icetro IM Series Technician's Handbook
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icetro IM Series Technician's Handbook

Air/water/remote ice machines
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IM-Series
Air/Water/Remote Ice Machines
Technician's Handbook
Revision Date: 1/24/22

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Summary of Contents for icetro IM Series

  • Page 1 IM-Series Air/Water/Remote Ice Machines Technician’s Handbook Revision Date: 1/24/22...
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  • Page 4 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 5 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 6 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 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 •...
  • 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 Appliance.
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  • Page 10: Table Of Contents

    Calculating Allowable Line Set Distance ..25 Calculating Line Set Distance ......26 Tightening Remote Fittings ......27 Remote Ice Machine Usage with Non-Icetro Multi-Circuit Condensers ....28 Headmaster Valve ...........29 Refrigerant Charge ..........30 Remote Condenser Internal Volume ....31 Visual Inspection Checklist ........32 Water System Checklist ........33 Maintenance Cleaning and Sanitizing .........35...
  • Page 11 Table of Contents Cleaning/Sanitizing Procedure ......37 Cleaning Procedure .........37 Sanitizing Procedure ........39 Parts Removal for Cleaning/Sanitizing ..41 Removal from Service/Winterization ....43 Air-Cooled Ice Machines .........43 ......44 Water-Cooled Ice Machines Operation Operational Checks ..........48 General ..............48 Ice Thickness Check .........49 FND Timeouts ...........50 Sequence of Operation ...........51 Self Contained Air or Water Cooled ....51 Energized Parts Chart Self Contained...
  • Page 12 Table of Contents Troubleshooting Error Codes ......67 Er_1 ..............67 Er_3 ..............68 Er_11 ..............69 Er_12 ..............70 Er_13 ..............71 Er_14 ..............72 Er_15 ..............73 Er_16 ..............74 Er_17 ..............75 Er_18 ..............76 Ice Production Check ..........77 Ice Formation Pattern ..........79 Testing the Expansion Valve ........81 Hot Gas Valve Analysis ..........82 Discharge Line Temp Analysis ......84 Freeze Cycle Discharge Temp...
  • Page 13 Table of Contents Thermistors .............114 Compressor Electrical Diagnostics .....115 Diagnosing Start Components .....117 Refrigeration Components .........118 Headmaster ............118 Harvest Pressure Regulating (HPR) System Remote Condenser Only ....122 Water Regulating Valve ........125 Refrigerant Recover/Evacuation ......126 Self-Contained Model Procedure ....126 Remote Condenser Model Procedure ..130 System Contamination Clean-Up ......136 Determining Severity of Contamination ..136 Clean-Up Procedure ........138...
  • Page 14 Table of Contents Diagrams Wiring Diagram .............155 Wiring Diagram ..........156 PCB Layout ..............157 PCB Dip Switches ...........158 Refrigeration Schematic ........159 Self-Contained Air or Water Cooled ...159 Remote Condenser Models ......159...
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  • Page 16: General Information

    General Information How to Read a Model Number...

  • Page 17: How To Read A Serial Number

    How to Read a Serial Number...

  • Page 18: Ice Cube Sizes

    (bin, dispenser, etc.) to incorporate an ice deflector. Prior to using a non-Icetro ice storage system with other Icetro ice machines, contact the manufactuere to assure their ice deflector is compatible with Icetro ice machines.

  • Page 19: Model Numbers

    Model Numbers AIR-WATER-REMOTE CONDENSER MODELS Self-Contained Self-Contained Remote Air-Cooled Water-Cooled IM-0350-AC ---- ---- IM-0350-AH ---- ---- IM-0350-AC-22 ---- ---- IM-0350-AH-22 ---- ---- IM-0460-AC IM-0460-WC ---- IM-0460AH IM-0460-WH ---- ---- ---- IM-0460-AC-22 ---- ---- IM-0460-AH-22 IM-0550-AC ---- IM-0550-WC IM-0550AH IM-0550-WH ---- IM-0550-AC-22 ---- ----...

  • Page 20: Installation

    Installation Warning PERSONAL INJURY POTENTIAL Remove all ice machine panels before lifting. Caution The ice machine head section must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused exposure to freezing temperatures is not covered the warranty.

  • Page 21: Location Of Ice Machine

    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 free of airborne and other • contaminants. Self contained air and water cooled - The air •...

  • Page 22: Ice Machine Heat Of Rejection

    Ice Machine Heat of Rejection Series Ice Heat of Rejection Machine Air Conditioning* Peak IM-0350 4600 5450 IM0460 5400 6300 IM0500 6100 6900 IM0680/IM0750 9000 13900 IM1100 18300 24500 *BTU/Hour Because the heat of rejection varies during the ice making cycle, the figure shown is an average.

