Koolaire KDT0300A Technician's Handbook
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Koolaire KDT0300A Technician's Handbook

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Koolaire
KT Model Ice Machines
Technician's Handbook
Part Number STH063 9/17

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Summary of Contents for Koolaire KDT0300A

  • Page 1 Koolaire KT Model Ice Machines Technician’s Handbook Part Number STH063 9/17...

  • 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. • Refer to nameplate to identify the type of refrigerant in your equipment. • Only trained and qualified personnel aware of the dangers are allowed to work on the equipment. •...
  • 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 Warning 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 Appliance.

  • Page 9: Table Of Contents

    Table of Contents General Information Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 How to Read a Model Number .
  • Page 10 Maintenance Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . 35 General.
  • Page 11 Component Check Procedures Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Bin Switch .
  • Page 12 Charts Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115 KT0300A Self-contained Air-cooled .

  • Page 13: General Information

    General Information Model Numbers This manual covers the following models: Self-Contained Self-Contained Remote Air-Cooled Water-Cooled KDT0300A ---- ---- KYT0300A ---- ---- KDT0400A KDT0400W ---- KYT0400A KYT0400W ---- KDT0420A KDT0420W ---- KYT0420A KYT0420W ---- KDT0500A KDT0500W ---- KYT0500A KYT0500W ---- KDT0700A...

  • Page 14: How To Read A Model Number

    How to Read a Model Number Cube Size Capacity Condenser Series Type K D T 0300 A E T - R410A E - WRAS 50Hz Refrigerant R - Regular A - Air-cooled D - Dice W - Water-cooled Y - Half-dice Warning An ice machine contains high voltage electricity and refrigerant charge.

  • Page 15: 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 16: Ice Machine Clearance Requirements

    Ice Machine Clearance Requirements Warning Do not obstruct ice machine vents or openings. Self-Contained Self-Contained KT0300 Air-Cooled Water-Cooled Top/Sides 12" (30.5 cm) Back 5" (12.7 cm)* KT0400 - KT0420 Self-Contained Water-Cooled KT0500 - KT0700 Air-Cooled and Remote KT1000 - KT1700 Top/Sides 8"...

  • Page 17: Ice Machine Heat Of Rejection

    Ice Machine Heat of Rejection Series Heat of Rejection Ice Machine Air Conditioning Peak KT0300 4600 5450 KT0400 3800 6000 KT0420 5400 6300 KT0500 5300 6100 KT0700 9000 13900 KT1000 17000 20700 KT1700 24700 29000 1 B.T.U./Hour 2 Because the heat of rejection varies during the ice making cycle, the figure shown is an average.

  • Page 18: 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). Fuse/Circuit Breaker A separate fuse/circuit breaker must be provided for each ice machine.

  • Page 19: Water Service/Drains

    (Check valves on sink faucets, dishwashers, etc.) • If water pressure exceeds the maximum recommended pressure, 80 psig (5.5 bar) obtain a water pressure regulator from your Koolaire distributor. • Install a water shut-off valve for ice making potable water. •...

  • Page 20: Drain Connections

    DRAIN CONNECTIONS Follow these guidelines when installing drain lines to prevent drain water from flowing back into the ice machine and storage bin: • Drain lines must have a 1.5-inch drop per 5 feet of run (2.5 cm per meter), and must not create traps. •...

  • Page 21: Water Supply And Drain Line Sizing/Connections

    WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS Part Number STH063 9/17...

