User manual SCOTSMAN CMS1402R

CMS1402R INTRODUCTION To the owner or user: This service manual is intended to provide you and the maintenance or service technician with the information needed to install, start up, clean, maintain and service this ice system. Table of Contents Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For the Installer Location & Assembly Stacking ................................ 3 4 7 8 9 10 12 13 15 17 19 20 21 25 2 ..................................... ................................. .................................. .................................. For the Electrician For the Plumber Final Check List Initial Start Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freeze Cycle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Cycle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Component Description ............................... Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Service Diagnosis ................................. Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts Lists and Wiring Diagrams are located in the center of this manual, printed on yellow paper. September 1993 Page 1 CMS1402R FOR THE INSTALLER The CMS1402R will fit the following Scotsman ice storage bins: A remote condenser and precharged tubing kit are required to assemble this ice system. The normal finish for the machine is enamel sandalwood. An optional stainless steel panel kit (SPKCMS48) can be field installed. It contains a stainless steel top, left side panel, an overlay right side panel, and front panels. · BH900 · BH1000 (with bin top KBT21) · BH1360 and it will stack (with kits)onto the following ice machines: · CMS1402B (with stacking kit KSCMS48) · CMS1202B (with stacking kit KSCMS48) Scotsman Ice Systems are designed and manufactured with the highest regard for safety and performance. They meet or exceed the standards of U.L., N.S.F., and C.S.A. Scotsman assumes no liability or responsibility of any kind for products manufactured by Scotsman that have been altered in any way, including the use of any parts and/or other components not specifically approved by Scotsman. Scotsman reserves the right to make design changes and/or improvements at any time. Specifications and designs are subject to change without notice. Model Number Dimensions (without bin) W" x D" x H" CMS1402RE-3B 48 x 243/8 x 271/2 Basic Electrical Refrigerant Minimum Maximum Refrigerant Condenser Charge** Type Fuse Type Circuit R-22 Ampacity* Size 20.5 31.4 30 30 256 oz. 256 oz. Remote Air Remote Air 208-230/60/3 R-22 208-230/60/1 R-22 CMS1402RE-32B 48 x 243/8 x 271/2 * Minimum Circuit Ampacity is used to determine wire size and type per the National Electric Code. ** The unit is shipped with the full charge in the receiver. For re-charging purposes, if the nameplate charge is different than this number, go by the nameplate. Use Scotsman remote condenser RC1422. Use precharged tubing kit RT2225 (25') or RT2240 (40"). This ice system (except remote condenser) is designed to be installed indoors, in a controlled environment. MINIMUM Air Temperature Water Temperature Water Pressure Voltage 500F. 400F. 20 psi -5% September 1993 Page 2 MAXIMUM 1000F. 1000F. 80 psi +10% CMS1402R FOR THE INSTALLER: Location & Assembly Location: After uncrating and inspection, the unit is ready for installation. It is important that the machine be installed in a location where it has enough space around it to be accessible for service. Try to avoid hot, dirty and crowded locations. Be sure that the location for the machine is within the envrionmental limitations. Storage Bin: Tip the storage bin on its back, using parts of the carton to protect the exterior finish. Install the legs packed with the BH900. If stacking use a heavy duty leg kit (KLP6). 1. Arrange for proper electric, water and drain. See instructions for the plumber and for the electrician. 2. After mounting the legs position the ice storage bin in the selected location: Note: Allow enough space to the left and back to service the machine. Do NOT push the bin into postion, instead, lift it there. Pushing a bin may damage the legs and leg mounts. Level the bin in both the front to rear and side to side directions by adjusting the leg levelers. 3. Inspect the bin top mounting gasket which should be flat, with no wrinkles, to provide a good water seal when the cuber is installed on top of the bin. Ice Maker: Install the modular cuber on top of the bin using care to be sure a good seal is made between the two cabinets. Use of a mechancial lift is recommended. Align the holes in the bottom rear of the cabinet to mate with the two mounting holes on the top rear of the bin. Use bolts and straps found on the back of the ice machine to secure the ice machine to the bin. When alignment and leveling are completed, tighten the bolts to secure the mounting straps. Remove the front panel, and remove the evaporator shipping brackets and hardware. SHIPPING BRACKETS ICE MACHINE AND BIN ASSEMBLY September 1993 Page 3 CMS1402R FOR THE INSTALLER: Location & Assembly Stacking Instructions A stacking kit, KSCMS48, is required to interconnect the ice level controls, seal the freezing compartments, support the bin with heavy duty legs, and retain the front panels. Follow the installation instructions of the stacking kit, but in general: Replace the original bin legs with heavy duty legs (KLP6). When stacking two units, remove the top panel and the evaporator cover from the lower icemaker. STACKING (The top removed from the lower icemaker will no longer have any function.) Add a strip of gasket (from the stacking kit) to the top edge of the bottom ice machines evaporator compartment. Install the panel retaining bracket onto the bottom ice machine before placing the upper unit on it. Place additional gasket onto the top edges of the bottom ice machine. Carefully lift the uncrated top unit onto the bottom one and align the two cabinets. Use of a mechanical lift is recommended for this step. At the back of the two icemakers, bolt the upper icemaker cabinet to the lower icemaker cabinet using the mounting straps and bolts from the hardware package. Add the relay kit to interconnect the two ice machine's bin control circuits. STAINLESS STEEL PANEL RETAINING BRACKET EVAPORATOR COVER September 1993 Page 4 CMS1402R FOR THE INSTALLER: Scotsman Remote Condenser Locate the condenser as near as possible to the interior location of the ice maker. Location of the condenser is limited by the specific length of precharged refrigerant tubing supplied for the application. The pre-charged tubing connects the icemaker to the remote condenser. The