  • Page 23: Installation On A Bin

    (22" or 30" ice machine) and is supplied by the dispenser manufacturer. A thermostat kit is also required when installing an ice machine on a dispenser (22" or 30" ice machine) and can be purchased from your local Icetro distributor (part # ITS-150KIT).

  • Page 24: Lineset Applications

    Lineset Applications Warning 60-month compressor warranty (including the 36-month labor replacement warranty) will not apply if the Icetro Ice Machine or Condenser Unit were installed according specifications. This warranty also will not apply if the refrigeration system modified with condenser,...

  • Page 25: Remote Condenser

    REMOTE CONDENSER Remote Single Ice Machine Line Set* Circuit Condenser IRT-20R404A IRC-1100 IM-1100R IRT-35R404A IRT-50R404A Return *Line Set Discharge 1/2" (1.27 cm) 3/8" (.375cm) Air Temperature Around the Condenser Minimum Maximum -20°F (-29°C) 120°F (49°C)

  • Page 26: Calculating Allowable Lineset Distance

    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 27: Calculating Line Set Distance

    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 29: Remote Ice Machine Usage With Non-Icetro Multi-Circuit Condensers

    Icetro remote condenser. If the design of the condenser meets the specifications, Icetro’s only approval is for full warranty coverage to be extended to the Icetro manufactured part of the system. Since Icetro does not test the condenser in conjunction...

  • Page 30: Headmaster Valve

    Internal Condenser Volume The multi-circuit condenser internal volume must not be less than or exceed that used by Icetro (see chart on page 31). Do not exceed internal volume and try to add charge to compensate, as compressor failure will result.

  • Page 31: Refrigerant Charge

    Refrigerant Charge Remote ice machines have the serial plate refrigerant charge (total system charge) located in the ice maker section. (Remote condensers and line sets are supplied with only a vapor charge.) CAUTION Never add more than nameplate charge to ice machine for any application.

  • Page 33: Visual Inspection Checklist

    Visual Inspection Checklist Inadequate Clearances Check all clearances on sides, back and top. • Reference ”Clearance Requirements” on page 20. 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.

  • Page 34: Water System Checklist

    Water System Checklist A water-related problem often causes the same symptoms refrigeration system component malfunction. Water system problems must be identified and eliminated prior to replacing refrigeration components. Water area (evaporator) is dirty Clean as needed. • Water inlet pressure not between 20 and 80 psig (1-5 Bar, 138-552 kPa).
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  • Page 36: Maintenance

    An extremely dirty ice machine must be taken apart for cleaning and sanitizing. Nickle Safe ice machine cleaner & sanitizer are the only products approved for use in Icetro ice machines. Caution Do not mix Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.

  • Page 37: Cleaning/Sanitizing Procedure

    CLEANING/SANITIZING PROCEDURE This procedure must be performed a minimum of once every six months. The ice machine and bin must be disassembled • cleaned and sanitized. All ice produced during the cleaning and sanitizing • procedures must be discarded. Removes mineral deposits from areas or surfaces •...

  • Page 38: Cleaning/Sanitizing Procedure

    Cleaning / Sanitizing Procedure Step 1 Open the front door to access the evaporator compartment. Ice must not be on the evaporator during the clean/sanitize cycle. Follow one of the methods below: • Set the 'ICE/OFF/WASH switch to 'OFF' and wait for the ice machine to stop after the harvest cycle ends and ice falls from the evaporator.
  • Page 39 Step 4 Wait until the 'WASH' cycle is complete (approximately 20-30 minutes). All ice machine operation will stop when complete. Then set 'ICE/OFF/ WASH' switch to 'OFF'. Warning Disconnect the electric power to the ice machine at the electric service switch box. Step 5 Remove parts for cleaning.

  • Page 40: Sanitizing Procedure

    Step 7 Use 1/2 of the cleaner/water mixture to clean all components. The cleaner solution will foam when it contacts lime scale and mineral deposits; once the foaming stops use a soft-bristle nylon brush, sponge or cloth (NOT a wire brush) to carefully clean the parts. Soak parts for 5 minutes (15 - 20 minutes for heavily scaled parts).
  • Page 41 Step 11 Use 1/2 of the sanitizer/water solution to sanitize all food zone surfaces of the ice machine and bin (or dispenser). Use a spray bottle to liberally apply the solution. When sanitizing, pay particular attention to the following areas: Side walls •...

  • Page 42: Parts Removal For Cleaning/Sanitizing

    PARTS REMOVAL FOR CLEANING/SANITIZING A. Remove the water curtain • Pull the curtain open abut 30° then lift up & pull forward to remove. B. Remove the water trough Depress tabs on right and left side of the water • trough.
  • Page 43 D. Remove the ice thickness probe Compress the hinge pin on the top of the ice • thickness probe. Pivot the ice thickness probe to disengage one • pin then the other. The ice thickness probe can be cleaned at this point without complete removal.

