User manual SCOTSMAN CME1656

CME1356 and CME1656 INTRODUCTION This product manual contains the information needed for the setup, installation, initial start up, sanitation and maintenance of this ice machine. Keep it for future reference. There are 2 models covered in this manual: Be certain that the information applies to the model in question. If no model is listed, the information applies to all models. This manual is organized in the same way as the expected use of the machine, it begins with specifications, goes thru unpacking and setup, shows where everything is; continues with initial start up, then describes how it works. After that is the sanitation section, followed by service diagnosis and repair. · CME1356, having 5 evaporators · CME1656, having 6 evaporators TABLE OF CONTENTS Specifications . . . . . . . . . . . . . . . . . PAGE 2 Air Cooled Layout . . . . . . . . . . . . . . . PAGE 3 Sanitation and Cleaning . . . . . . . . . . . . PAGE 24 Water Cooled Layout . . . . . . . . . . . . . PAGE 4 Additional Maintenance . . . . . . . . . . . . PAGE 25 Pre-Installation . . . . . . . . . . . . . . . . . PAGE 5 Additional Maintenance: Water Distributors . . PAGE 26 Location & Assembly . . . . . . . . . . . . . PAGE 6 Stacking . . . . . . . . . . . . . . . . . . . . PAGE 7 Stacking . . . . . . . . . . . . . . . . . . . . PAGE 8 Bin Control: Installation . . . . . . . . . . . . PAGE 9 Service Diagnosis: Controller Diagnostic Light Bin Control . . . . . . . . . . . . . . . . . . . PAGE 10 Analysis . . . . . . . . . . . . . . . . . . . . PAGE 29 Plumbing . . . . . . . . . . . . . . . . . . . . PAGE 11 Service Diagnosis . . . . . . . . . . . . . . . PAGE 30 Electrical . . . . . . . . . . . . . . . . . . . . PAGE 12 Service Diagnosis: Components . . . . . . . PAGE 31 After Utility Connections . . . . . . . . . . . . PAGE 13 PTCR . . . . . . . . . . . . . . . . . . . . . PAGE 32 Component Description and Function . . . . . PAGE 14 Operational Characteristics: CME1356 . . . . PAGE 33 System Controller . . . . . . . . . . . . . . . PAGE 15 Operational Characteristics: CME1656 . . . . PAGE 34 Initial Start Up . . . . . . . . . . . . . . . . . PAGE 16 Removal and Replacement . . . . . . . . . . PAGE 36 Adjustments . . . . . . . . . . . . . . . . . . PAGE 17 Removal and Replacement: System Controller PAGE 37 Adjustments . . . . . . . . . . . . . . . . . . PAGE 18 Removal and Replacement: Water Level Sensor . . . . . . . . . . . . . . . . . . . . . . . . PAGE 37 How To Operate The System Controller . . . PAGE 19 Removal and Replacement: Fan Blade and/or Fan How The Electronic Cuber Works . . . . . . . PAGE 20 Motor . . . . . . . . . . . . . . . . . . . . . PAGE 38 How The Electronic Cuber Works . . . . . . . PAGE 21 Access Valves . . . . . . . . . . . . . . . . . PAGE 39 Technicians Only: Freeze Cycle Operational Liquid Charging . . . . . . . . . . . . . . . . PAGE 40 Sequence . . . . . . . . . . . . . . . . . . . PAGE 22 Before Calling for Service . . . . . . . . . . . PAGE 41 Additional Maintenance: Inlet Water Valve Screen . . . . . . . . . . . . . . . . . . . . . PAGE 27 Additional Maintenance: Ice Sensors, Condenser . . . . . . . . . . . . . . . . . . . . . . . . PAGE 28 Technicians Only: Harvest Cycle Operational Sequence . . . . . . . . . . . . . . . . . . . PAGE 23 Parts Lists and Wiring Diagrams are Located in the Center of this Manual May 2000 Page 1 CME1356 and CME1656 Specifications These ice machines are designed to be installed indoors, in a controlled environment. They can operate satisfactorily under a wide variety of conditions. Do NOT operate the machine in temperatures it has not been designed for. Do NOT operate the machine above or below the voltage limits for the particular model. Do NOT operate the machine with too little or too much water pressure. Voltage note: The control system transformer in the control box of this ice machine has two primary taps, one for 208 volt power and one for 240 volt power. The machine ships with the power supply connected to the 208 volt tap. Change to the 240 volt tap when the voltage supplied to the unit is greater than 229 volts All models will fit a standard, 48" wide Scotsman Ice Storage Bin. Some examples are BH900, BH1100, BH1300, BH1600. There may be other bins that can be used, check Scotsman's sales literature for application information. Slope front bins must have an internal baffle like the BH900. Baffle must be approximately in the position shown in the diagram on page 5. Scotsman reserves the right to make design changes and/or improvements at any time. Specifications and designs are subject to change without notice. Dateplates on the ice machine contain charge and electrical requirements. Always go by the dataplate information. The table below is for reference. Operational Limits Minimum Air Temperature Water Temperature Water Pressure Voltage (60 Hz model) Voltage (50 Hz model) 50oF. 40oF. 20 psi 198 207 Maximum 100oF. 100oF. 80 psi 253 253 Inlet water flow required is 2.7 GPM. A stacking kit, for like models, is KSCME6-LG-B Basic Information Model Number CME1356AS-32 Model Series Dimensions W" x D" x H" (w/o bin) Basic Electrical Condenser Type Minimum Maximum Refrigerant Circuit Fuse Charge Ampacity Size (R-404A) 26.7 23.9 23.9 17.8 14.9 14.9 26.7 23.9 23.9 26.7 23.9 23.9 17.8 14.9 14.9 26.7 23.9 23.9 30 30 30 20 20 20 30 30 30 30 30 30 20 20 20 30 30 30 64 ounces 62 ounces 58 ounces 64 ounces 62 ounces 58 ounces 64 ounces 62 ounces 58 ounces 64 ounces 62 ounces 58 ounces 64 ounces 62 ounces 58 ounces 64 ounces 62 ounces 58 ounces A thru E 48 ½ x 24 x 28 208-230/60/1 Air Cooled 208-230/60/1 Water Cooled 208-230/60/1 Water Cooled 208-230/60/3 Air Cooled 208-230/60/3 Water Cooled 208-230/60/3 Water Cooled 230/50/1 230/50/1 230/50/1 Air Cooled Water Cooled Water Cooled same CME1356WS-32 A thru E same CME1356WS-32 F CME1356AS-3 CME1356WS-3 CME1356WS-3 CME1356AS-6 CME1356WS-6 CME1356WS-6 CME1656AS-32 A thru E same A thru E same F same A thru E same A thru E same F same A thru D same same 208-230/60/1 Air Cooled 208-230/60/1 Water Cooled 208-230/60/1 Water Cooled 208-230/60/3 Air Cooled 208-230/60/3 Water Cooled 208-230/60/3 Water Cooled 230/50/1 230/50/1 230/50/1 Air Cooled Water Cooled Water Cooled CME1656WS-32 A thru E same CME1656WS-32 F CME1656AS-3 CME1656WS-3 CME1656WS-3 CME1656AS-6 CME1656WS-6 CME1656WS-6 A thru E same A thru E same F same A thru E same A thru E same F same November 2004 Page 2 CME1356 and CME1656 Air Cooled Layout 26.10 in 66.3 cm MINIMUM BIN TOP OPENING 6.00 in MINIMUM FOR 15.2 cm UTILITY CONNECTIONS PLAN VIEW 18.75 in ICE 47.6 cm OPENING 6.00 in 15.2 cm MINIMUM FOR AIR VENTILATION 4.20 in 10.7 cm ICE OPENING 10.15 in 25.8 cm 3.81 in 9.7 cm 6.00 in 15.2 cm MINIMUM FOR AIR VENTILATION .88 DIA. KNOCKOUT ELECTRICAL INLET CONDENSER FINS 2.50 in 6.4 cm WATER INLET 3/8" FLARE 23.87 in 60.6 cm BACK VIEW DUMP VALVE DRAIN 3/4" F.P .T. 5.87 in 14.9 cm 12.30 in 31.2 cm 1.96 in 5.0 cm 2.82 in 7.2 cm May 2000 Page 3 CME1356 and CME1656 Water Cooled Layout 26.10 in 66.3 cm MINIMUM BIN TOP OPENING 6.00 in MINIMUM FOR 15.2 cm UTILITY CONNECTIONS PLAN VIEW 18.75 in 47.6 cm ICE OPENING 6.00 in 15.2 cm MINIMUM FOR AIR VENTILATION 4.20 in 10.7 cm ICE OPENING 10.15 in 25.8 cm 3.81 in 9.7 cm .88 DIA. KNOCKOUT ELECTRICAL INLET 2.50 in 6.4 cm CONDENSER DRAIN 1/2" F.P .T. INLET WATER 3/8" FLARE CONDENSER INLET 3/8" F.P .T. 23.30 in 59.2 cm 21.87 in 55.5 cm 23.87 in 60.6 cm 11.87 in 30.1 cm BACK VIEW DUMP VALVE DRAIN 3/4" F.P .T. 5.96 in 15.1 cm 18.67 in 47.4 cm 5.87 in 14.9 cm 2.46 in 6.2 cm 3.58 in 9.1 cm May 2000 Page 4 CME1356 and CME1656 Pre-Installation Other Applications: Check Scotsman sales information for recommendations regarding applications. Check the nameplate for electrical requirements. The nameplate is located on the back of the ice machine. While the model and serial number are on the nameplate, a serial number plate is located at the front of the machine, near the purge valve.. Water: There is no such thing as pure water. All water contains some impurities. There are two ways water carries the impurities: suspended and dissolved. Suspended solids can be filtered out. Dissolved solids must be diluted or treated. Water filters are recommended to remove suspended solids. Some filters have treatment in them for suspended solids. Check with a water treatment service for a recommendation. Cube Ice machines use more water than what ends up in the bin as ice. While most water is used during ice making, a portion is designed to "rinse" out the water system to keep hard water scale from clogging up the machine. That water rinse, combined with water filters, prolongs the times between needed water system cleaning. Service Technicians: All models covered here come set from the factory at a "standard" water rinse, which is compatible with typical water conditions. They may be adjusted to "Minimum" or "Maximum" water rinse after start up. If the prior ice machine worked acceptably well with the local water conditions, leave the machine at the factory setting. If severe water conditions are present, and water filters do not solve the problem acceptably, adjust the machine to use more water. If water conditions are excellent, adjust the machine to use less water. See the Adjustments section. Note: Water use adjustments are customer convenience adjustments; they are NOT factory defects and are NOT covered by warranty. Nameplate Serial Number Plate Note: Slope front bins must have an internal baffle. Scotsman's BH900 has the required baffle. Baffle must be approximately in the position shown in the diagram. Baffle Side View May 2000 Page 5 4.0" 12.0" CME1356 and CME1656 Location & Assembly The air cooled models take room temperature air in from the left side and the front and discharge warm air out the back. A 6 inch minimum clearance on the back, and both sides is required for the proper operation and service of the air cooled model. Cabinet Panel Removal: Note: The top panel holds the upper edges of the side panels in place. 