Follett D400A Installation, Operation And Service Manual

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Follett D400A Installation, Operation And Service Manual | Manualzz

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T400A/W, MCD400A/W, R400A/W,

MFD400A/W, D400A/W Ice Machines

Installation, Operation and Service Manual

Following installation, please forward this manual to the appropriate operations person.

801 Church Lane • Easton, PA 18040, USA

Toll free (877) 612-5086 • +1 (610) 252-7301 www.follettice.com

208600R20

2

Table of contents

Welcome to Follett Corporation

Specifi cations

Installation

Top mount ice machines (models T400A/W, MCD400A/W and MFD400A/W)

RIDE ™ model ice machines (models MCD400A/W, R400A/W)

Ventilation

Ice transport tube

Operation

Cleaning

Weekly exterior care

Monthly condenser cleaning

Semi-annual evaporator cleaning

Service

Ice machine operation

Refrigeration system diagram

Refrigeration pressure data

MCD400A/W wiring diagram

Electrical control system operation

Troubleshooting

Replacement parts

20

20

20

20

21

17

18

18

19

19

14

15

17

17

17

8

8

4

5

9

29

29

30

32

21

22

28

29

29

3

Welcome to Follett

Follett equipment enjoys a well-deserved reputation for excellent performance, long-term reliability and outstanding after-the-sale support. To ensure that this equipment delivers that same degree of service, we ask that you review the installation portion of this manual before beginning to install the unit. Our instructions are designed to help you achieve a trouble-free installation. Should you have any questions or require technical help at any time, please call our technical service group at (877) 612-5086 or +1 (610) 252-7301.

Before you begin

After uncrating and removing all packing material, inspect the equipment for concealed shipping damage. If damage is found, notify the shipper immediately and contact Follett Corporation so that we can help in the fi ling of a claim, if necessary.

Check your paperwork to determine which model you have. Follett model numbers are designed to provide information about the type and capacity of Follett equipment. Following is an explanation of the different model numbers in the

400 series.

MCD400ABT

Ice machine capacity and refrigerant

400 – 400 lbs (181kg)/day, R404A

Voltage

D – 115V 60Hz

Condenser type

A – air-cooled

W – water-cooled

Application

V – Vision

B – Bin

H – Harmony

Configuration

S – RIDE

T – top-mount

Ice machine series

Nugget ice machine

MCD – RIDE model installation, Vision

ice and beverage dispensers and top installation, Follett ice storage bins

R – Remote installation, Symphony ™ ice and water dispensers

D – Replacement icemaker, Symphony ice and water dispensers

Flake ice machine

MFD – Top installation, Follett ice storage bins

!

Moving parts. Do not operate with front cover removed.

Hot parts. Do not operate with cover removed.

To reduce risk of shock disconnect power before servicing.

Most ice machine cleaners contain citric or phosphoric acid, which can cause skin irritation. Read caution label on product and follow instructions carefully.

Ice is slippery. Maintain counters and fl oors around dispenser in a clean and ice-free condition.

Ice is food. Follow recommended cleaning instructions to maintain cleanliness of delivered ice.

4

Specifi cations

Electrical

Each ice machine and dispenser require a separate circuit with electrical disconnect within 10 ft (6m).

Equipment ground required.

Standard electrical – 115V, 60Hz, 1 phase.

Maximum dispenser fuse – 15A,

Maximum ice machine fuse – 20A each

Maximum ice machine amperage – 11A each

Cord and plug provided on ice machine and dispenser

Electrical connections

Model

25FB400A/W, 50FB400A/W, 110FB400A/W

Electrical connection Circuits required

cord & plug provided 115/60/1, 20A max. fuse size

25CT400A/W, 50CT400A/W, 110CT400A/W

25CR400A/W, 50CR400A/W, 110CR400A/W

VU155R400A/W, VU300R400A/W

VU155BR400A/W, VU300BR400A/W

VU155R400A/WX, VU155BR400A/WX

VU155NR400A/W, UD300R400A/W

VU155R800A/W, VU300R800A/W,

VU155R800A/WX,

VU155BR800A/W, VU300BR800A/W, cord & plug provided 115/60/1, 20A max. fuse size dispenser, ice machine 115/60/1, (2) circuits required and bin signal: dispenser: 15A max. fuse size cord & plug provided ice machine: 20A max. fuse size dispenser, ice machine 115/60/1, (2) circuits required and bin signal: dispenser: 15A max. fuse size cord & plug provided ice machine: 20A max. fuse size dispenser, ice machine 115/60/1, (3) circuits required and bin signal: cord & plug provided dispenser: 15A max. fuse size

(2) ice machines: 20A max. fuse

CAUTION

• Check start relay before supplying power

• Start relay is gravity sensitive, and MUST be in “up” position

• Failure to comply may cause equipment to overheat, resulting in equipment failure, equipment damage or fire hazard

UP

UP

UP

top mount and

RIDE model position freestanding position

5

Plumbing

3/8" OD push-in water inlet

3/4" MPT drain

3/8" FPT condenser inlet (water-cooled condenser only – 1.25 gpm minimum available fl ow)

3/8" FPT condenser drain (water-cooled condenser only)

Notes: Slope to drain of 1/4" per foot (6mm per 30.4cm run) with a 1/2" min. is recommended.

Water shut-off recommended within 10 feet (3m), drain to be hard piped and insulated.

Separate drains for ice machine and condenser. To prevent back fl ow, do NOT connect drains.

Follett recommends installation of an activated carbon fi lter in ice machine inlet water line.

Ambient

Air temperature

Water temperature

Water pressure

100 F/38 C max.

90 F/32 C max.

70 P.S.I max. (482 kPA)

50 F/10 C min. (best performance below 80 F/27 C)

40˚F/4˚C min. (best performance below 70 F/21 C)

10 P.S.I. min. (89 kPA)

6

Dimensions and clearances

Entire front of ice machine must be clear of obstructions/connections to allow removal.

12" (305mm) clearance above ice machine for service.

6" (153mm) minimum clearance between exhaust side of ice machine and any adjacent equipment.

MCD400A & R400A – 18" (457mm) minimum, 10 ft (3m) maximum clearance between discharge and air intake grilles.

Front view — air-cooled top mount

Back view — air-cooled top mount

13.00"

(331mm)

C

Front view — air-cooled

RIDE model

C

F

1.875" (48mm)

B

A

Side view — air-cooled and water-cooled top mount and RIDE model

22.75" (578mm)

20.75" (527mm)

12.875"

(327mm)

8.375"

(213mm)

4.75"

(121mm)

2.25"

(57mm)

4.875"

(124mm)

2.375"

(61mm)

B

A

Front view — water-cooled

RIDE model

Back view — water-cooled top mount

C

F

D

E

1.875" (48mm)

7.00" (178mm)

B

A

Ice machine plug configuration

NEMA 5-20

6.875"

(175mm)

2"

(51mm)

17.00"

(432mm)

RIDE model air-cooled units only

A – 3/4" MPT drain

B – 3/8" OD push-in water inlet

C – Electrical cord

D – 3/8" FPT condenser inlet

E – 3/8" FPT condenser drain

F – Bin signal cord

7

Installation

Ice machine performance is very sensitive to the quality of installation. To ensure proper performance, ease of service and warranty coverage, it is critical that you follow the requirements detailed in this manual. If you cannot meet these requirements or have questions, call our technical service group immediately at (877) 612-5086 or

+1 (610) 252-7301.

Top mount ice machine on bin installation procedure

(models MCD400A/WBT and MFD400A/WBT)

Install ice machine and rough-in utilities

1. Install ice storage bin in its fi nal location.

2. Install one supplied grommet in large knockout in base of ice machine and second supplied grommet in ice hole provided in top of ice storage bin.

3. Rough in plumbing and electrical per specs provided.

4. Flush all water lines before fi nal hook up.

5. Position ice machine with utility connections facing rear of bin.

A. If new storage bin and ice machine – position ice machine with connections facing rear of bin.

B. If using existing bin – place supplied gasket 2.5" (64mm) from front of bin (Fig. 2). Position ice machine with utility connections facing rear of bin.

6. Make fi nal plumbing and electrical connections.

7. Working from inside bin storage area, push end of transport tube without fasteners up through grommets into ice machine, leaving about 2" (51mm) hanging down in bin.

