Installation and Service Manual - Ice-O

Installation and Service Manual - Ice-O

Ice-O-Matic

11100 East 45th Ave

Denver, Colorado 80239

Installation and Service Manual

GEM-MFI Series

8

GEM-MFI SERIES Introduction

How To Use This Manual

Ice-O-Matic provides this manual as an aid to the end user and service technician in installation and maintenance of the GEM-MFI Series ice machines. Do not attempt to perform installation, start-up or maintenance unless you have read and fully understand this manual.

If, at any time, you encounter conditions that are not addressed in this manual, call, E-mail or write the

Ice-O-Matic Service Department:

Ice-O-Matic

11100 E. 45 th

Ave.

Denver, Co. 80239

Attn: Technical Service Department

E-Mail: [email protected]

Telephone Numbers Any Service communication must include:

888-349-4423 Technical Assistance Only

303-371-3737

 Model Number

 Serial number

 A detailed explanation of the problem

Keep this manual for future reference.

The GEM-MFI Series Service Parts Manual is available separately.

Ice-O-Matic icemakers and dispensers are not approved for outdoor installation.

WARNING: Always disconnect electrical power and shut off water supply whenever maintenance or repairs are performed on the ice machine and related equipment.

CAUTION: Always wear protective eyewear whenever maintenance or repairs are performed on the ice machine and related equipment

Page i

GEM-MFI SERIES Table Of Contents

Table of Contents

Introduction .................................................................................................................................. Page i

Table Of Contents ........................................................................................................................ Page ii

Freight Claim Procedure .............................................................................................................. Page iii

Warranty ...................................................................................................................................... Page iv

For The Installer (Guidelines) ...................................................................................................... Page 1

For The Installer (Applications) .................................................................................................... Page 4

For The Installer (Location) .......................................................................................................... Page 6

Remote Condenser ...................................................................................................................... Page 7

For The Plumber .......................................................................................................................... Page 12

For The Electrician ....................................................................................................................... Page 14

For The Installer (Completed Remote Installation) ...................................................................... Page 16

For The Installer (Check List) ...................................................................................................... Page 17

Start Up ........................................................................................................................................ Page 19

Component Description ............................................................................................................... Page 20

Electrical Sequence ..................................................................................................................... Page 24

Operation: Water ......................................................................................................................... Page 25

Operation: Refrigeration (Remote) .............................................................................................. Page 26

Operation: Performance .............................................................................................................. Page 29

Sanitizing and Cleaning ............................................................................................................... Page 31

Remote Condenser Maintenance ................................................................................................ Page 32

Air Cooled Maintenance .............................................................................................................. Page 33

Bearing Maintenance ................................................................................................................... Page 34

Sensor Maintenance .................................................................................................................... Page 35

Auger Maintenance ...................................................................................................................... Page 36

Service Diagnosis ........................................................................................................................ Page 37

Control System Diagnostics ......................................................................................................... Page 39

Removal and Replacement: Water Reservoir and Bin Controls .................................................. Page 40

Removal and Replacement: Bearing and Breaker ...................................................................... Page 41

Removal and Replacement: Auger .............................................................................................. Page 42

Removal and Replacement: Water Seal ...................................................................................... Page 43

Removal and Replacement: Evaporator ...................................................................................... Page 44

Removal and Replacement: Gear Motor ..................................................................................... Page 45

Removal and Replacement: Fan Blade and Fan Motor ............................................................... Page 46

Refrigeration System Service ...................................................................................................... Page 48

Wiring Diagrams………………………………………………………………………………………… Page 50

Service History ............................................................................................................................. Page 62

Page ii

GEM-MFI SERIES

Important!

Freight Claim Procedure

Inspect Promptly

This merchandise has been carefully inspected and packed in accordance with the carrier’s packing specifications. Responsibility for safe delivery has been assumed by the carrier. If loss or damage occurs, you as the consignee must file a claim with the carrier and hold the container for carrier’s inspection.

Visible Loss or Damage

Any external evidence of loss or damage must be fully described and noted on your freight bill or express receipt and signed by the carrier’s agent. Claim should be filed on a form available from the carrier.

Concealed Loss or Damage

If loss or damage does not appear until merchandise has been unpacked, make a written request for inspection by the carrier within 15 days of the delivery date. Then file a claim on a form from the carrier.

File Claim Without Delay Do Not Return Damaged Merchandise to Ice-O-Matic

Page iii

GEM-MFI SERIES Warranty

Ice-O-Matic

Parts and Labor

Domestic & International Limited Warranty

Mile High Equipment LLC (the “Company”) warrants Ice-O-Matic brand ice machines, ice dispensers, remote condensers, water filters, and ice storage bins to the end customer against defects in material and factory workmanship for the following:

 Cube ice machines,”GEM” model compressed ice machines  Ice storage bins -Twenty-four (24) month parts and labor

,” MFI” model flake ice machines and remote condensers. -

Thirty-six (36) months parts and labor

 “EF” and “EMF” model flake ice machines - Twenty-four (24) months parts and labor

 CD model dispensers - Thirty-six (36) months parts and labor

 IOD model dispensers - Twenty-four (24) months parts, Twelve (12) months labor

 Water filter systems - Twelve (12) months parts and labor (not including filter cartridges)

An additional twenty-four (24) month warranty on parts (excluding labor) will be extended to all cube ice machine evaporator plates and compressors,

“GEM” model compressed ice machine compressors, and “MFI” model flake ice machine compressors from the date of original installation. An additional thirty-six (36) month warranty on parts (excluding labor) will be extended to all “EF” and “EMF” model flake ice machine compressors from the date of original installation. The company will replace EXW (Incoterms 2000) the Company plant or, EXW (Incoterms 2000) the Company-authorized distributor, without cost to the Customer, that part of any such machine that becomes defective. In the event that the Warranty Registration Card indicating the installation date has not been returned to Ice-O-Matic, the warranty period will begin on the date of shipment from the Company. Irrespective of the actual installation date, the product will be warranted for a maximum of seventy-two (72) months from date of shipment from the Company.

ICE-model cube ice machines which are registered in the Water Filter Extended Warranty Program will receive a total of eighty-four (84) months parts and labor coverage on the evaporator plate from the date of original installation. Water filters must be installed at the time of installation and registered with the Company at that time. Water filter cartridges must be changed every six (6) months and that change reported to the Company to maintain the extended evaporator warranty.

No replacement will be made for any part or assembly which (I) has been subject to an alteration or accident; (II) was used in any way which, in the

Company’s opinion, adversely affects the machine’s performance; (III) is from a machine on which the serial number has been altered or removed; or,

(IV) uses any replacement part not authorized by the Company. This warranty does not apply to destruction or damage caused by unauthorized service, using other than Ice-O-Matic authorized replacements, risks of transportation, damage resulting from adverse environmental or water conditions, accidents, misuse, abuse, improper drainage, interruption in the electrical or water supply, charges related to the replacement of non-defective parts or components, damage by fire, flood, or acts of God.

This warranty is valid only when installation, service, and preventive maintenance are performed by a Company-authorized distributor, a Companyauthorized service agency, or a Company Regional Manager. The Company reserves the right to refuse claims made for ice machines or bins used in

more than one location. This Limited Warranty does not cover ice bills, normal maintenance, after-install adjustments, and cleaning.

Limitation of Warranty

This warranty is valid only for products produced and shipped from the Company after January, 2007. A product produced or installed before that date shall be covered by the Limited Warranty in effect at the date of its shipment. The liability of the Company for breach of this warranty shall, in any case, be limited to the cost of a new part to replace any part, which proves to be defective. The Company makes no

representations or warranties of any character as to accessories or auxiliary equipment not manufactured by the Company. REPAIR OR

REPLACEMENT AS PROVIDED UNDER THIS WARRANTY IS THE EXCLUSIVE REMEDY OF THE CUSTOMER. MILE HIGH EQUIPMENT SHALL

NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS

PRODUCT. EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW, ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS

FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE LENGTH OF THIS WARRANTY.

Filing a Claim

All claims for reimbursement must be received at the factory within 90 days from date of service to be eligible for credit. All claims outside this

time period will be void. The model, the serial number and, if necessary, proof of installation, must be included in the claim. Claims for labor to replace defective parts must be included with the part claim to receive consideration. Payment on claims for labor will be limited to the published labor time allowance hours in effect at the time of repair. The Company may elect to require the return of components to validate a claim. Any defective part returned must be shipped to the Company or the Company-authorized distributor, transportation charges pre-paid, and properly sealed and tagged. The

Company does not assume any responsibility for any expenses incurred in the field incidental to the repair of equipment covered by this warranty. The decision of the Company with respect to repair or replacement of a part shall be final. No person is authorized to give any other warranties or to assume any other liability on the Company’s behalf unless done in writing by an officer of the Company.

GOVERNING LAW

This Limited Warranty shall be governed by the laws of the state of Delaware, U.S.A., excluding their conflicts of law principles. The United Nations

Convention on Contracts for the International Sale of Goods is hereby excluded in its entirety from application to this Limited Warranty.

