KOOLAIRE
Ice Machines
Technician’s Handbook
This manual is updated as new information and models
are released. Visit our website for the latest manual.
www.kool-aire.com
Part Number STH045 11/16
Safety Notices
As you work on Manitowoc equipment, be sure to pay
close attention to the safety notices in this handbook.
Disregarding the notices may lead to serious injury and/
or damage to the equipment.
Throughout this handbook, you will see the following
types of safety notices:
nWarning
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the Warning
statement before proceeding, and work carefully.
,Caution
Text in a Caution box alerts you to a situation in which
you could damage the equipment. Be sure to read
the Caution statement before proceeding, and work
carefully.
Procedural Notices
As you work on Manitowoc equipment, be sure to read
the procedural notices in this handbook. These notices
supply helpful information which may assist you as you
work.
Throughout this handbook, you will see the following
types of procedural notices:
Importan
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will
not cause damage or injury, but it may slow you
down as you work.
NOTE: Text set off as a Note provides you with simple, but
useful, extra information about the procedure you are
performing.
Read These Before Proceeding:
,Caution
Proper installation, care and maintenance are
essential for maximum performance and troublefree operation of your Manitowoc equipment. If you
encounter problems not covered by this manual, do
not proceed, contact Manitowoc Foodservice. We will
be happy to provide assistance.
,Caution
Proper installation, care and maintenance are
essential for maximum performance and trouble-free
operation of your equipment. Visit our website www.
manitowocfsg.com for manual updates, translations,
or contact information for service agents in your area.
Importan
Routine adjustments and maintenance procedures
outlined in this handbook are not covered by the
warranty.
nWarning
Read this manual thoroughly before operating,
installing or performing maintenance on the
equipment. Failure to follow instructions in this
manual can cause property damage, injury or death.
nWarning
Do not use electrical appliances or accessories other
than those supplied by Manitowoc for your ice
machine model.
nWarning
Two or more people or a lifting device are required to
lift this appliance.
nWarning
This equipment contains high voltage electricity and
refrigerant charge. Installation and repairs are to be
performed by properly trained technicians aware of
the dangers of dealing with high voltage electricity
and refrigerant under pressure. The technician must
also be certified in proper refrigerant handling
and servicing procedures. All lockout and tag out
procedures must be followed when working on this
equipment.
nWarning
Do not damage the refrigeration circuit when installing,
maintaining or servicing the unit.
nWarning
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
This appliance is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision
concerning use of the appliance by a person
responsible for their safety. Do not allow children to
play with this appliance.
nWarning
All covers and access panels must be in place and
properly secured, before operating this equipment.
nWarning
Do not obstruct machine vents or openings.
nWarning
Do not store gasoline or other flammable vapors or
liquids in the vicinity of this or any other appliance.
nWarning
Do not clean with water jet.
nWarning
It is the responsibility of the equipment owner to
perform a Personal Protective Equipment Hazard
Assessment to ensure adequate protection during
maintenance procedures.
nWarning
Two or more people are required to move this
equipment to prevent tipping.
nWarning
When using electric appliances, basic precautions
must always be followed, including the following:
a. Read all the instructions before using the
appliance.
b. To reduce the risk of injury, close supervision
is necessary when an appliance is used near
children.
c. Do not contact moving parts.
d. Only use attachments recommended or sold
by the manufacturer.
e. Do not use outdoors.
f. For a cord-connected appliance, the following
must be included:
• Do not unplug by pulling on cord. To
unplug, grasp the plug, not the cord.
• Unplug from outlet when not in use and
before servicing or cleaning.
• Do not operate any appliance with
a damaged cord or plug, or after the
appliance malfunctions or is dropped
or damaged in any manner. Contact
the nearest authorized service facility
for examination, repair, or electrical or
mechanical adjustment.
g. Follow applicable lock out tag out procedures
before working on equipment.
h. Connect to a properly grounded outlet only.
We reserve the right to make product improvements at
any time. Specifications and design are subject to change
without notice.
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Table of Contents
General Information
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Ice Machine Warranty Information . . . . . . . . . . . . 15
How to Read a Model Number . . . . . . . . . . . . . . . . . 16
Installation
Location of Ice Machine . . . . . . . . . . . . . . . . . . . . . . .
Ice Machine Clearance Requirements . . . . . . . . .
Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . .
Leveling the Ice Machine . . . . . . . . . . . . . . . . . . . . . .
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . .
Water Service/Drains . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . .
Cooling Tower Applications . . . . . . . . . . . . . . . .
Water Supply and Drain Line Sizing/
Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Condenser . . . . . . . . . . . . . . . . . . . . . . . .
17
18
19
19
20
21
21
21
22
22
23
24
Maintenance
Interior Cleaning and Sanitizing . . . . . . . . . . . . . .
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning and Sanitizing Procedure . . . . . . . . .
Toggle Switch Operation . . . . . . . . . . . . . . . . . . .
Remove Parts for Cleaning . . . . . . . . . . . . . . . . .
Preventative Maintenance Cleaning . . . . . . . . . .
Ice Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . .
Removal from Service/Winterization . . . . . . . . . .
Air-cooled Models . . . . . . . . . . . . . . . . . . . . . . . . .
Water-cooled Models . . . . . . . . . . . . . . . . . . . . . .
29
29
29
30
34
36
37
38
39
39
39
Part Number STH045 11/16
11
Operation
Ice Making Sequence of Operation . . . . . . . . . . . .
Control Board Timers . . . . . . . . . . . . . . . . . . . . . .
Safety Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Energized Parts Chart . . . . . . . . . . . . . . . . . . . . . .
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . .
41
42
43
45
47
47
Troubleshooting
Control Board Test Mode . . . . . . . . . . . . . . . . . . . . . . 49
Diagnosing an Ice Machine that Will Not Run . 50
Ice Machine Does Not Cycle Into Harvest when
Water Loses Contact with the Harvest Float
Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Ice Machine Cycles Into Harvest Before Water
Loses Contact with the Harvest Float Switch . . 53
Ice Production Check . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Installation/Visual Inspection Checklist . . . . . . . 55
Water System Checklist . . . . . . . . . . . . . . . . . . . . . . . . 56
Ice Formation Pattern . . . . . . . . . . . . . . . . . . . . . . . . . 57
Safety Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Analyzing Discharge Pressure . . . . . . . . . . . . . . . . 67
Analyzing Suction Pressure . . . . . . . . . . . . . . . . . . . 69
Harvest Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Comparing Evaporator Inlet/Outlet
Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Discharge Line Temperature Analysis . . . . . . . . . 78
Refrigeration Component Diagnostics . . . . . . . . 80
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Final Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Refrigeration Component Diagnostic Chart . . . 83
12
Part Number STH045 11/16
Component Check Procedures
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Float Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Compressor Electrical Diagnostics . . . . . . . . . . . . 92
Fan Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
High Pressure Cutout (HPCO) Control . . . . . . . . . 95
Refrigeration Components . . . . . . . . . . . . . . . . . . . . 96
Head Pressure Control Valve . . . . . . . . . . . . . . . . 96
Freeze Cycle Operation All Models . . . . . . . . . . 97
Harvest Cycle Operation . . . . . . . . . . . . . . . . . . . 97
HARVEST PRESSURE REGULATING (HPR)
SYSTEM REMOTE CONDENSER ONLY . . . . . . . . . 100
Water Regulating Valve . . . . . . . . . . . . . . . . . . . 103
Refrigerant Recovery/Evacuation . . . . . . . . . . . . 104
Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Refrigerant Re-use Policy . . . . . . . . . . . . . . . . . . 105
Recovery and Recharging Procedures . . . . . 107
Remote Condenser Model Procedure . . . . . . 110
Remote Charging Procedures . . . . . . . . . . . . . 112
System Contamination Cleanup . . . . . . . . . . . . . . 113
Determining Severity of Contamination . . . 113
Mild System Contamination Cleanup
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
Severe System Contamination Cleanup
Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Replacing Pressure Controls without
Removing Refrigerant Charge . . . . . . . . . . . . . 117
Refrigerant Amount . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Part Number STH045 11/16
13
Charts
Cycle Times, 24 Hr. Ice Production and
Refrigerant Pressure Charts . . . . . . . . . . . . . . . . . . 121
K0250A Self-contained Air-cooled . . . . . . . . . 122
K0350A Self-contained Air-cooled . . . . . . . . . 123
K0350W Self-contained Water-cooled . . . . . 124
K0420A Self-contained Air-cooled . . . . . . . . . 125
K0420W Self-contained Water-cooled . . . . . 126
K0500W Self-contained Water-cooled . . . . . 128
K0600A Self-contained Air-cooled . . . . . . . . . 129
K0600W Self-contained Water-cooled . . . . . 130
K1000A Self-contained Air-cooled . . . . . . . . . 131
K1000W Self-contained Water-cooled . . . . . 132
K1000N Remote Air-cooled . . . . . . . . . . . . . . . 133
K1350A Self-contained Air-cooled . . . . . . . . . 134
K1350W Self-contained Water-cooled . . . . . 135
K1350N Remote Air-cooled . . . . . . . . . . . . . . . 136
K1800A Self-contained Air-cooled . . . . . . . . . 137
K1800N Remote Air-cooled . . . . . . . . . . . . . . . 138
Diagrams
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
K0250, K0350, K0420, K0500, K0600, K1000 1
Ph
Self-contained Air/Water-cooled . . . . . . . . . . 140
K1000 1Ph Remote Air-cooled Condenser . 142
K1350, K1800 1 Ph
Self-contained Air/Water-cooled . . . . . . . . . . 144
K1350, K1800 3Ph Self-contained Air/Watercooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
K1350, K1800 1 Ph Remote Air-cooled
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
K1350, K1800 3 Ph Remote Air-cooled
Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Electronic Control Board . . . . . . . . . . . . . . . . . . 152
Refrigeration Tubing Schematics . . . . . . . . . . . . . 153
Self-contained Air or Water-cooled . . . . . . . . 153
Remote Air-cooled . . . . . . . . . . . . . . . . . . . . . . . . 154
14
Part Number STH045 11/16
General Information
Model Numbers
This manual covers the following models:
Self-Contained
Air-Cooled
KD0250A
KY0250A
KD0350A
KY0350A
KD0420A
KY0420A
KD0500A
KY0500A
KD0600A
KY0600A
KD1000A
KY1000A
KD1350A
KY1350A
KD1800A
KY1800A
Self-Contained
Water-Cooled
------KD0350W
KY0350W
KD0420W
KY0420W
KD0500W
KY0500W
KD0600W
KY0600W
KD1000W
KY1000W
KD1350W
KY1350W
KD1800W
KY1800W
Remote
------------------------------KY1000N
KD1000N
KY1350N
KD1350N
KY1800N
KD1800N
Ice Machine Warranty Information
For warranty information visit:
http://www.manitowocice.com/Service/Warranty
•
Warranty Verification
•
Warranty Registration
•
View and download a copy of the warranty Owner
Warranty Registration Card
Warranty coverage begins the day the ice machine is
installed.
Part Number STH045 11/16
15
How to Read a Model Number
Cube Size
Capacity
Condenser
Type
Series
K D 0350 A E
E - WRAS 50Hz
R - Regular
D - Dice
Y - Half-dice
A - Air-cooled
W - Water-cooled
nWarning
An ice machine contains high voltage electricity and
refrigerant charge. Repairs are to be performed by
properly trained refrigeration technicians aware of
the dangers of dealing with high voltage electricity
and refrigerant under pressure.
16
Part Number STH045 11/16
Installation
Location of Ice Machine
The location selected for the ice machine must meet
the following criteria. If any of these criteria are not met,
select another location.
•
The location must be indoors.
•
The location must be free of airborne and other
contaminants.
•
Air temperature: Must be at least 40°F (4°C) but must
not exceed 110°F (43.4°C).
•
The location must not be near heat-generating
equipment or in direct sunlight.
•
The location must be capable of supporting the
weight of the ice machine and a full bin of ice.
•
The location must allow enough clearance for water,
drain, and electrical connections in the rear of the ice
machine.
•
The location must not obstruct airflow through or
around the ice machine (condenser air flow is in
the back and out the sides). Refer to the chart for
clearance requirements.
•
The ice machine must be protected if it will be
subjected to temperatures below 32°F (0°C). Failure
caused by exposure to freezing temperatures is not
covered by the warranty.
Part Number STH045 11/16
17
Ice Machine Clearance Requirements
nWarning
Do not obstruct ice machine vents or openings.
K0250
Top/Sides
Back
K0350 - K0420
K0500 - K0600
K1000 - K1350
Top/Sides
Back
Self-Contained
Air-Cooled
12" (30.5 cm)
5" (12.7 cm)*
Self-Contained
Water-Cooled
n/a
n/a
Self-Contained
Air-Cooled
Water-Cooled
and Remote
8" (20.3 cm)
5" (12.7 cm)
8" (20.3 cm)
5" (12.7 cm)
,Caution
The ice machine must be protected if it will be
subjected to temperatures below 32°F (0°C). Failure
caused by exposure to freezing temperatures is not
covered by the warranty.
18
Part Number STH045 11/16
Ice Machine Heat of Rejection
Series
Heat of Rejection1
Ice Machine
Air Conditioning2
Peak
K0250
4600
5450
K0350
3800
6000
K0420
5400
6300
K0500
5300
6100
K0600
9000
13900
K1000
16250
18600
K1350
28300
34300
K1800
28800
34700
1B.T.U./Hour
2Because the heat of rejection varies during the ice making
cycle, the figure shown is an average.
Ice machines, like other refrigeration equipment, reject heat
through the condenser. It is helpful to know the amount of
heat rejected by the ice machine when sizing air conditioning
equipment where self-contained air-cooled ice machines are
installed.
Leveling the Ice Machine
1. The leveling legs must be screwed into the bottom
of the bin as far as possible.
,Caution
The legs must be screwed in tightly to prevent them
from bending.
2. Move the bin into its final position.
3. Use a level on top of the bin. Adjust each foot as
necessary and level from front to back and side to
side.
Part Number STH045 11/16
19
Electrical Requirements
Voltage
The maximum allowable voltage variation is ±10% of the
rated voltage on the ice machine model/serial number
plate at start-up (when the electrical load is highest).
Fuse/Circuit Breaker
A separate fuse/circuit breaker must be provided for each
ice machine.
Total Circuit Ampacity
The total circuit ampacity is used to help select the wire
size of the electrical supply.
The wire size (or gauge) is also dependent upon
location, materials used, length of run, etc., so it must be
determined by a qualified electrician.
Refer to ice machine data plate, for electrical
requirements. The ice machine data plate information
overrides all other published data.
nWarning
All wiring must conform to local, state and national
codes.
nWarning
The ice machine must be grounded in accordance
with national and local electrical code.
20
Part Number STH045 11/16
Water Service/Drains
WATER SUPPLY
Local water conditions may require treatment of the
water to inhibit scale formation, filter sediment, and
remove chlorine odor and taste.
Importan
If you are installing a water filter system, refer to
the Installation Instructions supplied with the filter
system for ice making water inlet connections.
nWarning
For ice making, connect to a potable water supply
only.
WATER INLET LINES
Follow these guidelines to install water inlet lines:
•
Do not connect the ice machine to a hot water
supply. Be sure all hot water restrictors installed for
other equipment are working. (Check valves on sink
faucets, dishwashers, etc.)
•
If water pressure exceeds the maximum
recommended pressure, 80 psig (5.5 bar) obtain
a water pressure regulator from your Koolaire
distributor.
•
Install a water shut-off valve for ice making potable
water.
•
Insulate water inlet lines to prevent condensation.
Part Number STH045 11/16
21
DRAIN CONNECTIONS
Follow these guidelines when installing drain lines
to prevent drain water from flowing back into the ice
machine and storage bin:
•
Drain lines must have a 1.5-inch drop per 5 feet of run
(2.5 cm per meter), and must not create traps.
•
The floor drain must be large enough to
accommodate drainage from all drains.
•
Install a tee to vent the ice machine drain to the
atmosphere.
•
Insulate drain lines to prevent condensation.
COOLING TOWER APPLICATIONS
Water Cooled Models Only
A water-cooling tower installation does not require
modification of the ice machine. The water regulator
valve for the condenser continues to control the
refrigeration discharge pressure.
It is necessary to know the amount of heat rejected, and
the pressure drop through the condenser and water
valves (inlet to outlet) when using a cooling tower on an
ice machine.
•
Water entering the condenser must not exceed 90°F
(32.2°C).
•
Water flow through the condenser must not exceed 5
gallons (19 liters) per minute.
•
Allow for a pressure drop of 7 psig (.48 bar) between
the condenser water inlet and the outlet of the ice
machine.
•
Water exiting the condenser must not exceed 110°F
(43.3°C).