1. Remove the front panel by removing the two screws connecting the front panel to the machine. 2. Lift up at the front edge and push the top panel back until it releases from the tabs connecting it to the back panel. 3. Remove the screws at the front edge of the left side panel, and pull forward until it releases from the tabs connecting it to the back panel. Unpacking and Assembly: Begin with unpacking the ice storage bin. Remove the carton, and using part of the carton as a cushion, tip the bin on its back to remove the skid and attach the legs or casters. Note: Stacked applications may not use casters. Return the bin to an upright position. Check the bin top gasket for gaps and tears, fill any in with food grade sealant prior to placing the ice machine on the bin. Level the top edge of the bin front to back and left to right. If the ice machine has not been unpacked, do so now. Remove the carton from the skid. After removal of the shipping straps, lift the ice machine off the skid directly onto the bin. Note: The machine is heavy! Use a mechanical hoist if necessary. Secure the ice machine to the bin with the hardware provided (two metal straps and 4 bolts). Locate the Bin Thermostat Bracket and hardware. Retain for later use. Aiir cooled: Remove baffle from its shipping position and secure to the back of the cabinet. Follow the directions on the baffle for proper installation. August 2003 Page 6 CME1356 and CME1656 Stacking - Kit KSCME6-LG-B Only like models may be stacked. Begin after the bottom unit has been placed on the ice storage bin and secured. Stacking requires heavy duty leg kits. Casters are NOT recommended. Note: Instructions are for either model. Bottom Machine: 1. Remove front panel, left side panel, and top panel. 2. Remove & discard top cover from over the freezing compartment. 3. Install gasket materials to freezing compartment: Cut about 22" of gasket material from the roll in the kit. Apply it to the back side top edge of the freezing compartment. Cut two lengths of gasket material to fit the right side top edge of the freezing compartment and apply them. 4. Place a bead of food grade sealant to the top of the back wall's gasket. 5. Place the shield bracket (has a large hole in the center) from the kit over the center of the freezing compartment. Insert the tabs of the bracket into slots on the back of the unit. 11. Remove two existing screws and secure the bracket to the: freezing compartment, back panel and front channel with the 2 existing screws and 1 large and 4 small screws from the kit. Both Machines: 12. Place the top ice machine onto the bottom one. Secure together with hardware from the top machine. Remove left front and left side panels. 13. At the back of the ice machines, on the compressor end, remove the upper knock-out from the bottom machine and the lower knock out from the upper machine. 14. Place a strain relief (from the kit) into each hole. 15. Insert wire harness from kit thru strain-relief and hole in upper corner of the lower ice machine's back panel. NOTE: Harness is marked which end goes to which machine. Bottom Machine: 16. Remove harness from controller terminal 7 and bin thermostat. 17. Route wire harness in lower ice machine to the controller. Connect to terminal #7. Plug the two free wires onto the thermostat terminals #1 and #2. 18. Return left side panel to its original position on 6. Secure bracket at the front with screws from the the lower ice machine. kit. Top Machine: 7. Hang the plastic shields from the bracket installed in the prior step. Use the slots in the 19. Remove harness from controller terminal 7. shields to hang them from the stainless steel 20. Route wire harness thru upper unit's lower hooks. knock-out hole and strain relief and continue Note: The notch in the bottom of the shield goes internally to the controller. Plug wire onto terminal 7 to the front. of the controller. Note: The tabs on the shields must fit inside the ice outlet port. 8. Check the position of the shields. They must move freely and be vertical. Note: The suction line may need to be moved slightly so the tubing clears the bracket & shields. 9. Place a bead of food grade sealant onto the top left edge of the freezing compartment. 10. Install the front-to-back support bracket over the left edge of the freezing compartment. 21. Return all panels and covers to their normal positions. 22. Complete the balance of the installation. Service Notes: A. The shields must be positioned so they hang vertically and move freely left to right. Their purpose is to guide the ice past the bottom machine's evaporators and into its cube port. B. The drain lines from each ice machine must be kept separate. May 2001 Page 7 CME1356 and CME1656 Stacking Upper Unit Gasket on Plastic Wall of Lower Unit Gasket for Metal Edges of Bottom Unit Front-to-Back Bracket Shield Hanger Bracket Mounting Straps and Hardware Shield May 2001 Page 8 CME1356 and CME1656 Bin Control: Installation The bin control is a thermostat. It must be field installed after the ice machine has been placed on the bin. Before starting, remove the left front panel and any baffle in the bin. 1. Locate bin thermostat bulb. 2. Route bulb thru routing tube (located between the compressor and the reservoir). 3. Locate bin thermostat bracket. 4. Carefully position the thermostat bulb on the bracket (see the diagram on the next page). 5. Fasten the bracket to the bottom of the ice machine with the two 3-pronged knobs supplied with the unit. 6. Pull back into the ice machine any excess capillary tubing. 7. Return the baffle to the bin and continue with the installation. Bin Thermostat Bulb Note: If the machine is located at an altitude higher than 2,000 ft., adjust the thermostat by removing the plastic cover and rotating the adjustment screw per the table. Bin Thermostat Altitude Correction Table CW Turns of Range Screw (under plastic cover) Feet 2000 4000 6000 Turns 55o 160o 250o Feet 8000 9000 10000 Turns 340o 385o 405o Use This Table to Adjust Thermostat Bin Thermostat Body Thermostat Bulb Routing Tube Route Bin Thermostat Bulb Into Bin May 2000 Page 9 CME1356 and CME1656 Bin Control Bin Thermostat Bracket Bin Thermostat Capillary Tube Insert Bulb Tip Here Mount Thermostat Capillary Tube Here Attach Thermostat Bulb to Bracket Three-Pronged Knob Minimize Excess Tube in Bin Thermostat and Bracket Attach Bracket to Bottom of Ice Machine May 2000 Page 10 CME1356 and CME1656 Plumbing All models require an adequate potable water supply and a gravity drain. The recommendations for tubing are: All Drain Tubing Material must be RIGID. Flexible tubing will eventually cause a restricted drain. Drain: Air cooled models have 1 gravity drain connection, a 3/4" FPT fitting at the back of the cabinet. Use only RIGID TUBING. Flexible tubing may be easily kinked or become cracked. The drain tube must be vented at the back of the cabinet. Use an 18" high vent. · Water supply to be 3/8" OD. · Drain to be 3/4" OD. Note: When replacing a prior ice machine, do not take a short cut and reuse the old inlet and drain system. INSTALL A NEW SYSTEM. Supply: Air cooled models have 1 water supply connection, Water cooled models have an additional condenser a 3/8" male flare at the back of the cabinet. Connect drain. It is a ½ " FPT fitting at the back of the to cold potable water that has adequate pressure. cabinet. Do NOT vent this drain. Note: Using water supply tubing smaller than 3/8" will cause severe operational issues. Water cooled models have an additional 3 8 " FPT condenser inlet connection at the back of the cabinet. Water Filters: The ice storage bin will have a drain out the back or base, depending upon the model. The drain for the ice machine and the ice storage bin must be SEPARATE or the ice machine's drain water may run into the bin and MELT THE ICE. Insulation is recommended for the ice machine reservoir and bin drains. The water filters must flow at least 2.7 GPM or they Follow all applicable codes will cause severe operational issues. Check with the filter manufacturer. When replacing a prior ice machine, do NOT assume that the water flow capacity of the filter will be adequate. Vent Water Inlet Potable Water Inlet Drain Bin Drain Floor Drain May 2000 Page 11 CME1356 and CME1656 Electrical All models must be installed with the correct wire size and type per the National Electric Code. Locate the nameplate on the back of the cabinet and find the numbers for Voltage, Phase, Minimum Circuit Ampacity and Maximum Fuse Size. Either fuses or HACR type circuit breakers may be used. Electrical connections are made in the junction box in the back of the cabinet. 