the guard during installation 7 Carefully lift the crusher and place onto the gasketed bin Remove the front cover and note the alignment of the mounting holes in the chassis if mounting means are provided on the bin Follow the bin installation instructions for securing the crusher to the bin 60 Series Service Manual rev 1 2012 69 KOLD DRAFT Note The plastic selector knob must be removed before the front cover can be removed on older machines 8 Insert the straight thermostat holder tube into the rubber grommet located directly behind the crusher motor Route the crushed ice thermostat capillary tube through the straight thermostat tube holder Ensure that the capillary tube is slightly protruding from the bottom of the tube holder Place the cube ice thermostat capillary tube into the bent thermostat tube holder Ensure that the capillary tube is slightly protruding from the bottom of the tube holder Mount the tube holder as shown using the supplied hardware Tighten the clamp screws The picture below is a view of the right side of the crusher assembly from within the crusher frame This portion will be above the un crushed cube side of the bin CLAMPS CUB
67. e tip of this probe is at the bottom of the tube The next longest probe is the LOW PROBE When the water level is low enough to separate from the tip of this probe the controller is signaled to start the harvest cycle The shortest probe is the HIGH PROBE When the water level touches the tip of this probe during the water fill the controller will de energize the water inlet valve Adjustment reference probe should be adjusted all the way down The Low Probe should be adjusted so the tip is approximately 60 15 mm from the bottom of the probe tube The High Probe determines how much water is taken into the system at the beginning of a cycle It is adjusted as required by the size of the cube or and the desired fullness dimple size of each cube Typically all cubes should have a small dimple at the end of the freeze cycle Lack of a dimple in the cubes is an indicator that the water tank level is too high at the start of the cycle Note Making cubes without a dimple will reduce ice machine capacity and may damage the water plate surface in extreme cases If the control stream is draining water for more than 15 seconds at the end of the ice making cycle the water level in the tank is too high Lower the high probe or raise the low probe slightly until proper operation is evident 60 Series Service Manual rev 1 2012 1 7 KOLD DRAFT Plate Up Switch This switch is actuated by the water plate
68. eak the circuit to the motor If either the front panel of the crusher or the front panel of the bottom ice maker is removed a switch will open the motor circuit The crusher safety switch is mounted in the crusher control box 12 Install a grommet in the pre cut hole in the floor of the ice maker s compressor compartment directly behind the controller box 13 Push the safety switch wire assembly wires with insulated 90 flag terminals and the motor control wire assembly wires with piggyback terminals through the grommet into the ice maker 14 Connect the safety switch wires from the crusher to the Common and Normally Open terminals of the ice maker safety switch the two outer terminals See Wiring Diagram Note There are two motor control wire assemblies of different lengths When using a stacked machine the shorter wire assembly gets connected to the lower ice maker and the longer wire gets connected to the upper ice maker If the ice maker is not a stacked unit the longer wire is unused 15 Disconnect the white plug assembly from the ice maker hot gas valve If installing a GB1064 ice maker there are two hot gas valves Use the lower of the two to connect the crusher 60 Series Service Manual rev 1 2012 71 KOLD DRAFT 16 Connect piggyback terminals of the motor control wire assembly to the tabs of the hot gas valve on the ice maker 17 Reconnect the white plug assembly to the piggyback terminals of the motor control
69. equate clearance may result in reduced capacities and high system pressures Ice machine drains and bin drains may be insulated to prevent condensation The use of water treatment may increase the intervals between cleaning operations and the overall machine life If a water pressure regulator is used the recommended setting is 30 to 50 psig 0 2 MPa to 0 3 MPa dynamic Do not connect the ice machine to a hot water supply line Insulate the water line from sources of heat for greater operating efficiency Supply water temperatures higher than the recommended maximum will cause reduced capacities Normal protector size is based on rated voltage and operation at lower than extreme temperature limits Branch circuit conductors may be sized to allow increasing the protector value up to the specified maximum This may avoid nuisance protector opening under harsh operating conditions Additional Pre install Information for Cooling Tower Applications L models The ice machine does not need to be modified for use with a cooling tower provided the cooling tower is properly designed for the application Information regarding the amount of heat rejection as well as the pressure drop through the condenser and liquid valves is required to properly select or design a cooling tower application for an ice machine Coolant entering the condenser must not exceed 90 32 26 Coolant exiting the condenser must not exceed 110 43 36 Allow for a pressure