,Caution
Plumbing must conform to state and local codes
22
Part Number STH045 11/16
Ice Making
Water Inlet
Condenser
Water Inlet
Condenser
Water Drain
Location
20 psi (1.38 bar) min.
80 psi (5.5 bar) max.
20 psi (1.38 bar) min.
150 psi (10.3 bar) max.
—
—
Water
Pressure
33°F (0.6°C) min.
90°F (32.2°C) max.
33°F (0.6°C) min.
90°F (32.2°C) max.
Water
Temperature
3/8" Female
Pipe Thread
3/8" Female
Pipe Thread
3/8" Female
Pipe Thread
Ice Machine
Fitting
Tubing Size Up
to Ice Machine
Fitting
3/8" (9.5 mm) min.
inside diameter
3/8" (9.5 mm) min.
inside diameter
3/8" (9.5 mm) min.
inside diameter
WATER SUPPLY AND DRAIN LINE SIZING/
CONNECTIONS
Part Number STH045 11/16
23
REMOTE CONDENSER
Ice Machine
Remote Single
Circuit Condenser
K1000
KC1000
K1350
K1800
KC1395
*Line Set
RTK
RLK
Discharge Line
1/2" (1.27 cm)
1/2" (1.27 cm)
Line Set*
RTK-20-R410A
RTK-35-R410A
RTK-50-R410A
RLK-20-R410A
RLK-35-R410A
RLK-50-R410A
Liquid Line
5/16" (.79 cm)
3/8" (.95 cm)
Air Temperature Around the Condenser
Minimum
Maximum
-20°F (-29°C)
120°F (49°C)
Additional Refrigerant Charge For 51’ to 100’ Line Sets
Ice Machine
Condenser
K1000
K1350
K1800
KC1000
24
KC1395
Additional Amount of
Refrigerant To Be Added To The
Nameplate Charge
2 lbs - 907g
2 lbs - 907g
2 lbs - 907g
Part Number STH045 11/16
Calculating Allowable Lineset Distance
Line Set Length
The maximum length is 100’ (30.5 m).
Line Set Rise/Drop
The maximum rise is 35’ (10.7 m).
The maximum drop is 15’ (4.5 m).
35 FT. (10.7 M)
MAXIMUM
DISTANCE
35 ft. (10.7 m) Rise: The maximum distance the
Condenser or Condensing Unit can be above the ice
machine.
15 FT. (4.5 M)
MAXIMUM
DISTANCE
15 ft. (4.5 m) Drop: The maximum distance the
Condenser or Condensing Unit can be below the ice
machine.
Part Number STH045 11/16
25
Calculated Line Set Distance
The maximum calculated distance is 150’ (45.7 m).
Line set rises, drops, horizontal runs (or combinations
of these) in excess of the stated maximums will exceed
compressor start-up and design limits. This will cause
poor oil return to the compressor.
Make the following calculations to make sure the line set
layout is within specifications.
1. Insert the measured rise into the formula below.
Multiply by 1.7 to get the calculated rise.
(Example: A condenser located 10 feet above the ice
machine has a calculated rise of 17 feet.)
2. Insert the measured drop into the formula below.
Multiply by 6.6 to get the calculated drop.
(Example. A condenser located 10 feet below the ice
machine has a calculated drop of 66 feet.)
3. Insert the measured horizontal distance into the
formula below. No calculation is necessary.
4. Add together the calculated rise, calculated drop,
and horizontal distance to get the total calculated
distance. If this total exceeds 150’ (45.7 m), move
the condenser to a new location and perform the
calculations again.
26
Part Number STH045 11/16
Maximum Line Set Distance Formula
Step 1
Measured Rise ____ X 1.7 = ______Calculated Rise
(35 ft. Max)
Step 2
Measured Drop ____ X 6.6 = ______Calculated Drop
(15 ft. Max.)
Step 3
Measured Horizontal Distance = _________Horizontal
(100 ft. Max.)
Distance
Step 4
Total Calculated Distance = ________Total Calculated
(150 ft. Max.)
Distance
Part Number STH045 11/16
27
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28
Part Number STH045 11/16
Maintenance
Interior Cleaning and Sanitizing
GENERAL
Clean and sanitize the ice machine every six months
for efficient operation. If the ice machine requires
more frequent cleaning and sanitizing, consult a
qualified service company to test the water quality and
recommend appropriate water treatment.
The ice machine must be taken apart for cleaning and
sanitizing.
,Caution
Use only Manitowoc approved Ice Machine Cleaner
(part number 9405463) and Sanitizer (part number
9405653). It is a violation of Federal law to use these
solutions in a manner inconsistent with their labeling.
Read and understand all labels printed on bottles
before use.
CLEANING AND SANITIZING PROCEDURE
Ice machine cleaner is used to remove lime scale and
mineral deposits. Ice machine sanitizer disinfects and
removes algae and slime.
Part Number STH045 11/16
29
TOGGLE SWITCH OPERATION
Moving the toggle switch to clean will start a Clean cycle.
•
Setting the ice machine to stop after the clean
cycle: Place the toggle switch in the clean position.
The ice machine will stop after the clean cycle.
•
Pausing the cleaning cycle: Move the toggle switch
to Off. Moving the toggle switch to clean will restart
the clean cycle.
•
Setting the ice machine to start ice making after
the clean cycle: Place the toggle switch in the Ice
position more than 2 minutes into the clean cycle.
Step 1 Place the toggle switch in the clean position
after ice falls from the evaporator at the end of a Harvest
cycle. Or, place the toggle switch in the off position and
allow the ice to melt off the evaporator.
,Caution
Never use anything to force ice from the evaporator.
Damage may result.
Step 2
Remove all ice from the bin.
nWarning
Wear rubber gloves and safety goggles (and/or
face shield) when handling Ice Machine Cleaner or
Sanitizer.
30
Part Number STH045 11/16
,Caution
Do not mix Ice Machine Cleaner and Sanitizer
solutions together. It is a violation of Federal law to
use these solutions in a manner inconsistent with
their labeling.
Step 3 To start a cleaning cycle, move the toggle
switch to Clean. Water will flow through the water dump
valve and down the drain. Wait until the water trough
refills, then add the proper amount of ice machine
cleaner to the water trough.
Model
K0250 K0350 K0420
K0500 K0600 K1000
K1350 K1800
Amount of Cleaner
3 ounces (90 ml)
5 ounces (150 ml)
9 ounces (265 ml)
Step 4 Wait until the clean cycle is complete
(approximately 24 minutes) then place the toggle switch
in the off position and disconnect power and water
supplies to the ice machine.
Step 5 Remove parts for cleaning.
Refer to the proper parts removal for your machine.
Continue with Step 6 when the parts have been removed.
Part Number STH045 11/16
31
Step 6 Mix a solution of cleaner and lukewarm water.
Depending on the amount of mineral buildup, a larger
quantity of solution may be required. Use the ratio in the
table below to mix enough solution to thoroughly clean
all parts.
Solution Type
Cleaner
Water
1 gal. (4 l)
Mixed with
16 oz (500 ml) cleaner
Step 7 Use half of the cleaner/water solution to clean
all components. The cleaner solution will foam when
it contacts lime scale and mineral deposits; once the
foaming stops use a soft bristle brush, sponge or cloth
(not a wire brush) to carefully clean the parts. Soak the
parts for 5 minutes (15 – 20 minutes for heavily scaled
parts). Rinse all components with clean water.
Step 8 While components are soaking, use half of the
cleaner/water solution to clean all foodzone surfaces of
the ice machine and bin. Use a nylon brush or cloth to
thoroughly clean the following ice machine areas:
•
Evaporator plastic parts – including top, bottom and
sides
•
Bin bottom, sides and top
•
Rinse all areas thoroughly with clean water.
32
Part Number STH045 11/16
Step 9
Mix a solution of sanitizer and warm water.
Solution Type
Sanitizer
Water
3 gal. (12 l)
Mixed With
2 oz (60 ml) sanitizer
Step 10 Use half of the sanitizer/water solution to
sanitize all removed components. Use a spray bottle to
liberally apply the solution to all surfaces of the removed
parts or soak the removed parts in the sanitizer/water
solution. Do not rinse parts after sanitizing.
Step 11 Use half of the sanitizer/water solution to
sanitize all foodzone surfaces of the ice machine and bin.
Use a spray bottle to liberally apply the solution. When
sanitizing, pay particular attention to the following areas:
•
Evaporator plastic parts - including top, bottom and
sides
•
Bin bottom, sides and top
Do not rinse the sanitized areas.
Step 12 Replace all removed components.
Step 13 Wait 25 minutes.
Step 14 Reapply power and water to the ice machine
and place the toggle switch in the ice position.
Step 15 Water will flow through the water dump valve
and down the drain. Wait until the water trough refills,
then add the proper amount of ice machine sanitizer to
the water trough.
Model
K0250 K0350 K0420
K0500 K0600 K1000
K1350 K1800
Amount of Sanitizer
3 ounces (90 ml)
6 ounces (180 ml)
Wait until the sanitize cycle is complete (approximately 24
minutes) then place the toggle switch in the ice position
to start ice making.
Part Number STH045 11/16
33
REMOVE PARTS FOR CLEANING
nWarning
Disconnect electric power to the ice machine at the
electric switch box before proceeding.
1. Remove the water curtain
• Gently flex the curtain in the center and remove it
from the right side.
• Slide the left pin out.
2. Remove the water trough
• Depress tabs on right and left side of the water
trough.
• Allow front of water trough to drop as you pull
forward to disengage the rear pins.
3. Remove the ice thickness and harvest float switches
• Pull the float switch straight down to disengage.
• Lower the float switch until the wiring connector
is visible. y
• Disconnect the wire lead from the float switch.
• Remove the float switch from the ice machine.
4. Remove the water distribution tube
NOTE: Distribution tube thumbscrews are retained
to prevent loss. Loosen thumbscrews but do not pull
thumbscrews out of distribution tube.
• Loosen the two outer screws (do not remove
screws completely they are retained to prevent
loss) and pull forward on the distribution tube to
release from slip joint.
• Disassemble distribution tube by loosening the
two (2) middle thumbscrews and dividing the
distribution tube into two pieces.
• Proceed to page 32 Step 6.
34
Part Number STH045 11/16
5. Remove the Water Trough
• Depress tabs on right and left side of the water
trough.
• Allow front of water trough to drop as you pull
forward to disengage the rear pins.
• Remove the water trough from the bin area.
Part Number STH045 11/16
35
Preventative Maintenance Cleaning
This cleaning procedure can be performed between the
bi-annual cleaning and sanitizing cycles. This procedure
does not require removing the ice from the bin.
Step 1 Place the toggle switch in the off position after
ice falls from the evaporator at the end of a Harvest cycle.
Or, place the toggle switch in the off position and allow
the ice to melt off the evaporator.
,Caution
Never use anything to force ice from the evaporator.
Damage may result.
nWarning
Wear rubber gloves and safety goggles (and/or
face shield) when handling Ice Machine Cleaner or
Sanitizer.
Step 2 To start a cleaning cycle, place the toggle
switch in the clean position. Water will flow through the
water dump valve and down the drain. Wait until the
water trough refills, then add the proper amount of ice
machine cleaner to the water trough.
Model
K0250 K0350 K0420
K0500 K0600 K1000
K1350 K1800
Amount of Cleaner
3 ounces (90 ml)
5 ounces (150 ml)
9 ounces (265 ml)
Step 3 Wait until the clean cycle is complete
(approximately 24 minutes) then place the toggle switch
in the off position.
36
Part Number STH045 11/16
Ice Machine Inspection
Check all water fittings and lines for leaks. Also, make
sure the refrigeration tubing is not rubbing or vibrating
against other tubing, panels, etc.
There must be adequate airflow through and around the
ice machine to maximize ice production and ensure long
component life.
Exterior Cleaning
Clean the area around the ice machine as often as
necessary to maintain cleanliness and efficient operation.
Sponge any dust and dirt off the outside of the ice
machine with mild soap and water. Wipe dry with a clean,
soft cloth.
Cleanup any fallen ice or water spills as they occur.
Part Number STH045 11/16
37
Cleaning the Condenser
General
nWarning
Disconnect electric power to the ice machine head
section and the remote condensing unit at the electric
service switches before cleaning the condenser.
A dirty condenser restricts airflow, resulting in excessively
high operating temperatures. This reduces ice production
and shortens component life.
•
Clean the condenser at least every six months.
nWarning
The condenser fins are sharp. Use care when cleaning
them.
•
Shine a flashlight through the condenser to check for
dirt between the fins.
•
Blow compressed air or rinse with water from the
inside out (opposite direction of airflow).
•
If dirt still remains call a service agent to clean the
condenser.
38
Part Number STH045 11/16
Removal from Service/Winterization
AIR-COOLED MODELS
1. Clean and sanitize the ice machine.
2. Place the toggle switch in the off position to turn off
the ice machine.
3. Turn off the water supply, disconnect and drain the
incoming ice-making water line at the rear of the ice
machine and drain the water trough.
4. Energize the ice machine, wait one minute for the
water inlet valve to open and blow compressed air in
both the incoming water and the drain openings in
the rear of the ice machine to remove all water.
5. Place the toggle switch in the off position and
disconnect the electric power at the circuit breaker
or the electric service switch.
6. Fill spray bottle with sanitizer and spray all interior
food zone surfaces. Do not rinse and allow to air dry.
7. Replace all panels.
WATER-COOLED MODELS
1. Perform Steps 1 – 6 under “Air-Cooled Models.”
2. Disconnect the incoming water and drain line from
the water-cooled condenser.
3. Energize the ice machine in the freeze cycle. The
increasing refrigerant pressure will open the water
regulating valve.
4. Blow compressed air through the condenser until no
water remains.
Part Number STH045 11/16
39
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40
Part Number STH045 11/16
Operation
Ice Making Sequence of Operation
NOTE: The toggle switch must be in the ON position and
the water curtain must be closed before the ice machine
will start.
Water Purge Cycle
The ice machine purges any remaining water from the
water trough down the drain.
Freeze Cycle
Prechill - The refrigeration system chills the evaporator
before water flow over the evaporator starts. The water
inlet valve energizes during the pre-chill and remains on
until the ice thickness float switch is satisfied.
Freeze - Water flowing across the evaporator freezes
and builds ice on the evaporator. After a sheet of ice has
formed, the Harvest float switch signals the control board
to start a harvest cycle.
Harvest Cycle
Any remaining water is purged down the drain as
refrigerant gas warms the evaporator. When the
evaporator warms, the sheet of cubes slides off the
evaporator and into the storage bin. If all cubes fall clear
of the water curtain, the ice machine starts another freeze
cycle.
Full Bin Cycle
If the water curtain is held open by ice cubes the ice
machine shuts off. When the water curtain closes the ice
machine starts a new cycle at the water purge.
Part Number STH045 11/16
41
CONTROL BOARD TIMERS
•
The ice machine is locked into the freeze cycle for
6 minutes before a harvest cycle can be initiated.
•
The freeze time lock in feature is bypassed on the
initial cycle (manual start or after a full bin/safety limit
condition).
•
If the harvest float switch is in the down position for
10 continuous seconds during the start of a freeze
cycle, a harvest sequence is initiated.
•
The maximum freeze time is 60 minutes at which
time the control board automatically initiates a
harvest sequence.
•
The maximum harvest time is 3.5 minutes. The
control board automatically initiates a freeze
sequence when these times are exceeded.
•
The ice machine will continue to fill with with water
for up to six minutes, or until the high water float
opens for 5 continuous seconds. The control board
will energize the water inlet valve one more time
3 minutes into the freeze cycle.
42
Part Number STH045 11/16
SAFETY LIMITS
Safety limits are stored and indicated by the control
board. The number of cycles required to stop the ice
machine varies for each safety limit.
Safety limits can be reset by cycling the toggle switch Off/
On and starting a new ice making cycle.
A safety limit is indicated by a flashing light on the control
board.
Safety Limit 1
If the freeze time reaches 60 minutes, the control board
automatically initiates a harvest cycle.
•
After 3 consecutive 60 minute cycles control board
light SL#1 light will flash on/off at 1 second intervals.
•
If 6 consecutive 60-minute freeze cycles occur, the
ice machine stops and the SL#1 light on the control
board will be on continuously.
Safety Limit 2
If the harvest time reaches 3.5 minutes, the control board
automatically returns the ice machine to the freeze cycle.
•
If three consecutive 3.5 minute harvest cycles occur
the SL#2 light on the control board will flash on/off at
1 second intervals. After 75 consecutive 3.5 minutes
harvest cycles the SL#2 light will be energized
continuously.
