SERVICE MANUAL. Der Link zu den Icematic Eiswürfelmaschinen der N-Serie bei Kälte-Berlin. Ihr Icematic Fachhändler :

Transcription

1 SERVICE MANUAL Der Lik zu de Icematic Eiswürfelmaschie der N-Serie bei Kälte-Berli E L E C T R O N I C M O D U L A R C U B E S Ihr Icematic Fachhädler : Kälte-Berli Am Pfarracker Berli Fo: +49 (0) 30 / Fax: +49 (0) 30 / ifo@kaelte-berli.de Iteret: N 132M N 192M N 202M N 302M N 402M N 502M OUR SYSTEMS COMPLY WITH EEC DIRECTIVE 2006/95/EEC /108/EEC SERVICE MANUAL Cod /0 - Rev.01 - GB - 03/2010

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3 INDEX Table of cotets... 3 Specificatios FOR THE INSTALLER Itroductio Storage bi Stadard legs Importat operatig requiremets Select locatio Storage bi Ice machie Fial check list FOR THE PLUMBER Coform to all applicable codes Water ilet Drais For the electricia Electrical coectios START-UP Start-up cycle Freezig cycle Harvest cycle OPERATION Refrigeratio durig freeze Water system Refrigeratio system durig harvest Water system Cotrol sequece Alarm coditios PC Board set up SERVICE SPECIFICATIONS Compoet Operatig characteristics COMPONENT DESCRIPTION Compoet descriptio WIRING DIAGRAM N air/water cooled N air/water cooled SERVICE DIAGNOSIS Service diagosis MAINTENANCE & CLEANING INSTRUCTION Icemaker Ice storage bi Cabiet erxterior Cleaig (Icemaker)

4 SPECIFICATIONS MODULAR CUBER N 132M KS201/301 KN mm 23 mm 23 mm 11 mm 26 mm 26 mm D201 D310 STANDARD HALF DICE Model Cod. uit Fiish Comp. HP N132M - A N132M - W Model N132M - A N132M - W Air Water Basic electr. amps /50/1 4,5 3,3 Stailess Steel 7/8 Start amps 29 watts Electric power cos. Kwhx24 HR. 17** 13,3** Water req. lt/24 HR 168** 2568** N. of wires Amps Fuse 3x1,5 mm 2 10 NOTE. To keep your Modular cuber performig at its maximum capacity, it is ecessary to perform periodic maiteace as outlied o the last pages of this maual. 4 Cubes per harvest: 234 Full Half * With water at 15 C ** t air 32 C - t water 21 C

5 SPECIFICATIONS MODULAR CUBER N 192M KS201/301 KN mm 23 mm 23 mm 11 mm 26 mm 26 mm D201 D310 STANDARD HALF DICE Model Cod. uit Fiish Comp. HP N192M - A N192M - W Model N192M - A N192M - W Air Water Basic electr. amps /50/1 7,5 4,9 Stailess Steel 1 3/8 Start amps 32 watts Electric power cos. Kwhx24 HR. 23,50** 19,50** Water req. lt/24 HR 264** 3024** N. of wires Amps Fuse 3x1,5 mm 2 16 NOTE. To keep your Modular cuber performig at its maximum capacity, it is ecessary to perform periodic maiteace as outlied o the last pages of this maual. Cubes per harvest: 234 Full Half * With water at 15 C ** t air 32 C - t water 21 C 5

6 SPECIFICATIONS MODULAR CUBER N 202M KS201/301 KN mm 26.5 mm 26.5 mm 13 mm 26 mm 26 mm D201 D310 STANDARD HALF DICE Model Cod. uit Fiish Comp. HP N202M - A N202M - W Model N202M - A N202M - W Air Water Basic electr. amps /50/1 4,5 4,0 Stailess Steel 7/8 Start amps 29 Water req. lt/24 HR * NOTE. To keep your Modular cuber performig at its maximum capacity, it is ecessary to perform periodic maiteace as outlied o the last pages of this maual. watts Electric power cos. Kwhx24 HR. N. of wires Amps Fuse 24,48** 3x1,5 mm Cubes per harvest: 234 Full Half * With water at 15 C ** t air 32 C - t water 21 C

7 SPECIFICATIONS MODULAR CUBER N 302M KS201/301 KN mm 26.5 mm 26.5 mm 13 mm 26 mm 26 mm D201 D310 STANDARD HALF DICE Model Cod. uit Fiish Comp. HP N302M - A N302M - W Model N302M - A N302M - W Air Water Basic electr. amps /50/1 6,2 5,2 Stailess Steel 1 3/8 Start amps 32 Water req. lt/24 HR * NOTE. To keep your Modular cuber performig at its maximum capacity, it is ecessary to perform periodic maiteace as outlied o the last pages of this maual. watts Electric power cos. Kwhx24 HR. N. of wires Amps Fuse 28,63** 3x1,5 mm 2 16 Cubes per harvest: 234 Full Half * With water at 15 C ** t air 32 C - t water 21 C 7

8 SPECIFICATIONS MODULAR CUBER N 402M N402M N402M N402M KS401 KN311 N402M 26.5 mm 26.5 mm 26.5 mm 13 mm 26 mm 26 mm D201 D310 STANDARD HALF DICE Model Cod. uit Fiish Comp. HP N402M - A N402M - W Model N402M - A N402M - W Air Water Basic electr. amps /50/1 9,0 8,0 Stailess Steel 1 5/8 Start amps 31 Water req. lt/24 HR * NOTE. To keep your Modular cuber performig at its maximum capacity, it is ecessary to perform periodic maiteace as outlied o the last pages of this maual. watts Electric power cos. Kwhx24 HR. N. of wires Amps Fuse 40,00** 3x1,5 mm Cubes per harvest: 342 Full Half * With water at 15 C ** t air 32 C - t water 21 C

