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Manitowoc KOOLAIRE KT1000 Technician's Handbook
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Manitowoc KOOLAIRE KT1000 Technician's Handbook

Manitowoc KOOLAIRE KT1000 Technician's Handbook

Air/water/remote condenser modular ice machines
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Technician's Handbooks
K & KT Models
Air/Water/Remote Condenser
Modular Ice Machines
K & KF Models
UnderCounter Ice Machines
Part Number 000017439 Rev 01 4/24

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Summary of Contents for Manitowoc KOOLAIRE KT1000

  • Page 1 Technician’s Handbooks K & KT Models Air/Water/Remote Condenser Modular Ice Machines K & KF Models UnderCounter Ice Machines Part Number 000017439 Rev 01 4/24...
  • Page 3 K & KT Models Air/Water/Remote Condenser Modular Ice Machines Technician’s Handbook Part Number 000017439 Rev 01 4/24...

  • Page 5: 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 6: Definitions

    Definitions DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious injury. This applies to the most extreme situations. Warning Indicates a hazardous situation that, if not avoided, could result in death or serious injury. Caution Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
  • Page 7 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 8 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. • Connect to a potable water supply only. • To avoid instability the installation area must be capable of supporting the combined weight of the equipment and product.
  • Page 9 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 10 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 11 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 12 Warning Follow these precautions to prevent personal injury during use and maintenance of this equipment: • Units with two power cords must be plugged into individual branch circuits. During movement, cleaning or repair it is necessary to unplug both power cords. •...

  • Page 13: Table Of Contents

    Table of Contents - Modular Koolaire UnderCounter Cover ........205 Table of Contents - UnderCounter ........213 Safety Notices .......5 Definitions .
  • Page 14 Maintenance De-scaling and Sanitizing .....37 General....... .37 Detailed De-scaling and Sanitizing Procedure.
  • Page 15 Component Check Procedures Main Fuse ....... .107 Bin Switch ....... .108 Float Switch .
  • Page 16 Charts Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts ......145 K0250A Self-Contained Air-Cooled ..146 KT0300A Self-Contained Air-Cooled .
  • Page 17 Diagrams Wiring Diagrams ......179 K0250, KT0300, K0350, KT400, K0420, KT0420, K0500, K0600, KT0700, K1000, KT1000 Without PTCR 1 Ph Self-Contained Air/Water-Cooled .
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  • Page 19: General Information

    General Information Model Numbers This manual covers the following models: KT 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 KDT0700W...

  • Page 20: Ice Machine Warranty Information

    Ice Machine Warranty Information Warranty For warranty information visit: www.kool-aire.com/Service/Warranty • Warranty Coverage Information • Warranty Registration • Warranty Verification Warranty coverage begins the day the ice machine is installed. Warranty Registration Completing the warranty registration process is a quick and easy way to protect your investment.

  • Page 21: How To Read A Model Number

    How to Read a Model Number Part Number 000017439 Rev 01 4/24 Modular - 21...
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  • Page 23: 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 24: 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 25: 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 12400 13900 KT1000 60 Hz 15400 17100 KT1000 50 Hz 14600 16200 KT1700 24700 29000 Series...

  • Page 26: Leveling The Ice Machine

    Leveling the Ice Machine 1. The leveling legs must be screwed into the bottom of the bin as far as possible. Caution The legs must be screwed in tightly to prevent them from bending. 2. Move the bin into its final position. 3.

  • Page 27: 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 28: Water Service/Drains

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

  • Page 29: 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 30: Water Supply And Drain Line Sizing/Connections

    WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS 30 - Modular Part Number 000017439 Rev 01 4/24...

  • Page 31: Remote Condenser Kt Models

    REMOTE CONDENSER KT MODELS 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" (0.79 cm) 1/2" (1.27 cm) 3/8" (0.95 cm) NOTE: All line sets must be insulated with 1/4"...