70. er when the cam arms are in the 7 o clock position water plate down so the actuator motor can be de energized Adjustment The switch operator which is attached to the output shaft of the actuator motor can be rotated on the shaft and fixed in place with a set screw When adjusted properly the cam arm will stop in the 7 o clock position The motor stops when the flat spot on the switch operator allows the switch lever to drop down Do not allow under travel or over travel so that the water plate is not in the most fully open position critical with HK models Contactor Provided with all models to carry the compressor load On self contained and remote air cooled models the condenser fan motor is also connected to the contactor The contactor coil is rated for line voltage and the contacts are rated for definite purpose applications FLA and LRA High Pressure Cutoff A manual reset pressure switch is provided which will open the circuit to the contactor coil if the discharge pressure should reach 435 psig 2 38 MPa gauge GB106x Series Unique Components Stacking Chute Provided to direct the ice from the upper ice making section down through the lower ice making section of these machines Ice Deflectors Upper Front and Rear Provided to direct the falling ice from the upper ice making section to the stacking chute 18 Controller Programming Port
71. erate equipment that has been altered from the original KOLD DRAFT specifications Use of non approved parts when servicing KOLD DRAFT equipment will void the equipment warranty Warning Use only genuine KOLD DRAFT replacement parts Use of non approved parts when servicing KOLD DRAFT equipment may create a safety hazard cause equipment damage property damage and will void the warranty 60 Series Service Manual rev 1 2012 ICE MAKER IDENTIFICATION Serial Number Plate Location oee the following for the location of the serial number plate P EL ss KDINDUSTRIES INC ERIE PA U S A MODEL NO SERIALNO CODE GB564AK 000000 5HT 208 230V 60HZ 1PH 3002 R 404a Note A complete model number and date code are essential for the accurate selection of replacement parts The sticker will be applied to the front of the top cross member of the machine Date Code Key YEAR KEY 5K 2000 5A 2001 5B 2002 5C 2003 5D 2004 5E 2005 2006 5G 2007 5H 2008 5J 2009 6K 2010 6A 2011 6B 2012 6C 2013 6D 2014 6E 2015 6F 2016 6G 2017 6H 2018 6J 2019 7K 2020 2021 7B 2022 7C 2023 7D 2024 2025 2026 2027 7H 2028 2029 8K 2030 2031 2032 8 2033 80 2034 2035 2036 2037
72. f the machine minimum circuit ampacity listed on the back of the machine does not indicate a typical running current value Use the minimum ampacity value for sizing branch circuit conductors up to 8 meters 26 feet in length For a conductor length over 8 meters increase the wire gauge as required by code 68 Assembly Installation 1 Position the ice storage bin maintaining the minimum clearances specified in the ice maker instructions 2 Level the bin with adjusters on its legs or by shimming if the bin is to be sealed to the floor If there are gaps between the bin and the floor greater than 1 8 inch install a cove molding around the bin bottom Seal the bin and molding to the floor with NSF Certified RTV sealant Dow Corning RTV 732 or equivalent 3 Install gasketing on top of bin if not already installed Gasket material must be positioned so that it extends to the outside edge of the perimeter of the ice crusher chassis when the ice crusher is in place To apply the gasket peel away the white backing strip and press firmly in place 4 Place the crusher on a flat surface If the floor is a rough or marring surface place a large rag or rubber mat on the floor to the left of the crusher and stand the crusher on its left side 5 Position the bottom guard so that the right side flange is hung over the ice breaker bar MOUNTING STUD 2 1 4 20 LOCK NUT 2 BREAKER BAR 6 Install the left side flange over th
73. fire Refer all maintenance to qualified personnel Hisk of personal injury property damage equipment failure or fire Never operate this equipment with covers panels or other parts removed or not properly secured Warn all users to clean up spillage immediately keep storage bin doors closed and report any apparent leakage or unusual sounds to maintenance personnel Proper installation must include KOLD DRAFT GB Series Ice maker mounted above Crusher 60 Series Service Manual rev 1 2012 67 KOLD DRAFT ICE CRUSHER INSTALLATION Notes Check for freight damage before proceeding with the equipment installation Be sure to inspect the equipment carefully for any damage that may not have been evident on the outside of the carton Contact the freight carrier immediately to report any damage and file a claim optimal efficiency and productivity these installation instructions should be followed accurately All machines have been tested and adjusted for correct performance at the factory e This equipment must be installed in compliance with the applicable federal state province and or local plumbing electrical and health sanitation codes and requirements Warning Do not operate equipment that has been damaged Refer all maintenance to qualified personnel Instruct all personnel in the proper use of the equipment Clean up any liquid spills immediately Always install equipment on a stable and
74. g this switch in the cleaning position does not complete the cleaning and sanitizing of the cuber Instructions pertaining to the cleaning of a machine can be found on page 11 of this manual Note The frequency of the need for cleaning is determined by the supply water characteristics The cuber should be cleaned no less frequently than once each 6 months and it may require more frequent cleaning The requirement for sanitizing frequency may be contained in local health code regulations Water Plate Closure Problems lf the plate up switch is not properly actuated due to mis adjustment weak springs or an obstruction to the water plate travel such as ice which did not slide off of the plate the actuator motor will immediately reverse and re open the water plate Shutdown High Pressure All models are provided with a high pressure cutoff which interrupts power only to the compressor and to the condenser fan motor if so equipped when the high side pressure rises to the cutoff setting The high pressure cutoff requires manual resetting to restore power in all models When this happens in air and remote cooled models be sure there is sufficient airflow a clean condenser and a properly functioning fan motor In liquid cooled models make sure the liquid regulator valve is adjusted properly and that there is sufficient flow of coolant 28 SIART METHODS Ice Making Mode Start Up At power up in the ice making mode the electronic control wil