1. Remove the junction box cover. 2. Knock out 1 hole for a field supplied strain relief. 3. Install wires and strain relief per code. 4. Connect to wires and secure ground wire to ground screw inside the junction box. Follow all Local, State and National codes. Electrical Power Supply Junction Box Condenser Water Supply Condenser Drain Water Cooled Model Shown May 2000 Page 12 CME1356 and CME1656 After Utility Connections 1. Level the cabinet, use the leg levelers on the end of the legs to adjust the cabinet height. 2. Wash out the bin. If desired, the interior of the bin could be sanitized. 3. Locate the ice scoop (if supplied) and have it available for use when needed. Final Check List: ___ 1. Is the unit located indoors in a controlled environment? ___ 2. Is the unit located where it can receive adequate cooling air? ___ 3. Has the correct electrical power been supplied to the machine? ___ 4. Have all the water supply connections been properly made? ___ 5. Have all the drain connections been properly made? ___ 6. Has the unit been leveled? ___ 7. Have all unpacking materials been removed? ___ 8. Has the bin control been installed? ___ 9. Is the water pressure adequate? ___ 10. Have the drain connections been checked for leaks? ___ 11. Has the bin interior been wiped clean or sanitized? ___ 12. Have any water filter cartridges been replaced? May 2000 Page 13 CME1356 and CME1656 Component Description and Function Reservoir: Contains the water for ice making. Water Inlet Valve: Opens to allow water into the reservoir. Water Level Sensor: Controls the size of the ice cube by measuring how much water is used in a cycle. It consists of a float, stem and electric eye. The stem will move slightly when the pump is on, this is normal. As the machine makes ice the reservoir water level will fall and the visible portion of the stem will slide down thru the slot in the sensor body. Evaporators/Freezing Compartment: Location of the evaporators. Ice forms on the evaporators and is released when warmed up during the harvest cycle. The freezing compartment is fully insulated for maximum efficiency. Cube Deflectors: The slots in the inclined deflectors let the water falling from the evaporators back into the reservoir, but when ice falls during harvest, the ice slides off into the bin. Refrigeration Service Access Valves: Only to be used by a certified technician. Allows access to the refrigeration system for diagnostic information. Water Pump: Forces the water from the reservoir to the top of the evaporators. The motor is separated from the reservoir water to minimize contact with the water. Hot Gas Valve: Closed during freeze, it opens during harvest to divert hot discharge refrigerant gas into the inlet of the evaporators. Purge Valve: Opens during the early part of the harvest cycle to drain the reservoir. Ice Sensor: A photo-electric eye set, located at the front and back of the cube port. Hot Gas Valve Evaporators Cube Deflector Cube Port Inlet Water Valve Purge Valve Reservoir Water Pump Water Level Sensor May 2000 Page 14 CME1356 and CME1656 AutoIQ Controller Indicator Lights: Cycle Definitions: · Bin Full: On when bin is full, goes on and · · · · · · off as ice falls during a harvest cycle. Freeze: On when the unit is in the Freeze cycle, blinks when a freeze mode is pending. Harvest: On when the unit is in the Harvest cycle. Clean: On when the unit is in the Clean cycle, blinks when preparing for a clean mode. Off: On when the unit has been switched off, blinks when the machine is preparing to shut off. Water: On when the controller has identified a problem with the water system. Refrigeration: On when the controller has identified a problem with the refrigeration system. · Freeze: The refrigeration system is operating to remove heat from the evaporators. The compressor, fan motor (if air cooled) and water pump are ON. · Harvest: The refrigeration and water systems are operating to harvest the ice cubes. While the compressor is on for the full cycle, the water pump will be off at the beginning and inlet water valve will switch off before the end. · Clean: The Inlet Water Valve opens to fill the reservoir. The Water Pump starts. The Clean indicator light is switched ON. A manually initiated rinse flushes the system. LOW VOLTAGE IN/OUT WATER VALVE HOT GAS VALVE PURGE VALVE TIMER CONTACTOR COIL HI VOLTAGE IN/OUT WATER PUMP 8 9 STACKING and/or THERMOSTAT FUTURE USE RESERVOIR & DISCHARGE LINE THERMISTORS 7 6 5 4 3 2 1 PUSH BUTTON CONTROL SWITCHES INDICATOR LIGHTS: BIN FULL FREEZE HARVEST CLEAN ICE SENSOR ICE SENSOR RESERVOIR WATER LEVEL SENSOR FACTORY USE OFF DIAGNOSTIC LIGHTS: WATER REFRIGERATION May 2000 Page 15 CME1356 and CME1656 Initial Start Up 1. Remove the front panel. 2. Locate the AutoIQ Controller. ·The Bin Full indicator light will go on and off as ice falls from the evaporators. 6. Machines are shipped from the factory with the purge level set to accommodate average water conditions. To achieve optimal machine performance, set the purge level to the minimum setting. 3. Switch on the electrical power. The controller's indicator lights all flashed on briefly. Blue controllers also begin to flash their red lights and the Freeze light will be on. After 20 seconds the red lights stop flashing, the Freeze light goes out, the Bin Full and Off lights switch on and then the Note: While the amount of water purge is Bin Full light goes out. The Off light will be glowing. adjustable, only those installations with a water supply known to be excellent (very low TDS) 4. Open the water supply valve. should adjust to the minimum setting. See page 18 5. Push and release the Freeze switch (the Freeze for purge adjustment instructions. indicator light blinks until the compressor starts). 7. The machine's correct cube size should result in Initial Start ice falling from the evaporator in vertical strips of 8 ·The Freeze light will begin to blink. - 10 cubes; the top 2 cubes might fall individually. ·The Hot Gas Solenoid valve will be open. 8. After about 6 minutes the machine will return to ·The Purge valve will be open. ·The Water pump is on. ·The hot gas and purge valves close and the ·The compressor starts. inlet water valve opens to fill the reservoir and shuts off when the reservoir is full. a freeze cycle. Note: After the first harvest, the controller will adjust harvest time as needed to release all ice. 9. The water valve will re-fill the reservoir at the beginning of freeze. 10. Collect and discard the first batch of ice. Rinse out the bin. 11. Fill out the Customer Evaluation and Warranty Registration. Send it to Scotsman. 12. Replace the left front panel. 13. Inform the user of the location and telephone number of the local service company. Also inform the user of the required maintenance of the machine. Notes On Operation: 1. The bin control signals the ice machine to shut off whenever the bin becomes full, but the machine will not stop until it has finished the next harvest cycle. This last harvest cycle will be longer than the rest. 2. After the bin has filled the unit will not be able to restart for 4 minutes. However, if needed, the Freeze button may be pushed to restart the unit. For example: If ice is removed from the bin immediately after the machine has filled up and shut off, the Bin Full light will be ON and the machine will not restart for 4 minutes. 3. If the bin controls sense a bin full signal before any water is used (float stem up), the machine will shut off on bin full Freeze Cycle: ·The Freeze indicator light will be on. The machine will stay in a Freeze cycle for many minutes. ·The pump will stop for a few seconds a few minutes into the freeze cycle. ·The fan motor (of air cooled models) will begin to turn and soon warm air will be forced out the back of the cabinet. ·The freeze cycle will continue until the water level in the reservoir drops to its factory set point; the first time that happens in the freeze cycle will cause the controller to open the inlet water valve to refill the reservoir, the second time in the freeze cycle that this set point is reached starts the Harvest Cycle. Harvest Cycle: ·The Harvest indicator light will be ON, ·The hot gas valve will open. ·The purge valve will be open for 74 seconds. ·The water pump will stop. It will restart in less than 74 seconds. ·The purge valve closes and the Inlet water valve will open for a short time to add water. March 2003 Page 16 CME1356 and CME1656 Adjustments If there was a problem during Initial Start Up: If an error light came on, check the following. 1. Water error. A water error could have been determined by the AutoIQ Controller if the inlet water valve does not fill the reservoir, or if the water pump does not start and lower the water level. 