•
If 100 consecutive 3.5 minute harvest cycles occur,
the ice machine stops and the SL#2 light on the
control board will be on continuously.
Part Number STH045 11/16
43
Safety Limit 3
If the harvest float switch hasn’t opened for 10
continuous seconds within 4 minutes of the water inlet
valve energizing the ice machine stops.
•
Safety Limit 3 is bypassed on the initial cycle (manual
start or after a full bin/safety limit condition). For
all subsequent cycles the ice machine stops for 30
minutes when the water inlet valve is energized for
4 minutes and the harvest float valve didn’t open.
Control board lights SL#1 and SL#2 will flash on/off at
1 second intervals.
•
The ice machine automatically restarts at the end of
the 30 minute delay period and stops flashing the
control board lights.
•
If 100 consecutive failures occur the ice machine
stops and the SL#1 & SL#2 lights flash on/off at 1
second intervals.
•
SL#1 & SL#2 will flash 3 times on startup and
automatically erase after 100 normal cycles.
44
Part Number STH045 11/16
Part Number STH045 11/16
45
3. Pre chill
Freeze Sequence
Initial Start-up
1a. Water purge
1b. Delay period
2. Refrigeration
System Start-up
2a. Equalize
Pressure
2b. Compressor
Start-up
ICE MAKING
SEQUENCE OF
OPERATION
on
on
off
off
off
off
off
off
on
Harvest
Valve
on
Water Pump
Self-Contained Ice Machines
ENERGIZED PARTS CHART
on
off
off
off
off
off
off
off
off
on
on
on
off
off
off
open
closed
closed
closed
closed
closed
closed
closed
closed
closed
Compressor
Ice
Water Inlet
&
Harvest
Dump Valve
Thickness
Valve
Condenser Float Switch
Float Switch
Fan Motor*
120
Seconds
initial cycle
Thereafter
60 seconds
5 seconds
5 seconds
5 seconds
45 seconds
Length of
Time
46
Part Number STH045 11/16
off
7. Automatic
Shut-off
off
on
on
off
Harvest
Valve
off
off
off
on
off
off
on
off
off
on
on
on
closed
closed
closed
open then
closed
Length of
Time
closed
closed
closed
Bin switch
activation
Until bin
switch
re-closes
45 seconds
Until
Harvest
closed then Float Switch
open
closes for
10 continual
seconds
Compressor
Ice
Water Inlet
&
Harvest
Dump Valve
Thickness
Valve
Condenser Float Switch
Float Switch
Fan Motor*
* Condenser Fan Motor: The fan motor is wired through a fan cycle pressure control; therefore, it may cycle on and off.
off
6. Harvest
5. Water Purge
on
on
4. Freeze
Harvest
Sequence
Water Pump
ICE MAKING
SEQUENCE OF
OPERATION
Operational Checks
ICE THICKNESS CHECK
After a harvest cycle, inspect the ice cubes in the ice
storage bin. The ice bridge connects the ice cubes and
must be set to maintain an ice bridge thickness of 1/8"
(3 mm). To adjust the thickness of the bridge refer to ice
thickness adjustment.
The ice thickness float switch is factory-set to maintain
the ice bridge thickness at 1/8" (3 mm).
NOTE: Make sure the water curtain is in place when
performing this check. It prevents water from splashing
out of the water trough.
1. Inspect the bridge connecting the cubes. It should
be about 1/8" (3 mm) thick.
2. If adjustment is necessary, turn the ice thickness
float switch clockwise to increase bridge thickness,
counterclockwise to decrease bridge thickness.
Adjust to achieve a 1/8" (3 mm) bridge thickness.
NOTE: The float can be adjusted with a 3/4" wrench while
the water trough is in-place. Test run two cycles to verify
ice bridge thickness.
Ice Thickness Float
Switch Adjustment
Part Number STH045 11/16
47
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48
Part Number STH045 11/16
Troubleshooting
Control Board Test Mode
NOTE: The water curtain/bin switch can be open or closed
and does not affect the operation of the test mode.
To enter the test mode, move the toggle switch to off,
then press and hold the test button on the control board
for 3 seconds. The control board test mode performs the
following functions for a 2-minute time period:
•
Energizes all control board relays
•
Energizes all control board lights
After 2 minutes, the control board will automatically
initiate and complete one ice-making cycle, then stop.
Canceling a test cycle:
To cancel a test cycle, press the test button a second time.
Restarting a test cycle:
The test cycle will restart each time the test button is
pressed for a 3-second time period.
Part Number STH045 11/16
49
Diagnosing an Ice Machine that Will Not Run
nWarning
High (line) voltage is applied to the control board
at all times. Removing the control board fuse or
pressing the power button will not remove the power
supplied to the control board.
1. Verify primary voltage is supplied to ice machine and
the fuse/circuit breaker is closed.
2. Verify control board fuse is okay.
NOTE: If any control board lights are on, the fuse is okay.
3. Verify the bin switch functions properly. A defective
bin switch can falsely indicate a full bin of ice.
4. Verify toggle switch functions properly. A defective
toggle switch may keep the ice machine in the OFF
mode. Refer to toggle switch diagnostics when Steps
1 – 3 test good.
5. Be sure Steps 1 – 4 were followed thoroughly.
Intermittent problems are not usually related to the
control board. Replace control board if toggle switch
operation is correct.
50
Part Number STH045 11/16
Ice Machine Does Not Cycle Into Harvest
when Water Loses Contact with the Harvest
Float Switch
NOTE: The ice machine will make a thick or double
slab when a new freeze cycle is started with ice already
present on the evaporator.
Two of the most common scenarios are:
•
Power is cycled off/on with ice on the evaporator.
•
The water curtain/bin switch is opened/closed in the
harvest cycle before the ice releases.
Remove all ice from the evaporator before starting
diagnostic procedures.
Freeze Time Lock-In Feature
The ice machine control system incorporates a freeze
time lock-in feature. This prevents the ice machine from
short cycling in and out of harvest. The control board
locks the ice machine in the freeze cycle for six minutes.
After six minutes a harvest cycle can be initiated. To allow
the service technician to initiate a harvest cycle without
delay, this feature is not used on the first cycle after
moving the toggle switch to OFF and back to ON.
ICE THICKNESS FLOAT
SWITCH
Part Number STH045 11/16
HARVEST FLOAT SWITCH
51
Step 1 Disconnect power to the ice machine, remove
the electrical panel to allow viewing of the control board
lights. Disconnect the harvest float switch wire from the
control board and place a jumper on the control board
harvest switch terminals.
Step 2 Bypass the freeze time lock-in feature by
moving the toggle switch Off/On to cycle the ice machine
on. Wait until water flows over the evaporator, then refer
to chart.
Result
10 seconds into the freeze
cycle the ice machine cycles
from freeze to harvest and the
control board harvest light
energizes.
The harvest light comes on,
but the ice machine remains in
the freeze cycle.
The harvest light stays off and
the ice machine remains in
freeze.
52
Correction
The ice thickness float switch,
connectors or wiring are
causing the malfunction.
The ice machine is in a
6 minute freeze lock Cycle on/off and retest.
Replace the control board.
Part Number STH045 11/16
Ice Machine Cycles Into Harvest Before
Water Loses Contact with the Harvest Float
Switch
Step 1 Disconnect power to the ice machine, remove
the electrical panel to allow viewing of the control board
lights and disconnect the harvest float switch from the
control board.
ICE THICKNESS FLOAT
SWITCH
HARVEST FLOAT SWITCH
Step 2 Reapply power and move the toggle switch
to Ice to bypass the freeze time lock-in feature. Wait until
water flows over the evaporator, then refer to chart.
Result
The harvest light does not
come on and the ice machine
stays in freeze.
10 seconds into the freeze
cycle the ice machine cycles
from freeze to harvest and the
control board harvest light
energizes.
Part Number STH045 11/16
Correction
The ice thickness float switch,
connectors or wiring are
causing the malfunction. Refer
to float switch diagnostics.
Replace the control board.
53
Ice Production Check
The amount of ice a machine produces directly relates to
the operating water and air temperatures. This means an
ice machine with a 70°F (21°C) ambient temperature and
50°F (10°C) water produces more ice than the same ice
machine with 90°F (32°C) ambient and 70°F (21°C) water.
1. Determine the ice machine operating conditions:
Air temp entering condenser:____°
Air temp around ice machine:____°
Water temp entering sump trough:____°
2. Refer to the appropriate 24-Hour Ice Production
Chart. Use the operating conditions determined
in Step 1 to find published 24-Hour Ice
Production:_____
• Times are in minutes.
Example: 1 min. 15 sec. converts to 1.25 min.
(15 seconds ÷ 60 seconds = .25 minutes)
• Weights are in pounds.
Example: 2 lb. 6 oz. converts to 2.375 lb.
(6 oz. ÷ 16 oz. = .375 lb.)
3. Perform an ice production check using the formula
below.
1.
+
Freeze Time
2.
1440
Minutes in 24 Hrs.
3.
Weight of One
Harvest
=
Harvest Time
÷
Total Cycle Time
=
Total Cycle Time
x
Cycles per Day
=
Cycles per Day
Actual 24-Hour
Production
Weighing the ice is the only 100% accurate check.
4. Compare the results of Step 3 with Step 2. Ice
production is normal when these numbers match
closely. If they match closely, determine if:
• Another larger ice machine is required.
• Relocating the existing equipment to lower the
load conditions is required.
Contact the local distributor for information on available
options and accessories.
54
Part Number STH045 11/16
Installation/Visual Inspection Checklist
Ice machine is not level
• Level the ice machine
Condenser is dirty
• Clean the condenser
Water filtration is plugged (if used)
• Install a new water filter
Water drains are not run separately and/or are not
vented
• Run and vent drains according to the Installation
Manual
Part Number STH045 11/16
55
Water System Checklist
A water-related problem often causes the same
symptoms as a refrigeration system component
malfunction.
Example: A water dump valve leaking during the freeze
cycle, a system low on charge, and a starving TXV have
similar symptoms.
Water system problems must be identified and
eliminated prior to replacing refrigeration components.
Water area (evaporator) is dirty
• Clean as needed
Water inlet pressure not between 20 and 80 psig
(1–5 bar, 138–552 kPa)
• Install a water regulator valve or increase the water
pressure
Incoming water temperature is not between 35°F (1.7°C)
and 90°F (32.2°C)
• If too hot, check the hot water line check valves in
other store equipment
Water filtration is plugged (if used)
• Install a new water filter
Vent tube is not installed on water outlet drain
• See Installation Instructions
Hoses, fittings, etc., are leaking water
• Repair/replace as needed
Water valve is stuck open, closed or is leaking
• Clean/replace as needed
Water is spraying out of the sump trough area
• Stop the water spray
Uneven water flow across the evaporator
• Clean the ice machine
Water is freezing behind the evaporator
• Correct the water flow
Plastic extrusions and gaskets are not secured to the
evaporator
• Remount/replace as needed
56
Part Number STH045 11/16
Ice Formation Pattern
Evaporator ice formation pattern analysis is helpful in ice
machine diagnostics.
Analyzing the ice formation pattern alone cannot
diagnose an ice machine malfunction. However, when
this analysis is used along with the Refrigeration System
Operational Analysis Table, it can help diagnose an ice
machine malfunction.
OUTLET
INLET
Example of Evaporator Tubing Routing
Normal Ice Formation
Ice forms across the entire evaporator surface.
At the beginning of the Freeze cycle, it may appear that
more ice is forming on the inlet of the evaporator than at
the outlet. At the end of the Freeze cycle, ice formation
at the outlet will be close to, or just a bit thinner than, ice
formation at the inlet. The dimples in the cubes at the
outlet of the evaporator may be more pronounced than
those at the inlet. This is normal.
If ice forms uniformly across the evaporator surface, but
does not do so in the proper amount of time, this is still
considered a normal ice fill pattern.
Part Number STH045 11/16
57
Extremely Thin at Evaporator Outlet
There is no ice, or a considerable lack of ice formation on
the outlet of the evaporator.
Examples: No ice at all at the outlet of the evaporator, but
ice forms at the inlet half of the evaporator. Or, the ice at
the outlet of the evaporator reaches the correct thickness,
but the outlet of the evaporator already has 1/2" to 1" of
ice formation.
Extremely Thin at Evaporator Inlet
There is no ice, or a considerable lack of ice formation at
the inlet of the evaporator. Examples: The ice at the outlet
of the evaporator reaches the correct thickness, but there
is no ice formation at all at the inlet of the evaporator.
No Ice Formation
The ice machine operates for an extended period, but
there is no ice formation at all on the evaporator.
Evaporator Tubing Routing
Routing of the tubing on the back of the evaporator
determines the ice fill pattern failure mode.
One Evaporator, One TXV Models
The evaporator outlet tubing does not exit directly at the
top of the evaporator, but exits several inches below the
top of the evaporator. Extremely Thin at the Evaporator
Outlet will first be visible several inches below the top
of the evaporator. Extremely Thin at Evaporator Inlet will
first be visible at the bottom of the evaporator.
Outlet
ICE
ICE
Inlet
Thin at Inlet
58
Thin at Outlet
Part Number STH045 11/16
One Evaporator, Two TXV 48” Models
Tubing routing for one evaporator with two TXV’s is
different. The evaporator has two inlets and outlets. Fill
pattern varies depending on which circuit is affected,
Extremely Thin at the Evaporator Outlet
Will first be visible 1/3 of the way down the evaporator.
Only one side of the evaporator may be affected
depending on failure. A TXV failure will usually show on
only one side, while low on refrigerant can affect one or
both sides depending on the amount of refrigerant loss
and ambient temperature.
Outlet
Thin at Inlet
ICE
ICE
ICE
Inlet
Thin at Outlet
Extremely Thin at the Evaporator Inlet
Will show at the bottom of the evaporator. Depending
on the failure either the entire bottom of the evaporator
or one side of the bottom of the evaporator may be
affected.
Part Number STH045 11/16
59
SAFETY LIMITS
Safety limits are stored and indicated by the control
board. The number of cycles required to stop the ice
machine varies for each safety limit.
Safety limits can be reset by cycling the toggle switch Off/
On and starting a new ice making cycle.
A safety limit is indicated by a flashing light on the control
board.
Safety Limit 1
If the freeze time reaches 60 minutes, the control board
automatically initiates a harvest cycle.
•
After 3 consecutive 60 minute cycles, control board
light SL#1 light will flash on/off at 1 second intervals.
•
If 6 consecutive 60-minute freeze cycles occur, the
ice machine stops and the SL#1 light on the control
board will be on continuously.
Safety Limit 2
If the harvest time reaches 3.5 minutes, the control board
automatically returns the ice machine to the freeze cycle.
•
If three consecutive 3.5 minute harvest cycles occur,
the SL#2 light on the control board will flash on/off at
1 second intervals. After 75 consecutive 3.5 minutes
harvest cycles, the SL#2 light will be energized
continuously.
•
If 100 consecutive 3.5 minute harvest cycles occur,
the ice machine stops and the SL#2 light on the
control board will be on continuously.
60
Part Number STH045 11/16
Safety Limit 3
If the harvest float switch hasn’t opened for 10
continuous seconds within 4 minutes of the water inlet
valve energizing, the ice machine stops.
•
Safety Limit 3 is bypassed on the initial cycle (manual
start or after a full bin/safety limit condition). For
all subsequent cycles, the ice machine stops for 30
minutes when the water inlet valve is energized for
4 minutes and the harvest float valve didn’t open.
Control board lights SL#1 and SL#2 will flash on/off at
1 second intervals.
•
The ice machine automatically restarts at the end of
the 30 minute delay period and stops flashing the
control board lights.
•
If 100 consecutive failures occur, the ice machine
stops and the SL#1 & SL#2 lights flash on/off at 1
second intervals.
•
SL#1 & SL#2 will flash 3 times on start-up and
automatically erase after 100 normal cycles.
Part Number STH045 11/16
61
Determining Which Safety Limit Stopped the Ice
Machine:
1. Cycle the toggle switch Off.
2. Cycle the toggle switch On to start ice making.
3. Watch the safety limit lights.
• One will flash corresponding to safety limits 1
or 2.
4. Safety limit 3 is indicated by both SL#1 & SL#2
flashing.
After safety limit indication, the ice machine will restart
and run until a safety limit is exceeded again.
Safety Limit Notes
•
A continuous run of 100 harvests automatically erases
the safety limit code.
•
The control board will store and indicate only one
safety limit – the last one exceeded.
•
If the toggle switch is cycled OFF and then ON prior
to reaching the 100-harvest point, the last safety limit
exceeded will be indicated.
62
Part Number STH045 11/16
Safety Limit Checklist
The following checklists are designed to assist the service
technician in analysis. However, because there are many
possible external problems, do not limit your diagnosis to
only the items listed.