condenser must be above the ice maker. Select the best available location, protecting the condenser from extremes of dirt, dust, and sun. Meet all applicable building codes. Roof Attachment: Install and attach the remote condenser unit to the roof of the building, using the methods and practices of construction that conform to the local building codes, including having a roofing contractor secure the condenser to the roof. Precharged Line Routing /////////////////////////////CAUTION/////////////////////////////// Do not connect precharged tubing until all routing and forming of the tubing is complete. See the coupling instructions for connecting instructions. //////////////////////////////////////////////////////////////////////////// 1. Each set of precharged refrigerant lines consists of a 3/8 inch diameter liquid line, and a 1/2 inch diameter discharge line. Both ends of each line have quick connect couplings, the end without access valves goes to the icemaker. Note: The openings in the building ceiling or wall, listed in the next step, are the minimum sizes recommended for passing the refrigerant lines through. 2. Have the roofing contractor cut a minimum hole for the refrigerant lines of 1.75". Check local codes, a separate hole may be required for the electrical power to the condenser. /////////////////////////////CAUTION////////////////////////// ////// DO NOT KINK OR CRIMP REFRIGERANT TUBING WHEN INSTALLING IT. //////////////////////////////////////////////////////////////////////// //// REFRIGERANT CONNECTIONS 3. Route the refrigerant lines through the roof opening. Follow straight line routing whenever possible. Any excess tubing MUST be retained within the building. 4. Spiral any excess length of pre charged tubing inside the building. Use a horizontal spiral to avoid any traps in the lines. 5. Have the roofing contractor seal the holes in the roof per local codes. LOCATE CONDENSER NO LOWER THAN ICE MACHINE TYPICAL INSTALLATION September 1993 Page 5 CMS1402R FOR THE INSTALLER: Coupling Instructions ////////////////////////////////CAUTION///////////////////////////////// The couplings on the sets of precharged lines are self sealing when installed properly. Carefully follow the instructions: //////////////////////////////////////////////////////////////////////////////// Initial Connections: 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them. 2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil. · The 1/2 inch discharge line (schrader valve end) goes to the remote condenser fitting marked "discharge line". · The 3/8 inch liquid line (schrader valve end) goes to the remote condenser fitting marked "liquid line". Final Connections: 3. Begin tightening the couplings together by hand, then using two wrenches (it is important that ONLY the nut on the precharged lines be turned, the other parts of the couplings must NOT be allowed to turn or the process will tear out the diaphragms and they will be loose in the refrigeration system) tighten the coupling until it bottoms out or a definite increase in resistance is felt. TIGHTENING THE QUICK CONNECTS SCHRADER VALVES 4. Using a marker or pen, mark a line lengthwise from the coupling union nut to the bulkhead. Then tighten the coupling and additional 1/4 turn. As the nut turns, the line will show when 1/4 turn is made. 5. After all connections are made, and after the king valve has been opened, check the couplings for leaks. · The 1/2 inch discharge line goes to the icemaker fitting marked "discharge line". · The 3/8 inch liquid line goes to the icemaker fitting marked "liquid line." DISCHARGE LINE LIQUID LINE INSULATION September 1993 Page 6 CMS1402R FOR THE ELECTRICIAN SEE NAMEPLATE for current requirements to determine wire size to be used for electrical hookup. When the cuber and the remote condenser are connected, each must be grounded to the other using the ground screws provided in the respective junction boxes. The cuber then requires a solid chassis to chassis earth ground wire. See Wiring Diagram. Be certain the cuber is connected to its own electrical circuit and individually fused. Voltage variation should not exceed ten percent of the nameplate rating, even under starting conditions. Low voltages can cause erratic operation and may be responsible for serious damage to the icemaker. The Scotsman remote condenser is designed to be powered from the ice machine. There is a separate electrical junction box at the back of the ice maker for the remote condenser. Wire the remote condenser to the ice maker in accordance with local and national electric codes. All outdoor wiring must be in rainproof conduit. The condenser fan motor will run whenever the compressor is running. Electrical connections are made at the rear of the icemaker, inside the junction box. All external wiring should conform to the national, state and local electrical code requirements. Usually an electrical permit and services of a licensed electrician will be required. ELECTRICAL CONNECTIONS GROUND SCREW HAND DISCONNECT SWITCH DETAIL OF JUNCTION BOX, 3 PHASE SHOWN POWER SUPPLY INTERCONNECTING WIRES REMOTE CONNECTION September 1993 Page 7 CMS1402R FOR THE PLUMBER The recommended water supply line is a 3/8-inch O.D. copper tubing with a minimum operating pressure of 20 PSIG and a maximum of 80 PSIG. Connect to cold water supply line with standard plumbing fittings, with shut off valve installed in an accessible place between the water supply and the cuber. ln some cases a plumber will be required. Water Limitations: An ice machine is a food manufacturing plant, it takes in a raw material, water, and turns it into a food product, ice. The purity of the water is very important in obtaining pure ice and in maximizing product life. It is generally better to filter the water, although there is no one filter that will cure all water problems. A good filter combined with a polyphosphate feeder gives about the best overall performance. DRAIN Connections: All drains are gravity type and must have a minimum of 1/4-inch fall per foot on horizontal runs. The drains to be installed to conform with the local plumbing code. Install a vertical open vent on drain line high point to insure good draining. The ideal drain receptacle is a trapped and vented floor drain. Recommended bin drain is 5/8 inch O.D. copper tubing and should be vented and run separately. Insulation for high humidity areas is recommended. The ice machine sump drain is 3/4" FPT. There must be a vent at this connection for proper sump draining. POTABLE WATER SUPPLY SUMP DRAIN MUST BE VENTED 3/4" FPT HAND SHUT OFF VALVE OPTIONAL FILTER 3/8" MALE FLARE VENT BIN DRAIN AIR GAP BETWEEN DRAIN LINES AND BUILDING DRAIN WATER SUPPLY AND DRAIN CONNECTION September 1993 Page 8 CMS1402R FINAL CHECK LIST 1. Is the cabinet in a room where ambient temperatures are within the minimum and maximum temperatures specified? 