2. Refrigeration error. A refrigeration error could have been determined by the AutoIQ Controller if the water temperature did not drop during the freeze cycle. The controller will next check the compressor discharge temperature, If the discharge temperature is too low, the refrigerant error light will be switched on, and the machine will Shut Down. Note: Reset and restart the machine by pushing and releasing the Off push button switch, and then pushing and releasing the freeze push button switch. Splash Panel Positioning: It is critical that the lower splash panel be properly positioned. If removed during installation or start up, check that it has been properlyreturned to its original position. Insert Bottom Tabs in 5th Slot of Cube Deflectors Insert Into Slot Lower Inner Splash Panel Lower Splash Panel Positioning May 2000 Page 17 CME1356 and CME1656 Adjustments How to adjust the water cooled discharge pressure Water cooled models use a water regulating valve to control how much cooling water flows thru the water cooled condenser. At the top of that valve, located in the back of the ice machine, is an adjustment stem. To Adjust: 1. Attach a refrigeration manifold gage to the discharge access valve. 2. While the unit is in the freeze cycle, determine the discharge pressure, it should be about 245 PSIG. 3. If needed, rotate the adjustment stem to increase or decrease the pressure: A. To increase discharge pressure (reduce water flow) rotate the stem counter-clockwise. B. To decrease the discharge pressure (increase water flow) rotate the stem clockwise. Remove the manifold when done. Note: The water outlet temperature should be between 100-110 when the valve is properly set. How to Adjust the Amount of Water Purge Adjustment is done by use of the control buttons on the AutoIQ Controller. Examine the next section to become familiar with the AutoIQ Controller before beginning. 1. If the machine is on, push and hold the OFF button for more than 3 seconds, then release it. This switches the machine Off. 2. Push and hold the OFF button for more than 3 seconds (just until all lights flash on) then release it. Do not hold it in it too long. 3. Examine the green lights. They should have all flashed once, then certain ones will have turned on to indicate which purge level the machine is set at. There are 5 levels of purge available: · 1. Maximum Purge is when All 5 lights are ON. Use for extreme water conditions. Note: This setting may extend the Harvest cycle and reduce capacity. 2. Heavy Purge is when these 4 lights are ON: Freeze, Harvest, Clean, Off. Use for severe water conditions. 3. Standard Purge (factory setting) is when these 3 lights are ON: Harvest, Clean, Off. Use for moderate to severe water conditions. 4. Moderate Purge is when these 2 lights are ON: Clean, Off. This is for typical water conditions. 5. Minimum Purge is when this light is ON: Off. For excellent water conditions. · · · · Thermostatic Expansion Valve: The TXV is not adjustable, do not attempt to adjust it. Adjust by pushing and releasing the Freeze button. Pushing and releasing the Freeze button increases the purge one level up to the maximum, then it goes to the minimum. 4. The machine will automatically restart after 60 seconds of no switch inputs, or restart the machine by pushing in and holding the Off button for more than 3 seconds, then releasing it. The unit will then be Off. From there the machine may be placed in a freeze cycle by pushing and releasing the Freeze button. Typical Ice Level When Unit Shuts Off May 2000 Page 18 CME1356 and CME1656 How To Operate The AutoIQ Controller The AutoIQ Controller is a microprocessor based device that receives input from several sources and switches various components on and off. Its manual control is thru the use of the Push Button Control Switches 1. Freeze Button. Pushing and releasing this button starts or restarts the machine. The AutoIQ Controller remembers what cycle it was last in and returns to that cycle. 2. Harvest Button: Pushing and releasing this button will cause the machine to go directly to a Harvest Cycle. Can be done from Freeze or Off. The machine will switch Off at the end of the Harvest cycle. 3. Clean Button: Pushing and releasing this button will cause the machine to empty the reservoir, refill and leave only the water pump on for circulation of ice machine cleaner. After the ice machine cleaner has circulated for about 10 minutes a second push of this button will switch on the rinsing system to flush out the dissolved scale and ice machine cleaner. 4. Off Button: Pushing and releasing this button will switch the machine OFF at the end of the next cycle. If the button is pushed and HELD for more than 3 seconds, the unit will switch off immediately. To Reset Machine (machine off, error light on): First push and release the Off button, then push and release the Freeze button. 8 9 7 6 5 4 3 2 1 PUSH BUTTON CONTROL SWITCHES INDICATOR LIGHTS: BIN FULL FREEZE HARVEST CLEAN OFF DIAGNOSTIC LIGHTS: WATER REFRIGERATION May 2000 Page 19 CME1356 and CME1656 How The Electronic Cuber Works Controller Inputs: 1. Reservoir water temperature. This is measured by a thermistor located in the water pump outlet. 2. Discharge line temperature. This is measured by a thermistor located on the compressor discharge line. 3. Water level. This is measured by an infrared sensor and float. The float rises and falls with the water level, and switches the sensor on and off as it moves. 4. Bin fill level. A thermostat signals to the controller if ice is needed or not, based on the temperature at the thermostat's sensing bulb. 5. Time. The controller measures and compares how long it takes for various events to happen. It stores that data for future reference. Controller Outputs: A. 24 volt: · 1. Lights · 2. Inlet water valve · 3. Hot Gas Valve · 4. Contactor Coil B. High Voltage · 1. Water Pump · 2. Purge Valve · 3. Air cooled Fan Motor May 2000 Page 20 CME1356 and CME1656 How The Electronic Cuber Works This section is intended for the technician. It is not necessary for the normal operation and maintenance of the machine. Refrigeration System: The refrigeration system is similar to that of most commercial cube ice machines. Heat is removed The AutoIQ Controller operates the ice machine by from the water and discharged out the condenser during the freeze cycle. As liquid refrigerant passes monitoring several input measures and switching thru the Thermostatic Expansion Valve, it enters the various loads on and off. bottom of the evaporators, and will form on the bottom first. When cubes need to be released Water System: (Harvest) the Hot Gas Valve is opened and hot Water flows into the ice machine during the discharge gas flows directly from the compressor to harvest cycle thru the inlet water valve. The water the evaporator inlets. This warms up the valve will NOT be open the complete length of the evaporators and the surface of the ice frozen to the harvest cycle. The water pump forces water to the evaporator surface melts. Ice then falls into the bin. top of the evaporators, both in the Freeze and Harvest cycles. Un-frozen water falls thru the cube deflector and back into the reservoir. As water is turned into ice, the water level in the reservoir falls, and at the point where the cubes are fully formed, the Water Level Sensor indicates to the AutoIQ Controller that it is time to begin the Harvest cycle. During the Harvest cycle, water again enters the water reservoir, and a purge valve opens to drain the reservoir and dilute the concentration of accumulated minerals. The purge valve is opened for a fixed amount of time, but the water pump does not start right away, but at a time determined by the AutoIQ Controller's purge setting. The higher the purge setting, the sooner the water pump Hot Gas Valve will start, and more water will be drained out. Evaporators Cube Deflector Cube Port Inlet Water Valve Purge Valve Reservoir Water Pump May 2000 Page 21 Water Level Sensor CME1356 and CME1656 Technicians Only: Freeze Cycle Operational Sequence Assuming the machine has been operational, the Freeze cycle begins with the end of the Harvest Cycle: restarts, the inlet water valve opens to refill the reservoir. 8. As the machine makes ice, the water level in the reservoir will ultimately fall to the Harvest Level . The first time that happens during a freeze cycle prompts the controller to re-fill the reservoir. The next time it happens, the unit will begin to go into a harvest cycle. Air cooled models will switch off the fan motor a few AutoIQ Controller Operation, Beginning freeze: seconds before harvest begins. 1. Switches on the Freeze indicator light and shuts Note: If the freeze cycle exceeds the preset Maximum (36 minutes), the AutoIQ Controller will off the hot gas valve. Shut Down on a Refrigeration Error. 2. Opens the water valve to top off the reservoir. Water must fill the reservoir within 250 seconds or 9. At the end of Freeze cycle: the controller shuts the machine down. It will · Water level = below harvest position automatically try to restart in 20 minutes. · Condenser fan will be off 3. Measures the discharge temperature. · Water inlet valve will be off 4. Starts the fan motor (air cooled only). The · Water pump will be ON Controller checks the discharge temperature and · Compressor will be ON cycles the fan every on for 30 seconds and off for · Hot gas valve will be off 20 seconds if the temperature is low. If the discharge temperature exceeds the design maximum, shuts the machine down on a Refrigeration Error. 