  • Page 22: Remote Condenser

    REMOTE CONDENSER Remote Single Ice Machine Line Set* Circuit Condenser RT-20R-R410A KT1000 JCT1200 RT-35R-R410A RT-50R-R410A RL-20R-R410A KT1700 JCT1500 RL-35R-R410A RL-50R-R410A *Line Set Discharge Line Liquid Line 1/2" (1.27 cm) 5/16" (.79 cm) 1/2" (1.27 cm) 3/8" (.95 cm) Air Temperature Around the Condenser Minimum Maximum -20°F (-29°C)
  • Page 23 Calculating Allowable Lineset Distance Line Set Length The maximum length is 100’ (30.5 m). Line Set Rise/Drop The maximum rise is 35’ (10.7 m). The maximum drop is 15’ (4.5 m). 35 FT. (10.7 M) MAXIMUM DISTANCE 35 ft. (10.7 m) Rise: The maximum distance the Condenser or Condensing Unit can be above the ice machine.
  • Page 24 Calculated Line Set Distance The maximum calculated distance is 150’ (45.7 m). Line set rises, drops, horizontal runs (or combinations of these) in excess of the stated maximums will exceed compressor start-up and design limits. This will cause poor oil return to the compressor. Make the following calculations to make sure the line set layout is within specifications.

  • Page 25: Maximum Line Set Distance Formula

    Maximum Line Set Distance Formula Step 1 Measured Rise ____ X 1.7 = ______Calculated Rise (35 ft. Max) Step 2 Measured Drop ____ X 6.6 = ______Calculated Drop (15 ft. Max.) Step 3 Measured Horizontal Distance = _________Horizontal (100 ft. Max.) Distance Step 4 Total Calculated Distance = ________Total Calculated...
  • Page 26 THIS PAGE INTENTIONALLY LEFT BLANK Part Number STH063 9/17...

  • Page 27: Operation

    Operation Ice Making Sequence of Operation NOTE: The toggle switch must be in the ON position and the water curtain must be closed before the ice machine will start. Water Purge Cycle The ice machine purges any remaining water from the water trough down the drain.

  • Page 28: Control Board Timers

    CONTROL BOARD TIMERS • The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated. • The freeze time lock in feature is bypassed on the initial cycle (manual start or after a full bin/safety limit condition).

  • Page 29: Safety Limits

    SAFETY LIMITS Safety limits are stored and indicated by the control board. The number of cycles required to stop the ice machine varies for each safety limit. Safety limits can be reset by cycling the toggle switch Off/ On and starting a new ice making cycle. A safety limit is indicated by a flashing light on the control board.
  • Page 30 Safety Limit 3 If the harvest float switch hasn’t opened for 10 continuous seconds within 4 minutes of the water inlet valve energizing the ice machine stops. • Safety Limit 3 is bypassed on the initial cycle (manual start or after a full bin/safety limit condition). For all subsequent cycles the ice machine stops for 30 minutes when the water inlet valve is energized for 4 minutes and the harvest float valve didn’t open.

  • Page 31: Energized Parts Chart

    Part Number STH063 9/17...
  • Page 32 Part Number STH063 9/17...

  • Page 33: Operational Checks

    Operational Checks ICE THICKNESS CHECK After a harvest cycle, inspect the ice cubes in the ice storage bin. The ice bridge connects the ice cubes and must be set to maintain an ice bridge thickness of 1/8" (3 mm). To adjust the thickness of the bridge refer to ice thickness adjustment.

  • Page 34: Minimum/Maximum Slab Weights

    MINIMUM/MAXIMUM SLAB WEIGHTS Adjust ice thickness to meet chart specifications. Minimum Ice Weight Maximum Ice Model Per Cycle Weight Per Cycle 3.4 lbs 3.9 lbs KT0300 1542 g 1769 g 3.4 lbs 3.9 lbs KT0400 1542 g 1769 g 3.4 lbs 3.9 lbs KT0420 1542 g...

  • Page 35: Interior Cleaning And Sanitizing

    Maintenance 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.

  • Page 36: Toggle Switch Operation

    TOGGLE SWITCH OPERATION Moving the toggle switch to clean will start a Clean cycle. • Setting the ice machine to stop after the clean cycle: Place the toggle switch in the clean position. The ice machine will stop after the clean cycle. •...
  • Page 37 Caution Do not mix Ice Machine Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. To start a cleaning cycle, move the toggle switch Step 3 to Clean.
  • Page 38 Mix a solution of cleaner and lukewarm water. Step 6 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.
  • Page 39 Mix a solution of sanitizer and warm water. Step 9 Solution Type Water Mixed With Sanitizer 3 gal. (12 l) 2 oz (60 ml) sanitizer Use half of the sanitizer/water solution to Step 10 sanitize all removed components. Use a spray bottle to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution.