2. Is there clearance at the left and back sides of the cabinet for service access? 3. Has water supply pressure been checked to insure a minimum of 20 PSIG and a maximum of 80 PSIG operating pressure? 4. Is the cabinet level? 5. Check that any shipping material has been removed from inside the cabinet. 6. Check that the reservoir is properly secured to the bottom of the evaporator plates. 7. Have all electrical, water and drain connections been made? 8. Is the water supply line shut off valve installed and electrical wiring properly connected? 9. Check all refrigerant lines and conduit lines, to guard against vibration or rubbing and possible failure. 10. Have the bin and cabinet been wiped clean? 11. Has the Manufacturers Registration form been properly filled out? Check for correct model and serial numbers from Serial nameplate, then mail to the SCOTSMAN factory. 12. Has the owner/user been given the Service Manual and instructed how to operate and maintain the icemaker? 13. Has the owner been given the name and telephone number of the authorized SCOTSMAN Service Agency serving him? SUMP DRAIN HAND SHUT OFF VALVE OPTIONAL FILTER FINAL INSTALLATION PRECHARGED LINES CONNECTED LEVEL ASSEMBLY BIN DRAIN September 1993 Page 9 CMS1402R INITIAL START UP Before Start Up: 1. Check that both the ICE-OFF-WASH rocker switch and the COMPRESSOR ON-OFF toggle switch are in the OFF position. 2. Switch on the electrical power. Electrical power must be supplied to the ice machine for 12 hours before starting the compressor for the first time. The crankcase heater will now heat the compressor's oil. The oil is warmed to evaporate any refrigerant that may have collected in it. If there is refrigerant in the oil when the compressor starts, the oil will foam and will not lubricate the compressor properly, shortening its life. Do NOT start the compressor for the first time unless the dome of the compressor is warm. Start Up 1. Remove front panels by removing screws at the base and pulling out. 2. Remove two screws and the control box cover. 3. OPEN the water supply line shut off valve. 4. Open the "king" valve on the receiver. 5. Inside the control box is the shaft of the timer and switch assembly. Rotate the shaft of the timer clockwise until the actuator arm on the microswitch drops off outer cam into cam slot. See "Front View of Timer". 6. Move the ICE-OFF-WASH to the ICE position. 7. Check the water fill cycle: For several minutes the inlet water valve will be open and water will flow into the reservoir. Near the end of the fill cycle water should be draining thru the reservoir drain. If at the end of the fill cycle the reservoir is not full, repeat step 5. Check that the sump covers are snapped in place. Check that the water distributors are properly seated at the top of the evaporators and that water is flowing over all cube cells. Note: Some water spray from the evaporators is normal when the machine is new. The spray wil quit after a few cycles. 8. When the sump has filled, move the compressor ON-OFF toggle switch, to the ON position. TIMER FRONT VIEW OF TIMER ACTUATOR BUTTON MICROSWITCH CAM HARVEST PORTION FREEZE PORTION CONTROL BOX CUBE SIZE CONTROL ICE/OFF/WASH BIN ICE LEVEL SWITCH September 1993 Page 10 CMS1402R INITIAL START UP 9. Check operation of the freezing cycle: Ice will begin to form from the top of the evaporators down. After the first cycle, freezing time will range between 12 and 15 minutes. Longer time for temperatures above 70oF. and shorter time required when temperatures are below 70oF. Average complete cycle time is about 14 minutes. 10. After an ice harvest, check Cube Size. There is just enough water available in the reservoir to make one full sized batch of cubes. As the water level drops, the water pump may pick up some air at the end of the freezing cycle so some bubbles in the pump discharge hose at the end of freeze is normal. If the water pump runs out of water before the end of freeze, the cube size control may be set too cold, or the water system may be leaking water. Compare cube size to the "Cube Size Diagram" To adjust the cube size, locate cube size control in the front of the control box, and rotate the adjustment screw one eighth of a turn: TOO SMALL When the cubes are the correct size, they will be connected together vertically, and drop off in strips. The batch weight will be about 13.5 to 14.5 lb. Note: if the cubes at the bottom rows of some evaporators are smaller than others, the size difference does not affect capacity or performance. However, there should be ice in all cells. If not, contact the Factory. CUBE SIZE DIAGRAM JUST RIGHT · COUNTER Clockwise for SMALLER ice cubes · Clockwise for LARGER ice cubes Observe size of the ice in the next ice cube harvest and repeat adjustment until correct ice cube is achieved. 11. Check Harvest Time. There must be enough time in harvest to defrost all the cubes but not an excessive amount that will waste capacity. The length of the harvest cycle is determined by the timer cam positions. If needed, adjust the harvest time so there are about 15 seconds of harvest time left after the last cube has fallen from the evaporators. Because harvest time varies with the water and air temperatures at the ice machine, colder air and water will result in faster ice making but require longer harvest cycles. Do NOT adjust harvest time too short or the unit will not harvest all the ice. The harvest time is set by: loosening the set screw on the cam, rotating the shaft to open or close the distance between the high part of the cams, and retightening the set screw. More of an opening between the cams high areas=more harvest time. An adjustment of the cube size may be needed after the harvest time has been changed, so check the cube size again. CAMS ADJUSTMENT OF THE TIMER SET SCREW 12. Check Bin Ice Level Control. When the unit is in the harvest cycle, place something solid against the transducer socket (located in the base to the left of the evaporators). The machine will switch off at the END OF THE HARVEST CYCLE, and will restart when the object is removed. The control has a Full and a Partial position. At Full, the machine will switch off when ice is 8" from the transducer socket. The control will not work on bins taller than 8'. Note: Even when full the unit will make a batch of ice if switched off and then on. 13. Replace all covers, panels and screws. 