  • 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 some components could result.

  • Page 45: Water-Cooled Ice Machines

    WATER-COOLED ICE MACHINES 1. Perform steps 1-6 under “Self-Contained Air-Cooled Ice Machines. ” 2. Disconnect the incoming water and drain line from the water-cooled condenser. 3. Remove the cover from the control box and push in the contactor so that the compressor starts. The increasing refrigerant pressure will open the water regulating valve.
  • Page 46 FND Operation FND Features The Flexible Numeric Display (FND) offers a series of ice machine settings and error codes, which can be displayed on the FND's display panel, for quick machine diagnostics and performance customization. BUTTONS Mode Button: Initializes the FND and saves adjusted settings.
  • Page 47 Operation: In standby mode, the FND is off. Pressing the 'MODE' button will turn on the FND display and either show the latest error code (if there is one) OR the first setting. While the FND is on, press the 'UP' of 'DOWN' buttons to navigate through the available settings.
  • Page 48 Flexible Numeric Display (FND) Functions...

  • Page 49: Operation

    Operation Operational Checks GENERAL Icetro ice machines are factory-operated before shipment. Normally, new installations do not require any adjustment. To ensure proper operation, always follow the Operational Checks: When starting the ice machine for the first time • After a prolonged out of service period •...

  • Page 50: Ice Thickness Check

    ICE THICKNESS CHECK The ice thickness probe should be set to maintain an ice bridge thickness of approximately 1/8" thick. NOTE: If the water curtain is removed while the ice machine is in a freeze cycle, the machine's magnetic bin switch will open and the machine will stop until the water curtain is replaced.

  • Page 51: Fnd Timeouts

    FND Timeouts The FND board has the following non-adjustable timeouts: When the 'ICE/OFF/WASH' switch is moved from • 'ICE' to 'OFF' the ice machine will not stop until the current freeze/harvest cycle is completed. This can be overridden by initiating a forced harvest. Refer to page 46 for further details.

  • Page 52: Sequence Of Operation

    Sequence of Operation SELF CONTAINED AIR OR WATER COOLED NOTE: The 'ICE/OFF/WASH' switch must be in the 'ICE' position and the water curtain must be in place on the evaporator before the ice machine will start. Initial Start-Up or Start-Up After Automatic Shutdown 1.
  • Page 53 Freeze Sequence 3. Prechill The compressor runs for approximately 15 seconds, with no water circulation, to lower the temperature of the evaporator before the water pump is energized. 4. Freeze Water Pump The water pump energizes and water flows over the evaporator.
  • Page 54 Harvest Sequence 5. Harvest With the water pump de-energized, the hot gas valve is energized. The refrigerant gas warms the evaporator causing the cubes to slide, as a sheet, off the evaporator and into the storage bin. The sliding sheet of cubes opens the water curtain and bin switch.
  • Page 55 Automatic Shut-Off 7. Automatic Shut-Off When the storage bin is full at the end of a harvest sequence, the sheet of cubes fails to clear the water curtain and will hold it open. After the water curtain is held open for 10 seconds, the ice machine shuts off. The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to clear the water curtain.

  • Page 58: Remote Condenser

    Sequence of Operation REMOTE AIR-COOLED CONDENSER NOTE: The 'ICE/OFF/WASH' switch must be in the 'ICE' position and the water curtain must be in place on the evaporator before the ice machine will start. Initial Start-Up or Start-Up After Automatic Shutdown 1.
  • Page 59 Freeze Sequence 3. Prechill The compressor runs for approximately 15 seconds, with no water circulation, to lower the temperature of the evaporator before the water pump is energized. 4. Freeze Water Pump The water pump energizes and water flows over the evaporator.
  • Page 60 Harvest Sequence 5. Harvest With the water pump de-energized, the hot gas valve and HPR solenoid valves are energized. The refrigerant gas warms the evaporator causing the cubes to slide, as a sheet, off the evaporator and into the storage bin. The sliding sheet of cubes opens the water curtain and bin switch.
  • Page 61 Automatic Shut-Off 7. Automatic Shut-Off When the storage bin is full at the end of a harvest sequence, the sheet of cubes fails to clear the water curtain and will hold it open. After the water curtain is held open for 10 seconds, the ice machine shuts off. The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to clear the water curtain.

  • Page 64: Troubleshooting

    Troubleshooting Error Codes In addition to standard safety controls, the Flexible Numeric Display (FND) board will display Error Codes, which protect the ice machine from major component failures. Additionally, the LED lights on the front panel will light solid, or flash, to indicate an Error Code. Error Codes are stored and displayed by the FND.