  • Page 40: Remove Parts For Cleaning

    REMOVE PARTS FOR CLEANING Warning Disconnect electric power to the ice machine at the electric switch box before proceeding. 1. Remove the water curtain • Gently flex the curtain in the center and remove it from the right side. • Slide the left pin out. 2.
  • Page 41 5. Remove the Water Trough • Depress tabs on right and left side of the water trough. • Allow front of water trough to drop as you pull forward to disengage the rear pins. • Remove the water trough from the bin area. Part Number STH063 9/17...

  • Page 42: Preventative Maintenance Cleaning

    Preventative Maintenance Cleaning This cleaning procedure can be performed between the bi- annual cleaning and sanitizing cycles. This procedure does not require removing the ice from the bin. Place the toggle switch in the off position after Step 1 ice falls from the evaporator at the end of a Harvest cycle. Or, place the toggle switch in the off position and allow the ice to melt off the evaporator.

  • Page 43: Ice Machine Inspection

    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. There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life.

  • Page 44: Cleaning The Condenser

    Cleaning the Condenser General Warning Disconnect electric power to the ice machine head section and the remote condensing unit at the electric service switches before cleaning the condenser. A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces ice production and shortens component life.

  • Page 45: Removal From Service/Winterization

    Removal from Service/Winterization AIR-COOLED MODELS 1. Clean and sanitize the ice machine. 2. Place the toggle switch in the off position to turn off the ice machine. 3. Turn off the water supply, disconnect and drain the incoming ice-making water line at the rear of the ice machine and drain the water trough.
  • Page 46 THIS PAGE INTENTIONALLY LEFT BLANK Part Number STH063 9/17...

  • Page 47: Troubleshooting

    Troubleshooting Control Board Test Mode NOTE: The water curtain/bin switch can be open or closed and does not affect the operation of the test mode. To enter the test mode, move the toggle switch to off, then press and hold the test button on the control board for 3 seconds.

  • Page 48: Diagnosing An Ice Machine That Will Not Run

    Diagnosing an Ice Machine that Will Not Run Warning High (line) voltage is applied to the control board at all times. Removing the control board fuse or pressing the power button will not remove the power supplied to the control board. 1.

  • Page 49: Ice Machine Does Not Cycle Into Harvest When

    Ice Machine Does Not Cycle Into Harvest when Water Loses Contact with the Harvest Float Switch NOTE: The ice machine will make a thick or double slab when a new freeze cycle is started with ice already present on the evaporator. Two of the most common scenarios are: •...
  • Page 50 Disconnect power to the ice machine, remove Step 1 the electrical panel to allow viewing of the control board lights. Disconnect the harvest float switch wire from the control board and place a jumper on the control board harvest switch terminals. Bypass the freeze time lock-in feature by Step 2 moving the toggle switch Off/On to cycle the ice machine...

  • Page 51: Ice Machine Cycles Into Harvest Before Water Loses Contact With The Harvest Float Switch

    Ice Machine Cycles Into Harvest Before Water Loses Contact with the Harvest Float Switch Disconnect power to the ice machine, remove Step 1 the electrical panel to allow viewing of the control board lights and disconnect the harvest float switch from the control board.

  • Page 52: 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°C) ambient temperature and 50°F (10°C) water produces more ice than the same ice machine with 90°F (32°C) ambient and 70°F (21°C) water.

  • Page 53: Installation/Visual Inspection Checklist

    Installation/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 54: 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 55: 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 56 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 57 Evaporator Tubing Routing Routing of the tubing on the back of the evaporator determines the ice fill pattern failure mode. One Evaporator, One TXV Models The evaporator outlet tubing does not exit directly at the top of the evaporator, but exits several inches below the top of the evaporator.