Mile High Equipment LLC, 11100 East 45 th

Avenue, Denver, Colorado 80239 (303) 371-3737

January 2007

Page iv

GEM-MFI SERIES For the Installer

Installation Guidelines:

For proper operation of the Ice-O-Matic ice machine, the following installation guidelines must be followed.

Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties.

Ambient Operating Temperatures: (Not including remote condenser)

Minimum Operating Temperature: 50°F (10°C)

Maximum Operating Temperature 100°F (38°C)

Note: Ice-O-Matic ice makers and dispensers are not approved for outdoor installation.

Incoming Water Supply

Minimum incoming water temperature: 40°F (4.5°C)

Maximum incoming water temperature: 100°F (38°C)

Minimum incoming water pressure: 20 psi (1.4 bar)

Maximum incoming water pressure: 80 psi (4.1 bar)

Note: If water pressure exceeds 80 psi a water pressure regulator must be installed.

Drains

All drain lines must be installed per local codes. Flexible tubing is not recommended. Route bin drain, vented float overflow drain and water condenser drain individually to a floor drain. The use of condensate pumps for draining water is not recommended by Ice-O-Matic. Cold water drains should be insulated to prevent condensation from forming. Ice-O-Matic assumes no responsibility for improperly installed equipment.

Water Filtration

A water filter system should be installed with the ice machine.

Clearance Requirements: Self contained air cooled ice machines must have a minimum of 6 inches (15cm) of clearance at the rear, top, and sides of the ice machine for proper air circulation.

Stacking

Ice-O-Matic GEM-MFI ice machines are not designed to be stacked.

Dispenser Application

The GEM ice machine is approved for specific dispenser applications, reference page 4.

The MFI Series is not approved for dispenser applications.

Electrical Specifications

Refer to the serial plate at the rear of the ice machine to make sure proper voltage and circuit breaker size have been supplied. Make sure the machine is on a dedicated circuit. The GEM-MFI Series are not supplied with an electrical power cord and will need to be installed and wired per local electrical codes.

Adjustments

Level the machine within 1/8 inch in all directions. Adjust the cabinet or bin legs as required.

Check the bin control for proper operation.

Check the water level in the reservoir for proper adjustment.

Check the water regulating valve adjustment if water cooled.

GEM-MFI SERIES

Air and Water Cooled

For The Installer

Page 2

GEM-MFI SERIES

Remote

For The Installer

Page 3

GEM-MFI SERIES For the Installer

Bin Application

The GEM Series are designed to fit the following Ice-O-Matic Bins

●B42, using Bin Top KBT 24 (Note: 21 inch wide cabinet ONLY)

●B25, B40 B55 using Bin Top KBT 19.

●B100-B120 using Bin Top KBT 23 (one unit) or KBT 22 (two units).

● B150, B170 Not designed for GEM-MFI Series.

Dispenser Application

The GEM Series can be placed on and used with certain ice and beverage dispensers. Kits are required for proper operation. The MFI Series is not approved for dispenser applications.

IOM Gem Accessory List

Dispenser GEM0450 GEM0650 GEM0956

ICE-O-Matic IOD150

KBT15022, KGEMDIV KBT15022, KGEMDIV KBT15022, KGEMDIV

ICE-O-Matic IOD200 or IOD250

KBT25022_KGEMDIV+KGEMBIOD KBT25022_KGEMDIV+KGEMBIOD KBT25022_KGEMDIV+KGEMBIOD,

Cornelius ED or DF150

Cornelius ED or DF200

KBT25022+KGEM200 KBT25022+ KGEM200 KBT25022+ KGEM200

Cornelius ED or DF250

KBT25022+ KGEM250 KBT25022+ KGEM250 KBT25022+ KGEM250

Cornelius ED300

Cornelius Flavor Fusion

Lancer (Must have N in the part number) 30 Inch 4500

KDIL-N-CFF+62988681 Black*

KDIL-N-L and Lancer Part Number 82-

3491

KDIL-N-CFF+62988681 Black*

KDIL-N-L and Lancer Part Number

82-3491

KDIL-N-CFF+62988681 Black*

KDIL-N-L and Lancer Part Number

82-3491

Model

* Cornelius Part Number

All the dispensers have automatic agitation to keep the ice from clumping. If agitation is too frequent, the Pearl Ice will be damaged and will become difficult to dispense. The Ice-O-Matic and Cornelius dispensers need to be set to 2 seconds on every 3 hours and the Lancer needs to be set to 4 seconds on, 150 seconds off.

The Ice-O-Matic and most Cornelius dispensers also have a restrictor plate at the outlet of the hopper. When used, that plate should be adjusted to be 1.5 inch open to limit the speed of the Pearl Ice flows out during dispensing.

Ice Machine Specifications

Model WxDxH

Number (Inches)

GEM0450A 2 21x24x27

GEM0450W2

GEM0650A2

GEM0650W2

GEM0650R2

GEM0655A2

GEM0655W2

GEM0956A 2

GEM0956W2

GEM0956R2

GEM0955A 2

GEM0955W2

MFI0500A2

MFI0500W2

MFI0800A2

MFI0800W2

MFI0800R2

MFI0805A2

MFI0805W2

MFI1256A2

MFI1256W2

MFI1256R2

MFI1255A2

MFI1255W2

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

230/50/1 Air

230/50/1 Water

21x24x27

21x24x27

208-230/60/1

208-230/60/1

21x24x27 208-230/60/1

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

21x24x27

Basic Electrical

115/60/1

115/60/1

115/60/1

115/60/1

115/60/1

230/50/1

230/50/1

115/60/1

115/60/1

115/60/1

115/60/1

115/60/1

230/50/1

230/50/1

208-230/60/1

208-230/60/1

208-230/60/1

230/50/1

230/50/1

Condenser

Air

Water

16.00

14.35

Air 21.00

Water 19.50

Remote 23.50

Air

Water

Remote

Air

Water

Air

Water

Air

Water

Remote

Air

Water

Air

Water

Remote

Air

Water

Ampacity

10.10

9.50

11.80

11.20

15.30

13.40

13.10

16.00

14.35

21.00

19.50

23.50

10.10

9.50

11.80

11.20

15.30

13.40

13.10

Minimum Circuit Maximum Fuse

Size

20

20

30

30

30

15

15

15

15

20

20

15

20

20

30

30

30

15

15

15

15

20

20

15

Refrigerant Charge oz. R404

22

18

24

19

208

24

19

30

22

208

30

22

22

18

24

19

208

24

19

30

22

208

30

22

GEM-MFI SERIES For the Installer

Location:

Ice-O-Matic ice machines are designed to be installed indoors in a controlled environment. Install the ice machine in a location where it has enough space around it to be accessible for service. A minimum of 6 inches must be allowed at the back for air circulation on air cooled models. Try to avoid hot, dirty and crowded locations. Be sure that the location of the machine is within the environmental limitations.

Storage Bin:

Remove the bin packaging. Tip the storage bin on its back, using parts of the packaging to protect the exterior finish. Remove the skid and install the legs into the threaded holes in the bottom of the bin. Turn the leg levelers all the way in preparation for leveling later. Return the bin to the upright position.

Note: Do not push the bin into position, but lift it there. Pushing a bin, especially one with ice in it, can cause damage to the bin legs and mounts.

Install the appropriate bin top according to the instructions provided with the bin top.

Ice machine:

The ice machine is heavy, so the use of a mechanical lift is recommended for lifting the machine high enough to install on top of the bin. After the unit is placed on the bin, line it up so it is even with the back side. Secure the ice machine to the bin with the hardware provided with the ice machine. Remove the front panel and remove any shipping blocks or packaging material.

Proper functioning of the bin door requires the bin door, when it is opened, to be in a stable position. If the ice machine is too far forward on the bin, the opened door may not be stable, resulting in an unexpected closing of the bin door.

If the ice machine is to be mounted on a bin or dispenser other than an Ice-O-Matic, refer to the manufacturer’s instructions for machine mounting. Ice-O-Matic will not be responsible for damage or injury that results from unexpected closing of the bin door as a result of the ice machine being too far forward on the bin.

Water Limitations:

An ice machine is a food manufacturing plant: it takes a raw material, water and transforms it into a food product, ice. The purity of the water is very important in obtaining pure ice and maximizing product life. This section is not intended as a complete resource for water related questions, but it does offer these general recommendations:

●Check with a water treatment specialist for a water test and recommendations regarding water filters and treatment.

●In most cases, the water used to make ice should be filtered or treated, depending upon the water.

There is no one type of water filter that is effective in all situations. That is why a water test in important.

RO Water Limitations:

Water conductivity must be no less that 35 microSiemens/cm.

Notice:

Ice-O-Matic ice machines are designed and manufactured with the highest regard for safety and performance and meet or exceed the standards of UL, NSF and CUL.

Ice-O-Matic assumes no liability or responsibility of any kind for products manufactured by Ice-O-Matic that have been altered in any way, including the use of any part and/or other components not specifically approved by Ice-O-Matic.