8. Route free end of tube to evaporator port.

9. Slip a hose clamp in free end of tube.

10. Push free end of tube on evaporator port and tighten clamp, making sure clamp is positioned on evaporator side of fl ange (no fl ange on MFD400 series fl ake ice machine).

11. Position ice tube under fl oat bracket retaining tab.

12. Carefully slip ice level control stat alongside transport tube through both grommets and down into bin.

13. Run ice level control stat down through one side of cap tube fasteners attached to ice transport tube, form a

180˚ bend at end of tube and run back up through fastener (Fig. 1).

14. Adjust loop length to provide desired ice level. Loop must below end of ice transport tube.

15. Carefully bend end of cap tube to prevent it from slipping out of clamp.

Fig. 1

ice level control stat fastener ice level control stat bin top

Fig. 2 – Replacing existing ice machines

bin top top view shown ice transport tube

Apply supplied gasket to bin top as shown. Position ice machine on bin top.

add gasket

2.5"

(64mm) existing gasket front of ice machine

Before turning power on

1. Clean and sanitize ice storage bin in accordance with cleaning procedure in ice storage bin installation information packed with ice storage bin.

2. Turn water to ice machine on.

3. Remove cover on fl oat reservoir.

4. Push down on fl oat to force water out overfl ow tube and into evaporator drain pan.

5. Check that water drains freely from evaporator drain pan.

6. Lift fl oat and check that fl oat valve shuts off incoming water when raised.

8

After turning power on

1. Turn power to ice machine on and confi rm that gearmotor, compressor and fan motor start immediately.

2. Check that ice begins to enter bin within approximately 10 minutes.

3. With ice machine running, check that fl oat reservoir water level is approximately 3/8" (10mm) below internal overfl ow and adjust to this level (raised line on side of reservoir) if necessary.

4. After making ice for 10 minutes, put ice against ice level control stat cap tube and check that ice machine shuts down.

5. Warm ice level control stat with your fi ngers and check that ice machine restarts in approximately 20 minutes.

(Bin must be calling for ice.)

RIDE model ice machine installation procedure

(models MCD400A/WHS and MCD400A/WVS)

RIDE model ice machine performance is very sensitive to the quality of installation. To ensure proper performance, ease of service and warranty coverage. it is critical that you follow the requirements detailed in this manual. If you can not meet these requirements or have questions, call our technical service group immediately at (877) 612-5086 or +1 (610) 252-7301.

Installing

RIDE model

ice machine and rough-in utilities without optional slide-out accessory

The requirements below are for ice machine installation without the Follett slide-out accessory. These procedures ensure that the ice machine can be easily removed as one unit for cleaning and maintenance. For installation with the slide-out accessory, refer to instructions to install ice machine and rough-in utilities with optional slide-out accessory.

General requirements

Front of ice machine free of obstructions, plumbing lines, electric conduits.

12" (305mm) minimum clearance above ice machine for access to ice machine components.

6" (153mm) minimum clearance between exhaust side of ice machine and adjacent equipment.

Do NOT weld ice machine to counter channels.

Large, removable panels in counter face to allow ice machine removal.

Machine stand accessory required for ice machines not supported on counter channels.

Connection requirements

Compression fi ttings for water and drain lines.

Separate drains for condenser and ice machine. Do NOT connect drains.

20A power supply with 6 feet.

bin signal from dispenser to ice machine separate power to dispenser front of ice machine clear

12"

305mm

clearance separate power to ice machine water shut off compression fittings for water and drain lines

Note: Diagram intended as guide only. All fi eld wiring to be installed in accordance with NEC and local electrical codes.

9

Field wiring diagrams for RIDE model ice machine installations

All fi eld wiring must be installed in accordance with NEC and local electrical codes.

Field wiring diagram is intended only to aid electrician or technician in understanding how equipment works.

Should local codes require a hard-wired connection and/or shielded wiring, eliminate the cord and plug(s) and follow the appropriate fi eld wiring diagram.

MCD400A/W and R400A/W ice machines have separate power supply from dispenser.

Electric disconnects required within 10 ft (3m) for all hard-wired connections.

Recommended junction box preparation of hard-wired RIDE model ice machines.

1. Cut plugs from supplied power cords.

2. Replace upper (power) strain relief with a cord connector.

3. Mount two 2" x 4" junction boxes using supplied holes in ice machine face.

4. Make power and bin signal connections.

25, 50 or 110 ice and water dispenser with ONE RIDE model ice machine

(dispenser models 25CR400A/W, 25HR400A/W, 50CR400A/W, 50HR400A/W, 110CR400A/W)

Electric power source

Electric power source

Dispenser junction box

Lower ice machine junction box

(bin signal)

Upper ice machine junction box

(power)

GND GRN

X

X

B

GND GRN

X

W

R

W

B

W

B

B

W

GRN

BL

Y

RD

LEGEND

WIRENUT FIELD

CONNECTIONS

EQUIPMENT

GROUND

BLACK

WHITE

GREEN

BLUE

YELLOW

RED

VU155/VU300 ice and beverage dispenser with ONE or TWO RIDE model ice machines

Note: 24V bin signal; Verify black bin signal wire is on the 24V terminal

Ice machine #1

(optional)

Lower junction box

(24V bin signal)

Electric power source

Upper junction box

(power)

Electric power source

DISPENSER

Left junction box Right junction box

B

W

W

B

GND

X

GRN

W

B

BL

GND

GRN

Y

RD

Ice machine #2

(optional)

Lower junction box

(24V bin signal)

Electric power source

Upper junction box

(power)

W

B

W

B

GND

X

GRN

10

Installing RIDE model ice machine and rough-in utilities with optional slide-out accessory

The slide-out accessory allows the ice machine to be pulled out on a track from below a counter without disconnecting utilities. A leg supports the ice machine in the full-out position. If your order did not include a

slide-out accessory proceed to ice machine ventilation and exhaust.

Step 1 – Installing track accessory (Follow either A or B below for RIDE model ice machine)

Track must be positioned fl ush against inside of counter and slightly above counter access opening.

A. When ice machine stand is used (required if ice machine is not supported on counter channels)

1. Bolt vertical utility panel to slide-out track assembly with supplied 10/32 screws.

2. Secure slide-out track assembly to ice machine stand with 10/32 screws provided.

3. Position ice machine stand in desired location and adjust stand legs to proper height and level in both directions.

4. Using holes in fl anged legs as template, mark fl oor for 12 anchoring holes to be drilled.

5. Remove stand/track assembly and drill marked holes.

6. Reposition and anchor stand to fl oor with 12 fasteners appropriate to fl oor material (not supplied).

Stand MUST be anchored to avoid tipping and possible injury when ice machine is pulled out.

B. When ice machine is supported on counter channels

1. Bolt vertical utility panel to slide-out track assembly with supplied 10/32 screws.

2. Position track assembly on counter channels (Fig. 3).

3. Using holes in track assembly as a template, mark and drill required holes in counter channels.

4. Remove track assembly on channels and drill marked holes.

5. Reposition track assembly on channels and secure using appropriate hardware (not supplied).

14"

(356mm)

13"

(331mm) verical utility pane

14"

(356mm)

12.75

(324mm)

11

Step 2 – Installing RIDE model ice machine on slide-out track

A. When ice machine is shipped with slide-out track accessory (follow either A or B)

1. Connect inlet water, drain, and power supply to back of vertical utility panel.

2. Place ice machine on slide-out track assembly.

3. Connect drain and water lines.

4. Connect electrical plugs from ice machine to utility panel.

B. When ice machine is installed in and shipped with counter

1. Remove two outer rear screws from ice machine and install supplied spacer and screw (Fig. 3).

2. Place ice machine on slide-out track assembly.

3. Connect drain and water lines.

4. Connect electrical plug from ice machine to utility panel.

5. Remove pin from adjustable leg.

6. Place hold-down strap over leg block and secure strap to slide-out assembly with supplied screws (Fig. 4).

7. Reinstall pin in leg block.

8. At job site remove hold-down strap and make utility connections at rear utility panel.

position track accessory so that 2" (51mm) duct supplied with air-cooled RIDE model ice machine mates with back of counter opening.

counter front grille supplied with aircooled RIDE model ice machines bin signal cord

(icemaker connection) power cord bin signal cord

(customer connection) air in

(air-cooled units only)

Fig. 3

Fig. 4

hold-down strap

(for installation; remove and discard)