75. he water plate Water plate closes but re opens before water fill is completed 60 Series Service Manual rev 1 2012 Replace compressor See compressor test procedure for more information Heplace motor if it does not run when cool or at normal operating conditions Fan motor defective Replace motor oystem is overcharged with refrigerant Remove refrigerant and recharge the system to specifications Adjust repair or replace liquid regulating valve Ambient temperature must be 60 15 C minimum Adjust web thickness to specifications Reduce the water fill level until ice cubes are produced with small dimples Increase the water level until ice cubes are produced with small dimples Carefully straighten grids or replace evaporator if the damage Is severe Adjust water plate up switch actuator on water plate until it pushes up the switch lever completely Eliminate obstruction Adjust the evaporator temperature probe so all ice is out of the evaporator before the water plate begins to close defective springs Replace broken spring or reattach disconnected spring TROUBLE SHOOTING Possible Cause Solution Evaporator temperature probe is defective and not sensing warm evaporator temperature Actuator motor will not run No voltage measured at actuator motor Water plate will not close after defrost Actuator motor will not run No voltage
76. heated and off due high temperature Allow the motor to cool down before starting the test procedure Always refer to the proper wiring diagram when troubleshooting Motor winding resistances at 75 24 C out of the circuit are as follows HEX 115 volt motors white to black or yellow approximately 95 ohms HEX 230 volt motors white to red or yellow approximately 400 ohms Voltages for Actuator Motor Electrical Tests Actuator Motor Test Parameters oltage Reading 115 volt motors reads 180 240 or Good Good Tap gear case to align 230 volt motors reads 290 370 bearings Line voltage for any voltage motor Open Good Replace capacitor Line voltage for any voltage motor Open and gt One motor Replace capacitor and in one actuator switch position and winding open volts in the other position 115 volt motors reads 180 240 or Good One motor Replace motor 230 volt motors reads 290 370 winding open in one actuator switch position and volts in the other position volts in both actuator switch shorted or Both motor Disconnect the actuator positions Be sure there is power to windings open motor from the circuit and the motor line voltage by leaving test the winding resistance one probe on either capacitor lead If approximately 500 ohms and placing the other probe on the from white to red or yellow replace the capacitor If the resistance is erratic replace the motor white motor lead 40 PROBE TEST P
77. ice machine is installed on an installed with an accessory such as a crusher follow the installation instructions with the other equipment 7 plumbing and electrical connections to the machine and ice storage bin in accordance with local regulations 8 Remove the strap securing the bin level probe and install through the bottom of the ice machine Ice machines on top of other ice machines or ice crushers should have the bin probe stuck through the bottom of the machine directly above the bin The hole for the bin probe will be in the same location on all variations of these machines just to the right of the ice making compartment or the ice chute in GT 56x applications TO CONTROLLEI M E N GB Models BIN LEVEL PROBE WIRE 4 Lo tH gt gt lt 2 NDENSING UNIT PAN BIN LEVEL PROBE PROBE SLEEVE 9 Install the ice deflectors Front Deflectors Rear Deflectors 60 Series Service Manual rev 1 2012 9 KOLD DRAFT INITIAL START PROCEDURE Be sure that the on off switch is in the off position and the ice clean switch is in the clean position Turn on the power and water supply and check all supply lines for leaks Make sure all pump and water tank hoses are connected then pour 1 2 quart 1 2 liter of clean potable water into the circulation system to lubricate and prime the pump s Note this can be done by either
78. ing solution into water level probe tube and the other half into the control stream box Allow the solution to circulate for 15 minutes Pull down on the right side of the water plate to cause it to open and dump the sanitizing solution and then refill with water Repeat this process two times to be sure all the cleaning solution is rinsed out of the machine If necessary adjust the water level probes to the proper levels While the cleaning and sanitizing solutions are circulating clean and rinse all accessible parts and surfaces of the ice machine with clean towels and Mix a cleaning solution containing 8 tablespoons 1 2 cup 96g baking soda and 1 Gal 3 8 Liter of warm water and a sanitizing solution containing 1 teaspoon 5 mL 5 1 496 sodium hypochlorite and two quarts 1 9 Liter of clean water After cleaning has been completed move the Ice Clean Switch to the Ice position Check the operation of the machine particularly the water level and subsequent ice cube formation Adjust the water level probes if needed 60 Series Service Manual rev 1 2012 11 KOLD DRAFT SPECIFICATIONS Machine Capacities Capacity and Energy Input Ratings Water Use gal 100 l kg 70 50 Ambient Water kJ kg 27602247 55 16 5059 68 19 425657 n n GT364AHK 255 116 332 150 59 4 84 384 23 6 1 97 n n n n 358 162 98 369 167 22 458 207 74 575 260 81