9 SPECIFICATIONS MODULAR CUBER N 502M N502M N502M N502M KS501 KN311 N502M 26.5 mm 26.5 mm 26.5 mm 13 mm 26 mm 26 mm D201 D310 STANDARD HALF DICE Model Cod. uit Fiish Comp. HP N502M - A N502M - W Model N502M - A N502M - W Air Water Basic electr. amps /50/3 3,5 3,3 Stailess Steel 2 Start amps 24 Water req. lt/24 HR * NOTE. To keep your Modular cuber performig at its maximum capacity, it is ecessary to perform periodic maiteace as outlied o the last pages of this maual. watts Electric power cos. Kwhx24 HR. N. of wires Amps Fuse 43,70** 3x1,5 mm 2 10 Cubes per harvest: 342 Full Half * With water at 15 C ** t air 32 C - t water 21 C 9

10 FOR THE INSTALLER INTRODUCTION These istructios provide the specificatios ad the step-by-step procedures for the istallatio, start up ad operatio for the model N Modular Cubers. The Modular Cubers are quality desiged, egieerig ad costructed, ad are thoroughly tested icemakig systems, providig the utmost i flexibility to fit the eeds of a particular user. IMPORTANT OPERATING REQUIREMENTS MINIMUM MAXIMUM Air Temperature 10 C (50 F) 40 C (100 F) Water Temperature 5 C (40 F) 35 C (90 F)0 Water Pressures 1 bar gauge 5 bar gauge Electrical Voltage Variatios Voltage ratig specified o ameplate -10% +10% Exteded periods of operatio exceedig these limitatios costitues misuse uder the terms of Maufacturer s Limited Warraty, resultig i a loss of warraty coverage. SELECT LOCATION The first step i istallig the equipmet is to select the locatio. The purchaser of the uit will have a desired spot i mid, check out that spot to isure that it is: - idoors, i a eviromet that does ot exceed the air ad water temperature limitatios for the equipmet. - that the ecessary utilities are available icludig the correct voltage electrical power. - that there be space aroud the istalled machie for service, 15 cm. miimum left, right, ad rear for aircooled models. STORAGE BIN The Icematic bis for these uits are the D 201 ad D 310. Other bis may be available with bi tops to vary the storage capacity. Lay the bi o its back, usig cardboard from the carto to support it, screw i the legs. Stad the bi upright, ad correct ay possible small tears i the machie moutig gasket with food grade silicoe sealat. INSTALLATION NOTE: Allow 15 cm. miimum space at sides ad back for vetilatio ad utility coectios. STORAGE BIN The models N stack oto Icematic bi model D D 310. Refrigerat R 404 A Charge per ameplate ratig. STANDARD LEGS: Furished with storage bi. Four legs screw ito moutig sockets o cabiet base. Provide 18.5 cm. (7 ) miimum height icludig adjustable levelig foot. 10

11 ICE MACHINE The use of a mechaical lift is recommeded for liftig the ucrated icemaker oto the bi. Remove frot, top ad sides paels. Place the uit directly oto the bi, alig it with the back of the bi. Locate the hardware package, take out two moutig screws, ad use them to secure the Icemaker to the two sides of the bi. See illustratio below. Remove all shippig material as well as the maskig tapes from the ice deflector/evaporator cover. AIR BAFFLE Istall o the back side of the machie the air baffle as per istructio provided with it. ATTENZIONE - ATTENTION - ACHTUNG QUESTO DEFLETTORE VA INSTALLATO PER IMPEDIRE LA RICIRCOLAZIONE DELL'ARIA CALDA NEL CONDENSATORE ISTRUZIONI PER IL MONTAGGIO ASSEMBLY INSTRUCTIONS Remove first the ice deflector/evaporator cover the the maskig tape from the ice thickess sesor. INSTRUCTIONS DE MONTAGE INSTALLATIONSANWEISUNGEN FOR THE PLUMBER CONFORM TO ALL APPLICABLE CODES WATER INLET AIR-COOLED MODELS: The recommeded water supply is cold water coected to the - 3/4' gas - male fittig at the back of the cabiet. Istall a had valve ear the machie to cotrol the water supply. 1) Switch 2) Plug receptacle 3) Electrical plug 4) Water ilet 5) Shut-off valve 6) Water filter 7) Water outlet lie 8) Bi water outlet lie 9) Ope veted water drai 10) Water outlet from the codeser: water cooled versio oly. 11

