Scotsman C2648 Service Manual
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Scotsman C2648 Service Manual

Modular cuber induding prodigy plus
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Service Manual for
Modular Cuber
Model C2648
induding
Prodigy Plus

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Summary of Contents for Scotsman C2648

  • Page 1 Service Manual for Modular Cuber Model C2648 induding Prodigy Plus...

  • Page 2: Table Of Contents

    C2648 Prodigy and Prodigy Plus Service Manual Introduction The design of this modular remote cuber is the result of years of experience with remote ice machine refrigeration systems. Standard features of this product include front accessible on-off switches, always-visible indicator lights, mechanical assist ice harvest for extra efficiency, automatically adjusting water purge and a control system that optimizes system operation.

  • Page 3: Installation: Product Specifications

    C2648 Prodigy and Prodigy Plus Service Manual Installation: Product Specifications Location Limitations Remote condenser This ice system is made up of three parts, the ice Minimum Maximum making machine, or head; the remote condenser; and Air temperature the interconnecting tubing. The ice making machine must be installed indoors, in a controlled environment.

  • Page 4: Model Number Description

    C2648 Prodigy and Prodigy Plus Service Manual Model Number Description Standard bin applications – Adapter information Example • C2648SR-3D Model BH1100, BH1300 or BH1600 • C=cuber C2648 Adapter panels included with bin, no adapter needed • 24=nominal capacity in 100s of pounds •...

  • Page 5: Product Description, Electrical Requirements

    C2648 Prodigy and Prodigy Plus Service Manual Product Description, Electrical Requirements Ice Machine Model Electrical Minimum Maximum Suggested Dimensions condenser Circuit Fuse* Size Fuse* Size w” x d” x h” Ampacity 48 x 28 x 31 C2648SR-3 208-230/60/3 PRC241-32A 21.6...

  • Page 6: Condenser And Ice Machine Layouts

    C2648 Prodigy and Prodigy Plus Service Manual Condenser and Ice Machine Layouts January 2015 Page 6...

  • Page 7: Water

    A triple head filter is recommended. Either the purged based on the purity of the water supplied to it. Scotsman SSM3 taste and odor filter system, or the The water purge rate can also be set manually. ADS-AP3 AquaPatrol system.

  • Page 8: Panel Removal

    C2648 Prodigy and Prodigy Plus Service Manual Panel Removal 1. Locate and loosen the two screws at the bottom Install the bin top adapter if one is required for the edge of the front panel. application. 2. Pull the front panel out at the bottom until it clears If the ice machine has not been unpacked, do so the bin.
  • Page 9 C2648 Prodigy and Prodigy Plus Service Manual Remote Condenser Location Run = dd+rd+hd = Calculated Line Length Use the following for planning the placement of the Configurations that do NOT meet these requirements condenser relative to the ice machine must receive prior written authorization from Scotsman.
  • Page 10 C2648 Prodigy and Prodigy Plus Service Manual For The Installer: Remote Condenser Roof Attachment Locate the condenser as near as possible to the Install and attach the remote condenser to the roof interior location of the ice machine. of the building, using the methods and practices of...

  • Page 11: Precharged Line Routing

    C2648 Prodigy and Prodigy Plus Service Manual Precharged Line Routing Do not connect the precharged tubing until all routing Caution: Do NOT kink the refrigerant tubing while and forming of the tubing is complete. See the routing it. Coupling Instructions for final connections.

  • Page 12: Coupling Instructions

    C2648 Prodigy and Prodigy Plus Service Manual Coupling Instructions The couplings on the ends of the pre-charged line It is important that ONLY the nut on the pre-charged sets are self-sealing when installed properly. tube be turned, or the diaphragms will be torn out by the piercing knives and they will be loose in the Follow these instructions carefully.

  • Page 13: Plumbing Requirements

    C2648 Prodigy and Prodigy Plus Service Manual Plumbing Requirements All models require connection to cold, potable water. 1. Connect water supply to water inlet fittings. A hand actuated valve within site of the machine is 2. Connect drain tubing to drain fitting.

  • Page 14: Electrical

    C2648 Prodigy and Prodigy Plus Service Manual Electrical The machine is not supplied with a power cord, one Electrical connections are made inside the junction must either be field installed or the machine hard- box in the back panel of the ice machine.

