Ford 2011 Escape Hybrid Automobile User Manual

a Division of ITW (UK) Ltd.
F/FCI/SM/02/03
Service Manual
Tel: 01553 691122
Fax: 01553 691447
Website: www.fosterrefrigerator.co.uk
E-mail: sales@foster-uk.com
Service Manual
Foster Refrigerator
Oldmedow Road, King’s Lynn,
Norfolk PE30 4JU
England
F20, F40, F60, F85
&
FCI20, FCI30, FCI40
FCI60, FCI85
Cube Ice Maker
Notes
Foster Ice Cuber Machine
CONTENTS
Page
1.
General Information and Installation Instructions
1.1
Introduction
1.2
Unpacking and Inspection
1.3
Location and Leveling
1.4
Water Supply and Drain Connections
1.5
Final Checklist
1.6
Installation Practice
2
2
2
2
2-3
3
3
2.
3.
F20 and F40 Technical Data and Operating Instructions
F60 and F85 Technical Data and Operating Instructions
3.2
Cleaning/Rinsing For F20, F40, F60, F85
3.3
F20 F40, F60 F85, Wiring Diagrams
4
5-6
6
7
4.
5.
6.
8
8-9
9-11
8.
Technical Specification R22 Machines FCI 20, 30, 40, 60, 85
Operating Instructions
Principles of Operation
Wiring Diagrams
Dip Switch Positions And Settings
Plus Dip Switch Settings for FCI 20,30, R134A Machines
Circuit Board and Component Sequence of Operation
9.
10.
11.
12.
13.
Technical Specification R134A Machines FCI 40,60,85
Operating Instructions
Principles of Operation
Components Description
Dip Switch Settings
7.
14. Wiring Diagram
15. Circuit Board and Component Sequence of Operation
16. Maintenance and Cleaning Instructions All Models
1
12
13
14
14-16
16-17
17-18
18
19
20
21-22
1.
1.1
General Information and Installation Instructions
Notes
Introduction
The Electronic Cubers are quality designed, engineered and manufactured.
Their ice making systems are thoroughly tested providing the utmost in flexibility to fit the needs of a particular user.
These icemakers have been engineered to our own rigid safety and performance standards.
The VDE – SEV – WRC seals signify that it is listed with them and that it complies with the materials and manufacturing standards of them.
Note. To retain the safety and performance built into this icemaker, it is important that installation and maintenance is conducted as
outlined in this manual.
1.2
Unpacking and Inspection.
1.
Visually inspect the exterior of the packaging and pallet. Report any damage to the delivery carrier and your distributor.
2.
a) Cut and remove the plastic strip securing the carton to the pallet.
b) Cut open the top of the carton and remove the polystyrene protection sheet.
c) Pull out the polystyrene posts from the corners and then remove the carton.
3.
Remove the front and rear panels of the unit and inspect for any concealed damage. Report the damage to the
4.
Remove all internal support packing and masking tape.
5.
Check that refrigerant lines do not rub against or touch other lines or surfaces, and that the fan blade moves freely.
6.
Use a clean damp cloth to wipe the surfaces inside the storage bin and the exterior of the cabinet.
7.
See the data plate on the rear of the machine and check that the local mains voltage corresponds with the voltage specified on the plate.
distributor.
CAUTION. INCORRECT VOLTAGE APPLIED TO THE MACHINE WILL INVALIDATE THE WARRANTY.
1.3
Location and Leveling.
1.
Position the machine in the selected permanent location. The criteria for the location includes:
a) Minimum room temperature 10°C (50°F) and maximum room temperature 40°C (100°F°
b) Water inlet temperatures: minimum 5°C (40°F) and maximum 40°C (100°F)
c) Well ventilated location for air cooled models. Clean the air cooled condenser at regular intervals.
d) Service access: adequate space must be left for all service connections through the rear of the ice maker. A minimum clearance of 15cm
(6in) must be left at the sides of the machine for routing cooling air drawn into and exhausted out of the compartment to maintain proper
condensing operation of the air cooled models.
Warning. This Ice Cuber is designed for indoor installation only. Extended periods of operation at temperatures exceeding the following
limitations will constitute misuse under the terms of the Manufacturers Limited Warranty resulting in Loss of warranty coverage.
NOTE. With the machine in ‘built-in’ conditions, the ice product is gradually reduced in respect of the levels shown in the table, up to a maximum
of 10% at room temperatures higher than 32°C.
The daily ice-making capacity is directly related to the condenser air inlet temperature, water temperature and also the age of the machine.
To keep the CUBER at peak performance levels, periodic maintenance checks must be carried out as indicated in the Cleaning Section of this
manual.
2.
Level the unit in both left to right and front to rear directions.
3.
ELECTRICAL CONNECTIONS.
See data plate for current requirements to determine wire size to be used on electrical connections. All ice makers require solid earth wire.
The ‘F’ series ice machines are supplied from the factory pre- wired and are fitted with a suitably fused thirteen Amp UK plug. The FCI models
have a power cable that requires electrical connections to be made to the cable at the back of the machine, making sure that it is connected to
its own circuit and individually fused (see data for the correctly fuse size).
The maximum allowable voltage variation should not exceed –10% and +6% of the data plate rating. Low voltage can cause faulty functioning
and may be responsible for serious damage to the overload switch and motor windings.
NOTE. All external wiring should conform to national, state and local standards and regulations.
Check voltage on the line and the ice machines data before connecting the unit.
1.4
Water Supply and Drain Connections.
GENERAL.
When choosing the water supply for the ice cuber consideration should be given to:
a) Length of run.
b) Water clarity and purity.
c) Adequate water supply pressure.
Since water is the most important single ingredient in producing ice you cannot emphasize too much the three items listed above.
Low water pressure below 1bar may cause the malfunction of the machine.
Water containing excessive minerals will tend to produce cloudy coloured ice cubes, plus scale build-up on parts of the water system
WATER SUPPLY.
Connect the male fitting of the solenoid water inlet valve, using the flexible tubing supplied, to the cold water supply line with regular plumbing
2
fittings and a shut off valve installed in an accessible position between the water supply line and the unit.
Fig. 11
WATER SUPPLY - WATER COOLED MODELS.
The water cooled versions require two separate inlet water supplies on models 40 and 60, one to supply water for the ice production and one
for the water cooled condenser.
Connect the male fitting of the condenser water inlet solenoid valve, using the second flexible tubing supplied, to the cold water supply line
with regular plumbing fittings and a shut off valve installed in an accessible position between the water supply line and the unit.
WATER DRAIN.
The recommended drain tube is a plastic or flexible tube with 18mm (3/4in) I.D. that runs to an open trapped and vented drain. When the drain
is along run, allow 3cm pitch per metre (1/4in per foot).
A vertical open vent, at the unit drain connection is also required for proper sump drainage.
6. (R134A Machines Fig. 8)
WATER DRAIN – WATER COOLED MODELS.
The water drain line from the condenser, on water cooled versions, is internally connected with the drain fitting of the unit.
It is strongly recommended therefore to install a vertical open vent to the high point of the drain line high enough to ensure good drainage and
to direct the drain line to a trapped and vented floor drain receptacle.
This ensures proper flow of the drained water as, in the case of poor drainage, the water running out of the condenser may leak through the
unit drain tubing into the ice storage bin or into the sump reservoir.
NOTE. The water supply and the water drain must be installed to conform to the local codes. In some cases a licensed plumber and/or
a plumbing permit is required.
NOTE With the system in CLEANING/RINSING mode the water pump is the only component in operation to circulate the cleaning solution in
the
entire water system.
7. Let the unit remain in the CLEANING/RINSING mode for about 20 minutes then turn the program selector on STAND BY again.
8. Flush out the cleaning solution from the sump reservoir then pour onto the evaporator cavity two or three litres of clean potable water to
rinse
the mould cups and the platen.
If necessary remove the water spray platen to clean it separately as per step 3 of paragraph B.
9. Turn again the program selector on CLEANING/RINSING. The water pump is again in operation to circulate the water in order to rinse
the
entire water system.
10. Flush out the rinsing water from the sump reservoir then turn the program selector on RESET/HI TEMPERATURE position and
immediately
afterwards to FREEZING OPERATION.
NOTE By setting the selector on RE-SET first and then to FREEZING OPERATION the ice maker will perform the 5 minutes WATER FILLING
phase i.e. the water inlet solenoid valve opens to allow the incoming water to rinse again the water system and to properly fill-up the sump
reservoir for the next freezing cycle.
1.5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Final Checklist.
Is the machine in a room where the ambient temperatures are within a minimum of 10°C (50°F) even in winter months?
Is there at least a 15cm (6in) clearance around the unit for proper air circulation?
Is the machine level? (IMPORTANT)
Have all the electrical and plumbing connections been made, and is the water supply shut-off valve open?
Has the voltage been tested and checked against the rating on the data plate?
Has the water supply pressure been checked to ensure a water pressure of at least 1 bar (14psi)?
Check all refrigerant lines and conduit lines to guard against vibration and possible failure?
Has the bin liner and cabinet been wiped clean?
Has the owner/user been given the User Manual and been instructed on the importance of periodic maintenance checks?
Has the owner/user been given the name and telephone number of the authorised Service Agency in case of breakdown.
11. Replace the evaporator cover and the unit service panels.
12. At completion of the freezing and harvest cycle make sure of proper texture and clearness of the ice cubes and that, they do not have
any
acid taste.
ATTENTION In case the Ice cubes are cloudy-white and have an acid taste, melt them Immediately by pouring on some warm water In order
to prevent somebody using them.
13.
Wipe clean and rinse the inner surfaces of the storage bin.
REMEMBER To prevent the accumulation of undesirable bacteria it is necessary to sanitise the interior of the storage bin with an anti-algae
disinfectant solution every week.
22
3
2.
2.1
Technical Data
A
F20
19.5
6.5
16
0.28
20.7
11Amps/2Amps
320w
8.5
R134A
250 grms
-7°C
-27°C
-5°C
-26°C
540
55dBA
F40
34.5
15
24
0.42
17.5
17Amps/3.3Amps
450w
8.5
R134A
320 grms
-9°C
-24°C
-6°C
-24°C
850
58 dBA
Switch on the power to the machine. The unit starts its first freezing cycle with the following components in operation:
COMPRESSOR
WATER PUMP
FAN MOTOR. (The condenser fan is controlled by a thermostat, factory set at approximately 33°C).
C
The ice making process takes place thereby, the water is sprayed into the molds which gets gradually refrigerated by the heat exchanged with
the refrigerant flowing into the evaporator serpentine.
D
When the evaporator temperature reaches a pre-set value the evaporator thermostat changes its contacts, the freezing cycle ends and the
defrost/harvest cycle starts.
Freezing time will range between 17 and 22 minutes (depending on model, see table) in a 21°C ambient. Longer time for temperature above,
shorter when below.
Average complete cycle range is about 17 to 25 minutes (depending on model, see table above)
2.3
Check, during the first defrost/harvest cycle, that the incoming water flows correctly into the sump reservoir in order to re-fill it and the surplus
overflows down the overflow drain tube.
During this cycle the components energised are:
COMPRESSOR.
HOT GAS SOLENOID.
WATER INLET SOLENOID VALVE.
The FAN MOTOR and the WATER PUMP are also in operation if ambient temperature exceeds 33°C.
Note. During the defrost cycle, the water inlet solenoid valve is energised. The water flows through the valve to the back of the
evaporator platen and then down to fill up the icemaker sump tank for the next freezing cycle.
The following maintenance should be scheduled at least twice per year on these ice makers.
1. Check and clean the water line strainer.
2. Check that the ice maker is levelled side to side and in front to rear directions.
3. Clean the water system, the evaporator, the bin and spray platen using a solution of Ice Machine Cleaner.
Refer to procedure 15.3 cleaning instructions and after cleaning will indicate frequency and procedure to be followed in local areas.
NOTE Cleaning requirements vary according to the local water conditions and
individual user operation. Continuous check of the clarity of ice cubes and visual
inspection of the water spraying parts before and after cleaning will indicate
frequency and procedure to be followed in local areas.
4.
5.
6.
7.
With the ice machine and fan motor OFF on air cooled models, clean condenser using vacuum cleaner, soft brush or non metallic brush.
Check for water leaks and tighten drain line connections. Pour water down bin drain line to be sure that drain line is open and clear.
Check size, condition and texture of ice cubes. Perform adjustment of DIP SWITCH keys as required.
Check the ice level control sensor to test shut-off.
Put a shovelful of ice cubes in contact with the control sensor during the defrost cycle.
This should cause the ice maker to shut off at the end of the defrost cycle and the light up the 3rd RED LED.
Within a few seconds after the removal of the shovelful of ice from the sensing probe, the ice maker restarts in freezing cycle.
NOTE The RANGE OF THE ICE LEVEL CONTROL SENSOR can be adjusted as shown on table D of PRINCIPLE OF OPERATION; its cut
out setting remains however at +2˚C (35˚F).
8. Check for refrigerant leaks.
16.3 Cleaning Instructions of Water System
1. Remove the rear and top panels to gain access either to the control box or to the evaporator.
2. Wait till the end of defrost cycle then, with the help of a normal screwdriver, turn the program selector head on STAND BY position to
temporarily stop the operation (Fig. 10). + (Fig. 8) (R134A Machines Fig. 7).
Fig. 10
Check the texture of the ice cubes just released. The correct size has a small depression (about 5-6mm) in their crown. If not, wait for the second
defrost/harvest cycle before making any adjustments.
Adjustments
G
If after the second harvest the cubes are not correct adjustment to the evaporator thermostat may be necessary.
Remove the front panel and locate the cube size thermostat, using a flat bladed screwdriver turn towards the ‘+’ to increase the cube size and
towards the ‘-’ to decrease the cube size. (See fig 1)
H
To check the bin full thermostat hold a handful of ice against the bulb of the storage bin
thermostat, the ice maker will switch off in about one to two minutes.
Once the machine has stopped remove the ice and dispose of it, the machine will restart
automatically in three to four minutes.
Note. The bin thermostat is factory set at 1°C (35°F) CUT OUT and 4°C (39°F) CUT IN.
(The set temperature can be adjusted if required by using a flat bladed screwdriver
turn towards the ‘+’ to increase the bin temperature and towards the ‘-’ to decrease
the bin temperature). (See fig 1)
Refit the bottom front panel then instruct the owner/user on the general operation of the
machine and about the cleaning and care it requires.
I.
16.2 Icemaker
Start Up
Check through the ice discharge opening that the spray plate is correctly seated and that the water jets uniformly reach the interior of the inverted
cup molds; also make sure that the plastic curtain is hanging freely and that water is not spilling through it excessively.
F
The periods and the procedures for maintenance and cleaning are given as guides and are not to be construed as absolute or invariable.
Cleaning, especially, will vary depending upon local water and ambient conditions and the ice volume produced; and, each ice maker must be
maintained individually, in accordance with its particular. location requirements.
After having correctly installed the ice machine and completed the plumbing and electrical connections, perform the following “Start-up”
procedure.
B
E
Maintenance and Cleaning Instructions
16.1 General
Model
Output – kg/24hr
Bin storage capacity – kg
Cubes per cycle
Cubes kg per cycle
Cycle time – minutes
Amps start/run
Watts consumption (30°C Ambient Temp)
Water consumption (Water Temp at 15°C Ambient Temp 21°C)
Refrigerant
Refrigerant charge grams
Evaporator Temp with Gas Pressure at 10.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 7.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 13 Bar ( Ambient Temp 32°C)
Evaporator Temp with Gas Pressure at 8 Bar ( Ambient Temp 32°C)
Heat Emission, watts
Noise Level dBA at 2 meters
2.2
16.
F20 and F40 Technical Data and Operating Instructions
3. Prepare the cleaning solution by diluting in a plastic container one or two litres of warm water (45-50˚C) with 0.1-0.2 litres of Ice Machine
Cleaner.
WARNING The Ice Machine Cleaner contain: Phosphoric and Hydroxyacetic acids.
These compound: are corrosive and may cause bums if swallowed, DO NOT induce vomiting. Give large amount: of water or milk. Call Physician
Immediately.
In case of external contact flush with water.
KEEP OUT OF THE REACH OF CHILDREN.
4. Scoop out all the ice cubes stored into the bin in order to prevent them from being contaminated with the cleaning solution then flush out
the
water from the sump reservoir by removing the plastic plug.
5. Remove the evaporator cover then slowly pour onto the evaporator platen the cleaning solution. With the help of a brush dissolve the
most
resistant and remote scale deposits in the platen.
6. Set the program selector head on CLEANING/RINSING (Fig. 11) + (Fig. 9).
The machine may stop working if the condenser temperature exceeds the pre-set temperature
of the Over Temperature Thermostat (non-adjustable) due to a very high ambient temperature,
condenser fan failure, dirty/ blocked condenser. To restart the machine depresses the
protruding button on the Alarm Reset.
Fig. 1
4
21
15.
Circuit Board and Component
Sequence of Operation
Fig./ABB 1
3.
3.1
Fig./ABB 3
START OF FREEZE CYCLE
Fig./ABB 4
LED BLINKING EVAPORATOR
TEMPERATURE HIGH
LED CONSTANT CONDENSER TEMPERATURE HIGH
Fig./ABB 5
3.2
PHASE 2 OF FREEZE CYCLE
Fig./ABB 6
DEFROST CYCLE
F60
60
27
48
0.84
19.0
19/4.1
630
12.0
R134A
450 grms
-10°C
-6°C
-10°C
-7°C
1100
60
F85
83
27
48
0.84
15.5
26/5.5
780
16.0
R134A
540 grms
-26°C
-25°C
-28°C
-24°C
1400
63
Start Up
After having correctly installed the ice machine and completed the plumbing and electrical connections, perform the following “Start-up”
procedure.
A.
Switch on the power to the machine. The unit starts its first freezing cycle with the following components in operation:
COMPRESSOR
WATER PUMP
FAN MOTOR. (The condenser fan is controlled by a thermostat, which is factory set).
B.
Check through the ice discharge opening that the spray plate is correctly seated and that the water jets uniformly reach the interior of the inverted
cup molds; also make sure that the plastic curtain is hanging freely and that water is not spilling through it excessively.
