Koolaire KY0275W Technician's Handbook
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Koolaire KY0275W Technician's Handbook

Undercounter ice machines
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Undercounter Ice Machines
Technician's Handbook
This manual is updated as new information and models
are released. Visit our website for the latest manual.
www.kool-aire.com
Part Number STH047 5/16

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Summary of Contents for Koolaire KY0275W

  • Page 1 Undercounter Ice Machines Technician’s Handbook This manual is updated as new information and models are released. Visit our website for the latest manual. www.kool-aire.com Part Number STH047 5/16...

  • Page 3: Safety Notices

    Safety Notices Read these precautions to prevent personal injury: • Read this manual thoroughly before operating, installing or performing maintenance on the equipment. Failure to follow instructions in this manual can cause property damage, injury or death. • Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.
  • Page 4 Warning Follow these electrical requirements during installation of this equipment. • All field wiring must conform to all applicable codes of the authority having jurisdiction. It is the responsibility of the end user to provide the disconnect means to satisfy local codes. Refer to rating plate for proper voltage.
  • Page 5 Warning Follow these precautions to prevent personal injury during installation of this equipment: • Installation must comply with all applicable equipment fire and health codes with the authority having jurisdiction. • To avoid instability the installation area must be capable of supporting the combined weight of the equipment and product.
  • Page 6 Warning Follow these precautions to prevent personal injury while operating or maintaining this equipment. • Legs or casters must be installed and the legs/ casters must be screwed in completely. When casters are installed the mass of this unit will allow it to move uncontrolled on an inclined surface.
  • Page 7 Warning Follow these precautions to prevent personal injury while operating or maintaining this equipment. • Objects placed or dropped in the bin can affect human health and safety. Locate and remove any objects immediately. • Never use sharp objects or tools to remove ice or frost.
  • Page 8 DANGER Follow these precautions to prevent personal injury during use and maintenance of this equipment: • It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures. • Do Not Store Or Use Gasoline Or Other Flammable Vapors Or Liquids In The Vicinity Of This Or Any Other...

  • Page 9: Table Of Contents

    Table of Contents General Information Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 How to Read a Model Number .
  • Page 10 Maintenance Ice Machine Inspection . . . . . . . . . . . . . . . . . . . . 29 Exterior Cleaning .
  • Page 11 Component Check Procedures Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Bin Switch .
  • Page 12 Component Specifications Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121 Bin Switch .

  • Page 13: General Information

    KY0174A KR0270A KR0271W KD0272A KD0273W KY0274A KY0275W Warning An ice machine contains high voltage electricity and refrigerant charge. Repairs are to be performed by properly trained refrigeration technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.

  • Page 14: How To Read A Model Number

    Manitowoc Ice Machine Cleaner and Sanitizer are available in convenient 16 oz. (473 ml) and 1 gal (3.78 l) bottles. These are the only cleaner and sanitizer approved for use with Koolaire products. Cleaner Part Number Sanitizer Part Number 16 oz...

  • Page 15: Model/Serial Number Location

    Model/Serial Number Location The model and serial numbers are required when requesting information from your local distributor, service representative, or Manitowoc KitchenCare®. The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD. They are also listed on the MODEL/ SERIAL NUMBER DECAL affixed to the ice machine.
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  • Page 17: Installation

    Installation Location of Ice Machine The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location. • The location must be indoors. • The location must be free of airborne and other contaminants.

  • Page 18: Ice Machine Clearance Requirements

    Ice Machine Clearance Requirements Self-contained Air-cooled Top/Sides 5" (127 mm)* Back 5" (127 mm)* *NOTE: The ice machine may be built into a cabinet. There is no minimum clearance requirement for the top or left and right sides of the ice machine. The listed values are recommended for efficient operation and servicing only.

  • Page 19: Leveling The Ice Machine

    Leveling the Ice Machine 1. Screw the leveling legs onto the bottom of the ice machine. 2. Screw the foot of each leg in as far as possible. Caution The legs must be screwed in tightly to prevent them from bending. 3.

  • Page 20: Electrical Requirements

    Electrical Requirements VOLTAGE The maximum allowable voltage variation is ±10% of the rated voltage on the ice machine model/serial number plate at start-up (when the electrical load is highest). The 115/1/60 ice machines are factory pre-wired with a 6' (1.8 m) power cord, and NEMA 5-15P-plug configuration. The 208-230/1/60 and 230/1/50 ice machines are factory pre-wired with a power cord only, no plug is supplied.