79. is out of the and terminates defrost too early evaporator Evaporator grids are distorted slowing the fall of the ice from the evaporator 46 adjustment counter clockwise warmer to extend defrost time Be sure the evaporator temperature probe is fully inserted into the evaporator probe holder Carefully straighten grids or replace evaporator if the damage Is severe TROUBLE SHOOTING Possible Cause Solution The water supply pressure must be a minimum of 5 PSI 34 kPa dynamic at the water valve Be sure that the supply line is of adequate size This is especially important for liquid cooled models Slow water fill where the potable water and condenser coolant water are supplied by the same water line Check for restrictions in the water supply line including clogged filters Check the water line strainer and clean it if needed This is normal operation of the unit if the water supply is too cold Very cold water will not rinse the ice residue from the water plate causing it to build up and affect normal operation Defrost valve opens during water fill Cold potable water supply Ice frozen into the water plate surface Thick web between ice cubes Adjust web thickness to specifications Ice remains attached Ice frozen into the water plate Reduce the water level until ice to the water plate surface Cubes are fully formed cubes are produced with small surface at the end of without small dimples
80. ive test the run capacitor by determining if there is continuity across the terminals Use a meter set to the 1 scale If there is continuity the capacitor is shorted and must be replaced Another alternative is to set the meter to the 100 000 scale If there is no needle deflection on an analog meter when placing the probes across the capacitor terminals or if infinite resistance is indicated on a digital meter the capacitor is open and needs to be replaced The capacitor may also malfunction if the relay contacts are not working properly or if the capacitor is subjected to prolonged operation of the start cycle because the start relay is incorrect the starting load is too high or the supply voltage is more than 1096 lower than the rated voltage 60 Series Service Manual rev 1 2012 35 KOLD DRAFT Additional Service Information e Testing the External Thermal Protector e After allowing sufficient time for the thermal protector to reset disconnect it and test for continuity across the terminals If there is no continuity replace the thermal protector Disconnect and test the compressor wiring by confirming that there is continuity between relay terminal 5 and compressor terminal C and also between terminals 2 and S as well as 4 and R e Replace the potential relay if all other tests do not reveal the problem new relay will eliminate any electrical problems that cannot be determined with the previous testing lf a
81. l finish ADJUSTMENT AND LUBRICATION 1 Oil the crusher motor if ports are provided and grease the shaft bearings Do not over lubricate 2 Check the belt and pulleys for excessive wear Adjust the belt tension to deflect 5 32 inch with two pounds applied to the center of the span 3 Tighten any loose set screws machine screws nuts and electrical connections 74 WIRING DIAGRAM LO 2100 SOG N33M9 MOTT3A M9 X M 3018 311lHM NMO38 43019 ng 31IHM MOV 18 M 8 3000 40709 NMOM8 ZH 09 022 802 amg OG A 06 072 31H ZH 09 40700 3MIM 2 32 7 09 0 lt 7 0 6 002 7161 7 09 06 7 001 001 TTA SNIIVM T1VO9IM19313 1300N YSHSNHO 39 641435 01 1721 SAVSOVIG ONISIM C E
82. l monitor the following criteria If the evaporator temperature is colder than the Harvest Termination temperature at start up the controller will switch to the Lower state If there is an obstruction preventing the water plate from closing the Plate Up switch at startup the controller will switch to the Lower state If the water plate is not in the up position at start up and the evaporator temperature is warmer than the Harvest Termination temperature the controller will switch to the Raise state Cleaning Mode Start Up At power up in the wash mode the electronic control will monitor the following criteria If there is an obstruction preventing the water plate from closing the Plate Up switch at startup the controller will switch to the Lower state If the water plate is not in the up position at start up the controller will switch to the Raise state 60 Series Service Manual rev 1 2012 29 KOLD DRAFT GT36X GT56X GB56X WIRING DIAGRAM DESCRIPTION CONTACTOI FF iL SIGNAL INPUTS
83. l the short probe is reached If water solenoid valve has power amp water but does not open replace the valve 4 Verify wire connection is securely crimped on top of probe amp back to Controller 5 Verify wire connection is securely crimped on top of probe amp back to Controller 6 Replace Controller 1 No action required Increase incoming water temp to 45F for best results 2 Tighten switches 3 Wiring should be to the Common amp Normally Closed NC positions with black wire to the bottom front NC terminal and red wire to bottom rear NC terminal White wires should go to the Common terminals on top 4 Straighten bracket 5 Cam flats should be almost opposite each other See Water Plate Up Down adjustment page 35 of Service Manual 6 Replace stuck shorted Arms Up Switch or check solutions 2 5 above 7 Replace stuck shorted Arms Down Switch or check solutions 2 5 above 1 Replace jumper to restore normal energy efficient minimum rinse mode 1 No action required 2 Repair wiring replace Bin Probe or replace Controller SEQUENCE OF OPERATION The following tables describe the general states and sequence of operation for the ice machine models in ice making mode with an additional table depicting the status when the ice bin is full and the cleaning mode The charts provide information about the inputs to the controller and the corresponding AC outputs associated with each part of the ice making cycle
84. m Pin is broken 2 Cam Spring disengaged or broken 3 Plate Up Switch stuck open or not actuating 4 Over freeze causing ice to stick on waterplate 5 Silicone coating on Waterplate worn away 6 During harvest the Evaporator Probe is out of adjustment reads too warm or is defective 7 Arms Up Switch stuck closed Plate stays down 8 Bin Probe is out of position or faulty and not shutting off ice maker when the ice bin is full Ice back up onto the Water Plate is blocking the Plate from closing 1 Not enough air or liquid flow through condenser 2 Low level harvest probe shorted or touching side of glass tube 3 Inoperative water pump 4 Refrigeration problem 5 Bad Contactor Compressor would be off 6 Inlet Water Valve stuck open Water Tank will be overflowing 7 Controller not shutting off Water Valve 8 Hot Gas Valve HGV stuck partially open or with a liquid cooled compressor HGV stuck fully open but Evaporator never gets hot enough 120F to give a an Error Code 10 S SOLUTION 1 Repair replace wiring or replace Probe 2 Pull down the Water Plate and verify that Hot Gas Valve closes after the Water Plate closes Repeat with power to the Hot Gas Valve coil disconnected If Hot Gas Valve does not close replace it 3 Replace Control Board 4 Replace Actuator Motor Motor never raises Plate to actuate Plate Switch so HGV stays open amp Evap temp rises gt 120F 1 Replac