12 Whe choosig the water supply for the N Cuber, cosideratio should be give to: A. Legth of ru. B. Water clarity ad purity. C. Adequate water supply pressures. Sice water is the most importat sigle igrediet i producig ice you caot over emphasize the three items listed above. Low water pressure, below 1 bar may cause malfuctio, of the icemaker uit. Water cotaiig excessive mierals will ted to produce cloudy colored ice cubes, plus scale build-up o parts i the water system. Heavily chloriated water ca be cotrolled usig charcoal or carbo filters. DRAINS AIR-COOLED MODELS: There is oe 20 mm. dia sump drai fittig at the back of the cabiet. Isulatios i high humidity areas is recommeded. The ideal drai receptacle would be a trapped ad veted floor drai. WATER-COOLED MODELS: Besides the above drai, a separate codeser drai must be ru. Coect it to the - 3/4' gas - codeser drai coectio at the back of the cabiet. STORAGE BIN: A separate gravity type drai eeds to be ru, similar to the air-cooled sump drai. Isulatio of this drai lie is recommeded. FOR THE ELECTRICIAN ELECTRICAL CONNECTIONS The uit come equipped with a electrical cord for power supply. The lead wires must be coected to a electrical plug that correspods to the local electrical codes ad requiremets or to a separate two poles discoect box with opeig to the cotacts of about 3 millimeters. The discoect box shoulds be placed close to the selected ice maker locatio to be easily ad prompt reached. Udersized wirig or uproperly istalled electrical circuit will result i major problems ad malfuctios. Voltage variatios shoud ot exceed te percet. IMPORTANT: All plumbig ad electrical coectios must be made by licesed plumbers ad electricias, this oe must follow the electrical specificatios prited o the ice maker ameplate. NOTE: All ICEMATIC Cubers require a eutral wire ad a solid earth groud wire to prevet possible severe Electrical Shock Ijury to idividuals or extesive damage to equipmets. FINAL CHECK LIST 1. Is the cabiet/bi level? 2. Is the cuber i a locatio where ambiet temperatures are a miimum of 10 C (50-degrees F.) all year aroud ad to ot exceed a maximum of 40 C. (100 F.). 3. Is there at least a 15 cm. clearace behid ad aroud the cabiet for all coectios ad for proper air circulatio? 4. Have all electrical ad pipig coectios bee made? 5. Has the electrical power supply wirig bee properly coected ad the voltage tested ad checked agaist the ameplate ratig? Has the uit properly grouded. 6. Is the water supply lie shutoff valve istalled ad opeed ad has the ilet water supply pressure bee checked to isure a miimum of 1 bar without exceedig a maximum of 5 bar. 7. Have the compressor holddow bolts bee checked to be sure the compressor is sug o the moutig pads. 8. Check all refrigerat lies ad coduit lies to gard agaist vibratio ad possible failure. 9. Has the cuber ad the bi bee wiped clea with clea damp cloths? 10. Has the ower/user bee give the User Maual ad istructed o how to operate the icemaker ad the importace of periodic maiteace? 11. Has the ower/user bee give the ame ad telephoe umber of the Authorized ICEMATIC Distributor or Service Agecy servig him? 12. Has the Maufacturer s Registratio Card bee properly filled out? Check for correct Model ad Serial Numbers from ameplate, the mail the completed card to the Maufactured. 12

13 START-UP START-UP CYCLE 1. Ope the water tap/valve ad switch ON the power o the electrical supply lie. 2. The models N eter i the Start Up mode with the PC Board eergized as well as the Gree LED of the machie uder power while the models N eter i 90 miutes delay time cotrolled by a special Start-up Delay PC Board. 3. Water is comig ito the water through the Water Ilet Soleoid Valve till the water reservoir if filled up to the maximum level cotrolled by a Water Level Sesor secods later, the Water Pump starts up. 5. After few miutes (3-5) from the start up of the freezig cycle, the Water Ilet Soleoid Valve is activated agai for few secods to re-fill the water reservoir up to the maximum level so to reduce ay possibility of slush ice formatio. 6. I the meatime the codeser sesor starts to trasmit the curret to the PC Board keepig i operatio the Fa Motor i ON-OFF mode or cotiuously accordig to the codeser temperature. The Gree LED of machie i operatio is eergized too, blikig fast for 40 secods. NOTE: The models N 502 is equipped with a compressor crakcase heater ad a Start up Delay PC Board set up at 90 miutes. Durig the first 90 miutes oly the compressor crakcase heater is eergized warig up the compressor. 3. Durig the Start Up cycle the compoets i operatio are: Hot gas valve Water Drai Valve Water Pump Harvest assist soleoid (pusher). FREEZING CYCLE 1. After the Start Up cycle the machie eters directly ito the Freezig cycle with the followig compoets eergized: Water Ilet valve Compressor Fa motor (i cotiuous operatio for the first 3 miutes). 2. The LED eergized are: Machie uder power Machie i operatio (steady) NOTE: Do ot remove the evaporator deflector cover as it will cause the switchig off of the machie at "STORAGE BIN FULL". 7. The machie remais i the freezig cycle with the ice that become thicker till the two metal plates of the Ice Thickess Sesor are covered by the water cascadig through the frot surface of the ice plate. 8. Whe the Power is trasmitted back to the PC Board cotiuously through the metal plates of the Ice Thickess Sesor for more the 6", the machie eters i the Pre-Harvest or directly ito the Harvest Cycle mode accordig to: FAN MOTOR IN ON-OFF MODE DURING THE PREVIOUS FREEZING CYCLE RISE UP THE CUT IN TEMPERATURE OF THE CONDENSER SENSOR TO 38 C (FAN MOTOR OFF) AND EXTEND THE LENGTH OF FREEZ- ING CYCLE BY 30" MORE THEN GO INTO HAR- VEST CYCLE FAN MOTOR ALWAYS IN OPERATION DURING THE PREVIOUS FREEZING CYCLE GO STRAIGHT TO THE HARVEST CYCLE 9. First freezig time will rage betwee 13 ad 17 miutes. Loger time for temperature above 25 C ad shorter time required whe temperature are below 25 C. Average complete cycle time is about 15 mi. 13

