Manitowoc MAF-35, MAF-67 User manual

Manitowoc MAF-35, MAF-67 User manual
 Manilowoc
ICE FLAKER
SERVICE MANUAL
via equipment works MANITOWOC
ou
MANITOWOC manufactures two types of Ice Making equipment. They are:
1. Ice Flakers to produce a fine dry crushed ice.
2. Ice Cubers, to produce crystal clear cubes, sized approximately
1-1/4x1-1/4x1-1/4 inches and diced cubes, sized approximately
3/4 x 3/4 x 3/4.
This manual covers Ice Flaker machines. Refer to Manual No. 80-0186 for Ice Cubers
and Diced Cube machines.
Refer to the index sectionbelow for your convenience in installing and servicing this equip-
ment.
SUBJECT
Serial and Electrical Plate
Installation -
Power Supply and Hook Up
Water Supply and Hook Up
Drain and Hook Ups
Float Valve, Adjustments and Cleaning
Filters
Gear Drive Unit
Control Adjustments
Bin Control
Thermostatic
Electric Eye
Low Pressure Cut Out
High Pressure Cut Out
CLEANING
Refrigeration System:
A. Checking Compressor
Changing Compressor
Cleaning Contaminated System
Evacuating and Charging
Changing Drier
Expansion Valves - Settings and Changing
Replacing and Adjusting Water Valve
Water Cooled Condensers
1, Operation
2, Cleaning
I. Changing Gear Drive Unit
J. Changing Evaporator
K. Changing Solenoid
Trouble Shooting
Part Specifications
Wiring Schematics
Refrigeration Schematics
Production Capacity Curves
Specifications
A. Dimensions
B. Refrigerant Charge
C. Electrical Resistance
D. Compressors - Relays - Overloads - Capacitors
Condensing Units
HOYHOQU
PAGE
co LN
7 & 8
7 &8
10 & 12
2 ET
13 & 14
— 14
14, 15, 16 & 17
18
18
19
19
21
21
21
21
22
23
23
30
30
23
26, 27, 28 & 29
32
23, 24, & 25
12
33
17
31
31
31
19820
Your MANITOWOC Flaker was designed to produce ample quantities of top quality ice. It
is constructed of heavy duty, commercial grade material to withstand the adverse condi-
tions this type of equipment operates in. The ice making compartment is isolated from O
the machinery compartment. The ice making parts can be completely disassembled for
cleaning without the use of tools. The parts are made of materials recommended by the
National Sanitation Foundation for use with potable water. They are designed without
Cracks or crevices and with ample radiuses for easy cleaning.
Service problems should be infrequent because the only mechanical operating parts in the
ice making section are the gear drive unit with auger, and the float valve. The sealed
motor of the gear drive unit is protected by an internal overload device. The float valve
can be disconnected and the entire assembly removed for cleaning.
The sealed condensing unit of the air cooled model is mounted with the finned condenser to
the front for regular inspection and easy cleaning. The complete condensing unit pulls out
for access to the compressor, fan, solenoid, condenser and water regulating valves on
water cooled models. (NOTE) In ambients higher than 90 degrees it is recommended the
grill covering the condenser be removed on air cooled models.
The head unit (compressor and ice making section) is separate from the seamless poly-
ethelene lined foam insulated metal storage bin. This permits leveling up and sealing the
light weight bin section to the floor before setting the heavy head unit in place. It also
makes practical the removal to a service shop of the head unit should major repairs be
necessary.
SERIAL AND ELECTRICAL PLATE (See Fig. 1)
The combined serial and electrical plate is located on the right end of the head unit or on
the front rail below the condensing unit. Be sure to send the complete serial number (14
numbers) and the model number when calling for service or parts.
Fig, 2
_ CONDENSER
DRAIN-
(CS MODEL SERIAL | WATER COOLED
MODELS ONLY
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WATER INLET
90” 0-17 INSTALL
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PROVIDED
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COMPRESSOR SEEN WATER PUMP BEE SOLENOID SF ,
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MANITOWOC EQUIPMENT WORKS
MANITOWOC- WISCONSIM
Fig. 1
UNCRATING
The bin complete with door is shipped in a corrugated carton with fold up inserts for added
protection. Before opening the carton, inspect for punctures, dents, or evidence of mis-
handling. Notify the carrier requesting their representative be present if you suspect con-
cealed damage. Insist that freight bills be marked. If you find the bin damaged and no
external evidence, save the carton and all packaging for the carrier's inspection. Once
inspection has been made, advise the carrier of the cost of repairs, loss due to discounted
price or replacement cost if bin can't be salvaged.
The head unit covered with a polyethylene film is bolted to a wooden skid, and crated with
an open slat type wooden crate. The open construction makes a visual inspection for
damage practical before removing the crate. Lift off the crate after removing nails se-
curing the crate to the base. We suggest leaving the unit on the skid until ready to lift it
onto the bin.
LOCATION
Most models are designed to slide under a 42 inch bar or any other convenient location. For
maximum efficiency pick a location away from sources of heat like radiators, ovens, other
refrigeration condensing units, direct sunlight, etc. Provide space around the cabinet for
air circulation. Air cooled models require a minimum of 3 inches at any louvered open-
ing to the compressor compartment. Cabinets located in unheated areas must be protected
from freezing or shut down and drained.
INSTALLING BIN (Fig. 4)
We recommend wherever possible one of the two available base leg assemblies be used.
Base Leg Kit #07-0001 provides 6 inches clear space under the bin, Base Leg Kit #07-0009
provides 12 inches. Each base assembly has four sanitary adjustable feet for easy level-
o ing and are designed to lock in place on the underside of the bin without the use of tools.
Each kit comes with all parts and complete instructions.
Should space limitation make use of either base leg impractical proceed as follows to set
up bin.
(a) Set bin in correct position. NOTE: Make sure any piping and wiring is in
place unless there is adequate room to work around the ice maker.
(b) Use a level on the top gasketed surface and shim until bin is level. LEVEL-
ING IS IMPORTANT FOR PROPER OPERATION,
(с) Use caulking compound to seal bin to floor. (This is recommended by the Na-
tional Sanitation Foundation (NSF).
GASKET RETAINER ANGLE BIN CONSTRUCTION
GASKET A = | Te
Ja
at
и
Au
poor’ NY
GASKET
GASKET
RETAINER ANGLE
— GASKET
REAR CORNER
DIFFERENT RETAINER
ANGLE FOR BIN GASKET.
RUBSERIZED FABRIC HINGE
NIN TO HEAD UNIT GASKET & HOLD DOWN ANGLES
OUTER SHELL GALY. STEEL
LINEAR POLYETHELENE
BIN JOINT COVER STRIP
INSTA LLING HEAD UNIT
Carefully clean the gasketed surfaces on the top of the bin. Remove the bolts securing
the head unit to the base. Peel off the polyethylene film used to protect the underside of
the head unit base, and set the head unit in place on the bin as illustrated in Fig, 4. Use o
screws furnished to attach the 2 positioning angles found nailed to the skids or packed in-
side to the underside of the head unit base. Ends of angle are correctly installed when
front edges are 1" from the front of the base. I angles are installed before setting head
unit on base, do not set unit on bin with angles resting on front rail. The rail will bend
and disrupt door seal.