Remove screw. Install supplied screws and spacers.

supplied screws (for installation; remove and discard)

12

Front view

3/8" OD push-in condenser inlet

(water-cooled only)

3/8" OD push-in condenser drain

(water-cooled only)

3/8" OD push-in icemaker water inlet barbed push-on icemaker drain

5.25"

(134mm) ice machine power outlet ice machine twist-lock bin signal cord

25.875"

(658mm)

Side view

(All customer fi eld connections are made to rear of vertical utility panel)

3/8" OD push-in condenser inlet

(water-cooled only)

3/8" OD push-in condenser drain

(water-cooled only)

3/8" OD push-in ice machine water inlet icemaker power cord bin signal cord connector

(to connect to dispenser bin signal cord)

3/4" MPT ice machine drain

22.75"

(578mm) cord holder vertical utility panel

16.75"

(415mm)

Plan view

22.75"

(578mm)

1.563"

(40mm)

Ice machine front

16"

(407mm)

19.25"

(489mm)

25.875"

(658mm)

13

1.563"

(40mm)

RIDE model ice machine ventilation and exhaust requirements

Fabricator-supplied, custom air intake grilles must have 12" x 12" (305mm x 305mm) opening yielding 100 sq. inches (645 sq. cm) of open air space within duct perimeter. Block off any open area outside of the air duct.

Intake air requirements — air-cooled ice machines (MCD400AHS, MCD400AVS & R400A only)

1. Check that 2" (51mm) duct is installed on condenser front.

2. Cut a 12" x 12" (305mm x 305mm) opening in counter face to align with duct.

3. Position ice machine to mate duct fl ush with back of counter opening.

4. Install supplied grille on outside of counter opening.

Exhaust air — all ice machines (MCD400A/W & R400A/W)

Provide 100 sq. in. (645 sq. cm) of counter opening for exhaust air at least 18" (457mm) from intake opening but not more than 10 ft (3m) away.

MCD400AHS, MCD400AVS & R400A — Side View

Standard louvered grille

(supplied)

Air intake

Exhaust air

Standard 51mm

(2") duct mates counter opening

(behind grille) to condenser front

Supplied 2" (51mm) duct MUST be installed to front of ice machine and mated flush to insid of counter face opening.

Front View

Exhaust air out side to opening at least

457mm (18" ) from air intake

Air in through louver

Air out through louver

Provide at least 645 sq. cm

(100 sq. inches) of counter opening for exhaust air

14

RIDE model ice machine ice transport tube installation

Incorrect ice transport tube installation can result in wet ice and dispensing problems. Follow guidelines below to ensure correct installation. Call factory for assistance if you are unable to meet these requirements.

General requirements

Maximum length of tube run – 20 ft (6m). Factory approval required for longer runs.

Run tube without dips.

One continuous length of tube; no splices.

Minimum radius of bends in tube – 6" (153mm) inside radius.

Maximum number of bends – 6.

Insulation on entire run of ice tube.

Procedure

1. If installing MCD series ice machine refer to additional connection specifi cations for Vision series ice and beverage dispensers instructions below.

2. Select side, rear or top knockout in ice machine cabinet for tube entrance.

3. Install supplied grommet in knockout.

4. Remove ice machine top panel.

5. Install supplied insulation on entire length of tube.

6. Run insulated tube without dips between ice machine and dispenser and secure in place.

7. Cut insulation off tube where tube enters grommet.

8. Slide end of tube without insulation through grommet and run to evaporator port.

9. Cut tube to that length.

10. Install a section of insulation on tube from grommet to evaporator port.

11. Slip supplied hose clamp over free end of tube.

12. Pull insulation back from free end of tube.

13. Push tube on evaporator port.

14. Position clamp behind lip on evaporator port and tighten clamp.

Correct installation

• Length of run no more than 20 ft (6m)

• Tube run continuously from ice machine to dispenser

• Insulation on entire run of tube

• No dips or tight bends

• Tube secured in place

• No splices

Incorrect installation

• Dips in tube where water can collect

• Splice or tight bend that restricts ice fl ow

• Uninsulated tube that results in wet ice and potential dispensing problems

15

Additional ice transport tube connection specifi cations for Vision series ice and beverage dispensers

Check to make sure bin signal on ice machine control board is switched to 24 volt connection.

1. Push one end of ice transport tube(s) through hole(s) provided in side of dispenser.

2. Route tube into ice tube bracket inside dispenser and engage bracket tabs in holes located in end of ice transport tube(s) (see drawings below).

3. Verify bin thermostat capillary tube is mounted correctly (see drawings below).

Ice tube retainer bracket

1" (26mm) ice tube retaining bracket

Bin thermostat capillary tube mounting

Front View, VU155

thermostat ice tube retaining bracket thermostat ice tube tabs in ice tube retainer bracket engage holes in ice tube and hold tube in place

Front View, VU300

ice tube retaining bracket ice tube thermostat

16

Ice transport tube installation detail

install insulation on full run of tube

1

Dispenser

2

Evaporator

grommet

Heat end of transport tube in cup of 160 F

(71 C) hot water to soften (1) and spread with pliers before making connection (2).

install clamp behind lip on evaporator port

RIDE model ice machine start up procedure

The start-up procedure below is intended to ensure that ice machine is operating properly after installation has been made. Check each item listed and call factory immediately for assistance if you experience problems with unit.

Before turning on power

1. Turn on water to ice machine.

2. Push down on fl oat to force water through overfl ow chamber into evaporator drain pan and check for proper drainage of drain pan.

3. Check that fl oat valve shuts off incoming water when raised.

4. Check that hose clamp securely holds ice transport tube on evaporator port.

After turning on power

1. Turn on power to ice machine and confi rm that gearmotor, fan motor and compressor start immediately.

2. Check that ice begins to enter dispenser bin area within approximately 10 minutes.

3. Check that fl oat reservoir water level is approximately 3/8" (.95mm) below overfl ow during ice machine operation and adjust to this level if necessary.

4. Put ice against bin level thermostat in dispenser bin and check that compressor and fan motor shut down approximately 10 seconds after thermostat opens. Gearmotor should run for an additional 60 seconds.

5. Check that ice machine comes back on in approximately 20 minutes (bin signal must be present).

Operation

Cleaning and preventive maintenance (all models)

Preventive maintenance

Periodic cleaning of Follett’s ice machine system is required to ensure peak performance and delivery of clean, sanitary ice. The recommended cleaning procedures that follow should be performed at least as frequently as recommended and more often if environmental conditions dictate.

Cleaning of the condenser can usually be performed by facility personnel. Cleaning of the ice machine system, in most cases, should be performed by your facility’s maintenance staff or a Follett authorized service agent.

Regardless of who performs the cleaning, it is the operator’s responsibility to see that this cleaning is performed according to the schedule below. Service problems resulting from lack of preventive maintenance will not be covered under the Follett warranty.

Weekly exterior care

The exterior may be cleaned with a stainless cleaner such as 3M* Stainless Steel Cleaner & Polish or equivalent.

* 3M is a trademark of 3M Company.

17

Monthly condenser cleaning (air-cooled ice machine only)

1. Use a vacuum cleaner or stiff brush to carefully clean condenser coils of air-cooled ice machines to ensure

2. When reinstalling counter panels in front of RIDE model ice machines, be sure that ventilation louvers line up with condenser air duct.

Semi-annual evaporator cleaning (every 6 months)

Fig. 5

Solution A – Ice machine cleaner: Prepare one gallon (3.8L) of Follett SafeCLEAN™

Ice Machine Cleaner (one 7 oz packet) or equivalent. Solution temperature must be at least 120 F (49 C).

Warning: Most ice machine cleaners contain citric or phosphoric acid that can cause skin irritation. Read caution label on product and follow instructions carefully.

Solution B – Sanitizing solution: Prepare 2 gallons (8L)

Combine 1/4 oz. (7 ml) of bleach with 2 gal. (8 L) of hot water (at least 120 F (49 C) to form a 50 ppm solution of 5.25% sodium hypochlorite, or equivalent.

1. Disconnect power to ice machine.

2. Remove any ice machine panels required to gain access to water reservoir and electrical control box.

3. Turn compressor switch on electrical box of ice machine to OFF position.

4. Remove water reservoir cover and block up reservoir fl oat or close water supply valve.

5. Drain water from reservoir by releasing evaporator drain tube (Fig. 5.1) from fl oat reservoir bracket (Fig. 5.2), removing plug from drain tube and releasing

(unclamping) pinch valve (Fig. 5.3) (if equipped).