  • Page 65: Er_11

    Error Code 11 - If the ice thickness probe does not • sense water contact after 65 minutes, 3 consecutive times, the machine will stop and display Er_11. Error Code 12 - If curtain switch is not detected 5 • minutes into the harvest cycle, 3 consecutive times, the machine will stop and display Er_12.

  • Page 66: Er_14

    Error Code 14 - If high pressure switch opens, 3 • consecutive times, the machine will stop and display Er_14. Water-cooled machines will attempt to restart every hour. Error Code 15 - If the water level sensor (high-level • probe) is not detected after 5 minutes from start of a water fill, the machine will stop and display Er_15.

  • Page 67: Er_1

    Error Code 17 - If excessive cooling is detected • when the machine is FULL, the machine will continue to run, but display Er_17. WATER-COOLED ONLY! Error Code 17 - If excessive cooling is detected • when the machine is OFF, the machine will continue to run, but display Er_17.

  • Page 68: Troubleshooting Error Codes

    TROUBLESHOOTING ERROR CODES Error codes are designed to notify the technician of a problem and, in some cases, stop the ice machine prior to a major component failure. This may be difficult to diagnose, as many external problems occur intermittently. The following checklists are designed to assist the service technician in analysis.

  • Page 69: Er_3

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #3 Error Code 3 - If the evaporator temperature exceeds 23°F after 30 minutes in the freeze cycle, the machine will continue to run and display Er_3 on the FND.

  • Page 70: Er_11

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #11 Error Code 11 - If the ice thickness probe does not sense water contact after 65 minutes, 3 consecutive times, the machine will stop and display Er_11. Possible cause checklist Refrigeration System Undercharged system (too little refrigerant).

  • Page 71: Er_12

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #12 Error Code 12 - If curtain switch is not detected 5 minutes into the harvest cycle, 3 consecutive times, the machine will stop and display Er_12. Possible cause checklist Refrigeration System Hot gas valve not opening.

  • Page 72: Er_13

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #13 Error Code 13 - If the high pressure switch opens, the machine will stop and display Er_13 and close when the pressure drops. Possible cause checklist Refrigeration System Overcharged system (too much refrigerant).

  • Page 73: Er_14

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #14 Error Code 14 - If high pressure switch opens, 3 consecutive times, the machine will stop and display Er_14. Water-cooled machines will attempt to restart every hour. Possible cause checklist Refrigeration System Overcharged system (too much refrigerant).

  • Page 74: Er_15

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #15 Error Code 15 - If the water level sensor (high-level probe) is not detected after 5 minutes from start of a water fill, the machine will stop and display Er_15. The machine will resume operation if the problem is resolved after automatically attempting to re-start every hour.

  • Page 75: Er_16

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #16 Error Code 16 - If water level sensor detects water at the high-level probe at the end of a freeze cycle, the machine will stop and display Er_16. The machine will resume operation if the problem is resolved after automatically attempting to re-sart every hour.

  • Page 76: Er_17

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #17 (WATER-COOLED ONLY) Error Code 17 - If excessive cooling is detected when the machine is FULL or OFF, the machine will continue to run, but display Er_17. Possible cause checklist Water System •...

  • Page 77: Er_18

    ANALYZING WHY AN ERROR CODE STOPPED THE ICE MACHINE (CONTINUED) ERROR CODE #18 Error Code If dump valve is energized, but the water level sensor does not reach low-level probe within 5 minutes, the machine will stop and display Er_18. Possible cause checklist Water System Dump valve faulty or in need of...

  • Page 78: Ice Production Check

    Ice Production Check The amount of ice a machine produces directly relates to the operating water and air temperatures. This means a condensing unit with a 70°F (21°C) outdoor ambient temperature and 50°F (10°C) water produces more ice than the same model condensing unit with a 90°F (32°C) outdoor ambient temperature and 70°F (21°C) water.
  • Page 79 If they match closely, determine if: Another ice machine is required. • More storage capacity is required. • Relocating the existing equipment to lower the • load conditions is required. Contact the local Icetro Distributor for information on available options and accessories.

  • Page 80: Ice Formation Pattern

    Ice Formation Pattern Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. Analyzing the ice formation pattern can help diagnose an ice machine malfunction. However, it's important to keep in mind that any number of problems can cause improper ice formation. Keep the water curtain in place while checking the ice formation pattern to ensure no water is lost.
  • Page 81 2. Extremely Thin at Evaporator Outlet There is no ice, or a considerable lack of ice formation, at the outlet of the evaporator. Examples: No ice at all on the outlet half of the evaporator, but ice forms on the inlet half of the evaporator.