85. measured at actuator motor and controller output terminal Actuator motor will not run Voltage measured at actuator motor Actuator motor overheated Open thermal overload Water level probe does not sense Defrost does not Lat the water level is low initiate when water level drops below low water level probe Waiter level probes are OK but no voltage measured at the controller output terminals to the actuator motor water valve or defrost valve Test probe and replace if defective Actuator motor output shaft is tuning C am pin is broken or missing but front cam is not turning Inspect operation of arms up and arms down switches Adjust or replace if defective Test controller and replace if defective defective actuator motor or capacitor See actuator motor test Actuator motor or capacitor defective procedure for additional information Let motor cool and determine why motor is running continuously Be sure there is no continuity path between the probes through water or mineral deposits on the probe cap Make sure the cap is clean and dry especially after cleaning the ice machine Test controller and replace if defective Evaporator temperature adjustment is Adjust evaporator temperature set too cold and terminates defrost Defrost cycle ends 190 early and water plate The evaporator temperature probe closes before all ice has poor contact with the evaporator
86. n of the rotation of the actuator motor Cam Arms These are attached to the actuator motor output shaft and function initially to separate the water plate from the evaporator and then to support the water plate as it opens fully Water Plate Springs Function as the connection between the cam arms and the water plate They also act as a safety mechanism stretching if any ice remains on the water plate surface as itis closing against the evaporator Drain Pan Provided to catch the dreg water at the end of the ice making cleaning and sanitizing cycles and directs it to the drain Ice Deflectors Front and Rear Provided to direct the falling ice to the storage bin Controller Controls the ice machine utilizing multiple sensors Provides power directly to many of the ice machine components through solid state relay outputs and indirectly to the compressor and condenser fan motor if so equipped by operation of a contactor The controller also provides status indication of the ice machine and components as well as diagnostics for service personnel On Off Switch The On position provides power to the controller to operate the ice machine The Off position interrupts power to the controller to shut down the ice machine Ice Clean Switch The Ice position signals the controller to provide full operation of the ice machine The Clean position signals the controller to exclude operation of the contactor and thereby the compressor and
87. nce polishes finish preservatives or cleaners in areas that could contact ice Warning Always clean the ice maker first following the ice maker cleaning instructions Remove all ice from the bin before starting the cleaning procedure Clean and sanitize storage bin last 1 Remove ice maker panels ice chute deflectors drain pan crusher front panel and belt guard 2 Wash interior with a solution of 2 tablespoons of baking soda per quart of clean warm water 140 60 C max The crusher ice hopper can be acc essed from the front and left side of the ice maker Use a long handled brush to clean inside the hopper as crusher teeth are sharp and can cause injury 3 The bottom area of the crusher ice hopper can be accessed from inside the ice bin Use a long handled brush 4 Wipe down internal cabinet walls with a cloth soaked in cleaning solution 5 Rinse with clean tap water 6 Sanitize all ice contact surfaces with a solution of 1 2 teaspoon 5 1 4 sodium hypochlorite chlorine bleach per quart of clean tap water minimum 100 PPM free chlorine A spray bottle will facilitate this process 7 Pour the remaining solution into the crusher chute slowly while rotating the cutter wheel by hand turning the pulley 8 After adjusting and lubricating crusher See following section replace all enclosure panels and connect the electrical supply 9 Exterior surfaces may be cleaned by standard methods suitable to the stainless stee
88. nel Lock Pliers Pre Install Checklist e Ambient air temperatures at the install location are between 45 7 C and 90 32 the machine must be installed indoors The machine will have the minimum opening sizes listed below Heights listed are strictly the ice machine and do not include the height of the bin Depths listed are adjusted to accommodate plumbing and electrical hookups Width Height cm in cm in GI36xA amp 54 3 GB106xRC_ 54 137 3 Each ice maker and each ice bin must enter the drain stack through separate connections Models equipped with a liquid condenser that does not recirculate coolant must have a drain for each condenser that enters the drain stack through separate connections e he drain hose or pipe will remain a constant diameter from the machine to the drain o The building drain must be able to accommodate all the drain water from the ice machine operation e Individual drains will not be directly connected to a common manifold drain or standpipe individual drains are to be discharged into a common manifold drain or standpipe a minimum 38mm 1 5 air gap must be provided at each connection This is to prevent any backflow of drain water into the ice maker or ice bin e Drain lines will be installed with a minimum drop of 1 per 3 run 2 5cm per meter run e The temperatures of the water supply fall between 45 7