C.
The ice making process takes place thereby, the water is sprayed into the molds which gets gradually refrigerated by the heat exchanged with
the refrigerant flowing into the evaporator serpentine.
D.
When the evaporator temperature reaches a pre-set value (approximately -15°C) the evaporator thermostat changes its contacts and starts the
time clock, when the first timed portion has elapsed the freezing cycle ends and the second timed portion starts the defrost/harvest cycle.
Freezing time will range between 20 and 22 minutes (depending on model, see table) in a 21°C ambient. Longer time for temperature above,
shorter when below.
Average complete cycle range is about 23 to 25 minutes (depending on model, see table above)
E.
Check, during the first defrost/harvest cycle, that the incoming water flows correctly into the sump reservoir in order to re-fill it and the surplus
overflows down the overflow drain tube.
During this cycle the components energised are:
COMPRESSOR.
HOT GAS SOLENOID.
WATER INLET SOLENOID VALVE.
TIMER MOTOR
FAN MOTOR (if ambient temperature exceeds 30°C).
BIN FULL
Fig./ABB 7
Technical Data
Model
Output – kg/24hr
Bin storage capacity – kg
Cubes per cycle
Cubes kg per cycle
Cycle time – minutes
Amps start/run
Watts consumption (30°C Ambient Temp)
Water consumption (Water Temp at 15°C Air Temp 21°C)
Refrigerant
Refrigerant charge grams
Evaporator Temp with Gas Pressure at 10.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 7.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 13 Bar ( Ambient Temp 32°C)
Evaporator Temp with Gas Pressure at 8 Bar ( Ambient Temp 32°C)
Heat Emission, watts
Noise Level dBA at 2 meters
Fig./ABB 2
START UP
F60 and F85 Technical Data and Operating Instructions
Fig./ABB 8
Note. During the defrost cycle, the water inlet solenoid valve is energised. The
water flows through the valve to the back side of the evaporator platen and
then down to fill up the icemaker sump tank for the next freezing cycle.
C.
3.3
STAND BY
COMPRESSOR
(G)
DP SWITCH
(O)
WATER INLET VALVE
(B)
ICE LEVEL SENSOR
(H)
ELECTRIC TIMER
(P)
HOT GAS VALVE
(C)
SENSORS
(I)
MICRO PROCESSOR
(Q)
CONTRACTOR COIL
(D)
EVAP. TEMPERATURE
(L)
TRANSFORMER
(R)
FAN MOTOR
(E)
COND. TEMPERATURE
(M)
RELAY
(S)
WATER PUMP
(F)
AMBIENT TEMP.
(N)
TRIAC
(T)
P.C. BOARD
20
Adjustments
G.
If after the second harvest the cubes are not correct adjustment to the cube size
thermostat may be necessary.
Using a flat bladed screwdriver turn towards the ‘+’ to increase the cube size and
towards the ‘-’ to decrease the cube size. (See fig 2)
H.
To check the bin full thermostat hold a handful of ice against the bulb of the storage
bin thermostat, the ice maker will switch off in about one to two minutes.
Once the machine has stopped remove the ice and dispose of it, the machine will
restart automatically in three to four minutes.
Note. The bin thermostat is factory set at 1°C (35°F) CUT OUT and 4°C (39°F)
CUT IN. (The set temperature can be adjusted if required by using a flat bladed
screwdriver turn towards the ‘+’ to increase the bin temperature and towards
the ‘-‘ to decrease the bin temperature). (See fig 2)
Refit the bottom front panel then instruct the owner/user on the general operation
of the machine and about the cleaning and care it requires.
CLEANING
(A)
Check the texture of the ice cubes just released. The correct size has a small
depression (about 5-6mm) in their crown. If not, wait for the second defrost/harvest
cycle before making any adjustments.
5
Fig 2
I.
The machine may stop working if the condenser temperature exceeds the pre-set temperature of the Over Temperature Thermostat (nonadjustable) due to a very high ambient temperature, condenser fan failure, dirty/ blocked condenser. To restart the machine, depress the
protruding button on the Alarm Reset.
J.
Changes to the defrost time. Under normal circumstances no adjustments should be necessary.
The fixed time can be adjusted by releasing the tension on the cam screw, turning the dial anti-clockwise to increase the defrost time and
clockwise to decrease the defrost time, retighten the screw when the adjustment has been completed.
Note. If adjustment are made it will effect the freeze cycle.
Increasing the defrost time will shorten the freeze time so adjustments to the cube size thermostat may need to be made to increase
the freeze temperature.
Decreasing the defrost time will increase the freeze time so adjustments to the cube size thermostat may need to be made to decrease
the freeze temperature.
3.4
14.
Wiring Diagram
WIRING DIAGRAM - SCHEMA ELETTRICO
SCHÉMA ÉLECTRIQUE - SCHALTUNGSCHEMA
AIR & WATER COOLED - RAFFREDDAMENTO AD ARIA ED AD ACQUA.
REFROIDISSEMENT A AIR ET A EAU - LUFT UND WASSERGEKÜHLT
220-240/50/1
Cleaning/Rinsing For F20, 40, 60, 85
A.
Remove the bottom front panel and locate the changeover switch.
B.
Remove the top cover to gain access to the evaporator.
D.
Wait till the machine finishes its freeze cycle and then turn off the electrical supply to the machine.
D.
Prepare the cleaning solution as per the manufactures instructions on the Ice Machine Cleaner.
Warning. The Ice Machine Cleaner contains Phosphoric and Hydroxyacetic acids. These compounds are corrosive and may cause burns if
swallowed. If swallowed DO NOT induce vomiting, drink lots of water or milk and contact your Doctor immediately.
In case of external contact wash off with clean water.
E.
Scoop out all of the ice cubes stored in the bin in order to prevent them from being contaminated by the cleaning solution then drain the water
from the sump reservoir by removing the plastic overflow pipe. Once the water has drained from the sump replace the pipe.
F.
Remove the evaporator cover and slowly pour the solution onto the evaporator platen. Use a soft brush if necessary to remove stubborn
deposits.
G.
Press the switch to the clean position and restore the electrical supply to the machine.
H.
Leave the machine in the cleaning/rinsing mode for at least twenty minutes then turn the machine off at the electrical supply to the machine.
It may be necessary to clean the water spray separately. If required remove the spray plate from the machine, mix a solution of the cleaner in
a bowl or bucket and immerse the plate in it. When clean thoroughly rinse with clean water and re-fit it into the machine.
I.
Drain the cleaning solution from the sump reservoir by removing the plastic overflow pipe. Once the solution has drained from the sump replace
the pipe.
J.
Pour two to three litres of clean water over the evaporator platen to rinse of the remaining solution and ensure sufficient water is in the reservoir.
Ensure that the switch is still in the ‘CLEAN’ position and turn on the electrical supply to the machine. Leave the machine in the cleaning mode
for at least five minutes to thoroughly rinse the entire water system.
K.
Drain the rinsing water from the sump reservoir by removing the plastic overflow pipe. Once the rinsing water has drained from the sump replace
the pipe and thoroughly wipe the interior of the machine.
L.
Replace the evaporator cover and top service panel, turn on the electrical supply to the machine with the switch still in the wash position.
Leave the switch in this position for approximately five minutes to allow the water reservoir to fill up.
M.
Change the switch setting to the freeze position to start the freeze process.
N.
At the completion of the freezing and harvest cycle make sure the ice cubes are the proper texture and do not have an acid taste.
Attention. If the ice cubes are cloudy-white and have an acid taste, discard them immediately by pouring warm water over them to prevent them
from being used.
O.
Once you are satisfied that all of the cleaning solution has been removed from the machine rinse the storage bin with clean water and wipe
clean.
Remember. To prevent the accumulation of undesirable bacteria it is necessary to sanitize the interior of the storage bin with an antialgae solution each week.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Printed Circuit Board
Fuse
Rinsing
Freezing Oper.
Too High Temperature
Bin Full
Power On
Reset to High Temp.
Freezing Oper.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Stand By
Rinsing
Sensors
Evaporator Temperature
Condenser Temperature
Ambient Temp.
Ice Level Sensor
Water Pump
Hot Gas Valve
JUST FOR AIR COOLED UNIT
6
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Water Inlet Valve
Fan Motor
Compressor
Contactor
Autotransformer
Fuse
Terminal Board
* USED ONLY UNIT 240V
19
the service and inspection operations.
IN OPERATION: The unit is running through the freezing and defrost cycle stopping automatically only at full bin situation.
RE-SET/HI TEMPERATURE: To be selected to resume the unit operation when the ice maker shuts off due to the intervention of the condenser
temperature sensor (too high condensing temperature).
The five LEDS, placed in a row in the front of the P.C. BOARD, monitor the following situations:
GREEN LIGHT:
Unit under electrical power
YELLOW LIGHT:
Unit shut-off at full storage bin
RED LIGHT:
Unit shut-off due to hi-condensing
temperature
Blinking:
Unit shut-off due to hi-evaporating
temperature
YELLOW LIGHT:
Unit in freezing operation
Unit in cleaning/rinsing mode
YELLOW LIGHT:
F20 & F40 A/W Wiring Diagram
12.6 DIP SWITCH
The P.C. BOARD which controls the entire operation of the ice maker, has a DIP SWITCH with ten switching keys which allow to set up the
micro processor program in order to extend or to shorten the length of freezing and defrost cycles in relation to the different models and versions
of ice machines.
The DIP SWITCH first four keys setting determines the length of the 2nd phase of freezing cycle (controlled by the electronic timer) as detailed
in Table B.
The DIP SWITCH keys 5, 6 and 7 setting determines the length of the defrost cycle according to the ambient temperature sensor as specified
in table C.
The 8th DIP SWITCH key allows to make a rapid check up of the P.C. BOARD output connections (compressor, water pump, fan motor, water
inlet and hot gas solenoid valves) energizing them in rapid sequence (2 seconds) one by one.
DURING THE AUTOMATIC OPERATION OF THE ICE MAKER THIS KEY MUST BE SET IN OFF POSITION.
ATTENTION: The check up of the P.C. BOARD output must be performed in a very short time in order to avoid frequent starts and stops (every
few seconds) of the electrical components which may damage them, especially the compressor.
The 9th key allows the operation of the water pump even during the defrost cycle. On B 90 it must be set all the time to OFF position.
The 10th key is used to supply power to the water pump during the first 15-20 seconds of the defrost cycle to drain out all remaining water from
the sump tank in the unit equipped with the solenoid drain valve i.e. the KWD drain system.
13. Dip Switch Settings FCI 40-60-85
Table A
Dip switch
1
2
3
4
5
6
7
8
9
10
FCI 40
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 40 W
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 60
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 60 W
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 85
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
FCI 85 W
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
Table B
LENGTH OF TIMED PORTION OF FREEZING CYCLE ACCORDING TO DIP SWITH COMBINATIONS
1
2
3
4
1
2
3
4
1
ON
ON
OFF
OFF
25 min
8
OFF
ON
OFF
ON
11 min
2
OFF
OFF
ON
OFF
23 min
9
ON
ON
OFF
ON
9 min
3
ON
OFF
ON
4
OFF
ON
ON
OFF
21 min
10
OFF
OFF
ON
ON
7min
OFF
19 min
11
ON
OFF
ON
ON
5 min
5
ON
ON
ON
OFF
17 min
12
OFF
ON
ON
ON
3 min
6
OFF
OFF
OFF
ON
15 min
13
ON
ON
ON
ON
1 min
7
ON
OFF
OFF
ON
13 min
Table C
LENGTH OF DEFROST CYCLE (IN SEC.) ACCORDING TO THE AMBIENT TEMPERATURE AND TO
DIP SWITCH SETTING COMBINATIONS
5
6
7
0-5°C
5-10°C
10-15°C
15-20°C
20-25°C
25-30°C
30-35°C
35-40°C
ON
ON
OFF
180 sec
150 sec
120 sec
90 sec
90 sec
90 sec
90 sec
90 sec
OFF
OFF
ON
210 sec
180 sec
150 sec
120 sec
120 sec
120 sec
90 sec
90sec
ON
OFF
ON
240 sec
210 sec
180 sec
150 sec
150 sec
120 sec
120 sec
90 sec
OFF
ON
ON
240 sec
210 sec
180 sec
150 sec
150 sec
120 sec
120 sec
120 sec
ON
ON
ON
270 sec
240 sec
210 sec
180 sec
180 sec
150 sec
150 sec
150 sec
18
7
4.
Technical Specification - R22 Machines
MODEL
FCI 20
FCI 30
FCI 40
FCI 60
FCI 85
18 (20.5)
26 (34)
34 (42)
57 (70)
78 (90)
Bin storage capacity – kg
6.5
15
15
27
27
Cubes per cycle
16
24
24
48
48
0.28 (0.38)
0.42 (0.6)
0.42 (0.6)
0.82 (1.2)
0.82 (1.2)
22 (25)
23.5 (24.5)
15.75 (19.15)
20.5 (23.6)
15.25 (18.75)
9.5/1.9 (9.5/1.9)
11/2.2 (11/2.1)
16/3.3 (16/3.3)
16/3.5 (16/4)
24.5/4.4 (24.5/4)
Watts consumption
300 (280)
350 (330)
450 (450)
650 (650)
810 (760)
Water consumption
5.8lt/hr
5lt/hr
6.3lt/hr
12.5lt/hr
15.5lt/hr
R22
R22
R22
R22
R22
Ref. charge, grams
300gr
280gr
290gr
420gr
460gr
Heat rejection, watts
500
600
850
1100
1600
Output – kg/24hr.
kg per cycle
Cycle time – minutes
Amps start/run
Refrigerant
5.
5.1
A.
C.
D.
E.
F.
Affer having correctly installed the ice maker and completed the plumbing and electrical connections, perform the following ‘Start-up’
procedure.
Give power to the unit to start it up by switching ‘ON’ the power line main disconnect switch.
The 1st GREEN LED will glow.
During the water filling operation, check to see that the incoming water dribbles, through the evaporator platen dribbler holes, down into the
sump reservoir to fill it up and also that the incoming surplus of water flows out through the overflow pipe into the drain line.
During the water filling phase the components energised are:
THE WATER INLET SOLENOID VALVE, THE HOT GAS SOLENOID VALVE, WATER DRAIN VALVE
Operational Checks
At completion of the water filling phase (5 minutes) the unit passes automatically into the freezing cycle with the start up of: COMPRESSOR
WATER PUMP FAN MOTOR in air cooled version (Fig. 2) Page 13 and the glowing of the 6th RED LED.
Check to see through the curtained ice discharge opening that the spray system is correctly seated and that the water jets uniformly reach the
interior of the inverted mould cups; also make sure that the plastic curtain is hanging freely and there is no excessive water spilling through it.
The ice making process takes place thereby, with the water sprayed into the moulds getting gradually refrigerated by the heat exchange occurring
with the refrigerant flowing into the evaporator serpentine.
During the freezing process, when the evaporator temperature falls to 0˚C (35˚F) the evaporator temperature sensor, located in contact with
the evaporator serpentine, supplies a low voltage power signal to the electronic control device (P.C. BOARD) which in first instance generates
the glowing of the 5th RED LED located in the front of the printed circuit board (Fig. 3). Page 13
The unit remains however in its normal freezing cycle mode until the evaporator temperature detected by the sensor reaches the temperature
of -13˚C (8.5˚F) on models 20, 30 40 and 60 and to -16˚C (3˚F) on model 85.
When the evaporator temperature falls below the above value, the evaporator temperature sensor supplies a low voltage power signal to the
P.C. BOARD in order to activate the electronic timer. This takes over the control of the freezing cycle up to the complete formation of the ice
cubes (Fig. 4) Page 13, with the lighting up of the 4th RED LED located just above the previous lighted one.
NOTE The length of the entire freezing cycle is the sum of the lengths of three phases, two of which, (T1 + T2) controlled by the evaporator
tempemtum sensor, which has its probe placed in contact with the evaporator serpentine (non adjustable), and ONE. (Ta) by the electronic
tImer (Adjustable) incorporated in the P.C. BOARD.
The lengths of the first two phases, related to the evaporator temperature and controlled by its sensor, are:
TI - The time elapsed since the beginning of freezing cycle up to when the evaporator reaches the temperature of 0˚C (35˚F).
T2 - The time required for the evaporator to fall from 0˚C (35˚F) to -13˚C (8.5˚F) or to 16˚C (3˚F).
The third time Ta - Time added - is in relation to one of the different combinations of the five keys 3,4,5, 6, and 7 of the DIP SWITCH located
in the front of the P.C. BOARD. The combination is factory set in consideration of the ice maker type and of its cooling version. It is possible,
however, to vary the timed length of the freezing cycle, by changing the DIP SWITCH keys settings.
In Table B are shown the various time extensions of the freezing cycle third phase Ta, in relation with the different DIP SWITCH keys
settings.
G.
At the end of the defrost cycle, both the hot gas and the water inlet valves close, so the machine initiates another freezing cycle.
11.4 Operation - Control Sequence
At the start of the freezing cycle, the evaporator temperature sensor controls the length of the first part of the freezing cycle. As it reaches a
pre-determined temperature, it supplies a low voltage current to the P.C. BOARD in order to activate the electronic timer which takes over the
control of the freezing cycle for a pre-fixed time according to the DIP SWITCH keys setting (see Table B). Page 18.
NOTE: The evaporator temperature sensor, factory pre-set, is the same for all the models and is not adjustable in the field.
Once completed the freezing cycle 2nd phase the system goes automatically into the defrost cycle which has also a pre-fixed length that can
vary depending upon the actual ambient temperature as shown in Table C. Page 18.
At completion of the defrost cycle the P.C. BOARD command the unit to start again a new freezing cycle.
Start Up
NOTE: If in the 5 minutes length of the water filling phase the machine sump reservoir does not fill up to the rim of the overflow pipe, it is
advisable to check:
1. The water pressure of the water supply line that must be at least 1 bar (14 psig) Minimum (Max 5 bar-70 psig).
2. The filtering device installed in the water line that may reduce the water pressure below the Minimum value of 1 bar (14 psig).