14 HARVEST CYCLE 1. Durig the harvest cycle the compoets i operatio are: Hot Gas valve Harvest assist soleoid (pusher) Water Drai/Purge Valve Water Pump for the first 40" Compressor ad both Machie Uder Power Machie i Operatio secods after the begiig of the Harvest Cycle, the Water Ilet Soleoid Valve is eergized for 10 secods oly i order to have a short flush of fresh water ito the sump while the Water Pump is still i operatio. 3. The Fa Motor remais i OFF mode uless the Codeser Sesor probe rise up to more the 38 C (same set up as per ed of freezig cycle). 4. Whe the ice plate is fallig dow from the evaporator, the magetic switch is activated for a while providig the sigal to the PC Board to restart a ew freezig cycle. 5. Observe first ice cube harvest ad check size of ice cubes; if a adjustmet is required thread dow or out screw N. 1 as show o below illustratio. NOTE: This type of machie produce a "ICE PLATE" that breaks whe falls dow ito the storage bi. Settig the ice thickess sesor i order to have sigle ice cubes may cause malfuctio of the machie. 6. Observe secod ad third cube harvest. Check if size ad shape combiatio is correct. I areas where extreme problem water coditios exist, filterig or purifyg equipmet is recommeded. NOTE: If water used is too soft, "demieralized" the ice thickess sesor might ot be able to sese the water o its reeds, there by it will ot switch the uit o harvest cycle. A safety system built i the P.C. Board switches the uit o harvest cycle wheever the freezig period gets loger the 30 or 40 miutes. NOTE: To assure a correct operatio of the machie the water must have a miimum electrical coductivity of 20 us. 7. Check operatio of magetic switch cotrollig it by keepig ope the bottom ed of plastic deflector for more tha 30 secods. The machie must switch off at storage bi full. Release the plastic deflector. The machie should restart i the freezig cycle mode withi few secods goig through a 3 miutes delay time. 8. Place agai all cabiet paels ad screws previously removed. 9. Thoroughly explai to ower/user the sigificat specificatios of the ice maker start-up, reset ad operatio, goig through the procedures i the operatig istructios. Aswer all questios about the ice maker by the ower ad iform the ower himseft of the ame ad telephoe umber of the authorized service agecy servig him. Ice Thickess Sesor Adjustmet This screw positio determies the distace betwee the sesor reeds ad the egg-crate evaporator thus keepig the ice cube at a proper thickess. 14

15 OPERATION FREEZE CYCLE EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE COMPRESSOR STRAINER X AIR OR WATER CONDENSER DRIER RECEIVER (WATER COOLED ONLY) HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID REFRIGERATION SYSTEM SCHEMATIC LOW PRESSURE VAPOR REFRIGERATION DURING FREEZE: This ice machie employes either air or water as a codesig media, the refrigeratio system for either oe is a follows: At the hermetic compressor, Refrigerat is compressed ito a high temperature, high pressure gas. The gas moves through the discharge lie ito the codeser, air or water-cooled. If air-cooled, the discharge pressure will chage with the heat load ad the ambiet air temperature. If water-cooled, the discharge pressure is cotrolled by the amout of water flowig through the codeser - which is determied by the water regulatig valve. After the gas is cooled i the codeser, givig up much of its heat, the gas codeses ito a high pressure liquid. This liquid travels through the liquid lie to the meterig device, a thermostatic expasio valve. The thermostatic expasio valve meters how much liquid refrigerat is to be allowed ito the evaporator sectio of the refrigeratio system. This is determied by the temperature of the TXV sesig bulb, located o the suctio lie maifold, at the outlet of the evaporator. If the bulb seses a warm suctio lie, more refrigerat is allowed ito the evaporator, (commo at the begiig of the freeze cycle) ad whe the temperature begis to fall, less refrigerat is allowed through. This is why the suctio side gauge pressure will declie throughout the freeze cycle. At the evaporator, the liquid refrigerat released from high pressure, boils off i the low pressure eviromet ad absorbs heat, thus coolig the evaporator surface ad aythig ear it, such as water. The low pressure refrigerat vapor the is forced through the heat exchager where ay excess liquid refrigerat boils-off, allowig oly refrigerat vapor to eter the compressor suctio tube, where it is recompressed ito high pressure, high temperature gas agai ad the cycle repeats. 15

16 WATER SYSTEM A combiatio of a soleoid water ilet valve with a water level sesor is used to cotrol the level of the water ito the reservoir/sump. A pump, ruig cotiuously, after the first 30" of freezig cycle, forces the water to the top of the evaporator, where it is distributed through a water tube ad the cascades dow the evaporator surface by gravity. As it flows accross the refrigerated evaporator, some of the water will be chilled eough to chage form, tur to ice, ad stay froze oto the evaporator cells. Most of the water returs to the reservoir, to be sucked back ito the pump, ad repumped over the evaporator. WATER SPRAY TUBE PURGE VALVE WATER INLET VALVE WATER PUMP WATER LEVEL SENSOR 16

17 HARVEST (DEFROST) CYCLE EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE COMPRESSOR STRAINER AIR OR WATER CONDENSER DRIER RECEIVER (WATER COOLED ONLY) HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR REFRIGERATION SYSTEM SCHEMATIC REFRIGERATION SYSTEM DURING HARVEST The refrigeratio system performs the harvest of ice by use of a hot gas bypass valve. Whe the time comes to de-ice the evaporators, the hot gas valve is eergized, ad the high temperature, high pressure gas bypasses the codeser, ad is allowed directly ito the evaporator. The high pressure gas is cooled by the cold evaporator so it codeses ito a liquid, givig up its heat as it does so. This heat warms the evaporator ad the ice froze oto the evaporator surface melts, releasig the froze cubes. Ice the falls ito the storage bi pushed out by meas of the harvest assist soleoid. The liquid refrigerat goes through the suctio lie ito the heat exchager where it boils-off so that oly refrigerat vapor is draw ito the suctio tube of the compressor. WATER SYSTEM Durig the harvest cycle, the electric water drai valve is eergized thereby opeig the drai lie. Most of the water remaied i the reservoir at the ed of freezig cycle is pumped-out, to the waste, through the water soleoid ad drai lie durig the first part of the defrost cycle elimiatig ay possible build-up ad accumulatio of mierals cocetratio ad impurities i the water reservoir. Whe the released ice cubes drop ito the bi, they ope-up for a while the bottom ed of plastic deflector. This deflector swigig motio is eough to reset the cotact of the magetic switch which - via electroic cotrol board - moves back the uit to a ew freezig cycle. The harvest cycle lasts about 1.5 miutes. CONTROL SEQUENCE At the start of the freezig cycle, the cotacts of the magetic switch mechaically operated by the actuator plate of the deflector cover are closed, thereby - via electroic cotrol board - closig the circuit to the mai cotactor coil ad cosequetly to the compressor ad fa motors ad 30" later, to the water pump motors. The, as the ice thickess reaches the value that correspods to the full cube size, the film of water that costatly cascades over the slab of ice formed o the evaporator, arrives to establish a cotact betwee the two figers (eergised at low voltage) of the ice sesor cotrol, located o the frot upper right side of the evaporator. If the cotact betwee the two figers of the ice sesor remais established - by the film of 17