89. ng holes for the supplied bolts at the four corners of the machine The hole for the drain pan outlet should be 2 5 in diameter to allow sufficient access for the clamp Drain hoses for drain pan outlets in GT36x GT56xA GB56x and the lower halves of GB106x models get directed through the back of the ice bin Drain hoses for drain pan outlets in GT56xL and the upper halves of GB106x models get directed through pre cut holes in the back of the ice machine frames Drain pans should never be allowed to drain directly into the ice bin After installation seal around the drain tube where it leaves the machine Note KOLD DRAFT bins will have a provision for the drain pan outlet tube to exit the rear of the bin Ice machines that will be used on bins not manufactured by KOLD DRAFT will require a drain riser adapter made by KOLD DRAFT to allow sufficient clearance for the drain pan outlet tube to exit the back of the assembly Install gasketing on top of bin if not already installed Gasket material must be positioned so that it extends to the outside edge of the perimeter of the ice maker chassis when the ice maker is in place To apply the gasket peel away the white backing strip and press firmly in place Carefully lift the ice machine and position it on the ice storage bin Securely attach the ice machine to the ice storage bin with the supplied washers and bolts or other non corroding hardware if not installed on a KOLD DRAFT bin If the
90. nstall the equipment in unprotected outdoor areas Always securely attach individual component sections together Bins Bagging Machines Dispensers Crushers Ice Machines etc Do not install the equipment in wet areas Do not locate the equipment near any heat source in direct sunlight in high ambient areas or without proper clearance for ventilation Placing equipment in these locations will result in reduced capacities high system pressures and may cause equipment failure Note Each Kold Draft ice machine has successfully completed a quality assurance test and has been factory inspected before shipping When receiving the unit please inspect it for physical damage If damage is found 1 Have carrier note the damage on the bill of lading 2 File a damage claim report with the carrier immediately 3 Call Kold Draft with your claim number to arrange replacement or repair Whats in the Box Kold Draft Ice Machine Warranty card attached to the front of the machine Two ice deflectors four ice deflectors with a GB106x machine Drain Pan hose with clamp Two hoses and two clamps with a GB106x machine Adhesive backed foam weather strip tape Information packet o Duplicate warranty card Installation And Operation Manual 4x 1 4 20 stainless steel bolts 4x 1 4 stainless steel washers 2x 8 32 pan head stainless steel Philips head screws O O O O Required Tools e 2 Philips Head Screwdriver e 7 16 Socket and Wrench e Chan
91. nt and back holes are no longer required 11 With the open end of the water plate to the right m slide it back into the machine and to the left of its J Y Y normal position LEN i 7j 12 Hook up the main springs to the water plate rear qn za m spring first ES DETERMINED 13 Hook on and snap into place the plastic hinge M oe brackets BRACKET 14 Secure the pump mounting screw holding the water plate brace CLEARANCE SPECIFICATION 075 FULL CUBE C amp HALF CUBE HK 15 Remove the water level probe assembly and Bua UOCE E S eoe reposition the control stream drain tube Position and secure the control module box to mounting bracket Check adjustment of plastic lift bolt TVAPORATOR Heconnect harvest switch if present WATER PLATE 16 Water plate must be aligned with the evaporator drawing illustration 2 063 16 32 THD o 1 938 T u 2 HOLES N O d 975 1 ry E LA 7 18 2 W N b N N 1 1 Lr i i DRILL 28 1405 O 4 HOLES p 625 N goce D T a 4 1 750 N 4 60 Series Service Manual rev 1 2012 37 KOLD DRAFT WATER PLATE ALIGNMENT If the water
92. or repair open wiring 6 Free up adjust or replace Arms Down Switch or repair shorted wiring 7 Check power from the Controller to the Valve Coil to determine if problem is electrical or the Valve is just stuck closed Replace Coil Controller wiring or Valve as required 8 Adjust Evaporator Probe warmer or replace if not responding 9 Replace Contactor Check pins 2 amp 10 for upper Actuator Motor on a dual Evaporator machine ERROR CODE TROUBLESHOOTING CODE 60 70 80 90 FAULT CODE INDICATES Rev 1 1 1 2 Water fill exceeds 5 min Rev 1 3 Water fill exceeds 3 min then the Valve closes amp waits 10 minutes as Code 60 LED flashes Valve then opens amp tries again This routine repeats 3X and results in a solid Code 60 if the fill is not completed on the third try Rev 1 1 1 2 Evaporator Temperature 31F during water fill only System opens Hot Gas Valve to compensate until an Evaporator temp of about 38 F is reached This temp range is adjustable from about 35 46 F Rev 1 3 Both Arm Up Arm Down Cam Switches Closed un actuated at the same time not allowed Rev 1 3 only Machine is in Full Rinse Mode Left Jumper is pulled on Controller Rev 1 3 only Ice Bin Full A cold Bin Probe will shut down the icemaker right after the next harvest is complete 60 Series Service Manual rev 1 2012 Before troubleshooting first check the Control Board and