6. Following manufacturer’s instructions, prepare one gallon (3.8L) of Follett

SafeCLEAN

environmentally friendly ice machine cleaner (one 7 oz packet) or equivalent. Solution temperature must be at least 120 F (48.9 C).

WARNING: Most ice machine cleaners contain citric or phosphoric acid that

3

Fig. 6

1

2

1

can cause skin irritation. Read caution label on product and follow instructions carefully.

7. Plug drain hose, replace drain line in reservoir bracket and pour part of cleaning solution into reservoir (Fig. 5.4), fi lling it almost to overfl owing.

8. Remove stainless steel compression nozzle (Fig. 6.1) and drain lines. Submerge in a cup of cleaning solution while cleaning rest of system. (Flake ice machines have no compression nozzle and drain lines.)

CAUTION: To avoid potential pitting, do not soak parts in SafeCLEAN environmentally friendly ice machine cleaner for more than 45 minutes.

9. Restore power to ice machine (gearmotor will run; compressor and fan will not).

2

3

10. After 15 minutes, turn power OFF; drain solution from reservoir and evaporator.

11. Fill reservoir almost to overfl owing with clean, 120 F (48.9 C) water, and drain.

Repeat three times.

12. Following manufacturer’s instructions, prepare 1 gallon (3.8L) of 200ppm 5.25%

Sodium Hypochlorite solution (mix 1 oz household bleach to 2 gallons water) or equivalent. Solution temperature must be at least 120 F (48.9 C).

13. Rinse compression nozzle in clean water and submerge in a cup of sanitizing solution while following steps 14-19.

14. Connect ice transport tube (Fig. 6.2) directly onto evaporator outlet port (Fig. 6.3) without compression nozzle.

NOTE: If bin will not be cleaned at this time, place a large pan in bin storage area to catch ice or connect a separate ice transport tube to evaporator and divert ice into separate container.

15. Fill reservoir almost to overfl owing with sanitizing solution.

16. Restore power to ice machine (gearmotor will run; compressor and fan will not).

17. After 10 minutes, turn compressor switch to ON position.

18. As unit starts to make ice, continue to pour sanitizing solution into reservoir, maintaining level just below reservoir overfl ow.

19. Continue to make ice with sanitizing solution for 20 minutes.

20. Turn power to ice machine OFF.

21. Disconnect transport tube from evaporator outlet port. Rinse compression nozzle in clean water and reinstall on evaporator outlet. Reconnect transport tube to compression nozzle.

22. Drain any remaining sanitizing solution from evaporator.

23. Fill reservoir almost to overfl owing with clean, 120 F (48.9 C) water, and drain. Repeat three times. Re-clamp pinch valve, replace plug, and re-secure drain tube.

24. Unblock fl oat (or open water supply valve) and replace reservoir cover; restore power to ice machine and ensure compressor switch is in ON position. Make ice for at least 15 minutes to fl ush any remaining solution from system (RIDE model ice machines with long ice transport hoses may take longer to fl ush out). Discard this and all ice made during sanitizing.

25. Inspect evaporator drain pan and drain line and remove any accumulated scale build up.

26. Replace any panels removed prior to cleaning.

18

Service

Ice machine Operation (all models)

Follett’s ice machine consists of four distinct functional systems:

• Refrigeration system

• Harvesting system

• Electrical control system

These four systems work together to accomplish the production and harvesting of ice. A problem in any one of these systems will result in improper operation of the entire ice production cycle. When troubleshooting the ice machine, it is important to analyze the entire system operation to determine which system is not functioning properly, then pinpoint the component within that system that is malfunctioning. Determine what corrective action must be taken before making any adjustments or replacing any components.

The icemaking process

The Follett ice machine uses a stainless steel jacketed evaporator and operates on a continuous freezing cycle. Water is supplied to the evaporator from the water reservoir where the water level is controlled by a fl oat valve. This valve also shuts off the water supply when the ice machine is not running.

When the ice machine is running, a layer of ice forms on the interior surface of the evaporator. This ice is continuously removed by a slowly rotating (12 RPM) auger. The auger carries the ice upward into the cavity formed by the top bearing housing and the compression loop, where it is compressed to remove excess water. When the ice reaches the desired hardness it rotates within the cavity and is forced through a discharge port and compression nozzle and into the ice transport tube. The discharge tube and compression nozzle are slightly restricted to further compress the ice and produce the desired hardness. Note: MFD series fl ake ice machines have no compression nozzle. As the formation of ice continues, ice in the transport tube is pushed through the tube to the storage compartment in the ice dispenser or ice storage bin.

A solid state control board located in the electrical box of the ice machine controls the normal operation of the ice machine and monitors gearmotor torque. This control board will shut down the ice machine should an over-torque condition occur. It is very important that you familiarize yourself with the operational sequences detailed in this manual before attempting to service the ice machine.

Harvest system diagram

water inlet evaporator port ice transport tube compression nozzle auger

19

Technical specifi cations (all models)

Refrigeration system diagram

high side service port condenser high pressure switch filter dryer low side service port compressor evaporator thermostatic expansion valve high pressure vapor high pressure liquid low pressure liquid low pressure vapor

Refrigeration pressure data

Notes: 1) Water regulating valve is factory set at 225 PSIG head pressure.

2) Readings within 10% of above table values should be considered normal.

Air-cooled Ice machine

Refrigeration Pressure

Discharge Pressure/Suction Pressure

Ambient air temperature ˚F/˚C

Water-cooled Ice machine

Refrigeration Pressure

Discharge Pressure/Suction Pressure

Condenser inlet water temperature ˚F/˚C

°C,°@

60/16 80/27 100/38

˚F/˚C

50/10 70/21 90/32

50/10

174/23 245/31 237/37 psi 50/10

236/28 235/29 250/34 psi

70/21 174/23 244/30 326/38 psi 70/21

237/28 230/30 250/34 psi

90/32

190/25 265/32 347/40 psi

90/32

236/28 235/30 250/34 psi

Compressor data

Compressor current draw

Air-cooled

Ambient air temp. 60 F/15.6 C 70 F/21.1 C 80 F/26.7 C 90 F/32.2 C 100 F/37.8 C

Water-cooled

Water temp. at fl oat 50 F/10 C 60 F/15.6 C 70 F/21.1 C 80 F/26.7 C 90 F/32.2 C

6.6A 6.7A 6.7A 6.8A 6.9A

Locked rotor amps 58.8

20

Air-cooled ice machine capacity/24 hrs.

Ambient Air Temperature ˚F/˚C

60

16

70

21

F

C

50

10

80

27

90

32

60

16

510

232

482

219

454

206

424

193

394

179

70

21

454

206

435

198

417

190

385

175

354

161

80

27

397

180

389

177

380

173

347

158

313

142

90

32

335

152

329

150

323

147

297

135

270

123

100

38

273

124

270

123

266

121

247

112

227

103 lbs.

kg.

lbs.

kg.

lbs.

kg.

lbs.

kg.

lbs.

kg.

Water-cooled ice machine capacity/24 hrs.

Performance with new RG Group 1/2 ton coil

(Note: Data expressed in lbs/hr and kg/hr)

Ambient Air Temperature ˚F/˚C

F

C

50

10

60

16

70

21

80

27

90

32

60

16

451

204

423

192

394

179

371

168

352

160

390

177

361

163

342

155

70

21

447

202

413

187

380

172

352

160

333

151

80

27

442

200

409

185

Note: Nominal values – actual production may vary by ± 10%

90

32

437

199

399

181

371

168

342

155

323

146

361

163

333

151

309

140

100

38

428

194

394

179 lbs.

kg.

lbs.

kg.

lbs.

kg.

lbs.

kg.

lbs.

kg.

Gearmotor data

Gearmotor current

Locked rotor amps

2.25A (nominal)

14A

Electrical control system operation

MCD400A/WBT, MCD400A/WHT and MFD400A/WBT wiring diagram

Follett ice machines used on top of an ice storage bin have a slightly different circuitry. A diagram for these ice machines is shown below. The operational and diagnostic stages for these ice machines will be otherwise the same as the following stages 1 - 10.