  • Page 82: Testing The Expansion Valve

    5. Testing the Expansion Valve The expansion valve (TXV) is designed to modulate the flow of refrigerant, depending upon the needs of the evaporator. Extremely thin ice at the evaporator outlet could be a sign that the machine is undercharged or that the TXV is starving the evaporator for refrigerant.

  • Page 83: Hot Gas Valve Analysis

    Hot Gas Valve Analysis Symptoms of a hot gas valve remaining partially open during the freeze cycle can be similar to symptoms of either an expansion valve or compressor problem. The best way to diagnose a hot gas valve is by using the following procedures to determine if a hot gas valve is remaining partially open during the freeze cycle.
  • Page 84 Findings Comments Normal Operation The inlet of the hot gas This is normal as the discharge valve is cool enough to line should always be too hot touch and the compressor to touch and the hot gas valve discharge line is hot. inlet, although too hot to touch during harvest, should be cool Cool &...

  • Page 85: Discharge Line Temp Analysis

    Discharge Line Temperature Analysis GENERAL Knowing if the discharge line temperature is increasing, decreasing or remaining constant can be an important diagnostic tool. Compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle. Ambient air temperatures affect the discharge line temperature.

  • Page 86: High Checklist

    • Dirty condenser. • Dirty/Defective water regulating valve. • Water regulating valve out of adjustment • Other Overcharged. • Non-condensable (air) in system. • Wrong type of refrigerant. • Non-Icetro components in system. • High side refrigerant lines/component restricted. •...

  • Page 87: Low Checklist

    Defective fan cycle control, stuck closed • “Fan Cycle Control” on page 113. Water Cooled Condensers Water Regulating Valve out of adjustment. • Water Regulating Valve Defective • Other Undercharged. • Wrong type of refrigerant. • Non-Icetro components in system. • Liquid line/component restricted. •...

  • Page 88: Suction Pressure High Checklist

    Overcharged (also see “Freeze Cycle Discharge • Pressure High Checklist” on page 85). Wrong type of refrigerant. • Non-condensables in system. • Components Hot Gas valve leaking. • HPR solenoid valve leaking. • TXV flooding. • Defective compressor. • Other Non-Icetro components in system. •...

  • Page 89: Suction Pressure Low Checklist

    Checklist” on page 86. Improper Refrigerant Charge Undercharged. • Wrong type of refrigerant. • Other Non-Icetro components in system. • Improper water supply over evaporator – refer to • “Water System Checklist” on page 33. Restricted/plugged liquid line drier. •...

  • Page 90: Water Regulating Valve

    Water Regulating Valve Problem (Freeze Cycle) Valve not maintaining discharge pressure. Valve incorrectly set, dirty or defective. Adjust valve • to correct discharge pressure for your model (refer to cycle times/24 hour productions charts), clean or replace valve. Discharge pressure extremely high; Liquid line entering receiver feels hot.

  • Page 91: Final Analysis

    Final Analysis - Self-contained Air, Water & Remote Condenser Models HOT GAS VALVE LEAKING Replace the valve as required. LOW CHARGE/TXV STARVING Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures. A low refrigerant charge normally affects both pressures.

  • Page 92: Harvest Problems

    HARVEST PROBLEMS SELF-CONTAINED AIR, WATER & REMOTE CONDENSER MODELS Normal Ice Cube Melted Out ice Cube Definition of a harvest problem: At the end of a 5 minute harvest cycle the slab of ice is still contacting the evaporator. The slab of ice may or may not be removable by hand.
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  • Page 94: Component Check Procedures

    Component Check Procedures Electrical Components CONTROL BOARD (PCB) FUNCTION The PCB is what controls the operation of all the major components within the ice machine. Each major component has a white relay above it's terminal connection on the PCB. Above that relay is a green light that will illuminate anytime power is being sent to that component.
  • Page 95 CONTROL BOARD (PCB) Cont. FREEZE MODE: Sequence of Operation Water inlet valve (yellow) energized for water fill. Water pump (white) & dump valve (black) energized for water flush.
  • Page 96 CONTROL BOARD (PCB) Cont. FREEZE MODE: Sequence of Operation Water inlet valve (yellow) energized for 2nd water fill. Hot gas valve (red) energized to equalize pressure.
  • Page 97 CONTROL BOARD (PCB) Cont. FREEZE MODE: Sequence of Operation Compressor (brown) & condenser (blue) energized during pre-chill. Compressor (brown), condenser (blue), water pump (white) energized to circulate & freeze water to evaporator.
  • Page 98 CONTROL BOARD (PCB) Cont. HARVEST MODE: Sequence of Operation Compressor (brown), condenser (blue) , & hot gas valve (red) energized for harvest.