  • Page 21: Electrical Specifications

    Electrical Specifications AIR-COOLED ICE MACHINE Ice Machine Voltage Phase Max. Fuse/ Total Cycle Circuit Amps Breaker K170 115/1/60 15 amp 208/1/60 15 amp 230/1/50 15 amp K270 115/1/60 15 amp 10.7 208-230/1/60 15 amp 230/1/50 15 amp Warning All wiring must conform to local, state and national codes.

  • Page 22: Water-Cooled Ice Machines

    WATER-COOLED ICE MACHINES Ice Machine Voltage Max. Fuse/ Total Phase Cycle Circuit Amps Breaker K170 115/1/60 15 amp 208/1/60 15 amp 230/1/50 15 amp K270 115/1/60 15 amp 208-230/1/60 15 amp 230/1/50 15 amp Part Number STH047 5/16...

  • Page 23: Water Service/Drains

    Water Service/Drains WATER SUPPLY Local water conditions may require treatment of the water to inhibit scale formation, filter sediment, and remove chlorine odor and taste. Important If you are installing a water filter system, refer to the Installation Instructions supplied with the filter system for ice making water inlet connections.

  • Page 24: Water Supply And Drain Line Sizing

    WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS Part Number STH047 5/16...

  • Page 25: Cooling Tower Applications

    COOLING TOWER APPLICATIONS Water Cooled Models Only A water-cooling tower installation does not require modification of the ice machine. The water regulator valve for the condenser continues to control the refrigeration discharge pressure. It is necessary to know the amount of heat rejected, and the pressure drop through the condenser and water valves (inlet to outlet) when using a cooling tower on an ice machine.
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  • Page 27: Component Identification

    Component Identification Evaporator Compartment ICE THICKNESS PROBE DISTRIBUTION TUBE DAMPER WATER PUMP WATER TROUGH SV1694A FLOAT VALVE SIPHON CAP BIN SWITCH MAGNET SV1695A Evaporator Compartment Part Number STH047 5/16...
  • Page 28 ON/OFF/WASH TOGGLE SWITCH COMPRESSOR CONDENSED AIR COMPARTMENT FILTER ACCESS SCREWS SV1686G K170 Ice Machines ON/OFF/WASH TOGGLE SWITCH CONDENSED AIR FILTER COMPRESSOR COMPARTMENT ACCESS SCREWS PT1288 K270 Ice Machines Part Number STH047 5/16...

  • Page 29: Ice Machine Inspection

    Maintenance ICE MACHINE INSPECTION Check all water fittings and lines for leaks. Also, make sure the refrigeration tubing is not rubbing or vibrating against other tubing, panels, etc. Do not put anything (boxes, etc.) in front of the ice machine. There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life.
  • Page 30 Air-cooled Condenser A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces ice production and shortens component life. Clean the condenser at least every six months. Follow the steps below. Warning The condenser fins are sharp. Use care when cleaning them.