Ice-O-Matic reserves the right to make design changes and/or improvements at anytime. Specifications and design are subject to change without notice.

GEM-MFI SERIES

Allow 6 “Clearance for Air Circulation

Allow 6 “Clearance for Air Circulation

For the Installer

A proper installation locates the ice machine indoors, but in a place where the heat and noise it produces are not objectionable.

Air cooled machines discharge hot air out the back and must have a minimum of 6 inches of clearance behind the ice machine.

Space for maintenance access is also important. If two units are placed side by side on a bin, side access becomes even more important.

Two Units on One Bin

GEM-MFI SERIES Remote Condenser

ERC Dimensions (Inches) GRC1001

B

C

D

E

F

G

H

GEM-MFI Model Number

GEM0650R

Line Sets

RT325404 25 Foot Precharged Line Set

RT340404 40 Foot Precharged Line Set

RT345404 45 Foot Precharged Line Set

RT360404 60 Foot Precharged Line Set

GRC1061

GEM0956R-MFI1256R

GEM-MFI SERIES Remote Condenser Location

Use the following

for planning the placement of the remote condenser relative to the ice machine.

Location Limits: Remote condenser location must not exceed ANY of the following:

Maximum rise from the ice machine to the remote condenser is 35 physical feet.

Maximum drop from the ice machine to the remote condenser is 15 physical feet.

Physical line set maximum length is 100 feet.

Calculated line set length maximum is 150 feet.

Calculation Formula

Drop = dd x 6.6 (dd= distance in feet)

Rise = rd x 1.7 (rd = distance in feet)

Horizontal Run = hd x 1 (hd = distance in feet)

Calculation: Drop(s) + Rise(s) + Horizontal Run = dd+rd+hd=Calculated Line Length

Configurations that do NOT meet these requirements must receive written authorization from

Ice-O-Matic. This includes multipass or rack system remote condensers.

Do NOT:

Route a line set that rises, then falls, then rises.

Route a line set that falls, then rises, then falls.

Calculation Example 1:

The remote condenser is to be located 5 feet below the ice machine and then 20 feet away horizontally.

(5 feet x 6.6=33 feet) + (20 feet) = 53 feet. This location would be acceptable.

Calculation Example 2:

The remote condenser is to be located 35 feet above the ice machine and then 100 feet away horizontally.

(35 feet x 1.7=59.5 feet) + (100 feet) = 159.5 feet. 159.5 feet is greater than the 150 maximum is NOT acceptable.

GEM-MFI SERIES For the Installer

Remote Condenser Location:

Limited to a 25 foot or a 40 foot length of precharged refrigerant tubing connecting the ice machine to the remote condenser. The remote condenser must be above or level with the ice machine. Select the best available location, protecting the remote condenser from extremes of dirt, dust and sun. Meet all applicable building codes. Usually the services of a licensed electrician are required.

Roof Attachment:

1. Install and attach the remote condenser to the roof of the building, using the methods and practices of construction that conform to the local building codes, including having a roofing contractor secure the remote condenser to the roof.

2. Have an electrician connect the remote condenser fan motor to the ice machine, using the junction box at the back of the ice machine.

Precharged Line Set Routing

CAUTION: Do not connect the precharged tubing until all routing and forming of the tubing is complete. See the coupling instructions for connecting information.

1. Each set of preharged tubing refrigerant lines consists of a 3/8 diameter liquid line and a 1/2 inch diameter discharge line. Both ends of each line have quick connect couplings, one end has a Schrader valve connection, that end goes to the condenser.

Note: The openings in the building ceiling or wall, listed in the next step, are the minimum sizes recommended for passing the refrigerant lines through.

2. Have the roofing contractor cut a minimum hole for the refrigerant lines of 1.750 inch.

Check local codes, a separate hole may be required for the electrical power to the condenser.

CAUTION: DO NOT KINK OR CRIMP

REFRIGERANT TUBING WHEN

INSTALLING IT.

3. Route the refrigerant lines through the roof opening. Follow straight line routing whenever possible. Any excess tubing MUST remain within the building.

4. Spiral the excess length of precharged tubing inside the building. Use a horizontal spiral

(does not need to be as tight as illustrated) to avoid any traps in the lines.

5. Have the roofing contractor seal the holes in the roof per local codes.

CAUTION: The couplings on the sets of precharged lines are self sealing when installed properly. Carefully follow the instructions:

GEM-MFI SERIES

Typical Installation

REMOTE CONDENSER

For the Installer

ICE MACHINE

GEM-MFI SERIES For the Installer

Coupling Instructions:

Initial Connections:

1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them.

2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil.

3. Position the fittings on the correct connections on the remote condenser and ice machine.

●The 1/2 inch discharge line (Schrader valve end) goes to the remote condenser fitting marked “Discharge Line”

●The 3/8 inch liquid line (Schrader valve end) goes to the remote condenser fitting marked “Liquid Line”.

●The 1/2 inch discharge line goes to the ice machine fitting marked

“Discharge Line”.

●The 3/8 inch liquid line goes to the ice machine fitting marked “Liquid

Line”.

Final Connections:

4a. Begin by tightening the couplings together by hand. Continue to turn the swivel nuts by hand until it is certain that the threads are properly engaged.

4b. Using two wrenches, one to rotate the swivel nut and one to hold the tubing, tighten each coupling.

It is CRITICAL that ONLY the NUT on the precharged tube be turned or the diaphragms will be torn loose by the piercing knives and be loose in the refrigeration system causing severe operational problems.

Note

: As the coupling is tightened, the diaphragms in the quick connect couplings will begin to be pierced. As that happens, there will be increased resistance to tightening the swivel nut.

4c. Continue tightening the swivel until it bottoms out or a very definite increase in resistance is felt (no threads should be showing). Do NOT over tighten.

5. Using a marker or pen, mark a line lengthwise from the coupling union nut to the bulkhead. Then tighten the coupling and additional 1/4 turn. As the nut turns, the line will show when the 1/4 turn is made.

6. After all connections are made, and after the king valve has been opened, check the couplings for leaks.

GEM-MFI SERIES For the Plumber

Water Inlet:

●Air Cooled Models: The recommended water supply is clean, cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 FPT at the back of the cabinet. Install a hand valve near the machine to control the water supply.

●Water Cooled Models: A separate 3/8 inch O.D. copper line is recommended, with a separate hand valve to control it. Connect to the 3/8 inch FPT condenser inlet at the back of the cabinet. The water pressure to all lines must always be above 20 psig, and below 80 psig.

●Water Treatment: In most areas, a water filter of some type will be useful. In areas where the water is highly concentrated with minerals, the water should be tested by a water treatment specialist, and the recommendations of the specialist regarding filtration and/or treatment should be followed.

Drains:

●Air Cooled Models: Connect a rigid drain tube to the ¾ FPT drain fitting at the back of the cabinet. The drain is a gravity type, and a ¼ inch per foot fall is the minimum acceptable pitch for the drain. There should be a vent at the highest point of the drain line, and the ideal drain receptacle would be a trapped and vented floor drain. Use only ¾ inch rigid tubing.

●Water Cooled Models: Connect a separate drain line to the ½ inch condenser drain connection at the back of the cabinet. Do not vent this drain.

●Storage Bin: Connect a separate gravity type drain line to the ice storage bin drain. Vent this drain if there is a long horizontal run from the bin to the floor drain. Insulation of this drain line is recommended.

WATER COOLED MODELS

AIR COOLED MODELS

Condenser Inlet

Water Filter

Hand Valve

Vented Drain

Water Filter

Vented Drain

Hand Valve

Condenser Drain

Water In

Vented Drain Vented Drain

Condenser Inlet

Water Inlet

Water In

Condenser Drain

Bin Drain

Bin Drain

Floor Drain

GEM-MFI SERIES

Water Inlet:

●Remote Cooled Models:

For the Plumber

The recommended water supply is cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 inch FPT on the back of the cabinet. Install a hand valve near the machine to control the water supply.

Drains:

●Remote Cooled Models:

There is one 3/4 inch FPT drain at the back of the cabinet; the drain line is of the gravity type, and 1/4 inch per foot fall is an acceptable pitch for the drain tubing. There should be a vent at the highest point of the drain line, and the ideal drain receptacle would be a trapped and vented floor drain. Use only ¾ inch rigid tubing.

Storage Bin:

Install a separate gravity type drain. Insulation of this drain line is recommended.

3/8

FPT

GEM-MFI SERIES For the Electrician

Electrical Connections:

Check the ice machine nameplate (located on the back panel) for the voltage requirements, and minimum circuit ampacity. The ice machine requires a solid chassis to earth ground.

Connect the ice machine to its own electrical circuit so it is individually fused. Voltage variation must remain within the limitations, even under starting conditions.

Note: All external wiring must conform to national, state and local electrical codes.

The use of a licensed electrician is required to perform the electrical installation.

Water Cooled Models

Power

Supply

Electrical Inlet

Air Cooled Models

GEM-MFI SERIES For the Electrician

INSTALLATION MUST CONFORM TO ALL APPLICABLE CODES.