14. Fill out the Warranty Registration and Customer Evaluation form. Explain to the user the maintenance requirements of the ice machine. Inform the user of the name and telephone number of the local SCOTSMAN Distributor or service agency. September 1993 Page 11 CMS1402R FREEZING CYCLE OPERATION Water from the sump assembly is pumped to the water distributor system at the top of each evaporator plate. From the water distributor the water cascades by gravity over all cells of the plate and to the sump assembly below. At the beginning of the freezing cycle, the electrical circuit is completed to the compressor and the water pump. The water pump operates continuously, through both the freezing cycle and the harvest cycle. During the freezing cycle, the hot gas solenoid valve is CLOSED and the water inlet solenoid valve is CLOSED. When the ice cubes are partially formed, the cube size control will sense the temperature at which it is preset to CLOSE. This will complete the electrical circuit to the timer. The timer then controls the remainder of the freezing cycle. The timer will keep the icemaker operating in the freezing cycle for a selected length of time. This will give the ice cubes time to fully form. after that selected length of time, the timer will switch the icemaker into the harvest cycle, through the contacts of the timer assembly microswitch. Low Temperature Freeze: When the outside air temperature is low, the Head Pressure Regulator will close off the liquid line to the receiver, causing liquid refrigerant to back up into the condenser unitl the head pressure builds up to 220 PSIG. While this is occuring, the head pressure regulator passes discharge gas into the receiver to keep the refrigerant flowing. WATER DISTRIBUTION INLET WATER VALVE DRAIN RESERVOIR WATER SCHEMATIC REFRIGERATION SCHEMATIC September 1993 Page 12 CMS1402R HARVEST CYCLE - HOT GAS BYPASS When the timer switches the icemaker into the harvest cycle, high pressure, high temperature gas refrigerant being discharged from the compressor is diverted from the condenser through the hot gas solenoid valve into each evaporator plate. During this cycle, the refrigerant bypasses the condenser. ln the electrical circuit, both the compressor and the water pump are operating and the hot gas solenoid valve is energized and OPEN and the water inlet solenoid valve is OPEN. The finished ice cubes are released from the sides of each evaporator plate by the warming effect of the hot gas condensing in each evaporator plate and the water cascading over the ice cubes. The released ice cubes drop into the ice storage bin below. At the end of the harvest cycle, the timer cam will push the actuator arm to the microswitch IN. If the ice level control is still CLOSED, a whole new cycle will begin. If the ice level control is OPEN, the icemaker will begin to shut OFF. Pump Down Cycle: When the ice level control is open at the end of the harvest cycle, power is removed from the liquid line valve coil, and the pump down cycle begins. The compressor will continue to run until the pump down control, sensing low side pressure, opens at 20 PSIG. WATER DISTRIBUTION INLET WATER VALVE DRAIN RESERVOIR WATER SCHEMATIC REFRIGERATION SCHEMATIC September 1993 Page 13 CMS1402R COMPONENT DESCRIPTION Cube Size Control This reverse acting thermostat controls the length of the freezing cycle. It is sensing the temperature of the suction line. When the suction line gets cold enough, the cube size control closes (on temperature fall) and starts the timer. A change in either ambient air or incoming water temperature will affect the efficiency of the refrigeration system, and this will vary the length of time it takes the evaporator to reach the temperature at which the cube size control is preset to close. See CUBE SIZE ADJUSTMENT BEFORE attempting to adJust the control. Relay The multi-function, three pole, double throw, plug-in relay is installed directly into a receptacle on the printed circuit board in the control box. The relay functions in part to by-pass the bin thermostat control to prevent the icemaker from shutting OFF, when the bin thermostat opens during the freezing cycle. The bypass action serves to ensure full-sized ice cubes with each harvest cycle. Timer - Timer & Switch Assembly The function of the timer begins when activated by the cube size control. The outer surface, or large diameter lobe of the timer cam, determines the timer cycle for finish freezing of the ice cubes, while the inner surface, or small diameter lobe, determines the time cycle for the harvest cycle. When the microswitch button is pushed in there is power connected to the coil of the relay, and the unit is in the freeze cycle. When the microswitch button is released, the power to the relay is stopped, and the unit goes into harvest. The microswitch is actuated by a cam assembly directly connected to the timer motor. One complete rotation of the cam will take eight minutes. Harvest is preset at three and one half minutes, but is adjustable. High Pressure Safety Control This is a manual reset control that shuts down the icemaker, should the discharge pressure ever reach 400 PSIG. Located below the control box. Low Pressure Control (Pump Down) This pressure control connects power to the compressor contactor coil. Its Cut In is 35 PSIG and its Cut Out is 20 PSIG. Located below the control box. CONTROL BOX CUBE SIZE CONTROL RELAY TIMER & SWITCH September 1993 Page 14 CMS1402R COMPONENT DESCRIPTION Bin Level Control This electronic control uses sound waves to measure the distance between the bottom of the ice machine and the top of the ice in the bin. It is designed to control the machine's ice production to maintain that distance. The control is adjustable so that the ice machine will maintain a certain height of ice. When set at FULL it will not allow the machine to fill the bin any closer to the ice machine than about 8", and it will not work if the distance to the bottom of the bin is greater than 8 feet. BIN ICE LEVEL SELECTOR SWITCH Because it uses sound waves, a slight "ticking" sound can be heard coming from the bottom of the machine. There are three parts to the control, the transducer, the circuit board, and the ice level control switch. ICE/OFF/WASH SWITCH THE USER CAN SELECT THE AMOUNT OF ICE TO BE MAINTAINED IN THE BIN. SOUND WAVES FULL PARTIAL September 1993 Page 15 CMS1402R COMPONENT DESCRIPTION Water Inlet Solenoid Valve The water inlet solenoid valve fills the sump assembly with water and excess water overflows out the standpipe and down the drain. This action fills and rinses the sump during each harvest