  • Page 31: Interior Cleaning And Sanitizing

    INTERIOR CLEANING AND SANITIZING General Clean and sanitize the ice machine every six months for efficient operation. If the ice machine requires more frequent cleaning and sanitizing, consult a qualified service company to test the water quality and recommend appropriate water treatment. The ice machine must be taken apart for cleaning and sanitizing.
  • Page 32 Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle. Or, set the switch to the OFF position and allow the ice to melt off the evaporator. Caution Never use anything to force ice from the evaporator.
  • Page 33 Step 6 Remove parts for cleaning. Remove Two Thumbscrews and Water Pump Cover (When Used). Remove the Vinyl Hose Connecting the Water Pump and Water Distribution Tube Remove Water Pump • Disconnect the water pump power cord • Loosen the screws securing the pump- mounting bracket to the bulkhead •...
  • Page 34 Remove the Ice Thickness Probe • Compress the side of the ice thickness probe near the top hinge pin and remove it from the bracket. THICKNESS PROBE COMPRESS SIDES OF ICE THICKNESS PROBE SV1138A Ice Thickness Probe Removal NOTE: At this point, the ice thickness probe can easily be cleaned.
  • Page 35 Remove the Water Distribution Tube 1. LIFT UP 2. SLIDE BACK 3. SLIDE TO RIGHT DISTRIBUTION TUBE THUMBSCREW THUMBSCREW SV1630 Water Distribution Tube Removal • Loosen the two thumbscrews, which secure the distribution tube. • Lift the right side of the distribution tube up off the locating pin, then slide it back and to the right.
  • Page 36 Disassembly • Twist both of the inner tube ends until the tabs line up with the keyways. • Pull the inner tube ends outward. INNER TUBE INNER TUBE KEYWAY SV1211 Water Distribution Tube Disassembly Part Number STH047 5/16...
  • Page 37 Remove the Float Valve • Turn the splash shield counterclockwise one or two turns. FLOAT VALVE BRACKET COMPRESSION FITTING SHUT-OFF VALVE CAP AND FILTER SCREEN SPLASH SHIELD FLOAT SV1695-2 Float Valve Removal • Pull the float valve forward and off the mounting bracket.
  • Page 38 Remove the Water Trough • Apply downward pressure on the siphon tube and remove from the bottom of the water trough. • Remove the upper thumbscrew. • While supporting the water trough remove the two thumbscrews from beneath the water trough. •...
  • Page 39 Remove the ice damper • Grasp ice damper and apply pressure toward the left- hand mounting bracket. • Apply pressure to the right-hand mounting bracket with thumb. • Pull ice damper forward when the right-hand ice damper pin disengages. STEP 3 STEP 2 STEP 1 SV1742A...
  • Page 40 Remove the Bin Door • Grasp the rear of the bin door and pull bin door forward approximately 5". • Slide bin door to the rear while applying upward pressure (The rear door pins will ride up into the track slot and slide backward to the stop tab).
  • Page 41 Step 7 Mix a solution of cleaner and warm water. Depending on the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly clean all parts. Solution Type Water Mixed with...
  • Page 42 Step 11 Use 1/2 of the sanitizer/water solution to sanitize all removed components. Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/ water solution. Do not rinse parts after sanitizing. Step 12 Use 1/2 of the sanitizer/water solution to sanitize all foodzone surfaces of the ice machine and...
  • Page 43 Step 17 Mix a solution of sanitizer and warm water. Solution Type Water Mixed With Sanitizer 6 gal. (23 l) 4 oz (120 ml) sanitizer Step 18 Use 1/2 of the sanitizer/water solution to sanitize all removed components. Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/ water solution.

  • Page 44: Removal From Service/Winterization

    Removal from Service/Winterization General Special precautions must be taken if the ice machine is to be removed from service for an extended period of time or exposed to ambient temperatures of 32°F (0°C) or below. Caution If water is allowed to remain in the ice machine in freezing temperatures, severe damage to some components could result.
  • Page 45 Water-cooled Ice Machines 1. Perform steps 1-6 under “Self-contained Air-cooled Models” on page 44. 2. Disconnect the incoming water and drain lines from the water-cooled condenser. 3. Insert a large screwdriver between the bottom spring coils of the water regulating valve. Pry upward to open the valve.
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  • Page 47: Operation

    Operation INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF 1. Pressure Equalization Before the compressor starts the harvest valve is energized for 15 seconds to equalize pressures during the initial refrigeration system start-up. 2. Refrigeration System Start-up The compressor starts after the 15-second pressure equalization, and remains on throughout the entire Freeze and Harvest Sequences.

  • Page 48: Harvest Sequence

    HARVEST SEQUENCE 5. Harvest The water pump de-energizes stopping flow over the evaporator. The rising level of water in the sump trough diverts water out of the overflow tube, purging excess minerals from the sump trough. The harvest valve also opens to divert hot refrigerant gas into the evaporator.

  • Page 49: Energized Parts Chart

    ENERGIZED PARTS CHART * Condenser Fan Motor: The fan motor is wired through a fan cycle pressure control; therefore, it may cycle on and off. Part Number STH047 5/16...
  • Page 50 Part Number STH047 5/16...

  • Page 51: Operational Checks

    Operational Checks Siphon System To reduce mineral build-up and cleaning frequency, the water in the sump trough must be purged during each harvest cycle. When the water pump de-energizes, the level in the water trough rises above the standpipe, starting a siphon action.
  • Page 52 Water Level Check The float valve is factory-set for the proper water level. If adjustments are necessary: 1. Verify the ice machine is level. 2. Remove the siphon cap from the standpipe. 3. Place the main ON/OFF/WASH toggle switch to the ON position, and wait until the float valve stops adding water.

  • Page 53: Ice Thickness Adjustment

    ADJUSTING SCREW 1/8" ICE BRIDGE THICKNESS SV3114 SV3113 Ice Thickness Adjustment 2. Make sure the ice thickness probe wire and bracket does not restrict movement of the probe. Part Number STH047 5/16...

  • Page 54: Troubleshooting

    Troubleshooting DIAGNOSING AN ICE MACHINE THAT WILL NOT RUN Warning High (line) voltage is applied to the control board (terminals #2 and #4) at all times. Removing control board fuse or moving the toggle switch to OFF will not remove the power supplied to the control board. 1.