Connect the electrical power to the unit to the wires in the junction box at the rear of the machine. Check the nameplate (located on the back panel) for the voltage requirements, and for the minimum circuit ampacity.

The machine requires a solid chassis to earth ground wire.

Connect the ice machine to its own electrical circuit so it is individually fused. Voltage variation must remain within design limitations, even under starting conditions.

There is a separate junction box for the remote condenser fan motor. Install an interconnecting wire between the remote condenser and the junction box at the back of the ice machine.

The remote condenser must be wired to the ice machine in accordance with local and national electrical codes with a minimum of 18 AWG. wire with a ground bonding wire connected to the ground screw provided in both the condenser and machine field wiring boxes. All outdoor wiring must be in rainproof conduit.

All external wiring must conform to national, state and local electrical codes. The use of a licensed electrician is required to perform the electrical installation.

GEM-MFI SERIES

Completed Installation

For the Installer

A typical installation should generally appear as illustrated below. The best place for the remote condenser is above the ice machine, although other locations are permissible.

Roof Cut-A-Way

GEM-MFI SERIES For the Installer

Final Check List: Air and Water Cooled

_______

1. Is the ice machine installed indoors in a location where the air and water temperatures are controlled and where they do not exceed the design limitations?

_____2. Is there an electrical service disconnect within sight of the installed machine?

_____3. Has the voltage been checked and compared to the nameplate requirements?

_____4. Have all the plumbing connections been made and checked for leaks?

_____5. Is the ice machine and storage bin level?

_____6. Is there a minimum of 6 inches of clearance at the back of the machine for proper service access and air circulation?

_____7. Is the water pressure a minimum of 20 psig?

_____8. Has the ice machine been secured to the bin?

_____9. Is there clearance over the top of the ice machine for service access?

____10. Is there a water shut off valve installed near the ice machine?

____11. Have all the shipping blocks been removed from the ice machine?

Insure the machine is level

Note: Fasten the ice machine to the bin with the hardware supplied with the ice machine

GEM-MFI SERIES For the Installer

Final Check List: Remote

___1. Is the ice system installed indoors in a location where air and water temperatures are controlled, and where they do not exceed the design limitations?

___2. Is there an electrical service within sight of the installed machine? Has the voltage been checked, and compared to nameplate requirements?

___3. Have all the plumbing connections been made and checked for leaks?

___4. Has the machine and bin been leveled?

___5. Is there a minimum of 6 inches clearance at the rear, left and right of the machine for proper service access?

___6. Is the water pressure a minimum of

20 psig?

___7. Has the machine been secured to the bin or dispenser?

___8. Is there a water shut off valve installed near the machine?

___9. Is the remote condenser installed per local codes, and in a place where it has adequate ventilation and minimal solar heat gain?

___10. Has all shipping material and literature (inside front panel) been removed from the units?

___11.Have the remote condenser and pre-charged lines been properly installed?

Remote condenser secured?

Plumbing?

Power Supply?

Condenser Leveled?

___12. Has the electrical connection between the ice maker and condenser been made?

Roof Holes Sealed?

Machine Leveled?

___13. Verify that the master switch is in the OFF position.

___14. Switch ON the electrical power.

___15. Refer to the Pre-Start instructions

GEM-MFI SERIES Start Up

Pre-Start Inspection: Air and Water Cooled

1. Remove the front and side service panels.

2. Check that any shipping blocks have been removed.

3. Inspect the interior of the ice machine for loose screws or wires.

4. Check that no refrigerant lines are rubbing each other.

5. Check that the fan blades turn freely (Air Cooled).

6. Check that the unit is installed correctly according to the final check list.

Start Up:

1. Go through the pre-start inspection.

2. Open the hand valve, observe that water enters the water reservoir, fills the tube from the water reservoir to the evaporator and then shuts off. (Water cooled only, Turn the water supply ON to the water cooled condenser). Check for leaks.

3. Switch the master (mode) switch ON. The electrical start up sequence in automatic. a. There should be a short (15 second) delay before the gear motor starts. b. After the gear motor starts, the compressor will start.

4. On air cooled models, the condenser will begin to discharge warm air, on water cooled models, the water regulating valve will open and warm water will be discharged into the drain.

5. The unit should soon be making ice, if desired; the low side pressure may be checked: it should be

34-38 psig.

The suction line temperature at the compressor is normally very cold, nearly to the point of frost up to the compressor body, but not on it.

The air cooled discharge pressure will depend upon air and water temperatures, but should be between

200 psig and 280 psig.

The water cooled discharge pressure should be a constant at about 245 psig.

Note: The above pressures are for new, clean machines. You can expect to see some values higher, and some lower between different units.

6. There are no adjustments to make, so replace the panels.

7. Clean and/or sanitize the storage bin interior, wipe off the exterior with a clean, damp cloth.

8. Give the owner/user the service manual, instruct him/her in the operation of the unit, and make sure they know who to call for service.

9. Fill out the manufacturer’s registration and mail it to Ice-O-Matic.

GEM-MFI SERIES Start Up

Pre-Start Inspection: Remote

1. Remove the front and side service panels.

2. Check that any shipping blocks have been removed.

3. Inspect the interior of the ice machine for loose screws or wires.

4. Check that no refrigerant lines are rubbing each other.

5. Check that the fan blades turn freely (Remote Condenser).

6. Check that the refrigerant lines are properly installed.

7. Check that the electrical power has been on for at least 4 hours and that the compressor dome is warm.

8. Check that the unit is installed correctly according to the final check list.

Start Up:

1. Go through the pre-start inspection.

2. Open the hand valve, observe that water enters the water reservoir, fills the tube from the water reservoir to the evaporator and then shuts off. (Water cooled only, Turn the water supply ON to the water cooled condenser). Check for leaks.

3. Open the King Valve.

4. Switch the master switch ON. The electrical start up sequence in automatic. a. There should be a short (15 second) delay before the gear motor starts and the liquid line opens. b. After the liquid line opens, the low pressure control will close and the compressor will start.

5. The remote condenser fan turns, and the condenser begins to discharge warm air.

6. The unit should soon be making ice, if desired; the low side pressure may be checked: it should be

28-35 psig.

The air cooled discharge pressure will depend upon air and water temperatures, but should be between

200 psig and 280 psig.

7. There are no adjustments to make, so replace the panels.

8. Clean and/or sanitize the storage bin interior, wipe off the exterior with a clean, damp cloth.

9. Give the owner/user the service manual, instruct him/her in the operation of the unit, and make sure they know who to call for service.

10. Fill out the manufacturer’s registration and mail it to Ice-O-Matic.

GEM-MFI SERIES Component Description

●Control Box: Contains the electrical controls that operate the machine.

●High Pressure Cut Out Switch: An auto-reset switch sensing the high side refrigeration pressure. It will shut the machine off if the discharge pressure exceeds 450 psig.

●Pump Down Control: A switch to control the compressor, depending upon low side pressure: closes at 30

PSIG and opens at 15 PSIG.

●Evaporator: A vertical stainless steel tube, refrigerated and water filled. Utilizes a stainless steel auger.

●Water Reservoir: Float operated, it maintains the water level in the evaporator at a constant level, and it also contains the water level sensor.

●Water Level Sensor: Senses if there is water in the reservoir to make ice out of. Will shut the ice machine off if there is no water in the reservoir.

●Ice Discharge Chute: Directs the ice produced by the evaporator into the storage bin.

●Ice Level Sensor: An “electronic eye”, it senses the presence of ice in the bottom of the discharge chute.

Operates to turn on and off automatically as the level of ice in the bin changes.

●Gear Motor: An oil filled, speed reduction gearbox, driving the auger.

●Cleaning Drain Tube: When uncapped and lowered, drains the evaporator.

●Compressor: The refrigerant vapor pump.

●Expansion Valve: The refrigerant metering device.

Control Box

Reservoir

Water Level Sensor

(Inside Reservoir)

Compressor

High Pressure Cut Out

Ice Chute

Expansion Valve

Gear Motor

Evaporator

Cleaning Drain Tube

Ice Level Sensors

Water OK Light

Power Light

Service Light

Freeze Light

Bin Full Light

LED1

GEM-MFI SERIES Component Description

●Contactor: A definite purpose contactor connecting the compressor and the fan motor to the power supply.

●Circuit Board: Controls the operation of the ice machine using input from the sensors and pressure controls.

Switches loads on and off thru relays. (Reference Photo Below)

●Potential Relay: The compressor start relay.

●Mode (ON/OFF) Switch: Manual control for the machine.

Control Board

Compressor Relay

LED3 Auger Relay

GEM-MFI SERIES Component Description

●Evaporator: A refrigerated vertical tube filled with water and containing a water seal and auger.

●Auger: A solid stainless steel double spiral auger, it pushes the ice crystals up to the top of the evaporator.

●Water Seal: A two part “face” seal, the top half rotating with the auger, the bottom half stationary, the sealing action being where the two “faces” meet.