WHITE

W

INPUT

POWER

B

G

WATER

SENSOR

GRD

WHITE

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

C

BLACK

S

R

ORANGE

M

S

L

1

BLACK

BLACK

RED

BLACK

BLACK BLACK

HIGH PRESSURE

SAFETY SWITCH

RED

START

RELAY

4

2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN T.O.L.

START CAP.

RED

BISON GEARMOTOR

OR

GEAR MOTOR

START

RUN

T.O.L.

LINIX GEARMOTOR

GRD

L1

L1

L2

L2

L2

L2

L2

CONTROL

BOARD

LINE VAC

COMMON

COMPRESSOR

FAN

DRIVE

21

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

WHITE

COMPRESSOR

SWITCH

BLACK

BIN T-STAT

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

Electrical control system operation

The D400A/W, MCD400A/WVS and R400A/W wiring diagrams which follow illustrate the circuitry of Follett ice machines used with ice dispensers. Both normal operation of the ice machine (Stages 1 - 6) and non-normal diagnostic sequences showing torque-out (Stages 7 - 10) for use in troubleshooting ice machine problems are shown.

Follett ice machines used on top of an ice storage bin have a slightly different circuitry. The operational and diagnostic stages for these ice machines will be otherwise the same as Stages 1 - 10 that follow.

Circuitry notes

When the ice machine is used with a dispenser it receives power from two sources – the main power supply and the bin control signal power from the dispenser. Disconnect both power sources before performing service. When performing electrical service, always use a meter to determine whether or not the components being serviced are energized.

High pressure cutout opens at 425 PSI and closes at 287 PSI (auto reset).

Compressor switch should read open in on position.

Compressor start relay is position sensitive. See label on start relay for proper orientation.

Bin signal may be 120V, 60Hz; 230V, 50Hz; or 24V, 60Hz. If bin signal is 24V, 60Hz, black bin signal wire must be moved from LINE VAC terminal to 24V terminal.

Flashing water LED at any time indicates that water signal to board had been lost for more than one second.

Ten-second delay: There is a 10 second delay in reaction to loss of water (WTR) or bin (B-E) signals. If signals are not lost for more than 10 seconds, no reaction will occur.

Normal operation – Stage 1

Power is supplied to L1 of the control board. The ice level control in the dispenser is closed and calling for ice, supplying signal voltage to the control board. The control board will now go through the start-up sequence. Less than 30 seconds will elapse as the water sensor located in the fl oat reservoir checks for water in the reservoir.

The Bin Empty LED (B-E) will be on.

INPUT

POWER

G

B

W

WHITE

GRD

WATER

SENSOR

WHITE

BLACK

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

GEAR MOTOR

START

RUN

T.O.L.

BISON GEARMOTOR

OR

LINIX GEARMOTOR

GRD

L2

L2

L2

L2

L1

L1

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

blk wire is on 24V)

BIN T-STAT

(MCD400A/WVS series –

22

Normal operation – Stage 2

The water sensor verifi es water in the fl oat. The Water OK LED (WTR) comes on. At the same time, the gearmotor, compressor, and condenser fan motor come on, lighting the Drive LED (DR) and compressor LED

(C). The compressor is started through a current style relay that is pulled in by the initial high current draw of the compressor. The gearmotor start windings are also energized through a current relay (or start capacitor). The B-E and WTR LED remain on.

INPUT

POWER

G

B

W

GRD

BLACK

COMPRESSOR

S

R

FAN

M

BLACK

WATER

SENSOR

WHITE

WHITE

RED

GRD

L2

L2

L2

L2

L1

L1

L2

CONTROL

BOARD

COMMON

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

T.O.L.

RED

C

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

COMPRESSOR

FAN

DRIVE

RED

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

RED

COMPRESSOR

SWITCH

WHITE

WHITE

START

RELAY

4 2

3

START CAP.

RED

GEAR MOTOR

START

RUN

T.O.L.

BISON GEARMOTOR

OR

LINIX GEARMOTOR

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

blk wire is on 24V)

BIN T-STAT

(MCD400A/WVS series –

Normal operation – Stage 3

After the initial high current draw drops off, the gearmotor start relay contacts open dropping out the start winding

(or start capacitor). As the compressor comes up to normal running speed, the compressor start relay contacts open, dropping out the start winding of the compressor. The ice machine is now in a normal icemaking mode. The ice machine will produce ice until the bin level control in the ice dispenser is satisfi ed. The B-E, DR, C and WTR

LEDs are all on.

INPUT

POWER

G

B

GRD

WATER

SENSOR

W

WHITE

BLACK

COMPRESSOR

T.O.L.

RED

C

S

R

FAN

M

BLACK

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

WHITE

WHITE

RED

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

BISON GEARMOTOR

OR

GEAR MOTOR

START

RUN

T.O.L.

LINIX GEARMOTOR

GRD

L2

L2

L2

L2

L1

L1

L2

CONTROL

BOARD

COMPRESSOR

FAN

DRIVE

COMMON

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

(MCD400A/WVS series –

blk wire is on 24V)

BIN T-STAT

23

Normal operation – Stage 4

Once the ice level control opens, the B-E LED goes out. After a 10 second delay the LED (C), compressor, and fan motor go off and the B-T LED comes on. (Should the ice level control not remain open for 10 seconds, the ice machine will continue to run.) The gearmotor continues to run for 60 seconds. The purpose of this function is to drive the remaining ice out of the evaporator and to boil off any refrigerant remaining in the evaporator.

INPUT

POWER

G

B

W

WHITE

GRD

WATER

SENSOR

WHITE

BLACK

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

BISON GEARMOTOR

OR

GEAR MOTOR

START

RUN

T.O.L.

LINIX GEARMOTOR

GRD

L1

L1

L2

L2

L2

L2

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

blk wire is on 24V)

BIN T-STAT

(MCD400A/WVS series –

Normal operation – Stage 5

The B-T LED will remain on for 20 minutes. The ice machine will not start while the B-T LED is on. To restart the ice machine for troubleshooting purposes, depress the reset button to clear the control board.

INPUT

POWER

G

B

W

WHITE

GRD

WATER

SENSOR

WHITE

BLACK

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

4

2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

BISON GEARMOTOR

OR

GEAR MOTOR

START

RUN

T.O.L.

LINIX GEARMOTOR

GRD

L2

L2

L2

L2

L1

L1

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

(MCD400A/WVS series –

blk wire is on 24V)

BIN T-STAT

24

Normal operation – Stage 6

When the dwell time of 20 minutes has expired, the B-T LED goes off. The ice machine will go through the normal start-up sequence when the bin level control signals the control board for ice. The WTR LED will remain on as long as the water sensor in the fl oat reservoir senses water.

INPUT

POWER

G

B

W

WHITE

GRD

BLACK

FAN

M

BLACK

WATER

SENSOR

WHITE

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

GEAR MOTOR

START

RUN

T.O.L.

BISON GEARMOTOR

OR

LINIX GEARMOTOR

L2

L2

L2

L2

GRD

L1

L1

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

(MCD400A/WVS series –

blk wire is on 24V)

BIN T-STAT

Diagnostic sequence – Stage 7

The 20 minute error LED (20M) is on indicating that the control board has sensed an over-torque condition (above

3A on the gearmotor) and shut the ice machine down. The 20M LED will remain on for 20 minutes after an overtorque condition has occurred. The ice machine will remain off as long as the 20M LED is on. When the 20M LED goes off, the control board will try to go through a normal start-up sequence. The WTR LED remains on as long as the water sensor in the fl oat reservoir senses water.

INPUT

POWER

G

B

W

WHITE

GRD

WATER

SENSOR

WHITE

BLACK

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

GEAR MOTOR

START

RUN

T.O.L.

BISON GEARMOTOR

OR

LINIX GEARMOTOR

GRD

L1

L1

L2

L2

L2

L2

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

blk wire is on 24V)

BIN T-STAT

(MCD400A/WVS series –

25

Diagnostic sequence – Stage 8

If the restart is successful the 20M LED goes off, the 60 minute timer LED (60M) comes on. The 60M LED will remain on for 60 minutes from restart. A lighted 60M LED tells the technician that the ice machine has experienced an over-torque condition. If the ice machine runs without problems for 60 minutes and no additional torque errors occur, the 60M LED will go off and the ice machine will continue normal operation.

INPUT

POWER

G

B

W

WHITE

T.O.L.