  • Page 55: Diagnosing Ice Thickness Control Circuitry

    DIAGNOSING ICE THICKNESS CONTROL CIRCUITRY Ice Machine Does Not Cycle Into Harvest when Water Contacts the Ice Thickness Control Probe Step 1 Bypass the freeze time lock-in feature by moving the ON/OFF/WASH switch to OFF and back to ON. Wait until the water starts to flow over the evaporator. Step 2 Clip the jumper wire to the ice thickness probe and any cabinet ground.
  • Page 56 Step 3 Disconnect the ice thickness probe from the control board terminal. Clip the jumper wire to the terminal on the control board and any cabinet ground. Monitor the harvest light. PROBE CONNECTION ICE THICKNESS JUMPER WIRE PROBE GROUND BIN SWITCH EVAPORATOR HARVEST LIGHT LIGHT...
  • Page 57 Ice Machine Cycles Into Harvest Before Water Contact with the Ice Thickness Probe Step 1 Bypass the freeze time lock-in feature by moving the ON/OFF/WASH switch to OFF and back to ON. Wait until the water starts to flow over the evaporator, then monitor the harvest light.

  • Page 58: Ice Production Check

    ICE PRODUCTION CHECK The amount of ice a machine produces directly relates to the operating water and air temperatures. This means an ice machine with a 70°F (21.2°C) ambient temperature and 50°F (10.0°C) water produces more ice than the same ice machine with 90°F (32.2°C) ambient and 70°F (21.2°C) water.
  • Page 59 Weighing the ice is the only 100% accurate check. However, if the ice pattern is normal and the 1/8" (.44 cm) thickness is maintained, the ice slab weights listed with the 24-Hour Ice Production Charts may be used. 4. Compare the results of step 3 with step 2. Ice production is normal when these numbers match closely.

  • Page 60: Installation And Visual Inspection Checklist

    INSTALLATION AND VISUAL INSPECTION CHECKLIST Ice machine is not level Level the ice machine Condenser is dirty • Clean the condenser Water filtration is plugged (if used) • Install a new water filter Water drains are not run separately and/or are not vented •...

  • Page 61: Water System Checklist

    WATER SYSTEM CHECKLIST A water-related problem often causes the same symptoms as a refrigeration system component malfunction. Example: A water dump valve leaking during the freeze cycle, a system low on charge, and a starving TXV have similar symptoms. Water system problems must be identified and eliminated prior to replacing refrigeration components.

  • Page 62: Ice Formation Pattern

    ICE FORMATION PATTERN Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction. However, when this analysis is used along with the Refrigeration System Operational Analysis Table, it can help diagnose an ice machine malfunction.
  • Page 63 Extremely Thin at Evaporator Outlet There is no ice, or a considerable lack of ice formation on the outlet of the evaporator. Examples: No ice at all at the outlet of the evaporator, but ice forms at the inlet half of the evaporator. Or, the ice at the outlet of the evaporator reaches the correct thickness, but the outlet of the evaporator already has 1/2"...

  • Page 64: Safety Limit Feature

    SAFETY LIMIT FEATURE In addition to the standard safety controls, your Koolaire ice machine features built-in safety limits that will stop the ice machine if conditions arise which could cause a major component failure. Before calling for service, re-start the ice machine using the following procedure: 1.
  • Page 65 Safety Limits In addition to standard safety controls, the control board has two built in safety limit controls which protect the ice machine from major component failures. Safety Limit #1: If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle. 3 cycles outside the time limit = 1 hour Stand-by Mode.
  • Page 66 Safety Limit Notes • A safety limit indication is completed before the water pump starts. Water contacting the ice thickness probe in the freeze cycle will cause the harvest light to flash. Do not mistake a harvest light flashing in the freeze cycle with a safety limit indication.
  • Page 67 ANALYZING WHY SAFETY LIMITS MAY STOP THE ICE MACHINE According to the refrigeration industry, a high percentage of compressor failure is a result of external causes. These can include flooding or starving expansion valves, dirty condensers, water loss to the ice machine, etc. The safety limits protect the ice machine (primarily the compressor) from external failures by stopping ice machine operation before major component damage occurs.
  • Page 68 Safety Limit Checklist The following checklists are designed to assist the service technician in analysis. However, because there are many possible external problems, do not limit your diagnosis to only the items listed. Safety Limit #1 Freeze time exceeds 60 minutes for 6 consecutive freeze cycles.
  • Page 69 Refrigeration System • Restricted condenser air flow • Condenser discharge air re-circulation • Dirty condenser fins • Non-OEM components • Improper refrigerant charge • Defective compressor • TXV starving or flooding (check bulb mounting) • Non-condensable in refrigeration system • Plugged or restricted high side refrigerant lines or component •...
  • Page 70 Safety Limit #2 Harvest time exceeds 3.5 minutes for 6 Consecutive harvest cycles. Possible Cause Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 60. Water System • Water area (evaporator) dirty • Dirty/defective water dump valve •...