THE ANGLES ARE IMPORTANT TO KEEP THE HEAD UNIT FROM SHIFTING ON THE
BINS, (NOTE) It may be advisable to connect power supply lines prior to installing head
unit if top can't be removed when cabinet is in position.
RETAINER
CLAMP § SCREW
4
o €
DRAIN FITTING
i
IN HEAD UNIT ~~ toy /2 INCH PIPE
BASE DF SIN ——e — {
1
1
NEOPRENE “oO”
RING SEAL
THROW AWAY
HANDLES ON
HEAD UNIT
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—]————
"0" RINGS
DRAIN FITTING
~~ A FPT SWIVEL DRAIN
FITTING.
ALTERNATE AT DRAIN
RIDGES LOCK INTO
BASE OF BIN.
Fig. 4 O
POSITIONING SPREADER(S) See Fig. 5
The spreader(s) is shipped taped to the base inside of the ice making section. Remove
filler strip used to protect the spreader(s) mounting bracket. The spreader(s) can now be
pushed back in position until it locks in place. The spreader(s) distributes ice over a
larger area but ice still tends to pyramid under the spreader(s). Knock down or spread
out the ice in order to increase bin capacity.
On Flakers with a thermostatic bin control, pull the control bulb down from inside of the
ice chute and clip in place on under side of the spreader. This prevents ice sliding down
spreader from contacting bulb and stopping the unit before the bin is full. See Fig. 5.
Test control action by holding a handful of ice in contact with the control bulb. The unit
should stop in two (2) minutes or less. See Thermostatic Bin Control - page 14. No. 1-B
for delayed action in unit starting.
MOUNTING SPREADER
UNITS WITH ELECTRIC EYE
BIN CONTROL
ICE CHUTE
< FRONT-—
- SPREADER
MOUNTING
BRACKET
MOUNTING CAPILLARY ON UNITS
WITH THERMOSTATIC BIN CONTROL
ICE CHUTE CONTROL CAPILLARY
« FRONT—
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|
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|
BASE 1 | 7
| 41
li
SPREADER —
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(cur BULB IN PLACE
Fig. 5 $
FRONT PANEL REMOVAL (See Fig. 6)
Remove screws near bottom of panel. Using handles, pull panel outward at bottom and
downward.
COMPRESSOR HOLD DOWN BOLTS (See Fig. 19)
Loosen front compressor hold down bolts on the 67 series. This will require removing
the machine screw at the center of the condensing unit base and the tie strip over the
opening where the heat exchanger passes through the center partition. The condensing
unit can now be pulled out. Be sure to check for tube rattles and that fan turns freely
before pushing condensing unit back in. (NOTE) On water cooled models compressor hold
down bolts are accessible without pulling out unit.
WATER SUPPLY
Quality and ice making capacity are affected more by chemistry, temperature and foreign
matter in supply water than any other factor. A survey made of water departments of
large cities all over the country made it obvious that external filters or strainers should
be installed. Such equipment is very effective in improving ice quality and reducing the
frequency of cleaning out the ice making sections.
LOCATION OF FILTER SCREENS
1. External filter is packed inside the ice making section or will be found installed in
water inlet connection. See Connecting Water Supply for installation.
2. The float valve has an internal screen. See Fig. 7.
FLAKER FLOAT ASSEMBLY
COMPRESSION FITTING —
ORIFICE E SCREEN
RETAINER
SCREEN
PLASTIC ORIFICE —
MACHINE SLOTS FOR ADJUSTING
SCREWS
WATER LEVEL
Fig. 6
Fig. 7
CONNECTING WATER SUPPLY
A 1/2" female pipe fitting is provided on the right end of the head unit. On the water
cooled models, this one connection tee's off inside, furnishing both the condenser and ice
making section. If it is necessary or desirable, these parts can be supplied separately by
drilling a hole and running a second line directly to condenser. Provide shut off valve in
the water supply line and install the proper filter (Fig. 1) in the ice making water line
positioned so screen can be removed for cleaning.
Every effort should be made to keep the water supply as cool as possible to improve ice
making capacity. For example, uninsulated water lines should not be run close to heat
sources or in the sun. All water lines supplying ice makers should be thoroughly flushed
before connecting to machine.
DRAIN CONNECTIONS
The fiber glass bins and some head units have 1/2" FIP drain connections. New simplified
separate drain connections are provided from the head unit and metal bin for connection to
vented or trapped drains. Fitting may be either copper with one (1) Neoprene "O" ring,
or brass with two (2) Neoprene "O" rings, and is installed by wetting "O" ring and pushing
fitting into drain. Secure with one or two screws, see Fig. 4. Use standard pipe fittings
to connect to the 1/2" FIP (90° ell) connectors provided or copper sweat joints to connect
to optional copper T (vented) connector. NOTE: Remove fittings and "O" rings before
making sweat connections. The fittings provided rotate 360° without removing the screw
making it simple to connect drain lines. It is essential that drain connections be made so
waste water can't back up into the head unit or bin. On water cooled models a separate
connection is provided for discharging condenser water. All connections are labeled. See
Figs. 1 and 8. We recommend covering all drains with cork insulating tape to prevent
sweating. If head unit and bin drains are tied together through a" T'' connection we sug-
gest using a 3/4" pipe and a stand pipe vented to the atmosphere to prevent water traps.
Drains must be at least 1/2" inside diameter and have 1-1/2" drop per 5 feet of run. If
drains are not close enough to allow drop for proper drainage, or water is to be drained
in a stationary sink higher than ice machine drains, use an automatic condensate disposal
pump such as the model C-12 available from Eddington Metal Specialty Co., Eddington,
Pennsylvania. (Check and follow local plumbing codes)
WATER COOLED
CONDENSER YENT TO
ATMOSPHERE
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HEAD UNIT
RAIN
TTT || 0 “ =
| - — — TEE
DRAIN
CONNECTOR
WITH “O”
Fig. 8
GENERAL REQUIREMENT
All electrical and water supply and drain connections must conform to local codes,
ELECTRICAL CONNECTIONS O
Check nameplate for correct power supply. Remove screws at each end and lift off cabinet
top for access to the wiring box located on the right wall of the compressor compartment.
Provisions are made to run supply leads through the rear wall of the compartment to the
box. All that is necessary is to connect supply leads to bare leads in box. We recom-
mend separate supply lines individually fused be provided for each ice maker. While a
shut off switch close to the cabinet is convenient for service it should be protected from
unauthorized persons. All internal wiring is complete to supply box.
WIRE GAGE AND FUSETRON RATING
115V 230 V
Air Water Air Water
Model Wire Gauge Cooled Cooled Wire Gauge Cooled Cooled
MAF-35 #14 15-A 15-A #14 10-A 10-A
MAF-67 #10 25-A 25-À #14 12-A 12-A
Replace top. Be sure you check and follow local codes.
CHECK LIST PRIOR TO STARTING UNIT
1. Hold down bolts on MAF-67 units should be loosened. See page 6.
2. All water lines supplying ice makers should be thoroughly flushed before con-
necting to machine.
3. Provide at least 3" clearance for air circulation at all grilles. e
4. Unit must set level for proper drainage and operation of the float valve.
5. Drain retainers must be secured to prevent drains being inadvertently loosen-
ed or disconnected. (See Fig. 4)
6. All drain and water supply tubes should be wrapped with insulating material to
prevent condensation dripping on floor.