5. Checks for a "bin full" signal throughout the cycle. At this point Harvest begins and the AutoIQ Controller switches the Harvest indicator light ON. Restarts: If restarting after shutting off because the bin was full, the first freeze cycle sequence is like this: · · · · · Condenser fan is OFF Water Inlet Valve is CLOSED Water Pump may be ON Compressor is ON Hot Gas Valve is OPEN 6. Measures the reservoir water temperature. If the 1. Purge valve is open. machine is operating correctly, the reservoir water temperature will fall at a standard rate. The AutoIQ 2. Pump starts. Controller will be checking to see if the water 3. Purge valve closes. temperature fall matches that rate. If not, it re-checks the discharge line temperature. If too low, it Shuts Down on a Refrigeration Error. If the discharge temperature is acceptable, the water system is checked by shutting off the water pump and determining if the water level goes up enough. If it does not, it is assumed that there is a water pump problem and the machine Shuts Down on a Water Error. If the water level does "measure up" the water pump is restarted and the AutoIQ Controller then measures how long it takes to lower the water level. If the water level does not fall, the machine Shuts Down on a Water Error. 7. Once per cycle the machine will shut off the water pump. It only does this when the water temperature reaches a preset minimum. The pump will only be off for a few seconds. After the pump 4. Water valve opens to fill the reservoir. 5. Compressor starts. Note: If there is a power interruption, after power is restored the machine will restart, go thru a brief Freeze cycle and then go thru a 6 minute Harvest cycle. The Freeze light will be blinking - even when the machine is in harvest. Error Restarts: The machine automatically attempts to restart 50 minutes after a shut down. If another problem occurs in the next cycle, the machine will attempt one more restart. If another problem occurs in the next cycle, the machine will be off and must be manually reset. May 2000 Page 22 CME1356 and CME1656 Technicians Only: Harvest Cycle Operational Sequence Harvest The (air cooled model) fan is off. The purge valve opens, and will remain open for 74 seconds. If the bottom unit is in harvest and receives a signal from the top unit that it is also in Harvest, the bottom unit will stay in harvest for about 6 minutes. If the bottom unit is shut off, but its controller still has power, the top unit may continue to operate. If The water pump shuts off, it will restart in less than the bottom unit's power is shut off, the top unit will 74 seconds, depending upon the Purge Level set. shut down on bin full at the end of the next cycle. If the top unit's power is shut off, it does not impact The water pump restarts and pumps out water thru the lower unit. the open purge valve until the valve closes. An error shut down on one unit does not affect the other. Either may be switched off at the controller. The inlet water valve then opens for about 30 seconds to add some water. Diagnostic Lights and Manual Resets During the Harvest Cycle, ice will be falling from The controller will shut the machine off if a the evaporators and between the ice sensor's malfunction is sensed. The Controller will restart the electric eyes. The AutoIQ Controller monitors the machine 2 times, with a 50 minute interval between ice falling and stays in the Harvest Cycle until ice restarts. If a malfunction is still present after the quits going thru the electric eyes. second restart, the machine will then shut off and The maximum harvest time is 14 minutes. The first must be manually reset. During the restart interval, the machine will be off and a diagnostic code Harvest after a restart will be a long one to establish a base line, then the actual time it took to indicated. release the ice is used to determine the length of The exception to this is lack of water. The machine the next harvest cycle. will always try to re-fill the reservoir every 20 minutes. If no cubes fall (or are sensed) by the end of Maximum Harvest Time, the machine senses a Diagnostic Code Table refrigeration error. If the next cycle also produces a refrigeration error, the machine Shuts Down. Note: The last harvest cycle before shutting off on bin full is 6 minutes long. The machine will not restart for 4 minutes after switching off on Bin Full, unless the freeze button is pressed. Note: If during a Bin Full shut down, the machine has not restarted for 12 hours, the compressor will run for 30 seconds to clear the oil of refrigerant. Continuous Run Time: A unit that operates 24 hours a day 7 days a week is too small for the user's needs. To maintain harvest integrity, the controller will extend the harvest time to 6 minutes minimum every 15th consecutive harvest cycle. Bin Thermostat (for those units so equipped): In normal ambients the thermostat will react to ice on the bulb in a few seconds. Reaction after removal will take about a minute under normal conditions, and longer in colder rooms. Stacked Units: May 2000 Page 23 Is ON all the time Both On all the time If a Diagnostic Light Blinks once and repeats Blinks twice and repeats Blinks three times and repeats Water Light Water pump did not start Lack of water fill Refrigeration Light Very long ice harvest No harvest of ice High Discharge Temperature Check for low discharge temperature or long freeze cycle not used Water valve leaking thru rapidly Check for thermistor set unplugged or failed CME1356 and CME1656 Sanitation and Cleaning It is the User's responsibility to keep the ice machine and ice storage bin in a sanitary condition. Without human intervention, sanitation will not be maintained. Ice machines also require occasional cleaning of their water systems with a specifically designed chemical. This chemical dissolves mineral build up that forms during the ice making process. Sanitize the ice storage bin as frequently as local health codes require, and every time the ice machine is cleaned and sanitized. The ice machine's water system should be cleaned and sanitized a minimum of twice per year. In Place Cleaning of the Ice Machine Water System: 1. Remove all ice from the bin. 2. Remove the front panels. 3. Push and release the Harvest button (this releases any ice that may be on the evaporators and warms them up). 4. Wait for the machine to finish the Harvest cycle (the machine will stop). 5. Remove the the insulated plastic evaporator cover, the two inner splash panels (part number 02-3680-01 and the one above it), both cube deflectors, and the ice sensors. Place the splash panels and the cube deflectors in a separate container. Place the ice sensors in the reservoir, but be sure that the ends of the connecting wires are not in the water. 6. Push and release the Clean button. The Clean indicator light will be blinking, and the pump will restart. 7. Pour 24 ounces of Scotsman Ice Machine Cleaner into the reservoir water. Return the evaporator cover to its normal position. 8. Mix a solution of 8 ounces of Scotsman ice machine cleaner and 1 gallon of warm (95-115oF.) water. Use the solution to scrub the splash panels and cube deflectors in the separate container. Scotsman Ice Machine Cleaner contains acids. Acids may cause burns. If concentrated cleaner comes in contact with skin, flush with water. If swallowed, do NOT induce vomiting. Give large amounts of water or Milk. Call Physician immediately. Keep out of the reach of children. 9. After the ice machine cleaner has circulated for 10 minutes, push and release the Clean button. This starts the rinsing process. The Clean indicator light will be ON. Note: The rinse process flushes any residual cleaner out of the ice machine's water system. 10. Continue the rinsing process for 20 minutes, then push the off button to switch the machine off. 11. Go to the next step to sanitize the machine or go to step 19 to finish the cleaning process. 12. Mix 2 gallons of Sanitizer solution. Follow local codes for Sanitizer. Note: A possible sanitizing solution may be made by mixing 1 ounce of liquid household bleach with 2 gallons of warm (95-115oF.) potable water. 13. Push and release the Clean button again. 14. Pour 24 ounces of Sanitizer solution into the reservoir water. 15. After the solution has circulated for 10 minutes push and release the Clean button. This starts the rinse process. Sanitize the ice storage bin while waiting. 16. Continue the rinsing process for 20 minutes, then push the off button to switch the machine off. 17. Remove the evaporator cover and spray or wash all interior surfaces of the freezing compartment including the evaporator cover with sanitizer solution. 18. Thoroughly immerse the splash panels and cube deflectors in the sanitizing solution. 19. Return the ice sensors, splash panels and cube deflectors to their original positions. 20. Return the evaporator cover to its original position. Push and release the Freeze button. 21. Return the front panels to their normal positions and secure them to the machine with the original screws. May 2000 Page 24 CME1356 and CME1656 Additional Maintenance To drain reservoir completely (if desired): 1. Remove front panel. 2. Push and hold the Off button. To Sanitize the Ice Storage Bin 1. Remove all ice. 2. Remove baffle. 3. Push and hold the Clean button for 3 seconds to 3. Switch ice machine OFF or wait for it to be in a activate the purge valve. cleaning cycle. 4. Push and release Freeze button. 5. Replace front panel. 4. Mix a 1 gallon solution of warm (95-115oF.) water and sanitizer. Follow local codes for sanitizer. 