  • Page 15: Final Check List

    C2648 Prodigy and Prodigy Plus Service Manual Final Check List: 1. Is the unit located indoors in a controlled environment? 2. Is the unit located where it can receive adequate cooling air? 3. Has the correct electrical power been supplied to the machine? 4.

  • Page 16: Initial Start Up

    C2648 Prodigy and Prodigy Plus Service Manual Initial Start Up Remove front and left side panels. Check machine 7. When the ice has frozen enough, the Ready for for any packing or wires rubbing moving parts. Note Harvest indicator light will be on steady. After it’s...

  • Page 17: Adjustments

    C2648 Prodigy and Prodigy Plus Service Manual Adjustments Bridge Thickness - For A Service Tech Only 1/8 to 3/16” bridge 1. Push and hold Off till the machine stops. 2. Remove evaporator cover. 3. Remove left curtain. 4. Use a box wrench and rotate the bridge thickness adjustment screw in 1/8 turn increments CW to increase bridge thickness.

  • Page 18: Use And Operation

    C2648 Prodigy and Prodigy Plus Service Manual Use and Operation Once started, the ice machine will automatically make ice until the bin or dispenser is full of ice. When ice level drops, the ice machine will resume making ice. There are four indicator lights at the front of the machine that provide information on the condition of the machine.

  • Page 19: Switch Panel Area

    C2648 Prodigy and Prodigy Plus Service Manual Switch Panel Area The On and Off switches are front accessible at the knob and an additional indicator light to the right of the lower left corner. controller’s switches near the top of the unit.

  • Page 20: Options And Other Information

    C2648 Prodigy and Prodigy Plus Service Manual Options and Other Information Smart-Board When this option is present there is an additional display panel in the area below the main control board. It is not visible when the front panel is on.

  • Page 21: Cleaning, Sanitation And Maintenance

    5. Wait until the Code Display blinks the characters 18. Thoroughly wash the shelf of the ice machine A d 1, then pour 24 ounces of Scotsman Clear cabinet where the reservoir was resting. 1 Scale remover into the water reservoir. The 19.
  • Page 22 27. Push and release the green ON button to resume ice making. Remove and discard all ice. Clean Storage Bin Mix a solution of Scotsman Clear 1 ice machine scale remover and wash all interior surfaces of the ice storage bin to remove any mineral scale build up.

  • Page 23: Remote Condenser And Other Maintenance

    C2648 Prodigy and Prodigy Plus Service Manual Remote condenser and other maintenance The condenser fins will need to be cleaned. Push and release the Off button. Wait until the machine stops. Note: Lock out the controller or the ice machine power supply to prevent an unauthorized fan motor restart.

  • Page 24: What To Do Before Calling For Service

    C2648 Prodigy and Prodigy Plus Service Manual What to do before calling for service Reasons the machine might shut itself off: To Manually Reset the machine. • Lack of water. 1. Open the switch door • Freeze cycle takes too long.

  • Page 25: Overall System Types

    C2648 Prodigy and Prodigy Plus Service Manual Overall System Types: • Refrigeration: Mechanical remote cooled. Includes reciprocating hermetic compressor, head pressure control valve (headmaster), receiver and liquid line solenoid valve. • Water System: Inlet water solenoid valve fills reservoir once per cycle. Purge solenoid valve opens to discharge some reservoir water once per cycle.

  • Page 26: Controller Information

    C2648 Prodigy and Prodigy Plus Service Manual Controller Information Machine Indicator Lights • Power • Status • Water • Clean Code Display Main codes - automatically displayed F ..Freeze Cycle F flashes Freeze Cycle is Pending H .

  • Page 27: Controller Information

    C2648 Prodigy and Prodigy Plus Service Manual Controller Information Component Indicator Lights • Condenser Fan / Aux (Aux = liquid line solenoid) • Water Pump • Purge Valve • Water Solenoid • Hot Gas • Compressor • Ready to Harvest •...

  • Page 28: How It Works

    C2648 Prodigy and Prodigy Plus Service Manual How It Works Freeze Cycle. At start up the controller drains and refills the reservoir. The reservoir refills when the mid length water level sensor probe is uncovered and continues to fill until the top probe is in contact with water. When the reservoir has filled, the liquid line valve, compressor and water pumps are switched on.