Safety Limit #1
Freeze time exceeds 60 minutes for 3 consecutive
freeze cycles.
Possible Cause Checklist
Improper installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55
Water System
• Float switch or water escaping water trough
•
Low water pressure (20 psig min.)
•
High water pressure (80 psig max.)
•
High water temperature (90°F/32.2°C max.)
•
Clogged water distribution tube
•
Dirty/defective water inlet valve
•
Defective water pump
Electrical System
• Harvest cycle not initiated electrically
•
Contactor not energizing
•
Compressor electrically non-operational
•
Restricted condenser air flow
•
High inlet air temperature (110°F/43.3°C max.)
•
Condenser discharge air re-circulation
•
Dirty condenser fins
•
Defective fan cycling control
•
Defective fan motor
•
Dirty condenser
Part Number STH045 11/16
63
Refrigeration System
• Non-OEM components
•
Improper refrigerant charge
•
Defective compressor
•
TXV starving or flooding (check bulb mounting)
•
Non-condensible in refrigeration system
•
Plugged or restricted high side refrigerant lines or
component
•
Defective harvest valve
64
Part Number STH045 11/16
Safety Limit #2
Harvest time exceeds 3.5 minutes for 100 Consecutive
harvest cycles.
Possible Cause Checklist
Improper installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55
Water System
• Water area (evaporator) dirty
•
Dirty/defective water dump valve
•
Vent tube not installed on water outlet drain
•
Water freezing behind evaporator
•
Plastic extrusions and gaskets not securely mounted
to the evaporator
Electrical System
• Bin switch defective
•
Premature harvest
Refrigeration System
• Non-OEM components
•
Improper refrigerant charge
•
Defective harvest valve
•
TXV flooding (check bulb mounting)
•
Defective fan cycling control
Part Number STH045 11/16
65
Safety Limit 3
The harvest float switch hasn’t opened for 10
continuous seconds within 4 minutes of the water
inlet valve energizing.
Possible Cause Checklist
Improper installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55
Water System
• Water dump valve
•
Harvest float valve dirty or defective
•
Low water pressure (20 psig min.)
•
Dirty defective water filter (when used)
•
Loss of water from sump area
•
Dirty/defective water inlet valve
Electrical System
• Water inlet valve coil defective
•
66
Harvest float valve defective
Part Number STH045 11/16
Analyzing Discharge Pressure
1. Determine the ice machine operating conditions:
Air temp. entering condenser
______
Air temp. around ice machine
______
Water temp. entering sump trough ______
2. Refer to “Cycle Times, 24 Hr. Ice Production and
Refrigerant Pressure Charts” on page 121 for ice
machine being checked.
Use the operating conditions determined in Step 1 to find
the published normal discharge pressures.
Freeze Cycle
______
Harvest Cycle
______
3. Perform an actual discharge pressure check.
Beginning of
Cycle
Middle of
Cycle
End of
Cycle
Freeze Cycle
PSIG
Harvest Cycle
PSIG
__________
__________
__________
__________
__________
__________
4. Compare the actual discharge pressure (Step 3) with
the published discharge pressure (Step 2).
The discharge pressure is normal when the actual
pressure falls within the published pressure range for the
ice machine’s operating conditions. It is normal for the
discharge pressure to be higher at the beginning of the
freeze cycle (when load is greatest), then drop through
out the freeze cycle.
Part Number STH045 11/16
67
Discharge Pressure High Checklist
Improper Installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55.
Condenser Air Flow
• High inlet air temperature
•
Condenser discharge air re-circulation
•
Dirty condenser fins
•
Defective fan cycling control
•
Defective fan motor
Improper Refrigerant Charge
• Overcharged
•
Non-condensible in system
•
Wrong type of refrigerant
Other
• Non-OEM components in system
•
High side refrigerant lines/component restricted
(before mid-condenser)
Freeze Cycle Discharge Pressure Low Checklist
Improper Installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55.
Improper Refrigerant Charge
• Undercharged
•
Wrong type of refrigerant
Other
• Non-OEM components in system
•
High side refrigerant lines/component restricted
(before mid-condenser)
•
Defective fan cycle control
NOTE: Do not limit your diagnosis to only the items listed
in the checklists.
68
Part Number STH045 11/16
Analyzing Suction Pressure
The suction pressure gradually drops throughout the
freeze cycle. The actual suction pressure (and drop rate)
changes as the air and water temperature entering the
ice machine changes. These variables also determine the
freeze cycle times.
To analyze and identify the proper suction pressure drop
throughout the freeze cycle, compare the published
suction pressure to the published freeze cycle time.
NOTE: Analyze discharge pressure before analyzing
suction pressure. High or low discharge pressure may be
causing high or low suction pressure.
Part Number STH045 11/16
69
Procedure
Step
1. Determine the ice machine operating conditions.
Example:
Air temp. entering condenser: 90°F/32.2°C
Air temp. around ice machine: 80°F/26.7°C
Water temp. entering water fill valve: 70°F/21.1°C
2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice
machine model being checked. Using operating conditions
from Step 1, determine published freeze cycle time and
published freeze cycle suction pressure.
Example:
Published freeze cycle time: 14.8 - 15.9 minutes
Published freeze cycle suction pressure: 65 - 26 psig
2B. Compare the published freeze cycle time and published
freeze cycle suction pressure. Develop a chart.
Example:
Published Freeze Cycle Time (minutes)
1 2 4 7 101214
|||||||
65554739343026
Published Freeze Cycle Suction Pressure (psig)
In the example, the proper suction pressure should be
approximately 39 psig at 7 minutes; 30 psig at 12 minutes; etc.
3. Perform an actual suction pressure check at the beginning,
middle and end of the freeze cycle. Note the times at which the
readings are taken.
Example:
Manifold gauges were connected to the example ice machine
and suction pressure readings taken as follows: ________ PSIG
Beginning of freeze cycle: 79 (at 1 min.)
Middle of freeze cycle: 48 (at 7 min.)
End of freeze cycle: 40 (at 14 min.)
4. Compare the actual freeze cycle suction pressure (Step 3)
to the published freeze cycle time and pressure comparison
(Step 2B). Determine if the suction pressure is high, low or
acceptable.
Example:
In this example, the suction pressure is considered high
throughout the freeze cycle. It should have been:
Approximately 65 psig (at 1 minute) – not 79
Approximately 39 psig (at 7 minutes) – not 48
Approximately 26 psig (at 14 minutes) – not 40
70
Part Number STH045 11/16
Suction Pressure High Checklist
Improper Installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55.
Discharge Pressure
• Discharge pressure is too high and is affecting suction
pressure, refer to ”Discharge Pressure High Checklist”
on page 68.
Improper Refrigerant Charge
• Overcharged
•
Wrong type of refrigerant
•
Non-condensible in system
Other
• Non-OEM components in system
•
Harvest valve leaking
•
TXV flooding (check bulb mounting)
•
Defective compressor
Part Number STH045 11/16
71
Suction Pressure Low Checklist
Improper Installation
• Refer to “Installation/Visual Inspection Checklist” on
page 55.
Discharge Pressure
• Discharge pressure is too low, and is affecting suction
pressure, refer to “Freeze Cycle Discharge Pressure
Low Checklist” on page 68
Improper Refrigerant Charge
• Undercharged
•
Wrong type of refrigerant
Other
• Non-OEM components in system
•
Improper water supply over evaporator refer to
“Water System Checklist” on page 56.
•
Loss of heat transfer from tubing on back side of
evaporator
•
Restricted/plugged liquid line drier
•
Restricted/plugged tubing in suction side of
refrigeration system
•
TXV starving
NOTE: Do not limit your diagnosis to only the items listed
in the checklists.
72
Part Number STH045 11/16
Harvest Valve
General
The harvest valve is an electrically operated valve that
opens when energized, and closes when de-energized.
Normal Operation
The valve is de-energized (closed) during the freeze cycle
and energized (open) during the harvest cycle. The valve
is positioned between the compressor discharge line and
the evaporator and performs two functions:
1. Prevents refrigerant from entering the evaporator
during the freeze cycle.
The harvest valve is not used during the freeze
cycle. The harvest valve is de-energized (closed)
preventing refrigerant flow from the receiver into
the evaporator.
2. Allows refrigerant vapor to enter the evaporator in
the harvest cycle.
During the harvest cycle, the harvest valve is
energized (open) allowing refrigerant gas from the
discharge line of the compressor to flow into the
evaporator. The heat is absorbed by the evaporator
and allows release of the ice slab.
Exact pressures vary according to ambient temperature
and ice machine model. Harvest pressures can be found
in the Cycle Time/24 Hour Ice Production/ Refrigerant
Pressure Charts in this book.
Part Number STH045 11/16
73
Harvest Valve Analysis
The valve can fail in two positions:
•
Valve will not open in the harvest cycle.
•
Valve remains open during the freeze cycle.
VALVE WILL NOT OPEN IN THE HARVEST CYCLE
Although the circuit board has initiated a harvest cycle,
the evaporator temperature remains unchanged from the
freeze cycle.
VALVE REMAINS OPEN IN THE FREEZE CYCLE:
Symptoms of a harvest valve remaining partially open
during the freeze cycle can be similar to symptoms of an
expansion valve or compressor problem. Symptoms are
dependent on the amount of leakage in the freeze cycle.
A small amount of leakage will cause increased freeze
times and an ice fill pattern that is “Thin at the Outlet”, but
fills in at the end of the cycle.
As the amount of leakage increases, the length of the
freeze cycle increases and the amount of ice at the outlet
of the evaporator decreases.
Refer to the Parts Manual for proper valve application. If
replacement is necessary, use only “original” replacement
parts.
74
Part Number STH045 11/16
Use the following procedure and table to help determine
if a harvest valve is remaining partially open during the
freeze cycle.
1. Wait five minutes into the freeze cycle.
2. Feel the inlet of the harvest valve(s).
Importan
Feeling the harvest valve outlet or across the harvest
valve itself will not work for this comparison.
The harvest valve outlet is on the suction side (cool
refrigerant). It may be cool enough to touch even if
the valve is leaking.
3. Feel the compressor discharge line.
nWarning
The inlet of the harvest valve and the compressor
discharge line could be hot enough to burn your
hand. Just touch them momentarily.
4. Compare the temperature of the inlet of the harvest
valves to the temperature of the compressor
discharge line.
Part Number STH045 11/16
75
Findings
Comments
The inlet of the harvest valve This is normal as the discharge
is cool enough to touch and
line should always be too hot
the compressor discharge line to touch and the harvest valve
is hot.
inlet, although too hot to
touch during harvest, should
Cool & Hot
be cool enough to touch after
5 minutes into the freeze cycle.
The inlet of the harvest
This is an indication something
valve is hot and approaches
is wrong, as the harvest
the temperature of a hot
valve inlet did not cool down
compressor discharge line.
during the freeze cycle. If
the compressor dome is also
Hot & Hot
entirely hot, the problem is not
a harvest valve leaking, but
rather something causing the
compressor (and the entire ice
machine) to get hot.
Both the inlet of the harvest This is an indication something
valve and the compressor
is wrong, causing the
discharge line are cool enough compressor discharge line to
to touch.
be cool to the touch. This is
not caused by a harvest valve
Cool & Cool
leaking.
5. Record your findings on the table.
76
Part Number STH045 11/16
Comparing Evaporator Inlet/Outlet
Temperatures
The temperatures of the suction lines entering and
leaving the evaporator alone cannot diagnose an ice
machine. However, comparing these temperatures during
the freeze cycle, along with the Refrigeration System
Operational Analysis Table, can help diagnose an ice
machine malfunction.
The actual temperatures entering and leaving the
evaporator vary by model, and change throughout
the freeze cycle. This makes documenting the “normal”
inlet and outlet temperature readings difficult. The key
to the diagnosis lies in the difference between the two
temperatures five minutes into the freeze cycle. These
temperatures must be within 7°F (4°C) of each other.
Use this procedure to document freeze cycle inlet and
outlet temperatures.
1. Use a quality temperature meter, capable of taking
temperature readings on curved copper lines.
2. Attach the temperature meter sensing device to the
copper lines entering and leaving the evaporator.
Importan
Do not simply insert the sensing device under the
insulation. It must be attached to and reading the
actual temperature of the copper line.
3. Wait five minutes into the freeze cycle.
4. Record the temperatures below and determine the
difference between them.
___________
Inlet
Temperature
___________
Difference must be within
7°F (4°C) at 5 minutes into
the freeze cycle
___________
Outlet
Temperature
5. Use this with other information gathered on the
Refrigeration System Operational Analysis Table to
determine the ice machine malfunction.
Part Number STH045 11/16
77
Discharge Line Temperature Analysis
GENERAL
Knowing if the discharge line temperature is
increasing, decreasing or remaining constant can be
an important diagnostic tool. Maximum compressor
discharge line temperature on a normally operating
ice machine steadily increases throughout the freeze
cycle. Comparing the temperatures over several cycles
will result in a consistent maximum discharge line
temperature.
Ambient air temperatures affect the maximum discharge
line temperature.
Higher ambient air temperatures at the condenser =
higher discharge line temperatures at the compressor.
Lower ambient air temperatures at the condenser = lower
discharge line temperatures at the compressor.
Regardless of ambient temperature, the freeze cycle
discharge line temperature will be higher than 150°F
(66°C) on a normally operating ice machine.
PROCEDURE
Connect a temperature probe on the compressor
discharge line within 6" (15 cm) of the compressor.
Observe the discharge line temperature for the last three
minutes of the freeze cycle and record the maximum
discharge line temperature.
78
Part Number STH045 11/16
Discharge Line Temperature Above 150°F (66°C) at
End of Freeze Cycle:
Ice machines that are operating normally will have
consistent maximum discharge line temperatures above
150°F (66°C).
Verify the expansion valve sensing bulb is positioned and
secured correctly.
Discharge Line Temperature Below 150°F (66°C) at
End of Freeze Cycle
Ice machines that have a flooding expansion valve
will have a maximum discharge line temperature that
decreases each cycle.
Verify the expansion valve sensing bulb is 100% insulated
and sealed airtight. Condenser air contacting an
incorrectly insulated sensing bulb will cause overfeeding
of the expansion valve.
Part Number STH045 11/16
79
Refrigeration Component Diagnostics
All electrical and water related problems must be
corrected before these charts will work properly. These
tables must be used with charts, checklists and other
references to eliminate refrigeration components not
listed and external items and problems that will cause
good refrigeration components to appear defective.
The tables list four different defects that may affect the
ice machine’s operation.
NOTE: A low-on-charge ice machine and a starving
expansion valve have very similar characteristics and are
listed under the same column.
80
Part Number STH045 11/16
PROCEDURE
Step 1 Complete each item individually in the
“Operational Analysis” column.
Enter check marks () in the boxes.
Each time the actual findings of an item in the
“Operational Analysis” column matches the published
findings on the table, enter a check mark.
Example: Freeze cycle suction pressure is determined to
be low. Enter a check mark in the “low” box.
Perform the procedures and check all information listed.
Each item in this column has supporting reference
material.
While analyzing each item separately, you may find an
“external problem” causing a good refrigerant component
to appear bad. Correct problems as they are found. If
the operational problem is found, it is not necessary
to complete the remaining procedures.
Step 2 Add the check marks listed under each of the
four columns. Note the column number with the highest
total and proceed to “Final Analysis.”
NOTE: If two columns have matching high numbers,
a procedure was not performed properly and/or
supporting material was not analyzed correctly.
Part Number STH045 11/16
81
FINAL ANALYSIS
The column with the highest number of check marks
identifies the refrigeration problem.
Column 1 – Harvest Valve Leaking
A leaking harvest valve must be replaced.
Column 2 – Low Charge/TXV Starving
Normally, a starving expansion valve only affects the
freeze cycle pressures, not the harvest cycle pressures. A
low refrigerant charge normally affects both pressures.
Verify the ice machine is not low on charge before
replacing an expansion valve.
Add refrigerant charge in 2 oz. increments as a diagnostic
procedure to verify a low charge. (Do not add more
than the total charge of refrigerant.) If the problem is
corrected, the ice machine is low on charge. Find the
refrigerant leak.
The ice machine must operate with the nameplate
charge. If the leak cannot be found, proper refrigerant
procedures must still be followed. Change the liquid
line drier, evacuate the system and weigh in the proper
charge.
If the problem is not corrected by adding charge, the
expansion valve is faulty.
Column 3 – TXV Flooding
A loose or improperly mounted expansion valve
bulb causes the expansion valve to flood. Check bulb
mounting, insulation, etc., before changing the valve.
Column 4 – Compressor
Replace the compressor and start components. To
receive warranty credit, the compressor ports must be
properly sealed by crimping and soldering them closed.