  • Page 99: Main Fuse

    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, 5 amp. Warning High (line) voltage is applied to the control board (TB1) at all times. Removing the control board fuse or turning the 'ICE/OFF/WASH' switch to 'OFF' will not remove the power supplied to the control board.

  • Page 100: Bin Switch

    BIN SWITCH FUNCTION Movement of the water curtain bin switch operation. 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 10 seconds during the Harvest cycle.
  • Page 101 Diagnostics SYMPTOMS Bin Switch Fails Open The ice machine will not start an ice making cycle • and the display indicates “Full Bin”. Bin Switch Fails Closed If running, error code 12 (Er_12) is displayed on the • FND indicating a long harvest. Machine may be off on error code 12.
  • Page 102 DIAGNOSTICS 1. Verify bin switch, curtain and curtain magnet are in place. 2. Open and close the water curtain repeatedly while observing the 'FULL' LED light on the front panel. Curtain switch cycles open/closed and 'FULL' LED light energizes/de-energizes - Bin switch is operating normally Curtain switch remains closed and 'FULL' LED light remains on - Go to step 3...

  • Page 103: Water Level Control Circuitry

    WATER LEVEL CONTROL FUNCTION The water level probe controls the water level by sensing whether water is or is not contacting the water level probe. The water level probe has three sensing probes. Two probes are equal in length and measure resistance from both long probes to the short probe.
  • Page 104 Prechill & Freeze Cycle Operation The water inlet valve energizes and de-energizes in conjunction with the water level probe located in the water trough. The water inlet valve is ON when there is no water • in contact with the water level probes. The water inlet valve turns OFF after water contacts •...
  • Page 105 Diagnostics SYMPTOMS Water trough overfills • Water trough will not fill • WATER TROUGH OVERFILLING DURING THE FREEZE CYCLE Step 1 Move the 'OFF/ICE/WASH' switch to the 'OFF' position to turn the machine off. Step 2 If water continues to flow with the ice machine off, disconnect power.
  • Page 106 Testing the water level sensor (Before S/N Starting With VC)
  • Page 107 Testing the water level sensor (After S/N Starting With VC) For machines manufactured after January 1, 2022, the water level sensor was changed from the 3-probe sensor to a float switch. To test the float switch, simply check for continuity between the to wires found in the harness connector.

  • Page 108: Ice Thickness Probe (Initiates Harvest)

    ICE THICKNESS PROBE (INITIATES HARVEST) FUNCTION The ice thickness probe senses proper ice thickness when the ice bridge is thick enough to allow water to touch the probe, which signals the control board to start a harvest cycle. SPECIFICATIONS Maximum Freeze Time The maximum freeze time is 65 minutes at which time the control board automatically initiates a harvest sequence.
  • Page 109 Ice Thickness Check The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8 inch. NOTE: Make sure the water curtain is in place when performing this check. It prevents water from splashing out of the water trough. Remove the curtain to make an adjustment, then replace immediately after the adjustment is made.
  • Page 110 Ice Machine Doesn’t Harvest Properly ICE MACHINE CYCLES INTO HARVEST PREMATURELY ICE MACHINE DOES NOT CYCLE INTO HARVEST Symptoms Low ice production • Thin or thick ice in bin • Freeze cycles are shorter or longer than published • cycle times Large sheet of ice on evaporator •...
  • Page 111 9. If the problem persists, use a jumper wire between the (red) ice thickness connector at the control box and any cabinet ground. If after 5 seconds the machine goes into harvest, replace the probe. If the machine continues in the freeze cycle, the control board is causing the malfunction.

  • Page 112: High Pressure (Hpco) Cutout 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 Specifications Cut-Out Cut-In 426 psig 355 psig Automatic Reset SYMPTOM Opening the HPCO will cause machine operation to stop.
  • Page 113 CHECK PROCEDURE Testing HPCO switch 1. Leave all wiring connectors attached and perform testing within the 60 minute time delay period 2. Check for line voltage at CN10 connector on control board (Two wire connector with black & blue wires). Line voltage present - HPCO switch has reset and closed.

  • Page 114: 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 CHECK PROCEDURE 1. Verify fan motor windings are not open or grounded, and fan spins freely.

  • Page 115: Thermistors

    THERMISTORS FUNCTION Thermistor resistance changes with temperature. The value supplied to the control board is used to identify temperature at the thermistor location. CHECK PROCEDURE Using an electrical meter, check to see if the thermistor is open or shorted. If it is, replace it. Using a temperature probe/clamp, check the temperature of the line that the thermistor is attached to after 5 minutes of operation and compare the...