  • Page 29: Electrical Sequence - Remote Cooled

    C2648 Prodigy and Prodigy Plus Service Manual Electrical Sequence - Remote Cooled Power connected, unit previously switched Off. Control board does a self check. If the self check fails, the unit displays an E and no further action will occur.

  • Page 30: Electrical Component Details

    C2648 Prodigy and Prodigy Plus Service Manual Electrical Component Details Compressor • Operated by the compressor contactor. Contactor • Operated by the controller and the high pressure cut out switch. Line voltage coil. When energized the Compressor indicator light will be ON.

  • Page 31: Electrical Component Details

    C2648 Prodigy and Prodigy Plus Service Manual Electrical Component Details Controller • Senses ice thickness, water level, water temperature, discharge temperature. Controls compressor contactor, fan motor, water pump, inlet water valve, hot gas valve, purge valve, harvest assist solenoid. Indicates status and component operation. 12 volt.

  • Page 32: Component Indicator Light Table

    C2648 Prodigy and Prodigy Plus Service Manual Component Indicator Light Table System Indicator Light ON Condenser Fan or Liquid Line Valve LLV open Water Pump Pump Motor Powered Purge Valve Purge Valve Opens Inlet Water Solenoid Valve Inlet Water Valve Opens...

  • Page 33: Refrigeration

    C2648 Prodigy and Prodigy Plus Service Manual Refrigeration Refrigerant: R-404A Charge: 240 ounces Compressor: Copeland hermetic Compressor Amps: • Freeze - 13.2 to 12.9, declining to 9.6 at the end of the freeze cycle. 11.6 to 11.9 at five minutes.

  • Page 34: Refrigeration Schematic

    C2648 Prodigy and Prodigy Plus Service Manual Refrigeration Schematic Remote Condenser Suction Evaporator Discharge Head Pressure Control Hot Gas Valve Liquid Valve Compressor Receiver Liquid Line Valve Liquid Heat Exchange Accumulator C2648R January 2015 Page 34...

  • Page 35: Water System

    C2648 Prodigy and Prodigy Plus Service Manual Water System Batch type. Water reservoir contains full water charge for each ice making cycle. Water valve: Solenoid type. Opens to fill reservoir when mid sensor probe no longer makes a circuit to the bottom probe.

  • Page 36: Control Operation

    C2648 Prodigy and Prodigy Plus Service Manual Control Operation Standard control: • Electronic controller operating from a 12 AC volt power supply. Will operate within a voltage range between 10 and 15.5. • User’s Indicator lights, four front visible: Power, Status, Water, De-scale/Sanitize.

  • Page 37: Control Safeties

    C2648 Prodigy and Prodigy Plus Service Manual Control Safeties Max freeze time – 45 minutes When exceeded, the controller will attempt another freeze cycle. If the next cycle's freeze time is less than maximum, the control will continue normal ice making. If the next freeze cycle was too long, the control will again attempt another freeze cycle.

  • Page 38: Restarts

    C2648 Prodigy and Prodigy Plus Service Manual Restarts Power Interruption The controller will automatically restart the ice machine after adequate voltage has been restored. • H blinks on code display • Status indicator light blinks • Reservoir is drained and refilled Default harvest is initiated.

  • Page 39: Control Button Use (From Standby)

    C2648 Prodigy and Prodigy Plus Service Manual Control Button Use (from standby) Set purge level, 1-5 (1 is minimum, 5 is maximum) or Automatic: • Hold off button in for 3 seconds. Release. • Press and release the On button to cycle through and select one of the five purge settings or to use the Automatic setting.

  • Page 40: Diagnostics

    C2648 Prodigy and Prodigy Plus Service Manual Diagnostics Problem Likely Cause Probable Solution No power to unit Power disconnected Check breaker or fuse. Reset or replace, restart and check No power to controller Transformer open Replace transformer Shut down on max. water fill time...

  • Page 41: Diagnostics

    C2648 Prodigy and Prodigy Plus Service Manual Diagnostics Problem Likely Cause Probable Solution Shut Down on Maximum Freeze Compressor not operating Check compressor temperature Time (continued) (continued) Check compressor voltage Check compressor windings Low refrigerant charge Add some refrigerant and restart unit.

