F200! Service Manual
ELECTRONIC MODULAR
FLAKERS AND SUPERFLAKERS
F 100 C
F 100
F 120
F 200
SF 300
SF 500
SF 1000
Gas R134a - R 404a
UR SYSTEMS COMPLY WITH EEC DIRECTIVE 73/23 - 89/336
SERVICE MANUAL
Cod. 71503382/0-GB - Rev. 001 - 01/2001
GB
TABLE OF CONTENTS
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
Specifications
F 100C
F 100
F 120
F200
SF 300
SF 500
SF 1000
pagina
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6
8
10
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14
GENERAL INFORMATION AND INSTALLATION
Introduction
Unpacking and Inspection - Ice maker
Unpacking and Inspection - Storage bin
Location and levelling
Electrical connections
Water supply and drain connections
Final check list
Installation practice
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OPERATING INSTRUCTIONS
Start up
Operational checks
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PRINCIPLE OF OPERATION (How it works)
Water circuit
Refrigerant circuit
Mechanical system
Operating characteristics
Operating pressures
Components description
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ADJUSTMENT, REMOVAL AND REPLACEMENT PROCEDURES
Adjustment of the evaporator water level
Replacement of evaporator temperature sensor
Replacement of condenser temperature sensor
Replacement of ice level light control
Replacement of P.C. Board
Replacement of the ice spout
Replacement of the auger, water seal, bearings and coupling
Replacement of the gear motor assy
Replacement of fan motor
Replacement of drier
Replacement of the freezing cylinder
Replacement of air cooled condenser
Replacement of water cooled condenser
Replacement of water regulating valve (water cooled models)
Replacement of compressor
Wiring diagram
Service diagnosis
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MAINTENANCE AND CLEANING INSTRUCTIONS
General
Icemaker
Cleaning instructions of water system
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SPECIFICATIONS
ELECTRONIC MODULAR FLAKER
MODEL F 100C (R 134a)
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3
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SPECIFICATIONS
ELECTRONIC MODULAR FLAKER
MODEL F 100 (R 134a)
KG/24 H
83
89
92
95
10
78
84
87
90
76
82
85
88
21
76
82
85
88
72
78
81
84
32
64
70
73
76
70
76
79
82
38
60
66
69
72
32 21 15 10
F 100 W
RAFFR. ACQUA
WATER COOLED
°C
TEMPERATURA AMBIENTE
AMBIENT TEMPERATURE
43
4
32 21 15 10
F 100 A
RAFFR. ARIA
AIR COOLED
°C
TEMPERATURA ACQUA
WATER TEMPERATURE
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5
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SPECIFICATIONS
ELECTRONIC MODULAR FLAKER
MODEL F 120 (R 134a)
KG/24 H
104 112 116 120
10
104 112 116 120
94 102 106 110
21
98 106 110 114
89
97 101 105
32
87
95
99 103
87
95
38
80
88
92
99 103
32 21 15 10
F 100 W
RAFFR. ACQUA
WATER COOLED
°C
TEMPERATURA AMBIENTE
AMBIENT TEMPERATURE
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6
96
32 21 15 10
F 100 A
RAFFR. ARIA
AIR COOLED
°C
TEMPERATURA ACQUA
WATER TEMPERATURE
83 (3 17/64)
82 (3 1/4)
305 (15 5/32)
188 (7 13/32)
103 (4 1/16)
295 (11 21/32)
354 (13 15/16)
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F 120
F 120
F 120
3/8
3,2
17
500
11
110
10
7
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SPECIFICATIONS
ELECTRONIC MODULAR FLAKER
MODEL F 200 (R 404a)
KG/24 H
154 172 182 190
10
168 184 192 200
152 170 180 188
21
160 176 184 192
150 168 178 186
32
135 153 163 172
146 164 173 182
38
125 143 153 162
32 21 15 10
F 200 W
RAFFR. ACQUA
WATER COOLED
°C
TEMPERATURA AMBIENTE
AMBIENT TEMPERATURE
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8
32 21 15 10
F 200 A
RAFFR. ARIA
AIR COOLED
°C
TEMPERATURA ACQUA
WATER TEMPERATURE
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SPECIFICATIONS
ELECTRONIC MODULAR SUPERFLAKER
MODEL SF 300 (R 404a)
KG/24 H
270 300 315 330
10
260 290 305 320
265 295 310 325
21