5. Wash or spray the entire interior of the ice storage bin with the sanitizer solution. This includes the bottom of the ice machine and the inside of the door, the door gaskets (if any) and door frame. 6. Pour excess sanitizer into the bin to flush the drain system. 7. If the approved sanitizer requires a rinse, rinse all interior surfaces with potable water. May 2000 Page 25 CME1356 and CME1656 Additional Maintenance: Water Distributors It may become necessary to remove the water distributors from the top of the evaporator and clean (de-mineralize) them outside of the ice machine. 1. Remove front panes. 2. Push and release the OFF button. 3. Remove the evaporator covers. 4. Pull the tab at the front of the evaporators forward and lift the front of the water distributors up until they clear the tab. 9. Examine the water distributors. Although they are made of a material that is resistant to mineral build up, some may be present. Soak or scrub the distributors in or with a solution of Scotsman Ice Machine Cleaner and warm potable water. 10. Return the water distributors to their normal installed position. 11. Return the two inner splash panels and the evaporator cover to their original positions. Check That Water Channels Are Clear Water Distributors Remove Distributors as a Set 5. Repeat for all evaporators and distributors. 6. Pull the distributors forward as a set. Manifold 12. Push and release the clean button to flush the water system. Insert Bottom Tabs in 5th Slot of Cube Deflectors Pull Manifold Out 7. Remove the distributors from the manifolds. 8. Examine the top of the evaporators. The Water Distribution Channels must be free from mineral build up. If build up is evident, scrub the channels with Scotsman Ice Machine Cleaner and a plastic bristle brush. 13. After the machine stops, push and release the Freeze button. 14. Replace the front panel. May 2000 Page 26 CME1356 and CME1656 Additional Maintenance: Inlet Water Valve Screen The inlet water valve has a screen on its inlet side to keep debris from flowing into the valve. In some cases, this screen may become clogged or restricted by debris build up. Check for the proper water flow: Flow rate is 2.7 G.P.M. 1. Remove left front panel. 2. Obtain a measuring cup and a watch. 3. Pull the water discharge tube out of the reservoir and place it in the cup. 4. Push and release the Harvest button. 5. If working properly, the water valve will fill a 16 oz cup in about 3 seconds. Be prepared to push the Off button. If it does not, the water valve inlet or other water device is restricted. To Check the Inlet Water Valve Screen. 1. Disconnect the electrical power. 2. Shut off the water supply. 3. Remove the left front panel. 4. Unplug the electrical connection of the inlet water valve. 5. Remove the screws holding the inlet water valve to the cabinet. 6. Remove outlet tube from inlet water valve. 7. Rotate inlet water valve from inlet fitting and remove valve from machine. 8. Examine the inlet screen, if dirty, brush off screen. Note: Screen is not replaceable, and may only be removed by taking off the covering bracket. The bracket forms part of the inlet water system, and must be water tight to the valve body, removal is not recommended. 9. Reverse to reassemble. Air Filter Replacement 1. Remove the left front panel. 2. Remove a screw holding one clip to the front panel. 3. Replace the air filter. Note: Filter size is 20 x 20 x 1. Use a like replacement, equal to UL class 2, 377A. 4. Return the front panel to its original position. Secure it to the cabinet. May 2000 Page 27 CME1356 and CME1656 Additional Maintenance: Ice Sensors, Condenser The ice sensors use a system of infrared emitting and receiving components to sense ice. They are located at the bottom of the ice outlet port. They must be free of mineral build up to function properly. To check: 1. Remove front panels. 2. Push and release the off button. To Clean the Air Cooled Condenser 1. Remove the front panel. 2. Push and release the Off button. 3. Remove the top panel. 4. Remove the left side panel. 5. Clean or replace the air filter. 6. Check the fan blade and condenser for grease or dust build up. Because air flow is from the inside of the cabinet out, the inside of the condenser fins will have the most build up. A. Place the inlet hose of a vacuum cleaner in the condenser shroud. B. While the vacuum cleaner is on, blow compressed air from the back of the condenser thru the fins. C. If grease is present, use coil cleaner on the condenser. Be sure to wipe up any excess coil cleaner. 7. Additional access can be gained by removing the top of the fan shroud. Upper Half of Fan Shroud 3. Remove the evaporator cover. 4. Remove the lower splash panel. 5. Push the front sensor back and out of its holder. 6. Pull the back sensor forward and into the cube port. 7. Examine the bottom of the brackets, there are two sensors in each bracket, check that they are clear of mineral build up. They may be wiped clean with ice machine cleaner to assist in removal of the build up. Be sure to drain the reservoir or go thru a Clean cycle to remove residual cleaner. Note: Do NOT use abrasive materials or cleaner on the bin sensor lenses. A soft toothbrush is an effective tool for cleaning these sensors. Insert Bottom Tabs in 5th Slot of Cube Deflectors Remove 4 Screws to Remove Upper Half 8. After cleaning, return all panels except the right front to their original positions. 9. Push and release the Freeze button. 8. Reverse to reassemble. 10. Replace the front panel. May 2000 Page 28 CME1356 and CME1656 Service Diagnosis: Controller Diagnostic Light Analysis Problem or Symptom Machine is off Possible Cause Bin is full, ice in cube port Power is off, check lights. Bin thermostat is closed Transformer is open Unit has been switched off Off lite is glowing Compressor will not start Unit has Shut Down Unit is off & Water diagnostic light is ON or BLINKING Water inlet valve malfunction Water pump malfunction Water level not sensed or not high enough Unit is off & Refrigeration diagnostic light is ON or BLINKING Low discharge or long freeze cycle Harvest problem Probable Correction Use some ice If all lights are out, check power supply, restore power if off Check thermostat for ice on the bulb. If none, check adjustment. If all lights are out and there is power, check transformer output for 24 vac Push and release Freeze button to restart unit. Not enough water or water not sensed. Check for Refrigeration or Water Error Check water diagnostic light, if it blinks 2 times and repeats, check the water inlet valve for proper water flow.** Check that pump hose is attached and if pump is plugged in and working. Check harness from sensor. If the Refrigeration light is glowing steadily, there is a probable refrigeration problem If the Refrigeration light blinks once and repeats, look for a harvest problem.** This also indicates that cubes were "sensed" by the bin controls. If the lite blinks 2 times and repeats, check for a harvest error - no cubes sensed. High Discharge Temp If the refrigeration diagnostic light blinks 3 times and then repeats, check for a reason for high discharge temperatures. Push and release Off button. Push and release Freeze button. Check operation. Push cube size float down and check operation. Check for cause of long harvest cycle** Replace the temperature sensor set (water and discharge). Reset and check water temp and sensor. Unit does not go into harvest - exceeds maximum freeze time Exceeds maximum harvest time Unit runs and both Diagnostic lites are ON Same, but 1 light is on Temperature sensors out of range Reservoir temp. wrong * Machine may be reset by pushing and releasing the Off button, then pushing and releasing the Freeze button. ** See following pages May 2000 Page 29 CME1356 and CME1656 Service Diagnosis Problem or Symptom Unit is off because of a "Harvest Problem" Possible Cause Bin controls did not sense ice falling, unit stayed in harvest until the maximum harvest time ran out. Probable Correction Check bin controls. The bin full light should be off. If it is on or blinking the bin controls may be dirty. Clean if dirty. The board and bin controls may also need to be checked. Push and release Off button. Push and release Freeze button. Check machine operation. Check if ice is made and harvests. Bin controls or AutoIQ Controller may have failed. Other components may have failed Cubes are too large Cube size control float is sticking. Inlet water valve leaks thru Cubes are too small Low ice capacity Purge valve leaks thru Not enough water Dirty condenser or filter Recirculation of air Low refrigerant charge See "Unit does not shut off" below. Check the next page Check/clean Check water valve Check purge valve Check for leak in reservoir Replace filters, clean condenser Block air re-circulation or move condenser Check system. If there is a low charge, find the leak, recover the refrigerant, repair the leak, replace the dryer, evacuate and weigh in the nameplate charge. Check for inlet water valve leak thru Check ice sensors. Check bin full light, if off, place something between the electric eyes. The bin full light should begin to blink (after 20 seconds of continuous blockage it will glow steadily). If not, check operation of electric eyes by unplugging #4 and jumping out the two