  • Page 58: Safety Limits

    SAFETY LIMITS Safety limits are stored and indicated by the control board. The number of cycles required to stop the ice machine varies for each safety limit. Safety limits can be reset by cycling the toggle switch Off/ On and starting a new ice making cycle. A safety limit is indicated by a flashing light on the control board.
  • Page 59 Safety Limit 3 If the harvest float switch hasn’t opened for 10 continuous seconds within 4 minutes of the water inlet valve energizing, the ice machine stops. • Safety Limit 3 is bypassed on the initial cycle (manual start or after a full bin/safety limit condition). For all subsequent cycles, the ice machine stops for 30 minutes when the water inlet valve is energized for 4 minutes and the harvest float valve didn’t open.
  • Page 60 Determining Which Safety Limit Stopped the Ice Machine: 1. Cycle the toggle switch Off. 2. Cycle the toggle switch On to start ice making. 3. Watch the safety limit lights. • One will flash corresponding to safety limits 1 or 2. 4.
  • Page 61 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 3 consecutive freeze cycles.
  • Page 62 Refrigeration System • Non-OEM components • Improper refrigerant charge • Defective compressor • TXV starving or flooding (check bulb mounting) • Non-condensible in refrigeration system • Plugged or restricted high side refrigerant lines or component • Defective harvest valve Part Number STH063 9/17...
  • Page 63 Safety Limit #2 Harvest time exceeds 3.5 minutes for 100 Consecutive harvest cycles. Possible Cause Checklist Improper installation • Refer to “Installation/Visual Inspection Checklist” on page 53 Water System • Water area (evaporator) dirty • Dirty/defective water dump valve • Vent tube not installed on water outlet drain •...
  • Page 64 Safety Limit 3 The harvest float switch hasn’t opened for 10 continuous seconds within 4 minutes of the water inlet valve energizing. Possible Cause Checklist Improper installation • Refer to “Installation/Visual Inspection Checklist” on page 53 Water System • Water dump valve •...

  • Page 65: 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 115 for ice machine being checked.
  • Page 66 Discharge Pressure High Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 53. Condenser Air Flow • High inlet air temperature • Condenser discharge air re-circulation • Dirty condenser fins • Defective fan cycling control • Defective fan motor Improper Refrigerant Charge •...

  • Page 67: Analyzing Suction Pressure

    Freeze Cycle Discharge Pressure Low Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 53. Improper Refrigerant Charge • Undercharged • Wrong type of refrigerant Other • Non-OEM components in system • High side refrigerant lines/component restricted (before mid-condenser) •...
  • Page 68 Procedure 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 69 Suction Pressure High Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 53. Discharge Pressure • Discharge pressure is too high and is affecting suction pressure, refer to ”Discharge Pressure High Checklist” on page 66. Improper Refrigerant Charge •...
  • Page 70 Suction Pressure Low Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 53. Discharge Pressure • Discharge pressure is too low, and is affecting suction pressure, refer to “” on page 66 Improper Refrigerant Charge • Undercharged • Wrong type of refrigerant Other •...

  • Page 71: 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 compressor discharge line and the evaporator and performs two functions: 1.
  • Page 72 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 73 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(s). mportant Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison.
  • Page 74 Findings Comments The inlet of the harvest valve This is normal as the discharge is cool enough to touch and line should always be too hot the compressor discharge line to touch and the harvest valve is hot. inlet, although too hot to touch during harvest, should be cool enough to touch after 5 Cool &...

  • Page 75: Comparing Evaporator Inlet/Outlet Temperatures

    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 the Refrigeration System Operational Analysis Table, can help diagnose an ice machine malfunction.

  • Page 76: 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 77 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 decreases...

  • Page 78: Refrigeration Component Diagnostics

    Refrigeration Component Diagnostics 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 79: Procedure

    PROCEDURE Complete each item individually in the Step 1 “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 80: Final Analysis

    Part Number STH063 9/17...