  • Page 42: Diagnostics

    C2648 Prodigy and Prodigy Plus Service Manual Diagnostics Problem Likely Cause Probable Solution Shut down on maximum harvest Curtain switch does not open when Check switch with ohmmeter time (continued) curtain does Machine in very cold ambient Move machine to a warmer...

  • Page 43: Test Procedures - Sensors

    C2648 Prodigy and Prodigy Plus Service Manual Test Procedures - Sensors All electrical components in this ice machine can be diagnosed with a volt-ohmmeter. Curtain Switch: 1. Test using the controller’s indicator lights. Observe SW1 and SW2 and the Period in the display code.

  • Page 44: Ice Thickness Sensor

    C2648 Prodigy and Prodigy Plus Service Manual Ice Thickness Sensor 1. Test using the controller’s indicator light. Observe the Ready To Harvest light. Shut the machine off. Use a wire to connect the metal part of the Ice Thickness sensor to the evaporator or simply remove the Ice Thickness Sensor and touch its metal surface to the metal control box wall.

  • Page 45: Water Level Sensor

    C2648 Prodigy and Prodigy Plus Service Manual Water Level Sensor 1. Test using the controller’s indicator lights (sump empty and sump full). Unit must be powered up and there must be water in the sump. Add some manually if needed. Locate water level sensor. Release from sump cover and slowly lift up until the mid-length probe is out of the water.

  • Page 46: Temperature Sensors

    C2648 Prodigy and Prodigy Plus Service Manual Temperature Sensors 1. Check controller. If the sensor calibration is completely out of range, the code display will read either 5 or 7. 2. Check with an ohmmeter. Open control box cover, unplug sensor from J6. Water temperature probe: Measure the temperature of the water.

  • Page 47: Water Pumps

    C2648 Prodigy and Prodigy Plus Service Manual Water Pumps Test using the controller’s indicator lights. 1. Check the indicator light during the freeze cycle. The light will be On for all but the 30 second anti-slush period, so observe the light for one minute. When it is On, check the water pumps, both should be operating.

  • Page 48: Purge Valve

    C2648 Prodigy and Prodigy Plus Service Manual Purge valve Test using the controller’s indicator lights. 1. Shut unit off by holding the Off button for 3 seconds. 2. Wait four minutes. Push and release the On button, observe the Purge Valve indicator light. As the unit drains the reservoir, the purge valve will be powered.

  • Page 49: Compressor Contactor

    C2648 Prodigy and Prodigy Plus Service Manual Compressor contactor Test using the controller’s indicator lights. 1. When the unit is in ice making mode the compressor contactor will have power. Check the Compressor indicator light, when it is on the compressor contactor will have pulled in. If it is not, do a voltage check.

  • Page 50: Pressure Switch

    C2648 Prodigy and Prodigy Plus Service Manual Pressure switch High pressure cut out. The high pressure cut out switch will open at a preset pressure, shutting off power to the compressor contactor. After the pressure has fallen to another preset level, the switch will re-close and the contactor coil will be energized.

  • Page 51: Liquid Line Solenoid

    C2648 Prodigy and Prodigy Plus Service Manual Liquid Line Solenoid Test using the controller’s indicator lights. 1. Put the controller into test mode (depress Off for 3 seconds then depress Clean for 3 seconds). At the end of the test cycle, the liquid line valve will be powered and the Condenser Fan motor indicator light will be on.

  • Page 52: Inlet Water Solenoid Valve

    C2648 Prodigy and Prodigy Plus Service Manual Inlet Water Solenoid Valve Test using the controller’s indicator lights. 1. Shut unit off by holding the Off button for 3 seconds. Wait four minutes. 2. Push and release the On button, observe the Water Solenoid indicator light. After the unit drains the reservoir, the inlet water valve will be powered to refill the reservoir.

  • Page 53: Harvest Assist

    C2648 Prodigy and Prodigy Plus Service Manual Harvest Assist Test using the controller’s indicator lights. Harvest Assist Solenoid - No Longer Used on This Model Push and release the Harvest button. The Hot Gas indicator light will be on. At the same time the Harvest Assist Solenoid will be powered.

  • Page 54: Reservoir Removal

    C2648 Prodigy and Prodigy Plus Service Manual Reservoir Removal The reservoir may be removed from the cabinet if needed. 1. Drain water by holding in the Clean button repeatedly until no more water will drain. 2. Disconnect electrical power. 3. Twist counterclockwise and lift water pumps up and tip to one side.