cycle. The flow rate is 1 g.p.m. Water Distribution System The water distribution system evenly supplies water to all cells of the evaporator plates. The water pump pumps water from the sump up the vertical tygon tube to the tee. From there water is channeled through the water manifold to the water distributors, above each evaporator plate, and from six holes within each distributor, water flows to the cells of each side of the evaporator plates. Gravity flow returns the unfrozen excess portion of water to the sump reservoir for recirculation. Hot Gas Solenoid Valve The hot gas solenoid valve functions only during the harvest cycle, to divert the hot discharge gas from the compressor, by passing the condenser, for direct flow in the evaporator plates to release ice cubes from the ice cube molds. The hot gas solenoid valve is installed in a branch of the discharge line. When the harvest cycle begins the energized solenoid coil lifts the valve stem within the valve body, to cause the hot discharge gas to be diverted to the evaporators. Strainer A water strainer is located in the potable inlet water line before the water inlet solenoid valve. Clean the water strainer frequently. WATER DISTRIBUTORS SUMP STAND PIPE OPTIONAL WATER FILTER HAND VALVE SUMP PUMP COMPONENT LOCATION September 1993 Page 16 DRAIN CAP CMS1402R CLEANING ///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// A Scotsman Ice System represents a sizable investment of time and money in any company's business. In order to receive the best return for that investment, it MUST receive periodic maintenance. Maintenance and Cleaning should be scheduled at a minimum of twice per year. ///////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////////// 7. Pour the cleaning solution into the reservoir until CLEANING: ICEMAKER full. 1. Remove screws and the front panel. 2. Switch the compressor switch to OFF. Switch 8. Move the master switch to the WASH position. 9. Let the unit operate for 30 minutes. During the wash cycle, if the machine runs out of solution, mix 2 more gallons of solution per step 6, refill the sump and continue the wash cycle for the remainder of the 30 minutes. 10. Move the ICE-OFF-WASH switch to the OFF (center) position. 11. Remove the cap and drain the cleaning solution from the sump. Replace the drain cap. 12. Rotate the shaft of the timer and switch assembly CLOCKWISE to the harvest position (low part of the cam against microswitch). Move the ICE-OFF-WASH switch to the ICE position to start the Harvest cycle. If after completing this procedure one or more evaporator plates does not have a full flow of water for each vertical column of cubes, shut down the operation and remove and clean all water distributor manifolds. Reinstall the water distributor manifolds. Electrical Shock Hazard. Electrical shock can cause personal injury. Cleaning procedures are done with the power ON. the ICE-OFF-WASH rocker switch to OFF. 3. Remove the control box cover, and rotate the shaft of the timer and switch assembly CLOCKWISE advancing to the freezing cycle. (Beginning of the higher part of the cam against the microswitch). 4. Open the ice storage bin door and discard all the ice. 5. Remove the hose clamp, rubber cap and drain all the water from the sump assembly into the bin. Replace the rubber cap and hose clamp. 6. Mix 24 ounces of Scotsman Ice Machine Cleaner with 2 gallons of warm (950F. - 1150F.) water. Scotsman Ice Machine Cleaner contains acids. These compounds may cause burns. If swallowed, DO NOT induce vomiting. Give large amounts of water or milk. Call Physician immediately. In case of external contact, flush with water. KEEP OUT OF THE REACH OF CHILDREN. Note: The ice making portion of the water system should be sanitized after cleaning by repeating steps 2-12 and substituting a sanitizing solution for the cleaning solution. 13. Move the compressor switch to the ON position to start the icemaking process. ///////////////////////////////////CAUTION/////////////////////////////// DO NOT use ice produced from the cleaning solution. Be sure none remains in the bin. /////////////////////////////////////////////////////////////////////////////////// 14. Check the next ice cube harvest to be certain that the ice cubes are clear and the acid taste is gone. 15. Add hot water to the bin to melt the ice. 16. Replace all panels. September 1993 Page 17 CMS1402R CLEANING Remote Condenser 1. Shut off the ice machine. The fan blade can cause personal injury. Disconnect power before beginning to clean condenser. 2. Remove dirt and debris that might be under the condenser. 3. Brush off the bottom of the condenser fins. Do not use a wire brush. 4. Check to see that the inside of the condenser is clean; light should be visible through the fins. If not, clean the internal parts by vacuum, pressure washer and/or coil cleaner. Ice Storage Bin The interior liner of the bin is in contact with a food grade product: ice. The storage bin must be cleaned regularly to maintain a sanitary environment. Once a week cleaning with soap and water, a hot water rinse and and air dry is a basic procedure. Scale that may form on the plastic liner of a bin may be removed by scrubbing the surface of the line with a mixture of Scotsman Ice Machine Cleaner and hot water. Remove any scale prior to sanitizing. To remove scale: 1. Mix a cleaning solution of 4 ounces of Scotsman Ice Machine Cleaner to 4 pints of hot (950 F. to 1100F.) water. Scotsman Ice Machine Cleaner contains acids. These compounds may cause burns. If swallowed, DO NOT induce vomiting. Give large amounts of water or milk. Call Physician immediately. In case of external contact, flush with water. KEEP OUT OF THE REACH OF CHILDREN. 2. Remove all ice from the bin. 3. Using rubber gloves, dip a nylon scouring pad into the cleaning solution, and scub the scale off of the liner. 4. After the scale has been removed, rinse all of the surfaces inside the bin with clean, potable water. To sanitize the bin and ice machine: Follow local codes for frequency of sanitizing. Use an approved sanitizer and follow the directions and warnings of that santitizer or use the following instructions for use of household bleach, if it meets local codes: 1. Remove all ice from the bin. 2. Mix a sanitizing solution of 1 ounce of household bleach to 2 gallons of water. 3. Using clean rubber gloves and a clean cloth, wipe all interior surfaces of the ice machine and ice storage bin with the sanitizing solution. Immerse any small parts in the sanitizing solution and wash the parts, flushing the solution thoroughly in, over and through all parts and surfaces of the parts being cleaned. 