  • Page 71: Analyzing Discharge Pressure

    ANALYZING DISCHARGE PRESSURE 1. Determine the ice machine operating conditions: Air temp. entering condenser ______ Air temp. around ice machine ______ Water temp. entering sump trough ______ 2. Refer to “Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts” on page 123 for ice machine being checked.
  • Page 72 Discharge Pressure High Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 60. Restricted Condenser Air Flow • High inlet air temperature • Condenser discharge air re-circulation • Dirty condenser fins • Defective fan cycling control •...

  • Page 73: Analyzing Suction Pressure

    ANALYZING SUCTION PRESSURE The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times. To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time.
  • Page 74 Procedure Step 1. Determine the ice machine operating conditions. Example: Air temp. entering condenser: 90°F/32.2°C Air temp. around ice machine: 80°F/26.7°C Water temp. entering water fill valve: 70°F/21.1°C 2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice machine model being checked. Using operating conditions from Step 1, determine published freeze cycle time and published freeze cycle suction pressure.
  • Page 75 Suction Pressure High Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 60. Discharge Pressure • Discharge pressure is too high, and is affecting suction pressure, refer to “Discharge Pressure High Checklist” on page 72. Improper Refrigerant Charge •...
  • Page 76 Suction Pressure Low Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 60. Discharge Pressure • Discharge pressure is too low, and is affecting suction pressure, refer to “Freeze Cycle Discharge Pressure Low Checklist” Improper Refrigerant Charge •...

  • Page 77: Harvest Valve

    HARVEST VALVE General The harvest valve is an electrically operated valve that opens when energized, and closes when de-energized. Normal Operation The valve is de-energized (closed) during the freeze cycle and energized (open) during the harvest cycle. The valve is positioned between the receiver and the evaporator and performs two functions: 1.
  • Page 78 Harvest Valve Analysis The valve can fail in two positions: • Valve will not open in the harvest cycle. • Valve remains open during the freeze cycle. VALVE WILL NOT OPEN IN THE HARVEST CYCLE Although the circuit board has initiated a harvest cycle, the evaporator temperature remains unchanged from the freeze cycle.
  • Page 79 Use the following procedure and table to help determine if a harvest valve is remaining partially open during the freeze cycle. 1. Wait five minutes into the freeze cycle. 2. Feel the inlet of the harvest valve. Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison.
  • Page 80 Findings Comments The inlet of the harvest valve is This is normal as the cool enough to touch and the discharge line should compressor discharge line is hot. always be too hot to touch and the harvest valve inlet, Cool & Hot although too hot to touch during harvest, should be cool enough to touch after 5...

  • Page 81: Comparing Evaporator Inlet/Outlet

    COMPARING EVAPORATOR INLET/OUTLET TEMPERATURES The temperatures of the suction lines entering and leaving the evaporator alone cannot diagnose an ice machine. However, comparing these temperatures during the freeze cycle, along with using the Refrigeration System Operational Analysis Table, can help diagnose an ice machine malfunction.

  • Page 82: Discharge Line Temperature Analysis

    DISCHARGE LINE TEMPERATURE ANALYSIS GENERAL Knowing if the discharge line temperature is increasing, decreasing or remaining constant can be an important diagnostic tool. Maximum compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle. Comparing the temperatures over several cycles will result in a consistent maximum discharge line temperature.
  • Page 83 Discharge Line Temperature Above 150°F (66°C) at End of Freeze Cycle: Ice machines that are operating normally will have consistent maximum discharge line temperatures above 150°F (66°C). Verify the expansion valve sensing bulb is positioned and secured correctly. Discharge Line Temperature Below 150°F (66°C) at End of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that...

  • Page 84: Refrigeration Component Diagnostic Chart

    REFRIGERATION COMPONENT DIAGNOSTIC CHART All electrical and water related problems must be corrected before these charts will work properly. These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed and external items and problems that will cause good refrigeration components to appear defective.

  • Page 85: Procedure

    PROCEDURE Step 1 Complete each item individually in the “Operational Analysis” column. Enter check marks () in the boxes. Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a check mark. Example: Freeze cycle suction pressure is determined to be low.