18 water - for more tha 10 secods, a small relay of the electroic board, get eergized, cotrollig - simultaeously the hot gas valve, the water drai valve ad the harvest assist soleoid. ALARM CONDITIONS NOTE: i case of failure of ice level sesor, the P.C. Board turs - o automatically the uit ito the defrost cycle whe the freezig cycle reaches 30 or 40 miutes accordig to the operatio of the fa motor durig the freezig cycle. At this poit, the uit iitiates the defrost cycle. The hot gas circulatig ito the evaporator serpetie causes a slight meltig of ice cubes which get released from their molds. I the mea time the harvest assist soleoid is also eergized pushig out the ice plate. Oce etirely released the ice cubes drop simultaeously ito the ice storage bi below; by doig so they move apart from the evaporator bottom ed the plastic deflector. This plastic deflector has o its side a magetic switch that o accout of the deflector swigig motio, caused by the ice while droppig i the bi, opes ad closes their cotacts. This will, i tur, disactivate the relay cotacts that cotrols the hot gas, harvest assist soleoid ad water drai valve which get deeergized allowig the uit to start a ew freezig cycle. Whe the ice bi is full of ice, the last batch of ice cubes released from the evaporator accumulates to keep the bottom ed of the plastic deflector i ope positio; with the magetic switch cotacts ope for loger tha 30' the etire uit stops with the glowig of the correspodig LED. The machie will restart whe the ice deflector will be back i its ormal vertical positio provided that 3' are elapsed from uit stop. If ot the machie will delay its restart till 3' are elapsed with the blikig of the gree LED. Both the last two Red LED are ON STEADY: Codeser Sesor OUT OF ORDER. Both the last two Red LED are BLINKING SLOW: WATER ERROR Water level iside the water sump too low after 3' from the activatio of the Water Ilet Valve. Both the last two Red LED are BLINKING FAST: RESET MODE: Chargig water through the Water ilet Soleoid Valve after the trippig OFF o WATER ERROR The fourth Red LED is ON STEADY: Harvest Cycle loger the 3' 30" The fourth Red LED is BLINKING SLOW: TOO HI CONDENSING TEMPERATURE. The codeser sesor detected a temperature > 65 C The fourth Red LED is BLINKING FAST: RESET MODE: Codeser Sesor < 50 C Fa motor i operatio for 3' the back o Start Up Cycle Mode The fifth Red LED is ON STEADY: TOO HI DIS- CHARGE PRESSURE > 33 bar (460 PSI) The fifth Red LED is BLINKING FAST: RESET MODE: After pushig the Reset Butto of the Pressure Cotrol the fa motor starts up first for 3' the the machie eters o the Start Up Cycle Mode. The PC Board is also checkig the maximum time of the freezig cycle that chages accordig to the operatio of the fa motor durig the freezig cycle (room temperature): Fa motor i Max. freezig cycle legth ON-OFF mode: equal to 30' Fa motor ON Max. freezig cycle legth All the time: equal to 40' Wheever the machie remais i the Freezig Cycle for the Maximum time (30 or 40 miutes), the PC Board moves the uit directly ito the Harvest Cycle. 18

19 PC BOARD SET UP The PC Board ca be set up for: Water fills up oly at begiig of freezig cycle (stadard) - JUMP IN Cotiuous water fills up durig the freezig cycle (optio for N USPH versio for istallatio o board) - JUMP OUT 19

20 SERVICE SPECIFICATION I servicig a machie, it is ofte, useful to compare that idividual uits operatig characteristics to those of a ormally operatig machie. The data that follows gives those characteristics; however, be aware that these values are for NEW, CLEAN machie operatig at 21 C ambiet ad 15 C water. USE THESE NUM- BERS AS A GUIDELINE ONLY. OPERATING CHARACTERISTICS O air-cooled models durig the freezig cycle, the discharge pressure is maitaied betwee two preset values by meas of fa cotrol (codeser sesor); ad at the same time, the suctio pressure will also declie reachig it s lowest poit just before harvest. Compressor amps experiece a similar drop. O water-cooled, the discharge pressure is costatly, maitaied durig the freeze cycle by the water regulatig valve. However, suctio pressure ad compressor amps, will still declie as the machie freezes ice. MODEL Disch. Pressure Freeze max bar Disch. Pressure Freeze mi bar Hi Pressure CUT OUT bar Suctio Pressure Begiig Freeze bar Suctio Pressure ed Freeze bar Cycle time miutes Amps Compressor Amps Begiig Compressor Freeze ed Freeze N132M - 230/50/1 17,5 14,0 30 4,3 2,3 15 3,8 3,2 N192M - 230/50/1 16,5 16,5 30 4,3 2,4 16 3,6 3,1 N202M - 230/50/1 17,5 15,5 33 3,5 2,0 15 4,7 3,6 N202M W - 230/50/1 16,5 16,5 30 3,5 2,2 16 4,2 3,4 N302M - 230/50/ ,7 1,5 13 6,2 4,8 N302M W - 230/50/1 16,5 16,5 30 3,2 1,7 13 5,8 4,5 N402M - 230/50/1 18,5 16,5 33 2,0 1,8 12,5 8,6 6,4 N402M W - 230/50/1 16,5 16,5 30 3,5 1,9 14,5 9,0 6,7 N502M - 400/50/ ,9 1,6 12 3,7 3,0 N502M W - 400/50/3 16,5 16,5 30 3,2 1,8 13,5 3,6 2,8 Refrigerat charge R 404 A - gr. MODEL N132M N192M N202M N302M N402M N502M Air Cooled Water cooled Refrigerat meterig device Thermostatic expasio valve. NOTE: Always check ameplate o idividual icemachie for special refrigerat charge before chargig the refrigeratio system. Such refrigerat charge is the average charge for the N Modular Cubers. However it is importat to check ameplate for each machie. 20