3. Any clogging situation in the water circuit like the inlet water strainer and/or the flow control.
5.2
NOTE: The length of the defrost cycle, factory set, can vary in accordance with the actual ambient temperature (as shown on Table C). Page
18. For instance, in a high ambient temperature situation it can be reduced to recover some of the time spent for the longer freezing cycle.
Operating Instructions - R22 Machines
NOTE: Every time the unit returns under power, after having been switched off, both the water inlet valve and the hot gas valve get energised
for a period of 5 minutes, thus to admit new water to the machine sump reservoir to fill it up and, eventually, to wash off any dirt that may be
deposited in it during the unit oft period (Fig. 1). Page 13
B.
ambient temperature as detailed in Table C. Page 18.
The electrical components in operation during this phase are:
COMPRESSOR
WATER PUMP
WATER INLET SOLENOID VALVE
HOT GAS SOLENOID VALVE
The incoming water, passing through the water inlet valve and the flow control, runs over the evaporator platen and then flows by gravity through
the dribbler holes down into the sump/reservoir.
The water filling the sump/reservior forces part of the surplus water from the previous freezing cycle to go out to the waste through the overflow
pipe. This overflow limits the level of the sump water which will be used to produce the next batch of ice cubes.
Meanwhile, the high pressure, high temperature refrigerant, discharged from the compressor, flows through the hot gas valve directly into the
evaporator serpentine by-passing the condenser.
The hot gas circulating into the serpentine of the evaporator warms up the copper moulds causing the defrosting of the ice cubes. The ice
cubes, released from the cups, drop by gravity onto a slanted cube chute, then through a curtained opening they fall into the storage bin.
After about 20-22 minutes from the beginning of the freezing cycle, in a hypothetic ambient temperature of 21˚C (70˚F), the defrost cycle takes
place with the hot gas and the water inlet valves being simultaneously activated (Fig. 5). Page 13
The electrical components in operation in this new situation are:
8
12.
Components Description
12.1 Evaporator Temperature Sensor
The evaporator temperature sensor probe, located in contact with the evaporator serpentine detects the dropping of the evaporator temperature
during the freezing cycle and signals it by supplying a current flow to the micro processor of the P.C. BOARD.
According to the current received, the evaporator sensor supplies power to the P.C. BOARD first, when it reaches 0°C (32°F), second at -15°C
(5°F); in this second case its supply power to the electronic timer built into the P.C. BOARD so that it may take control of the length of the 2nd
phase of freezing cycle.
The length of the timed phase is pre-fixed by the setting of the keys 1, 2, 3 and 4 of the DIP SWITCH.
The activation of the electronic timer (-15°C -5°F) is monitored by the lighting up of the RED LED placed in the front of the P.C. BOARD. This
lighting up occurs usually in the mid period of the freezing cycle and signals the switching from the first to the second phase of the freezing
cycle.
12.2 Condenser Temperature Sensor
The condenser temperature sensor probe, located within the condenser fins (air cooled version) or in contact with the tube coil (water cooled
version) detects the condenser temperature variations and signals them by supplying current, at low voltage, to the P.C. BOARD.
In the air cooled versions, in relation to the different current received, the micro processor of the the P.C. BOARD supplies, through a TRIAC,
the power at high voltage to the fan motor so to cool the condenser and to reduce its temperature rises and reaches 75°C (170°F) the current
arriving to the micro processor is such to cause an immediate and total stop of the machine operation.
12.3 Ambient Temperature Sensor
The probe of this sensor, located in the front of the ice maker condenser (air cooled version) and in the water supply line to the condenser
(water cooled version) has the function to detect the ambient or the water temperature and, by changing its own electrical resistance, supplies
a different current flow to the P.C. BOARD.
This different current flow received by the P.C. BOARD, is processed by the micro processor in order to extend or shorten the defrost cycle
length (longer in cold ambient situations, shorter in warm ones).
12.4 Ice Bin Level Light Control
The electronic ice bin level control, located into the storage bin, has the function to stop the operation of the ice machine when the light beam
between the light source and the sensor is interrupted by the ice cubes stored in the bin. When the light beam is interrupted the RED LED
located in the front of the P.C. BOARD goes off; in case the light beam is constantly interrupted for more than 60 seconds, the ice machine
stops with the glowing-up of the 2nd YELLOW LED to monitor the situation of ice bin full. The 60 seconds of delay prevent that an ice scoop
movement or the ice dropping through the ice chute (interrupting for a while the light beam) can stop the operation of the unit.
As soon as the ice is scooped out (with the resumption of the light beam between the two infrared sensor of ice level control) the RED LED is
lighted up and after 6 seconds the ice machine restarts again with the extinguishing of the 2nd YELLOW LED.
12.5 E.P.C. Board (Data processor)
The P.C. BOARD, fitted in its plastic box located in the front of the unit, consists of two separated printed circuits one at high and the other
at low voltage integrated with a program selector, of two fuses one on power in (100m A) and one on power out (16 A) of five aligned LEDS
monitoring the operation of the machine, of two extra monitoring RED LEDS, of one DIP SWITCH with ten keys, of two small plugs located on
its back side, of input terminals for the leads of the sensor probes and input and output terminals for the leads of the ice maker electrical wires.
The P.C. BOARD is the brain of the system and it processes, through its micro processor, the signals received from the four sensors in order
to control the operation of the different electrical components of the ice maker (compressor, water, pump, solenoid valves, etc.).
By turning the program selector it is possible to put the unit in the following different situations.
CLEANING/RINSING: The water pump is the only electrical component in operation and it must be used during the cleaning or the rinsing
procedure of the water system of ice machine.
STAND BY: The unit remain under electrical power but OUT of operation. It can be used by the service engineer in order to stop the unit during
17
11.
Principle of Operation
COMPRESSOR, WATER INLET SOLENOID VALVE, HOT GAS VALVE
NOTE: The length of the defrost cycle is (non-adjustable) automatically determined by the microprocessor of The P.C. BOARD in relation to
the time T2 necessary for the unit to reduce the evaporator temperature from 0˚C (35˚F) to -1 3˚C (8.5˚F) and of the ambient temperature, as
illustrated in Table C.
As shown it is possible to have a different length of the defrost cycle in connection with the different length of the second phase of the freezing
cycle T2 relative to the ambient temperature situations; shorter when the ambient temperature is high and longer in colder ambients so to
partially compensate the length of the freezing cycle, which is longer in high ambient temperatures and shorter in low ones.
11.1 How it works
In the cube ice makers the water used to make the ice is kept constantly in circulation by an electric water pump which primes it to the spray
system nozzles from where it is diverted into the inverted mould cups of the evaporator. A small quantity of the sprayed water freezes into ice;
the rest of it cascades by gravity into the sump assembly below for recirculation.
11.2 Freezing Cycle
The Hot refrigerant gas discharged out from the compressor reaches the condenser where, being cooled down, condenses into liquid. Flowing
into the liquid line it passes through the drier filter, then it goes all the way through the capillary tube where, due to the heat exchanging action,
it loses some of its heat content so that its pressure and temperature are lowered as well.
Next the refrigerant enters into the evaporator serpentine (which has a larger I.D. then the capillary) and starts to boil off; this reaction is
emphasized by the heat transferred by the sprayed water.
The refrigerant then increases in volume and changes entirely into vapour.
The refrigerant vapour then passes through the suction accumulator (used to prevent any small amount of liquid refrigerant from reaching the
compressor) and through the suction line. In both the accumulator and the suction line it exchanges heat with the refrigerant flowing into the
capillary tube (warmer), before being sucked in the compressor and to be recirculated as high pressure, high temperature gas.
The freezing cycle is controlled by the evaporator temperature sensor (which has its probe in contact with the evaporator serpentine) that
determines the length of the cycle first portion.
When the temperature of the evaporator serpentine drops to a pre-set value, the evaporator sensor probe changes its electrical resistance
allowing a low voltage current (8-10 volts) to flow to the P.C. BOARD which in turn activates an electronic timer.
The timer, which is built-in the P.C. BOARD, takes over, from the evaporator temperature sensor, the control of the freezing cycle up to its
completion.
H.
Check, during the defrost cycle, that the incoming water flows correctly into the sump reservoir in order to refill it and that its surplus overflows
through the overflow drain tube.
I.
Check the texture of ice cubes just released. They have to be the right shape with a small depression of about 5-6mm in their crown.
If not, wait for the completion of the second cycle before performing any adjustment.
If the ice cubes require a correction to their shape, it is possible to modity the length of the timed freezing cycle by changing the DIP SWITCH
keys setting as illustrated in table B.
It the ice cubes are shallow and cloudy, it is possible that the ice maker runs short of water during the freezing cycle second phase or, the quality
of the supplied water requires the use of an appropriate water filter or conditioner or the installation of the optional water drain valve kit KWD.
To be sure of the correct operation of the ice level temperature sensor, located in one side of storage bin liner, during the defrost cycle place
one shovel of ice cubes in contact with its probe for approx. 30 sec.-1 minute.
As the temperature of storage bin sensor reaches the value of +2˚C (35˚F), the ice level control transmits a signal to the microprocessor of the
P.C. BOARD in order to stop the ice maker operation at the end of the defrost cycle with the simultaneous glowing of the 3rd RED LIGHT, to
monitor the BIN FULL situation (Fig.6). Page 13
With no more ice cubes in touch with the ice level control the temperature of its probe progressively rises to reach + 4.5˚C (40˚F) and at this
point the ice machine restarts to initiate a new freezing cycle with the simultaneous extinguishing of the 3rd RED LIGHT.
J.
NOTE The CUT-IN RANGE OF THE ICE LEVEL CONTROL SENSOR can be adjusted as shown in table D; its cut out setting remains however
at + 2˚C (35˚F).
NOTE: The change of the electrical potential of the evaporator sensor with the consequent activation of the timer (Time mode) is signalled by
the glowing-up of the RED LED located in the front of the P.C. BOARD.
ATTENTION: In case, after 15 minutes from the beginning of the freezing cycle, the temperature of the evaporator sensor probe is higher then
0°C (32°F) (Shortage of refrigerant, inoperative hot gas valve, etc.) the P.C. BOARD switch OFF immediately the unit with the simultaneous
blinking of the WARNING RED LED.
The length of the second portion of the freezing cycle is pre-fixed and related to the setting of the first four DIP SWITCH keys which is made in
relation with the different unit versions.
The DIP SWITCH keys setting is made in consideration of the type of condenser used.
In Table B, page 18, are indicated the various lengths of the second portion of freezing cycle (Time mode) in relation to the different combinations
of the DIP SWITCH KEYS.
In Table A, page 18, is illustrated the DIP SWITCH keys combinations for the different unit versions as they are set in the factory.
The electrical components in operation during the freezing cycle are:
COMPRESSOR
FAN MOTOR (in air cooled version)
WATER PUMP
CONTACTOR COIL
and during the second phase of freezing cycle (Time mode) they are joined by the
ELECTRONIC TIMER
The refrigerant head pressure, in the course of the freezing cycle, ranges between 13.5 and 14.5 bars (190-205 psig) being controlled by the
temperature sensor probe located within the condenser fins (Air cooled version) or, it is kept constant at 14 bars (195 psig) by means of the
water regulating valve (water cooled version).
On the air cooled version, the condenser temperature sensor, when senses a rising of the condenser temperature beyond the pre-fixed limit,
changes its electrical resistance and send a low voltage power signal to the Micro Processor of P.C. BOARD which in turn energizes, through
a TRIAC, the FAN MOTOR.
When the opposite situation occurs, i.e. the condenser temperature gets below the pre-fixed limit, the temperature sensor changes again its
electrical resistance reducing therefore the current flow to the P.C. BOARD to cause the fan motor to temporary cut-off.
NOTE: In case the condensor temperature probe senses that the condensor temperature has rised to 70°C (160°F) - on air cooled versions
- or 62°C (145°F) - on water cooled versions - for one of the following abnormal reasons:
CLOGGED CONDENSOR (Air cooled version)
FAN MOTOR OUT OF OPERATION (Air cooled version)
INSUFFICIENT FLOW OF COOLING WATER (Water cooled version)
AMBIENT TEMPERATURE HIGHER THEN 40°C (100°F)
it causes the total and immediate SHUT-OFF of the machine in order to prevent the unit from operating in abnormal and dangerous conditions.
When the ice maker stops on account of this protective device, there is a simultaneous glowing of the RED LED, warning the user of the Hi
Temperature situation. After having eliminated the source of the condensor hi-temperature, to restart the machine it is necessary first, to rotate
for a while the program selector on RE-SET position then, to rotate it again on OPERATION position.
The same can be done by just switching OFF and ON the unit at main line switch.
The ice machcine resumes its normal operation by going through the 5 minutes water filling phase.
At the start of the freezing cycle the refrigerant suction or lo-pressure lowers rapidly to 3.3 bar-45 psig then it declines gradually - in relation
with the growing of the ice thickness - to reach, at the end of the cycle, approx. 1 bar -14 psig with the cubes fully formed in the cup moulds.
The total length of the freezing cycle ranges from 15-18 minutes.
11.3 Defrost or Harvest Cycle
As the electronic timer has carried the system throughout the second phase of freezing cycle, the defrost cycle starts.
ATTENTION: In case the unit is be able to reach 0°C (32°F) evaporating temperature within 15 minutes, or after 45 minutes from the beginning
of the freezing cycle it has not yet reached the evaporator temperature of -15°C (5°F), the machine goes straight into the defrost cycle omitting
the timed portion of the freezing cycle related to the setting of the first four DIP SWITCHES.
6.
6.1
6.2
Principle of Operation
How it works
In the cube ice makers the water used to make the ice is kept constantly in circulation by an electric water pump which primes it to the spray
system nozzles from where it is diverted into the inverted mould cups of the evaporator. A small quantity of the sprayed water freezes into ice;
the rest of it cascades by gravity into the sump assembly below for recirculation.
Freezing Cycle
The hot gas refrigerant discharged out from the compressor reaches the condenser where, being cooled down, condenses into liquid. Flowing
into the liquid line it passes through the drier filter, then it goes all the way through the capillary tube where, due to the heat exchanging action,
it loses some of its heat content so that its pressure and temperature are lowered as well.
Next the refrigerant enters into the evaporator serpentine (which has a larger l.D. than the capillary) and starts to boil off; this reaction is
emphasised by the heat transferred by the sprayed water.
The refrigerant then increases in volume and changes entirely into vapour.
The vapour refrigerant then passes through the suction accumulator (used to prevent any small amount of liquid refrigerant reaching the
compressor) and through the suction line. In both the accumulator and the suction line it exchanges heat with the refrigerant flowing into the
capillary tube (warmer), before being sucked into the compressor and recirculated as hot compressed refrigerant gas.
The freezing cycle is controlled by the evaporator temperature sensor (which has its probe in contact with the evaporator serpentine) which
determines the length of the first and second portion of it and it is signalled by the glowing of the 6th RED LED.
The first portion length or time T1 (non-adjustable) is equal to the time required by the temperature sensor to fall to 0˚C (35˚F). When reached,
it is signalled by the glowing of the 5th RED LED.
NOTE If, after 15 minutes, the evaporator temperature has not yet reached the value of 0˚C (35˚F) (due to a partially or total shortage of
refrigerant or to a too high condensing temperature, etc.) the sensor, through the P.C. BOARD, causes the unit to stop the operation with the
simultaneous glowing of the SECOND RED WARNING LED (Fig. 7). Page 13. After having eliminated the source of the unit trip off, to restart
the machine operation it is necessary first to rotate the program selector to the RE-SET position, then put it again on to OPERATION position
or, alternatively, switch OFF and ON the unit at the power line Main Switch.
The second portion length of freezing cycle or time T2 (non-adjustable) is equal to the time required by the evaporator temperature to go from
0˚C (35˚F) to -13˚C (8.5˚F) on models 20, 30, 40 and 60 or to -16˚C (3˚F) on model 85. The sensor will light-up the 4th RED LED.
NOTE In case the time T2 gets longer than 45 minutes, the unit stops with the glowing of the second RED WARNING LED.
Also in this case, after having eliminated the source of the trip OFF to restart the machine it is necessary first to rotate the program selector to
the RESET position then put it again on OPERATION or, switch OFF and ON the unit at power line Main Switch.
The third portion or time Ta (added time) of the freezing cycle is controlled by the electronic timer of P.C. BOARD. As the evaporator temperature
reaches the value of -13˚C (8.5˚F) or to -16˚C (3˚F); the sensing probe of the evaporator sensor (in contact with the serpentine) changes its
electrical resistance causing a low voltage current to flow to the P.C. BOARD which, thereby, activates an electronic timer.
NOTE The activation of the timer (Time mode) of P.C. BOARD is signalled by the glowing of fourth RED LED located in the front of the P.C.
BOARD.
ATTENTION In case the length of the second portion of freezing cycle or time T2, lasts as long as between 35 and 45 minutes, the
third portion or time Ta gets skipped by the P.C BOARD which puts the unit directly in the defrost or harvest cycle.
The length of the third portion of the freezing cycle (adjustable) is pre-fixed and related to the setting of the DIP SWITCH keys 3, 4, 5, 6 and
NOTE: The length of the defrost cycle is pre-determined by the setting of the DIP SWITCH KEYS NO. 5, 6 and 7 and it is related as well to the
16
9
7. The DIP. SWITCH keys setting is made in consideration of the model and of the type of condenser used (air or water cooled).
In Table B, page 12, are indicated the various lengths of the third portion of freezing cycle (Time mode) in accordance with the different
combinations of the DIP. SWITCH KEYS.
In Table A, page 12, are indicated the DIP. SWITCH keys combinations for the different models and versions as they are set in the factory.
The electrical components in operation during the freezing cycle are:
COMPRESSOR
FAN MOTOR (in air cooled version)
WATER PUMP and during the timed phase of freezing cycle (Time mode) they are joined by the ELECTRONIC TIMER.