93. ovided Water Plate Functions as a water manifold with a flat surface and to regulate the web thickness between the cubes This surface is positioned close to the evaporator and acts to form the sixth side of the ice cubes The water plate surface has one spray hole for each cell in the evaporator to provide water to the freezing surfaces water plate surface also has two drain holes under each cell to allow unfrozen water to return to the water tank to be re circulated The water plate swings down during the harvest cycle to allow the ice cubes to fall out of the evaporator Note If at any time during the Fill Freeze or Circulate cycle the water plate is manually opened the controller will switch to the step 3 of the ice making sequence on page 26 60 Series Service Manual rev 1 2012 15 KOLD DRAFT Water Pump Continuously circulates the water the water tank through the water plate during the ice making cycle The water pump also operates during the wash cycle to circulate cleaning and sanitizing solution Actuator Motor Rotates the cam arms counter clockwise at the beginning of the ice harvest cycle to lower the water plate so the ice can fall out of the evaporator It then rotates clockwise at the end of the harvest cycle to close the water plate for the next ice making cycle Actuator Motor Capacitor Installed between the two actuator motor windings the function of this capacitor is to determine the directio
94. ower is applied to the defrost valve coil allowing hot gas to circulate through the evaporator The evaporator begins to defrost and the water plate begins to open immediately When the cam arms down switch is activated the water plate will stop Harvest As long as the evaporator remains cold the water plate s remain in the open position with the water solenoid valve de energized The defrost valve remains energized and the evaporator s become warm enough to release the ice which drops by gravity into the ice storage area Raise After the ice is out and the evaporator s warm to the reset temperature required by the controller the actuator motor s will be energized to close the water plate s The water solenoid valve will be energized to begin the water fill for the next ice making cycle the defrost valve will be de energized and the evaporator will begin to cool Ice Bin Full When the level of ice reaches the bin probe the ice maker stops automatically and it remains off until the bin probe warms up when the ice level is lowered Note in remote condenser models r the compressor continues to run after bin control shutdown until the low side is pumped down to the setting of the pumpdown controller This pressure should be between 5 and 10 psig and must never be vacuum Cleaning Mode All of the cuber s operational components except refrigeration are able to function with the make ice clean switch in the clean position Simply placin
95. r more information Remove refrigerant and recharge the system to specifications Adjust the expansion valve to decrease the evaporator superheat Adjust the expansion valve to increase the evaporator superheat Confirm proper operation of the arms up and arms down switches and replace if needed Confirm proper settings of the switch operators and adjust as required Adjust switch operators so the cam arms are at the 12 o clock position when the water plate is fully closed and at the 7 o clock position when the water plate is fully open See the cam arm switch and switch operator relationship illustration for more information PARTS DIAGRAMS GT36x Parts Left Side 5 Spring 2x 6 Front Cam w Springs 2 Evaporator 4 Evap Bin Temp Sensor Assembly 7 Rear Cam w Springs 3 Plate Cam Switch 3x 8 Actuator Motor 9 High Pressure Cut Out 1 Water Plate 20 Filter Drier 19 Expansion Valve 10 Ice Clean Switch 18 Probe Tube Assy 11 Controller 17 Water Pump 14 On Off Switch 13 Fuse Holder w 4A fuse 16 Drain Pan 15 Water Tank Par Description PartNo e Description Model Parto Fuse Holder With Fuse damp Al 102144901 Fo E Temperature Probe Assy GT36x 102143901 T GBR00909 GT36x 102142201 17 Tanstrmeralzsv 102145401 Actuator m GT361 102140901 EM GT36x 102140401 Actuator Motor
96. s a small clear box divided into two sections and located on the front face of the water plate It is a safety valve that ensures evacuation of the water reservoir so that harvest cycles will begin without undue delay Water flowing into the left section of the box is returned to the water tank and re circulated through the system Water flowing into the right section of the box is drained out of the system The velocity of the stream flowing in the box during the ice making cycle is an indicator of the water pressure inside the water plate This pressure will increase as the ice cubes fill out in the evaporator covering the drain holes provided for each cell This pressure increase will cause the stream normally flowing into the left section of the box to flow over the partition and into the right section draining the system of excess water Adjustment Turn the Philips head screw located behind the expansion valve such that the stream of water falls to the left of the control stream box partition during the early portion of the ice making cycle before the cubes are full Water Level Probe Assembly This assembly consists of three stainless steel probes which are positioned in a clear water level tube The water level tube is mounted in front of the water tank and is connected to it by a hose The water level in the tank is visible in the tube The water level probes are positioned in the water level tube The longest is a reference probe and th
97. se or tripped circuit breaker is an indication of a ground fault Energizing a compressor with a ground fault may cause terminal pin ejection which will allow oil and refrigerant to spray out of the system This oil spray combined with an electrical spark can ignite causing harm to personnel and property Discharge all capacitors with a 20 000 ohm resister before working with them or removing them from the ice machine This must be done to avoid damage to measuring devices and the risk of electrical shock Note When servicing KOLD DRAFT ice machine refrigeration systems all work performed must be consistent with the best refrigeration service practices These systems must remain clean dry and properly charged with refrigerant in order for the ice machine to operate as designed e See the Remote Air Cooled Condenser section of the manual for additional service information related to these ice machines e All KOLD DRAFT ice machine models utilize capacitor start capacitor run compressors Each model includes a potential start relay a start capacitor and a run capacitor in the compressor circuitry to start and operate these compressors properly and with maximum efficiency All compressors also include thermal protectors external on GT36x GT56x and GB56x models and internal on GB106x models This procedure will help diagnose problems with these compressors and all related components 60 Series Service Manual rev 1 2012 33