  • Page 81: Refrigeration Component Diagnostic Chart

    Part Number STH063 9/17...
  • Page 82 Part Number STH063 9/17...
  • Page 83 Part Number STH063 9/17...
  • Page 84 Part Number STH063 9/17...

  • Page 85: 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, 3.15 amp. Warning High (line) voltage is applied to the control board at all times.

  • Page 86: Bin Switch

    Bin Switch Function Bin switch operation is controlled by the movement of the water curtain. 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 30 seconds of opening during the harvest cycle.
  • Page 87 Ohm Test 1. Disconnect the bin switch wires from the control board. 2. Connect an ohmmeter to the disconnected bin switch. 3. Cycle the bin switch open and closed numerous times by opening and closing the water curtain. NOTE: To prevent misdiagnosis: •...

  • Page 88: Float Switch

    Float Switch Function Open and close to indicate to the control board the level of water in the water trough. Specifications Normally closed, float operated magnetic reed switch. The float switch contacts are closed in the down position. When water raises the float to the up position the magnet in the float opens the contacts.
  • Page 89 If the control board light does not respond to the float, proceed with Step 1 below. 1. Disconnect power to the ice machine and pull the float switch and connector through the ice machine base and disconnect. 2. Attach an ohm meter lead to each float switch wire. 3.

  • Page 90: 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 91 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 gauge. 2. Try to start the compressor. 3. Watch the pressures closely. •...

  • Page 92: 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-In Cut-Out (Close) (Open) KT0300 KT0400 335 psig ±5 275 psig ±5 KT0420 KT0500...

  • Page 93: 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: 600 psig ±10 4137 kPa ±10 Cut-in: 450 psig ±10 3103 kPa ±10 (Must be below 450 psig - 3103 kPa to reset).

  • Page 94: Refrigeration Components

    Refrigeration Components HEAD PRESSURE CONTROL VALVE Manitowoc remote systems require head pressure control valves with special settings. Replace defective head pressure control valves only with “original” Manitowoc replacement parts. Refrigerant Charge Verification The correct amount of refrigerant (name plate charge) is required to operate correctly at all ambient conditions.

  • Page 95: Freeze Cycle Operation All Models

    FREEZE CYCLE OPERATION ALL MODELS The head pressure control valve is non adjustable. At ambient temperatures of approximately 70°F (21°C) or above, refrigerant flows through the valve from the condenser to the receiver inlet. At temperatures below this (or at higher temperatures if it is raining), the head pressure control dome’s nitrogen charge closes the condenser port and opens the bypass port from the compressor discharge line.
  • Page 96 NOTE: A head pressure control valve that will not bypass, will function properly with condenser air temperatures of approximately 70°F (21°C) or above. When the temperature drops below 70°F (21°C), the head pressure control valve fails to bypass and the ice machine malfunctions.
  • Page 97 Harvest Cycle REMOTE CONDENSER The head pressure control cycles into full bypass due to the pressure drop when the harvest valve opens. Refrigerant flows from the compressor to the evaporator through the harvest valve and the head pressure valve is out of the circuit.

  • Page 98: Harvest Pressure Regulating (Hpr) System Remote Condenser Only

    HARVEST PRESSURE REGULATING (HPR) SYSTEM REMOTE CONDENSER ONLY GENERAL The harvest pressure regulating (HPR) system includes: • Harvest pressure regulating solenoid valve (HPR solenoid). This is an electrically operated valve which opens when energized, and closes when de-energized. • Harvest pressure regulating valve (HPR valve). This is a pressure regulating valve which modulates open and closed, based on the refrigerant pressure at the outlet of the valve.
  • Page 99 FREEZE CYCLE The HPR system is not used during the freeze cycle. The HPR solenoid is closed (de-energized), preventing refrigerant flow into the HPR valve. HARVEST CYCLE During the harvest cycle, the check valve in the discharge line prevents refrigerant in the remote condenser and receiver from back feeding into the evaporator and condensing to liquid.
  • Page 100 3. Freeze time normal? (Refer to Cycle Times/Refrigerant Pressures/24 Hour Ice Production Charts). Shorter freeze cycles? Refer to head pressure control valve diagnostics. Longer freeze cycles? Refer to water system checklist, then refer to Refrigeration Diagnostic Procedures. 4. Harvest time is longer than normal and control board indicates safety limit #2? (Refer to Cycle Times/Refrigerant Pressures/24 Hour Ice Production Charts).