21 COMPONENT DESCRIPTION 1. Frot Cosole Pael Equipped with five LED plus a push butto that whe glow or blik are moitorig: LED Nr. 1 Electrical power supply. LED Nr. 2 Operatio. LED Nr. 3 Bi full./washig. LED Nr. 4 Alarm. LED Nr. 5 Alarm high pressure. BUTTON B Reset/Washig. FAF ANN MOTORS S PC BOARD COMPRESSOR, C HOT GAS, WATERR INLETI AND DRAIN VALVESS WATERW PUMP P POWERP INN ANDA SAFETYY PRESSURP RESSUREE CONTROLS S FUSF USEE - + J2 N.O. N - JUMP OUTT CONTINUOUS S WATERW FILLINGG N.C. N - JUMP INN WATERW FILL UPP BEGINNING G FREEZEF ONLYY WATEW ATERR SENSITIVITS ENSITIVITYY ADJUSTMENT T J1 FORF FACTORYY USEU ONLYY SERIAS ERIALL CONNECTOR R DISPLAD ISPLAYY CONNECTOR R ICEI THICKNESS S SENSOS ENSORR WATERW LEVELL SENSOS ENSORR MAGNETIC C SWITCS WITCHH CONDENSER R SENSOS ENSORR 2. P.C. Board Located i the cotrol box, this board is the brai of the system as it govers the ice machie cyclematic through sesors, relays ad switch. It cosists of two separated prited circuits oe at high ad the other at low voltage itegrated with a fuse, of four coectors for the sesors/switches (codeser sesor - BLACK -, magetic switch - GREEN - ice thickess sesor - RED - water level sesor - BLUE), of two jumpers (oe J1 for factory use oly - ad the secod J2 for the selectio betwee oe water fill up or cotiuous water fill up), of oe outlet coector (frot LED display - black) oe serial port coector (black) ad of four plug i termials for iput ad output power. With J2 closed the P.C. Board is set up for water fill up at begiig freeze mode. Whe J2 is ope the PC Board is set up for cotiuous water fillig mode. The P.C. Board is equipped by a electroic safety timer that turs-o automatically the uit to defrost cycle whe freezig cycle is loger the 30 or 40 miutes ad trips-off completely uit whe defrost cycle is loger the 3,5 miutes (4th Red LED ON). A trimmer, located close to the trasformer, ca chage the curret received back from the Ice Tickess Sesor accordig to the Electrical Coductivity of the water. 3. Compressor Cotactor Located i the cotrol box, the compressor cotactor fuctios to carry the compressor lie curret. The cotactor is wired to receive power from the P.C. Board. 21

22 4. Ice Thickess Sesor Located i the frot upper right side off the evaporator, the sesor is made with two metal reeds i which passes power at low voltage. The two metal reeds, which are idividually isulated, are set, through a settig screw, to maitai a miimum clearece from the evaporator (3 5 mm). Oce ice is formed ito each mold ad is thick eough to fill-up that miimum clearace existig betwee the two sesor reeds ad the evaporator, the water that cascades over the ice has gradually approached to make cotact betwee the two sesor reeds. It is eough that this cotact remais there for about 10 secods that the P.C. Board receives the sigals to put the ice machie o defrost. Note: iditatios may be deeper o C0322 ad C0330 Ice Bridge Thickess Measuremet 5. Magetic Switch Located i the frot of the evaporator plastic curtai, this switch seds a pulse to the P.C. Board which switches the machie back i the freezig cycle. 6. Hot Gas Soleoid Valve The Hot Gas Soleoid Valve fuctios oly durig the Harvest Cycle, to divert the hot discharge gas from the Compressor, bypassig the Codedeser ad thermostatic expasio valve, for direct flow to the Evaporator Plate Assembly to release ice cubes from the ice cube molds. The Hot Gas Soleoid Valve is comprised of two parts, the Body & Pluger ad the Coil assembles. Istalled i the discharge lie of the Compressor, the eergized soleoid coil lifts the valve stem withi the valve body to cause the hot discarge gas to be diverted whe the ice Thickess sesor has sigalled to the P.C. Board to start the Harvest Cycle. 7. Codeser temperature sesor The codeser temperature sesor probe (located i cotact with the codeser tube coil) detects the codeser temperature variatios ad sigals them by supplyig curret, at low voltage, to the P.C. BOARD. I the air cooled versios, i relatio to the differet curret received, the micro processor of the P.C. BOARD supplies, through a TRIAC, the power at high voltage to the fa motor so to cool the codeser ad to reduce its temperature. I case the codeser temperature rises ad reaches 65 C (150 F) the curret arrivig to the micro processor is such to cause a immediate ad total stop of the machie operatio with the blikig of the Red LED. 8. High Pressure Cotrol The high Pressure Cotrol, a safety cotrol, is factory set to cut-out, at 30 bar ad cut-i at 22 bar. 22