  • Page 116: 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 assure that the overload is closed and the resistance readings will be accurate.
  • Page 117 CHECK MOTOR WINDINGS TO GROUND Check continuity between all three terminals and the compressor shell or copper refrigeration line. Scrape metal surface to get good contact. If continuity is present, the compressor windings are grounded and the compressor should be replaced. COMPRESSOR DRAWING LOCKED ROTOR To determine if the compressor is seized, check the amp draw while the compressor is trying to start and compare...

  • Page 118: 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. Capacitor 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 119: Refrigeration Components

    Refrigeration Components HEADMASTER VALVE Icetro remote systems require a headmaster valve with special settings. Replace defective headmaster valves only with (O.E.M.) Icetro replacement parts. Refrigerant Charge Verification The correct amount of refrigerant (name plate charge) is required to operate correctly at all ambient conditions.
  • Page 120 Freeze Cycle Operation All Models The R404A headmaster 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 121 NOTE: A headmaster 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. Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle.
  • Page 122 Harvest Cycle REMOTE CONDENSER The headmaster valve cycles into full bypass due to the pressure drop when the hot gas valve opens. Refrigerant flows from the compressor to the evaporator through the hot gas valve and the headmaster valve is out of the circuit. Undercharge Symptoms Error code #11 (Er_11) or error code #12 (Er_12) •...

  • Page 123: 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 •...
  • Page 124 HPR DIAGNOSTICS Steps 1 through 5 can be quickly verified without attaching a manifold gauge set or thermometer. All questions must have a yes answer to continue the diagnostic procedure. 1. Liquid line warm? (Body temperature is normal) If liquid line is cooler than body temperature, refer to “Headmaster Valve”...
  • Page 125 5. Discharge line temperature is greater than 150°F (66°C) at the end of the freeze cycle? See “Discharge Line Temperature Analysis” on page 84. 6. Connect refrigeration manifold gauge set to the access valves on the front of the ice machine. Establish baseline by recording suction and discharge pressure and freeze &...

  • Page 126: 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 127: Refrigerant Recover/Evacuation

    Refrigerant Recovery/Evacuation SELF-CONTAINED MODEL PROCEDURE Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. IMPORTANT Icetro America 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 128 Self-Contained Recovery/Evacuation 1. Use the 'ICE/OFF/WASH' switch to turn the ice machine off. 2. Install manifold gauges, scale and recovery unit or two-stage vacuum pump and open high and low side on manifold gauges. MANIFOLD SET OPEN OPEN LOW SIDE HIGH SIDE ACCESS ACCESS...
  • Page 129 Self-Contained Charging Procedures IMPORTANT The charge is critical on all Icetro ice machines. Use a scale to ensure the proper charge is installed. 1. Be sure the ice machine is off. MANIFOLD SET CLOSED OPEN LOW SIDE HIGH SIDE ACCESS...
  • Page 130 2. Close the vacuum pump valve, the low side service valve, and the low side manifold gauge valve. 3. Open the high side manifold gauge valve. 4. Open the charging cylinder and add the proper refrigerant charge (shown on nameplate) through the discharge service valve.

  • Page 131: Remote Condenser Model Procedure

    IMPORTANT Replace the liquid line drier after recovering the refrigerant before evacuating recharging. Use only an Icetro (O.E.M.) liquid line filter drier to prevent voiding the warranty.
  • Page 132 NOTE: Icetro recommends using an access valve core removal and installation tool on the discharge line quick-connect fitting. This permits access valve core removal.
  • Page 133 REMOTE CONDENSER RECOVERY/EVACUATION 1. Use the 'ICE/OFF/WASH' switch to turn the ice machine off. 2. Install manifold gauges, scale and recovery unit or two-stage vacuum pump. 3. Open high and low side on the manifold gauge set. 4. Perform recovery or evacuation: Recovery: Operate the recovery unit as directed by the manufacturer’s instructions.
  • Page 134 SERVICE REMOTE RECOVERY/EVACUATION CONNECTIONS...
  • Page 135 Remote Charging Procedures 1. Close the vacuum pump valve and the low side manifold gauge valve. 2. Open the refrigerant cylinder and add the proper refrigerant charge (shown on nameplate) into the system high side (receiver outlet valve and discharge lines quick-connect fitting).
  • Page 136 HEAT EXCHANGER EVAPORATOR EXPANSION VALVE SOLENOID VALVE LOW SIDE ACCESS VALVE STRAINER COMPRESSOR HARVEST PRESSURE HARVEST CHECK SOLENOID PRESSURE VALVE VALVE REGULATING VALVE HIGH SIDE LIQUID ACCESS VALVE LINE SOLENOID DISCHARGE LINE DRIER QUICK CONNECT SCHRAEDER FITTING REMOTE CONDENSER RECEIVER ACCESS VALVE CHECK VALVE HEAD PRESSURE...