  • Page 101: Water Regulating Valve

    WATER REGULATING VALVE Water-Cooled Models Only FUNCTION The water regulating valve maintains the freeze cycle discharge pressure. CHECK PROCEDURE 1. Determine if the head pressure is high or low (refer to cycle time/24 hour ice production and operational pressure chart for the model you are servicing). 2.

  • Page 102: 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 103: Refrigerant Re-Use Policy

    REFRIGERANT RE-USE POLICY Koolaire recognizes and supports the need for proper handling, re-use, and disposal of 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 104 • Refer to “Remote Condenser Model Procedure” on page 94 to test for contamination. 5. “Substitute” or “Alternative” Refrigerant • Must use only Koolaire-approved alternative refrigerants. • Must follow Koolaire-published conversion procedures. Part Number STH063 9/17...

  • Page 105: 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 106 CHARGING PROCEDURES mportant The charge is critical on all Koolaire machines. Use a scale or a charging cylinder to ensure the proper charge is installed. 1. Cycle the toggle switch Off. 2. Close the vacuum pump valve and isolate the low and high side access valves.

  • Page 107: 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 108 Contamination/Cleanup Chart Symptoms/Findings Required Cleanup Procedure No symptoms or suspicion of Normal evacuation/ contamination recharging procedure Moisture/Air Contamination symptoms Mild contamination Refrigeration system open to atmosphere cleanup procedure for longer than 15 minutes Refrigeration test kit and/or acid oil test shows contamination No burnout deposits in open compressor lines...

  • Page 109: Mild System Contamination Cleanup Procedure

    MILD SYSTEM CONTAMINATION 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 110: Severe System Contamination Cleanup Procedure

    SEVERE SYSTEM CONTAMINATION CLEANUP PROCEDURE 1. Remove the refrigerant charge. 2. Remove the compressor. 3. Remove the compressor and inspect the refrigeration lines. If burnout deposits are found, install a new harvest valve, replace the manifold strainer, TXV and harvest pressure regulating valve. 4.

  • Page 111: Replacing Pressure Controls Without Removing Refrigerant Charge

    11. Charge the system with the proper refrigerant to the nameplate charge. 12. 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.
  • Page 112 Warning Do not unsolder a defective component. Cut it out of the system. Do not remove the pinch-off tool until the new component is securely in place. 3. Cut the tubing of the defective component with a small tubing cutter. 4.

  • Page 113: Refrigerant Amount

    Refrigerant Amount NOTE: All models charged with R410A refrigerant. Nameplate information overrides all data in this chart. Model Air-Cooled Water- Remote 51’ to 100’ Cooled Line sets* KT0300 15 oz 60Hz 425 g KT0300 17 oz 50Hz 482 g KT0400 18 oz 14 oz 60Hz...
  • Page 114 THIS PAGE INTENTIONALLY LEFT BLANK Part Number STH063 9/17...

  • Page 115: Cycle Times, 24 Hr. Ice Production And Refrigerant

    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. Production and cycle times are for dice cube - Half dice cube cycle times can be 1-2 minutes faster depending on model and ambient temperature.

  • Page 116: Kt0300A Self-Contained Air-Cooled

    KT0300A 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 13.3-15.5 16.0-18.6 18.1-21.0 80/27...

  • Page 117: Kt0400A Self-Contained Air-Cooled

    KT0400A 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 9.6-11.3 10.4-12.2 12.5-14.5 80/27...