4. Allow to air dry. September 1993 Page 18 CMS1402R SYSTEM SPECIFICATIONS The following numbers can be used as a guideline . There will be some variation from unit to unit. Typical Cycle Time · 14-15 minutes @ 70oF. air and 50oF. water; 17-18 minutes @ 90oF. air and 70oF. water. Typical Harvest Ice Weight · 13-14 lbs. Typical Low Side Pressure · 20-21 PSIG @ 70oF. air and 50oF. water · 21-22 PSIG @ 90oF. air and 70oF. water Typical Freeze Cycle Discharge Pressure · 280-240 PSIG @ 90oF. air/70oF. water; 220-210 PSIG @70oF. air/50oF. water by end of freeze. Refrigerant Charge · 256 ounces of R-22 Harvest Time · Preset at 3.5 minutes, may be adjusted to suit local conditions Typical Suction Pressure in Harvest · 60-70 PSIG @ 70oF. air and 50oF. water · 70-80 PSIG @ 90oF. air and 70oF. water Typical Discharge Pressure in Harvest · 100-110 PSIG @ 70oF. air and 50oF. water · 120-130 PSIG @ 90oF. air and 70oF. water. Typical Compressor Amp Draw Single phase · Beginning freeze = 13-14, End of Freeze = 11-12, Harvest = 16-17 Three phase · Three phase amps vary between 8 and 12 High Pressure Cut Out · High pressure safety, (air cooled) Manual reset, cut out at 400 PSIG Compressor · Copeland CRL3-0350-PFV-270 (single phase) · Copeland CRL3-0350-TF5-270 (three phase) Ice Level Control · Maximum Range = 8 feet · Partial Fill Setting:= 21" - 22" from the base of the ice machine Timer · 1 revolution takes 8 minutes Cube Size Control · Cut In adjustable between 0oF. and +250F. Inlet Water Valve · Flow rate is 1 GPM September 1993 Page 19 CMS1402R ADJUSTMENTS MICROSWITCH Electrical power present in the control box can cause personal injury. Disconnect power before beginning to adjust timer. Adjustment Of The Timer & Switch Assembly One complete revolution of the cam on the timer takes eight minutes. The normal setting is three and a half minutes, as set at the factory. lt is important that the length of the harvest cycle allow enough time for all the ice cubes to fall from the evaporator. Too short of a time will cause the evaporator to freeze up and stop ejecting ice into the bin. Too much time wastes icemaking capacity, energy and water. Adjustment of the harvest cycle may require a corresponding adjustment of the cube size control. Rotating the shaft of the timer cam clockwise will allow putting the machine into either the freezing cycle or harvest cycle, as required in the cleaning instructions. CLOSE UP VIEW OF TIMER SWITCH ACTUATOR CAM To Adjust The Timer & Switch Assembly: The length of the harvest cycle can be changed by loosening the set screw on the cam, and then rotating the shaft so that the opening between the cams change. More of an opening between the cams = more harvest time. The harvest time may be reduced if not needed. This will yield more ice per day. TIMER CAM ADJUSTING TIMER September 1993 Page 20 CMS1402R SERVICE DIAGNOSIS: Water SYMPTOM No ice is made POSSIBLE CAUSE Inlet water valve will not open or is dirty No water being pumped over evaporators. PROBABLE FIX Clean inlet screen, check coil, replace valve if required Check pump motor, replace pump if motor will not run. No water in reservoir, check inlet water valve, check reservoir for leak. Water inlet valve leaks thru at high rate Cubes are not uniform in shape Long Freeze Cycle Makes thick ice/freezes up Water distributors are dirty Inlet water valve leaks through See electrical/adjustment Water inlet valve restricted Low water pressure Sump covers out of position Cubes too large Low Capacity Unit runs out of water Inlet water valve leaks through See electrical/adjustment Incoming water very warm Lack of water Reservoir leaks Inlet water valve restricted Short harvest cycle Water pressure too low Replace inlet water valve Clean water system Replace inlet water valve See electrical/adjustment Clean or replace valve Check water filter or supply Re-position sump covers Replace inlet water valve See electrical/adjustment Check water temperature to building See unit runs out of water Repair leak Clean or replace valve Adjust timer Check supply September 1993 Page 21 CMS1402R SERVICE DIAGNOSIS: Electrical and/or Adjustments SYMPTOM Machine does not operate POSSIBLE CAUSE No power High pressure control open High temperature cut out open P. C. Board Open Master switch open Timer contacts open Bin ice level control holding machine off Makes thick ice/freezes up Harvest Cycle too short Low water pressure Hot gas valve defective Sump covers out of position Cubes too small Cube size control stuck open Runs, makes no ice Pump problem or water leak in reservoir Water inlet valve either lets in no water or leaks through Timer stuck PROBABLE FIX Reconnect power Reset, check machine Hot gas valve leaks thru, replace Replace board Test/replace Replace timer See page 24 Adjust timer Check water filter or supply Replace hot gas valve Re-position sump covers Adjust cube size Replace cube size control Check water system and pump Replace inlet water valve Replace timer Relay does not energize; unit stuck in Replace relay harvest Long freeze cycle Cubes too small Cubes too large Compressor cycles on and off on pump down control Water inlet valve leaks through Water temperature too high Cube size set wrong Cubes size control stuck closed Water inlet valve leaks through Low refrigerant charge Replace inlet water valve Advise user Adjust cube size Replace cube size control Replace inlet water valve and adjust cube size control Locate leak, repair, replace drier, evacuate and weigh in nameplate charge. Check and replace Check and replace Check/replace head pressure control valve Check pump down control for proper operation Check/replace contactor Check replace compressor Replace PC board Liquid line valve or drier restricted TXV restricted Head pressure control valve not working (low condensing temp.) Compressor will not run Low pressure control will not close Contactor coil open Compressor windings open Unit cycles on and off anytime in any cycle Loose connection in PC board September 1993 Page 22 CMS1402R SERVICE DIAGNOSIS: Refrigeration and/or Mechanical SYMPTOM Poor harvest POSSIBLE CAUSE Hot gas valve does not open PROBABLE FIX Check for power to the coil, check for not opening, replace Head pressure control valve does not Replace head pressure control valve. maintain enough head pressure. Unit cycles off during freeze or harvest Low capacity Hi temperature switch opens and closes High head pressure, from dirty condenser, faulty fan motor Non condensable gas in the system Extreme hot location Overcharge of refrigerant Hot gas valve leaks thru Hot gas valve leaks thru, replace it Clean