Old start components must be returned with the faulty
compressor.
82
Part Number STH045 11/16
Part Number STH045 11/16
83
4
All installation and water related problems must be corrected
before proceeding with chart.
3
Installation and Water
System
2
Published 24 hour ice production________________
Calculated (actual) 24 hour ice production_______________
NOTE: The ice machine is operating properly if the ice fill pattern is normal and ice production is within
10% of charted capacity.
1
Ice Production
Operational Analysis
Refrigeration Component Diagnostic Chart
84
Part Number STH045 11/16
Safety Limits
Refer to “Analyzing Safety
Limits” to eliminate all nonrefrigeration problems.
Ice Formation Pattern
Operational Analysis
2
Stops on safety limit:
1 or 2
Stops on safety limit:
1
Ice formation is
Ice formation extremely
extremely thin on outlet
thin on outlet of
of evaporator
evaporator
-or-orNo ice formation on
No ice formation on
entire evaporator
entire evaporator
1
Stops on safety limit:
1 or 2
Ice formation is normal
-orIce formation is
extremely thin on the
bottom of evaporator
-orNo ice formation on
evaporator
3
Stops on safety limit:
1
Ice formation is normal
-orNo ice formation on
entire evaporator
4
Part Number STH045 11/16
85
2
3
4
If discharge pressure is High or Low, refer to freeze cycle high or low discharge pressure problem
checklist to eliminate problems and/or components not listed on this table before proceeding.
1
Freeze Cycle
If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist to
Suction Pressure
eliminate problems and/or components not listed on this table before proceeding.
________ ______ ______
1 minute Middle End
Suction pressure is
Suction pressure is
Suction pressure is
Suction pressure is
High
Low
High
High
Freeze Cycle
Discharge Pressure
________ ______ ______
1 minute Middle End
Operational Analysis
86
Part Number STH045 11/16
Harvest Valve
Final Analysis
Enter total number of boxes
checked in each column.
The harvest valve
inlet is
COOL
and
The compressor
discharge line is
COOL
3
The harvest valve
inlet is
COOL
and
The compressor
discharge line is
HOT
4
Harvest Valve
Leaking
Low On Charge
-orTXV Starving
TXV Flooding
Compressor
Discharge line temp
Discharge line temp
Discharge line temp
Discharge line temp
150°F (66°C) or higher 150°F (66°C) or higher less than 150°F (66°C) 150°F (66°C) or higher
at the end of freeze cycle at the end of freeze cycle at the end of freeze cycle at the end of freeze cycle
The harvest valve
inlet is
COOL
and
The compressor
discharge line is
HOT
The harvest valve
inlet is
HOT
and
The compressor
discharge line is
HOT
Discharge Line Temp.
Record freeze cycle
discharge line temp at the
end of freeze cycle.
2
1
Operational Analysis
Component Check Procedures
Main Fuse
Function
The control board fuse stops ice machine operation if
electrical components fail causing high amp draw.
Specifications
•
The main fuse is 250 Volt, 3.15 amp.
nWarning
High (line) voltage is applied to the control board at
all times. Removing the control board fuse or cycling
the toggle switch Off/On will not remove the power
supplied to the control board.
Check Procedure
1. If the curtain light is on with the water curtain
closed, the fuse is good.
nWarning
Disconnect electrical power to the entire ice machine
before proceeding.
2. Remove the fuse. Check the resistance across the
fuse with an ohmmeter.
Reading
Open (OL)
Closed (O)
Part Number STH045 11/16
Result
Replace fuse
Fuse is good
87
Bin Switch
Function
Bin switch operation is controlled by the movement of
the water curtain. The bin switch has two main functions:
1. Terminating the harvest cycle and returning the ice
machine to the freeze cycle.
This occurs when the bin switch is opened and
closed again within 30 seconds of opening during
the harvest cycle.
2. Automatic ice machine shut-off.
If the storage bin is full at the end of a harvest cycle,
the sheet of cubes fails to clear the water curtain and
holds it down. After the water curtain is held down
for 30 seconds, the ice machine shuts off.
The ice machine remains off until enough ice is
removed from the storage bin to allow the sheet of
cubes to drop clear of the water curtain. As the water
curtain swings back to the operating position, the
bin switch closes and the ice machine restarts.
Importan
The ice damper must be up (bin switch closed) to
start ice making.
Check Procedure
1. Cycle the toggle switch OFF.
2. Watch the curtain light on the control board.
3. Move the water curtain upward, toward the
evaporator. The bin switch must close. The curtain
light “on” indicates the bin switch has closed
properly.
4. Move the water curtain away from the evaporator.
The bin switch must open. The curtain light “off”
indicates the bin switch has opened properly.
88
Part Number STH045 11/16
Ohm Test
1. Disconnect the bin switch wires from the control
board.
2. Connect an ohmmeter to the disconnected bin
switch.
3. Cycle the bin switch open and closed numerous
times by opening and closing the water curtain.
NOTE: To prevent misdiagnosis:
•
Always use the water curtain magnet to cycle the
switch (a larger or smaller magnet will affect switch
operation).
•
Watch for consistent readings when the bin switch is
cycled open and closed (bin switch failure could be
erratic).
Part Number STH045 11/16
89
Float Switch
Function
Open and close to indicate to the control board the level
of water in the water trough.
Specifications
Normally closed, float operated magnetic reed switch.
The float switch contacts are closed in the down position.
When water raises the float to the up position the magnet
in the float opens the contacts.
Check Procedure
The ice machine uses two float switches.
Ice Thickness Float - Indicates the water level has been
reached.
Harvest Float - Indicates a harvest cycle needs to be
initiated.
Initial testing can be performed by viewing the control
board light(s) while raising and lowering the float. The
corresponding control board light must turn on and off
when the float is raised and lowered.
Harvest Float Switch:
A. The light must be on in the up position.
B.
The light must be off in the down position.
Ice Thickness Float Switch:
A. The light must be off in the down position.
B.
90
The light must be on in the up position.
Part Number STH045 11/16
If the control board light does not respond to the float,
proceed with Step 1 below.
1. Disconnect power to the ice machine and pull the
float switch and connector through the ice machine
base and disconnect.
2. Attach an ohm meter lead to each float switch wire.
3. Place the float in the down position - The float switch
must be closed.
4. Place the float in the up position - The float switch
must be open.
5. If the float tests good, ohm the interconnecting
wires to the control board and inspect connectors.
NOTE: Make adjustments with the ice machine in the off
position. Making adjustments during the freeze cycle
may produce an initial sheet of ice that is thicker than
future cycles.
ICE
THICKNESS
FLOAT
Part Number STH045 11/16
WATER
LEVEL
FLOAT
91
Compressor Electrical Diagnostics
The compressor does not start or will trip repeatedly on
overload.
Check Resistance (Ohm) Values
NOTE: Compressor windings can have very low ohm
values. Use a properly calibrated meter.
Perform the resistance test after the compressor cools.
The compressor dome should be cool enough to touch
(below 120°F/49°C) to ensure that the overload is closed
and the resistance readings will be accurate.
Single Phase Compressors
1. Disconnect power and remove the wires from the
compressor terminals.
2. The resistance values between C and S and between
C and R, when added together should equal the
resistance value between S and R.
3. If the overload is open, there will be a resistance
reading between S and R, and open readings
between C and S and between C and R. Allow the
compressor to cool, then check the readings again.
Check Motor Windings to Ground
Check continuity between all three terminals and the
compressor shell or copper refrigeration line. Scrape
metal surface to get good contact. If continuity is
present, the compressor windings are grounded and the
compressor should be replaced.
To determine if the compressor is seized, check the amp
draw while the compressor is trying to start.
92
Part Number STH045 11/16
Compressor Drawing Locked Rotor
The two likely causes of this are:
•
Defective starting component
•
Mechanically seized compressor
To determine which you have:
1. Install high and low side gauge.
2. Try to start the compressor.
3. Watch the pressures closely.
• If the pressures do not move, the compressor is
seized. Replace the compressor.
• If the pressures move, the compressor is
turning slowly and is not seized. Check the start
components.
Compressor Drawing High Amps
The continuous amperage draw on start-up should not
be near the maximum fuse size indicated on the serial
tag.
The wiring must be correctly sized to minimize voltage
drop at compressor start-up. The voltage when the
compressor is trying to start must be within ±10% of the
nameplate voltage.
Part Number STH045 11/16
93
Fan Cycle Control
Function
Cycles the fan motor on and off to maintain proper
operating discharge pressure.
The fan cycle control closes on an increase, and opens on
a decrease in discharge pressure.
Specifications
Model
Ko350 K0420
K0500 K1000
K1300 K1800
Cut-In
(Close)
335 psig ±5
2310 kPa ±5
385 psig ±5
2654 kPa ±5
Cut-Out
(Open)
275 psig ±5
1896 kPa ±5
305 psig ±5
2103 kPa ±5
Check Procedure
Disconnect electrical power to the ice machine at the
electrical service disconnect.
Verify fan motor windings are not open or grounded, and
fan spins freely.
Connect manifold gauge to ice machine.
Hook voltmeter in parallel across the fan cycle control,
leaving wires attached.
Reconnect electrical power to the ice machine and Cycle
the toggle switch On.
Wait until water flows over the evaporator then refer to
chart below.
System
Pressure:
above cut-in
below cut-out
94
Reading
Should Be:
0 volts
line voltage
Fan
Should Be:
running
off
Part Number STH045 11/16
High Pressure Cutout (HPCO) Control
Function
Stops the ice machine if subjected to excessive high-side
pressure.
The HPCO control is normally closed, and opens on a rise
in discharge pressure.
Specifications
Cut-out: 600 psig ±10 4137 kPa ±10
Cut-in:
450 psig ±10 3103 kPa ±10
(Must be below 450 psig - 3103 kPa to reset).
Check Procedure
1. Move toggle switch to OFF.
2. Connect manifold gauge.
3. Hook voltmeter in parallel across the HPCO, leaving
wires attached.
4. On water-cooled models, close the water service
valve to the water condenser inlet. On self-contained
air-cooled models, disconnect the fan motor.
5. Move toggle switch to ON.
6. No water or air flowing through the condenser
will cause the HPCO control to open because of
excessive pressure. Watch the pressure gauge and
record the cut-out pressure.
nWarning
If discharge pressure exceeds 600 psig - 4137 kPa and
the HPCO control does not cut out, cycle the toggle
switch Off to stop ice machine operation.
Replace the HPCO control if it:
•
Will not reset (below 450 psig - 3103 kPa)
•
Does not open at the specified cut-out point
Part Number STH045 11/16
95
Refrigeration Components
HEAD PRESSURE CONTROL VALVE
Manitowoc remote systems require head pressure control
valves with special settings. Replace defective head
pressure control valves only with “original” Manitowoc
replacement parts.
Refrigerant Charge Verification
The correct amount of refrigerant (name plate charge) is
required to operate correctly at all ambient conditions.
An ice machine with an overcharge or undercharge of
refrigerant may function properly at higher ambient
temperatures and fails at lower ambient temperatures.
Symptoms of incorrect refrigerant amount are:
•Works during the day and malfunctions at night, and/or
fails whenever the outdoor temperature drops.
•A Safety limit is stored in control board memory.
Refrigerant loss and ambient temperature are directly
related to each other. As the ambient temperature drops,
more refrigerant is stored in the condenser.
When the refrigerant charge and ambient temperature
create an undercharge of refrigerant in the freeze cycle,
the receiver dip tube will lose it’s liquid seal. Without
liquid refrigerant to the TXV, the ice machine fails to
make a full sheet of ice in 60 minutes and a safety limit #1
results.
NOTE: When a head pressure control valve is being
replaced or refrigerant charge is suspected, verify the
refrigerant charge is correct by recovering the refrigerant,
weighing and comparing to the nameplate amount.
Refer to Refrigerant Recovery/Evacuation for recovery
procedures.
96
Part Number STH045 11/16
FREEZE CYCLE OPERATION ALL MODELS
The head pressure control valve is non adjustable.
At ambient temperatures of approximately 70°F (21°C)
or above, refrigerant flows through the valve from the
condenser to the receiver inlet. At temperatures below
this (or at higher temperatures if it is raining), the head
pressure control dome’s nitrogen charge closes the
condenser port and opens the bypass port from the
compressor discharge line.
In this modulating mode, the valve maintains minimum
head pressure by building up liquid in the condenser and
bypassing discharge gas directly to the receiver.
HARVEST CYCLE OPERATION
Remote Condenser Models
The head pressure control cycles into full bypass due
to the pressure drop when the harvest valve opens.
Refrigerant flows from the compressor to the evaporator
through the harvest valve and the head pressure valve is
out of the circuit.
Diagnostics
FREEZE CYCLE - REMOTE CONDENSER
1. Determine if the coil is clean.
2. Determine the air temperature entering the
condenser.
3. Determine if the head pressure is high or low in
relationship to the outside temperature. (Refer to
the proper “Cycle Times/24-Hour Ice Production/
Refrigerant Pressure Charts”).
4. Determine the temperature of the liquid line
entering the receiver by feeling it. This line is
normally warm; “body temperature.”
5. Using the information gathered, refer to the chart.
Part Number STH045 11/16
97
NOTE: A head pressure control valve that will not
bypass, will function properly with condenser air
temperatures of approximately 70°F (21°C) or above.
When the temperature drops below 70°F (21°C), the
head pressure control valve fails to bypass and the ice
machine malfunctions. Lower ambient conditions can
be simulated by rinsing the condenser with cool water
during the freeze cycle.
Condition
Discharge Pressure - High
Liquid Line Temperature
- Hot
Discharge Pressure - Low
Liquid Line Temperature
- Cold
Discharge Pressure - Low
Liquid Line Temperature
- Hot
98
Probable
Cause
Valve stuck in
bypass
Corrective
Measure
Replace valve
Valve not
bypassing
Replace valve
Ice Machine
Low on Charge
Refrigerant
Charge
Verification
Part Number STH045 11/16
Harvest Cycle
REMOTE CONDENSER
The head pressure control cycles into full bypass due
to the pressure drop when the harvest valve opens.
Refrigerant flows from the compressor to the evaporator
through the harvest valve and the head pressure valve is
out of the circuit.
Undercharge Symptoms
•
Safety limit #1 or Safety limit #2 in control board
memory, a flashing triangle alert and after pressing
left arrow Long Freeze or Long Harvest is displayed.
•
Harvest cycle suction pressure is low.
•
Harvest cycle discharge pressure is low.
•
Liquid line entering receiver feels warm to hot in the
freeze cycle.
Overcharge Symptoms
•
Safety limit #2 in control board memory, a flashing
triangle alert and after pressing left arrow Long
Harvest is displayed.
•
Harvest cycle discharge pressure is normal.
•
Freeze cycle time, suction and discharge pressure
are normal and the ice machine will not harvest. The
sheet of ice cubes show little or no sign of melting
when removed from the evaporator after the harvest
cycle has been completed. (If the cubes are melted
you have a release problem, clean the ice machine).
Part Number STH045 11/16
99
HARVEST PRESSURE REGULATING (HPR)
SYSTEM REMOTE CONDENSER ONLY
GENERAL
The harvest pressure regulating (HPR) system includes:
•
Harvest pressure regulating solenoid valve (HPR
solenoid). This is an electrically operated valve
which opens when energized, and closes when deenergized.
•
Harvest pressure regulating valve (HPR valve). This is a
pressure regulating valve which modulates open and
closed, based on the refrigerant pressure at the outlet
of the valve. The valve closes completely and stops
refrigerant flow when the pressure at the outlet rises
above the valve setting.
Inlet
Outlet
HPR VALVE
100
Part Number STH045 11/16
FREEZE CYCLE
The HPR system is not used during the freeze cycle.
The HPR solenoid is closed (de-energized), preventing
refrigerant flow into the HPR valve.
HARVEST CYCLE
During the harvest cycle, the check valve in the discharge
line prevents refrigerant in the remote condenser and
receiver from back feeding into the evaporator and
condensing to liquid.
The HPR solenoid is opened (energized) during the
harvest cycle, allowing refrigerant gas from the top of
the receiver to flow into the HPR valve. The HPR valve
modulates open and closed, raising the suction pressure
high enough to sustain heat for the harvest cycle,
without allowing refrigerant to condense to liquid in the
evaporator.
In general, harvest cycle suction pressure rises, then
stabilize. Exact pressures vary from model to model. Refer
to cycle time/24 hour ice production and operational
pressure charts.
HPR DIAGNOSTICS
Steps 1 through 5 can be quickly verified without
attaching a manifold gauge set or thermometer.
All questions must have a yes answer to continue the
diagnostic procedure.