23 to shut OFF electrical power to Icemaker, should a loss of water occur to the water cooled Codeser or a burt out of the fa motor o air cooled versios. The high Pressure Cotrol is maual reset with reset butto located o the rear side of the machie ad a moitorig light o the Frot Cosole Pael. 9. Water Regulatig Valve (Water Cooled Models) The Water Regulatig Valve fuctios maitai a costat Compressor head pressure, by regulatig the amout of icomig water flow through the Codeser, o water-cooled models. The valve operate through the refrigerat system high side pressure. Rotatig the adjustig screw located o top of the valve, ca INCREASE or DECREASE the water flow through the watercooled Codeser, which i tur, will DECREASE or INREASE the Compressor operatig head pressure. 10. Water Distributio System The Water Distributio System fuctio to evety supply water to all cells of the evaporator plate. The water pump pumps water from the sump to the tee. From there water is chaeled through the vertical tygo tube to the water distributors, above the evaporator plate, ad from the holes i the distributor tube water flows to the cells o oe side of the evaporator plate. Gravity flow returs the ufroze excess portio of water to the sump reservoir for recirculatio. 11. Water Drai Soleoid Valve The Water Outlet Soleoid Valve fuctios i cojuctio with the water pump to flush-out the sump assembly at the begiig (first 40") of every harvest cycle. This actio cleas-up ad rises the sump durig each harvest cycle prevetig dagerous water mierales cocetratio. 12. Thermostatic Expasio Valve The Thermostatic Expasio Valve regulates the flow of refrigerat to the evaporator ad reduces pressure of liquid refrigerat from codesig pressure to evaporatig pressure. 23

24 13. Water pump The water pump primes the water from the sump to the water distributor tube ad through the distributig holes it cascades dow oto the evaporator cells by gravity so to be froze ito clear ice cubes. The water pump remais off durig the first 30" secods of the freezig cycle (to avoid ay cavitatio problem) while it's kept ruig durig the first 10" of defrost/harvest cycle to drai out (purge) the remaiig water from the sump (reach i mieral salts). 15. Water level sesor The Water Level Sesor, located o the frot of the water sump, works i cojuctio with the P.C. Board i order to cotrol the water level at begiig of the freezig cycle by receivig a low power curret passig through the water. Whe the curret reaches the PC Board, the water ilet soleoid valve is de-eergised. I case the PC Board does t receive ay sigal (curret) from the Water Level Sesor withi the first 3 miutes of the freezig cycle, the PC Board trips OFF the operatio of the machie with the switchig ON of the Water Error LEDs. 14. Water ilet soleoid valve - 3/4" male fittig The Water Ilet Soleoid valve is eergised by the P.C. Board durig the begiig of the freezig cycle till the water reaches the maximum level ito the sump (cotrolled by the Water Level Sesor). After 3 miutes, from the start up of the freezig cycle, the Water Ilet Valve is eergised agai for a short period to re-fill the sump with water till agai to the max. level so to miimise ay possibility of slush ice formatio. A flow cotrol, fitted ito its outlet port, reduces the pressure of the water flow. 16. Start up delay PC Board Located i the back side of the uit it delays the start up of the etire machie by 90' so to avoid that compressor ca start up w/out be pre-heated. 17. Start up delay PC Board by-pass switch Located i the back side of the machie allows to bypass the delay time cotrolled by the delay PC Board. WARNING. It is IMPERATIVE to by-pass the delay time oly whe sure of proper warm up of compressor. 18. Harvest Assist Soleoid Operated by the cotroller i parallel with the hot gas valve. Cycles o ad off at the begiig of a restart. Eergized throughout the harvest cycle. Lie voltage coil. 24

25 Wirig Diagram N202M - N302M -N402M 220V / 50Hz / 1ph L m = brow bc = light blue gv = yellow gree b = white = black r = red a = orage v = viola F E G SP m bc bc m bc b r a v v m bc bc bc N bc M b bc v v r m A P1 P2 D A - Iput termial board B- Compressor remote cotrol switch C- Compressor D- Ice sesor E- Ed defrostig switch F- Water level sesor G- Codeser temperature probe H- Led card I - Electroic card J-Max pressure switch K- Automatic reset switch L- Water pump M- Water ilet valve N- Water discharge valve O- Hot gas valve SP- Soleoid harv assist P- Fa Motor (oly AIR cooled uit) Q- Fa Motor (oly WATER cooled uit) RC - Compressor relay CS - Start codeser CM- Ru codeser 25

26 Wirig Diagram N502M 400V / 50Hz / 3ph L m = brow bc = light blue gv = yellow gree b = white = black r = red a = orage v = viola F E G SP m bc bc m v v bc b r a m bc bc N bc M b bc v v r m D P1 P2 A - Iput termial board B- Compressor remote cotrol switch C- Compressor D- Ice sesor E- Ed defrostig switch F- Water level sesor G- Codeser temperature probe H- Led card I - Electroic card J-Max pressure switch K- Automatic reset switch L-Water pump M- Water ilet valve N- Water discharge valve O- Hot gas valve SP- Soleoid harv assist P1- Fa Motor 1 (oly AIR cooled uit) P2- Fa Motor 2 (oly AIR cooled uit) R- Crackase heater T-Start delay electroic board 26

