Double System RL TO THE OWNER OR USER: The service manual you are reading 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. The is the freezer portion of a commercial ice machine. It is designed to be connected to the condensing section of a refrigeration system, specifically a supermarket system. Table of Contents FOR THE INSTALLER: Specifications FOR THE INSTALLER ........................... Page 2 Page 3 Page 4 Page 5 Page 6 Page 7 Page 8 Page 9 Page 10 Page 11 Page 12 Page 13 Page 14 Page 15 Page 16 Page 17 Page 18 Page 19 Page 20 Page 21 Page 22 Page 23 Page 24 ................................... FOR THE ELECTRICIAN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOR THE PLUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FOR THE INSTALLER: Final Check List INITIAL START UP .......................... .................................... ........................ COMPONENT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPONENT DESCRIPTION: Control Box COMPONENT DESCRIPTION: Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . ELECTRICAL SEQUENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPERATION ........................................ ............................. OPERATION: Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . MAINTENANCE AND CLEANING CLEANING MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ........................................ ............................. ............................. ............................. SERVICE DIAGNOSIS: Condition - No Ice Being Produced . . . . . . . . . . . . . . . . REMOVAL AND REPLACEMENT REMOVAL AND REPLACEMENT REMOVAL AND REPLACEMENT REMOVAL AND REPLACEMENT: Bearing And Breaker . . . . . . . . . . . . . . . . . . REMOVAL AND REPLACEMENT: Evaporator . . . . . . . . . . . . . . . . . . . . . . . REMOVAL AND REPLACEMENT: Gearmotor . . . . . . . . . . . . . . . . . . . . . . . CIRCUIT BOARD TESTING ................................ Parts lists and wiring diagrams are in the center of this manual, printed on yellow paper. This manual was printed on recycled paper, keep it for future reference. Note the Warning symbol where it appears. It marks a potential hazard. March 1997 Page 1 Double System RL FOR THE INSTALLER: Specifications BACK VIEW 15.53" 3.1" SUCTION LINE CONNECTION 7/8" LIQUID LINE CONNECTION 1/2" 20.84" 9.43" 5.25" 3" 17.8" 18.8" 21.66" ELECTRICAL INLET POTABLE WATER INLET 3/8" FLARE DRAIN 3/4" FPT The machine is designed to fit the Scotsman storage bins BH800 or B90. Leg kit KLP4 is recommended when using both the B90 bin and an extension. Installation Limitations: The machine is designed for indoor installations only. The machine must also be in a controlled environment where the air temperature does not fall below 500F., or go above 1000F. The water temperature must be between 400F. and 1000F. The electrical power supply must not drop below -5% of the lowest nameplate voltage or go above 10% of the highest nameplate voltage. 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.U.L. 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. SPECIFICATIONS: System Refrigerant FME2400RL 42"w x 27"h x 24"d R-404A NME1850RL same R-404A FM2402RL same R-22 NM1852RL same R-22 Model Cabinet Size BTUH required 16,000 16,000 16,000 16,000 Voltage 208-230 208-230 208-230 208-230 Ice Type Flake Nugget Flake Nugget March 1997 Page 2 Double System RL FOR THE INSTALLER Select the Location: The unit can only be installed indoors within the limitations described on page 2. TYPICAL INSTALLATION: ALLOW ROOM FOR SERVICE ACCESS The ice machine will have to be connected to the building's R-404A refrigeration system, check to be sure that the system Ice Machine has enough extra capacity to handle a minimum of additional 16,000 BTU's per hour @ 1100F. liquid line temperature (assume a 00F. evaporator temperature). Storage Bin: Scotsman's B90 will be the presumed bin of choice. If using the bin extension BX87, install heavy duty leg kit KLP4 and place the bin into position. Remove the paper tape from the bin edge gasket, and install the bin extension onto the B90. Remove the paper tape from the bin extension top edge, and using a mechanical lift, install the FME2400RH onto the top of the storage bin assembly. Fasten the ice machine to the bin using (4) 5/15-18 2.5" cap screws. BX87 BIN Level the assembly by: EXTENSION a. Turning the leg levelers in or out on the standard legs. b. Use shims under the heavy duty legs of B90 STORAGE BIN the KLP4. Locate the Nameplate: The nameplate is located on the back panel of the machine, and contains the electrical characteristics particular to the unit being installed. Refrigeration Installation: The skills of a refrigeration technician are required to connect the ice machine to the buildings refrigeration system. Notes: ·Suction Line and Liquid Line Stubs are at the back of the cabinet. ·1.5 ounces of the appropriate refrigerant is in the system as a holding charge. ·Be sure there is enought BTU capacity. ·Be sure the liquid connection is NOT in series with another liquid line valve. ·Local Codes must be observed. ·A P-trap should be installed where there will be more than 10' of vertical rise in the suction line. March 1997 Page 3 Double System RL FOR THE ELECTRICIAN CONFORM TO ALL APPLICABLE CODES Electrical Connections: Locate the nameplate for the current requirements, and then determine the wire size and type per the National Electric Code. The machine requires a solid chassis to earth ground wire. Refer to the wiring diagram. The ice machine should be connected to it's own electrical circuit, and be individually fused. Voltage, when the unit is under full load, must remain within the limitations listed on page 2. LOW VOLTAGE CAN CAUSE EQUIPMENT MALFUNCTION AND/OR DAMAGE All external wiring should conform to the National, State, and local electrical codes. Usually the services of a licensed electrician will be required. DETAIL OF JUNCTION BOX JUNCTION BOX POWER SUPPLY March 1997 Page 4 Double System RL FOR THE PLUMBER CONFORM TO ALL APPLICABLE CODES Water Supply: The recommended water supply line is 3/8" O.D. copper tubing, with a minimum operation pressure of 20 PSIG, and a maximum of 80 PSIG. Connect to cold water using the male flare connection at the back of the machine. Install a shut off valve in an accessible space between the ice maker and the water supply. Drain System: All drains are of the gravity type, and must have a minimum of 1/4" fall per foot of horizontal run. The drains must be installed to conform to local plumbing codes. The use of a vent at the machine and at the bin will allow the system to drain properly. Use only rigid tubing for drains; insulation of the bin drain is recommended. 