  • Page 86: Final Analysis

    FINAL ANALYSIS The column with the highest number of check marks identifies the refrigeration problem. Column 1 – Harvest Valve Leaking A leaking harvest valve must be replaced. Column 2 – Low Charge/TXV Starving Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures.

  • Page 87: Refrigeration Component Diagnostic Chart

    Part Number STH047 5/16...
  • Page 88 Part Number STH047 5/16...
  • Page 89 Part Number STH047 5/16...

  • Page 90: Ice Quality Is Poor - Cubes Are Shallow

    ICE QUALITY IS POOR — CUBES ARE SHALLOW, INCOMPLETE OR WHITE Ice machine is dirty • Clean and sanitize the ice machine Water filtration is poor • Replace the filter Water softener is working improperly (if applicable) • Repair the water softener Poor incoming water quality •...

  • Page 91: Freeze Cycle Is Long, Low Ice Production

    FREEZE CYCLE IS LONG, LOW ICE PRODUCTION Water temperature is too high • Connect to a cold water supply, verify check valves in faucets and other equipment are functioning correctly Dirty Condenser • Clean condenser High air temperature entering condenser •...

  • Page 92: Ice Machine Runs And No Ice Is Produced

    ICE MACHINE RUNS AND NO ICE IS PRODUCED No water to ice machine • Correct water supply Incorrect incoming water pressure • Water pressure must be 20-80 psi (1.4-5.5 bar) Excessive mineral buildup • Clean and sanitize the ice machine Ambient temperature is too high or low •...

  • Page 93: Component Check Procedures

    Component Check Procedures Main Fuse Function The control board fuse stops ice machine operation if electrical components fail causing high amp draw. Specifications The main fuse is 250 Volt, 10 amp. Warning High (line) voltage is applied to the control board at all times.

  • Page 94: Bin Switch

    Bin Switch Function Bin switch operation is controlled by the movement of the ice damper. The bin switch has two main functions: 1. Terminating the harvest cycle and returning the ice machine to the freeze cycle. This occurs when the bin switch is opened and closed again within 7 seconds of opening during the harvest cycle.
  • Page 95 Ohm Test 1. Disconnect the bin switch wires to isolate the bin switch from the control board. 2. Connect an ohmmeter to the disconnected bin switch wires. 3. Cycle the bin switch open and closed numerous times by opening and closing the water curtain. NOTE: To prevent misdiagnosis: •...
  • Page 96 Bin Switch Removal 1. Disconnect power to the ice machine at service disconnect. 2. Disconnect bin switch wires in control box. 3. Insert a small screwdriver through the hole located in the top of the bin switch, and depress mounting tab slightly.

  • Page 97: Diagnosing Start Components

    Diagnosing Start Components If the compressor attempts to start, or hums and trips the overload protector, check the start components before replacing the compressor. CAPACTOR Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane. Do not assume a capacitor is good if no visual evidence is present.

  • Page 98: On/Off/Wash Toggle Switch

    ON/OFF/WASH Toggle Switch Function The switch is used to place the ice machine in ON, OFF or WASH mode of operation. Specifications Single-pole, double-throw switch. The switch is connected into a varying low D.C. voltage circuit. Check Procedure NOTE: Because of a wide variation in D.C. voltage, it is not recommended that a voltmeter be used to check toggle switch operation.

  • Page 99: Ice Thickness Probe

    ce Thickness Probe How the Probe Works Koolaire’s electronic sensing circuit does not rely on refrigerant pressure, evaporator temperature, water levels or timers to produce consistent ice formation. As ice forms on the evaporator, water (not ice) contacts the ice thickness probe. After the water completes this circuit across the probe continuously for 6-10 seconds, a harvest cycle is initiated.

  • Page 100: Ice Thickness Check

    CE THCKNESS CHECK The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8" (3.2 mm). NOTE: Make sure the water curtain is in place when performing this check. It prevents water from splashing out of the water trough. 1.

  • Page 101: Compressor Electrical Diagnostics

    Compressor Electrical Diagnostics The compressor does not start or will trip repeatedly on overload. Check Resistance (Ohm) Values NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter. Perform the resistance test after the compressor cools. The compressor dome should be cool enough to touch (below 120°F/49°C) to ensure that the overload is closed and the resistance readings will be accurate.
  • Page 102 Compressor Drawing Locked Rotor The two likely causes of this are: • Defective starting component • Mechanically seized compressor To determine which you have: 1. Install high and low side gauges. 2. Try to start the compressor. 3. Watch the pressures closely. •...