255 285 300 315
260 290 305 320
32
210 240 255 270
250 280 295 310
38
190 220 235 250
32 21 15 10
SF 300 W
RAFFR. ACQUA
WATER COOLED
°C
TEMPERATURA AMBIENTE
AMBIENT TEMPERATURE
43
10
32 21 15 10
SF 300 A
RAFFR. ARIA
AIR COOLED
°C
TEMPERATURA ACQUA
WATER TEMPERATURE
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11
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SPECIFICATIONS
ELECTRONIC MODULAR SUPERFLAKER
MODEL SF 500 (R 404a)
KG/24 H
480 540 570 600
10
440 520 560 600
470 530 560 585
21
420 500 540 580
460 520 550 580
32
360 440 480 520
450 510 540 570
38
330 410 450 490
32 21 15 10
SF 500 W
RAFFR. ACQUA
WATER COOLED
°C
TEMPERATURA AMBIENTE
AMBIENT TEMPERATURE
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12
32 21 15 10
SF 500 A
RAFFR. ARIA
AIR COOLED
°C
TEMPERATURA ACQUA
WATER TEMPERATURE
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SPECIFICATIONS
ELECTRONIC MODULAR SUPERFLAKER
MODEL SF 1000 (R 404a)
KG/24 H
1036 1090 1120 1150
10
950 1050 1100 1150
980 1030 1060 1080
21
870 970 1020 1070
975 1025 1055 1075
32
770 870 920 970
950 1000 1030 1070
38
720 820 870 920
32 21 15 10
SF 1000 W
RAFFR. ACQUA
WATER COOLED
°C
TEMPERATURA AMBIENTE
AMBIENT TEMPERATURE
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14
32 21 15 10
SF 1000 A
RAFFR. ARIA
AIR COOLED
°C
TEMPERATURA ACQUA
WATER TEMPERATURE
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15
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5. On the B 1025 S and B 1350 S Storage
Bin unloose the screws securing the S.S. Top
Cover to the storage bin and remove it.
6. Lay out on the bin top the plan of the ice
machine as it will be located on the bin and cut
an opening in the bin top for the ice drop area;
cover the edges of the opening with vinvyl tape
7. Install the gasket-on the bin top-around ice
drop opening of the bin top; apply sealant along
the inside of the gasket.
8. Position and install the four aluminium
front to rear stiffeners (U shaped) paying
attention to the guideline shown on the drawing.
NOTE. Bin wall gasket must be cut to clear
the stiffener ends as shown on drawing.
Do not put any stiffeners crossing the ice
drop opening
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9. Install the bin top in its position onto the bin
top by:
- place the rear side of top against rear
edge of the bin
- lower the front of the top onto the
stiffeners
- re-fit the screws previously removed as
per step 5
10. Install the Modular Flaker or Superflaker
onto the Top Cover of storage bin pay attention
to match the ice chute with the Bin Top opening.
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The regrigerant head pressure is kept
between two pre-set values (8÷9
[F100] 17÷18 bars [200-300-5001000]) by the condenser temperature
sensor which has its probe located
within the condenser fins - in air cooled
versions.
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On the water cooled versions, che refrigerant
head pressure is kept at the constant value of
8,5 bars [F100] 17 bars [200-300-500-100] by
the matered amount of water passing through
the condenser which is regulated by the action
of the Water Regulating Valve that has its
capillary tube connected to the liquid refrigerant
line. As pressure increases, the water regulating
valve opens to increase the flow of cooling water
to the condenser.
The refrigerant suction or Lo-pressure sets - in
normal ambient conditions - on the value of 0,5
bars [F100] 2,4÷2,6 bars [200-300-500-100]
after few minutes from the unit start-up.
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F
200
SF 300
SF 500
SF 1000
F100
F100C
F120
300 gr
440 gr
300 gr
380 gr
F100/F100C/F120
F200/SF300-500-1000
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The key 3 is OF NO USE therefore it can be
indifferently positioned in ON or OFF position
without influencing at all the unit operations.