External screen strainers furnished with unit must be installed in the ice-
making water line so screen can be removed (downward) for cleaning. See
=]
»
Fig. 1.
8. Separate drain must be run for condenser water on water cooled units.
9. Separate drains are recommended for head unit and bin unless drain goes
straight down a minimum of 6" below bin drain fitting, .
10. If head unit and bin drain are plumbed directly into sewer with trap or both
drains are tee'd together it is necessary totee in a stand-pipe 1 ft. high vented
to atmosphere to prevent trapping of drain water. Fig. 8. If head unit and bin
drains drain into a floor sink, a stand pipe is not necessary.
11, Drains over 12 feet long should be avoided.
12, Drains must have enough drop and be wrapped with insulated tape. Refer to
page 7.
13. Clean interior of bin and head unit.
14. Spreader should be installed.
15. Lift off circular cover on each ice making unit.
16, Loosen wing bolts on the metal base and slide locking bars forward. Retighten
enough to hold bars open. See Figs. 10 and 11,
17. Tilt ice making assembly(s) forward enough so that packing and auger assembly
can be pulled out.
18. Remove wrapping and reinstall auger. NOTE: Wet "0" ring before inserting
auger. Make sure auger bottoms in coupling. Replace cover and relock as-
semblies in original position.
19. Remove tape securing float assembly cover and float.
20. Open water valve and allow float enclosure to fill until floatlvalve shuts water off
when chamber is 2/3 full. Bend float arm to adjust water level if required.
21. Turn toggle switch located at the top opening of the compressor compartment
to the LEFT to start ice maker drive motor(s), On models equipped with
electric eye bin controls allow 5 minutes for circuit to warm up and energize
circuits. Unit will not start unless bin control is functioning. If unit still
doesn't start refer to section on Trouble Shooting. If motor(s) run okay turn
switch to extreme RIGHT position to start compressor and fan. Center posi-
tion of switch shuts off entire unit. It takes from 10 to 15 minutes to start
making ice.
22. Collect the first 15 minutes ice production in a pail and discard. This should
prevent residue in machine and connecting lines from getting into the bin.
23. On water cooled models use gauges to check factory head pressure setting of
120 psig. A higher setting will reduce water consumption and ice making
capacity. Turning the valve adjusting screw clockwise raises head pressure
on the AP valve but reduces head pressure on the Penn valve. Either valve
may be used.
24. Shut off water supply. Compressor should stop. Turn on water supply. Unit
should restart. This is to check the high pressure cut-out of water cooled
models or low pressure cut-out of air-cooled models. (NOTE) Time for unit
to stop may vary from 1/2 to 5 minutes.
25. The machine is shipped with 5 or 6 shims between the auger and head unit. If
wetter ice is desired, add more shims. If drier is desired, remove shims.
The head unit unscrews from the auger. See Fig. 9. (NOTE) Dry ice weighs
less and ice making capacity will be reduced.
26. Insert piece of paper along side ice chute to block light on units with electric
eye bin control. Unit should shut off in less than 3 minutes. It should restart
within 2 minutes after paper is removed.
217. Make sure that ice is dropping into the chute(s) and that no water is leakingbe-
fore replacing the front cover,
On new installations residue left in water supply lines frequently plug screens a few days
after starting machine. Frequency of cleaning thereafter depends on type water, etc. See
pages 10 and 12 for cleaning instructions.
STARTING SYSTEM
All valves in the refrigeration system are open when the unit is shipped. Once the check
list above has been completed it should only be necessary to turn the toggle switch to the
right to start making ice. See Item 21 above regarding delay caused by bin control. You
may hear a clattering noise when the compressor first starts. It should only last a few
seconds and is caused by oil or liquid refrigerant in the cylinders. If clattering persists
shut unit off for a few minutes, then restart. Repeat if necessary. While all controls are
set during test operation at the factory, adjustment may be required after installation due
to local conditions.
SERVICING ICE MAKING SECTION
Except for routine cleaning the ice making section has so few functional parts, little main-
tenance need be expected.
10
CLEANING (See Figs. 7, 9, 10 and 11)
1.
Turn off water and turn toggle switch to center or "OFF" position. Allow 10
minutes for ice to melt.
Loosen wing nuts securing flaker head to base, slide locking bars forward.
Tilt flaker head unit far enough forward so that auger can be removed.
(It pulls out from top.)
Loosen wing nuts on either side of ice collector pan, then lift up and twist ice
collector so that opening that normally engages the chute is to the front. Set
head unit back upright.
Remove plastic tubing to drain the float valve.
For "On Location" cleaning, proceed as follows:
a. Replace plastic water line on float and replace auger.
b. Pour cleaning solution (See 7b below for list of cleaning solutions) in
float and let parts soak for 1/2 hour,
€ Remove water line and auger and rinse parts thoroughly.
d. Connect hose, replace auger, turn on water,
Run for 10 minutes collecting ice which should be discarded. Turn
machine off.
f. Turn ice collector to its correct position engaging the ice chute and
tighten wing nuts. Replace cover and start unit. (NOTE) Care should
be used so as not to damage neoprene "O" ring on auger shaft. "O" ring
should be wet when inserted.
®
For "Off Location cleaning, proceed as follows:
a. Remove compression fitting at top of float.
b. Mark float mounting bracket with pencil so it can be replaced in its exact
position. Remove screws and float. Soak in commercial solvents such
as vinegar, Calgon Ice Machine Cleaner, a solution of 3 parts muriatic
acid in 7 parts water, Oakite #32 or Casco Ice Machine Cleaner. All
cleaning and sanitizing solutions must meet local Health Board require-
ments.
с. Use bottle brush and a commercial solvent listed above as required to
clean head unit tube.
d. - Clean the auger assembly by scrubbing with a plastic or non-scratching
scouring pad and detergent or solvent.
e. Rinse all parts thoroughly. |
f. Reassemble all parts and turn on water and power.
g. Run for 10 minutes collecting ice which should be discarded. Turn
machine off.
h. Turn ice collector to its correct position engaging ice chute and tighten
wing nuts. Replace cover and start unit.
++
—— oN TT
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to
1. Gasket Tie Plate
2. Refrigerstios Lines
3. Float Yalve Tank
4, Cover
5. lee Collector Pan
6. Wing Nut fer Callecter Pen Removal
7. Header Unit
8. Woter Inlet te Header
7. T.E.V. Bulb end Clemp
10. Thermostetic Expansion Yalve
11. Reduction Gear Bex
12. Moter
13. Bare
t4. Liquid Line
15. Suction Line
16. Locking Bar
17. Front Base Retainer
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11
CLEANING THE BASE
The one piece molded Cycolac base is easily cleaned with a non-scratching scouring pad
and detergent. The tilt to the drain at the right end permits flushing with clear water to
remove suds. CAUTION: Use care to avoid rinse water getting above the level of the ice
chute opening and draining into the storage bin.
REMOVING FLOAT ASSEMBLY
Shut off power and water supply, remove water inlet line at nut connection at top of float,
and remove plastic tubing on bottom of float. Remove the two screws on the float bracket,
then remove float. Care should be taken in replacing float assembly so as to insure proper
water level in auger. Marking the original location with a pencil makes replacement easy.