On the air cooled versions the refrigerant head pressure is gradually reduced from a value of approx. 15 bars (210psig), generally recorded at
the beginning of the freezing cycle with the unit at 21˚C (70˚F) ambient temperature, to a minimum value of approx. 11 bars (155psig) just at
the end of the freezing cycle a few seconds before the starting of the defrost cycle.
The above values are in relation as well to the ambient temperature of the ice maker site and are subject to rise with the increase of this
temperature.
On the water cooled versions the refrigerant head pressure ranges between 13.5 and 14.5 bars (190-205psig) being controlled by the automatic
high pressure control that energises a water solenoid valve located on the inlet water line to the condenser, which modulates the cooling water
rate to the condenser.
With the unit installed in standard location (21˚C ambient temperature) at the start of the freezing cycle the refrigerant suction or low-pressure
lowers rapidly to 3.5 bars (50psig) then declines gradually, in relation with the growing of the ice thickness, to reach, at the end of the cycle
approx. 1.0 to 1.3 bars (14-l8psig) on 20,30 and 65 and at approx. 0.6 bars (8.5psig) on 40 with the cubes fully formed in the cup moulds.
6.2
F.
In the water cooled models the discharge pressure is kept constant at the value of 14 bars (195 psig) by means of the water regulating valve
located in the water supply line to the condenser.
In case of condenser clogging such to prevent the proper flow of the cooling air or fan motor out of operation, the condenser temperature rises
and when it reaches 70°C (160°F) the condenser temperature sensor shuts-off the ice maker with the consequent light-up of the RED WARNING
LIGHT (Fig.3). Page 20.
The same happen even for the water cooled version where the condenser probe is placed in contact with the refrigerant liquid line.
When its temperature reaches 62°C (145°F) it trips-off automatically the machine.
After having diagnosed the reason of the rise in temperature and removed its cause, it is necessary to turn the head of the selector - always
using an appropriate screwdriver - first on the RE-SET position then return it on previous OPERATION position, thus to put the machine in
condition to initiate a new freezing cycle.
The same can also be done by just switching OFF and ON the unit at main line switch.
In both cases the machine restarts with the usual 5 minutes water filling phase in order to provide enough water into the sump tank.
Defrost or Harvest Cycle
NOTE: The length of the defrost cycle (non-adjustable) is related to the length of the second phase of freezing cycle T2 as detailed in Table C.
Page 12.
G.
Check to see through the ice discharge opening that the spray systems are correctly seated and that the water jets uniformly reach the interior
of the inverted mould cups; also make sure that the plastic curtain is hanging freely and there is no excessive water spillage through it.
The electrical components in operation during this phase are:
COMPRESSOR
WATER INLET SOLENOID VALVE
HOT GAS SOLENOID VALVE
H.
The ice making process takes place thereby, with water sprayed into the moulds that gets gradually refrigerated by the heat exchange with the
refrigerant flowing into the evaporator serpentine.
During the freezing process, when the evaporator temperature falls below an established value, the evaporator temperature sensor supplies a
low voltage power signal to the electronic control device (P.C. BOARD) in order to activate an electronic timer. This one takes over the control
of the freezing cycle up to the complete formation of the ice cubes (Fig.4) Page 20.
NOTE: The length of the entire freezing cycle if govened by the evaporator temperature sensor which has its probe placed in contact with
the evaporator serpentine (Non adjustable) in combination with the electronic timer (Adjustable) incorporated in the P.C. BOARD. The timer
adjustment is factory set in consideration of cooling version and ice cube size (Medium, Large).
It is possible, however, to modify the timed length of the freezing cycle, by changing the DIP SWITCH keys setting.
In Table B, Page 18 are shown the various time extensions of the freezing cycle second phase, in relation with the different DIP SWITCH
settings.
I.
Operation - Control Sequence
At the start of freezing cycle the evaporator temperature sensor controls the length of the first T1 and second T2 portion of the freezing cycle.
As it senses the predetermined evaporating temperature of -13˚C (8.5˚F) (-16˚C on 85) it supplies a low voltage current to the P.C. BOARD in
order to activate the electronic timer which takes over the control of the remaining portion of the freezing cycle for a pre-fixed time Ta subject
to the DIP SWITCH keys setting (see Table B). Page 12.
In case the length of the second portion of the freezing cycle or time T2 gets long as to be between 35 and 45 minutes, the total length of the
freezing cycle will be limited to:
Tc = T1 + T2
skipping the added time Ta, controlled by the electronic timer.
After about 15-18 minutes from the beginning of the freezing cycle, in an hypothetic ambient temperature of 21°C, the defrost cycle takes place
with the hot gas and the water inlet valves being simultaneously activated (Fig.5). Page 20. The electrical components in operation are:
COMPRESSOR
WATER INLET SOLENOID VALVE
HOT GAS VALVE
and, if installed
WATER DRAIN SOLENOID VALVE
NOTE: The length of the defrost cycle is determined by the DIP SWITCH keys setting in conjunction with the ambient temperature sensor
located just in front of the condenser. The length of defrost cycle can be adjusted by changing the combination setting of keys 5, 6 and 7 of
DIP SWITCH as illustrated on Table C. Page 18.
During the normal operation mode the length or the total time of the freezing cycle is equal to the sum of the three partial times i.e.:
Tc = T1 + T2 + Ta
A.
Install, if necessary, the refrigerant service gauges on both the high side and low side Schräder valves to check the compressor head and
suction pressures.
NOTE: On air cooled models, the condenser temperature sensor, which is located within the condenser fins, keep the head (condensing)
pressure between 13,5 and 14,5 bars (190-205 psig).
NOTE: The evaporator temperature sensor, factory pre-set, is the same for all models and is not adjustable in the field.
6.4
At completion of the water filling phase (5 minutes) the unit passes automatically into the freezing cycle with the start up of:
COMPRESSOR
WATER PUMP
FAN MOTOR (in air cooled version) controlled by the condensing temperature sensor located within the condenser fins (Fig.2). Page 20.
10.2 Operational Checks
As the electronic timer has carried the system throughout the third phase of freezing cycle or as soon as the second phase T2 is over (when
its length has been as long as 35 to 45 minutes) the defrost cycle starts.
The incoming water, passing through the water inlet valve and its flow control, runs over the evaporator platen and then flows by gravity through
the dribbler holes down into the sump / reservoir.
The overflow, located in the sump tank, limits the level of the water which will be used to produce the next batch of ice cubes.
Meanwhile, the refrigerant as hot gas, discharged from the compressor, flows through the hot gas valve directly into the evaporator serpentine
bypassing the condenser.
The hot gas circulating in the serpentine of the evaporator warms up the copper moulds causing the ice cubes to defrost. The ice cubes, released
from the cups, drop by gravity onto a slanted cube chute, then through a curtained opening fall into the storage bin.
At the end of the defrost cycle, both the hot gas and the water inlet valves close and the machine starts again a new freezing cycle.
6.3
E.
As shown, per each individual key combination, it is possible to have a different length of the defrost cycle in relation to the different ambient
temperature situations; shorter when the ambient temperature is high and longer in colder ambient’s to partially compensate for the length of
the freezing cycle, which is longer in high ambient temperatures and shorter in low ones.
J.
Check, during the defrost cycle, that the incoming water flows correctly into the sump reservoir in order to refill it and that the surplus overflows
through the overflow drain tube.
If instead the time T2 gets longer than 45 minutes the unit stops immediately with the lighting up of the warning RED LIGHT.
The same could happen in case the time T1 (1st portion of freezing cycle) gets longer than 15 minutes.
Once completed the freezing cycle 2nd or 3rd phase (this last one is dependent on the length of the second phase of freezing cycle - T2) the
system goes automatically into the defrost cycle Ts.
The defrost cycle also has a prefixed length that can vary in relation to the time T2, as shown in Table C.
At completion of the defrost cycle the P.C. BOARD puts the unit into a new freezing cycle.
K.
Check the texture of ice cubes just released. They have to be in the right shape with a small depression of about 5-6mm in their crown.
If not, wait for the completion of the second cycle before performing any adjustment.
If required, the length of the timed freezing cycle can be modified by changing the DIP SWITCH keys setting as illustrated in Table B Page
18.
If the ice cubes are shallow and cloudy, it is possible that the ice maker runs short of water during the freezing cycle second phase or, the quality
of the supplied water requires the use of an appropriate water filter or conditioner.
Components Description
L.
To be sure of the correct operation of ice level control device, place one hand between its sensing “eyes” to interrupt the light beam.
The RED LIGHT located in the front of the P.C. BOARD goes immediately OFF, and after 60 seconds, the unit stops with the simultaneous
glowing of the 2nd YELLOW LIGHT to monitor the BIN FULL situation (Fig.6) Page 20.
Take the hand out from the ice level control sensors to allow the resumption of the light beam; the RED LIGHT, located in the front of the P.C.
BOARD, will glow immediately.
After approximately 6 seconds the ice maker resumes its operation with the immediate glowing of the FOURTH YELLOW LIGHT indicating
UNIT IN OPERATION and the extinguishing of the “BIN FULL” YELLOW LIGHT.
EVAPORATOR TEMPERATURE SENSOR
The evaporator temperature sensor probe, located in contact with the evaporator serpentine, detects the dropping of the evaporator temperature
during the freezing cycle and signals it by supplying a current flow to the microprocessor of The P.C. BOARD.
According to the current signal and to how long after this is received, the microprocessor may or not give the consent to the ice maker to complete
the freezing cycle.
The low voltage current transmitted, from the evaporator temperature sensor to the P.C. BOARD, is signalled by the lighting up of the fourth (Time
T2) and fifth (Time T1) RED LEDS placed in the front of the P.C. BOARD to inform the service engineer, of the normal (regular) progression
of the freezing cycle.
NOTE: The ICE LEVEL CONTROL (INFRARED SYSTEM) is independent from the temperature however, the reliability of its detection can be
affected by external light radiation’s or by any sort of dirt and scale sediment which may deposit directly on the light source and on the receiver.
To prevent any possible ice maker malfunction, due to negative affection of the light detector, it is advisable to locate the unit where it is not
reached by any direct light beam or light radiation, also it is recommended to keep the bin door constantly closed and to follow the instructions
for the periodical cleaning of the light sensor elements as detailed in the MAINTENANCE AND CLEANING PROCEDURES.
M.
10
Remove, in installed, the refrigerant service gauges and re-fit the unit service panels previously removed.
15
9.
Technical Specification - R134A Machines
MODEL
B.
FCI 20
FCI 30
FCI 40
FCI 60
FCI 85
Output – kg/24hr.
18
26
34
57
76
Ice prod. per cycle
0.28kg
0.42kg
0.42kg
0.86kg
0.86kg
Freeze time cycle
19.5 min
21.2 min
16 min
19.5 min
14.5 min
Cubes per cycle
16
24
24
48
48
Bin capacity kg
6.5
15
15
27
27
Electrical Supply
230/1/50 Hz
230/1/50 Hz
230/1/50 Hz
230/1/50 Hz
230/1/50 Hz
Amp start / run
11amp/2amp
11amp/2.2amp
17amp/3.3amp
19amp/4.1amp
26amp/5.5amp
10A
10A
10A
10A
16A
320
340
450
630
780
Water consumption
7.5 litre per hr
5.6 litre per hr
6.2 litre per hr
11.0 litre per hr
14.5 litre per hr
Min evap Temp °C
-26°C
-26°C
-26°C
-26°C
-26°C
Heat rejection watts
0.540
0.580
0.850
1.1
1.4
< 70 dB
< 70 dB
< 70 dB
< 70 dB
< 70 dB
Fuse rating
Watts consumption
(30°C ambient)
Noise level dBA
NOTE: The ice maker, after the interruption of its operation due to the ice level control cut-out, always restarts from the beginning of the freezing
cycle.
By changing the combination of the DIP SWITCH Keys numbers 8 and 9 it is possible to change the range of the ice level control temperature
sensor. This is shown in table D, keeping its cut out temperature always at +2˚C (35˚F).
C.
R134A Ice Machines Technical Data
(air cooled)
Model
Refrig. & Charge
Start Cycle
21°C amb/15°C w
End Cycle
21°C amb/15°C w
Start Cycle
32°C amb/15°C w
End Cycle
32°C amb/15°C w
Cond
Evap
Cond
Evap
Cond
Evap
Cond
Evap
(bar)
(°C)
(bar)
(°C)
(bar)
(°C)
(bar)
(°C)
FCI 20
R134A 0.250kg
10
-7
6.5
-27
13
-5
8
-26
FCI 30
R134A 0.230kg
12
-5
7
-26
16.5
-2
9.5
-24
FCI 40
R134A 0.320kg
11
-9
8.5
-26
14
-6
9.5
-24
FCI 60
R134A 0.450kg
11
-8
8.5
-27
14
-6
9
-25
FCI 85
R134A 0.540kg
11
-8
8
-26
15
-6
9.5
-24
10.
Operating Instructions - FCI 40 - 60 - 85 Only
ICE BIN LEVEL SENSOR
The ice bin level temperature sensor, secured to one of the storage bin walls, stops the operation of the entire ice maker at the end of the defrost
cycle when its sensing probe (in contact with the stored ice) reaches the temperature of +2˚C (35˚F) lighting up, in the meantime, the third RED
LED.
Once the ice is removed from the sensing probe, its temperature progressively rises up and as it reaches the value of +4.5˚C (40˚F) the ice bin
level temperature sensor transmits a low voltage current flow to the P.C. BOARD to restart the operation of the unit.
(For FCI 20-30 see previous section)
10.1 Start Up
After having correctly installed the ice maker and completed the plumbing and electrical connections, perform the following “Start-up”
procedure.
A.
Remove the unit front panel and locate the control box.
B.
Through the control box cover locate the grooved head (similar to a fillister screw head) of the electronic program selector.
With the help of a regular screwdriver turn the selector head in the OPERATION position. (The screwdriver bit must fit the head slot end to end,
this to avoid damage to the selector head slot).
C.
Give power to the unit to start it up by switching ‘ON’ the power line main disconnect switch.
6.5
P.C. BOARD (Data processor)
The P.C. BOARD, fitted in its plastic box located in the front of the unit, consists of two separated printed circuits one at high and the other at
low voltage integrated with a program selector; of six aligned LEDS monitoring to the service engineer the operation of the machine; of one
DIP SWITCH with ten keys; of input terminals for the leads of the two sensor probes and of input and output terminals for the leads of the ice
maker electrical wires.
The P.C. BOARD is the brain of the system and it processes, through its microprocessor, the signals received from the two sensors in order to
control the operation of the different electrical components of the ice maker (compressor, water pump, solenoid valves, etc.).
By turning the program selector it is possible to put the unit in the following different situations:
CLEANING/RINSING The water pump is the only electrical component in operation and it must be used during the cleaning or the rinsing
procedure of the water system of ice machine.
STAND BY The unit remains under electrical power but OUT of operation. It can be used by the service engineer in order to stop the unit during
the service and inspection operations.
IN OPERATION The unit is running through the freezing and defrost cycles stopping automatically only at full bin situation.
RE-SET To be selected to resume the unit operation when the ice maker shuts off due to the intervention of the security of the P.C. BOARD in
relation to exceeding the time of freezing cycle portion T1 and T2.
The six LEDS (not visible through the panel) placed in a vertical row in the front of the P.C. BOARD, monitor, from the top to the bottom, the
following situations:
Unit under electrical power
GREEN LIGHT
RED LIGHT Unit shut-off due to P.C. BOARD security (T1 >15’ or T2>45’)
RED LIGHT Unit shut-off at full storage bin
RED LIGHT Evaporator sensor at -13˚C (85˚F) or -16˚C (3˚F)
RED LIGHT Evaporator sensor at 0˚C (35˚F)
RED LIGHT Unit in freezing cycle mode
The microprocessor of the P.C. BOARD has also the important function to establish the length of the defrost cycle Ts in relation with the duration
of the second phase of the freezing cycle or time T2 as shown in Table B. Page 12.
Dip Switch
The P.C. BOARD which controls the entire operation of the ice maker, has a DIP SWITCH with ten switching keys which allow set up of
the microprocessor program in order to extend or to shorten the length of freezing cycle in relation to the different models and versions of ice
machines and to modify the sensing range of the ice bin level temperature sensor.
The 1st DIP SWITCH key is used to supply power to the water pump during the first 15-20 seconds of the defrost cycle to pump out all remaining
water from the sump tank in the unit along with the water drain valve.
The 2nd DIP SWITCH key allows a rapid check up (auto-diagnosis) to be made of the P.C. BOARD output connections (compressor, water
pump, fan motor, water inlet and hot gas solenoid valves) energising them in rapid sequence (2 seconds) one by one.
DURING THE AUTOMATIC OPERATION OF THE ICE MAKER THIS KEY MUST BE SET IN OFF POSITION.
ATTENTION The check up of the P.C. BOARD output must be performed in a very short time in order to avoid frequent start and stop
(every few seconds) of the electrical components which may damage them - especially the compressor.
The setting of the DIP SWITCH keys 3, 4, 5, 6 and 7 determines the length of the 3rd phase of freezing cycle (controlled by the electronic
timer) as detailed in Table B. Page 12.
The DIP SWITCH keys 8 and 9 setting determines the range between cut in and cut out temperature of the ice bin level temperature sensor
as specified in Table D. Page 12.
The 10th DIP SWITCH key is used to change the setting of the evaporator temperature sensor from -13˚C (8.5˚F) - OFF position (20,30,40
and 60 to -16˚C (3˚F) - ON position on model 85.
NOTE: Every time the unit returns under power, after having been switched off, both the water inlet valve and the hot gas valve get energized
for a period of 5 minutes, thus to admit new water to the machine sump reservoir to fill it up and, eventually, to wash-off any dirt that can have
deposited in it during the unit off period (Fig.1).
D.
During the water filling operation, check to see that the incoming water dribbles through the evaporator platen dribbler holes, down into the
sump reservoir to fill it up and also that the incoming surplus of water flows out through the overflow pipe into the drain line.