RED

C

GRD

BLACK

COMPRESSOR

S

R

FAN

M

BLACK

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

WATER

SENSOR

WHITE

WHITE

RED

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

BISON GEARMOTOR

OR

GEAR MOTOR

START

RUN

T.O.L.

LINIX GEARMOTOR

GRD

L2

L2

L2

L2

L1

L1

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

(MCD400A/WVS series –

blk wire is on 24V)

BIN T-STAT

Diagnostic sequence – Stage 9

The second error (2ND) LED will come on if an over-torque condition occurs while the 60M LED is still lighted.

The 2ND LED will indicate to the technician that two consecutive over-torque situations have occurred. The ice machine will shut down at this time and lock out. It will not restart unless the manual reset button is depressed.

INPUT

POWER

G

B

W

WHITE

GRD

WATER

SENSOR

WHITE

BLACK

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

GEAR MOTOR

START

RUN

T.O.L.

BISON GEARMOTOR

OR

LINIX GEARMOTOR

GRD

L1

L1

L2

L2

L2

L2

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

(MCD400A/WVS series –

blk wire is on 24V)

BIN T-STAT

26

Diagnostic sequence – Stage 10

If the water level in the fl oat reservoir drops to an unacceptable level, the WTR LED will go out, shutting the ice machine off. Also, the BT LED will come on, preventing the ice machine from restarting for twenty minutes. If water is restored, the WTR LED will come back on and fl ash to alert the technician that water to ice machine has been lost. The ice machine will then restart at the end of the 20 minute time delay. The fl ashing WTR LED can be cleared by pressing the reset button.

INPUT

POWER

G

B

W

WHITE

GRD

WATER

SENSOR

WHITE

BLACK

FAN

M

BLACK

WHITE

COMPRESSOR

T.O.L.

RED

C

RED

S

R

BLACK

ORANGE

M

S

BLACK

HIGH PRESSURE

SAFETY SWITCH

L

1

BLACK

BLACK

BLACK

START

RELAY

4 2

3

BLACK

YELLOW

GEAR MOTOR

START

RUN

T.O.L.

START CAP.

RED

GEAR MOTOR

START

RUN

T.O.L.

BISON GEARMOTOR

OR

LINIX GEARMOTOR

GRD

L1

L1

L2

L2

L2

L2

L2

CONTROL

BOARD

COMMON

COMPRESSOR

FAN

DRIVE

PWR

RESET

DR

C

20M

60M

2ND

WTR

B-T

B-E

RED

RED

COMPRESSOR

SWITCH

WHITE

RED

BIN SIGNAL

FROM DISPENSER

JUNCTION BOX

blk wire is on 24V)

BIN T-STAT

(MCD400A/WVS series –

27

Refrigeration system (all models)

All service on refrigeration systems must be performed in accordance with all federal, state and local laws. It is the responsibility of the technician to ensure that these requirements are met. Recharging ice machine to other than factory specifi cations will void the warranty.

R404A ice machine charge specifi cations

T400A, MCD400A, MFD400A, R400A, D400A (air-cooled) 19oz (539g) R404A

T400W, MCD400W, MFD400W, R400W , D400W (water-cooled) 9oz (255g) R404A

Refrigerant replacement requirements

1. Non-contaminated refrigerant removed from any Follett refrigeration system can be recycled and returned to the same system after completing repairs. Recycled refrigerant must be stored in a clean, approved storage container. If additional refrigerant is required, virgin or reclaimed refrigerant that meets ARI standard 700-88 must be used.

2. In the event of system contamination (for example, a compressor burn out, refrigerant leak, presence of noncondensibles or moisture), the system must be repaired, evacuated and recharged using virgin or reclaimed refrigerant that meets ARI standard 700-88.

3. Follett Corporation does not approve of recovered refrigerants. Improper refrigeration servicing procedures will void the factory warranty.

Evacuation

Evacuate the system to a level of 500 microns. When the 500 micron level is reached, close valves and both manifold and shut down the vacuum pump. Allow the system to sit for approximately 20 minutes. During this period the system pressure should not rise. If the system pressure rises and stabilizes there is moisture in the system and further evacuation is needed. If the pressure continues to rise check the system for leaks.

Air temperature1 50 F/10 C 100 F/37.8 C

Water temperature2 40 F/4.4 C 90 F/32.2 C

1Ambient air temperature is measured at the air-cooled condenser coil inlet.

2Ambient water temperature is measured in the ice machine fl oat reservoir.

Ice capacity test

Ice machine production capacity can only be determined by weighing ice produced in a specifi c time period.

1. Replace all panels on ice machine.

2. Run ice machine for at least 15 minutes.

3. Weigh and record weight of container used to catch ice.

4. Catch ice for 15 or 20 minutes.

5. Weigh harvested ice and record total weight.

6. Subtract weight of container from total weight.

7. Convert fractions of pounds to decimal equivalents (ex. 6 lbs 8oz = 6.5 lbs).

8. Calculate production using following formula:

1440 min. x wt. of ice produced

Total test time in minutes

= Production capacity/24 hr. period

9. Calculated amount per 24 hours should be checked against rated capacity for same ambient and water temperatures in Ice Production Tables.

28

Service procedures

Evaporator disassembly (Fig. 7)

1. Disconnect power to ice machine.

2. Shut off water to ice machine.

3. Drain evaporator and fl oat tank.

4. Disconnect plastic tubing from evaporator water inlet, drain pan stub, compression nozzle tubing and reservoir overfl ow tubing from secured clip.

5. Disconnect ice transport tube from compression nozzle.

Note: No compression nozzle on MFD400 series fl ake ice machines.

6. Loosen nut and remove upper vee band coupling from top of evaporator.

7. Lift top bearing assembly straight up with a slight rotating motion and remove.

8. Remove ice compression loop located at top of auger.

9. Lift auger straight up and out of evaporator.

10. Remove nut and lower vee band coupling from bottom of evaporator.

11. Lift evaporator to clear bottom bearing assembly.

12. Loosen hex head bolt in side of mounting base with 5/16 wrench and lift lower bearing assembly.

13. Remove condensate shield.

14. Remove 4 Allen head machine screws holding mounting base to gearbox.

15. If replacing evaporator, remove compression nozzle from evaporator port.

Fig. 7

Evaporator reassembly (Fig. 7)

1. Clean gearmotor boss, output shaft and shaft well.

2. Install drain pan and evaporator mounting base.

3. Fill gearmotor shaft well with food-grade grease (Fig. 8).

4. Install condensate shield and seat against gearmotor boss.

5. Install mounting base O ring in groove in evaporator mounting base.

6. Lower bottom bearing assembly into evaporator mounting base.

7. While maintaining a downward pressure on bottom bearing assembly, tighten hex head bolt with a 5/16 wrench.

8. Position evaporator over lower bearing assembly and align grooves with pins in bearing assembly.

9. Install vee band clamp and nut and tighten to 70 in/lb.

10. Place auger in center of evaporator and rotate to mate with drive pin.

11. Install ice compression loop, orienting loop as shown in Fig. 7.

Note: No compression nozzle on MFD400 series fl ake ice machines.

12. Install upper bearing and seal assembly, rotating bearing to slip pin. into auger slot.

13. Install upper vee band clamp and nut and tighten to 70 in/lb.

14. If evaporator was replaced, reinstall compression nozzle.

Fig. 8

Gearmotor replacement (Fig. 8)

1. Disassemble evaporator as described above.

2. Disconnect the wire connectors.

3. Remove 4 screws holding gearmotor mounting plate to base of ice machine and lift gearbox and motor clear of ice machine (Fig. 8.1).

4. Remove machine screws holding mounting plate to motor (Fig. 8.2).

5. Install new motor in reverse order.

29

1

2

apply grease here

Troubleshooting chart

Flashing water LED at any time indicates that water signal to board had been lost for more than one second.

Ten-second delay: There is a 10 second delay in reaction to loss of water (WTR) or bin (B-E) signals. If signals are not lost for more than 10 seconds, no reaction will occur.

Problem Indicators/possible cause Corrective action

1. Ice machine will 1. No power to unit.

2. Open bin level control.

3. Water OK LED (WTR) not on.

4. 20M or 2ND LED is on indicating that fi rst

1. Check that unit is plugged in, circuit breakers are on.

2. Adjust or replace ice level control.

3. Check reservoir for water, restore compressor, or second torque error has occurred.

gearmotor, and fan 5. Gearmotor locked up (immediate torque motor inoperative.

error indicated by LEDs when board is reset).