●Ice Sweep: A plastic cap with “fingers”. It revolves with the auger to “sweep” the ice into the ice chute.

●Breaker (Divider): Where the ice is compressed and much of the extra water is squeezed out of it before it is discharged into the bin.

●Motor: A split phase motor that drives the gear reducer.

●Thrust Bearings: As the ice is pushed up the evaporator, the auger is thrust down, and pressure from the auger thrust is taken up by this bearing.

Ice Sweep

Bearing

Breaker/Divider

Auger

Evaporator

Motor

Water Seal

GEM-MFI SERIES Electrical Sequence

Electrical Sequence:

There are 7 indicator lights on the control board:

●WTR-OK: (Water OK) Green. Normal=Glowing. Glow when there is water in the reservoir.

●PWR-OK: (Power OK) Green. Normal=Glowing. Glows when the power board has power and is functional.

●Service: Red. Normally Off.

●Freeze: Red. Normally glowing when making ice.

●Bin Full: Red. Normally Off when making ice.

●LED1: White. Located next to the Control Board’s Compressor Relay. Normally glowing when making ice.

●LED2: White. Located next to the Control Board’s Auger Motor Relay. Normally glowing when making ice.

If the machine is switched OFF at the mode switch, but otherwise ready to go, switching the mode switch ON does the following:

●The PWR-OK light glows.

●If there is water in the float reservoir, the WTR-OK light glows.

●After 10 seconds the Freeze, LED1 and LED3 lights glow and the machine starts up.

Start Up:

●The compressor relay and auger motor relay become energized, connecting power to the windings of the auger motor and contactor coil.

●The contactor is energized, connecting power to the compressor, and the compressor starts.

●As ice is made it passes between the ice level sensors but because it is not a continuous stream it only interrupts the sensor’s infrared beam momentarily. The bin full light remains off and the machine stays on until ice builds up in the bin and blocks the path between the sensors for 6 seconds or longer. When that occurs the bin full light glows and the machine shuts down.

Shut Down:

●The compressor relays opens, LED1 goes out.

●The compressor contactor opens.

●The auger motor stays on for 1 more minute, clearing out ice in the evaporator, and then

●The auger motor relay opens, LED3 goes out and the auger motor stops.

The compressor will not restart until 2 minutes or more have passed after last shutdown. If the path between the ice level sensors remains clear for more than 10 seconds the ice machine will restart.

Control Board Protection Devices:

●When the water level in the reservoir falls below the water level sensor’s tip, the WTR-OK light goes out and the machine shuts down. When water refills the reservoir the WTR-OK light glows and the machine starts up again.

●If the auger drive motor currents becomes excessive the compressor and auger drive motor will be switched

OFF and the Service light will blink. The control board will restart the auger drive motor in 4 minutes. If during the first 60 seconds after restart the auger motor current stays within limits, the compressor is restarted and the machine returns to normal operation. If the auger motor’s current is excessive within 60 seconds after restart, the process will be repeated once more. If during that try the current is still excessive the machine shuts down and must be manually reset. The Service light will then be glowing continuously.

To Reset:

●Switch power to the unit off and then back on.

Other Protection Devices:

●If the high pressure control cut out switch opens the machine will stop immediately. It will automatically reset when the high pressure falls below its cut in point.

●If the low pressure control cut out switch opens the machine will stop immediately. It will automatically reset when the pressure rises above its cut in point.

●The mode (ON-OFF) switch is the manual control for the complete machine, but it is not a service disconnect.

GEM-MFI SERIES Operation: Water

Water

Water enters the machine through the 3/8 FPT at the rear of the cabinet, goes to the water reservoir which it enters through the float valve. The water then goes out the bottom of the reservoir tank to the bottom of the evaporator. Reservoir overflow or evaporator condensation is routed to the drain.

Water Level

The correct water level should be checked when the machine is making ice. Locate the water level in the reservoir, and compare it to the horizontal line molded into the side of the reservoir. The correct level should be between 1/8 inch above and 1/4 inch below the line. If needed, bend the float arm up or down to adjust the water level.

Water System

Water Inlet

Evaporator Drain

Reservoir

Water Level

Drain

Ice Chute

Evaporator Water Inlet

GEM-MFI SERIES Operation: Refrigeration-Remote

Beginning at the compressor, the refrigerant is compressed into a high temperature gas. The discharge line directs this gas to the condenser and to the head pressure control. At the remote condenser the gas is cooled by air and it then condenses into a liquid. This high pressure liquid then goes through the liquid line connection at the head pressure control. If the head pressure is high enough the liquid refrigerant will go through the valve and enter the receiver. From the receiver, the liquid refrigerant flows through the liquid line

valve and then to the expansion valve.

The thermostatic expansion valve meters liquid refrigerant into the evaporator, the volume of liquid refrigerant depending upon the temperature of the evaporator; warmer evaporators get more refrigerant and colder evaporators get less. At the evaporator, the refrigerant enters an area of relatively low pressure, where it can easily “boil off” or evaporate. As it evaporates, it absorbs heat from the evaporator and whatever is in contact with it (such as the water inside it). After the evaporator, the refrigerant, now a low pressure vapor, goes through the suction line back to the compressor, where the cycle is repeated.

Refrigeration Schematic

Remote Condenser

Discharge

Line

Liquid Line

Head Pressure

Control Valve

Detail of Head Pressure Control Valve

Liquid Line Valve

Thermostatic Expansion Valve

Evaporator

Receiver Compressor Suction Line

Page

GEM-MFI SERIES Operation: Refrigeration-Remote

Low Condensing Temperature

The refrigeration system under low condenser air temperatures is much the same as it is under higher temperatures, with the exception that the resulting low head pressures cause the head pressure control to close off the liquid line between the condenser and the receiver.

This forces more refrigerant into the condenser (with a small amount of discharge gas going into the receiver to maintain pressure until the head pressure is built back up to 180 PSIG). At that pressure the valve opens up the liquid line from the condenser to the receiver.

Refrigeration Schematic

Remote Condenser

Discharge

Line

Liquid Line

Detail of Head Pressure Control Valve

Liquid Line Valve

Thermostatic Expansion Valve

Head Pressure

Control Valve

Evaporator

Receiver Compressor

Suction Line

GEM-MFI SERIES Operation: Refrigeration-Remote

Pump Down

During the pump down cycle (usually initiated by the circuit board de-energizing the liquid line valve) the discharge gases flow through their normal path to the remote condenser, through the head pressure control and into the receiver. At this point the refrigerant flow is stopped by the closed liquid line valve.

This action forces the refrigerant into the receiver and keeps it out of the compressor. The pump down continues until the pump down control opens turning the compressor off.

Refrigeration Schematic

Remote Condenser

Discharge

Line

Liquid Line

Liquid Line Valve (Closed)

Head Pressure

Control Valve

Receiver Compressor

GEM-MFI SERIES Operation: Performance-A&W

Beginning at the compressor, the refrigerant is compressed into a high temperature gas. The discharge line directs this gas to the condenser. At the condenser (air or water cooled) the gas is cooled by either air or water and then it condenses into a liquid.

This high pressure liquid then goes through the liquid line to the expansion valve. The thermostatic expansion valve meters liquid refrigerant into the evaporator, the volume of liquid refrigerant depending upon the temperature of the evaporator.

At the evaporator, the refrigerant enters an area of relatively low pressure, where it can easily “boil off” or evaporate. As it evaporates, it absorbs heat from the evaporator and whatever is in contact with it (such as water inside it). After the evaporator, the refrigerant, now a low pressure vapor, goes through the suction line back to the compressor, where the cycle is repeated.

Typical Low Side Pressure:

Typical Discharge Pressure:

Typical Compressor Amp Draw:

GEM0450/MFI0500

GEM0650/MFI0800

GEM0655/MFI0805

GEM0956/MFI1256

GEM0955/MFI1255

115/60/1

115/60/1

230/50/1

208-230/60/1

230/50/1

Typical Auger Drive Motor Amp Draw:

GEM0450/MFI0500

GEM0650/MFI0800

GEM0655/MFI0805

GEM0956/MFI1256

115/60/1

115/60/1

230/50/1

208-230/60/1

GEM0955/MFI1255 230/50/1

High Pressure Cut Out- Automatic Reset:

Low Pressure Cut Out- Automatic Reset:

Refrigerant Charge: R404A

GEM0450/MFI0500

Air Cooled:

Water Cooled:

22 ounces

18 ounces

24 ounces

19 ounces

Air Cooled:

Water Cooled:

Air Cooled:

Water Cooled:

30 ounces

22 ounces

7.8 Amps

11.9 Amps

6.0 Amps

7.0 Amps

8.86 Amps

4.6 Amps

4.6 Amps

2.0 Amps

2.4 Amps

2.3 Amps

450 PSIG

15 PSIG

Air Cooled:

Water Cooled:

Air Cooled:

Water Cooled:

24 ounces

19 ounces

30 ounces

22 ounces

GEM-MFI SERIES

Typical Low Side Pressure:

Typical Discharge Pressure:

Typical Compressor Amp Draw:

Operation: Performance-Remote

Typical Auger Drive Motor Amp Draw:

High Pressure Cut Out- Automatic Reset:

Pump Down Cut Out- Automatic Reset:

Refrigerant Charge: R404A

450 PSIG

15 PSIG

Remote ounces

GEM-MFI SERIES Sanitizing and Cleaning

It is the USER’S RESPONSIBILITY to see that the unit is properly maintained. It is always preferable, and less costly in the long run, to avoid possible down time by keeping it clean; adjusting it as needed; and by replacing worn parts before they can cause failure. The following is a list of recommended maintenance that will help keep the machine running with a minimum of problems.