During the water filling phase the components energized are:
THE WATER INLET SOLENOID VALVE
THE HOT GAS SOLENOID VALVE
THE WATER DRAIN SOLENOID VALVE
(On request)
NOTE: If in the 5 minutes length of the water filling phase the machine sump reservoir does not get filled with water up to the rim of the overflow
pipe, it is advisable to check:
1. The water pressure of the water supply line that must be at least 1 bar (14 psig) Minimum (Max 5 Bar-70 psig).
2. The filtering device installed in the water line that may reduce the water pressure below the Minimum value of 1 bar (14 psig).
3. Any clogging situation in the water circuit like the inlet water strainer and/or the flow control.
14
11
7.
Dip Switch Positions
8.
Table A
Table C
DIP
SWITCHES
FCI 20
FCI 30
FCI 40
FCI 60
FCI 85
1
2
3
4
5
6
7
8
9
10
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
ON
OFF
OFF
ON
Circuit Board and Component Sequence of Operation
Fig. 1
Fig. 2
LENGTH OF THE DEFROST CYCLE Ts ACCORDING
TO THE TIME OF T2
T2
5’ <
6’ <
6’30” <
7’ <
8’ <
9 <
10’30”
12’ <
T2
Ts
< 5’
T2
T2
T2
T2
T2
T2
T2
T2
210”
195”
180”
165”
150”
135”
120”
105”
90”
<
<
<
<
<
<
<
6’
6’30”
7’
8’
9’
10’30”
12’
START UP
Fig. 3
START OF FREEZE CYCLE
Fig. 4
Table B
Table D
LENGTHS OF TIMED PORTION OF FREEZING CYCLE Ta ACCORDING TO
THE DIP SWITCH SETTING COMBINATIONS
3
4
5
6
7
Ta
min.
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
ICE LEVEL SENSOR CONTROL TEMPERATURE RANGE ACCORDING
TO THE 8 AND 9 DIP SWITCH SETTING COMBINATIONS
8
9
DELTA T °C
ON
OFF
ON
OFF
ON
ON
OFF
OFF
1
1.5
2
2.5
PHASE 2 OF FREEZE CYCLE
Fig. 5
DEFROST CYCLE
Fig. 7
Dip Switch Settings FCI 20 and FCI 30 - R134A Machines
Fig. 8
STAND BY
Fig. 9
1
2
3
4
5
6
7
8
9
10
FCI 20
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
FCI 20 W
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
FCI 30
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
FCI 30 W
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
12
BIN FULL
MACHINE FAULT RED LED ILLUMINATED
IT IS IMPORTANT TO NOTE THAT THE OPERATING INSTRUCTION AND PRINCIPLE OF
OPERATION FOR THE FCI 20 AND FCI 30 ARE THE SAME AS THE R22 MACHINES
Dip switch
PHASE 3 OF FREEZE CYCLE
Fig. 6
13
7.
Dip Switch Positions
8.
Table A
Table C
DIP
SWITCHES
FCI 20
FCI 30
FCI 40
FCI 60
FCI 85
1
2
3
4
5
6
7
8
9
10
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
ON
OFF
OFF
OFF
ON
OFF
ON
ON
ON
OFF
ON
OFF
OFF
ON
Circuit Board and Component Sequence of Operation
Fig. 1
Fig. 2
LENGTH OF THE DEFROST CYCLE Ts ACCORDING
TO THE TIME OF T2
T2
5’ <
6’ <
6’30” <
7’ <
8’ <
9 <
10’30”
12’ <
T2
Ts
< 5’
T2
T2
T2
T2
T2
T2
T2
T2
210”
195”
180”
165”
150”
135”
120”
105”
90”
<
<
<
<
<
<
<
6’
6’30”
7’
8’
9’
10’30”
12’
START UP
Fig. 3
START OF FREEZE CYCLE
Fig. 4
Table B
Table D
LENGTHS OF TIMED PORTION OF FREEZING CYCLE Ta ACCORDING TO
THE DIP SWITCH SETTING COMBINATIONS
3
4
5
6
7
Ta
min.
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
ON
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
OFF
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
ICE LEVEL SENSOR CONTROL TEMPERATURE RANGE ACCORDING
TO THE 8 AND 9 DIP SWITCH SETTING COMBINATIONS
8
9
DELTA T °C
ON
OFF
ON
OFF
ON
ON
OFF
OFF
1
1.5
2
2.5
PHASE 2 OF FREEZE CYCLE
Fig. 5
DEFROST CYCLE
Fig. 7
Dip Switch Settings FCI 20 and FCI 30 - R134A Machines
Fig. 8
STAND BY
Fig. 9
1
2
3
4
5
6
7
8
9
10
FCI 20
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
FCI 20 W
ON
OFF
OFF
ON
ON
OFF
ON
OFF
OFF
ON
FCI 30
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
FCI 30 W
ON
OFF
OFF
OFF
OFF
ON
ON
OFF
OFF
ON
12
BIN FULL
MACHINE FAULT RED LED ILLUMINATED
IT IS IMPORTANT TO NOTE THAT THE OPERATING INSTRUCTION AND PRINCIPLE OF
OPERATION FOR THE FCI 20 AND FCI 30 ARE THE SAME AS THE R22 MACHINES
Dip switch
PHASE 3 OF FREEZE CYCLE
Fig. 6
13
9.
Technical Specification - R134A Machines
MODEL
B.
FCI 20
FCI 30
FCI 40
FCI 60
FCI 85
Output – kg/24hr.
18
26
34
57
76
Ice prod. per cycle
0.28kg
0.42kg
0.42kg
0.86kg
0.86kg
Freeze time cycle
19.5 min
21.2 min
16 min
19.5 min
14.5 min
Cubes per cycle
16
24
24
48
48
Bin capacity kg
6.5
15
15
27
27
Electrical Supply
230/1/50 Hz
230/1/50 Hz
230/1/50 Hz
230/1/50 Hz
230/1/50 Hz
Amp start / run
11amp/2amp
11amp/2.2amp
17amp/3.3amp
19amp/4.1amp
26amp/5.5amp
10A
10A
10A
10A
16A
320
340
450
630
780
Water consumption
7.5 litre per hr
5.6 litre per hr
6.2 litre per hr
11.0 litre per hr
14.5 litre per hr
Min evap Temp °C
-26°C
-26°C
-26°C
-26°C
-26°C
Heat rejection watts
0.540
0.580
0.850
1.1
1.4
< 70 dB
< 70 dB
< 70 dB
< 70 dB
< 70 dB
Fuse rating
Watts consumption
(30°C ambient)
Noise level dBA
NOTE: The ice maker, after the interruption of its operation due to the ice level control cut-out, always restarts from the beginning of the freezing
cycle.
By changing the combination of the DIP SWITCH Keys numbers 8 and 9 it is possible to change the range of the ice level control temperature
sensor. This is shown in table D, keeping its cut out temperature always at +2˚C (35˚F).
C.
R134A Ice Machines Technical Data
(air cooled)
Model
Refrig. & Charge
Start Cycle
21°C amb/15°C w
End Cycle
21°C amb/15°C w
Start Cycle
32°C amb/15°C w
End Cycle
32°C amb/15°C w
Cond
Evap
Cond
Evap
Cond
Evap
Cond
Evap
(bar)
(°C)
(bar)
(°C)
(bar)
(°C)
(bar)
(°C)
FCI 20
R134A 0.250kg
10
-7
6.5
-27
13
-5
8
-26
FCI 30
R134A 0.230kg
12
-5
7
-26
16.5
-2
9.5
-24
FCI 40
R134A 0.320kg
11
-9
8.5
-26
14
-6
9.5
-24
FCI 60
R134A 0.450kg
11
-8
8.5
-27
14
-6
9
-25
FCI 85
R134A 0.540kg
11
-8
8
-26
15
-6
9.5
-24
10.
Operating Instructions - FCI 40 - 60 - 85 Only
ICE BIN LEVEL SENSOR
The ice bin level temperature sensor, secured to one of the storage bin walls, stops the operation of the entire ice maker at the end of the defrost
cycle when its sensing probe (in contact with the stored ice) reaches the temperature of +2˚C (35˚F) lighting up, in the meantime, the third RED
LED.
Once the ice is removed from the sensing probe, its temperature progressively rises up and as it reaches the value of +4.5˚C (40˚F) the ice bin
level temperature sensor transmits a low voltage current flow to the P.C. BOARD to restart the operation of the unit.
(For FCI 20-30 see previous section)
10.1 Start Up
After having correctly installed the ice maker and completed the plumbing and electrical connections, perform the following “Start-up”
procedure.
A.
Remove the unit front panel and locate the control box.
B.
Through the control box cover locate the grooved head (similar to a fillister screw head) of the electronic program selector.
With the help of a regular screwdriver turn the selector head in the OPERATION position. (The screwdriver bit must fit the head slot end to end,
this to avoid damage to the selector head slot).
C.
Give power to the unit to start it up by switching ‘ON’ the power line main disconnect switch.
6.5
P.C. BOARD (Data processor)
The P.C. BOARD, fitted in its plastic box located in the front of the unit, consists of two separated printed circuits one at high and the other at
low voltage integrated with a program selector; of six aligned LEDS monitoring to the service engineer the operation of the machine; of one
DIP SWITCH with ten keys; of input terminals for the leads of the two sensor probes and of input and output terminals for the leads of the ice
maker electrical wires.
The P.C. BOARD is the brain of the system and it processes, through its microprocessor, the signals received from the two sensors in order to
control the operation of the different electrical components of the ice maker (compressor, water pump, solenoid valves, etc.).
By turning the program selector it is possible to put the unit in the following different situations:
CLEANING/RINSING The water pump is the only electrical component in operation and it must be used during the cleaning or the rinsing
procedure of the water system of ice machine.
STAND BY The unit remains under electrical power but OUT of operation. It can be used by the service engineer in order to stop the unit during
the service and inspection operations.
IN OPERATION The unit is running through the freezing and defrost cycles stopping automatically only at full bin situation.
RE-SET To be selected to resume the unit operation when the ice maker shuts off due to the intervention of the security of the P.C. BOARD in
relation to exceeding the time of freezing cycle portion T1 and T2.
The six LEDS (not visible through the panel) placed in a vertical row in the front of the P.C. BOARD, monitor, from the top to the bottom, the
following situations:
Unit under electrical power
GREEN LIGHT
RED LIGHT Unit shut-off due to P.C. BOARD security (T1 >15’ or T2>45’)
RED LIGHT Unit shut-off at full storage bin
RED LIGHT Evaporator sensor at -13˚C (85˚F) or -16˚C (3˚F)
RED LIGHT Evaporator sensor at 0˚C (35˚F)
RED LIGHT Unit in freezing cycle mode
The microprocessor of the P.C. BOARD has also the important function to establish the length of the defrost cycle Ts in relation with the duration
of the second phase of the freezing cycle or time T2 as shown in Table B. Page 12.
Dip Switch
The P.C. BOARD which controls the entire operation of the ice maker, has a DIP SWITCH with ten switching keys which allow set up of
the microprocessor program in order to extend or to shorten the length of freezing cycle in relation to the different models and versions of ice
machines and to modify the sensing range of the ice bin level temperature sensor.
The 1st DIP SWITCH key is used to supply power to the water pump during the first 15-20 seconds of the defrost cycle to pump out all remaining
water from the sump tank in the unit along with the water drain valve.
The 2nd DIP SWITCH key allows a rapid check up (auto-diagnosis) to be made of the P.C. BOARD output connections (compressor, water
pump, fan motor, water inlet and hot gas solenoid valves) energising them in rapid sequence (2 seconds) one by one.
DURING THE AUTOMATIC OPERATION OF THE ICE MAKER THIS KEY MUST BE SET IN OFF POSITION.
ATTENTION The check up of the P.C. BOARD output must be performed in a very short time in order to avoid frequent start and stop
(every few seconds) of the electrical components which may damage them - especially the compressor.
The setting of the DIP SWITCH keys 3, 4, 5, 6 and 7 determines the length of the 3rd phase of freezing cycle (controlled by the electronic
timer) as detailed in Table B. Page 12.
The DIP SWITCH keys 8 and 9 setting determines the range between cut in and cut out temperature of the ice bin level temperature sensor
as specified in Table D. Page 12.
The 10th DIP SWITCH key is used to change the setting of the evaporator temperature sensor from -13˚C (8.5˚F) - OFF position (20,30,40
and 60 to -16˚C (3˚F) - ON position on model 85.
NOTE: Every time the unit returns under power, after having been switched off, both the water inlet valve and the hot gas valve get energized
for a period of 5 minutes, thus to admit new water to the machine sump reservoir to fill it up and, eventually, to wash-off any dirt that can have
deposited in it during the unit off period (Fig.1).
D.
During the water filling operation, check to see that the incoming water dribbles through the evaporator platen dribbler holes, down into the
sump reservoir to fill it up and also that the incoming surplus of water flows out through the overflow pipe into the drain line.
During the water filling phase the components energized are:
THE WATER INLET SOLENOID VALVE
THE HOT GAS SOLENOID VALVE
THE WATER DRAIN SOLENOID VALVE
(On request)
NOTE: If in the 5 minutes length of the water filling phase the machine sump reservoir does not get filled with water up to the rim of the overflow
pipe, it is advisable to check:
1. The water pressure of the water supply line that must be at least 1 bar (14 psig) Minimum (Max 5 Bar-70 psig).
2. The filtering device installed in the water line that may reduce the water pressure below the Minimum value of 1 bar (14 psig).
3. Any clogging situation in the water circuit like the inlet water strainer and/or the flow control.
14
11
7. The DIP. SWITCH keys setting is made in consideration of the model and of the type of condenser used (air or water cooled).
In Table B, page 12, are indicated the various lengths of the third portion of freezing cycle (Time mode) in accordance with the different
combinations of the DIP. SWITCH KEYS.
In Table A, page 12, are indicated the DIP. SWITCH keys combinations for the different models and versions as they are set in the factory.
The electrical components in operation during the freezing cycle are:
COMPRESSOR
FAN MOTOR (in air cooled version)
WATER PUMP and during the timed phase of freezing cycle (Time mode) they are joined by the ELECTRONIC TIMER.
On the air cooled versions the refrigerant head pressure is gradually reduced from a value of approx. 15 bars (210psig), generally recorded at
the beginning of the freezing cycle with the unit at 21˚C (70˚F) ambient temperature, to a minimum value of approx. 11 bars (155psig) just at
the end of the freezing cycle a few seconds before the starting of the defrost cycle.
The above values are in relation as well to the ambient temperature of the ice maker site and are subject to rise with the increase of this
temperature.
On the water cooled versions the refrigerant head pressure ranges between 13.5 and 14.5 bars (190-205psig) being controlled by the automatic
high pressure control that energises a water solenoid valve located on the inlet water line to the condenser, which modulates the cooling water
rate to the condenser.
With the unit installed in standard location (21˚C ambient temperature) at the start of the freezing cycle the refrigerant suction or low-pressure
lowers rapidly to 3.5 bars (50psig) then declines gradually, in relation with the growing of the ice thickness, to reach, at the end of the cycle
approx. 1.0 to 1.3 bars (14-l8psig) on 20,30 and 65 and at approx. 0.6 bars (8.5psig) on 40 with the cubes fully formed in the cup moulds.
6.2
F.
In the water cooled models the discharge pressure is kept constant at the value of 14 bars (195 psig) by means of the water regulating valve
located in the water supply line to the condenser.
In case of condenser clogging such to prevent the proper flow of the cooling air or fan motor out of operation, the condenser temperature rises
and when it reaches 70°C (160°F) the condenser temperature sensor shuts-off the ice maker with the consequent light-up of the RED WARNING
LIGHT (Fig.3). Page 20.
The same happen even for the water cooled version where the condenser probe is placed in contact with the refrigerant liquid line.
When its temperature reaches 62°C (145°F) it trips-off automatically the machine.
After having diagnosed the reason of the rise in temperature and removed its cause, it is necessary to turn the head of the selector - always
using an appropriate screwdriver - first on the RE-SET position then return it on previous OPERATION position, thus to put the machine in
condition to initiate a new freezing cycle.
The same can also be done by just switching OFF and ON the unit at main line switch.
In both cases the machine restarts with the usual 5 minutes water filling phase in order to provide enough water into the sump tank.
Defrost or Harvest Cycle
NOTE: The length of the defrost cycle (non-adjustable) is related to the length of the second phase of freezing cycle T2 as detailed in Table C.
Page 12.
G.
Check to see through the ice discharge opening that the spray systems are correctly seated and that the water jets uniformly reach the interior
of the inverted mould cups; also make sure that the plastic curtain is hanging freely and there is no excessive water spillage through it.
The electrical components in operation during this phase are:
COMPRESSOR
WATER INLET SOLENOID VALVE
HOT GAS SOLENOID VALVE
H.
The ice making process takes place thereby, with water sprayed into the moulds that gets gradually refrigerated by the heat exchange with the
refrigerant flowing into the evaporator serpentine.
During the freezing process, when the evaporator temperature falls below an established value, the evaporator temperature sensor supplies a
low voltage power signal to the electronic control device (P.C. BOARD) in order to activate an electronic timer. This one takes over the control
of the freezing cycle up to the complete formation of the ice cubes (Fig.4) Page 20.
NOTE: The length of the entire freezing cycle if govened by the evaporator temperature sensor which has its probe placed in contact with
the evaporator serpentine (Non adjustable) in combination with the electronic timer (Adjustable) incorporated in the P.C. BOARD. The timer
adjustment is factory set in consideration of cooling version and ice cube size (Medium, Large).
It is possible, however, to modify the timed length of the freezing cycle, by changing the DIP SWITCH keys setting.
In Table B, Page 18 are shown the various time extensions of the freezing cycle second phase, in relation with the different DIP SWITCH
settings.
I.
Operation - Control Sequence
At the start of freezing cycle the evaporator temperature sensor controls the length of the first T1 and second T2 portion of the freezing cycle.
As it senses the predetermined evaporating temperature of -13˚C (8.5˚F) (-16˚C on 85) it supplies a low voltage current to the P.C. BOARD in
order to activate the electronic timer which takes over the control of the remaining portion of the freezing cycle for a pre-fixed time Ta subject
to the DIP SWITCH keys setting (see Table B). Page 12.