  • Page 55: Controller Differences

    C2648 Prodigy and Prodigy Plus Service Manual Controller Differences The controllers are programmed at the factory for the model they are installed on, they cannot be moved from one model to another due to differences in: • Water purge time per setting •...

  • Page 56: Thermistor Values

    C2648 Prodigy and Prodigy Plus Service Manual Thermistor Values Deg. F Ohms Deg. F Ohms Deg. F Ohms Deg. F Ohms Deg. F Ohms 85325 19381 5569 1927 82661 18873 5446 1890 80090 18381 5325 1855 77607 17903 5208 1819...

  • Page 57: Performance Information

    C2648 Prodigy and Prodigy Plus Service Manual Performance Information Condenser Intake Air Temp., Degrees F Cycle Time Water Temp (minutes) 9-11 10-12 11-13 12-14 16-18 10-12 11-13 12-14 13-15 17-19 11-13 12-14 13-15 14-16 18-20 12-14 13-15 14-16 15-17 19-21...

  • Page 58: Repair Procedures

    C2648 Prodigy and Prodigy Plus Service Manual Repair Procedures 1. Inlet Water Solenoid Valve 2. Disconnect electrical power Electrical Shock Hazard Disconnect electrical power before beginning 3. Shut off the water supply. 4. Remove front panel. 5. Unplug wire from coil.

  • Page 59: Harvest Assist

    C2648 Prodigy and Prodigy Plus Service Manual Harvest Assist 1. Remove front panel. 2. Push and release Manual Harvest button, when unit shuts off go to next step. 3. Disconnect electrical supply Electrical Shock Hazard Disconnect electrical power before beginning 4.

  • Page 60: Ice Thickness Sensor

    C2648 Prodigy and Prodigy Plus Service Manual Ice thickness sensor 1. Push and release the Off switch. 2. Remove front and top panels. 3. Push and release the Harvest switch 4. Remove the evaporator cover. 5. Disconnect electrical power. Electrical Shock Hazard...

  • Page 61: Contactor Or Controller

    C2648 Prodigy and Prodigy Plus Service Manual Contactor or Controller Contactor 1. Disconnect electrical power. Electrical Shock Hazard Disconnect electrical power before beginning 2. Remove front panel. 3. Open control box cover. 4. Remove right side of control box. 5. Remove metal barrier from control box 6.

  • Page 62: Curtain Or Curtain Switch

    C2648 Prodigy and Prodigy Plus Service Manual Curtain or Curtain Switch Curtain 1. Push and hold the Off button to shut the machine off. 2. Remove front panel. 3. Remove evaporator cover. 4. Push inside tab in to release front curtain pin from holder.

  • Page 63: Purge Valve Or Water Level Sensor

    C2648 Prodigy and Prodigy Plus Service Manual Purge Valve or Water Level Sensor Purge valve 1. Push and hold the Off button to shut the machine off. 2. Disconnect electrical power. Electrical Shock Hazard Disconnect electrical power before beginning 3. Remove front panel.

  • Page 64: Water Pumps

    C2648 Prodigy and Prodigy Plus Service Manual Water pumps There are two water pumps. The front pump forces water to the two left evaporators and the back pump waters the right evaporator and drains the reservoir. 1. Push and hold the Off button until the machine shuts off.

  • Page 65: Evaporator

    C2648 Prodigy and Prodigy Plus Service Manual Evaporator 1. Remove front panel. 2. Remove evaporator cover. 3. Remove top and right side panels. 4. If the machine was in operation, push and release the Harvest button to warm up the evaporator.

  • Page 66: Compressor

    C2648 Prodigy and Prodigy Plus Service Manual Compressor 1. Remove front panel. 2. If the machine was in operation, push and release the Harvest button to shut it down. Wait until the harvest cycle has ended so the evaporator has no ice on it.

  • Page 67: Thermostatic Expansion Valve

    C2648 Prodigy and Prodigy Plus Service Manual Thermostatic Expansion Valve 1. Remove front panel. 2. If the machine was in operation, push and release the Harvest button to shut it down. Wait until the harvest cycle has ended so the evaporator has no ice on it.

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