Maintenance and Cleaning should be scheduled at a minimum of twice a year.

Note: Electrical power will be ON when doing in place cleaning.

ICE MAKING SYSTEM: In place cleaning.

1. Check and clean any water treatment devices, if any are installed.

2. Remove screws, and the front and top panel.

3. Move the ON-OFF switch to OFF.

4. Remove all the ice from the storage bin.

5. Remove the cover from the water reservoir and block up the float.

6. Drain the water reservoir and freezer assembly using the drain tube attached to the freezer water inlet.

Return the drain tube to its normal upright position and replace the end cap.

7. Prepare the cleaning solution: Mix eight (8) ounces of ice machine cleaner with three (3) quarts of hot water. The water should be between (95ºF-115ºF).

8. Slowly pour the cleaning solution into the water reservoir until full. Wait 15 minutes, then switch the master switch ON.

9. As the ice machine begins to use water from the reservoir, continue to add more cleaning solution to maintain a full reservoir.

10. After all of the cleaning solution has been added to the reservoir, and the reservoir is nearly empty, switch the master switch to OFF.

11. Drain the water reservoir and freezing assembly using the drain tube attached to the freezer water inlet.

Return the drain tube to its normal position and replace the end cap. Wash and rinse the water reservoir.

Sanitizing

To sanitize, use an approved sanitizing solution or mix one ounce of household bleach to 2 gallons of warm (95ºF-115ºF) water. Repeat steps 8-11 using the sanitizer solution in place of the cleaning solution.

12. Remove the block from the float in the water reservoir.

13. Switch the master switch ON.

14. Continue ice making for at least 15 minutes, to flush out any cleaning solution.

Note: DO NOT USE any ice produced from the cleaning solution! Be sure no ice remains in the bin!

15. Remove and discard all ice from the storage bin.

16. Add warm water to the ice storage bin and thoroughly wash and rinse all surfaces within the bin.

17. Sanitize the bin interior by thoroughly washing the interior of the bin and bin door with the balance of the sanitizing solution.

18. Replace the panels.

Warning! Ice machine cleaner contains acids. If swallowed, DO NOT induce vomiting. Give large amounts of water or milk. Call Physician immediately.

In case of external contact, flush with water.

KEEP OUT OF THE REACH OF CHILDREN.

GEM-MFI SERIES Condenser Maintenance: Remote

● Clean the condenser: the condenser may

Brush in direction of fins

appear to be clean on the surface, but it can still be clogged internally. Check with a flashlight from the front to see if light can be seen through the condenser fins.

The condenser coil must be kept clean. The condenser can be cleaned with compressed air or by using a brush.

If a brush is used, brush in the direction of the fins taking care not to bend or distort the fins.

Use a soft bristle nylon brush.

If the condenser fins are bent or distorted, this will restrict the airflow through the condenser and the fins will need to be straightened with a fin comb.

When cleaning the Condenser, check the fan blade for cleanliness and for balance. Balance is checked by spinning the blade by hand and looking for any wobble. Pull on the shaft in several directions to check the bearings of the motor.

The fins of the remote condenser require periodic cleaning.

Brush in direction of fins

At 6 month intervals the fins on the inlet side of the condenser (bottom as shown) should be brushed free of dust and dirt

Brush in the direction of the fins as noted by the arrows.

Additionally look through the fins, using a flashlight if required, to insure there is no other blockage obstructing air flow between the fins.

If the air flow appears to be blocked, blow out the condenser using CO2 gas.

Caution: Disconnect electrical power before servicing this equipment.

Caution: Protective eye wear and gloves should be worn when cleaning the condenser.

GEM-MFI SERIES Maintenance: Air Cooled

Clean the air cooled condenser:

Air flow on this model is from front to back, so the inside of the ice machine will have to be available to clean the air cooled condenser. Use a vacuum cleaner or coil cleaner if needed. DO NOT use a wire brush.

Disconnect electrical power, and remove the air filter if applicable. The filter may be cleaned or replaced.

● Clean the condenser: the condenser may appear to be clean on the surface, but it can still be clogged internally. Check with a flashlight from the front to see if light can be seen through the condenser fins.

GEM0956

Step 1. Remove the Top Panel

Step 2. Remove two screws and unplug fan motors.

Step 3. Pull fan motor assembly up and to the right to remove.

Step 4. Clean the condenser.

GEM0650

Step 1. Remove the Top Panel

Step 2. Remove the top portion of the fan shroud.

Step 3. Clean the condenser.

GEM-MFI SERIES Bearing Maintenance

Bearing Maintenance:

The bearing in the breaker should also be checked at least two (2) times per year.

Switch the machine OFF and check the bearing.

1. Remove the chute cover.

2. Unscrew the ice sweep

3. Removing the water shed and unscrewing the breaker cover.

Note: Left Hand Threads

4

.

Unscrewing the auger stud

5. Inspect the bearing. There should be plenty of grease in sight. If grease is needed the bearing and breaker should be removed to check the action of the bearing.

It should rotate freely.

6. To remove the breaker, remove the lower ice chute then take out all four (4) Allen head cap screws and pull the breaker off the auger and evaporator.

7. If the bearing only needs grease, inject grease into the bearing using a grease needle.

See Removal and Replacement Section to replace bearings and seals.

GEM-MFI SERIES

Bin Control Sensor:

The bin control uses devices that sense light, therefore they must be kept clean enough so that they can “see”.

At least twice a year, remove the bin control sensors from the base of the chute, and wipe the inside clean, as illustrated.

Ice Level Sensors

Ice Discharge Chute

Slide In and Out

Sensor Maintenance

Water Sensor:

The ice machine uses a probe in the water reservoir to determine if there is water.

At least twice a year remove the probe from the reservoir and wipe the tip clean of mineral build-up.

Clean the probe’s tip with ice machine cleaner and a soft

GEM-MFI SERIES Auger Maintenance

Auger:

In some areas, the water supply to the ice machine will contain a high concentration of minerals, and that will result in an evaporator and auger becoming coated with these minerals, requiring a more frequent removal than twice per year. If in doubt about the condition of the evaporator and auger, the auger can be removed so the parts can be inspected.

Note: Water filters can filter out suspended solids, but not dissolved solids. “Soft” water may not be the complete answer. Check with a water treatment specialist regarding water treatment.

For more information on removal of these parts, see Removal and Replacement.

1. Disconnect electrical power to the ice machine.

2. Turn off the water supply to the ice machine.

3. To remove the auger, remove the front and top panels.

4. Push back the bail clamp holding the ice chute cover to the ice chute, and remove cover.

5. Remove ice chute from evaporator.

6. Remove four (4) Allen screws holding breaker to evaporator.

7. Drain the evaporator by lowering and uncapping the evaporator drain hose.

8. Pull up to remove the auger. After the auger has been removed, allow the auger to dry: if the auger is not bright and shinny, it must be cleaned.

9. Clean the auger and evaporator as required. DO NOT HONE THE EVAPORATOR.

10. Replace the water seal.

11. Reverse to reassemble.

Ice Sweep

Breaker Cover

Allen Screws

Breaker, Bearing and Auger Assembly

GEM-MFI SERIES Service Diagnosis

No ice is made nothing operates. •Unit off due to no power

•Unit off due to master switch in OFF

position

•Restore Power

•Switch master Switch to ON

•Unit off due to low water level •Check water supply, filter

strainer, float valve. Correct supply.

•Unit off due to ice level sensors.

(Photo Eyes ) blocked.

•Check/clean ice level sensors.

•Unit off due to scale on water level •Clean water level sensor.

sensor.

•Unit off due to high pressure control open. •Check for water interruption cooled)

•Auger motor hums but does not turn.

failure.

•Auger can’t turn. Circuit board has shut

•Unit is shut down. •Circuit board has shut ice

machine down due to high motor Check cause draw,

including bearings, gear motor evaporator. pressure open. not failure; to:

failure on circuit board; or

•No to

drive train.

•TXV restricted or not metering.

Check bulb temperature.

leak.

•Check for a restricted system.

•Hi or low pressure cut outs open.

No ice, auger motor is turning. •Compressor contactor coil is open.

•Compressor start.

•Check/replace contactor.

•Check start relay.

•Check compressor windings.

GEM-MFI SERIES

Unit makes ice, but very slowly

Service Diagnosis

•High discharge pressure because of condenser.