In case the length of the second portion of the freezing cycle or time T2 gets long as to be between 35 and 45 minutes, the total length of the
freezing cycle will be limited to:
Tc = T1 + T2
skipping the added time Ta, controlled by the electronic timer.
After about 15-18 minutes from the beginning of the freezing cycle, in an hypothetic ambient temperature of 21°C, the defrost cycle takes place
with the hot gas and the water inlet valves being simultaneously activated (Fig.5). Page 20. The electrical components in operation are:
COMPRESSOR
WATER INLET SOLENOID VALVE
HOT GAS VALVE
and, if installed
WATER DRAIN SOLENOID VALVE
NOTE: The length of the defrost cycle is determined by the DIP SWITCH keys setting in conjunction with the ambient temperature sensor
located just in front of the condenser. The length of defrost cycle can be adjusted by changing the combination setting of keys 5, 6 and 7 of
DIP SWITCH as illustrated on Table C. Page 18.
During the normal operation mode the length or the total time of the freezing cycle is equal to the sum of the three partial times i.e.:
Tc = T1 + T2 + Ta
A.
Install, if necessary, the refrigerant service gauges on both the high side and low side Schräder valves to check the compressor head and
suction pressures.
NOTE: On air cooled models, the condenser temperature sensor, which is located within the condenser fins, keep the head (condensing)
pressure between 13,5 and 14,5 bars (190-205 psig).
NOTE: The evaporator temperature sensor, factory pre-set, is the same for all models and is not adjustable in the field.
6.4
At completion of the water filling phase (5 minutes) the unit passes automatically into the freezing cycle with the start up of:
COMPRESSOR
WATER PUMP
FAN MOTOR (in air cooled version) controlled by the condensing temperature sensor located within the condenser fins (Fig.2). Page 20.
10.2 Operational Checks
As the electronic timer has carried the system throughout the third phase of freezing cycle or as soon as the second phase T2 is over (when
its length has been as long as 35 to 45 minutes) the defrost cycle starts.
The incoming water, passing through the water inlet valve and its flow control, runs over the evaporator platen and then flows by gravity through
the dribbler holes down into the sump / reservoir.
The overflow, located in the sump tank, limits the level of the water which will be used to produce the next batch of ice cubes.
Meanwhile, the refrigerant as hot gas, discharged from the compressor, flows through the hot gas valve directly into the evaporator serpentine
bypassing the condenser.
The hot gas circulating in the serpentine of the evaporator warms up the copper moulds causing the ice cubes to defrost. The ice cubes, released
from the cups, drop by gravity onto a slanted cube chute, then through a curtained opening fall into the storage bin.
At the end of the defrost cycle, both the hot gas and the water inlet valves close and the machine starts again a new freezing cycle.
6.3
E.
As shown, per each individual key combination, it is possible to have a different length of the defrost cycle in relation to the different ambient
temperature situations; shorter when the ambient temperature is high and longer in colder ambient’s to partially compensate for the length of
the freezing cycle, which is longer in high ambient temperatures and shorter in low ones.
J.
Check, during the defrost cycle, that the incoming water flows correctly into the sump reservoir in order to refill it and that the surplus overflows
through the overflow drain tube.
If instead the time T2 gets longer than 45 minutes the unit stops immediately with the lighting up of the warning RED LIGHT.
The same could happen in case the time T1 (1st portion of freezing cycle) gets longer than 15 minutes.
Once completed the freezing cycle 2nd or 3rd phase (this last one is dependent on the length of the second phase of freezing cycle - T2) the
system goes automatically into the defrost cycle Ts.
The defrost cycle also has a prefixed length that can vary in relation to the time T2, as shown in Table C.
At completion of the defrost cycle the P.C. BOARD puts the unit into a new freezing cycle.
K.
Check the texture of ice cubes just released. They have to be in the right shape with a small depression of about 5-6mm in their crown.
If not, wait for the completion of the second cycle before performing any adjustment.
If required, the length of the timed freezing cycle can be modified by changing the DIP SWITCH keys setting as illustrated in Table B Page
18.
If the ice cubes are shallow and cloudy, it is possible that the ice maker runs short of water during the freezing cycle second phase or, the quality
of the supplied water requires the use of an appropriate water filter or conditioner.
Components Description
L.
To be sure of the correct operation of ice level control device, place one hand between its sensing “eyes” to interrupt the light beam.
The RED LIGHT located in the front of the P.C. BOARD goes immediately OFF, and after 60 seconds, the unit stops with the simultaneous
glowing of the 2nd YELLOW LIGHT to monitor the BIN FULL situation (Fig.6) Page 20.
Take the hand out from the ice level control sensors to allow the resumption of the light beam; the RED LIGHT, located in the front of the P.C.
BOARD, will glow immediately.
After approximately 6 seconds the ice maker resumes its operation with the immediate glowing of the FOURTH YELLOW LIGHT indicating
UNIT IN OPERATION and the extinguishing of the “BIN FULL” YELLOW LIGHT.
EVAPORATOR TEMPERATURE SENSOR
The evaporator temperature sensor probe, located in contact with the evaporator serpentine, detects the dropping of the evaporator temperature
during the freezing cycle and signals it by supplying a current flow to the microprocessor of The P.C. BOARD.
According to the current signal and to how long after this is received, the microprocessor may or not give the consent to the ice maker to complete
the freezing cycle.
The low voltage current transmitted, from the evaporator temperature sensor to the P.C. BOARD, is signalled by the lighting up of the fourth (Time
T2) and fifth (Time T1) RED LEDS placed in the front of the P.C. BOARD to inform the service engineer, of the normal (regular) progression
of the freezing cycle.
NOTE: The ICE LEVEL CONTROL (INFRARED SYSTEM) is independent from the temperature however, the reliability of its detection can be
affected by external light radiation’s or by any sort of dirt and scale sediment which may deposit directly on the light source and on the receiver.
To prevent any possible ice maker malfunction, due to negative affection of the light detector, it is advisable to locate the unit where it is not
reached by any direct light beam or light radiation, also it is recommended to keep the bin door constantly closed and to follow the instructions
for the periodical cleaning of the light sensor elements as detailed in the MAINTENANCE AND CLEANING PROCEDURES.
M.
10
Remove, in installed, the refrigerant service gauges and re-fit the unit service panels previously removed.
15
11.
Principle of Operation
COMPRESSOR, WATER INLET SOLENOID VALVE, HOT GAS VALVE
NOTE: The length of the defrost cycle is (non-adjustable) automatically determined by the microprocessor of The P.C. BOARD in relation to
the time T2 necessary for the unit to reduce the evaporator temperature from 0˚C (35˚F) to -1 3˚C (8.5˚F) and of the ambient temperature, as
illustrated in Table C.
As shown it is possible to have a different length of the defrost cycle in connection with the different length of the second phase of the freezing
cycle T2 relative to the ambient temperature situations; shorter when the ambient temperature is high and longer in colder ambients so to
partially compensate the length of the freezing cycle, which is longer in high ambient temperatures and shorter in low ones.
11.1 How it works
In the cube ice makers the water used to make the ice is kept constantly in circulation by an electric water pump which primes it to the spray
system nozzles from where it is diverted into the inverted mould cups of the evaporator. A small quantity of the sprayed water freezes into ice;
the rest of it cascades by gravity into the sump assembly below for recirculation.
11.2 Freezing Cycle
The Hot refrigerant gas discharged out from the compressor reaches the condenser where, being cooled down, condenses into liquid. Flowing
into the liquid line it passes through the drier filter, then it goes all the way through the capillary tube where, due to the heat exchanging action,
it loses some of its heat content so that its pressure and temperature are lowered as well.
Next the refrigerant enters into the evaporator serpentine (which has a larger I.D. then the capillary) and starts to boil off; this reaction is
emphasized by the heat transferred by the sprayed water.
The refrigerant then increases in volume and changes entirely into vapour.
The refrigerant vapour then passes through the suction accumulator (used to prevent any small amount of liquid refrigerant from reaching the
compressor) and through the suction line. In both the accumulator and the suction line it exchanges heat with the refrigerant flowing into the
capillary tube (warmer), before being sucked in the compressor and to be recirculated as high pressure, high temperature gas.
The freezing cycle is controlled by the evaporator temperature sensor (which has its probe in contact with the evaporator serpentine) that
determines the length of the cycle first portion.
When the temperature of the evaporator serpentine drops to a pre-set value, the evaporator sensor probe changes its electrical resistance
allowing a low voltage current (8-10 volts) to flow to the P.C. BOARD which in turn activates an electronic timer.
The timer, which is built-in the P.C. BOARD, takes over, from the evaporator temperature sensor, the control of the freezing cycle up to its
completion.
H.
Check, during the defrost cycle, that the incoming water flows correctly into the sump reservoir in order to refill it and that its surplus overflows
through the overflow drain tube.
I.
Check the texture of ice cubes just released. They have to be the right shape with a small depression of about 5-6mm in their crown.
If not, wait for the completion of the second cycle before performing any adjustment.
If the ice cubes require a correction to their shape, it is possible to modity the length of the timed freezing cycle by changing the DIP SWITCH
keys setting as illustrated in table B.
It the ice cubes are shallow and cloudy, it is possible that the ice maker runs short of water during the freezing cycle second phase or, the quality
of the supplied water requires the use of an appropriate water filter or conditioner or the installation of the optional water drain valve kit KWD.
To be sure of the correct operation of the ice level temperature sensor, located in one side of storage bin liner, during the defrost cycle place
one shovel of ice cubes in contact with its probe for approx. 30 sec.-1 minute.
As the temperature of storage bin sensor reaches the value of +2˚C (35˚F), the ice level control transmits a signal to the microprocessor of the
P.C. BOARD in order to stop the ice maker operation at the end of the defrost cycle with the simultaneous glowing of the 3rd RED LIGHT, to
monitor the BIN FULL situation (Fig.6). Page 13
With no more ice cubes in touch with the ice level control the temperature of its probe progressively rises to reach + 4.5˚C (40˚F) and at this
point the ice machine restarts to initiate a new freezing cycle with the simultaneous extinguishing of the 3rd RED LIGHT.
J.
NOTE The CUT-IN RANGE OF THE ICE LEVEL CONTROL SENSOR can be adjusted as shown in table D; its cut out setting remains however
at + 2˚C (35˚F).
NOTE: The change of the electrical potential of the evaporator sensor with the consequent activation of the timer (Time mode) is signalled by
the glowing-up of the RED LED located in the front of the P.C. BOARD.
ATTENTION: In case, after 15 minutes from the beginning of the freezing cycle, the temperature of the evaporator sensor probe is higher then
0°C (32°F) (Shortage of refrigerant, inoperative hot gas valve, etc.) the P.C. BOARD switch OFF immediately the unit with the simultaneous
blinking of the WARNING RED LED.
The length of the second portion of the freezing cycle is pre-fixed and related to the setting of the first four DIP SWITCH keys which is made in
relation with the different unit versions.
The DIP SWITCH keys setting is made in consideration of the type of condenser used.
In Table B, page 18, are indicated the various lengths of the second portion of freezing cycle (Time mode) in relation to the different combinations
of the DIP SWITCH KEYS.
In Table A, page 18, is illustrated the DIP SWITCH keys combinations for the different unit versions as they are set in the factory.
The electrical components in operation during the freezing cycle are:
COMPRESSOR
FAN MOTOR (in air cooled version)
WATER PUMP
CONTACTOR COIL
and during the second phase of freezing cycle (Time mode) they are joined by the
ELECTRONIC TIMER
The refrigerant head pressure, in the course of the freezing cycle, ranges between 13.5 and 14.5 bars (190-205 psig) being controlled by the
temperature sensor probe located within the condenser fins (Air cooled version) or, it is kept constant at 14 bars (195 psig) by means of the
water regulating valve (water cooled version).
On the air cooled version, the condenser temperature sensor, when senses a rising of the condenser temperature beyond the pre-fixed limit,
changes its electrical resistance and send a low voltage power signal to the Micro Processor of P.C. BOARD which in turn energizes, through
a TRIAC, the FAN MOTOR.
When the opposite situation occurs, i.e. the condenser temperature gets below the pre-fixed limit, the temperature sensor changes again its
electrical resistance reducing therefore the current flow to the P.C. BOARD to cause the fan motor to temporary cut-off.
NOTE: In case the condensor temperature probe senses that the condensor temperature has rised to 70°C (160°F) - on air cooled versions
- or 62°C (145°F) - on water cooled versions - for one of the following abnormal reasons:
CLOGGED CONDENSOR (Air cooled version)
FAN MOTOR OUT OF OPERATION (Air cooled version)
INSUFFICIENT FLOW OF COOLING WATER (Water cooled version)
AMBIENT TEMPERATURE HIGHER THEN 40°C (100°F)
it causes the total and immediate SHUT-OFF of the machine in order to prevent the unit from operating in abnormal and dangerous conditions.
When the ice maker stops on account of this protective device, there is a simultaneous glowing of the RED LED, warning the user of the Hi
Temperature situation. After having eliminated the source of the condensor hi-temperature, to restart the machine it is necessary first, to rotate
for a while the program selector on RE-SET position then, to rotate it again on OPERATION position.
The same can be done by just switching OFF and ON the unit at main line switch.
The ice machcine resumes its normal operation by going through the 5 minutes water filling phase.
At the start of the freezing cycle the refrigerant suction or lo-pressure lowers rapidly to 3.3 bar-45 psig then it declines gradually - in relation
with the growing of the ice thickness - to reach, at the end of the cycle, approx. 1 bar -14 psig with the cubes fully formed in the cup moulds.
The total length of the freezing cycle ranges from 15-18 minutes.
11.3 Defrost or Harvest Cycle
As the electronic timer has carried the system throughout the second phase of freezing cycle, the defrost cycle starts.
ATTENTION: In case the unit is be able to reach 0°C (32°F) evaporating temperature within 15 minutes, or after 45 minutes from the beginning
of the freezing cycle it has not yet reached the evaporator temperature of -15°C (5°F), the machine goes straight into the defrost cycle omitting
the timed portion of the freezing cycle related to the setting of the first four DIP SWITCHES.
6.
6.1
6.2
Principle of Operation
How it works
In the cube ice makers the water used to make the ice is kept constantly in circulation by an electric water pump which primes it to the spray
system nozzles from where it is diverted into the inverted mould cups of the evaporator. A small quantity of the sprayed water freezes into ice;
the rest of it cascades by gravity into the sump assembly below for recirculation.
Freezing Cycle
The hot gas refrigerant discharged out from the compressor reaches the condenser where, being cooled down, condenses into liquid. Flowing
into the liquid line it passes through the drier filter, then it goes all the way through the capillary tube where, due to the heat exchanging action,
it loses some of its heat content so that its pressure and temperature are lowered as well.
Next the refrigerant enters into the evaporator serpentine (which has a larger l.D. than the capillary) and starts to boil off; this reaction is
emphasised by the heat transferred by the sprayed water.
The refrigerant then increases in volume and changes entirely into vapour.
The vapour refrigerant then passes through the suction accumulator (used to prevent any small amount of liquid refrigerant reaching the
compressor) and through the suction line. In both the accumulator and the suction line it exchanges heat with the refrigerant flowing into the
capillary tube (warmer), before being sucked into the compressor and recirculated as hot compressed refrigerant gas.
The freezing cycle is controlled by the evaporator temperature sensor (which has its probe in contact with the evaporator serpentine) which
determines the length of the first and second portion of it and it is signalled by the glowing of the 6th RED LED.
The first portion length or time T1 (non-adjustable) is equal to the time required by the temperature sensor to fall to 0˚C (35˚F). When reached,
it is signalled by the glowing of the 5th RED LED.
NOTE If, after 15 minutes, the evaporator temperature has not yet reached the value of 0˚C (35˚F) (due to a partially or total shortage of
refrigerant or to a too high condensing temperature, etc.) the sensor, through the P.C. BOARD, causes the unit to stop the operation with the
simultaneous glowing of the SECOND RED WARNING LED (Fig. 7). Page 13. After having eliminated the source of the unit trip off, to restart
the machine operation it is necessary first to rotate the program selector to the RE-SET position, then put it again on to OPERATION position
or, alternatively, switch OFF and ON the unit at the power line Main Switch.
The second portion length of freezing cycle or time T2 (non-adjustable) is equal to the time required by the evaporator temperature to go from
0˚C (35˚F) to -13˚C (8.5˚F) on models 20, 30, 40 and 60 or to -16˚C (3˚F) on model 85. The sensor will light-up the 4th RED LED.
NOTE In case the time T2 gets longer than 45 minutes, the unit stops with the glowing of the second RED WARNING LED.
Also in this case, after having eliminated the source of the trip OFF to restart the machine it is necessary first to rotate the program selector to
the RESET position then put it again on OPERATION or, switch OFF and ON the unit at power line Main Switch.
The third portion or time Ta (added time) of the freezing cycle is controlled by the electronic timer of P.C. BOARD. As the evaporator temperature
reaches the value of -13˚C (8.5˚F) or to -16˚C (3˚F); the sensing probe of the evaporator sensor (in contact with the serpentine) changes its
electrical resistance causing a low voltage current to flow to the P.C. BOARD which, thereby, activates an electronic timer.
NOTE The activation of the timer (Time mode) of P.C. BOARD is signalled by the glowing of fourth RED LED located in the front of the P.C.
BOARD.
ATTENTION In case the length of the second portion of freezing cycle or time T2, lasts as long as between 35 and 45 minutes, the
third portion or time Ta gets skipped by the P.C BOARD which puts the unit directly in the defrost or harvest cycle.
The length of the third portion of the freezing cycle (adjustable) is pre-fixed and related to the setting of the DIP SWITCH keys 3, 4, 5, 6 and
NOTE: The length of the defrost cycle is pre-determined by the setting of the DIP SWITCH KEYS NO. 5, 6 and 7 and it is related as well to the
16
9
4.