REFRIGERATION SYSTEM (See Figs. 12 and 13)
Liquid refrigerant is metered by the expansion valve into a coil of copper tubing tightly
wrapped around the brass ice making tube. The bulb causes the valve to open letting in
refrigerant when this line warms up, and closes shutting off the refrigerant when the line
gets cold. Gas returning to the compressor cools the incoming liquid through the heat ex-
changer formed by soldering the suction and liquid lines together. The gas pressure is
raised by compression in the compressor, then pumped into the condenser where heat is
removed by the air or water. The removal of heat causes the gas to condense forming
liquid to meter to the expansion valve. The compressor will continue to run as long as
the water supply remains on and the bin thermostat is not satisfied.
AIR OR WATER
COOLED CONDENSER
EVAPORATOR
LIQUID LIME
THEA MOSTATIC
EXPANSION VALYE
Fig, 12 AIR OR WATER
COOLED CONDENSER
EV RATORS IN SER]
THERMOSTATIC
EXPANSION
VALVE
„”
CONTROL
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e
CLAMP
SUCTION LINE
COMPRESSOR
Fig. 13
ICE MAKING CYCLE
Water freezes to the inner surfaces of the brass evaporator column. The rotating auger
shaves off a thin layer which it carries up to the top edge of the column. The flakes are
compressed by the head as they pass through the opening into the collector tray. A re-
volving sweep arm pushes the flakes into the tube leading to the storage bin. Water
maintains the same level in the float chamber and the evaporator assembly. Be sure
there are no air bubbles or kinks in the plastic tube(s) connecting the float and evaporator.
FLAKER DRIVE
The ice making auger revolves at a constant rate of 6 RPM driven by the gear reduction
unit. A brass collar is secured to the shaft of the drive unit with a pin through both. The
square shaft of the auger bottoms in the square hole in the top of the brass collar. See
Fig. 14. A splined stainless steel coupling is optional.
NN AUGER
ALIGNING
EVAPORATOR
UNIT.
+ Za X.0157 BRASS
SHIM STRIPS (4)
WATER SEAL
GROMMET
COLLECTOR
wn PAN MOUNTING
OUTER JACKET
OF EVAPORATOR
DN
REFRIGERATION LINES
CASTING
BRASS COUPLING
—
AUGER
4
RETAINER
PIN
=>] — GEAR DRIVE
NEOPRENE — — SHAFT
To DN “O” RING ‘|
= VA Te — `
BRASS COUPLING ‘
GUIDE RING | LEGS OF
ий
GUIDE RING CAST CAST IN BASE EVAPORATOR CASTING
IN BASE, |
— — RETAINER PIN
GEAR DRIVE SHAFT
' 1
J 1
/ i [
Locos OF EVAPORATOR CASTING”
0
Fig. 14
13
14
The gear assembly and motor are a single unit factory assembled and lifetime lubricated.
Because of the special tools required, no attempt should be made to disassemble or lubri-
cate the gear drive. Should service be required, return original and request an exchange
unit. See Changing Gear Drive Unit on page 30.
The weight of the auger rides on the thrust bearing in the gear box. 1/4" below auger
blades is a Neoprene "O" ring which makes the water seal between the auger shaft and the
brass casing. There is . 040" diameter or . 020" radius clearance between the auger and
the brass tube. When the water starts to freeze it centers the auger, the ice acting as the
upper bearing.
A harvest arm is attached to the auger head to push ice to the ice chute. The stainless
steel auger head squeezes or compresses the ice, eliminating the free water. If a soft wet
ice is desired, as for snow cones, washers may be added between the head and auger. See
Fig. 9.
A grommet around the top of the brass ice making tube makes a water tight seal to the ice
collector pan.
The ice chute is fastened by a wing nut to a channel running the length of the freezing com-
partment behind the header unit and can be removed without removing the top of the cabi-
net.
The water level in the brass tube can be changed by loosening the two screws securing the
float assembly bracket and raising or lowering the float assembly as needed to bring water
level to 1-1/8" below top of brass tube.
CONTROL FUNCTIONS AND SETTINGS
I. Thermostatic Bin Control. Ranco Type A-10, See Fig. 15.
No Adjustment from Cut In Cut Out
front knob 459 34°
Range Adjustment Differential Adjustment
Remove fiber cover. Is on terminal end.
Turn screw C. C.W, to set range colder Turn C. C. W. to widen
Range-Changes both "CUT-IN" and differential. Differential
"CUT-OUT" affect "CUT-IN" only.
a. When the ice builds up in the bin and covers the sensing element of the bin
control, the normally open solenoid closes, shutting off the flow of refrigerant
to the evaporator.
b. The compressor keeps running, pumping down the unit until the suction pres-
sure reaches around five psig. The entire system is then shut off by the low
pressure control and will not start until the suction pressures reach 34 to 37
psig. This eliminates short cycling and the unit trying to start with the auger
frozen. Because suction pressure drops when the water supply is interrupted,
the low pressure switch protects the air-cooled models against interruptions
in the water supply.
II. Electric Eye Bin Control - Ranco Е-20. See Fig. 11.
Starting with Serial No. 37100356516101 the Flakers use an Electric Eye Bin level
Control. -
NO KNOB ADTUSTMENT
TURM SCREW CCW TO
JEAN SET RANGE COLDER
TURN CCW TO
SS
N
* DIFFERENTIAL
Fig. 15
The Electric Eye consists of a Lamp assembly, Part No. 23-0046, Sensor assembly,
Part No. 23-0047, and Power assembly, Part No. 23-0045. The Power assembly in- |
corporates an ON-OFF switch and Light Intensity Switch on the face of it, and Thermal
Relay at the bottom. The power Assembly has either 115 or 230 volts A.C. input and
14 volts D. C. output. The electrical connections on the Power Assembly for the Light
and Sensor assemblies are polarized. Care should be exercised to connect the proper
leads to the right terminals if any parts are changed. (See 6-A, Page 17.)
The Photocel Power Pack of the Electric Eye is mounted on the rear wall to the left in
the ice making compartment, encased in a protective cover. If the Light Beam switch
is in the "ON" position, the Lamp beam strikes the Sensor assembly, and the parallel
light beam is uninterrupted, the control should function properly.
OPERATION
A.
The light beam is directed through the ice chute just above the base.Whenice
pyramids up into the ice chute, this beam of light is broken and the electrical
circuit supplying the solenoid in the liquid line is broken. It takes about 2 min-
utes for the bin control to react. This time delay prevents nuisance trips due
to chips of ice falling through the light beam or by flickering of the lamp. The
ON-OFF switch should be ON during operation.
(See No. I '"B'' on Page 14)
Adjust Light Intensity switch CCW for brighter light, and CW for dimmer. The
light should be just bright enough to operate as full bright shortens the life of the
bulb. Life expectancy of this control is a minimum of 100, 000 operations. Lamp
replacement required approximately every 4 years.
There is a 2 to 5 minute delay in starting the ice flaker while the Electric Eye
light warms up.
NOTE: The compressor may start, run a short period, then shut off when system
if first energized due to lack of warm up.
The low pressure control restarts the unit when the auger temperature 15 above freezing.
This delay may be five (5) to thirty (30) minutes.
FUNCTIONAL CHECK
1.
Interrupt parallel light beam with cardboard or hand. Lamp should visibly dim,
15
16
then brighten when interruption is removed.
2, If lamp does not dim and brighten when checked, possible causes and corrections ©
are: ;
А. Incorrect alignment of Lamp and Sensor.
a. Align opposite and facing each other so beam strikes Sensor.