  • Page 137: System Contamination Clean-Up

    System Contamination Clean-Up General This section describes the basic requirements for restoring contaminated systems to reliable service. iMPORTANT Icetro Amierica assumes no responsibility for the contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 138 Contamination Cleanup Chart Symptoms/Findings Required Cleanup Procedure No symptoms or suspicion Normal evacuation/ of contamination. recharging procedure Moisture/Air Contamination symptoms. Refrigeration system open to atmosphere for longer than 15 minutes. Refrigeration test Mild contamination kit and/or acid oil test shows cleanup procedure contamination.

  • Page 139: Clean-Up Procedure

    CLEANUP PROCEDURE Mild System Contamination 1. Replace any failed components. 2. If the compressor is good, change the oil. 3. Replace the liquid line drier. IMPORTANT Dry nitrogen is recommended for this procedure. This will prevent CFC release. 4. Follow the normal evacuation procedure, except replace the evacuation step with the following: Pull vacuum to 1000 microns.
  • Page 140 Severe System Contamination 1. Remove the refrigerant charge. 2. Remove the compressor and inspect the refrigeration lines. If burnout deposits are found, install a new hot gas valve, replace the manifold strainer, TXV and HPR valve. 3. Wipe away any burnout deposits from suction and discharge lines at compressor.
  • Page 141 9. Follow the normal evacuation procedure, except replace the evacuation step with the following: Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psig (35 kPa,.35 bar). Change the vacuum pump oil. Pull vacuum to 500 microns.

  • Page 142: Replacing Pressure Controls Without Removing Refrigerant Charge

    REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT 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 (air cooled only) • Water regulating valve (water cooled •...

  • Page 143: Liquid Line Filter Driers

    Tubing may not re-round 100%. USING PINCH-OFF TOOL LIQUID LINE FILTER-DRIERS The filter-driers used on Icetro ice machines are manufactured to Icetro specifications. The size of the filter-drier is important. The refrigerant charge is critical. Using an improperly sized filter-drier will cause the ice machine to be improperly charged with refrigerant.
  • Page 145 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 146: Cycle Times/24-Hour Ice Production/Refrigerant Pressure Charts

    Charts Cycle Times/24-Hour Ice Production/ 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 •...

  • Page 147: Im0350A(22) Series

    IM0350 SERIES IM0350A(22) Self-Contained Air-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...

  • Page 148: Im0460A(22) Series

    IM0460 SERIES IM0460A(22) Self-Contained Air-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...
  • Page 149 IM0460 SERIES IM0460W Self-Contained Water-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...

  • Page 150: Im0550A(22) Series

    IM0550 SERIES IM0550A(22) Self-Contained Air-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...
  • Page 151 IM0550 SERIES IM0550W Self-Contained Water-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...

  • Page 152: Im0680/0750A Series

    IM0680/0750 SERIES IM0680/0750A Self-Contained Air-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...

  • Page 153: Im1100A/W Series

    IM1100 SERIES IM1100A/W Characteristics Self-Contained Air and Water-Cooled Models vary depending on operating conditions. CYCLE TIMES...

  • Page 154: Im1100R Series

    IM1100 SERIES IM1100R Remote Air-Cooled Model Characteristics vary depending on operating conditions. CYCLE TIMES...
  • Page 155 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 156: Wiring Diagram

    Diagrams Wiring Diagrams The following page contains an electrical wiring diagram. Warning Always disconnect power before working on electrical circuitry. Not all components are included on every machine. Please verify your model number to when using the diagram on the next page.

  • Page 157: Wiring Diagram

    Wiring Diagram...

  • Page 158: Pcb Layout

    PCB Layout...

  • Page 159: Pcb Dip Switches

    PCB Dip Switches...

  • Page 160: Refrigeration Schematic

    Refrigeration Tubing Schematics SELF-CONTAINED AIR OR WATER-COOLED S / L T h e r m i s t o r E V APO R ATO R H E AT E X C H A N G E R EXPANSION VALVE E v a p I n l e t T h e r m i s t o r H O T G A S S O L E N O I D V A L V E A I R O R W ATE R...
  • Page 161 SPACE FOR TECHNICIAN'S NOTES...
  • Page 162 SPACE FOR TECHNICIAN'S NOTES...
  • Page 163 SPACE FOR TECHNICIAN'S NOTES...
  • Page 164 SPACE FOR TECHNICIAN'S NOTES...
  • Page 166 ICETRO AMIERICA 1565 W BROADWAY ANAHEIM, CA 92802 (714) 215-4864 WWW.ICETROAMERICA.COM ©2022 Icetro America except where explicitly stated otherwise. All rights reserved. Continuing product improvement may necessitate change of specifications without notice.

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