1. Liquid line warm?
(Body temperature is normal)
If liquid line is cooler than body temperature, refer to
head pressure control valve diagnostics.
2. Ice fill pattern normal?
Refer to “Ice Formation Pattern” if ice fill is not
normal.
Part Number STH045 11/16
101
3. Freeze time normal?
(Refer to Cycle Times/Refrigerant Pressures/24 Hour
Ice Production Charts).
A. Shorter freeze cycles?
Refer to head pressure control valve diagnostics.
B.
Longer freeze cycles?
Refer to water system checklist, then refer to
Refrigeration Diagnostic Procedures.
4. Harvest time is longer than normal and control
board indicates safety limit #2?
(Refer to Cycle Times/Refrigerant Pressures/24 Hour
Ice Production Charts).
5. Discharge line temperature is greater than 160°F at
the end of the freeze cycle?
(Refer to Discharge Line Temperature Analysis)
6. Connect refrigeration manifold gauge set to the
access valves on the front of the ice machine.
Establish baseline by recording suction and
discharge pressure and freeze & harvest cycle
times. (Refer to “Freeze Cycle Refrigeration System
Operational Analysis Tables” for data collection
detail).
7. Freeze cycle Head Pressure is in the range indicated
in the cycle time/24 hour ice production and
operational pressure chart?
If the head pressure is low refer to head pressure
control valve diagnostics.
8. Freeze cycle Suction Pressure normal?
Refer to analyzing suction pressure if suction
pressure is high or low.
9. Harvest cycle suction and discharge pressures are
lower than indicated in the cycle times/refrigerant
pressures/24 hour ice production chart?
Replace Harvest Pressure Regulating solenoid
102
Part Number STH045 11/16
WATER REGULATING VALVE
Water-Cooled Models Only
FUNCTION
The water regulating valve maintains the freeze cycle
discharge pressure.
CHECK PROCEDURE
1. Determine if the head pressure is high or low (refer
to cycle time/24 hour ice production and operational
pressure chart for the model you are servicing).
2. Verify the condenser water meets specifications.
3. Adjust valve to increase or decrease discharge
pressure.
4. Determine the temperature of the liquid line
entering the receiver by feeling it. This line is
normally warm; body temperature.
5. Using the information gathered, refer to the list for
diagnosis.
Problem (Freeze Cycle)
VALVE NOT MAINTAINING DISCHARGE PRESSURE.
•
Valve incorrectly set, dirty or defective. Adjust, clean
or replace valve.
DISCHARGE PRESSURE EXTREMELY HIGH; LIQUID LINE
ENTERING RECEIVER FEELS HOT.
•
Water regulating valve incorrectly set or not opening.
DISCHARGE PRESSURE LOW, LIQUID LINE ENTERING
RECEIVER FEELS WARM TO HOT.
•
Ice machine low on charge - Verify Total System
Refrigerant Charge
Part Number STH045 11/16
103
Refrigerant Recovery/Evacuation
DEFINITIONS
Recover
To remove refrigerant, in any condition, from a system
and store it in an external container, without necessarily
testing or processing it in any way.
Recycle
To clean refrigerant for re-use by oil separation and
single or multiple passes through devices, such as
replaceable core filter-driers, which reduce moisture,
acidity and particulate matter. This term usually applies to
procedures implemented at the field job site or at a local
service shop.
Reclaim
To reprocess refrigerant to new product specifications
(see below) by means which may include distillation.
A chemical analysis of the refrigerant is required after
processing to be sure that product specifications are
met. This term usually implies the use of processes
and procedures available only at a reprocessing or
manufacturing facility.
Chemical analysis is the key requirement in this definition.
Regardless of the purity levels reached by a reprocessing
method, refrigerant is not considered “reclaimed” unless
it has been chemically analyzed and meets ARI Standard
700 (latest edition).
New Product Specifications
This means ARI Standard 700 (latest edition). Chemical
analysis is required to assure that this standard is met.
104
Part Number STH045 11/16
REFRIGERANT RE-USE POLICY
Koolaire recognizes and supports the need for proper
handling, re-use, and disposal of refrigerants. Koolaire
service procedures require recapturing refrigerants, not
venting them to the atmosphere.
It is not necessary, in or out of warranty, to reduce or
compromise the quality and reliability of your customers’
products to achieve this.
Importan
Koolaire assumes no responsibility for use of
contaminated refrigerant. Damage resulting from
the use of contaminated, recovered, or recycled
refrigerant is the sole responsibility of the servicing
company.
Koolaire approves the use of:
1. New Refrigerant
• Must be of original nameplate type.
2. Reclaimed Refrigerant
• Must be of original nameplate type.
• Must meet ARI Standard 700 (latest edition)
specifications.
3. Recovered or Recycled Refrigerant
• Must be recovered or recycled in accordance with
current local, state and federal laws.
• Must be recovered from and re-used in the same
Koolaire product. Re-use of recovered or recycled
refrigerant from other products is not approved.
• Recycling equipment must be certified to ARI
Standard 740 (latest edition) and be maintained
to consistently meet this standard.
Part Number STH045 11/16
105
4. Recovered refrigerant must come from a
“contaminant-free” system. To decide whether the
system is contaminant free, consider:
• Type(s) of previous failure(s)
• Whether the system was cleaned, evacuated and
recharged properly following failure(s)
• Whether the system has been contaminated by
this failure
• Compressor motor burnouts and improper past
service prevent refrigerant re-use.
• Refer to “Remote Condenser Model Procedure” on
page 110 to test for contamination.
5. “Substitute” or “Alternative” Refrigerant
• Must use only Koolaire-approved alternative
refrigerants.
• Must follow Koolaire-published conversion
procedures.
106
Part Number STH045 11/16
RECOVERY AND RECHARGING PROCEDURES
Do not purge refrigerant to the atmosphere. Capture
refrigerant using recovery equipment. Follow the
manufacturer’s recommendations.
Importan
Koolaire assumes no responsibility for the use of
contaminated refrigerant. Damage resulting from
the use of contaminated refrigerant is the sole
responsibility of the servicing company.
Importan
Replace the liquid line drier before evacuating and
recharging. Use only a Koolaire (O.E.M.) liquid line
filter drier to prevent voiding the warranty.
CONNECTIONS
1. Suction side of the compressor through the suction
service valve.
2. Discharge side of the compressor through the
discharge service valve.
Part Number STH045 11/16
107
SELF-CONTAINED RECOVERY/EVACUATION
1. Cycle the toggle switch Off.
2. Install manifold gauge set and recovery unit or twostage vacuum pump.
3. Perform recovery or evacuation:
A. Recovery: Operate the recovery unit as directed
by the manufacturer’s instructions.
B.
108
Evacuation prior to recharging: Pull the system
down to 500 microns. Then, allow the pump
to run for an additional half hour. Turn off the
pump and perform a standing vacuum leak
check.
Part Number STH045 11/16
CHARGING PROCEDURES
Importan
The charge is critical on all Koolaire machines. Use
a scale or a charging cylinder to ensure the proper
charge is installed.
1. Cycle the toggle switch Off.
2. Close the vacuum pump valve, the low side manifold
gauge valve.
3. Open the high side manifold gauge valve.
4. Open the charging cylinder and add the proper
refrigerant charge (shown on nameplate) through
the discharge service valve.
5. Let the system “settle” for 2 to 3 minutes.
6. Cycle the toggle switch On.
7. Close the high side on the manifold gauge set.
NOTE: Manifold gauge set must be removed properly to
ensure that no refrigerant contamination or loss occurs.
8. Make sure that all of the vapor in the charging hoses
is drawn into the ice machine before disconnecting
the charging hoses.
A. Run the ice machine in freeze cycle.
B.
Open the high and low side valves on the
manifold gauge set. Any refrigerant in the lines
will be pulled into the low side of the system.
C.
Disconnect the low loss fitting while the ice
machine is in the freeze cycle and install the
caps.
D. Check for leaks using an electronic leak
detector.
Part Number STH045 11/16
109
REMOTE CONDENSER MODEL PROCEDURE
Refrigerant Recovery/Evacuation
Do not purge refrigerant to the atmosphere. Capture
refrigerant using recovery equipment. Follow the
manufacturer’s recommendations.
Importan
Koolaire assumes no responsibility for the use of
contaminated refrigerant. Damage resulting from
the use of contaminated refrigerant is the sole
responsibility of the servicing company.
Importan
Replace the liquid line drier after recovering the
refrigerant and before evacuating and recharging.
Use only a Manitowoc (O.E.M.) liquid line filter drier to
prevent voiding the warranty.
Importan
Recovery/evacuation of a remote system requires
connections at four points for complete system
evacuation.
MAKE THESE CONNECTIONS:
•
Suction side of the compressor through the suction
service valve.
•
Discharge side of the compressor through the
discharge service valve.
•
Receiver outlet service valve, which evacuates the
area between the check valve in the liquid line and
the pump down solenoid.
110
Part Number STH045 11/16
•
Access valve on the discharge line quick-connect
fitting, located on the outside of the compressor/
evaporator compartment. This connection evacuates
the condenser. Without it, the magnetic check
valves would close when the pressure drops during
evacuation, preventing complete evacuation of the
condenser.
NOTE: Koolaire recommends using an access valve core
removal and installation tool on the discharge line quickconnect fitting. This permits access valve core removal.
This allows for faster evacuation and charging, without
removing the manifold gauge hose.
REMOTE CONDENSER RECOVERY/EVACUATION
1. Press the power button to stop the ice machine.
2. Install manifold gauge set, scale and recovery unit or
two-stage vacuum pump.
3. Open high and low side on the manifold gauge set.
4. Perform recovery or evacuation:
A. Recovery: Operate the recovery unit as directed
by the manufacturer’s instructions.
B.
Evacuation prior to recharging: Pull the system
down to 500 microns. Then, allow the pump to
run for an additional hour. Turn off the pump
and perform a standing vacuum leak check.
NOTE: Check for leaks with an electronic leak detector
after charging the ice machine.
5. Follow the Remote Charging Procedures.
Part Number STH045 11/16
111
REMOTE CHARGING PROCEDURES
1. Close the vacuum pump valve and the low side
manifold gauge valve.
2. Open the refrigerant cylinder and add the proper
refrigerant charge (shown on nameplate) into the
system high side (receiver outlet valve and discharge
lines quick-connect fitting).
3. If the high side does not take the entire charge, close
the high side on the manifold gauge set and start
the ice machine. Add the remaining charge through
the low side (in vapor form) until the machine is fully
charged.
NOTE: If an access valve core removal and installation
tool is used on any of the access valves, reinstall the cores
before disconnecting the access tool and hose.
4. Open the high and low side valves on the manifold
gauge set. Any refrigerant in the lines will be pulled
into the low side of the system.
5. Allow the pressures to equalize while the ice
machine is in the freeze cycle.
6. Remove the low side hose from the access valve and
install the caps.
112
Part Number STH045 11/16
System Contamination Cleanup
This section describes the basic requirements for
restoring contaminated systems to reliable service.
Importan
Koolaire assumes no responsibility for the use of
contaminated refrigerant. Damage resulting from
the use of contaminated refrigerant is the sole
responsibility of the servicing company.
DETERMINING SEVERITY OF CONTAMINATION
System contamination is generally caused by either
moisture or residue from compressor burnout entering
the refrigeration system.
Inspection of the refrigerant usually provides the first
indication of system contamination. Obvious moisture or
an acrid odor in the refrigerant indicates contamination.
If either condition is found, or if contamination is
suspected, use a Total Test Kit from Totaline or a similar
diagnostic tool. These devices sample refrigerant,
eliminating the need to take an oil sample. Follow the
manufacturer’s directions.
If a refrigerant test kit indicates harmful levels of
contamination, or if a test kit is not available, inspect the
compressor oil.
1. Remove the refrigerant charge from the ice machine.
2. Remove the compressor from the system.
3. Check the odor and appearance of the oil.
4. Inspect open suction and discharge lines at the
compressor for burnout deposits.
5. If no signs of contamination are present, perform
an acid oil test to determine the type of cleanup
required.
Part Number STH045 11/16
113
Contamination/Cleanup Chart
Symptoms/Findings
Required Cleanup
Procedure
No symptoms or suspicion of
Normal evacuation/
contamination
recharging
procedure
Moisture/Air Contamination symptoms Mild contamination
Refrigeration system open to atmosphere cleanup procedure
for longer than 15 minutes
Refrigeration test kit and/or acid oil test
shows contamination
No burnout deposits in open compressor
lines
Mild Compressor Burnout symptoms
Mild contamination
Oil appears clean but smells acrid
cleanup procedure
Refrigeration test kit or acid oil test shows
harmful acid content
No burnout deposits in open compressor
lines
Severe Compressor Burnout symptoms
Severe
Oil is discolored, acidic, and smells acrid
contamination
Burnout deposits found in the
cleanup procedure
compressor, lines, and other components
114
Part Number STH045 11/16
MILD SYSTEM CONTAMINATION CLEANUP
PROCEDURE
1. Replace any failed components.
2. If the compressor is good, change the oil.
3. Replace the liquid line drier.
NOTE: If the contamination is from moisture, use
heat lamps during evacuation. Position them at
the compressor, condenser and evaporator prior to
evacuation. Do not position heat lamps too close to
plastic components, or they may melt or warp.
4. Follow the normal evacuation procedure, except
replace the evacuation step with the following:
A. Pull vacuum to 1000 microns. Break the vacuum
with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 psig.
B.
Pull vacuum to 500 microns. Break the vacuum
with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 psig.
C.
Change the vacuum pump oil.
D. Pull vacuum to 500 microns. Run the vacuum
pump for 1/2 hour on self-contained models, 1
hour on remotes.
NOTE: You may perform a pressure test as a preliminary
leak check. You should use an electronic leak detector
after system charging to be sure there are no leaks.
5. Charge the system with the proper refrigerant to the
nameplate charge.
6. Operate the ice machine.
Part Number STH045 11/16
115
SEVERE SYSTEM CONTAMINATION CLEANUP
PROCEDURE
1. Remove the refrigerant charge.
2. Remove the compressor.
3. Disassemble the harvest solenoid valve. If burnout
deposits are found inside the valve, install a rebuild
kit, and replace the TXV and head pressure control
valve.
4. Wipe away any burnout deposits from suction and
discharge lines at compressor.
5. Sweep through the open system with dry nitrogen.
6. Install a new compressor and new start components.
7. Install suction line filter-drier in front of compressor.
8. Install a new liquid line drier.
9. Follow the normal evacuation procedure, except
replace the evacuation step with the following:
A. Pull vacuum to 1000 microns. Break the vacuum
with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 psig.
B. Change the vacuum pump oil.
C. Pull vacuum to 500 microns. Break the vacuum
with dry nitrogen and sweep the system.
Pressurize to a minimum of 5 psig.
D. Change the vacuum pump oil.
E. Pull vacuum to 500 microns. Run the vacuum
pump for 1 additional hour.
10. Charge the system with the proper refrigerant to the
nameplate charge.
11. Operate the ice machine for one hour. Then, check
the pressure drop across the suction line filter-drier.
A. If the pressure drop is less than 2 psig, the filterdrier should be adequate for complete cleanup.
B. If the pressure drop exceeds 2 psig, change the
suction line filter-drier and the liquid line drier.
Repeat until the pressure drop is acceptable.
12. Operate the ice machine for 48 – 72 hours. Replace
the suction line and liquid line drier if necessary.
13. Follow normal evacuation procedures.
116
Part Number STH045 11/16
REPLACING PRESSURE CONTROLS WITHOUT
REMOVING REFRIGERANT CHARGE
This procedure reduces repair time and cost. Use it when
any of the following components require replacement,
and the refrigeration system is operational and leak-free.
•
Fan cycle control
•
High pressure cut-out control
•
High side access valve
•
Low side access valve
Importan
This is a required in-warranty repair procedure.
1. Disconnect power to the ice machine.
2. Follow all manufacturers’ instructions supplied
with the pinch-off tool. Position the pinch-off tool
around the tubing as far from the pressure control as
feasible. (See the figure on next page.) Clamp down
on the tubing until the pinch-off is complete.
nWarning
Do not unsolder a defective component. Cut it out
of the system. Do not remove the pinch-off tool until
the new component is securely in place.
3. Cut the tubing of the defective component with a
small tubing cutter.
4. Solder the replacement component in place. Allow
the solder joint to cool.
5. Remove the pinch-off tool.
6. Re-round the tubing. Position the flattened tubing
in the proper hole in the pinch off tool. Tighten the
wing nuts until the block is tight and the tubing is
rounded.
NOTE: The pressure controls will operate normally once
the tubing is re-rounded. Tubing may not re-round 100%.