6. Open coil on gearmotor start relay causing an immediate torque error.

water to unit.

4. See Problem #6.

5. Repair or replace gear motor.

6. Replace gearmotor start relay.

2. Compressor will not run.

gearmotor and fan motor run.

3. Unit cycles intermittently.

1. Condenser coil plugged causing open overload or high pressure cut-out.

2. Defective starting capacitor.

3. Defective starting relay.

4. Open motor winding.

5. No power output from compressor output terminal on control board.

1. Clean condenser coil and replace overload if necessary.

2. Replace start capacitor.

3. Replace relay.

4. Check winding resistance and replace compressor if necessary.

5. Check terminal connection and replace control board if necessary.

1. Float reservoir running dry, sensing probe 1. Check water supply to fl oat and fl oat signalling for system to shut down.

operation. PC board will have fl ashing

WTR LED.

compressor, gear motor, and fan motor cycle.

4. Low ice production.

Poor quality ice.

1. Dirty condenser coil.

2. Restricted air fl ow to condenser coil.

3. Mineral coated evaporator.

4. High ambient water supply and/or air temperature.

5. Improper exhaust air provisions.

6. Faulty expansion valve.

7. Low refrigerant charge.

2. Remove obstruction.

3. Clean evaporator.

4. Precool water and/or install air duct per Follett installation manual.

5. Provide proper exhaust air provisions per Follett installation manual.

6. Replace expansion valve.

7. Check for leaks; repair, evacuate, and weigh in correct charge.

8. Check that TEV sensing bulb is securely clamped in place and not damaged; check that insulated bulb cover is in place. Replace TEV if necessary.

9. Replace compressor.

5. Water leaks from bottom of evaporator.

1. O ring seal broken.

1. Replace O ring.

30

Troubleshooting

Problem

Indicators/possible cause

11. Intermittent noises from evaporator.

1. Mineral build-up on evaporator surface.

Corrective action

6. Ice machine runs for short period of time and shuts down on torque error.

20M or 2nd LED are lit.

1. Kink in ice transport tube.

2. Bin level control remains in closed position.

3. Ice transport tube ruptured internally.

4. Worn evaporator bearings.

5. Faulty gearmotor start relay. Ice machine torques out within 5 seconds of start-up.

6. Torque-out occurs when storage bin fi lls to capacity.

7. Evaporator is iced up on the outside.

No ice production.

1. Gearmotor running but no output rotation.

2. Float reservoir empty.

3. Air bubble in water supply line. Water in reservoir but not in evaporator.

compressor, gearmotor and fan motor running.

8. Compressor cycles 1. Compressor start relay in wrong position.

intermittently.

2. High pressure cutout open due to high head pressure.

3. Clogged or dirty condenser coil.

gearmotor and fan motor run.

1. Check for broken gearmotor output shaft or damaged gearbox.

2. Check for defective water sensor

(water OK (WTR) LED remains on even when fl oat empty or probe removed from water).

3. Purge air from line.

1. Position relay with arrow or word “top” facing up.

2a. Check supply and temperature of water to w/c condenser.

2b. Check discharge pressure and adjust water regulator value.

3. Clean condenser coil.

4. Provide inlet and exhaust air provisions per Follett ice machine installation manual.

5. Replace compressor.

9. Unit runs but not making ice.

1. Clogged or dirty condenser coil.

2. Compressor not pumping.

3. Low refrigerant charge.

1. Clean condenser coil.

2. Replace compressor.

3. Check for leaks; repair, evacuate, and weigh in correct charge.

compressor, gearmotor and fan motor running.

10. Compressor and fan motor will not run. Gearmotor runs.

1. Compressor switch in OFF position.

2. No output on compressor and fan motor terminals on control board.

3. Failed fan motor causes high pressure cut-out to open.

1. Eliminate kink and check that tube routing complies with Follett ice machine installation manual.

2. Adjust or replace control.

3. Replace complete run of ice transport tube.

4. Inspect bearings for roughness or binding and replace if necessary.

5. Replace gearmotor start relay.

6. Ensure that ice contacts bin thermostat before backing ice up in transport tube. Reference dispenser manual for proper thermostat and ice tube mounting.

1. Turn compressor switch on.

2. Replace control board.

3. Replace fan motor.

1. Clean evaporator with liquid IM cleaner.

31

Replacement parts

Order parts online www.follettice.com

Evaporator

Part #

502735

502736

502110

Description

Coupling, vee band, includes nut

Bearing assembly, top

Loop, ice compression, beveled

Reference #

1

2

(all ice machines except MFD400 series –see fl aker-specifi c components below) 3

502737 Auger

502725

(all ice machines except MFD400A/W – see fl aker specifi c components below)

Evaporator (includes insulation jacket, 502740)

4

5

500496

502738

501063

O ring, bearing housing

Bearing assembly, bottom (includes O rings and condensate shield)

O ring, mounting base

501080

502733

502227

502730

502729

502220

502221

502727

502226

500680

502739

502740

502742

502744

502743

502775

Screw, Allen 1/4 20 x 1/2 (set of 4)

Mounting base, evap. (includes 501063)

Bolt, mounting base

Gearbox & motor assembly

Mounting base, gearbox

Compression nozzle, with double drain (no nozzle in MFD400 series)

Compression nozzle, with single drain (no nozzle in MFD400 series)

Drain pan, evaporator

Clamp, compression nozzle and screw

Tubing, compression nozzle drain(s) (sold by foot)

501111 Grease, Chevron SRI-2, 14oz

Bracket, drain hose

Insulation jacket, evaporator

Relay, start, gearmotor

Drip cover, gearmotor

Evaporator & gearmotor assembly

Oil, gearmotor (1 pint)

10

11

12

13

8

9

6

7

Not shown

14

15

16

17

18

Not shown

19

20

21

22

Not shown

Not shown

Flaker-specifi c components

Part #

00124123

00124115

Description

Auger (with paddle)

Loop, compression, notched

Reference #

3

4

32

Evaporator

15

14

18

17

5

2

1

4

3

18

19

22

6

9

7

1

8

10

11

12

16

20

Order parts online www.follettice.com

21

13

33

Air-cooled ice machines

Order parts online www.follettice.com

2

9

7

1

13

14

15

16

11

17

3

4

12

8

6

10

5

34

500672

501188

502782

502731

502728

500376

502920

501820

502734

502924

502925

502830

502698

00988238

Part #

502724

502116

501986

500504

00141440

502079

502078

502220

502221

502726

502727

502732

501966

502729

502730

501191

Air-cooled ice machines

Order parts online www.follettice.com

Description

Drier

Water sensor

Reservoir mounting bracket

Float valve & reservoir

Drain kit with Agion, evaporator

Reference #

1

2

Not shown

3

4

5

6 Evaporator (see page 32 and 33 for complete breakdown)

Tubing, polypropylene, reservoir supply (sold by foot)

Fitting, plastic, fl oat valve (includes sleeve & stem)

Compression nozzle, with double drain

Not shown

Not shown

Not shown

Not shown Compression nozzle, with single drain

Valve, expansion, thermal

Drain pan, evaporator

High pressure cutout

7

8

9

Tubing, evaporator drain, 3/4" (19mm) ID x 1" (26mm) OD

(sold by the foot)

Mounting bracket, gearbox

Gearbox & motor assembly, 115V, 60Hz

Tubing, plastic, food grade, 1/2" (13mm) ID (sold by foot)

Motor, fan, 115V, 60Hz

Bracket, fan motor

Overload, compressor, 115V, 60Hz

Compressor, 115V, 60Hz

Base – L400A

Strainer, water, threaded connections

Strainer, push-in connections

Shroud, condenser coil

Water inlet & drain assembly, brass

Water inlet fi tting, plastic

Water inlet elbow, plastic

Not shown

10

11

12

13

14

15

Not shown

16

17

Not shown

Not shown

Not shown

Not shown

Not shown

Not shown

Jacket, insulation, TXV

Bracket, ice tube entry

Pinch clamp

Not shown

Not shown

Not shown

Not shown

35

Water-cooled ice machines before serial number C57245

18

13

16

1

15

9

12

14

17

20

4

7

Order parts online www.follettice.com

5

8

10

3

11

6

2

19

36

Part #

502724

500537

501810

502116

500504

501986

502079

502078

502220

502221

00141440

502726

502727

501966

502730

502729

501191

500672

501188

502782

502731

Water-cooled ice machines before serial number C57245

500376

502920

502734

502924

502925

502348

502732

502830

00143941

502698

Description

Drier

Valve, water regulating (includes 501810)