condenser, repair fan motor Purge system, evacuate and weigh in nameplate charge Relocate the cabinet Evacuate and weigh in nameplate charge At the end of the freeze cycle there should be frost on the evaporator end of the hot gas tubes, if not replace the hot gas valve Separate and insulate them Move bin Ice level rocker switch to "Full". Check low side pressure, liquid line valve must open and low side pressure raise over 35 PSIG before pump down control will close to run compressor TXV not letting enough refrigerant into evaporators, adjust or replace TXV Mechanical fault with compressor, replace compressor Frost on compressor Some frost will not hurt TXV meters too much refrigerant Do nothing Adjust or replace TXV Liquid and discharge lines are in contact with each other Unit shuts off before bin is full Compressor cycles on and off Bin Ice level control is set to "Partial" Low pressure control opening and closing Compressor overheats September 1993 Page 23 CMS1402R SERVICE DIAGNOSIS: Bin Ice Level Control CONDITION Ice Machine does not run, it has power to it, the high pressure control is closed, the on/off switch is set to ON (the compressor will not operate until the liquid line valve opens, but the pump should be working if there is no ice in the bin). DETERMINE CAUSE A. Listen for a ticking sound from transducer. PROBABLE CORRECTION If no noise, go to C. If there is a noise, check for a light on the board (models built after 4/93). If there is a light on, check relay contacts N.O. and COM. The contacts should be CLOSED. If closed, go to D. If not, replace the board. If light is off, or prior model, go to B. If the inside of the transducer (above screen) was wet, replace it. Set bin level to FULL and aim at an object about 1-3 feet away. Machine should restart, if not go to D. B. Remove front panel(s), twist transducer 1/4 turn and pull out. DO NOT UNPLUG with power connected. Examine the transducer, the inside must be clean and dry. C. Check power to bin level control Should be 12 volts from transformer, board. if not replace transformer. If there is power go to D. D. Disconnect electrical power and test ice machine circuit by attaching a jumper wire between bin thermostat posts on circuit board part no. 12-1912-01 (the circuit board with the timer on it). Reconnect power. E. Transducer or ice level board assembly defective. If machine does not start go back to machine circuit. If machine starts, disconnect electrical power, remove jumper wire and reconnect electrical power. Then go to E. Replace transducer. Set bin level to FULL and aim at an object about 1-3 feet away. Machine should restart. If this does not repair unit, replace the board. Machine runs, makes ice, switches on and off, but ice level cannot be controlled. Machine runs, but will not shut off. Ice level switch may be defective. On Replace ice level switch boards with a light, check by moving switch & watching light. Board relay stuck closed. Check relay. If COM and N.O. are closed when power is off, replace board. If open, go to B above. PARTIAL VIEW OF CIRCUIT BOARD 12-1912-01 PLUG - IN RELAY Electrical Shock Hazard Can Cause Personal Injury. Disconnect Power Before Servicing. Bin Thermostat Posts at Line Voltage. TIMER BIN THERMOSTAT POSTS MENTIONED IN "B" ABOVE September 1993 Page 24 CMS1402R REMOVAL AND REPLACEMENT Cube Size Control To remove the cube size control: Electrical Shock Hazard. Electrical shock can cause personal injury. Disconnect power before beginning to service components. 1. Remove front panel. 2. Remove cover from control box. 3. Trace capillary tube, from the cube size control to the refrigerant suction line. NOTCH IN BACK OF CONTROL BOX Water Distributor Tubes And Manifold Tubes To remove the water distributor tube and manifold tube: 1. Remove the front panel. 2. Slide the water distributor tube to the front about 1/8-inch along the top of the evaporator plate, until the water distributor tube can be unsnapped from the flexible notch and lifted upward. WATER DISTRIBUTOR CUBE SIZE CONTROL REPLACEMENT OF THE CUBE SIZE CONTROL 4. Remove the coiled capillary tube bulb from the tube well on the suction line. 5. Remove electrical leads from the cube size control. 6. Remove screws and pull the capillary tube through the notch in the back of the control box. Remove the cube size control. To replace the cube size control, reverse the removal procedure. 3. Unsnap and disconnect water distributor tubes from the water manifold section. To replace the water distributor tubes and manifold tubes, reverse the removal procedure. BE SURE the notches in the water manifold tubes properly engage the alignment keys in the tee. BE SURE the water distributor tube is securely fastened at the notch at both sides of the evaporator plate. Check identical attachment for the left water distributor tube and notch; also, that the distributor/manifold connections at the top center of each evaporator plate is snug against the top of the plate. September 1993 Page 25 CMS1402R REMOVAL AND REPLACEMENT Inlet Water Solenoid Valve Assembly To remove the inlet water solenoid valve assembly: Electrical Shock Hazard. Electrical shock can cause personal injury. Disconnect power before beginning to service components. 1. Shut OFF water supply to machine. 2. Loosen and remove outlet water line from the inlet water solenoid valve assembly. 3. Remove screws and pull the water solenoid valve out to gain access. INLET WATER VALVE Water Pump 1. Remove front panel. 2. Unplug water pump electrical connection. 3. Drain water reservoir. 4. Use corbin clamp pliers to loosen and slide corbin clamps on hoses away from pump. 5. Remove screws retaining pump to bracket. 6. Pull pump out of ice machine. 7. Reverse to reassemble. 8. Replace front panel. 8. Reconnect electrical power. Transducer 1. Disconnect electrical power BEFORE removing transducer. 2. Remove the front panel and locate the transducer socket. 3. Twist inner portion of transducer counter-clockwise and push up gently. 4. Unplug transducer and remove from the machine. 5. Reverse steps 1-4 to reassemble. 4. Pull electrical cord from solenoid coil terminals. 5. Remove inlet water fitting from the water solenoid valve. To replace the inlet water valve assembly, reverse the removal procedures. Bin Ice Level Control Circuit Board 1. Disconnect Electrical Power before removing circuit board. 2. Remove front panel. 3. Remove control box cover. 4. Remove wires from circuit board connections. 5. Unlock circuit board fasteners by twisting 1/2 turn. 6. Pull circuit board of off fastener posts. 