B. Defective Sensor assembly.
a. Replace assembly
C. Defective Power assembly
a. Replace assembly.
3. If the lamp does not burn, possible causes and corrections are:
A. Burned out bulb.
a. Replace with new bulb Manitowoc Part No. 25-0154. (A No. 1474 or
No. 1487 bulb may be purchased locally at a radio or electronic
supply house.)
To replace bulb, proceed as follows:
1. Tip out head unit and remove ice chute as previously described.
2. Remove nuts and bolts that secure Lamp assembly to mounting bracket then
remove assembly. |
3. Bend back rubber retainer to remove glass face,
4. Unscrew bulb to replace.
5. Assemble parts in reverse order.
B. Defective Lamp assembly
a. Replace assembly as follows:
1. Follow steps (1) and (2) above (replacing bulb). |
2. Remove cover and Power assembly. e
3. Disconnect Lamp assembly wiring at quick disconnects on left side of
Power assembly. NOTE. Terminals are polarized so be sure to put
quick disconnects on proper terminals. (See 6-A, page 17)
4. Replace parts in reverse order.
C. Power not on.
a. Turn on line power.
b. Check line fuses
c. Turn on switch or Power assembly.
D. Defective switch (open)
a. Replace Power assembly.
E. Defective light intensity adjustment rheostat.
a. Replace Power assembly.
F. Defective Power assembly.
a. Replace Power assembly
4, With the Light and Sensor assemblies working as listed above, the thermal relay
should start the compressor after a nominal delay of 2 to 5 minutes. If the com-
pressor does not start, possible causes and corrections are:
A. Check line voltage.
a. Voltage should be between 115 or 230 volts = 10%.
В. Ii line voltage is OK, Power assembly thermal relay is bad.
a. Change Power assembly. €
5. If the compressor does not shut off after a nominal delay when the ice bin is full,
, possible causes and corrections are:
2 A. Defective relay.
a. Replace Power assembly.
B. Defective Sensor
a. Replace Sensor assembly in same manner as changing Lamp assembly.
6. To change Power assembly, remove cover, then assembly from wall. Quick dis-
connects are on left side of assembly. Be sure to connect wiring to proper con-
nections as terminals are polarized.
a. Tin plated quick connect goes on ribbed lead and brass quick connect goes on
plain lead of Sensor and Lamp assemblies.
| — = — — — = — — —
III Tg
J
|
|
| |
49% HEAD О.А.
— 48 7 HEAD BODY |
|
| L |
| === GRILLES - ON AIR |
—- COOLED UNITS ONLY
19% 395 —= af FRONT - END
= E BACK
Smari e
| = .
5 to Ï
29 % О.А:
7 48 4
3 20 79 SMALL
3112 LARGE
31 L 45 !2 LARGE BIN
| | 46 = SMALL BIN |
L ] L ; ]
| 21% | 447 |
TT] IN = ||
Fig. 16
RANCO TYPE “0” LOW PRESSURE CONTROL
CUT IN LBS,
NI Ed Ranco
=|:= 010-1402
5 |=
ROBERT SHAW
ТУРЕ АР - 20
LOW PRESSURE CONTROL
Fig. 17 Fig. 18
17
18
Ш.
IV.
VI.
VII.
Low Pressure Control - Either Ranco Type "0" or Robert Shaw Type AP20. See
Figs. 17 and 18.
This control cuts out at about 5 psig and cuts in automatically at about 35 psig.
Controls are factory set and should not require adjustment.
High Pressure Cut-Out - Ranco Type G-23.
Operation of any water cooled job is automatically stopped any time the discharge
pressure reaches 195#. It automatically restarts when pressures drop to 145#.
Control is not adjustable.
Safety switch for top of ice collector. See Figs. 11 and 19.
a. A micro switch actuated by an arm extending over the lid of the ice collector
shuts off the entire system if the ice backs into the head due to malfunction of
the electric eye or thermostatic bin control, or accidental blocking of the ice
chute. Once ice melts or passes through the chute the lid should close and
the system restart. Tray may or may not reposition itself after it is raised.
Be sure cover is in place while checking unit operation.
b. Adjust switch arm as follows:
1. Loosen Allen set screw of collar on rod in micro switch enclosure.
2, With rod in position on ice collector pan lid, move collar until switch
points close.
3. Tighten Allen set screw and try arm manually, readjusting as needed.
Low Pressure Cut-Out -Ranco Type G-20 (Optional on air cooled models).
Factory set to stop compressor when water pressure drops below 7 psig. Restarts
compressor when water pressure reaches 14 psig. (Non-adjustable)
Main Power Toggle Switch.
The main power toggle switch is located on a panel above the condensing unit. Cen-
ter position is OFF. Left position runs the flaker drive unit. Right position runs
the compressor, fan motor, and flaker drive.
MICRO SWITCH
OPERATING LEVER
LOW PRESSURE
CONTRO
COMPRESSOR
DOWN BOLTS
Fig. 19
Ë e de
CHECKING COMPRESSOR
Front seat the suction service valve. Adjust water valve or block condenser until head
pressure is at least 150 psig. Suction pressure should pull down to 25 inches of vacuum
in a few minutes and hold vacuum three to five minutes. If pressure rises immediately,
replace valve plate on the MAF-67 Models, or change the compressor on the MAF-35
Models.
Check compressor motor for electrical continuity and open or grounded circuits. If you
find any, replace the compressor. If not, proceed as follows: If compressor won't start
connect test set (Fig. 33) to compressor terminals. Depress starting button (not over 5
seconds). When compressor starts, release button. Compressor should continue to run.
If compressor won't start or keep running, replace it. If itstarts and keeps running deter -
mine by process of elimination whether to replace the relay, overload, or capacitor. Do
not overlook the possibility of a defective wire.
CHANGING COMPRESSORS
1. 1/3 H. P. Copelaweld on MAF-35. See Figs. 20, 21, 22 and 23.
Shut off power supply. Attach-gauge manifold to service valves and bleed off charge.
Unsolder or cut lines on compressor. Disconnect wiring and change compressor either
resoldering lines or using flare fitting. For burned out compressor, see Cleaning
Contaminated Systems. Replace drier, leak check, evacuate and charge system.
2, Copelematic on MAF-67. See Figs. 24 and 25.
Shut off power supply. Attach gauge manifold to high and low side service valves. If
compressor is not burned out and system not contaminated, service valves may be
front seated, the wiring disconnected, the compressor body changed and refrigerant
added if needed. If the compressor is burned out, bleed off charge, disconnect wiring,
change the compressor and clean complete system.
See next paragraphs for Cleaning Contaminated Systems, Evacuations and Charging
System.
MAF . 15. W WITH STANDARD PRODUCTS CONDENSER
A
Capacitor Start
10. Micro Switch
11. Supply Box
= ==
©
MAF .35-A
=
5
}
ESTA,
2 El:
PEE EET
revoca
MAR . 35
‚ #
MALSTED-MITCHELL CONDENSER
= e FT чё
Sere
Supply Bx
Topale Jwiteh
Selonald
Pa Y Do 14
= e
2 Ju
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333,33
en
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Fig. 23
Fig. 24
20
CLEANING CONTAMINATED SYSTEM
Remove Compressor. Flush liquid freon (F-11 preferred) through the system. Remove
the original dryer and install a clean up type dryer. Install replacement compressor and
evacuate the system thoroughly for at least one hour. After 24 hours operation replace
clean up dryer with new regular dryer.