Technical Specification - R22 Machines
MODEL
FCI 20
FCI 30
FCI 40
FCI 60
FCI 85
18 (20.5)
26 (34)
34 (42)
57 (70)
78 (90)
Bin storage capacity – kg
6.5
15
15
27
27
Cubes per cycle
16
24
24
48
48
0.28 (0.38)
0.42 (0.6)
0.42 (0.6)
0.82 (1.2)
0.82 (1.2)
22 (25)
23.5 (24.5)
15.75 (19.15)
20.5 (23.6)
15.25 (18.75)
9.5/1.9 (9.5/1.9)
11/2.2 (11/2.1)
16/3.3 (16/3.3)
16/3.5 (16/4)
24.5/4.4 (24.5/4)
Watts consumption
300 (280)
350 (330)
450 (450)
650 (650)
810 (760)
Water consumption
5.8lt/hr
5lt/hr
6.3lt/hr
12.5lt/hr
15.5lt/hr
R22
R22
R22
R22
R22
Ref. charge, grams
300gr
280gr
290gr
420gr
460gr
Heat rejection, watts
500
600
850
1100
1600
Output – kg/24hr.
kg per cycle
Cycle time – minutes
Amps start/run
Refrigerant
5.
5.1
A.
C.
D.
E.
F.
Affer having correctly installed the ice maker and completed the plumbing and electrical connections, perform the following ‘Start-up’
procedure.
Give power to the unit to start it up by switching ‘ON’ the power line main disconnect switch.
The 1st GREEN LED will glow.
During the water filling operation, check to see that the incoming water dribbles, through the evaporator platen dribbler holes, down into the
sump reservoir to fill it up and also that the incoming surplus of water flows out through the overflow pipe into the drain line.
During the water filling phase the components energised are:
THE WATER INLET SOLENOID VALVE, THE HOT GAS SOLENOID VALVE, WATER DRAIN VALVE
Operational Checks
At completion of the water filling phase (5 minutes) the unit passes automatically into the freezing cycle with the start up of: COMPRESSOR
WATER PUMP FAN MOTOR in air cooled version (Fig. 2) Page 13 and the glowing of the 6th RED LED.
Check to see through the curtained ice discharge opening that the spray system is correctly seated and that the water jets uniformly reach the
interior of the inverted mould cups; also make sure that the plastic curtain is hanging freely and there is no excessive water spilling through it.
The ice making process takes place thereby, with the water sprayed into the moulds getting gradually refrigerated by the heat exchange occurring
with the refrigerant flowing into the evaporator serpentine.
During the freezing process, when the evaporator temperature falls to 0˚C (35˚F) the evaporator temperature sensor, located in contact with
the evaporator serpentine, supplies a low voltage power signal to the electronic control device (P.C. BOARD) which in first instance generates
the glowing of the 5th RED LED located in the front of the printed circuit board (Fig. 3). Page 13
The unit remains however in its normal freezing cycle mode until the evaporator temperature detected by the sensor reaches the temperature
of -13˚C (8.5˚F) on models 20, 30 40 and 60 and to -16˚C (3˚F) on model 85.
When the evaporator temperature falls below the above value, the evaporator temperature sensor supplies a low voltage power signal to the
P.C. BOARD in order to activate the electronic timer. This takes over the control of the freezing cycle up to the complete formation of the ice
cubes (Fig. 4) Page 13, with the lighting up of the 4th RED LED located just above the previous lighted one.
NOTE The length of the entire freezing cycle is the sum of the lengths of three phases, two of which, (T1 + T2) controlled by the evaporator
tempemtum sensor, which has its probe placed in contact with the evaporator serpentine (non adjustable), and ONE. (Ta) by the electronic
tImer (Adjustable) incorporated in the P.C. BOARD.
The lengths of the first two phases, related to the evaporator temperature and controlled by its sensor, are:
TI - The time elapsed since the beginning of freezing cycle up to when the evaporator reaches the temperature of 0˚C (35˚F).
T2 - The time required for the evaporator to fall from 0˚C (35˚F) to -13˚C (8.5˚F) or to 16˚C (3˚F).
The third time Ta - Time added - is in relation to one of the different combinations of the five keys 3,4,5, 6, and 7 of the DIP SWITCH located
in the front of the P.C. BOARD. The combination is factory set in consideration of the ice maker type and of its cooling version. It is possible,
however, to vary the timed length of the freezing cycle, by changing the DIP SWITCH keys settings.
In Table B are shown the various time extensions of the freezing cycle third phase Ta, in relation with the different DIP SWITCH keys
settings.
G.
At the end of the defrost cycle, both the hot gas and the water inlet valves close, so the machine initiates another freezing cycle.
11.4 Operation - Control Sequence
At the start of the freezing cycle, the evaporator temperature sensor controls the length of the first part of the freezing cycle. As it reaches a
pre-determined temperature, it supplies a low voltage current to the P.C. BOARD in order to activate the electronic timer which takes over the
control of the freezing cycle for a pre-fixed time according to the DIP SWITCH keys setting (see Table B). Page 18.
NOTE: The evaporator temperature sensor, factory pre-set, is the same for all the models and is not adjustable in the field.
Once completed the freezing cycle 2nd phase the system goes automatically into the defrost cycle which has also a pre-fixed length that can
vary depending upon the actual ambient temperature as shown in Table C. Page 18.
At completion of the defrost cycle the P.C. BOARD command the unit to start again a new freezing cycle.
Start Up
NOTE: If in the 5 minutes length of the water filling phase the machine sump reservoir does not fill up to the rim of the overflow pipe, it is
advisable to check:
1. The water pressure of the water supply line that must be at least 1 bar (14 psig) Minimum (Max 5 bar-70 psig).
2. The filtering device installed in the water line that may reduce the water pressure below the Minimum value of 1 bar (14 psig).
3. Any clogging situation in the water circuit like the inlet water strainer and/or the flow control.
5.2
NOTE: The length of the defrost cycle, factory set, can vary in accordance with the actual ambient temperature (as shown on Table C). Page
18. For instance, in a high ambient temperature situation it can be reduced to recover some of the time spent for the longer freezing cycle.
Operating Instructions - R22 Machines
NOTE: Every time the unit returns under power, after having been switched off, both the water inlet valve and the hot gas valve get energised
for a period of 5 minutes, thus to admit new water to the machine sump reservoir to fill it up and, eventually, to wash off any dirt that may be
deposited in it during the unit oft period (Fig. 1). Page 13
B.
ambient temperature as detailed in Table C. Page 18.
The electrical components in operation during this phase are:
COMPRESSOR
WATER PUMP
WATER INLET SOLENOID VALVE
HOT GAS SOLENOID VALVE
The incoming water, passing through the water inlet valve and the flow control, runs over the evaporator platen and then flows by gravity through
the dribbler holes down into the sump/reservoir.
The water filling the sump/reservior forces part of the surplus water from the previous freezing cycle to go out to the waste through the overflow
pipe. This overflow limits the level of the sump water which will be used to produce the next batch of ice cubes.
Meanwhile, the high pressure, high temperature refrigerant, discharged from the compressor, flows through the hot gas valve directly into the
evaporator serpentine by-passing the condenser.
The hot gas circulating into the serpentine of the evaporator warms up the copper moulds causing the defrosting of the ice cubes. The ice
cubes, released from the cups, drop by gravity onto a slanted cube chute, then through a curtained opening they fall into the storage bin.
After about 20-22 minutes from the beginning of the freezing cycle, in a hypothetic ambient temperature of 21˚C (70˚F), the defrost cycle takes
place with the hot gas and the water inlet valves being simultaneously activated (Fig. 5). Page 13
The electrical components in operation in this new situation are:
8
12.
Components Description
12.1 Evaporator Temperature Sensor
The evaporator temperature sensor probe, located in contact with the evaporator serpentine detects the dropping of the evaporator temperature
during the freezing cycle and signals it by supplying a current flow to the micro processor of the P.C. BOARD.
According to the current received, the evaporator sensor supplies power to the P.C. BOARD first, when it reaches 0°C (32°F), second at -15°C
(5°F); in this second case its supply power to the electronic timer built into the P.C. BOARD so that it may take control of the length of the 2nd
phase of freezing cycle.
The length of the timed phase is pre-fixed by the setting of the keys 1, 2, 3 and 4 of the DIP SWITCH.
The activation of the electronic timer (-15°C -5°F) is monitored by the lighting up of the RED LED placed in the front of the P.C. BOARD. This
lighting up occurs usually in the mid period of the freezing cycle and signals the switching from the first to the second phase of the freezing
cycle.
12.2 Condenser Temperature Sensor
The condenser temperature sensor probe, located within the condenser fins (air cooled version) or in contact with the tube coil (water cooled
version) detects the condenser temperature variations and signals them by supplying current, at low voltage, to the P.C. BOARD.
In the air cooled versions, in relation to the different current received, the micro processor of the the P.C. BOARD supplies, through a TRIAC,
the power at high voltage to the fan motor so to cool the condenser and to reduce its temperature rises and reaches 75°C (170°F) the current
arriving to the micro processor is such to cause an immediate and total stop of the machine operation.
12.3 Ambient Temperature Sensor
The probe of this sensor, located in the front of the ice maker condenser (air cooled version) and in the water supply line to the condenser
(water cooled version) has the function to detect the ambient or the water temperature and, by changing its own electrical resistance, supplies
a different current flow to the P.C. BOARD.
This different current flow received by the P.C. BOARD, is processed by the micro processor in order to extend or shorten the defrost cycle
length (longer in cold ambient situations, shorter in warm ones).
12.4 Ice Bin Level Light Control
The electronic ice bin level control, located into the storage bin, has the function to stop the operation of the ice machine when the light beam
between the light source and the sensor is interrupted by the ice cubes stored in the bin. When the light beam is interrupted the RED LED
located in the front of the P.C. BOARD goes off; in case the light beam is constantly interrupted for more than 60 seconds, the ice machine
stops with the glowing-up of the 2nd YELLOW LED to monitor the situation of ice bin full. The 60 seconds of delay prevent that an ice scoop
movement or the ice dropping through the ice chute (interrupting for a while the light beam) can stop the operation of the unit.
As soon as the ice is scooped out (with the resumption of the light beam between the two infrared sensor of ice level control) the RED LED is
lighted up and after 6 seconds the ice machine restarts again with the extinguishing of the 2nd YELLOW LED.
12.5 E.P.C. Board (Data processor)
The P.C. BOARD, fitted in its plastic box located in the front of the unit, consists of two separated printed circuits one at high and the other
at low voltage integrated with a program selector, of two fuses one on power in (100m A) and one on power out (16 A) of five aligned LEDS
monitoring the operation of the machine, of two extra monitoring RED LEDS, of one DIP SWITCH with ten keys, of two small plugs located on
its back side, of input terminals for the leads of the sensor probes and input and output terminals for the leads of the ice maker electrical wires.
The P.C. BOARD is the brain of the system and it processes, through its micro processor, the signals received from the four sensors in order
to control the operation of the different electrical components of the ice maker (compressor, water, pump, solenoid valves, etc.).
By turning the program selector it is possible to put the unit in the following different situations.
CLEANING/RINSING: The water pump is the only electrical component in operation and it must be used during the cleaning or the rinsing
procedure of the water system of ice machine.
STAND BY: The unit remain under electrical power but OUT of operation. It can be used by the service engineer in order to stop the unit during
17
the service and inspection operations.
IN OPERATION: The unit is running through the freezing and defrost cycle stopping automatically only at full bin situation.
RE-SET/HI TEMPERATURE: To be selected to resume the unit operation when the ice maker shuts off due to the intervention of the condenser
temperature sensor (too high condensing temperature).
The five LEDS, placed in a row in the front of the P.C. BOARD, monitor the following situations:
GREEN LIGHT:
Unit under electrical power
YELLOW LIGHT:
Unit shut-off at full storage bin
RED LIGHT:
Unit shut-off due to hi-condensing
temperature
Blinking:
Unit shut-off due to hi-evaporating
temperature
YELLOW LIGHT:
Unit in freezing operation
Unit in cleaning/rinsing mode
YELLOW LIGHT:
F20 & F40 A/W Wiring Diagram
12.6 DIP SWITCH
The P.C. BOARD which controls the entire operation of the ice maker, has a DIP SWITCH with ten switching keys which allow to set up the
micro processor program in order to extend or to shorten the length of freezing and defrost cycles in relation to the different models and versions
of ice machines.
The DIP SWITCH first four keys setting determines the length of the 2nd phase of freezing cycle (controlled by the electronic timer) as detailed
in Table B.
The DIP SWITCH keys 5, 6 and 7 setting determines the length of the defrost cycle according to the ambient temperature sensor as specified
in table C.
The 8th DIP SWITCH key allows to make a rapid check up of the P.C. BOARD output connections (compressor, water pump, fan motor, water
inlet and hot gas solenoid valves) energizing them in rapid sequence (2 seconds) one by one.
DURING THE AUTOMATIC OPERATION OF THE ICE MAKER THIS KEY MUST BE SET IN OFF POSITION.
ATTENTION: The check up of the P.C. BOARD output must be performed in a very short time in order to avoid frequent starts and stops (every
few seconds) of the electrical components which may damage them, especially the compressor.
The 9th key allows the operation of the water pump even during the defrost cycle. On B 90 it must be set all the time to OFF position.
The 10th key is used to supply power to the water pump during the first 15-20 seconds of the defrost cycle to drain out all remaining water from
the sump tank in the unit equipped with the solenoid drain valve i.e. the KWD drain system.
13. Dip Switch Settings FCI 40-60-85
Table A
Dip switch
1
2
3
4
5
6
7
8
9
10
FCI 40
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 40 W
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 60
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 60 W
ON
ON
OFF
ON
ON
ON
OFF
OFF
ON
OFF
FCI 85
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
FCI 85 W
OFF
OFF
ON
ON
ON
ON
OFF
OFF
ON
OFF
Table B
LENGTH OF TIMED PORTION OF FREEZING CYCLE ACCORDING TO DIP SWITH COMBINATIONS
1
2
3
4
1
2
3
4
1
ON
ON
OFF
OFF
25 min
8
OFF
ON
OFF
ON
11 min
2
OFF
OFF
ON
OFF
23 min
9
ON
ON
OFF
ON
9 min
3
ON
OFF
ON
4
OFF
ON
ON
OFF
21 min
10
OFF
OFF
ON
ON
7min
OFF
19 min
11
ON
OFF
ON
ON
5 min
5
ON
ON
ON
OFF
17 min
12
OFF
ON
ON
ON
3 min
6
OFF
OFF
OFF
ON
15 min
13
ON
ON
ON
ON
1 min
7
ON
OFF
OFF
ON
13 min
Table C
LENGTH OF DEFROST CYCLE (IN SEC.) ACCORDING TO THE AMBIENT TEMPERATURE AND TO
DIP SWITCH SETTING COMBINATIONS
5
6
7
0-5°C
5-10°C
10-15°C
15-20°C
20-25°C
25-30°C
30-35°C
35-40°C
ON
ON
OFF
180 sec
150 sec
120 sec
90 sec
90 sec
90 sec
90 sec
90 sec
OFF
OFF
ON
210 sec
180 sec
150 sec
120 sec
120 sec
120 sec
90 sec
90sec
ON
OFF
ON
240 sec
210 sec
180 sec
150 sec
150 sec
120 sec
120 sec
90 sec
OFF
ON
ON
240 sec
210 sec
180 sec
150 sec
150 sec
120 sec
120 sec
120 sec
ON
ON
ON
270 sec
240 sec
210 sec
180 sec
180 sec
150 sec
150 sec
150 sec
18
7
I.
The machine may stop working if the condenser temperature exceeds the pre-set temperature of the Over Temperature Thermostat (nonadjustable) due to a very high ambient temperature, condenser fan failure, dirty/ blocked condenser. To restart the machine, depress the
protruding button on the Alarm Reset.
J.
Changes to the defrost time. Under normal circumstances no adjustments should be necessary.
The fixed time can be adjusted by releasing the tension on the cam screw, turning the dial anti-clockwise to increase the defrost time and
clockwise to decrease the defrost time, retighten the screw when the adjustment has been completed.
Note. If adjustment are made it will effect the freeze cycle.
Increasing the defrost time will shorten the freeze time so adjustments to the cube size thermostat may need to be made to increase
the freeze temperature.
Decreasing the defrost time will increase the freeze time so adjustments to the cube size thermostat may need to be made to decrease
the freeze temperature.
3.4
14.
Wiring Diagram
WIRING DIAGRAM - SCHEMA ELETTRICO
SCHÉMA ÉLECTRIQUE - SCHALTUNGSCHEMA
AIR & WATER COOLED - RAFFREDDAMENTO AD ARIA ED AD ACQUA.
REFROIDISSEMENT A AIR ET A EAU - LUFT UND WASSERGEKÜHLT
220-240/50/1
Cleaning/Rinsing For F20, 40, 60, 85
A.
Remove the bottom front panel and locate the changeover switch.
B.
Remove the top cover to gain access to the evaporator.
D.
Wait till the machine finishes its freeze cycle and then turn off the electrical supply to the machine.
D.
Prepare the cleaning solution as per the manufactures instructions on the Ice Machine Cleaner.
Warning. The Ice Machine Cleaner contains Phosphoric and Hydroxyacetic acids. These compounds are corrosive and may cause burns if
swallowed. If swallowed DO NOT induce vomiting, drink lots of water or milk and contact your Doctor immediately.
In case of external contact wash off with clean water.
E.
Scoop out all of the ice cubes stored in the bin in order to prevent them from being contaminated by the cleaning solution then drain the water
from the sump reservoir by removing the plastic overflow pipe. Once the water has drained from the sump replace the pipe.
F.
Remove the evaporator cover and slowly pour the solution onto the evaporator platen. Use a soft brush if necessary to remove stubborn
deposits.
G.
Press the switch to the clean position and restore the electrical supply to the machine.
H.
Leave the machine in the cleaning/rinsing mode for at least twenty minutes then turn the machine off at the electrical supply to the machine.
It may be necessary to clean the water spray separately. If required remove the spray plate from the machine, mix a solution of the cleaner in
a bowl or bucket and immerse the plate in it. When clean thoroughly rinse with clean water and re-fit it into the machine.
I.
Drain the cleaning solution from the sump reservoir by removing the plastic overflow pipe. Once the solution has drained from the sump replace
the pipe.