Part Number STH045 11/16
117
FIG. A - “PINCHING OFF” TUBING
FIG. B - RE-ROUNDING TUBING
SV1406
Using Pinch Off Tool
118
Part Number STH045 11/16
Refrigerant Amount
NOTE: All models charged with R410A refrigerant.
Model
Air-Cooled
WaterCooled
Remote
51’ to 100’
Line sets*
K0250 60Hz
15 oz
N/A
N/A
N/A
425 g
K0250 50Hz
17 oz
N/A
N/A
N/A
482 g
K0350 60Hz
18 oz
14 oz
N/A
N/A
510 g
397 g
K0350 50Hz
21 oz
14 oz
N/A
N/A
595 g
397 g
K0420 60Hz
16 oz
14 oz
N/A
N/A
and 50Hz
454 g
397 g
K0500 60Hz
18 oz
14 oz
N/A
N/A
and 50Hz
510 g
397 g
K0600 60Hz
24 oz
18 oz
N/A
N/A
and 50Hz
680 g
510 g
K1000 60hz
28 oz
24 oz
7 lbs 8 oz
2 lbs
794 g
680 g
3.4 kg
907 g
K1000 50hz
44 oz
24 oz
7 lbs 8 oz
2 lbs
1247 g
680 g
3.4 kg
907 g
K1350 60Hz
42 oz
24 oz
11 lbs 8 oz
2 lbs
and 50Hz
1191 g
680 g
5.2 kg
907 g
K1800 60Hz
46 oz
12 lbs
2 lbs
N/A
and 50Hz
1304 g
5.4 kg
907 g
* Additional amount of refrigerant to be added for remote
condenser with line sets that are 51’ to 100’ in length
Part Number STH045 11/16
119
THIS PAGE INTENTIONALLY LEFT BLANK
120
Part Number STH045 11/16
Charts
Cycle Times, 24 Hr. Ice Production and
Refrigerant Pressure Charts
These charts are used as guidelines to verify correct ice
machine operation.
Accurate collection of data is essential to obtain the
correct diagnosis.
•
Production and cycle times are for dice cube - Half
dice cube cycle times can be 1-2 minutes faster
depending on model and ambient temperature.
•
Ice production checks that are within 10% of the
chart are considered normal. This is due to variances
in water and air temperature. Actual temperatures
will seldom match the chart exactly.
•
Refer to “Operational Analysis Chart” for the list
of data that must be collected for refrigeration
diagnostics.
•
Zero out manifold gauge set before obtaining
pressure readings to avoid mis-diagnosis.
•
Discharge and suction pressure are highest at the
beginning of the cycle. Suction pressure will drop
throughout the cycle. Verify the pressures are within
the range indicated.
•
Record beginning of freeze cycle suction pressure
one minute after the water pump energizes.
Part Number STH045 11/16
121
K0250A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
9.3-11.5
10.8-12.9
12.3-14.6
80/27
10.6-12.6
12.3-14.6
13.5-16.0
90/32
11.8-14.0
13.9-16.4
15.0-17.7
100/38
13.2-15.7
14.6-17.3
16.2-19.2
110/43
15.0-17.7
15.8-18.7
17.7-20.9
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
310
280
250
80/27
285
250
230
90/32
260
225
210
100/38
235
215
195
110/43
210
200
180
Based on average ice slab weight of 3.40 – 3.90 lb (1.54 – 1.79 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
300-335
70-38
70/21
310-340
75-40
80/27
315-360
80-42
90/32
320-375
90-44
100/38
420-510
100-49
110/43
450-540
120-52
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
160-180
150-175
180-200
150-175
185-210
150-175
190-215
150-175
300-330
200-250
355-370
270-290
Suction pressure drops gradually throughout the freeze cycle
122
Part Number STH045 11/16
K0350A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
11.6-13.5
12.7-14.8
14.0-16.3
80/27
12.5-14.5
14.0-16.3
15.1-17.5
90/32
13.6-15.8
14.8-17.2
15.7-18.2
100/38
14.8-17.2
15.4-17.9
16.6-19.3
110/43
15.7-18.2
16.3-18.9
17.0-19.7
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
375
345
315
80/27
350
315
295
90/32
325
300
285
100/38
300
290
270
110/43
285
275
265
Based on average ice slab weight of 3.40 – 3.90 lb (1.54 – 1.79 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
260-320
55-32
70/21
275-340
60-33
80/27
285-395
65-34
90/32
335-410
70-35
100/38
400-500
80-40
110/43
450-520
85-42
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
130-200
90-140
150-200
100-140
170-230
105-165
190-250
110-175
280-340
160-220
320-360
190-235
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
123
K0350W SELF-CONTAINED WATER-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Around Ice
Water Temperature °F/°C
Machine
50/10
70/21
90/32
°F/°C
70/21
11.4-13.3
12.3-14.3
13.1-15.3
80/27
11.6-13.5
12.5-14.5
13.3-15.5
90/32
11.7-13.7
14.6-16.1
13.6-15.8
100/38
11.9-13.9
12.9-15.0
13.8-16.1
110/43
12.1-14.1
13.8-16.1
14.0-16.3
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp.
Water Temperature °F/°C
Around Ice
50/10
70/21
90/32
Machine °F/°C
70/21
380
355
335
80/27
375
350
330
90/32
370
340
325
100/38
365
330
320
110/43
360
320
315
Based on average ice slab weight of 3.40 – 3.90 lb (1.54 – 1.79 kg)
Water regulating valve set to maintain 320 PSIG discharge
pressure
Condenser Water usage per 100 lbs ice = 170 gal (45 kg = 644 L)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Around Ice Discharge Suction Discharge Suction
Machine
Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
315-330
60-34
150-210
110-150
70/21
315-330
60-34
150-210
110-150
80/27
315-330
60-34
150-210
110-150
90/32
315-330
60-34
150-210
110-150
100/38
315-335
60-34
150-210
110-150
110/43
315-340
65-36
150-210
110-150
Suction pressure drops gradually throughout the freeze cycle
124
Part Number STH045 11/16
K0420A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
11.7-13.7
12.5-14.5
13.6-15.8
80/27
12.9-15.0
13.8-16.1
15.4-17.9
90/32
14.0-16.3
14.6-16.9
16.6-19.3
100/38
15.7-18.2
17.0-19.7
18.1-21.0
110/43
17.7-20.5
18.9-21.9
20.3-23.5
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
370
350
325
80/27
340
320
290
90/32
315
305
270
100/38
285
265
250
110/43
255
240
225
Based on average ice slab weight of 3.40 – 3.90 lb (1.54 – 1.79 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
275-360
60-31
70/21
290-380
65-32
80/27
300-390
65-33
90/32
330-400
70-34
100/38
400-500
80-34
110/43
430-520
95-34
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
180-220
130-160
200-220
140-160
215-235
150-170
235-245
160-180
355-370
240-270
370-375
255-275
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
125
K0420W SELF-CONTAINED WATER-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Around Ice
Water Temperature °F/°C
Machine
50/10
70/21
90/32
°F/°C
70/21
11.7-13.7
11.2-15.2
12.7-13.5
80/27
13.1-14.0
14.6-15.5
12.9-17.7
90/32
13.3-14.2
11.7-15.8
13.1-18.1
100/38
13.1-14.9
15.1-17.5
17.3-18.4
110/43
14.0-15.0
15.4-16.4
17.7-18.8
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp.
Water Temperature °F/°C
Around Ice
50/10
70/21
90/32
Machine °F/°C
70/21
370
310
275
80/27
335
305
270
90/32
330
300
265
100/38
320
295
260
110/43
315
290
255
Based on average ice slab weight of 3.40 – 3.90 lb (1.54 – 1.79 kg)
Water regulating valve set to maintain 320 PSIG discharge
pressure
Condenser Water usage per 100 lbs ice = 170 gal (45 kg = 644 L)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Around Ice Discharge Suction Discharge Suction
Machine
Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
325-335
70-31
155-230
110-165
70/21
325-335
70-31
155-235
110-170
80/27
325-335
70-31
160-240
110-170
90/32
325-335
75-31
160-245
110-175
100/38
325-345
80-31
160-245
115-180
110/43
325-350
80-31
160-245
115-180
Suction pressure drops gradually throughout the freeze cycle
126
Part Number STH045 11/16
K0500A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
11.9-13.6
14.1-16.1
15.7-17.9
80/27
13.6-15.5
15.1-17.2
16.6-19.0
90/32
14.9-17.0
15.5-17.7
17.7-20.2
100/38
16.6-19.0
18.3-20.9
20.2-23.1
110/43
18.9-21.5
19.5-22.3
20.6-23.5
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
495
425
385
80/27
440
400
365
90/32
405
390
345
100/38
365
335
305
110/43
325
315
300
Based on average ice slab weight of 4.6 – 5.2 lb (2.1 – 2.36 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
260-325
60-36
70/21
270-340
65-37
80/27
275-380
65-37
90/32
340-400
75-38
100/38
380-500
80-42
110/43
440-520
80-44
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
140-175
100-120
150-185
105-130
165-200
110-150
190-220
130-160
280-320
180-235
290-330
185-240
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
127
K0500W SELF-CONTAINED WATER-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Around Ice
Water Temperature °F/°C
Machine
50/10
70/21
90/32
°F/°C
70/21
10.7-13.7
13.6-15.5
15.7-17.7
80/27
12.0-13.8
13.7-15.7
15.5-17.9
90/32
12.4-14.3
13.9-15.9
16.4-18.7
100/38
12.7-14.6
14.5-16.5
16.6-19.0
110/43
13.1-15.0
14.7-16.8
16.9-19.3
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp.
Water Temperature °F/°C
Around Ice
50/10
70/21
90/32
Machine °F/°C
70/21
545
440
390
80/27
490
435
385
90/32
475
430
370
100/38
465
415
365
110/43
455
410
360
Based on average ice slab weight of 4.6 – 5.2 lb (2.1– 2.4 kg)
Water regulating valve set to maintain 330 PSI discharge pressure
Condenser Water usage per 100 lbs ice = 160 gal (45 kg = 606 L)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Around Ice Discharge Suction Discharge Suction
Machine
Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
325-335
70-38
145-175
105-130
70/21
325-335
70-39
150-180
110-135
80/27
325-335
75-39
150-185
110-135
90/32
325-340
80-39
150-190
110-135
100/38
325-340
80-39
150-190
110-135
110/43
325-345
80-39
150-190
110-135
Suction pressure drops gradually throughout the freeze cycle
128
Part Number STH045 11/16
K0600A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
8.5-11.0
11.5-13.2
12.4-14.3
80/27
10.5-12.1
12.0-13.8
12.7-14.6
90/32
11.7-13.5
12.2-13.9
13.9-15.9
100/38
12.9-14.8
13.2-15.1
14.1-16.1
110/43
13.6-15.5
14.1-16.1
14.5-16.5
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
600
510
475
80/27
550
490
465
90/32
500
485
430
100/38
460
450
425
110/43
440
425
415
Based on average ice slab weight of 4.6 – 5.2 lb (2.1 – 2.4 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
260-325
60-28
70/21
275-350
65-30
80/27
275-380
70-31
90/32
350-415
75-35
100/38
380-520
80-36
110/43
440-540
80-36
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
140-175
90-120
165-200
100-130
165-210
105-150
310-370
170-215
310-375
170-235
310-375
170-225
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
129
K0600W SELF-CONTAINED WATER-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Around Ice
Water Temperature °F/°C
Machine
50/10
70/21
90/32
°F/°C
70/21
9.5-11.0
10.9-12.5
11.5-13.2
80/27
9.8-11.3
11.1-12.8
11.7-13.5
90/32
10.9-12.5
11.2-12.9
12.7-14.6
100/38
11.9-13.6
12.2-13.9
12.9-14.8
110/43
12.4-14.3
12.9-14.8
13.2-15.1
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp.
Water Temperature °F/°C
Around Ice
50/10
70/21
90/32
Machine °F/°C
70/21
600
535
510
80/27
585
525
500
90/32
535
520
465
100/38
495
485
460
110/43
475
460
450
Based on average ice slab weight of 4.6 – 5.2 lb (2.1 – 2.4 kg)
Water regulating valve set to maintain 320 PSI discharge pressure
Condenser Water usage per 100 lbs ice = 170 gal (45 kg = 644 L)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Around Ice Discharge Suction Discharge Suction
Machine
Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
315-325
55-31
160-210
100-135
70/21
315-325
55-32
180-225
100-140
80/27
315-325
60-32
180-230
105-140
90/32
315-325
65-32
180-230
105-140
100/38
315-325
65-32
180-230
105-140
110/43
315-325
65-32
180-230
105-140
Suction pressure drops gradually throughout the freeze cycle
130
Part Number STH045 11/16
K1000A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
8.5-10.1
9.9-11.7
11.6-12.6
80/27
9.4-11.1
10.2-12.1
10.9-12.9
90/32
10.2-12.1
11.0-13.0
12.0-14.2
100/38
11.1-13.1
12.6-14.8
13.1-15.5
110/43
12.1-14.3
13.0-15.4
13.9-16.4
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
895
785
735
80/27
820
765
720
90/32
765
715
660
100/38
710
635
610
110/43
655
615
580
Based on average ice slab weight of 6.2 – 7.2 lb (2.8 – 3.3 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
280-375
60-28
70/21
300-390
65-28
80/27
320-400
70-32
90/32
350-415
75-33
100/38
450-520
80-37
110/43
440-540
85-39
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
140-200
100-140
145-200
105-140
150-205
105-150
160-210
110-150
170-240
115-155
200-250
125-160
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
131
K1000W SELF-CONTAINED WATER-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Around Ice
Water Temperature °F/°C
Machine
50/10
70/21
90/32
°F/°C
70/21
8.3-9.8
8.8-10.4
9.7-11.5
80/27
9.0-10.7
9.7-11.5
10.8-12.8
90/32
9.9-11.8
10.7-12.7
11.0-13.0
100/38
10.2-12.1
11.1-13.1
11.4-13.5
110/43
10.8-12.8
11.3-13.4
11.8-14.0
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp.
Water Temperature °F/°C
Around Ice
50/10
70/21
90/32
Machine °F/°C
70/21
915
870
800
80/27
850
800
725
90/32
780
730
715
100/38
765
710
690
110/43
725
695
670
Based on average ice slab weight of 6.2 – 7.2 lb (2.8 – 3.3 kg)
Water regulating valve set to maintain 320 PSI discharge
pressure.
Condenser Water usage per 100 lbs ice = 180 gal (45 kg = 681 L)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Around Ice Discharge Suction Discharge Suction
Machine
Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
295-310
65-30
140-220
100-155
70/21
295-310
65-30
140-220
100-155
80/27
295-310
65-32
145-225
100-160
90/32
295-310
65-32
150-225
105-160
100/38
300-330
68-33
150-230
105-165
110/43
310-345
70-34
150-235
105-165
Suction pressure drops gradually throughout the freeze cycle
132
Part Number STH045 11/16
K1000N REMOTE AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
Cycle Times
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
8.2-9.7
8.5-10.1
9.4-11.1
80/27
9.1-10.8
9.9-11.7
10.2-12.1
90/32
9.7-11.5
10.8-12.5
11.3-13.3
100/38
10.6-12.5
11.4-13.5
12.2-14.5
110/43
12.0-14.2
12.5-14.7
13.4-15.8
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
925
890
820
80/27
845
785
760
90/32
800
725
700
100/38
740
690
650
110/43
660
640
600
Based on average ice slab weight of 6.2 – 7.2 lb (2.8 – 3.3 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
300-350
60-36
70/21
310-365
60-38
80/27
315-370
65-38
90/32
320-375
65-38
100/38
380-500
70-45
110/43
405-520
75-46
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
190-210
110-130
200-220
120-140
205-225
120-150
210-225
130-150
220-250
135-155
230-250
140-160
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
133
K1350A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
CYCLE TIMES
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
10.7-12.6
12.1-14.2
13.8-16.2
80/27
11.2-13.2
12.5-14.7
13.1-15.4
90/32
11.7-13.8
12.9-15.2
14.1-16.6
100/38
12.8-15.1
14.1-16.6
15.5-18.2
110/43
14.4-16.9
16.2-19.0
18.9-22.1
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
1540
1350
1190
80/27
1350
1215
1090
90/32
1235
1145
990
100/38
1160
1080
920
110/43
1040
950
870
Based on average ice slab weight of 12.75 - 14.75 lb (5.78– 6.69
kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Entering Discharge Suction
Condenser Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
300-380
66-34
70/21
300-380
66-34
80/27
315-410
73-36
90/32
330-450
81-39
100/38
375-490
91-42
110/43
420-530
101-46
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
165-190
125-135
165-190
125-135
175-205
130-140
185-220
135-150
200-240
150-170
230-260
165-185
Suction pressure drops gradually throughout the freeze cycle
134
Part Number STH045 11/16
K1350W SELF-CONTAINED WATER-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
CYCLE TIMES
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Around Ice
Water Temperature °F/°C
Machine
50/10
70/21
90/32
°F/°C
70/21
10.7-12.7
11.2-13.1
11.6-13.7
80/27
10.9-12.8
11.3-13.3
11.7-13.7
90/32
11.0-13.0
11.4-13.4
11.8-13.8
100/38
11.3-13.4
11.7-13.8
12.2-14.9
110/43
11.6-13.7
12.1-14.2
12.7-14.9
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp.