EVACUATING AND CHARGING
Run system long enough to heat up compressor slightly (10 minutes). Connect evacuating
tubes to the high and low side service valves using a manifold or T connections for high
and low side gauges. Turn valves in, two full turns. Replace valve caps. Run separate
evacuating pump for at least one hour. Connect a service drum to the low side service
valve through the manifold or by back seatingboth service valves and removing the evacua-
ting tube. After opening valve on tank, crack line at compressor to bleed off air, then re-
tighten. Open service valves and allow gas to enter system until pressure in tank and
system equalize. Start compressor and by closing off (front seating) the suction service
valve draw gas into the system. Use calibrated charging cylinder, or weigh proper charge
into drum as listed in Table 1 page 31.
CHANGING DRYER
Discharge system through service valve ports. Remove original dryer, then quickly un-
seal the replacement and install, check for leaks, then evacuate and recharge system.
CHANGING EXPANSION VALVE
Discharge system through service valve ports. Unclamp bulb and disconnect flared fit-
tings. Make sure parts are dry to keep moisture out of system. Install replacement ex-
pansion valve exactly as original was installed. Replace dryer, then check for leaks and
evacuate and recharge system.
SETTING SUPERHEAT
The replacement valve is factory set for 8 degrees superheat and should normally require
no adjustment. Should adjustment be required determine which valve system has, and pro-
ceed as follows:
ALCO MODEL B1/2FW55
This valve cannot be adjusted and should be replaced if defective.
DETROIT MODEL 717
Thermostatic expansion valve internally adjustable. When it is necessary to change
the superheat setting in the field, the adjustment can be made through the inlet con-
nection. Remove the strainer and insert an Allen set screw wrench into the adjust-
ment nut. One turn of the superheat adjustment changes the setting approximately
four degrees. Looking into the bottom of the valve, turning the adjustment screw
clockwise increases the superheat setting.
CONTROL CO, OF AMERICAN AP207C
Remove bottom cap and turn stem clockwise to increase superheat and counter-
clockwise to decrease superheat.
22
REPLACING WATER REGULATING VALVE
1.
1. Shut off water supply and drain system.
2. Front seat both service valves on the Copelmatic units and only the gas in the com-
pressor head and capillary line to the water valve will be lost.
3. Disconnect water pipe and bellows flare tube connections. Install replacement as
original was installed, vertically with bellows down,
4. Open service valves and water supply. Check for leaks.
5. Add gas if necessary.
SETTING WATER REGULATING VALVE (Factory setting 120 168.) See Fig. 26.
The capillary connection to the compressor dome causes a rise in head pressure to open
the water valve allowing more cooling water into the condenser which reduces the head
pressure. The reduced head pressure causes the valve to reduce the flow of cooling
water. The valve action maintains head pressure at a constant level.
On the Penn No. 246 water valve, the head pressure can be raised by turning the adjusting
screw counter-clockwise, and lowered by turning the adjusting screw clockwise. On the
A-P No. 65A water valve, the head pressure can be raised by turning the adjusting screw
clockwise, and lowered by turning the adjusting screw counter-clockwise. Once set, the
valve should need no further adjusting. (NOTE) Water usage can be reduced by setting
valve for a higher head pressure, but ice making capacity will be reduced. To manually
flush the Penn valve, insert screwdrivers or similar tools under both sides of main spring,
and lift upwards.
ADJUSTING SCREW
4 ADJUSTING SCREW TO RAISE PRESSURE TURN C.W.
1 y TO LOWER PRESSURE TURN C.C.W.
DIRECTION OF
WATER FLOW
«=== y Ya FIPT
ARROW INDICATES
WATER FLOW
MOUNT BELLOWS
DOWN
PENN 246
Fig, 26
WATER COOLED CONDENSER
А.
Operation
Water cooled condensers lose efficiency due to a build up of mineral deposits on the
inner surfaces, and periodically have to be cleaned. Frequency of cleaning will vary
with local water conditions. The symptoms of a limed-up condenser are loss of ice
capacity, the necessity for adjusting water valve for more water flow and inability to
maintain normal operating head pressures. See Table 1. For proper operation of
water valve, see Page 31. See Table 1 for normal water outlet temperature.
Cleaning
Upon ascertaining that condenser needs cleaning, proceed as follows: Shut off water
supply, disconnect lines at A and B. See Figs. 21, 22, 23 and 25, Pages 19 and 20.
On the American Standard condenser pump a solution of three parts muriatic acid and
seven parts water or commercial solvent through condenser until lime and scale is
removed. On the Halstead-Mitchell condenser the manifolds can be removed, and the
water tubes rodded out. Flush thoroughly with fresh water after cleaning, then rc-
assemble.
SOLENOID VALVE - (AP-67FS2 or AP-R291-A)
During the ice making or running times the solenoid is energized and open, and is de-
energized and closed when the bin control stops the ice making. To change valve body,
shut off power supply, attach gauge manifold to service valves and bleed off charge. Dis-
connect wiring and flare nuts, and change solenoid. Replace drier, leak check, evacuate
and charge system.
DOTTED PORTION | _ _ Megan = — — — -
FOR DOUBLE UNIT À DAIVE_ | !
® micro sw. /
GH PRESSURE ]
® Ht CUTOUT
Glow PRESSURE
cutout
- | FAN THERMOSTATIC BIN CONTROL
| maın SUPPLY
4° SWITCH
DOTTED PORTION | 4
FOR DOUBLE UNIT |.» L DRIVE 1
GEAR
DRIVE
(1) micro sw. /
] (2) BIN CONTROL
©) WATER SW. la
THERMOSTATIC BIN CONTROL (OPTIONAL) ] BRANCH FUSE SIZE
(D Low PRESSURE MAF-35 MAF 67
MSY, CUS À. 20A
O cuTouT SOL ov. --" 15 А.
COMPR.” | MAIN SUPPLY : 230V.
„” „” SWITCH
a a
SUPPLY
BRANCH FUSE $11 Е
MAF. 35
маст Fig. 27
115 Y. 115 А. 20A.
230Y. -- “= I5A.
| 0
SUPPLY
Fig. 28
23
COW VOLTAGE ELECTRIC EYE BIN CONTROL 115-Y AIR COOLED
LAMP
TURAN
SCREW ADJUST C.C.w. TO
MENT FOR LOW INCREASE
VOLTAGE LAME. LIGHT,
DOTTED PORTION br me
FOR DOUBLE UNIT.
— GEAR LL _
_DRIVE | !
SWITCH
BIN CONTROL
Fig, 29 ELECTRIC EYE
Grow PRESSURE
CUTOUT
(D)MicRo SwiTCH
24 YX BIN CONTROL
[sou | :
BRANCH FUSE SIZE
MAF-3S MAF-67
SUPPLY |115 м. ISA 20.
Low VOLTAGE ELECTRIC EYE BIN CONTROL 115.Y WATER COOLED
С)
К
TURN
SCREW ADIUST- C.C w. TO
MENT FOR LOW INCREASE
VOLTAGE LAMP. ) LIGHT.
N
DOTTED PORTION
FOR DOUBLE UNIT.