27 27

28 SERVICE DIAGNOSIS The table below is iteded as a quick referece to aid the Service Aget i determiig the cause of a particular type of malfuctio, as well as the recommeded repair. It is ot iteded to be a exclusive list. Referece to other portios of this maual, iclusig wirig diagrams, istallatio, ad operatio are recommeded to better determie the cause of a problem. SYMPTOM POSSIBLE CAUSE CORRECTION Warig Red LED ON No warig LED/LIGHT ON Bi full Yellow LED ON Machie rus, compressor does ot. Machie rus, makes ice, does ot try to harvest. Machie rus, makes ad harvests ice but very slowly. Low ice capacity. Machie makes irregular ice. See page 20 P.C. Board ioperative. No power to uit. Bi Full of ice. Magetic switch ioperative. P.C. Board compressor relay ope. Compressor cotactor ope. Compressor relay ope. Compressor widig ope. Ice thickess cotrol ope. Too soft water. Built-i relay o P.C. Board ope. Low refrigerat charge. High discharge pressure due to ot-codesableor overcharge. Iefficiet compressor. Codeser dirty. Low water flow (Water-cooled). High air temperature (air-cooled). Plugged water distributor. TXV supertheat wrog. Refrigerat charge low. See page 20 Remove board ad check. Check electrical source. Nome. Check ad replace. Test ad replace. Test ad replace. Test ad replace. Test ad replace. Check sesor figers if are ot covered with scale sedimet. Water electrical coductivity must be higher the 20 ms. Machie ca't ru with demieralized water. Check ad replace P.C. Board. Check system for correct refr. charge. Check for leak weight i charge. Evacuate ad weigh i charge. Replace. Clea. Check ad repair. Check temperature of air eterig codeser. Clea water distributor. Adjust or replace. Adjust-check for leak recharge. 28

29 MAINTENANCE & CLEANING & SANITATION INSTRUCTIONS A ICEMATIC Ice System represet a sizable ivestmet of time ad moey i ay compay s busiess. I order to receive the best retur for that ivestmet, i MUST receive periodic maiteace. It is the USER S RESPONSIBILITY to see that preferable, ad less costly i the log ru, to avoid possible dow time by keepig it clea, adjustig it as eeded ad by replacig wor parts before they ca cause failure. The followig is a list of recommeded maiteace that will help keep your machie ruig with a miimum of problems. Maiteace ad Cleaig should be scheduled at MINI- MUM twice per year while saitatio oce per moth. ICEMAKER THE FOLLOWING MAINTENANCE SHOULD BE SCHEDULED AT LEAST TWO TIMES PER YEAR ON THIS ICEMAKER. CALL YOUR AUTHORIZED ICEMAT- IC SERVICE AGENCY. 1. Check ad clea or service ay optioal water treatmet devices, if ay istalled. 2. Clea water straier. 3. Check that the cabiet is level, i the sideto- side ad frot-to-back directios. 4. Clea/Saitise the water system, evaporator plate ad sump assembly, usig a solutio of citric acid. Refer to CLEANING - Icemaker. NOTE: Cleaig/Saitisig requiremets vary accordig to local water coditios ad idividual user operatio. Cotiuous check of the clarity of ice cubes ad visual ispectio of the water system parts, evaporator plates ad the sump assembly before ad after cleaig will idicate frequecy ad procedure to be followed i local areas. 5. Check ad tighte all bolts ad screws. 6. Check for water leaks ad make correctios. 7. Check the bi cotrol to test shut-off. Holdig the evaporator deflector i ope Positio for more that 30", shold cause the ice maker to shut-off. Oce the evaporator deflector is released i its closed positio, the ice maker will restart. 8. Check cube size, adjust if required through settig screw of ice thickess cotrol sesor. 9. With uit out of operatio, clea the codeser usig vacuum, cleaer, wisk broom or brush. Istruct customer to clea codeser frequetly DO NOT USE A WIRE BRUSH. ICE STORAGE BIN The iterior lier of the bi is i cotact with a food product, ice, ad should be cleaed ad saitised regularly. Oce a week saitise it with a commercial food grade saitiser complig with the maufacturer dilutio. CABINET EXTERIOR Wipe clea uit ad bi cabiet exterior with a clea cloth or disposable paper wipers, soaked i warm water with mild deterget solutio. CLEANING - Ice maker 1. Empty bi of ice. 2. Remove frot pael. 3. Wait till the ed of the defrost/harvest cycle the push the RESET BUTTON for 6-8 secods. The machie should stop with the blikig of the Yellow LED (slow blik). 4. Pour o - N gr Citric Acid - N gr Citric Acid of Icematic Machie Citric Acid directly ito the reservoir the push agai the RESET BUTTON for a while. The water pump starts to operate with the fast blikig of the Yellow LED while the water ilet valve will be eergized till the fill up of the water sump. 5. After 15 miutes push the RESET BUTTON for a while. The P.C. Board put the machie i automatic risig mode with the special blikig (blik twice ad repeat) of the Yellow LED. NOTE: RINSING mode cosists of: a) eergize the water drai valve ad the water pump for 40 secods to empty the reservoir b) deeergize the water drai valve ad the water pump for 1 miute c) eergize the water ilet valve till the fill up of the water sump d) eergize the water pump for 1,5 miutes. The above sequece is repeted 7 times so to be sure to have removed ay possible trace of Citric Acid 6. At the ed of the 7th Risig cycle the P.C. Board stops the operatio of the machie with the blikig (slow) of the Yellow LED. 7. Pushig the RESET BUTTON for 6-8 secods the machie restarts i the freezig cycle. 8. Replace the evaporator cover deflector ad frot pael. 9. Check the ext batch of cubes to be sure all the Citric Acid is goe (o sour taste). CAUTION - DO NOT use ice cubes produced from the Citric Acid solutio. Be sure oe remais i the bi. 10. Pour hot water ito the storage bi melt the cubes, ad to also clea the bi drai. 29

30 Via del Lavoro, 9 C.P. 172 I Castelfraco Veeto (TV) Italy Tel Fax service@castelmac.it Web-site: Cod /0 - Rev.01 - GB - 03/2010 ISO 9001 Cert. N 0412