  • Page 103: Fan Cycle Control

    Fan Cycle Control Function Cycles the fan motor on and off to maintain proper operating discharge pressure. The fan cycle control closes on an increase, and opens on a decrease in discharge pressure. Specifications Model Cut-n (Close) Cut-Out (Open) K170 275 psig ±5 225 psig ±5 K270...

  • Page 104: High Pressure Cutout (Hpco) Control

    High Pressure Cutout (HPCO) Control Function Stops the ice machine if subjected to excessive high-side pressure. The HPCO control is normally closed, and opens on a rise in discharge pressure. Specifications Cut-out: 450 psig ±10 Cut-in: Automatic reset (Must be below 300 psig to reset). Check Procedure 1.

  • Page 105: Filter-Driers

    Koolaire specifications. The difference between a Koolaire drier and an off-the- shelf drier is in filtration. A Koolaire drier has dirt-retaining filtration, with fiberglass filters on both the inlet and outlet ends. This is very important because ice machines have a back-flushing action that takes place during every harvest cycle.

  • Page 106: Refrigerant Recovery/Evacuation

    Refrigerant Recovery/Evacuation Definitions Recover To remove refrigerant, in any condition, from a system and store it in an external container, without necessarily testing or processing it in any way. Recycle To clean refrigerant for re-use by oil separation and single or multiple passes through devices, such as replaceable core filter-driers, which reduce moisture, acidity and particulate matter.

  • Page 107: Refrigerant Re-Use Policy

    REFRGERANT RE-USE POLCY Koolaire recognizes and supports the need for proper handling, re-use, and disposal of CFC and HCFC refrigerants. Koolaire service procedures require recapturing refrigerants, not venting them to the atmosphere. It is not necessary, in or out of warranty, to reduce or compromise the quality and reliability of your customers’...
  • Page 108 Compressor motor burnouts and improper past service prevent refrigerant re-use. • Refer to “System Contamination Cleanup” on page 112 to test for contamination. 5. “Substitute” or “Alternative” Refrigerant • Must use only Koolaire-approved alternative refrigerants. • Must follow Koolaire-published conversion procedures. Part Number STH047 5/16...

  • Page 109: Recovery And Recharging Procedures

    Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. mportant Koolaire assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 110 Follow the Charging Procedures below. CHARGING PROCEDURES mportant The charge is critical on all Koolaire ice machines. Use a scale or a charging cylinder to ensure the proper charge is installed. 1. Be sure the toggle switch is in the OFF position.
  • Page 111 7. Close the high side on the manifold gauge set. Add any remaining vapor charge through the suction service valve (if necessary). NOTE: Manifold gauges must be removed properly to ensure that no refrigerant contamination or loss occurs. 8. Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses.

  • Page 112: System Contamination Cleanup

    This section describes the basic requirements for restoring contaminated systems to reliable service. mportant Koolaire assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 113 Contamination/Cleanup Chart Symptoms/Findings Required Cleanup Procedure No symptoms or suspicion of Normal contamination evacuation/ recharging procedure Moisture/Air Contamination symptoms Mild Refrigeration system open to atmosphere contamination for longer than 15 minutes cleanup procedure Refrigeration test kit and/or acid oil test shows contamination No burnout deposits in open compressor lines...

  • Page 114: Procedure

    MLD SYSTEM CONTAMNATON CLEANUP PROCEDURE 1. Replace any failed components. 2. If the compressor is good, change the oil. 3. Replace the liquid line drier. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation.

  • Page 115: Severe System Contamination Cleanup

    SEVERE SYSTEM CONTAMNATON CLEANUP PROCEDURE 1. Remove the refrigerant charge. 2. Remove the compressor. 3. Disassemble the harvest solenoid valve. If burnout deposits are found inside the valve, install a rebuild kit, and replace the TXV and head pressure control valve.
  • Page 116 11. Operate the ice machine for one hour. Then, check the pressure drop across the suction line filter-drier. If the pressure drop is less than 2 psig, the filter- drier should be adequate for complete cleanup. If the pressure drop exceeds 2 psig, change the suction line filter-drier and the liquid line drier.

  • Page 117: Replacing Pressure Controls Without

    REPLACNG PRESSURE CONTROLS WTHOUT REMOVNG REFRGERANT CHARGE This procedure reduces repair time and cost. Use it when any of the following components require replacement, and the refrigeration system is operational and leak-free. • Fan cycle control • High pressure cut-out control •...
  • Page 118 FG. A - “PNCHNG OFF” TUBNG FG. B - REROUNDNG TUBNG SV1406 Using Pinch Off Tool Part Number STH047 5/16...