Iso-washer (for water regulating valve)

Water sensor

Float valve & reservoir

Reservoir mounting bracket

Tubing, polypropylene, reservoir supply (sold by foot)

Fitting, plastic, fl oat valve (includes sleeve & stem)

Compression nozzle, with double drain

Compression nozzle, with single drain

Evaporator (see page 32 and 33 for complete breakdown)

Drain kit with Agion, evaporator

Valve, expansion, thermal

Drain pan, evaporator

Tubing, evaporator drain, 3/4" (19mm) ID x 1" (26mm) OD (sold by foot)

Gearbox & motor assembly, 115V, 60Hz

Mounting bracket, gearbox

Tubing, plastic, food grade, 1/2" (13mm) ID (sold by foot)

Motor, fan, 115V, 60Hz

Bracket, fan motor

Overload compressor, 115V, 60Hz

Compressor, 115V, 60Hz

Strainer, water, threaded connections

Strainer, push-in connections

Water inlet and drain assembly, brass

Water inlet fi tting, plastic

Water inlet elbow, plastic

Assembly, drain, single fi tting

High pressure cutout

Jacket, insulation, TXV

Fitting, condenser drain

Bracket, ice tube entry

Order parts online www.follettice.com

13

14

Not shown

15

9

10

11

12

16

17

Not shown

Not shown

Not shown

Not shown

Not shown

Not shown

Not shown

18

Not shown

19

20

Reference #

1

2

Not shown

Not shown

3

4

Not shown

Not shown

Not shown

Not shown

5

8

Not shown

6

7

37

Water-cooled ice machines after serial number C57244

15

13

16

1

12

9

16

7

5

Order parts online www.follettice.com

8

10

3

11

14

4

6

2

17

38

Part #

502724

500537

501810

502116

500504

501986

502079

502078

502220

502221

00141440

502726

502727

501966

502730

502729

501191

502782

502731

500376

502920

502734

502924

502925

502348

502732

502830

204584

00143941

502698

00988238

Water-cooled ice machines after serial number C57244

Description

Drier

Valve, water regulating (includes 501810)

Iso-washer (for water regulating valve)

Water sensor

Float valve & reservoir

Reservoir mounting bracket

Tubing, polypropylene, reservoir supply (sold by foot)

Fitting, plastic, fl oat valve (includes sleeve & stem)

Compression nozzle, with double drain

Compression nozzle, with single drain

Evaporator (see page 32 and 33 for complete breakdown)

Drain kit with Agion, evaporator

Valve, expansion, thermal

Drain pan, evaporator

Tubing, evaporator drain, 3/4" (19mm) ID x 1" (26mm) OD (sold by foot)

Gearbox & motor assembly, 115V, 60Hz

Mounting bracket, gearbox

Tubing, plastic, food grade, 1/2" (13mm) ID (sold by foot)

Overload compressor, 115V, 60Hz

Compressor, 115V, 60Hz

Strainer, water, threaded connections

Strainer, push-in connections

Water inlet and drain assembly, brass

Water inlet fi tting, plastic

Water inlet elbow, plastic

Assembly, drain, single fi tting

High pressure cutout

Jacket, insulation, TXV

Ty-rap (2 required)

Fitting, condenser drain

Bracket, ice tube entry

Pinch clamp

Order parts online www.follettice.com

9

10

11

Not shown

12

13

14

Not shown

Not shown

Not shown

Not shown

Not shown

Not shown

Not shown

15

Not shown

16

17

Not shown

Not shown

Reference #

1

2

Not shown

Not shown

3

4

Not shown

Not shown

Not shown

Not shown

5

8

Not shown

6

7

39

Electrical components

Part #

502780

501588

502331

502116

502392

500514

501959

1

2

EARTH

L1

L1

L2

L2

L2

L2

L2

COMP.

FAN

DRIVE

3

Description

Capacitor, start, compressor, 115V, 60Hz

Relay start, compressor, 115V, 60Hz

Board, control circuit, 115V, 60Hz

Water sensor

Switch, on/off, compressor

Bin thermostat (MCD400A/WBT, MCD400A/WHT, MFD400A/WBT and MFD400A/WHT only)

Board, stand off control (4 required)

I.D.

LABEL WATER

PROBE

POWER

RESET

SOFTWARE

I.D.

DR

C

20M

60M

2ND

WTR

B-T

B-E

LINE VA

Order parts online www.follettice.com

4

5

Reference #

1

2

3

Not shown

4

Not shown

5

40

Order parts online www.follettice.com

Water fi lter kits and cartridges

00130229 Follett QC4-FL4S water fi lter system (includes FL4S primary cartridge and head, coarse

pre-fi lter and head, pressure gauge, fl ushing valve; assembled and installed on mounting

bracket)

00130245

00130211

Follett FL4S primary replacement cartridge

Everpure coarse pre-fi lter cartridge

Ice machine cleaner

00132001 SafeCLEAN environmentally-friendly cleaner, carton of 24 x 7 oz packets

Miscellaneous

501860

501781

502775

501111

500377

501921

502783

502781

501425

501986

501759

501858

501786

501702

502051

502052

502333

502334

502235

502336

502794

502795

502796

502797

502798

502799

502800

502801

502802

502803

502874

502875

00918045

Regulator, water pressure (25 psi)

Oil, gearmotor, 1 pint

Grease, Chevron, SRI-2, 14 oz tube

Clamp, ice tube

Grommet, ice tube

Duct – 2" (51mm)

Gasket, air duct

Grille

Cord and plug (female), dispenser bin signal (F1105A/W)

Cord and plug (female), dispenser power (all 25, 50, 110 series dispensers)

Cord and plug (female), dispenser bin signal (all 25 and 50 series top mount and

Control board adapter (R404A to R12)

Cord and twist-lock plug (male), ice machine bin signal

Cord and twist-lock plug (male), ice machine power

Plug, twist-lock, two lead, male

Plug, twist-lock, two lead, female

Plug, twist-lock, three lead, male

Plug, twist-lock, three lead, female

Panel, right hand, louvered, R400A, MCD400A/W

Cover, top, R400A/W, MCD400A/W

Panel, front utility, R400A, MCD400A

Panel, top front, R400A,MCD400A

Panel, left hand & rear, R400A/W, MCD400A/W

Panel, front, R400W, MCD400W

Filler, base, R400A/W, MCD400A/W

Power cord, R400, MCD400

Bin signal cord, R400, MCD400

Grille, condenser, T400A and MCD400AHT

Filter, air, T400A and MCD400AHT

Assembly, front cover

41

Replacement ice machine ordering matrix

Order parts online www.follettice.com

Dispenser models Replacement

Dispensers with top mounted ice machines

50CT400A & 50HT400A

50HT400W & 50HT400W

ice machine model

D400A

D400W

25CT 400A & 25HT400A

25CT400W & 25HT400W

D400A

D400W

110CT400A D400A

110CT400W D400W

Dispensers with remote ice machines

25CR400A & 25HR400A

25CR400W & 25HR400W

50CR400A & 50HR400A

50CR400W & 50HR400W

R400A

R400W

R400A

R400W

110CR400A R400A

110CR400W R400W

All U150/VU155 series with air-cooled ice machines MCD400A

All U150/VU155 series with water-cooled ice machines MCD400W

All VU300 series with air-cooled ice machines MCD400A

All VU300 series with water-cooled ice machines MCD400W

Dispenser models Replacement ice machine model

Freestanding dispensers with ice machines in the base

25FB400A D400A

25FB400W D400W

50FB400A D400A

50FB400W D400W

110FB400A D400A

110FB400W D400W

Nugget ice machine on top of bin

MCD400ABT MCD400ABT

MCD400WBT MCD400WBT

Flake ice machine on top of bin

MFD400ABT MFD400ABT

MFD400WBT MFD400WBT

42

43

Harmony, SafeCLEAN, RIDE, Symphony and Vision are trademarks of Follett Corporation.

44

Toll free (877) 612-5086 • +1 (610) 252-7301 www.follettice.com

208600R20

3/12

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