~Jdoean I_ _
i ORE 4 1
SWITCH
BIN CONTROL
ÉLECTAIC EYE
Fig. 30
LOW PRESSURE
CUTOUT
© HIGH PRESSURE }
CUTOUT
(Dmicro SwITCH
24. 49 BIN CONTROL
| BRANCH FUSE SIZE
MAE-35 MAF-67
SUPPLY 115% ISA. ZOA.
OLTAGE ELECTRIC EYE BIN CONTROL 230-Y AIR COOLED
TURN
SCREW ADJUST C.CW. To
MENT FOR LOW INCREASE
VOLTAGE LAMP. o LIGHT.
7 MAIN SUPPLY
WITCH
DOTTED PORTION
FOR DOUBLE UNIT.
|L--) GEAR I_. _
SWITCH y ORIVE | !
Î
ELECTRIC EYE
Fig. 31 Low PRESSURE >
CUTOUT
12.39]
; : TRANSFORMER
(Dmicero SWITCH
~
3 BIN CONTROL
| | BRANCH FUSE SIZE
230Y. 15 AMP.
SUPPLY
24
LOW VOLTAGE
LAMP ELECTRIC EYE BIN CONTROL 230-V WATER COOLED
schcw aorusr. | | COW ro @
VOLTAGE LAMP. LIGHT. И Pi Ma SUPPLY
DOTTED PORTION e
FOR OOUBLE UNIT. NN.
SWITCH
ELECTRIC EYE
(Loy PRESSURE > | Fig, 32
u
Oe | cat TRANSFORMER
(micro SWITCH 115
2& A BIN CONTROL
Es
| | BRANCH FUSE SIZE
230 wv. 1S Amp.
SUPPLY
FUSETRON MALE PLUG
COMMON + | a
CONNECT TO T= — (
COMPRESSOR RUN |
TERMINALS {> q
START N
-
MRR / NORMALLY OPEN
CONNECT TO Com | PUSH BUTTON START SWITCH
CAPACITOR
I um TOGGLE SWITCH SHOULD
LEFT CLOSED WHEN
INSULATED ALLIGATOR CLIPS CAPAEITOR 15 NOT USED.
Fig. 33
25
26
TROUBLE SHOOTING
Complaint
Unit won't run
Insufficient Ice
Possible Causes
. Main switch off
. No power to unit
. Water supply turned off
. Out on bin control
. Out on Micro switch
Out on low pressure
control
. Solenoid off
Condenser air restricted
Condenser water
insufficient
Inlet water too warm
Defective condenser
fan motor
LTPP
>
Corrections
Turn on
Turn on switch
Replace fuse
Repair broken wires
Turn on valve
Repair or clean out blocked
supply line.
Wait for pressure in system
to reach 35 psig. (When eva-
porator defrosts)
Replace defective bin control
or bin control parts.
Make sure lid of collector pan
is down and switch arm is
resting on it.
Adjust switch arm.
Wait for evaporator to defrost
and pressure in system to
reach 35 psig.
. Remove any obstruction in
water supply
Main switch must be on
Make sure bin control is not
open
Replace defective solenoid
coil.
Clean condenser
. Remove inlet grill
Move unit or obstructions to
get more air.
Adjust water valve
. Flush water valve
Clean condenser
. Move supply line from heat
sources
Get larger capacity head unit
. Install pre-chiller to cool
inlet water
Lubricate or replace fan
motor
Complaint
Power Consumption
High
Using too much water
с.
Possible Causes
Unit short of gas
Bin control malfunction
Low pressure control
malfunction
Inefficient compressor
Expansion valve
malfunction
Undersized head unit
Door loose or off
Insufficent air supply
. Water supply warm
Condensing temperature
high
Heavy usage
"O" ring on auger leaking
Defective water valve
. Inefficient condenser
(On water cooled models)
. High Ambient
a.
cop
ВО ор
P
>
о
Correction
Find and repair leak, then
add gas.
Adjust or replace control
Adjust or replace control
Change valve plate
Replace compressor
. Correct low voltage
Clean
. Reset super heat on adjust-
able valves
. Replace
Replace with larger head unit
Get second unit
Replace or tighten
Readjust
Clean condenser
Remove obstruction
Replace fan mctor
Move to cooler location
Install pre-cooler
Relocate supply line
Reset water valve
Power flush and clean water
valve 7
. Reduce water temperature
. Clean condenser
Provide excess storage and
produce during slack periods
Get larger head unit
Install pre-chiller
Replace "O" ring
Clean and readjust valve
. Replace valve
Clean out lime deposits
Reset water valve
. Replace condenser
Relocate unit
Provide more air circulation
27
Complaint Possible Causes Correction
e. Cycling too often a. Reset thermostatic bin control
b. Short of refrigerant and shut-
ting off on pressure control.
Repair leak and recharge.
f. Water leak a. Find leak and repair
g. Float valve incorrectly a. Adjust float level
set
Compressor Cycles a. Insufficent water a. Clean and reset water valve
on Overload b. Clean condenser
c. Increase size of supply line
d. Repair kinked supply line
e. Clean water strainer
f. Clean float valve
b. High water temperature a. Install pre-chiller
b. Relocate water lines
c. Defective overload a. Replace
d. Defective relay b. Replace
e. Defective capacitor a. Replace
f. Air in system a. Determine cause and repair
b. Evacuate and recharge
g. Tight compressor a. Replace e
h. Compressor short of oil a. Add oil
a. Lubricate
b. Replace fan motor
c. Remove obstruction
i. Fan motor stuck
j. Low voltage a. Check wire size of supply
b. Run separate lines
Noisy a. Chattering water valve a. Clean and reset
b. Change valve
b. High head pressure
1. On water cooled units a. Clean and reset water valve
b. Replace water valve
c, Clean condenser
2. On air cooled units a. Change fan motor
b. Clean condenser
c. Check clearance at grills
c. Water level low a. Reset float level
d. Trap in water line from a. Remove trap by making
float to header unit gradual drop in line
causing air bubbles
Complaint
Wet Soft Ice
Hard Ice and Unit
Squeaks
Compressor runs but
gear motor does not
Compressor and gear
motor run, but auger
does not turn
Possible Causes
e. Compressing ice too much
a. Water level high
b. Excess clearance between
top of tube and head
a. Insufficient clearance between
top of tube and head.
b. Water level low
c. Water supply line kinked
or has air bubbles in it
d. Tube needs cleaning
a. Check for power to motor
b. Bad toggle switch
c. Damaged wiring
d. Thermal overload in
motor bad
a. Broken shaft on auger
b. Sheared pin on brass
coupling
C. Broken pin on drive
shaft inside reduction
gear unit
Correction
. Add shim between head and
auger
. Lower float assembly
. Adjust float
. Remove spacers
. Add spacers
. Raise float assembly
. Adjust float
. Straighten tube so it pitches
downhill all the way into
base of evaporator
. See "Cleaning Page 10
. Replace switch
. Check out and replace
. Replace motor and gear
drive unit
. Replace auger and coupling
. Replace pin and/or coupling
. Replace motor gear drive
unit
29
30
CHANGING GEAR DRIVE UNIT (Figs. 10, 11 and 14)
1,
2.
10.
11.
12,
13.
14,
15.
16,
Shut off power and water supply. Remove front panel and disconnect gear drive motor.
(a) If room is available above head unit, remove top and tip micro switch arm back
out of the way.