•Low capacity because the auger and are mineral

scale.

•Clean filter and condenser.

•Clean the water system.

•Locate leak. Recover the

in the nameplate charge. cover •Return water •Check base of evaporator and drip the water,

Excessive water use.

Check the gear motor for

water infiltration.

•Water cooled model, water regulating •Adjust to 245 PSIG discharge pressure.

•Reservoir float valve leaks thru. •Replace float valve or seat.

•Water model, in

•Water model, •Acid condenser.

Excessive ice meltage. •Bin drain clogged •Clean out bin drain.

•Drains must be separate. connected.

•Adjust or replace.

Machine makes too much noise. •Evaporator coated internally with minerals. •Clean with ice machine

cleaner.

GEM-MFI SERIES Control System Diagnostics

The Control System consists of:

●Control Board

●Water Sensors

●Ice Sensors

●High Pressure Cut Out

●Low Pressure Cut Out

If the unit is OFF, check the control board:

1. Is the Power OK light on? If not check power to the unit. If it has power, and the Power OK light is not on, check the high pressure and low pressure cut outs. If they are both closed, replace the board. If the

POWER OK

light is ON, go to the next step.

2. Is the Water OK light on? If it is, go to the next step. If not, check the water level in the reservoir. If there is water in the reservoir, check that the water sensor is plugged in. To check the water sensor:

a. Unplug the water sensor.

b. Pull the water sensor from the reservoir.

c. Place one ohmmeter lead on the sensor’s plug and the other on the sensor’s tip. The meter should show nearly zero (0) resistance. If it reads infinite resistance, check the tip for corrosion. If it is clean and still reads open, replace the sensor.

OR, connect a copper wire to the wire where the water sensor plugs into and place the other end in the water. The WATER OK should go ON. If it does not, replace the board.

3. Ice sensor Check. Is the BIN FULL light OFF? If it is OFF and the SERVICE light is OFF and the unit is not running, replace the control board.

a. If it is OFF and the auger motor is running but the compressor is not, check the compressor contactor coil.

b. If it is ON, the ice sensors may be blocked. Remove them and check for mineral scale.

4. High pressure cut out check. a. Disconnect electrical power.

b. Pull the wires off the high pressure cut out.

c. Use an ohmmeter to determine if the switch is OPEN. If it is, check the discharge pressure. If the discharge pressure is less than 300 PSIG, replace the high pressure cut out.

d. If the high pressure cut out is open and the system has high discharge pressure, check for the cause.

5. Low pressure cut out check. a. Disconnect electrical power.

b. Pull the wires off the low pressure cut out.

c. Use an ohmmeter to determine if the switch is OPEN. If it is, check the suction pressure. If the suction pressure is greater than 20 PSIG, replace the low pressure cut out.

d. If the low pressure cut out is open and the system has low suction pressure, check for the cause.

GEM-MFI SERIES

Water Reservoir:

1. Disconnect electrical power supply.

2. Shut off water supply to the ice maker.

3. Remove the front panel.

4. Disconnect water inlet tube from reservoir inlet fitting.

5. To remove float valve, push in “locking tabs” as shown and pull float up. Note: The plunger/seat is available separately as a part.

6. To remove reservoir, pull up and remove water sensor.

7. Disconnect water outlet tubes.

8. Remove mounting screws from reservoir bracket, and remove reservoir from ice maker.

9. Reverse to reassemble.

R&R- Water Reservoir, Bin Control

Water

Sensor

Float Assembly

Locking Tabs

Ice Chute

Slide Bin

Controls to

Remove

Bin Controls (Ice Level Sensors)

1. Disconnect electrical power supply.

2. Remove the front panel.

3. Remove the control box cover.

4. Locate ice chute, at the base of the chute, in front of and behind it are two plastic bin control mounts.

5. Slide each bin control to the left, and disconnect the electrical leads connecting the bin control to the circuit board.

6. Reverse to reassemble, be certain that the bin controls are aligned so that the ice level sensors are visible (centered) through the holes in the ice chute.

GEM-MFI SERIES R&R-Bearing and Breaker

Note: Removal of the auger, water seal, evaporator and gear motor must begin at the top of the assembly.

To Remove the Breaker Bearing Assembly:

1. Disconnect electrical power.

2. Remove panels.

3. Push back bail clamp and remove ice chute cover.

4. Unscrew and remove ice sweep.

5. Lift up and remove ice chute.

6. The breaker may be removed from the auger and evaporator without disturbing the auger. a. Unscrew breaker cover from breaker (Note: Left Hand Threads) b. Unscrew auger stud from top of auger. (Fig. 1) c. Unscrew four (4) Allen head cap screws holding breaker to evaporator. (Fig 2) d. Lift up, and remove breaker/bearing assembly from auger and evaporator. (Fig 3)

7. Service the bearing. Check for rust, rough spots and damage. a. The bearing is pressed into the breaker, to remove the bearing and replace it, an arbor press is needed. b. Replace lower seals before installing new bearing in breaker. Note: Seals must be pressed in with a tool pushing against the outer edge only, they will not install by hand. c. Replace parts as required. Re-grease bearings with Ice-O-Matic PN6051062-01 bearing grease. d. Replace top seal and check the O-Rings, replace if cut or torn.

8. Reverse to reassemble: Specific tools and materials are required to install properly. a. Add food grade grease such as Ice-O-Matic PN6051036-01 to the seal area before installing on the auger. b. Check the seal to shaft areas for cuts or rough spots, none are permitted.

Fig. 1 Fig. 2 Fig. 3

Bearing

Ice Sweep Seals

Auger Stud

Breaker Cover

GEM-MFI SERIES R&R-Auger

To Remove the Auger:

1. Disconnect electrical power.

2. Turn off the water to the machine.

3. Unclip the evaporator drain hose, pull it down and drain the evaporator into the bin or container.

4. Remove the top panel.

5. Swing bail clip down and remove the ice chute cover.

6. Unscrew ice sweep.

7. Remove ice chute body.

8. The auger and breaker/bearing may now be removed as an assembly. a. Unscrew four (4) Allen head cap screws holding breaker to evaporator. b. Lift up on breaker and remove auger from evaporator.

Note: If the auger is stuck, the breaker must be removed from the auger.

9. The breaker may be removed from the auger and evaporator without disturbing the auger. a. Unscrew breaker cover from the breaker. (Note: Left hand Threads) b. Unscrew auger stud from top of auger. c. Unscrew four (4) Allen head cap screws holding breaker to evaporator. d. Lift up and remove breaker from evaporator. e. If the auger is stuck, use a slide hammer type of puller to pull on the auger at the threaded hole.

The size of that hole is 5/8”-18.

10. Inspect the auger, the critical areas of the auger are: a. The auger body. It should be clean and shining. Sometimes an auger will appear clean when wet, but after it is dry it will be seen to be stained. Scrub the auger with ice machine cleaner and hot

Breaker and

Auger Assembly water. b. The water seal area. Because the auger has been removed, the water seal will have to be replaced.

Remove the water seal top half from the auger, and inspect the auger for minerals, clean as required.

WARNING!

The auger has sharp edges, handle with care.

Slide Hammer Puller

Thread into the Auger

Here

GEM-MFI SERIES

To Remove the Water Seal:

(Assuming all steps to remove the auger have been performed)

1. The gear motor/evaporator assembly will have to be exposed.

2. Remove the four (4) hex head cap screws holding the evaporator to the gear motor assembly. Lift the evaporator up and off the gear motor.

3. Remove the snap ring or wire retainer from the groove under the water seal.

4. Pull or drive out the lower half of the water seal.

Removal of the Water Seal

To Replace the Water Seal:

1. Lubricate the water seal with water, and push the water seal into the bottom of the evaporator slightly past the groove for the snap ring.

2. Replace the snap ring and pull the water seal down against it.

3. The part of the water seal that rotates with the auger must also be replaced. Remove the old part from the auger and clean the mounting area.

4. Place a small bead of food grade silastic sealant (Such as 732 RTV) on the area of the auger where the water seal is to be mounted.

5. Carefully push the water seal (Rubber side against the auger shoulder and the silastic.)

Caution: DO NOT get any silastic onto the face of the seal.

6. Allow the auger and seal to air dry until the silastic is dry on the surface.

7. If the original water seal was leaking, it would be a good idea to inspect the interior of the gear motor.

Replacing the Water Seal

R&R-Water Seal

Water

Seal

Retaining

Ring

Place Food

Grade Sealant

Here

GEM-MFI SERIES R&R-Evaporator

To Replace the Evaporator:

(Assuming all steps for removal of the thrust bearing, breaker, auger and water seal have been performed).

1. Recover the refrigerant from the ice machine.

2. Unsweat the refrigerant connections:

a. At the thermostatic expansion valve outlet.

Ice Sweep

Auger

b. At the suction line at the joint about three (3) inches from the evaporator.

3. Remove the evaporator.

4. Unsweat the drier from the liquid line.

5. After installing a new water seal in the new evaporator (see “to Replace the

Water Seal) sweat in the new evaporator at the old tubing connections.