3/8" MALE FLARE 3/4" FPT SHUT OFF VALVE VENT THIS DRAIN FIELD SUPPLIED WATER FILTER WATER INLET BIN DRAIN FLOOR DRAIN March 1997 Page 5 Double System RL FOR THE INSTALLER: Final Check List 1. Is the unit installed where the air and water temperatures are within and will remain within the limitations for the unit? 2. Is there 6" clearance at the rear of the machine for utility connections? 3. Has the water supply line be checked for pressures between 20 and 80? 4. Has the unit been leveled? 5. Has the shipping material been removed from inside the cabinet? 6. Have the electrical connections been made? 7. Have the drains been installed and checked for leaks? 8. Has the refrigeration supply been installed and checked for leaks? 9. Has the bin and cabinet been wiped clean or sanitized? 10. Has the warranty registration card been properly filled out and mailed to Scotsman? 11. Has the owner been given the service manual and been instructed on how to maintain the ice maker? 13. Has the owner been given the name and telephone number of the local Scotsman service agency? March 1997 Page 6 Double System RL INITIAL START UP 1. Remove the top and front panels. 2. Open the water valve, and observe that the two float reservoirs fill up with water and shut off. 3. Switch on the electrical power. 4. Open the hand valves (in the liquid lines). 5. Open the ball valves (in the suction lines). 6. Switch on one master switch, and observe: That liquid line valve opens The gearmotor runs Within a short time, that side of the machine begins to make ice. Water flows from the water reservoir, and the float drops, letting in more water. 8. With both sides operating, the sight glass should remain full, and the low side pressure will be about 2400 or 1850 models (R-404A) 36 PSIG, + or - 2 2402 or 1852 models (R-22) 25 PSIG, + or - 2 Gearmotor amp draw should not exceed the nameplate rating. 9. Check the system very carefully for any refrigerant leaks, repair as needed. 7. Switch on the other master switch, observe that: The liquid line valve opens The gearmotor runs Within a short time, that side of the machine begins to make ice. Water flows from the water reservoir, and the float drops, letting in more water. March 1997 Page 7 Double System RL COMPONENT IDENTIFICATION Liquid line valve(s) These valves operate to turn the ice making process on and off. When the ice level drops in the ice chute, the ice level sensor will cause the circuit board to close the liquid line relay, which energizes the liquid line valve for that side of the system. The liquid line valve opens, and liquid refrigerant flows to the thermostatic expansion valve. Thermostatic Expansion Valve The metering device of each system, the valve(s) sense the temperature of the suction line and vary the amount of liquid refrigerant that passes through the valve into the evaporator, thus maintaining a constant level of refrigeration. TXV's are factory set. Do not adjust unnecessarily. DO NOT ADJUST THE TXV UNTIL THE EPR HAS BEEN SET. The superheat setting is 4-80F. Measure the temperature of the evaporator outlet at the TXV bulb, and check the low side pressure at the EPR valve. Convert the pressure to temperature (using a temperature pressure chart) and subtract the amount from the outlet temperature. The result is the superheat. Use an electronic thermometer. EPR VALVE THERMO VALVE EPR: Evaporator Pressure Regulator Valve This valve maintains a constant pressure on its inlet (evaporators) side regardless of the pressure on the outlet (suction) side. The EPR is factory set, adjust only if needed. After adjusting, re-check TXV superheat. EPR Settings: R-22 models (2402/1852): 25 PSIG R-404A models (2400/1850): 36 PSIG Evaporators: Where the water is frozen into ice crystals. As the water cools, it begins to turn into ice, and the slowly turning auger lifts the ice, as it is being made, and forces it up and out of the "breaker" or spout where the extra water is compressed out of the ice. The ice then drops through the chute, into the storage bin. THERMO VALVE LIQUID LINE VALVE EVAPORATOR March 1997 Page 8 Double System RL COMPONENT DESCRIPTION: Control Box Circuit Board: Controlling the ice machine through sensors and relays. The sensors are: ice level, and water level. The relays are for the gear motor (with a built in time delay to clear the evaporator of ice when the unit turns off) and for the liquid line valve. Transformer: Supplies low voltage to the circuit board. On/Off Switch: Manual control for that side of the machine. ON/OFF SWITCH TERMINAL STRIP TRANSFORMER CIRCUIT BOARD March 1997 Page 9 Double System RL COMPONENT DESCRIPTION: Evaporator Evaporator: A refrigerated vertical tube filled water and containing a water seal and auger. Auger: A solid stainless steel double spiral auger, it pushes the ice crystals up to the top of the evaporator. Water Seal: A two part "face" seal, the top half rotating with the auger, the bottom half stationary, the sealing action being where the two seal "faces" meet. Ice Sweep: A plastic cap with "fingers". It revolves with the auger to "sweep" the ice into the ice chute. Divider: Where the ice is compressed and much of the extra water is squeezed out of it before it is discharged into the bin. Motor: A split phase motor that drives the gear reducer. Bearing: As the ice is pushed up the evaporator, the auger is thrust down, and pressure from the auger thrust is taken up by this bearing. BEARING ICE SWEEP DIVIDER EVAPORATOR ...