Water Temperature °F/°C
Around Ice
50/10
70/21
90/32
Machine °F/°C
70/21
1510
1290
1215
80/27
1500
1280
1205
90/32
1495
1225
1190
100/38
1485
1210
1170
110/43
1470
1190
1140
Based on average ice slab weight of 12.75 - 14.75 lb (5.78 – 6.69 kg)
Water regulating valve set to maintain 300 PSIG discharge pressure
Condenser Water usage per 100 lbs ice = 160 gal (45 kg = 606 L)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Around Ice Discharge Suction
Machine
Pressure
Pressure
°F/°C
PSIG
PSIG
50/10
290-305
64-36
70/21
290-305
64-36
80/27
290-310
68-37
90/32
295-335
72-39
100/38
305-335
73-41
110/43
310-340
74-44
Harvest Cycle
Discharge Suction
Pressure
Pressure
PSIG
PSIG
150-165
110-125
150-165
110-125
155-175
110-125
160-180
110-125
160-180
110-130
165-185
115-130
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
135
K1350N REMOTE AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
CYCLE TIMES
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
10.6-12.5
12.0-14.2
12.2-14.3
80/27
11.1-13.0
11.6-13.6
12.8-15.0
90/32
11.2-13.2
11.3-13.4
12.5-16.0
100/38
11.9-14.0
12.7-14.9
14.4-16.9
110/43
12.8-15.0
13.9-16.3
15.3-18.0
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
1470
1295
1195
80/27
1410
1250
1175
90/32
1340
1200
1130
100/38
1280
1115
1040
110/43
1160
1095
975
Based on average ice slab weight of 12.75 - 14.75 lb (4.65 –
5.22 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Entering Discharge Suction Discharge Suction
Condenser Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
300-365
70-33
165-190
115-140
70/21
300-365
70-33
165-190
115-140
80/27
305-370
75-35
170-190
115-140
90/32
305-380
75-38
170-195
120-145
100/38
330-410
82-42
175-195
125-145
110/43
400-490
95-48
180-200
130-150
Suction pressure drops gradually throughout the freeze cycle
136
Part Number STH045 11/16
K1800A SELF-CONTAINED AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
CYCLE TIMES
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
9.1-10.5
9.8-11.2
10.6-12.1
80/27
9.9-11.4
10.6-12.1
11.6-13.2
90/32
11.0-12.5
11.4-13.0
12.7-14.5
100/38
12.2-13.9
12.9-14.7
14.5-16.5
110/43
13.6-15.5
14.9-16.9
16.4-18.6
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
1735
1630
1520
80/27
1610
1520
1410
90/32
1480
1430
1295
100/38
1350
1280
1155
110/43
1220
1125
1030
Based on average ice slab weight of 12.80 - 14.4 lb (5.8– 6.5 kg).
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Entering Discharge Suction Discharge Suction
Condenser Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
295-395
85-35
175-205
115-145
70/21
295-395
85-35
175-205
115-145
80/27
310-410
85-36
185-215
125-150
90/32
330-430
85-38
195-225
135-155
100/38
400-500
90-40
210-250
150-170
110/43
430-555
110-45
230-290
160-190
Suction pressure drops gradually throughout the freeze cycle
Part Number STH045 11/16
137
K1800N REMOTE AIR-COOLED
NOTE: These characteristics may vary depending on
operating conditions.
CYCLE TIMES
Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Freeze Time
Entering
Water Temperature °F/°C
Condenser
50/10
70/21
90/32
°F/°C
70/21
9.5-10.8
10.1-11.5
10.7-12.2
80/27
10.0-11.5
10.7-12.2
11.5-13.1
90/32
10.7-12.2
11.5-13.2
12.4-14.1
100/38
11.4-13.0
12.3-14.0
13.3-15.2
110/43
12.2-13.9
13.2-15.1
14.5-16.5
Times in minutes
Harvest
Time
1.0-2.5
24 Hour Ice Production
Air Temp. Entering
Water Temperature °F/°C
Condenser °F/°C
50/10
70/21
90/32
70/21
1680
1595
1510
80/27
1600
1510
1420
90/32
1515
1415
1330
100/38
1430
1335
1245
110/43
1345
1250
1150
Based on average ice slab weight of 12.8 - 14.4 lb (5.8 - 6.5 kg)
230/50/1 production is approximately 12% lower than 230/60/1.
Operating Pressures
Air Temp.
Freeze Cycle
Harvest Cycle
Entering Discharge Suction Discharge Suction
Condenser Pressure
Pressure
Pressure
Pressure
°F/°C
PSIG
PSIG
PSIG
PSIG
50/10
300-365
70-35
175-195
110-135
70/21
300-365
70-35
175-195
110-135
80/27
300-380
75-37
180-200
115-140
90/32
300-400
80-38
180-205
120-140
100/38
350-480
90-40
190-215
125-145
110/43
450-520
95-42
205-225
135-150
Suction pressure drops gradually throughout the freeze cycle
138
Part Number STH045 11/16
Diagrams
Wiring Diagrams
The following pages contain electrical wiring diagrams.
Be sure you are referring to the correct diagram for the ice
machine you are servicing.
nWarning
Always disconnect power before working on
electrical circuitry.
Wiring Diagram Legend
The following symbols are used on all of the wiring
diagrams:
*Internal Compressor Overload
(Some models have external compressor
overloads)
**Fan Motor Run Capacitor
(Some models do not incorporate fan motor run
capacitor)
( )Wire Number Designation
(The number is marked at each end of the wire)
—>>—Multi-pin Connection
(Electrical Box Side) —>>—
(Compressor Compartment Side)
Part Number STH045 11/16
139
K0250, K0350, K0420, K0500, K0600, K1000 1 PH
SELF-CONTAINED AIR/WATER-COOLED
L1
GND
L2
13
(20) WHT
(21) BLU
5
15
10
(61) RED
(77) RED
35
(60) BLK
16
(22)
WHT
(99)
WHT
(80)
WHT
(76) BLK
30
(57) GRY
(98) GRY
4
(59) ORG
(88) PRPL
(58)
PRPL
1
7
(89)
PRPL
18
(42)
ORG
(74)
WHT
(56)
WHT
(81)
WHT
(75)
WHT
2
3
20
22
(55)
BLK
(R)
(S)
(47)
YEL
(C)
(47)
RED
25
(50) BLU
(48) BLK
L1
19
(51)
ORG
29
(85)
BLK
140
27
28
000010656_04
Part Number STH045 11/16
Number
1
2
3
4
5
7
10
13
15
16
18
19
20
22
25
27
28
29
30
35
Component
Control Board
Fuse
Transformer
On/Off/Clean Switch
Bin Switch
High Pressure Cutout
Harvest Solenoid Valve
Water Inlet Valve
Harvest Float switch
Water Level Float Switch
Contactor Coil
Contactor Contacts
Compressor
Compressor Run Capacitor
Compressor Overload
Condenser Fan Motor
Condenser Fan Motor Run Capacitor
Fan Cycle Control
Water Pump
Dump Valve
Wire Colors
BLK
Black
BLU
Blue
BRN
Brown
GRY
Grey
ORG
Orange
PRPL
Purple
RED
Red
WHT
White
YEL
Yellow
Refer to control board schematic for control board detail
Part Number STH045 11/16
141
K1000 1PH REMOTE AIR-COOLED CONDENSER
L1
GND
13
(22)
WHT
(20) BLU
(21) BLU
5
15
(82)
WHT
12
(76) RED
16
10
(61) RED
(80)
WHT
35
(81 )
WHT
(76) BLK
4
30
(57) GRY
(99)
WHT
(79)
WHT
(77) RED
(60) BLK
L2
(98) GRY
9
1
(59) ORG (83) ORG
(88) PRPL
(58)
PRPL
(89)
PRPL
18
(42)
ORG
7
(56) WHT
(74)
WHT
(81) WHT
2
3
(75)
WHT
20
(55)
BLK
RED
(S)
(R)
(C)
22
YEL
(50) BLU
25
(45)YEL
(48) BLK
L1
19
24
(51)
ORG
F1
27
28
142
000011562_02
Part Number STH045 11/16
Number
1
2
3
4
5
7
9
10
12
13
15
16
18
19
20
22
24
25
27
28
30
35
Component
Control Board
Fuse
Transformer
On/Off/Clean Switch
Bin Switch
High Pressure Cutout
Liquid Line Solenoid valve
Harvest Solenoid Valve
Harvest Pressure Regulating Solenoid Valve
Water Inlet valve
Harvest Float switch
Water Level Float Switch
Contactor Coil
Contactor Contacts
Compressor
Compressor Run Capacitor
Compressor PTCR
Compressor Overload
Condenser Fan Motor
Condenser Fan Motor Run Capacitor
Water Pump
Dump Valve
Wire Colors
BLK
Black
BLU
Blue
BRN
Brown
GRY
Grey
ORG
Orange
PRPL
Purple
RED
Red
WHT
White
YEL
Yellow
Refer to control board schematic for control board detail
Part Number STH045 11/16
143
K1350, K1800 1 PH
SELF-CONTAINED AIR/WATER-COOLED
13
5
15
11
16
10
4
33
1
35
30
7
2
18
3
20
22
25
19
44
29
27
28
144
000012160_3
Part Number STH045 11/16
Number
1
2
3
4
5
7
10
11
13
15
16
18
19
20
22
24
25
27
28
29
30
33
35
Component
Control Board
Fuse
Transformer
On/Off/Clean Switch
Bin Switch
High Pressure Cutout
Harvest Solenoid Valve Left Side
Harvest Solenoid Valve Right Side
Water Inlet Valve
Harvest Float switch
Water Level Float Switch
Contactor Coil
Contactor Contacts
Compressor
Compressor Run Capacitor
Compressor PTCR
Compressor Overload
Condenser Fan Motor
Condenser Fan Motor Run Capacitor
Fan Cycle Control
Water Pump
Harvest Assist Air Pump
Dump Valve
Wire Colors
BLK
Black
BLU
Blue
BRN
Brown
GRY
Grey
ORG
Orange
PRPL
Purple
RED
Red
WHT
White
YEL
Yellow
Refer to control board schematic for control board detail
Part Number STH045 11/16
145
K1350, K1800 3PH SELF-CONTAINED AIR/WATERCOOLED
13
5
15
11
16
10
4
33
1
35
30
7
2
18
3
27
28
20
146
000012160_3
Part Number STH045 11/16
Number
1
2
3
4
5
7
10
11
13
15
16
18
19
20
22
24
25
27
28
29
30
33
35
Component
Control Board
Fuse
Transformer
On/Off/Clean Switch
Bin Switch
High Pressure Cutout
Harvest Solenoid Valve Left Side
Harvest Solenoid Valve Right Side
Water Inlet Valve
Harvest Float switch
Water Level Float Switch
Contactor Coil
Contactor Contacts
Compressor
Compressor Run Capacitor
Compressor PTCR
Compressor Overload
Condenser Fan Motor
Condenser Fan Motor Run Capacitor
Fan Cycle Control
Water Pump
Harvest Assist Air Pump
Dump Valve
Wire Colors
BLK
Black
BLU
Blue
BRN
Brown
GRY
Grey
ORG
Orange
PRPL
Purple
RED
Red
WHT
White
YEL
Yellow
Refer to control board schematic for control board detail
Part Number STH045 11/16
147
K1350, K1800 1 PH REMOTE AIR-COOLED
CONDENSER
13
5
15
12
16
11
33
4
10
1
35
30
9
29
2
18
3
20
22
19
25
24
27
000012161_03
28
148
Part Number STH045 11/16
Number
1
2
3
4
5
7
9
10
12
13
15
16
18
19
20
22
24
25
27
28
30
35
Component
Control Board
Fuse
Transformer
On/Off/Clean Switch
Bin Switch
High Pressure Cutout
Liquid Line Solenoid valve
Harvest Solenoid Valve
Harvest Pressure Regulating Solenoid Valve
Water Inlet valve
Harvest Float switch
Water Level Float Switch
Contactor Coil
Contactor Contacts
Compressor
Compressor Run Capacitor
Compressor PTCR
Compressor Overload
Condenser Fan Motor
Condenser Fan Motor Run Capacitor
Water Pump
Dump Valve
Wire colors
BLK
Black
BLU
Blue
BRN
Brown
GRY
Grey
ORG
Orange
PRPL
Purple
RED
Red
WHT
White
YEL
Yellow
Refer to control board schematic for control board detail
Part Number STH045 11/16
149
K1350, K1800 3 PH REMOTE AIR-COOLED
CONDENSER
13
5
15
12
16
11
33
4
10
1
35
30
9
29
2
18
3
19
27
20
28
000012160_3
150
Part Number STH045 11/16
Number
1
2
3
4
5
7
9
10
12
13
15
16
18
19
20
22
24
25
27
28
30
35
Component
Control Board
Fuse
Transformer
On/Off/Clean Switch
Bin Switch
High Pressure Cutout
Liquid Line Solenoid valve
Harvest Solenoid Valve
Harvest Pressure Regulating Solenoid Valve
Water Inlet valve
Harvest Float switch
Water Level Float Switch
Contactor Coil
Contactor Contacts
Compressor
Compressor Run Capacitor
Compressor PTCR
Compressor Overload
Condenser Fan Motor
Condenser Fan Motor Run Capacitor
Water Pump
Dump Valve
Wire colors
BLK
Black
BLU
Blue
BRN
Brown
GRY
Grey
ORG
Orange
PRPL
Purple
RED
Red
WHT
White
YEL
Yellow
Refer to control board schematic for control board detail
Part Number STH045 11/16
151
152
CLEAN
HARVEST
WTR DUMP
COMPRESSOR
WTR PUMP
TEST SW
ICE FLT
WTR FLT
TEST MODE
HARVEST
SAFETY 1
SAFETY 2
BIN LEVEL
WTR LVL FLT
ICE LVL FLT
BIN LEVEL
WATER FILL
FUSE 3.15 A
ELECTRONIC CONTROL BOARD
Part Number STH045 11/16
Refrigeration Tubing Schematics
SELF-CONTAINED AIR OR WATER-COOLED
EVAPORATOR
HEAT EXCHANGER
EXPANSION
VALVE
HARVEST
SOLENOID VALVE
X
STRAINER
DRIER
COMPRESSOR
RECEIVER
(WATER COOLED ONLY)
Part Number STH045 11/16
AIR OR WATER
CONDENSER
153
154
DRIER
LIQUID
LINE
SOLENOID
VALVE
HEAT
EXCHANGER
RECEIVER
ACCESS
VALVE
H.P.R. SOLENOID
VALVE
RECEIVER
C
R
B
HEAD
PRESSURE
CONTROL
VALVE
HOT GAS SOLENOID VALVE
CHECK VALVE
CHECK VALVE
STRAINER
HARVEST PRESSURE
REGULATING VALVE
COMPRESSOR
EXPANSION
VALVE
REMOTE
CONDENSER
EVAPORATOR
REMOTE AIR-COOLED
Part Number STH045 11/16
THIS PAGE INTENTIONALLY LEFT BLANK
Part Number STH045 11/16
155
THIS PAGE INTENTIONALLY LEFT BLANK
156
Part Number STH045 11/16
MANITOWOC FOODSERVICE
ICE MACHINE DIVISION
2110 SOUTH 26TH STREET
MANITOWOC, WI 54220
800-545-5720
WWW.KOOL-AIRE.COM
Every new piece of Manitowoc Foodservice equipment comes with
KitchenCare™ and you choose the level of service that meets
your operational needs from one restaurant to multiple locations.
StarCare – Warranty & lifetime service, certified OEM parts, global parts inventory,
performance audited
ExtraCare – CareCode, 24/7 Support, online/mobile product information
LifeCare – Install & equipment orientation, planned maintenance, KitchenConnect™,
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brands can equip you, visit our global web site at
www.manitowocfoodservice.com, then discover
the regional or local resources available to you.
©2015 Manitowoc Foodservice except where explicitly stated otherwise. All rights reserved. Continuing
product improvement may necessitate change of specifications without notice.
Part Number STH045 11/16
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