7. Reverse to reassemble, refer to wiring diagram as needed. REMOVAL OF THE INLET WATER VALVE STRAINER September 1993 Page 26 CMS1402R REFRIGERATION SERVICE General: · Scotsman recommends that any work on the refrigeration system only be done when it is certain that the system needs repair. · Refrigerant should not be added except as a way to determine the proper operation of the product. If the system was low on refrigerant, there is a leak, and it must be found and repaired. · Although this system uses R-22, it should not be wasted to the atmosphere, but reclaimed. · This system has a critical charge, it must be recharged with the correct amount of refrigerant as listed on the nameplate of the ice machine, or performance will suffer. · Anytime the refrigeration system has been opened, the dryer should be replaced. · When brazing the tubing connections to the hot gas valve or thermostatic expansion valve, the component must be protected by heat sink material. Specifically: Recover, reclaim or recycle refrigerant. The method chosen is up to the service company. There are various mechanical devices that may be used to recycle refrigerant at the field level, however, Scotsman requires that any refrigerant placed into a Scotsman ice machine meet ARI spec 700. Reclaim programs are available thru most refrigerant wholesalers. Use conservation minded service procedures: equals minimal refrigerant discharged into the air. · If hi side pressure must be checked, use a quick connect at the end of the discharge hose to minimize the release of refrigerant, J/B Industires part number A33000 works well. · Scotsman's schrader valve caps must be tightened to 70 inch - pounds to insure that the valves will not leak. · If using recycled refrigerant, it must meet ARI spec 700 or have been cleaned by a machine capable of attaining ARI spec 700. If the refrigeration system must be serviced, the quality of service must insure that there will not be a repeat failure, as repeat failures will cause refrigerant to be discharged into the air by the failure or when the failure is corrected: · If there has been a compressor burn out, check for acid in the oil. If acid is indicated, extra steps must be taken to clean up the system. · Never use refrigerant, such as R-11, to clean up or flush out a refrigeration system. When system clean-up is required, the use of suction line filter-dryers and liquid line filter-dryers are recommended. · Always replace the dryer when repairing a leak or replacing a refrigeration component. · Evacuate the system with a good vacuum pump to 500 microns or less. If the triple evacuation method is used, the vacuum should be broken each time with dry nitrogen, not refrigerant. Evacuation must be from both sides of the system. · Weigh in or measure in the nameplate charge. Recharge into the high side. · Check for leaks with a high quality, electronic leak detector. Halide torches will not locate the very small leaks. · Scotsman's schrader valve caps must be tightened to 70 inch - pounds to insure that the valves will not leak. If an ice machine is to be discarded and still contains refrigerant, Scotsman recommends that the refrigerant be recovered, reclaimed, or recycled so that it is not discharged into the air. · Refrain from checking refrigeration pressures without reason. There are many ways to determine the proper operation of a Scotsman ice machine without using refrigerant gauges. Visual inspection of the water system, observation of the ice formation, amp draw, voltage, and other techniques will lead to proper diagnosis. Scotsman also recommends that, at the time of initial start up, gauges not be used. · If gauges must be used, do not always check the high side pressure. If the condenser is clean and seems to be operating correctly, it most likely is. The low side pressure is much more important on an ice machine than is the high side. · If gauges must be used, use very short hoses. Minimal refrigerant discharged into the hoses September 1993 Page 27 CMS1402R REMOVAL AND REPLACEMENT Thermostatic Expansion Valve 1. Before replaceing this valve, be certain that the valve is the cause of the problem, and cannot be adjusted. 2. Remove the front panel. 3. Discharge and recover the refrigerant. 4. Locate the TXV bulb (on the suction line), remove the clamps and bulb from the tube. 5. With the refrigeration system open, unsweat the TXV from the tubing. 6. Place the new TXV in position. 7. Wrap the new TXV body with heat sink material. Do not get any moisture in the valve. 8. Carefully braze the valve to the tubing. Examine the joints, if they look good procede to the next step, if not, re-do them. 9. Install a new dryer, and braze it in place also. 10. Reattach the TXV bulb to the suction line in the same place as the old one. 11. Evacuate the system to 500 microns. 12. Weigh or measure the nameplate charge into the receiver. 13. If the machine has been off on the breaker there may be refrigerant trapped in the oil of the compressor, so do not restart until the compressor has been warmed by the crankcase heater for 12 hours. If the compressor was warm throughout the replacement process, the ice machine may be restarted without waiting to re-warm the compressor. Hot Gas or Liquid Line Valve. 1. Before replaceing this valve, be certain that the valve is the cause of the problem. 2. Remove the front panel. 3. Discharge and reocver the refrigerant. 4. Unplug the coil of the valve. 5. With the refrigeration system open, unsweat the valve from the tubing. 6. Place the new valve in position. 7. Wrap the new valve body with heat sink material. Do not get any moisture in the valve. 8. Carefully braze the valve to the tubing. Examine the joints, if they look good procede to the next step, if not, re-do them. 9. Install a new dryer, and braze it in place also. 10. Plug the power cord back onto the coil. 11. Evacuate the system to 500 microns. 12. Weigh or measure the nameplate charge into the receiver. 13. If the machine has been off on the breaker there may be refrigerant trapped in the oil of the compressor, so do not restart until the compressor has been warmed by the crankcase heater for 12 hours. If the compressor was warm throughout the replacement process, the ice machine may be restarted without waiting to re-warm the compressor. Refrigerant: NO liquid refrigerant may be put into this system anywhere except the receiver. DO NOT use the access valves at the front of the machine for weighing in the charge: use the "king" or receiver service valve. All liquid R-22 must be weighed into the receiver through the "front seated" receiver outlet service valve. FRONT SEATED VALVE SERVICE PORT September 1993 Page 28