J.
Pour two to three litres of clean water over the evaporator platen to rinse of the remaining solution and ensure sufficient water is in the reservoir.
Ensure that the switch is still in the ‘CLEAN’ position and turn on the electrical supply to the machine. Leave the machine in the cleaning mode
for at least five minutes to thoroughly rinse the entire water system.
K.
Drain the rinsing water from the sump reservoir by removing the plastic overflow pipe. Once the rinsing water has drained from the sump replace
the pipe and thoroughly wipe the interior of the machine.
L.
Replace the evaporator cover and top service panel, turn on the electrical supply to the machine with the switch still in the wash position.
Leave the switch in this position for approximately five minutes to allow the water reservoir to fill up.
M.
Change the switch setting to the freeze position to start the freeze process.
N.
At the completion of the freezing and harvest cycle make sure the ice cubes are the proper texture and do not have an acid taste.
Attention. If the ice cubes are cloudy-white and have an acid taste, discard them immediately by pouring warm water over them to prevent them
from being used.
O.
Once you are satisfied that all of the cleaning solution has been removed from the machine rinse the storage bin with clean water and wipe
clean.
Remember. To prevent the accumulation of undesirable bacteria it is necessary to sanitize the interior of the storage bin with an antialgae solution each week.
(1)
(2)
(3)
(4)
(5)
(6)
(7)
(8)
(9)
Printed Circuit Board
Fuse
Rinsing
Freezing Oper.
Too High Temperature
Bin Full
Power On
Reset to High Temp.
Freezing Oper.
(10)
(11)
(12)
(13)
(14)
(15)
(16)
(17)
(18)
Stand By
Rinsing
Sensors
Evaporator Temperature
Condenser Temperature
Ambient Temp.
Ice Level Sensor
Water Pump
Hot Gas Valve
JUST FOR AIR COOLED UNIT
6
(19)
(20)
(21)
(22)
(23)
(24)
(25)
Water Inlet Valve
Fan Motor
Compressor
Contactor
Autotransformer
Fuse
Terminal Board
* USED ONLY UNIT 240V
19
15.
Circuit Board and Component
Sequence of Operation
Fig./ABB 1
3.
3.1
Fig./ABB 3
START OF FREEZE CYCLE
Fig./ABB 4
LED BLINKING EVAPORATOR
TEMPERATURE HIGH
LED CONSTANT CONDENSER TEMPERATURE HIGH
Fig./ABB 5
3.2
PHASE 2 OF FREEZE CYCLE
Fig./ABB 6
DEFROST CYCLE
F60
60
27
48
0.84
19.0
19/4.1
630
12.0
R134A
450 grms
-10°C
-6°C
-10°C
-7°C
1100
60
F85
83
27
48
0.84
15.5
26/5.5
780
16.0
R134A
540 grms
-26°C
-25°C
-28°C
-24°C
1400
63
Start Up
After having correctly installed the ice machine and completed the plumbing and electrical connections, perform the following “Start-up”
procedure.
A.
Switch on the power to the machine. The unit starts its first freezing cycle with the following components in operation:
COMPRESSOR
WATER PUMP
FAN MOTOR. (The condenser fan is controlled by a thermostat, which is factory set).
B.
Check through the ice discharge opening that the spray plate is correctly seated and that the water jets uniformly reach the interior of the inverted
cup molds; also make sure that the plastic curtain is hanging freely and that water is not spilling through it excessively.
C.
The ice making process takes place thereby, the water is sprayed into the molds which gets gradually refrigerated by the heat exchanged with
the refrigerant flowing into the evaporator serpentine.
D.
When the evaporator temperature reaches a pre-set value (approximately -15°C) the evaporator thermostat changes its contacts and starts the
time clock, when the first timed portion has elapsed the freezing cycle ends and the second timed portion starts the defrost/harvest cycle.
Freezing time will range between 20 and 22 minutes (depending on model, see table) in a 21°C ambient. Longer time for temperature above,
shorter when below.
Average complete cycle range is about 23 to 25 minutes (depending on model, see table above)
E.
Check, during the first defrost/harvest cycle, that the incoming water flows correctly into the sump reservoir in order to re-fill it and the surplus
overflows down the overflow drain tube.
During this cycle the components energised are:
COMPRESSOR.
HOT GAS SOLENOID.
WATER INLET SOLENOID VALVE.
TIMER MOTOR
FAN MOTOR (if ambient temperature exceeds 30°C).
BIN FULL
Fig./ABB 7
Technical Data
Model
Output – kg/24hr
Bin storage capacity – kg
Cubes per cycle
Cubes kg per cycle
Cycle time – minutes
Amps start/run
Watts consumption (30°C Ambient Temp)
Water consumption (Water Temp at 15°C Air Temp 21°C)
Refrigerant
Refrigerant charge grams
Evaporator Temp with Gas Pressure at 10.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 7.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 13 Bar ( Ambient Temp 32°C)
Evaporator Temp with Gas Pressure at 8 Bar ( Ambient Temp 32°C)
Heat Emission, watts
Noise Level dBA at 2 meters
Fig./ABB 2
START UP
F60 and F85 Technical Data and Operating Instructions
Fig./ABB 8
Note. During the defrost cycle, the water inlet solenoid valve is energised. The
water flows through the valve to the back side of the evaporator platen and
then down to fill up the icemaker sump tank for the next freezing cycle.
C.
3.3
STAND BY
COMPRESSOR
(G)
DP SWITCH
(O)
WATER INLET VALVE
(B)
ICE LEVEL SENSOR
(H)
ELECTRIC TIMER
(P)
HOT GAS VALVE
(C)
SENSORS
(I)
MICRO PROCESSOR
(Q)
CONTRACTOR COIL
(D)
EVAP. TEMPERATURE
(L)
TRANSFORMER
(R)
FAN MOTOR
(E)
COND. TEMPERATURE
(M)
RELAY
(S)
WATER PUMP
(F)
AMBIENT TEMP.
(N)
TRIAC
(T)
P.C. BOARD
20
Adjustments
G.
If after the second harvest the cubes are not correct adjustment to the cube size
thermostat may be necessary.
Using a flat bladed screwdriver turn towards the ‘+’ to increase the cube size and
towards the ‘-’ to decrease the cube size. (See fig 2)
H.
To check the bin full thermostat hold a handful of ice against the bulb of the storage
bin thermostat, the ice maker will switch off in about one to two minutes.
Once the machine has stopped remove the ice and dispose of it, the machine will
restart automatically in three to four minutes.
Note. The bin thermostat is factory set at 1°C (35°F) CUT OUT and 4°C (39°F)
CUT IN. (The set temperature can be adjusted if required by using a flat bladed
screwdriver turn towards the ‘+’ to increase the bin temperature and towards
the ‘-‘ to decrease the bin temperature). (See fig 2)
Refit the bottom front panel then instruct the owner/user on the general operation
of the machine and about the cleaning and care it requires.
CLEANING
(A)
Check the texture of the ice cubes just released. The correct size has a small
depression (about 5-6mm) in their crown. If not, wait for the second defrost/harvest
cycle before making any adjustments.
5
Fig 2
2.
2.1
Technical Data
A
F20
19.5
6.5
16
0.28
20.7
11Amps/2Amps
320w
8.5
R134A
250 grms
-7°C
-27°C
-5°C
-26°C
540
55dBA
F40
34.5
15
24
0.42
17.5
17Amps/3.3Amps
450w
8.5
R134A
320 grms
-9°C
-24°C
-6°C
-24°C
850
58 dBA
Switch on the power to the machine. The unit starts its first freezing cycle with the following components in operation:
COMPRESSOR
WATER PUMP
FAN MOTOR. (The condenser fan is controlled by a thermostat, factory set at approximately 33°C).
C
The ice making process takes place thereby, the water is sprayed into the molds which gets gradually refrigerated by the heat exchanged with
the refrigerant flowing into the evaporator serpentine.
D
When the evaporator temperature reaches a pre-set value the evaporator thermostat changes its contacts, the freezing cycle ends and the
defrost/harvest cycle starts.
Freezing time will range between 17 and 22 minutes (depending on model, see table) in a 21°C ambient. Longer time for temperature above,
shorter when below.
Average complete cycle range is about 17 to 25 minutes (depending on model, see table above)
2.3
Check, during the first defrost/harvest cycle, that the incoming water flows correctly into the sump reservoir in order to re-fill it and the surplus
overflows down the overflow drain tube.
During this cycle the components energised are:
COMPRESSOR.
HOT GAS SOLENOID.
WATER INLET SOLENOID VALVE.
The FAN MOTOR and the WATER PUMP are also in operation if ambient temperature exceeds 33°C.
Note. During the defrost cycle, the water inlet solenoid valve is energised. The water flows through the valve to the back of the
evaporator platen and then down to fill up the icemaker sump tank for the next freezing cycle.
The following maintenance should be scheduled at least twice per year on these ice makers.
1. Check and clean the water line strainer.
2. Check that the ice maker is levelled side to side and in front to rear directions.
3. Clean the water system, the evaporator, the bin and spray platen using a solution of Ice Machine Cleaner.
Refer to procedure 15.3 cleaning instructions and after cleaning will indicate frequency and procedure to be followed in local areas.
NOTE Cleaning requirements vary according to the local water conditions and
individual user operation. Continuous check of the clarity of ice cubes and visual
inspection of the water spraying parts before and after cleaning will indicate
frequency and procedure to be followed in local areas.
4.
5.
6.
7.
With the ice machine and fan motor OFF on air cooled models, clean condenser using vacuum cleaner, soft brush or non metallic brush.
Check for water leaks and tighten drain line connections. Pour water down bin drain line to be sure that drain line is open and clear.
Check size, condition and texture of ice cubes. Perform adjustment of DIP SWITCH keys as required.
Check the ice level control sensor to test shut-off.
Put a shovelful of ice cubes in contact with the control sensor during the defrost cycle.
This should cause the ice maker to shut off at the end of the defrost cycle and the light up the 3rd RED LED.
Within a few seconds after the removal of the shovelful of ice from the sensing probe, the ice maker restarts in freezing cycle.
NOTE The RANGE OF THE ICE LEVEL CONTROL SENSOR can be adjusted as shown on table D of PRINCIPLE OF OPERATION; its cut
out setting remains however at +2˚C (35˚F).
8. Check for refrigerant leaks.
16.3 Cleaning Instructions of Water System
1. Remove the rear and top panels to gain access either to the control box or to the evaporator.
2. Wait till the end of defrost cycle then, with the help of a normal screwdriver, turn the program selector head on STAND BY position to
temporarily stop the operation (Fig. 10). + (Fig. 8) (R134A Machines Fig. 7).
Fig. 10
Check the texture of the ice cubes just released. The correct size has a small depression (about 5-6mm) in their crown. If not, wait for the second
defrost/harvest cycle before making any adjustments.
Adjustments
G
If after the second harvest the cubes are not correct adjustment to the evaporator thermostat may be necessary.
Remove the front panel and locate the cube size thermostat, using a flat bladed screwdriver turn towards the ‘+’ to increase the cube size and
towards the ‘-’ to decrease the cube size. (See fig 1)
H
To check the bin full thermostat hold a handful of ice against the bulb of the storage bin
thermostat, the ice maker will switch off in about one to two minutes.
Once the machine has stopped remove the ice and dispose of it, the machine will restart
automatically in three to four minutes.
Note. The bin thermostat is factory set at 1°C (35°F) CUT OUT and 4°C (39°F) CUT IN.
(The set temperature can be adjusted if required by using a flat bladed screwdriver
turn towards the ‘+’ to increase the bin temperature and towards the ‘-’ to decrease
the bin temperature). (See fig 1)
Refit the bottom front panel then instruct the owner/user on the general operation of the
machine and about the cleaning and care it requires.
I.
16.2 Icemaker
Start Up
Check through the ice discharge opening that the spray plate is correctly seated and that the water jets uniformly reach the interior of the inverted
cup molds; also make sure that the plastic curtain is hanging freely and that water is not spilling through it excessively.
F
The periods and the procedures for maintenance and cleaning are given as guides and are not to be construed as absolute or invariable.
Cleaning, especially, will vary depending upon local water and ambient conditions and the ice volume produced; and, each ice maker must be
maintained individually, in accordance with its particular. location requirements.
After having correctly installed the ice machine and completed the plumbing and electrical connections, perform the following “Start-up”
procedure.
B
E
Maintenance and Cleaning Instructions
16.1 General
Model
Output – kg/24hr
Bin storage capacity – kg
Cubes per cycle
Cubes kg per cycle
Cycle time – minutes
Amps start/run
Watts consumption (30°C Ambient Temp)
Water consumption (Water Temp at 15°C Ambient Temp 21°C)
Refrigerant
Refrigerant charge grams
Evaporator Temp with Gas Pressure at 10.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 7.5 Bar ( Ambient Temp 21°C)
Evaporator Temp with Gas Pressure at 13 Bar ( Ambient Temp 32°C)
Evaporator Temp with Gas Pressure at 8 Bar ( Ambient Temp 32°C)
Heat Emission, watts
Noise Level dBA at 2 meters
2.2
16.
F20 and F40 Technical Data and Operating Instructions
3. Prepare the cleaning solution by diluting in a plastic container one or two litres of warm water (45-50˚C) with 0.1-0.2 litres of Ice Machine
Cleaner.
WARNING The Ice Machine Cleaner contain: Phosphoric and Hydroxyacetic acids.
These compound: are corrosive and may cause bums if swallowed, DO NOT induce vomiting. Give large amount: of water or milk. Call Physician
Immediately.
In case of external contact flush with water.
KEEP OUT OF THE REACH OF CHILDREN.
4. Scoop out all the ice cubes stored into the bin in order to prevent them from being contaminated with the cleaning solution then flush out
the
water from the sump reservoir by removing the plastic plug.
5. Remove the evaporator cover then slowly pour onto the evaporator platen the cleaning solution. With the help of a brush dissolve the
most
resistant and remote scale deposits in the platen.
6. Set the program selector head on CLEANING/RINSING (Fig. 11) + (Fig. 9).
The machine may stop working if the condenser temperature exceeds the pre-set temperature
of the Over Temperature Thermostat (non-adjustable) due to a very high ambient temperature,
condenser fan failure, dirty/ blocked condenser. To restart the machine depresses the
protruding button on the Alarm Reset.
Fig. 1
4
21
fittings and a shut off valve installed in an accessible position between the water supply line and the unit.
Fig. 11
WATER SUPPLY - WATER COOLED MODELS.
The water cooled versions require two separate inlet water supplies on models 40 and 60, one to supply water for the ice production and one
for the water cooled condenser.
Connect the male fitting of the condenser water inlet solenoid valve, using the second flexible tubing supplied, to the cold water supply line
with regular plumbing fittings and a shut off valve installed in an accessible position between the water supply line and the unit.
WATER DRAIN.
The recommended drain tube is a plastic or flexible tube with 18mm (3/4in) I.D. that runs to an open trapped and vented drain. When the drain
is along run, allow 3cm pitch per metre (1/4in per foot).
A vertical open vent, at the unit drain connection is also required for proper sump drainage.
6. (R134A Machines Fig. 8)
WATER DRAIN – WATER COOLED MODELS.
The water drain line from the condenser, on water cooled versions, is internally connected with the drain fitting of the unit.
It is strongly recommended therefore to install a vertical open vent to the high point of the drain line high enough to ensure good drainage and
to direct the drain line to a trapped and vented floor drain receptacle.
This ensures proper flow of the drained water as, in the case of poor drainage, the water running out of the condenser may leak through the
unit drain tubing into the ice storage bin or into the sump reservoir.
NOTE. The water supply and the water drain must be installed to conform to the local codes. In some cases a licensed plumber and/or
a plumbing permit is required.
NOTE With the system in CLEANING/RINSING mode the water pump is the only component in operation to circulate the cleaning solution in
the
entire water system.
7. Let the unit remain in the CLEANING/RINSING mode for about 20 minutes then turn the program selector on STAND BY again.
8. Flush out the cleaning solution from the sump reservoir then pour onto the evaporator cavity two or three litres of clean potable water to
rinse
the mould cups and the platen.
If necessary remove the water spray platen to clean it separately as per step 3 of paragraph B.
9. Turn again the program selector on CLEANING/RINSING. The water pump is again in operation to circulate the water in order to rinse
the
entire water system.
10. Flush out the rinsing water from the sump reservoir then turn the program selector on RESET/HI TEMPERATURE position and
immediately
afterwards to FREEZING OPERATION.
NOTE By setting the selector on RE-SET first and then to FREEZING OPERATION the ice maker will perform the 5 minutes WATER FILLING
phase i.e. the water inlet solenoid valve opens to allow the incoming water to rinse again the water system and to properly fill-up the sump
reservoir for the next freezing cycle.
1.5
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Final Checklist.
Is the machine in a room where the ambient temperatures are within a minimum of 10°C (50°F) even in winter months?
Is there at least a 15cm (6in) clearance around the unit for proper air circulation?
Is the machine level? (IMPORTANT)
Have all the electrical and plumbing connections been made, and is the water supply shut-off valve open?
Has the voltage been tested and checked against the rating on the data plate?
Has the water supply pressure been checked to ensure a water pressure of at least 1 bar (14psi)?
Check all refrigerant lines and conduit lines to guard against vibration and possible failure?
Has the bin liner and cabinet been wiped clean?
Has the owner/user been given the User Manual and been instructed on the importance of periodic maintenance checks?
Has the owner/user been given the name and telephone number of the authorised Service Agency in case of breakdown.
11. Replace the evaporator cover and the unit service panels.
12. At completion of the freezing and harvest cycle make sure of proper texture and clearness of the ice cubes and that, they do not have
any
acid taste.
ATTENTION In case the Ice cubes are cloudy-white and have an acid taste, melt them Immediately by pouring on some warm water In order
to prevent somebody using them.
13.
Wipe clean and rinse the inner surfaces of the storage bin.
REMEMBER To prevent the accumulation of undesirable bacteria it is necessary to sanitise the interior of the storage bin with an anti-algae
disinfectant solution every week.
22
3