6. Install a new drier in the liquid line.

7. Evacuate the system until dehydrated, then weigh in the nameplate charge.

Check for leaks.

8. Install auger, breaker, breaker bearing assembly and ice discharge chute in reverse order of disassembly.

To Reassemble the Evaporator and

Auger:

1. After the gear motor has been inspected, fasten the evaporator to the gear motor. Torque the bolts to

110 inch pounds

Ice Chute

Evaporator

2. Lower the auger into the evaporator barrel, slightly turning it to match up with the drive end. Do Not Drop the auger into the evaporator.

3. Complete the reassembly by reversing the disassembly for the breaker and thrust bearing.

Breaker/Divider

Caution: Heat sink the TXV body when unsweating or resweating the adjacent tubing.

GEM-MFI SERIES R&R-Gear Motor

To Check the Gear Motor:

1. Remove wires from terminals 1 and 2

2. Use an ohmeter to check for continuity. If there is none, replace only the motor. If there is continuity but the motor will not start, check the motor’s start switch.

3. Remove motor end bell or motor stator. With ohnmeter wires attached to 1 and 2 move centrifugal switch actuator up and down to simulate motor rotation. If the ohnmeter does not show any change, replace the switch or motor. If the ohmeter showns an open circuit, replace the switch or motor.

To Remove and Repair the Gear Motor Assembly:

(Assuming that the procedures through removal of the water seal have been performed)

1. Remove the electrical wires from the gear drive motor.

2. Unscrew the four (4) cap screws holding the gear motor to the base of the machine. remove the gear motor from the machine.

Note: Bench test the gear motor, check for oil leaks, noise and amp draw.

To Inspect the Gear Case Assembly:

1. The oil charge is 14 ounces. Do not overfill.

2. There are no serviceable parts in the gearcase assembly. If the gears or bearings are damaged the entire gearcase assembly will require replacement.

Cover and Output

Gear Assembly

Water Shed

Rotor Bearing

GEM-MFI SERIES R&R-Fan Blade and Motor

To Remove the Condenser Fan Motor Assembly: (GEM0956 Air Shown)

1. Disconnect electrical power to the ice machine

2. Remove top panel and the service panels.

3. Unplug the fan motor wire leadsfrom the fan motors.

4. Remove the two (2)head bolt from the top end of the fan motor assembly. (Fig 1)

5. Lift up the fan motors and bracket assembly about ½ inch and pull out the fan assembly out the right service access hole. (Fig 2)

6. Repair as needed.

7. To Reassemble: Place the fan motor assembly lower flange holes over the two Allen head cap screws in the base, and install the hex head boltsat the top of the assembly.

Plug the fan motors back in and replace the panels.

Fig.1 Fig. 2

GEM-MFI SERIES R&R-Fan Blade and Motor

To Remove the Remote Condenser Fan Motor Assembly:

1. Disconnect electrical power to the ice machine and/or remote condenser.

2. Remove fan guard.

3. Remove the fan blade.

4. Disconnect the electrical power lead to the fan motor.

5. Remove the four (4) bolts from the fan motor assembly.

6. Remove the fan motor assembly.

7. To Reassemble: Place the fan motor assembly on the condenser bracket and install the bolts. Wire the fan motor power leads, install the fan blade and replace the fan guard.

Fan Guard

Fan Blade

Fan Motor

GEM-MFI SERIES Refrigeration System Service

Refrigeration Service: Air and Water Cooled

General: This ice machine uses R404A refrigerant and polyolester oil. Do NOT use mineral oil in this refrigeration system.

●When the refrigeration system is serviced, a special liquid line drier is required. It is included with replacement compressor.

●R404A is not compatible with mineral oil so these ice machines use Polyolester oil. Polyolester oil absorbs water very easily. A system opened for service must be re-sealed as soon as possible (15 minutes maximum).

●Special leak detection equipment is required to locate small refrigerant leaks. Usually a leak detector capable of detecting Halongenated refrigerant or HFC-134a will work. Check with the leak detector manufacturer if in doubt.

●Evacuate to 300 microns.

●Liquid charge the system.

Access Valves:

To use the access valves:

Torque Stem to 6-8 ft.-lb.

Torque caps to 7-12 ft.-lbs

●Remove the cap from the stem, use a 3/16 inch Allen wrench to check that the valve is

CLOSED. Then remove the core cap.

●Close the valve and replace the caps when done. The valve must be closed and the caps tightened.

Instructions for Liquid Charging R404A:

In preparation for charging, the low side hose should have a sight glass, and/or a restricting device (such as a

“Charge Faster”) installed in it for metering liquid into the low side of the system.

1. After a through evacuation shut off the manifold valves and switch off the vacuum pump.

2. Place a drum of R404A onto an electronic scale.

3. Attach the charging hose to the drum.

4. Open the valve on the drum and purge the charging hose.

5. Zero out the scale.

6. Shut the low side access valve at the ice machine.

7. Open the discharge manifold valve full open.

8. Watch the scale, when the correct charge is shown, shut the manifold valve.

Note:

If all of the charge will not “go in” the discharge side: a. Shut the discharge access valve at the ice machine.

Low Side High Side

b. Switch the machine on.

c. Open the low side access valve at the ice machine.

d. Open the low side manifold valve and observe the sight glass to be certain that only gas is flowing into the system.

e. When the proper charge is indicated

R404A

Tank Must

Be in Liquid

Dispensing

Position.

Check Tank! on the scale, shut off the manifold valves.

9. Shut off the valve on the refrigerant drum.

10. Re-open the manifold valves until all liquid has flowed out of the hoses.

11. Shut the low side access valve on the ice machine.

12. Remove hoses from ice machine and replace all caps.

Hose Connection Schematic for Liquid Charging

GEM-MFI SERIES Refrigeration System Service

Refrigeration Service: Remote

General: This ice machine uses R404A refrigerant and polyolester oil. Do NOT use mineral oil in this refrigeration system.

●When the refrigeration system is serviced, a special liquid line drier is required. It is included with replacement compressors.

●R404A is not compatible with mineral oil so these ice machines use Polyolester oil. Polyolester oil absorbs water very easily. A system opened for service must be re-sealed as soon as possible (15 minutes maximum).

●Special leak detection equipment is required to locate small refrigerant leaks. Usually a leak detector capable of detecting Halongenated refrigerant or HFC-134a will work. Check with the leak detector manufacturer if in doubt.

●Evacuate to 300 microns.

●Liquid charge the system.

Access Valves:

To use the access valves:

Torque Stem to 6-8 ft.-lb.

Torque Caps to 7-12 ft.-lbs

●Remove the cap from the stem, use a 3/16 inch Allen wrench to check that the valve is

CLOSED. Then remove the core cap.

●Close the valve and replace the caps when done. The valve must be closed and the caps tightened.

Charging Procedure

●Extra care must be taken when charging this remote system. No liquid refrigerant may be placed in the system at the compressor. DO NOT use the access valves at the front of the unit for weighing in the charge.

All liquid refrigerant must be weighed into the receiver through the front seated “king valve”.

Receiver Front Seated King Valve

Charging Cylinder

Service Port

GEM-MFI SERIES

Wiring Diagram GEM0450A/W, MFI0500A/W

Wiring Diagram

GEM-MFI SERIES

Ladder Diagram GEM0450A/W, MFI0500A/W

Wiring Diagram

GEM-MFI SERIES

Wiring Diagram GEM0650A/W, MFI0800A/W

Wiring Diagram

GEM-MFI SERIES

Ladder Diagram GEM0650A/W, MFI0800A/W

Wiring Diagram

GEM-MFI SERIES

Wiring Diagram GEM0655A/W, MFI0805A/W

GEM0955A/W, MFI1255A/W

Wiring Diagram

GEM-MFI SERIES

Ladder Diagram GEM0655A/W, MFI0805A/W

GEM0955A/W, MFI1255A/W

Wiring Diagram

GEM-MFI SERIES

Wiring Diagram GEM0650R, MFI0800R

Wiring Diagram

GEM-MFI SERIES

Ladder Diagram GEM0650R, MFI0800R

Wiring Diagram

GEM-MFI SERIES

Wiring Diagram GEM0956A/W, MFI1256A/W

Wiring Diagram

GEM-MFI SERIES

Ladder Diagram GEM0956A/W, MFI1256A/W

Wiring Diagram

GEM-MFI SERIES

Wiring Diagram GEM0956R, MFI1256R

Wiring Diagram

GEM-MFI SERIES

Ladder Diagram GEM0956R, MFI1256R

Wiring Diagram

GEM-MFI SERIES Service History

What to Do Before Calling for Service:

●Check the water supply to the ice machine. The ice machine is designed to shut off if there is no water to it.

Check the water filters if there are any.

●Check the power supply to the ice machine. Reset the breaker if it is tripped.

●If both water and power have been checked and are available, try switching the power OFF and then ON.

After 2 minutes the machine should restart. If this procedure restarts the machine, service should be called the next time the machine stops.

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