pins on the controller (first discharge any static electricity by touching the cabinet with the tool). If the bin full light blinks, replace the bin controls. If it does not blink, replace the controller. Note: Leaving #4 unplugged and jumped for 20 seconds will shut the machine down on a bin full (at the end of the harvest cycle). It will restart after 4 minutes or may be reset by pushing the Freeze button. Too much water Unit does not shut off or cannot sense ice falling Ice sensor system may have failed. May 2000 Page 30 CME1356 and CME1656 Service Diagnosis: Components Problem or Symptom Fan motor does not turn. Refrigeration light may be on steadily or blinks 3 times and repeats. Pump motor does not turn Possible Cause Open motor windings, or seized bearings No power to fan motor Probable Correction Replace fan motor Fan motor unplugged, check for voltage from controller. If none, replace controller. Open motor windings, or seized bearings No power to pump Replace pump Check electrical connections. If the unit is in Freeze the pump should have power to it. If not, replace the AutoIQ Controller. Replace hot gas valve Replace hot gas valve Check wire connections, if ok, replace AutoIQ Controller Replace valve Hot Gas Valve does not open. Open solenoid coil. Stuck valve No power to coil in Harvest Hot Gas Valve leaks thru (warm tube temperatures on both sides of valve during freeze) Water Inlet Valve does not open Mechanical problem in valve Open solenoid coil Stuck valve No power to valve (early part of harvest) Replace valve Replace valve Check wire connections, if ok, replace AutoIQ Controller Check water filters and/or inlet screen. Water Inlet Valve does not flow enough water Water Inlet Valve leaks thru Compressor does not work Restriction in water supply Mechanical problem in valve Unit in Clean cycle Contactor coil open Open starting components Open windings Internal valve failure Water level too low or not sensed Replace valve Push and release Freeze button. Replace contactor Check and replace Check and replace compressor Replace compressor Unit must be full of water before controller will start compressor. Check water level and sensor and harness. May 2000 Page 31 CME1356 and CME1656 PTCR The "D" series cubers use a PTCR (Positive Temperature Coefficient Resistor) in place of a conventional start relay and start capacitor. Diagnosis: 1. Disconnect electrical power. Power from the contactor connects to the PTCR and 2. Check if the PTCR is cool enough to handle safely. If not, wait 5 minutes for it to cool off. to the Run Capacitor A wire connects the other terminal of the PTCR to the compressor's start winding. Another wire connects the run capacitor to the start winding. A parallel circuit connects power from the contactor to the Run winding of the compressor. A PTCR changes resistance sharply when its temperature changes. When the PTCR is cold, it connects full current to the compressor's start winding. After a very short time, the PTCR heats up and shuts off the current flow. Under normal conditions, the PTCR's case is at about 180oF. At that temperature the PTCR has very high resistance and will not allow current to flow. It must cool down to about 120oF. Before current will pas through it again. 3. Disconnect both leads to the PTCR and measure its resistance with an ohmmeter. If the PTCR reads less than 21 ohms or more than 39 ohms, replace May 2000 Page 32 CME1356 and CME1656 Operational Characteristics: CME1356 Cycle Times (minutes): Air Cooled Freeze Harvest 70oF. indoor air, 50oF. water 12 - 13 2½ -3 90oF. indoor air, 70oF. water 17 - 19 2 Water Cooled Freeze Harvest 70oF. indoor air, 50oF. water 13 - 14 2½ -3 90oF. indoor air, 70oF. water 15 - 16 2½ -3 System Pressures (PSIG): Air Cooled Suction: End of Freeze Suction: Peak in Harvest Discharge: 5 minutes into Freeze Discharge: Minimum in Harvest 70oF. indoor air, 50oF. water 27 - 29 82 - 84 215 - 225 165 - 175 90oF. indoor air, 70oF. water 31 - 33 92 - 94 285 - 295 165 - 175 Water Cooled Suction: End of Freeze Suction: Peak in Harvest Discharge: 70oF. indoor air, 50oF. water 28 - 30 81 - 83 245 90oF. indoor air, 70oF. water 29 - 31 93 - 95 245 Refrigerant Charge, R-404A Typical Harvest Ice Weight · Air cooled: 64 ounces · Water cooled: 62 ounces (A thru E series) · Water cooled: 58 ounces (F series) Typical Air Cooled Machine Amps Single Phase · 16 lb Superheat (near the end of freeze) · The TXV will control a nominal superheat point that can vary unit to unit from 11oF. to 17oF. While controlling that point the superheat can also range + or - 4oF. without affecting performance. Water Cooled: · 5 minutes into Freeze: 17 · Harvest: 13 Three phase · 5 minutes into Freeze 9.5 · Harvest 8.5 · Discharge Pressure: 245 PSIG · Hi Pressure Cuts Out at: 450 PSIG June 2002 Page 33 CME1356 and CME1656 Operational Characteristics: CME1656 Cycle Times (minutes): Air Cooled Freeze Harvest 70oF. indoor air, 50oF. water 15 - 17 3 90oF. indoor air, 70oF. water 18 - 20 2½ Water Cooled Freeze Harvest 70oF. indoor air, 50oF. water 14 - 16 2½ 90oF. indoor air, 70oF. water 16 - 17 2½ System Pressures (PSIG): Air Cooled Suction: End of Freeze Suction: Peak in Harvest Discharge: 5 minutes into Freeze Discharge: Minimum in Harvest 70oF. indoor air, 50oF. water 21 - 23 88 - 92 210 - 220 115 - 125 90oF. indoor air, 70oF. water 34 - 36 101 - 105 285 - 295 165 - 175 Water Cooled Suction: End of Freeze Suction: Peak in Harvest Discharge: 70oF. indoor air, 50oF. water 31 - 34 75 - 85 245 90oF. indoor air, 70oF. water 31 - 34 80 - 90 245 Refrigerant Charge, R-404A Typical Harvest Ice Weight · Air cooled: 64 ounces · Water cooled: 62 ounces (A thru E series) · Water cooled: 58 ounces (F series) Typical Air Cooled Machine Amps Single Phase · 19.2 lb Superheat (near the end of freeze) · The TXV will control a nominal superheat point that can vary unit to unit from 11oF. to 17oF. While controlling that point the superheat can also range + or - 4oF. without affecting performance. Water Cooled: · 5 minutes into freeze: 17 · Harvest: 15.5 Three Phase · 5 minutes into freeze: 11 · Harvest: 9 · Discharge Pressure: 245 PSIG · Hi Pressure Cuts Out at: 450 PSIG June 2002 Page 34 CME1356 and CME1656 Removal and Replacement Water Pump Inlet Water Valve 1. 1. Remove the left front panel. Electrical Shock Hazard Disconnect electrical power before beginning service 2. Shut off the water supply. 3. Push and release the OFF button. 4. Pull the wire harness off the inlet water valve. 5. Remove screws holding the inlet water valve to the cabinet. Disconnect the electrical power. 2. Remove the left front panel. 3. Check that controller lights are out. 4. Unplug water pump from its electrical connection. 5. Remove 1 plastic bolt and the reservoir cover. 6. Lift water pump up and disconnect outlet tube. 7. Pull float ball from float stem (it is a snap fit). Pull stem out. 8. Locate water level sensor mounting tabs, compress together to release sensor from bracket. 9. Remove water pump brackets from pump. 10. Reverse to replace. 11. Replace front panel. 12. Re-connect electrical power. 6. Pull the valve away from the cabinet and disconnect the outlet tube. 7. Unscrew the water valve from the water inlet tubing. 8. Reverse to reassemble. 9. Push and release the Freeze button 10. Return the left front panel to its original position and secure it to the cabinet. May 2000 Page 35 CME1356 and CME1656 Removal and Replacement: AutoIQ Controller Electric Eyes (Harvest Control Sensors) Electrical Shock Hazard Disconnect electrical power before beginning service These must be replaced as a set. 1. Remove front panels. 2. Push and release the Off button. 3. Remove evaporator cover. 1. Disconnect the electrical power. 2. Remove the front panel. 3. Remove mounting screw holding controller to cabinet. 4. Touch a metal surface to discharge any static electricity. 5. Pull controller out slightly and unplug all electrical connections. Note: Do NOT touch the back of the controller. 6. Carefully remove the new controller from its packaging. Again, do NOT touch the back of the controller. 7. Plug all electrical connectors into the new controller. 8. Re-attach the controller to the cabinet. 9. Switch on the electrical power. All lights should lite up. 10. Push and release the Freeze button. 11. Replace the front panel. 8 9 4. Remove both splash covers. 5. Reach into cube port area and pull the back sensor forward until the harness connector is available, then unplug it and remove the sensor from the cabinet. Back Sensor Front Sensor and Holder 6. Push front sensor back into the cube port. When it is free of the sensor holder, twist it 90 degrees and pull it up and out of the cube port. 7. Trace wire back to the controller and unplug. PUSH BUTTON CONTROL SWITCHES 7 6 5 4 3 2 1 8. Reverse all steps to reassemble. INDICATOR LIGHTS: BIN FULL FREEZE HARVEST CLEAN OFF DIAGNOSTIC LIGHTS: WATER REFRIGERATION May 2000 Page 36 CME1356 and CME1656 Removal and Replacement: Water Level Sensor 1. Remove front panel. 2. Push and hold the OFF button. Release it when the machine stops. 3. Trace wire harness from water level sensor to the AutoIQ Controller (#2). Unplug the harness from the controller. 4. Lift the pump and mounting plate up enough to remove the float from the stem. 5. Remove two screws holding the sensor to the pump bracket and lift the sensor up and out of the machine. 