RED LIGHT - BLINKING
- 3’ minutes stand by
RED LIGHT - STEADY
- Unit shut-off due to a too
hi-condensing temperature
- Unit shut-off due to a too
lo-ambient temperature
<+1°C
The 4th key allows the switching of the unit reset from manual (OFF setting) to automatic
(ON setting) when the machine operation has
been cut-out by any of the safety control
devices.
The keys 5, 6 an 7 may be used to vary the
temperature differntial determined by the
condenser temperature sensor for the cut-in
and cut-out of the fan motor, as indicated in the
following table.
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J.
The remaining key 8 is used to modify the CUT
OUT condensing temperature from 70°C ON
position, for the air cooled versions, to 62°C
OFF position for the water cooled versions.
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FREEZING CYLINDER or EVAPORATOR
(Two on SF1000 Model)
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3. On model F100/F200 unloose and
remove two screws and washers holding tight
the spout bracket to the freezing cylinder.
On models SF300/500/1000 unloose and
remove the four bolts securing the ice breaker
to the upper flange of the evaporator.
4. On model F100/F200 grasp the wire cap
hook at the top for the freezer and pull out the
auger, attached cap and ice breaker from the
top fo the freezer.
On models SF300/500/1000 with two flat
screwdrivers insert then on the space between
the icebreaker and the upper flange and by
tilting them lift the icebreaker and auger
assembly.
Grasp the icebreaker and remove the
icebreaker and auger assembly by lifting them
from the evaporator.
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NOTE. If the auger cannot be pulled out,
proceed to steps 10 and 11 of this
paragraph, to gain access to the auger
bottom. Then, with a rowhide mallet or
placing a piece of wood on the bottom end
of the auger, tap this bottom to break loose
the auger and be able then to pull it out as
in step 4 above.
NOTE. It is good practice to replace th
water seal assy and both the top and the
bottom bearings any time the auger is
removed.
To facilitate this, it is available a service Kit
which includes besides the above
mentioned parts, the ice breaker O ring and
a tube of food grade waterproof grease.
5. On model F 100C, F 100 and F 200, with
a circlip plier, remove the retaining ring and cap
hook from the ice breaker while, on the
superflaker models, remove the plastic cap
using a screwdriver as a lever.
13. Reach throught the adaptor and remove
the coupling parts.
14. Check both the coupling halves for
chipping and wear and do not hesitate to
replace them.
15. Install the bottom bearing into its brass
housing paying attention to have the white
plastic ring facing up.
16. Install the upper bearing into the ice
breaker starting by the radial portion that must
be fitted with the flat surface facing up.
17. Apply some lubricant (grease) on the
upper surface the install the rollers cage with
the smaller openings of the same facing up so
to leave a small gap between plastic cage and
flat surface of the botton portion of the bearing
(see drawing).
18. Apply some move lubricant then place the
S.S. trust washer.
10. Unloose and remove the three/four bolts
and lockwashers which attach the freezer assy
to the aluminium adaptor.
11. Raise the freezer assy of the adaptor,
secur it out of the way to allow room to work.
Using a suitable lenght and size wooden dowel
or stick inserted through the top of the open
freezer, tap the lower half of the water seal and
the lower bearing out the bottom of the freezer.
12. On the superflaker models, with two
screwdriver as a lever, remove from the bottom
of the freezer assy the lo bearing brass holding
ring.
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19. After to have replace the O ring into the
ice breaker fit the same on top of the auger and
secure it with the top bolt.
20. Install the auger/icebreaker into the
evaporator following the previous steps in
reverse.
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WIRING DIAGRAM F 100 - F 120 - F 200
AIR AND WATER COOLED
SINGLE PHASE
41
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WIRING DIAGRAM SF 300 - SF 500
AIR AND WATER COOLED
SINGLE PHASE
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WIRING DIAGRAM SF 500
AIR AND WATER COOLED
THREE PHASE
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WIRING DIAGRAM SF 1000
AIR AND WATER COOLED
THREE PHASE
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Via del Lavoro, 9 C.P. 67
I - 31033 Castelfranco Veneto (TV) Italy
Tel. (0423) 738455 - Fax (0423) 722811
E-mail: [email protected]
Web-site: www.castelmac.it
Cod. 71503382/0-GB - Rev. 001 - 01/2001
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