98. serve that the cam arms continue to turn opening the water plate fully dumping the water in the tank After a moment the cam arm rotation will reverse and close the water plate cam arm rotation will stop when the water plate is fully closed and the water fill process will repeat Move the ice clean switch to the ice position the water plate will cycle down and up one more time dumping the water When this completes the machine will begin to make ice observe that the compressor and the condenser fan motor if so equipped begin to run If possible with liquid cooled models ensure there is water flow during the ice making cycle the bin level control operation by holding ice against it Adjust the controller if required to shut off the ice machine within 30 seconds of contact between the ice and probe Make sure that the drain pan ice deflectors and stacking chute GB106x models and stacked ice machines only are properly installed Replace and secure all the cabinet panels The front panel gets secured to the machine with the provided stainless steel sheet metal screws Discard all the ice from the start up cycles then clean and sanitize the ice storage bin according to the instructions provided with the bin 10 Complete and mail the registration certificate to the factory Leave all instructions with the owner user 10 ICE MACHINE CLEANING PROCEDURE It is recommended to perform this cleaning procedure at
99. th over 8 meters increase the wire gauge as required by code Remote condenser ambient air temperature 1107 4 3 C maximum e Try to keep the compressor warmer than the condenser In most installations the ice maker runs enough so that residual motor heat minimizes liquid migration to the crankcase If the ice maker is in a cool location or if it will be OFF for extended periods a crankcase heater should be installed e Avoid placing the condenser in the exhaust air stream of other equipment or within a distance 78 equal to the width of the condenser from a wall or another piece of equipment Stay away from kitchen exhaust fans to prevent grease accumulation on the fins Use a curb which extends above the deepest expected pond in the condenser area of the roof Installation 1 Unpack the condenser and install the mounting legs 2 Fasten the condenser to its mounting surface using methods that will satisfy the building codes in your area The condenser must not be lower than the receiver 3 he line sets are packed separately with the quantity and length marked on the carton Make sure that the lines are correct for your installation 4 single circuit condenser installation which uses one line set will require a 1 3 4 dia hole to pass the lines through a ceiling or wall The lines for a 2 circuit condenser require a 2 dia hole 5 Each line set consists of a 3 8 liquid line and a 1 2 insulated discharge line Connect
100. when the water plate is closed Freeze Once the water fill cycle has been completed the water solenoid valve will remain de energized until the following harvest cycle The water level in the liquid level probe tube lowers as the water is frozen but no additional water will be introduced during the freeze cycle The control stream runs continuously during the freeze cycle with the water returning to the water tank through the hole which can be seen through the control stream box to the left of the dam in the box The control stream is a safety valve to insure the ability to initiate harvest rather than an ice quality control and it should never need to go over the dam for more than 15 seconds before harvest begins Note No water other than condensation should drip or run to the drain pan from the 60 Series Service Manual rev 1 2012 27 KOLD DRAFT control stream or from the water tank during the freeze cycle The water level in the liquid level probe tube must get below the level of the low water level probe initiate the harvest cycle If there is an excess of water in the water tank the water pump outlet pressure increases when the evaporator cells are full and the control stream rises and flows over the dam to the drain pan to evacuate the liquid level control tube Lower When the water level in the liquid level probe tube is below the low water level probe the controller senses the absence of continuity between the probes P
101. within the voltage tolerances listed below FullLoad Minimum 230 7 Series 220 380 8 Series 420 3 phase 210 1 phase e Breaker or fuse service must be no greater than the maximum rating as specified on the rating label attached to the back of the machine minimum circuit ampacity listed on the back of the machine does not indicate a typical running current value Use the minimum ampacity value for sizing branch circuit conductors up to 26 feet 8 meters in length For a conductor length over this length increase the wire gauge as required by code Warning Water Treatment There are no specific requirements for water treatment provided that the ice making supply water is potable and not laden with sediment The use of additional water treatment may facilitate or reduce the frequency of the need for cleaning Please consult your local water conditioning supplier for specific recommendations Note Ambient temperatures higher than the maximum specification will result reduced capacities and high system pressures in air cooled models Temperatures lower than the minimum will cause the machine to malfunction due to an inability to eject the ice from the evaporator Ambient temperatures less than 60 15 may cause the bin thermostat to malfunction Clearance must be provided for ventilation and access for service Ventilation is especially important for models with air cooled condensers Failure to provide ad

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