6. Reverse to reassemble. Float Stem 1. Remove the left front panel. 2. Remove the reservoir cover. 3. Pull up on float stem, reach under pump cover and pull the float off the stem. 4. Pull stem out and reverse to replace. Note: Replacement float stem depths are factory set, but confirm them before installing the new stem: CME1356 uses a tan float stem CME1656 uses a brown float stem Observe machine for proper cube size after replacement of the float stem. Water Temperature Sensor Note: This sensor is replaced as a set with the Discharge Temperature Sensor. 1. Remove left front panel. 2. Push and release Off button. 3. Remove 1 plastic bolt and the reservoir cover. 4. Locate water temperature sensor (inserted into pump discharge hose). 5. Pull out to remove. 6. Trace back to AutoIQ Controller, unplug from #5. 7. Remove the Discharge Line temperature sensor (see the next page). 8. Reverse to reassemble. Purge Valve Timer The purge valve timer is sensitive to electrostatic discharge. Be certain to touch a grounded surface before touching this component. Do the same when handling the replacement part. 1. Touch a grounded surface. 2. Remove left front panel. 3. Disconnect electrical power. Electrical Shock Hazard Disconnect electrical power before beginning service 4. Remove high voltage box cover. 5. Locate timer board at the back of the high voltage box. 6. Unplug all the wires to the board. 7. Compress each of the four stand-off posts to release the board from the stand-offs. 8. Remove the board from the unit. Reverse to reassemble. May 2000 Page 37 CME1356 and CME1656 Removal and Replacement: Fan Blade and/or Fan Motor 1. Disconnect electrical power. Note: If the transformer is not supplying power, check the AutoIQ Controller for blacking at the top connections. If the connections appear to have blacked, replace the AutoIQ Controller before the transformer is replaced. Discharge Line Temperature Sensor 1. Remove left front panel, push and release the Off button. 2. Remove top and left side panels. 3. Locate discharge line sensor. It is attached to the discharge line of the compressor, 6" from the compressor discharge port. 4. Unwrap the insulation and un-snap the clip holding the sensor to the discharge line. 5. Trace the sensor wires back to the controller, they are plugged into #5 with the water temperature sensor, and must be replaced with it. 6. Reverse to replace, be sure that the discharge line sensor is 6" up from the compressor discharge port. Be sure to re-wrap the insulation. Note: Route wires so they do NOT contact the discharge line. The sensor for the Discharge line is marked with a small piece of yellow tape. Do not reverse the sensors. Electrical Shock Hazard Disconnect electrical power before beginning service 2. Remove left front and top panels. If stacked, removal is possible thru the front only. Shut off the water and disconnect the inlet water line from the solenoid valve. Move it up and out of the way. Also remove the water pump to get better access to the fan motor. Skip steps 3 and 4. 3. Remove the 4 screws holding the top part of the fan shroud to the bottom fan shroud. 4. Tip the top of the fan shroud forward and pull it up and out of the cabinet. 5. Note location of fan blade on shaft and loosen fan blade set screw. 6. Remove the four bolts holding the fan motor to the bracket. 7. Tip fan motor and blade up, move fan blade as needed to clear internal parts. 8. Replace the blade or motor as needed. Note: The fan is properly on the motor shaft when the hub faces the motor and the shaft end is ½ " from the fan blade. Transformer and Compressor Starting Components Single phase compressors use a start relay, start capacitor and run capacitor. All are located in a sheet metal box to the right of the AutoIQ Controller. The compressor contactor is also located in that box. 1. Disconnect electrical power. 2. Remove left front panel. 3. Remove 2 screws at the front edge of the metal box, and pull the cover forward and out. 4. To check components, reconnect electrical power. Note: The contactor coil is 24 volt. May 2000 Page 38 CME1356 and CME1656 Access Valves To use the access valves: 1. Be sure that the valve is closed. Remove the stem cap and insert a 3/16" allen wrench. Check that the valve is closed. Allen Wrench Torque Stem to 6-8 ft. lb. Torque Stem Cap to 8-12 ft. lb. Torque Core Cap to 7-12 ft. lb. Refrigeration System Components Due to the expected level of training and experience of a refrigeration mechanic, detailed instructions regarding the replacement of refrigeration components will not be presented. However, critical items will be noted here. Refrigerant: 1. This ice machine uses R-404A or HP62 as a refrigerant. It has several unique characteristics. A. It is a near-azeotrope, and must be liquid charged. B. It must use polyol ester refrigerant oil, and that oil is very water absorbent. The system must not be open for more than 15 minutes. C. An electronic leak detector capable of locating HFC-134a type refrigerant must be used to locate refrigerant leaks. Access Valve Access Valve 2. Remove the port cap and attach refrigerant manifold hoses. 3. Open the valve and purge the hoses. 4. When service is complete, shut the discharge access valve first. Then, with the machine running and the middle hose outlet securely fastened to the manifold or refrigerant tank (closed) open both manifold valves. This allows any liquid refrigerant in the discharge hose to flow thru the manifold and into the suction side. 5. After the gages have equaled, shut the manifold valves and the suction access valve. 6. Remove the gages and replace the stem and port caps. Make certain that they are tightly closed. D. A special HFC type liquid line dryer must be used. E. When brazing, use a low pressure nitrogen purge. F. When evacuating, use of an electronic micron gage is recommend. Evacuate to 300 microns. May 2000 Page 39 CME1356 and CME1656 Liquid Charging Because R-404A is a near-azeotrope, only liquid refrigerant can be used to recharge the refrigeration system. To do that may take some special techniques: 1. Use an electronic scale to measure the charge. 2. Place a drum or cylinder of R-404A on the scale, liquid out side up (check container). 3. A refrigeration manifold should be attached to the service access valves. Attach the charging hose to the cylinder of R-404A. Open the cylinder's valve and purge the hose to the manifold. 4. Close the low side service access valve. 5. Open the discharge side manifold valve and weigh in the name plate charge. After the charge is weighed in, wait a few minutes and re-check the scale. 6. If all of the refrigerant charge has not been weighed into the discharge side, it must be carefully added thru the low side. Close the discharge service access valve. 7. With a sight glass or charge faster in the hose to the low side port, start the ice machine. 8. Open the low side service access valve. 9. Crack open the low side manifold valve and watch the scale and sight glass. Open and close the low side manifold valve to flow liquid into the manifold but flash off to vapor before it enters the suction side of the refrigeration system. This should only be a few ounces at most. 10. After the scale = the correct charge, shut off the valve on the refrigerant cylinder. 11. With the ice machine running and the discharge access valve closed, open both manifold valves to allow the refrigerant in the hoses to enter the system. 12. Shut the suction service access valve. 13. Remove the refrigeration manifold gages. 14. Replace and tighten all caps. Evaporators In the unlikely event that an evaporator may need to be replaced, do NOT braze the evaporator joints when the evaporators are seated in the freezing compartment, instead lift them up slightly so that the joints to be brazed are above the top edge of the freezing compartment. May 2000 Page 40 CME1356 and CME1656 Before Calling for Service Check the following: 1. Has the water supply to the ice machine or building been shut off? If yes, the ice machine will automatically restart within 25 minutes after water begins to flow to it. 2. Has power been shut off to the ice machine? If yes, the ice machine will automatically restart when power is restored. 3. Has someone shut the water off to a water cooled unit?. If yes, the ice machine may need to be manually reset. 4. Does the bin control have ice on it? If so, remove the ice and the machine should start in a few minutes. To Manually Reset the machine. 1. Remove the left front panel. 2. Locate the AutoIQ Controller. If a red diagnostic light is glowing, note which one and its blink rate. Then push and release the off button. 3. Push and release the Freeze button. 4. The machine should begin to operate. If there is a lack of water it will soon shut off again. 5. Return the front panel to its normal position. If the machine shuts down again, call for service. To Shut the Machine Off: 1. Remove the left front panel. AutoIQ Controller 7 6 5 4 3 2 1 PUSH BUTTON CONTROL SWITCHES 8 9 INDICATOR LIGHTS: BIN FULL FREEZE HARVEST CLEAN OFF DIAGNOSTIC LIGHTS: WATER REFRIGERATION 2. Locate the AutoIQ Controller. 3. Push and hold the Off button for 3 seconds or until the machine stops. May 2000 Page 41