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. Double System RL 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 · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 2 FOR THE INSTALLER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 3 FOR THE ELECTRICIAN · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 4 FOR THE PLUMBER · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 5 FOR THE INSTALLER: Final Check List · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 6 INITIAL START UP · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 7 COMPONENT IDENTIFICATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 8 COMPONENT DESCRIPTION: Evaporator · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 9 CONTROL BOX: Components · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 10 ELECTRICAL SEQUENCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 11 OPERATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 12 OPERATION: Refrigeration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 13 CLEANING and SANITATION · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 14 SENSOR MAINTENANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 15 BEARING MAINTENANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 16 AUGER MAINTENANCE · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 17 SERVICE DIAGNOSIS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 18 SERVICE DIAGNOSIS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 19 CONTROL SYSTEM DIAGNOSTICS · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 20 REMOVAL AND REPLACEMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 21 REMOVAL AND REPLACEMENT: Bearing And Breaker · · · · · · · · · · · · · · · · · · · · Page 22 REMOVAL AND REPLACEMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 23 REMOVAL AND REPLACEMENT · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · Page 24 REMOVAL AND REPLACEMENT: Evaporator · · · · · · · · · · · · · · · · · · · · · · · · · · Page 25 REMOVAL AND REPLACEMENT: Gearmotor · · · · · · · · · · · · · · · · · · · · · · · · · · Page 26 This manual was printed on recycled paper, keep it for future reference. Note the Warning symbol where it appears. It marks a potential hazard. November 2000 Page 1 Double System RL BACK VIEW FOR THE INSTALLER: Specifications 15.53" 3.1" SUCTION LINE CONNECTION 7 8" LIQUID LINE CONNECTION 12" 20.84" 9.43" 5.25" 3" 17.8" 18.8" 21.66" ELECTRICAL INLET POTABLE WATER INLET 3/8" FLARE The machine is designed to fit a variety of Scotsman storage bins such as BH800 or SB480. Installation Limitations: The machine is designed for indoor installations only. Air Temp Water Temp Voltage Water Pressure Minimum 50oF 40oF 198 VAC 20 psi Maximum 100oF 100oF 253 VAC 80 psi RO Water Limitation: Water conductivity must be no less than 35 microSiemens/cm. SPECIFICATIONS: Model FME2404RL NME1854RL FM2402RL-C NM1852RL-C FME3004RL Cabinet Size 42"w x 27"h x 24"d same same same same 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. DRAIN 3/4" FPT System Refrigerant R-404A R-404A R-22 R-22 R-404A BTUH required* 12,000 12,000 12,500 12,500 15,000 Voltage 208-230 208-230 208-230 208-230 208-230 208-230 Ice Type Flake Nugget Flake Nugget Flake Nugget NME2504RL same R-404A 15,000 * Use to determine needed condensing unit capacity. Not an AC load. January 2004 Page 2 FOR THE INSTALLER Double System RL 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 AT LEAST enough extra capacity to handle the BTUs (from table on page 2) 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 machine 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 building's refrigeration system. Notes: back of the cabinet. ·Suction Line and Liquid Line Stubs are at the ·R-404A models: 1.5 ounces of R-404A refrigerant is in the system as a holding charge. ·A P-trap should be installed where there will be more than 10' of vertical rise in the suction line. ·R-22 models: Nitrogen is the holding charge ·Be sure there is enough BTU capacity. ·Be sure the liquid connection is NOT in series with another liquid line valve. ·Local Codes must be observed. November 2000 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 November 2000 Page 4 FOR THE PLUMBER 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. Double System RL 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 VENT THIS DRAIN CONFORM TO ALL APPLICABLE CODES SHUT OFF VALVE FIELD SUPPLIED WATER FILTER WATER INLET BIN DRAIN FLOOR DRAIN November 2000 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? November 2000 Page 6 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 (mode) switch, and observe: Double System RL 7. Switch on the other master (mode) 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. 8. With both sides operating, the sight glass should remain full, and the low side pressure will be about model types 2404, 1854 , 3004 or 2504 (R-404A): · That liquid line valve opens · The gearmotor runs · Within a short time, that side of the machine begins to make ice. ·36 PSIG, + or - 2 model types 2402 or 1852 (R-22): ·25 PSIG, + or - 2 · Water flows from the water reservoir, and the float drops, letting in more water. Gearmotor amp draw should not exceed the nameplate rating. 9. Check the system very carefully for any refrigerant leaks, repair as needed. November 2000 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. THERMO VALVE EPR 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 (2404/1854, 3004/2504): 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 ...