  • Page 119: K270 Condenser Fan Motor Access

    K270 Condenser Fan Motor Access Access to remove, clean or replace the condenser fan/ motor can be obtained by performing the following: 1. Disconnect electrical power to the ice machine at the electrical service disconnect. 2. Remove the screws that secure the condenser to the cabinet and the base to the cabinet.
  • Page 120 THIS PAGE INTENTIONALLY LEFT BLANK Part Number STH047 5/16...

  • Page 121: Main Fuse

    Component Specifications Main Fuse Volt K170 - K270 Bin Switch Bin switch operation is controlled by the movement of the ice damper. ON/OFF/WASH Toggle Switch Single-pole, double-throw switch. The switch is connected into a varying low D.C. voltage circuit. Fan Control Cycle Model Cut-in (Close) Cut-out (Open)

  • Page 122: Total System Refrigerant Charge

    Total System Refrigerant Charge mportant This information is for reference only. Refer to the ice machine serial number tag to verify the system charge. Serial plate information overrides information listed on this page. Model Air-Cooled Water-Cooled Refrigerant Type K170 14 oz (397 g) R404A K270 22 oz (624 g)

  • Page 123: Cycle Times, 24 Hr. Ice Production And Refrigerant Pressure Charts

    Charts Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts These charts are used as guidelines to verify correct ice machine operation. Accurate collection of data is essential to obtain the correct diagnosis. • Refer to “Operational Analysis Chart” for the list of data that must be collected for refrigeration diagnostics.

  • Page 124: K170 Self-Contained Air-Cooled

    K170 SELF-CONTAINED AIR-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Air Temp. Freeze Time Harvest Entering Time Water Temperature °F/°C Condenser 50/10 70/21 90/32 °F/°C 70/21 17.6-20-1 24.5-28.0 80/27 20.9-23.9...

  • Page 125: K270 Self-Contained Air-Cooled

    K270 SELF-CONTAINED AIR-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Air Temp. Freeze Time Harvest Entering Time Water Temperature °F/°C Condenser 50/10 70/21 90/32 °F/°C 70/21 11.0-12.6 12.8-14.7 14.5-16.5 80/27...

  • Page 126: K270 Self-Contained Water-Cooled

    K270 SELF-CONTAINED WATER-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Air Temp. Freeze Time Harvest Around Ice Time Water Temperature °F/°C Machine 50/10 70/21 90/32 °F/°C 70/21 10.6-12.2 12.3-14.0 13.5-15.4...

  • Page 127: Wiring Diagrams

    Diagrams Wiring Diagrams The following pages contain electrical wiring diagrams. Be sure you are referring to the correct diagram for the ice machine you are servicing. Warning Always disconnect power before working on electrical circuitry. Wiring Diagram Legend The following symbols are used on all of the wiring diagrams: Internal Compressor Overload (Some models have external compressor...

  • Page 128: K170 / K270 Wiring Diagram

    K170 / K270 WIRING DIAGRAM NOTE: Diagram shown in the freeze cycle (22) (24) (23) (20) (10) (11) (21) (12) (14) (15) (13) Part Number STH047 5/16...
  • Page 129 Control Board Fuse Transformer On/Off /Clean Switch Bin Switch Bin Thermostat High Pressure Cut Out Contactor Coil Contactor Contacts Compressor Compressor Relay Compressor Start Capacitor Compressor Overload Condenser Fan Motor Fan Cycle Control Water Pump Ice Thickness Control Part Number STH047 5/16...

  • Page 130: Electronic Control Boards

    Electronic Control Boards ICE THICKNESS DC VOLTAGE PROBE ELECTRICAL PLUG BIN SWITCH LIGHT HARVEST LIGHT AC LINE VOLTAGE ELECTRICAL PLUG 10 AMP FUSE Part Number STH047 5/16...

  • Page 131: K170/K270 Tubing Schematic

    K170/K270 TUBING SCHEMATIC EVAPORATOR HEAT EXPANSION EXCHANGER VALVE HARVEST SOLENOID VALVE AIR OR WATER STRAINER CONDENSER DRIER COMPRESSOR RECEIVER (WATER COOLED ONLY) SV3023 Part Number STH047 5/16...
  • Page 132 MANITOWOC FOODSERVICE ICE MACHINE DIVISION 2110 SOUTH 26TH STREET MANITOWOC, WI 54220 800-545-5720 WWW.KOOL-AIRE.COM Every new piece of Manitowoc Foodservice equipment comes with KitchenCare™ and you choose the level of service that meets your operational needs from one restaurant to multiple locations. StarCare –...

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