(b) If room is not available above head unit, loosen wing bolts on the metal base, and
slide locking bars forward. Retighten to hold bars open. Tilt ice making assembly
forward and put block under base plate to hold unit in the tipped out position,
Lift off ice collector pan lid, loosen wing nuts on either side of ice collector pan and
lift off.
Remove auger.
Remove 4 nuts securing evaporator base casting to reduction gear housing.
Remove self tapping machine screws from front and rear ""Z'" clamps that hold gear
drive unit on base plate.
Raise or pull out evaporator assembly high enough to clear the 4 studs on the gear
housing, then remove gear drive and motor assembly. CAUTION: If unit is tipped
out, use care in removing "Z" clamps as gear drive and motor assembly is quite
heavy.
Gently tap out shear pin in brass drive coupling using a back up wedge or weight on
opposite side to prevent bearing damage on gear drive shaft. CAUTION: Do not run
drill through hole in coupling or shaft, as holes are precisely sized.
Assemble brass coupling on drive shaft of new unit and gently tap shear pin into
position flush on each side, using same procedure and care as on removal,
Using outside power, check rotation of gear drive shaft. The normal rotation of the
shaft is counter-clockwise, looking at the top. In case the motor manufacturer wired
the motor with the wrong rotation, reverse the red and black leads.
Remove 4 studs from old unit and screw into place on new unit.
Replace gear drive and motor assembly on base plate and secure with "Z'" clamps.
Set evaporator assembly back into position, tighten nuts on studs finger tight, then
back off nuts 1/2 turn.
Insert the four (4) 1/4"x.015" brass shims equadistant between the 4 grooves cut in
the evaporator tube and not more than 1/8" up from the bottom.
Insert auger to align evaporator assembly with brass coupling then tighten nuts on
base casting studs.
Remove auger, shims, then reassemble all parts in reverse order of removal.except
shims.
REPLACING EVAPORATOR ASSEMBLY (Figs. 10, 11 and 14)
1.
2
3
4,
5
6
O O —
10.
Shut off power and water supply and remove front panel.
Follow steps 2, 3 and 4 of Changing Gear Drive Unit.
. Remove insulating tape on refrigeration lines from evaporator outward 6".
Attach gauge manifold and bleed off charge.
Cut or unsolder lines at evaporator.
Remove 4 nuts securing evaporator base casting to reduction gear housing and Lift off
evaporator assembly.
Follow steps 13, 14, 15 and 16 of Changing Gear Drive Unit.
Swage refrigeration lines, connect, and solder gas tight.
Install new drier, leak check, evacuate and charge system.
Replace insulating tape on lines.
31
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TABLE IL
REFRIGERATION SYSTEM PARTS
VOLTAGE 0 MAF35A MAF35W MAF67A MAF 6TW
Compressor 115 14-0108 14-0108 14-0101 14-0089
Compressor 230 14-0102 14-0103
Relay 115 15-0158 15-0158 15-0154 15-0154
Relay 230 15-0161 15-0161
Starting Capacitor 115 15-0156 15-0156 15-0153 15-0153
Starting Capacitor 230 15-0163 15-0163
Overload Protector 115 (In Relay) (In Relay) 15-0144 15-0144
Overload Protector 230 15-0132 15-0132
Fan Motor 115 24-0131 24-0132
Fan Motor 230 24-0134
Dryer (Drymaster Mod. 8) 12-3004 12-3004 12-3004 12-3004
Water Valve - PENN, No. 246 or AP No. 65A 13-6040 | 13-6040
Therm. Exp. Valve AP-207-C 1/2 Ton 13-6053 13-6053 13-6053 13-6053
Thermostatic - RANCO-A-10 23-5053 23-5053 23-5053 23-5053
Bin Controls Electric Eye - RANCO-E-20 115 23-0042 23-0042 23-0042 23-0042
Electric Eye - RANCO-E-20 230 23-0043 23-0043
Power Assy. (14-V Output) 115 23-0045 23-0045 23-0045 23-0045
Power Assy. (14-V Output) 230 23-0048 23-0048
Lamp Assy. 23-0046 23-0046 23-0046 23-0046
Sensor Assy. 23-0047 23-0047 23-0047 23-0047
Quick Connect - Tin Plated 25-0152 25-0152 25-0152 25-0152
Quick Connect - Brass 20-0153 25-0153 25-0153 25-0153
Bulb (#1487 - 14 V) 25-0154 25-0154 25-0154 25-0154
Transformer - GE9T51Y3 230 Input, 115 Output 24-0173 24-0173 24-0173 24-0173
High Pressure - Cut-Out RANCO G-23 23-5045 23-5045
Low Pressure - Cut-out RANCO G-20 (Optional) 23-5052 23-5052
Low Pressure Switch - RANCO "OQ" or ROBERT SHAW 24-0168 24-0168 24-0168 24-0168
Toggle Switch - DPDT- Center OFF 23-0033 23-0033 23-0033 23-0033
Float Valve 13-6050 13-6050 13-6050 13-6050
Micro Switch - Cherry El3-00H 23-0039 23-0039 23-0039 23-0039
Flaker Motor and Reduction Gear Assembly 1/4 H, P, 115 24-0080 24-0080 24-0080 24-0080
Flaker Motor and Reduction Gear Assembly 1/4 H,P. 230 24-0098 24-0098
Flaker Motor and Reduction Gear Assembly 1/6 H. P, 115 24-0141 24-0141 24-0141 24-0141
Flaker Motor and Reduction Gear Assembly 1/6 H.P. 230 24-0142 24-0142
Solenoid AP R-291 115 24-0176 24-0176 24-0176 24-0176
Solenoid AP R-291 230 24-0177 24-0177 24-0177 24-0177
"O" Ring Auger Shaft 43-0094 43-0094 43-0094 43-0094
"QO" Ring Drain Adapter 43-0113 43-0113 43-0113 43-0113
Drain Adapter 13-0033 13-0033 13-0033 13-0033
Compression Valve (Water Supply) 13-6056 13-6056 13-6056 13-6056
Condenser - Air 11-5010 11-5009
Condenser - Water J-51 or J-98 11-0014 11-0014
32
TABLE IH
co POUNDS ICE PER 24 HOURS POUNDS ICE PER 24 HOURS co
o Aa Un a: o O = pea N N WwW
$ $ 8 8 8 $8 & 8 8 8 s 8 8
N
07
creme | 00
05 07
N.
/
/
LY
On
en o
: / E: | | Е
> o o 2 © o
=8 o < ©
> / / EE [1]
> ° / F = Nu >
7 Y $, = © ¿o
т A) > 5 7
58 — Se >
2/7 7 3/1 Ill |
78 и 8
3 / / > |
= 8 3 AMBIENT TEMP" (°F) © = 8 S
AMBIENT TEMP. (°F)
POUNDS ICE PER 24 HOURS POUNDS ICE PER 24 HOURS
EN a QU» On o O N — — ND N
© 3 e 8 © 3 8 3 о 3 3 e ©
, LM x ///
| / / / /
2 Y 2
wn a
3 7 ES И e
Zo A Q Zo ©
< 7 z < И z
2 LA > Zw >
3° // f & хо / / &
+ A N и ©
= / = Ée / €
ve / ‚о ©
= // do Й
3 7 © |
9 / 3 ZEN
O = SY AMBIENT TEMP. (°F) © 8S AMBIENT TEMP. (°F)
33
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