  • Page 118: Kt0400W Self-Contained Water-Cooled

    KT0400W 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 10.0-11.7 9.9-11.6 11.7-13.7...

  • Page 119: Kt0420A Self-Contained Air-Cooled

    KT0420A 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 9.6-11.3 10.4-12.2 12.5-14.5 80/27...

  • Page 120: Kt0420W Self-Contained Water-Cooled

    KT0420W 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 10.0-11.7 9.9-11.6 11.7-13.7...

  • Page 121: Kt0500A Self-Contained Air-Cooled

    KT0500A 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 10.0-11.8 12.5-14.6 13.4-15.6 80/27...

  • Page 122: Kt0500W Self-Contained Water-Cooled

    KT0500W SELF-CONTAINED WATER-COOLED 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 9.7-11.4 12.0-14.0 13.0-15.2 80/27 12.0-13.8 13.7-15.7 15.5-17.9 90/32 12.4-14.3 12.6-14.8 16.4-18.7 1.0-2.5...

  • Page 123: Kt0700A Self-Contained Air-Cooled

    KT0700A 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 7.3-8.6 8.7-10.2 9.3-10.9 80/27...

  • Page 124: Kt0700W Self-Contained Water-Cooled

    KT0700W 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 7.5-8.9 8.2-9.7 9.6-11.3...

  • Page 125: Kt1000A Self-Contained Air-Cooled

    KT1000A 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 10.2-11.0 11.6-12.5 12.6-13.6 80/27...

  • Page 126: Kt1000W Self-Contained Water-Cooled

    KT1000W 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 11.0-11.9 11.6-12.5 13.4-14.4...

  • Page 127: Kt1000N Remote Air-Cooled

    KT1000N REMOTE 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 10.8-11.6 11.2-12.1 11.4-12.3 80/27...

  • Page 128: Kt1700A Self-Contained Air-Cooled

    KT1700A 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 9.1-10.3 9.7-11.1 10.3-11.7 80/27...

  • Page 129: Kt1700W Self-Contained Water-Cooled

    KT1700W 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 9.3-10.6 9.6-10.9 11.3-12.6...

  • Page 130: Kt1700N Remote Air-Cooled

    KT1700N REMOTE 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 9.8-11.2 10.2-14.8 10.6-12.1 80/27...

  • Page 131: 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 132: Kt0300, Kt0500, Kt0700, Kt1000 1 Ph Self-Contained Air/Water-Cooled

    KT0300, KT0500, KT0700, KT1000 1 PH SELF-CONTAINED AIR/WATER-COOLED (20) WHT (99) (21) BLU (22) (61) RED (77) RED (80) (60) BLK (76) BLK (57) GRY (98) GRY (59) ORG (88) PRPL (89) PRPL (58) (42) PRPL (74) (56) (81) (75) 28 54 (49) RED (47) YEL...
  • Page 133 Number Component Bin Switch Compressor Compressor Overload Compressor PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail Solenoid Valve - Harvest Transformer...

  • Page 134: Kt0420 1Ph Self-Contained Air/Water-Cooled

    KT0420 1PH SELF-CONTAINED AIR/WATER-COOLED (20) WHT (99) (21) BLU (22) (61) RED (77) RED (80) (60) BLK (76) BLK (57) GRY (98) GRY (59) ORG (88) PRPL (89) PRPL (58) (42) PRPL (74) (56) (81) (75) 28 54 (49) RED (47) YEL (50) BLU (47) ORG...
  • Page 135 Number Component Bin Switch Compressor Compressor Overload Compressor PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail Solenoid Valve - Harvest Transformer...

  • Page 136: Kt1000 1Ph Remote Air-Cooled Condenser

    KT1000 1PH REMOTE AIR-COOLED CONDENSER (22) (20) BLU (99) (21) BLU (82) (78) RED (79) (61) RED (77) RED (80) (60) BLK (81 ) (57) GRY (98) GRY (83) ORG (59) ORG (58) (88) PRPL PRPL (89) PRPL (42) (74) (56) WHT (81) WHT (75)
  • Page 137 Number Component Bin Switch Compressor Compressor Overload PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail Solenoid Valve - Harvest Solenoid Valve - Harvest Pressure Regulating Solenoid Valve - Liquid Line Solenoid...

  • Page 138: Kt1700 1Ph Self-Contained Air/Water-Cooled

    KT1700 1PH SELF-CONTAINED AIR/WATER-COOLED (21) BLU (20) BLU (80) (22) (87) (88) RED (61) RED (77) RED (26) (60) BLK (76) BLK (81 ) (99) (57) GRY (98) GRY (83) ORG (59) (58) (88) PRPL PRPL (89) (42) PRPL (56) WHT (74) (81) WHT (75)WHT...
  • Page 139 Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload Compressor PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail...

  • Page 140: Kt1700 3Ph Self-Contained Air/Water-Cooled

    KT1700 3PH SELF-CONTAINED AIR/WATER-COOLED (21) BLU (22) WHT (20) BLU (80) (87) (88) RED (77) RED (61) RED (26) (60) BLK (76) BLK (81) (99) (57) GRY (98) GRY (59) (58) (88) PRPL PRPL (89) (42) PRPL (56) WHT (74) (55) (75)WHT (81) WHT...
  • Page 141 Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail...

  • Page 142: Kt1700 1Ph Remote Air-Cooled Condenser

    KT1700 1PH REMOTE AIR-COOLED CONDENSER 28 54 000012161_03 Part Number STH063 9/17...
  • Page 143 Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail...

  • Page 144: Kt1700 3Ph Remote Air-Cooled Condenser

    KT1700 3PH REMOTE AIR-COOLED CONDENSER 28 54 000012161_3 Part Number STH063 9/17...
  • Page 145 Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor On/Off/Clean Switch Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout See Control Board Schematic For Detail...

  • Page 146: Electronic Control Board

    ELECTRONIC CONTROL BOARD Part Number STH063 9/17...
  • Page 147 Electronic Control Board Number Component LED Water Pump Relay LED Compressor Relay LED Water Dump Valve Relay LED Harvest Solenoid Valve LED Clean Thermistor Thermistor Thermistor LED Water Fill Valve LED Harvest Float LED Water Level Float LED Bin Switch LED Safety Limit 2 LED Safety Limit 1 LED Harvest...

  • Page 148: Refrigeration Tubing Schematics

    Refrigeration Tubing Schematics SELF-CONTAINED AIR OR WATER-COOLED Number Component Compressor Condenser - Air or Water Cooled Receiver - Water Cooled Only Liquid Line Filter Drier Heat Exchanger TXV - Thermostatic Expansion Valve Evaporator Strainer Harvest Solenoid Valve Part Number STH063 9/17...

  • Page 149: Remote Air-Cooled Condenser

    REMOTE AIR-COOLED CONDENSER Number Component Compressor Strainer Condenser - Remote Air-Cooled Head Pressure Control Valve Liquid Line Check Valve Receiver Liquid Line Filter Drier Liquid Line Solenoid Valve Heat Exchanger TXV - Thermostatic Expansion Valve Evaporator Strainer Harvest Solenoid Valve Part Number STH063 9/17...
  • Page 150 THIS PAGE INTENTIONALLY LEFT BLANK Part Number STH063 9/17...
  • Page 152 MANITOWOC FOODSERVICE ICE MACHINE DIVISION 2110 SOUTH 26TH STREET MANITOWOC, WI 54220 800-545-5720 WWW.KOOL-AIRE.COM WWW.WELBILT.COM Welbilt provides the world’s top chefs, and premier chain operators or growing independents with industry leading equipment and solutions. Our cutting- edge designs and lean manufacturing tactics are powered by deep knowledge, operator insights, and culinary expertise.

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