  • Page 32: Remote Condenser K Models

    REMOTE CONDENSER K MODELS Remote Single Ice Machine Line Set* Circuit Condenser RTK-20-R410A K1000 KC1000 RTK-35-R410A RTK-50-R410A RLK-20-R410A K1350 KC1350 RLK-35-R410A K1800 RLK-50-R410A *Line Set Discharge Line Liquid Line 1/2" (1.27 cm) 5/16" (0.79 cm) 1/2" (1.27 cm) 3/8" (0.95 cm) NOTE: All line sets must be insulated with 1/4"...
  • Page 33 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 34 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 35 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...
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  • Page 37: De-Scaling And Sanitizing

    The ice machine must be taken apart for de-scaling and sanitizing. Caution Use only Manitowoc Ice Machine De-scaler (part number 9405463) and Sanitizer (part number 9405653). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.

  • Page 38: Detailed De-Scaling And Sanitizing Procedure

    DETAILED DE-SCALING AND SANITIZING PROCEDURE Ice machine de-scaler is used to remove lime scale and mineral deposits. Ice machine sanitizer disinfects and removes algae and slime. TOGGLE SWITCH OPERATION Moving the toggle switch to clean will start a Clean cycle. •...
  • Page 39 Caution Do not mix Ice Machine De-scaler and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Step 3 To start a de-scaling cycle, move the toggle switch to Clean. Water will flow through the water dump valve and down the drain.
  • Page 40 Step 6 Mix a solution of de-scaler and lukewarm water. Depending on the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly de-scale all parts. Solution Type Water Mixed with...
  • Page 41 Step 9 Mix a solution of sanitizer and warm water. Solution Type Water Mixed With Sanitizer 3 gal. (12 l) 2 oz (60 ml) sanitizer Step 10 Use half of the sanitizer/water solution to 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 42: Remove Parts For De-Scaling

    REMOVE PARTS FOR DE-SCALING 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 43 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 000017439 Rev 01 4/24 Modular - 43...

  • Page 44: Remedial Cleaning Procedure

    Remedial Cleaning Procedure This procedure can be performed between the bi- annual detailed de-scaling and sanitizing procedure. This procedure does not require removing the ice from the bin. Step 1 Place the toggle switch in the off position after 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 45: 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 46: 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 47: Removal From Service/Winterization

    Removal from Service/Winterization AIR-COOLED MODELS 1. De-scale 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.
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  • Page 49: Operation

    Operation Ice Making Sequence of Operation NOTE: The toggle switch must be in the ICE 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 50: 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 51: 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 52 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 53: Energized Parts Chart

    Part Number 000017439 Rev 01 4/24 Modular - 53...
  • Page 54 54 - Modular Part Number 000017439 Rev 01 4/24...

  • Page 55: 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 56: 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 57: Troubleshooting

    Troubleshooting 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 58: Safety Limit 3

    SAFETY LIMIT 3 If the harvest float switch hasn’t opened for 10 continuous seconds within the first 4 minutes of the freeze cycle, 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 harvest float switch hasn’t opened for 10 continuous seconds within the first 4 minutes...
  • Page 59 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 60: Safety Limit Checklist

    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 Control board software revision 3.2 and higher Freeze time exceeds 35 minutes for 6 consecutive freeze cycles.
  • Page 61 Electrical System • Harvest cycle not initiated electrically • Contactor not energizing • Compressor electrically non-operational • Restricted condenser air flow • High inlet air temperature (110°F/43.3°C max.) • Condenser discharge air re-circulation • Dirty condenser fins • Defective fan cycling control •...
  • Page 62 Safety Limit #2 Harvest time exceeds 7 minutes for 100 Consecutive harvest cycles. Possible Cause Checklist Improper installation • Refer to “Installation/Visual Inspection Checklist” on page 79 Water System • Water area (evaporator) dirty • Dirty/defective water dump valve • Vent tube not installed on water outlet drain •...
  • Page 63 Safety Limit 3 The harvest float switch hasn’t opened for 10 continuous seconds in the first 4 minutes of the freeze cycle. Possible Cause Checklist Improper installation • Refer to “Installation/Visual Inspection Checklist” on page 79 Water System • Water dump valve •...

  • Page 64: Control Board Test Mode

    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 65: 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 66: Troubleshooting By Symptom

    Troubleshooting By Symptom The troubleshooting procedures follow diagnostic charts. There are four symptoms, the symptom that you are experiencing will determine which diagnostic chart to use. The chart asks yes and no questions to determine the problem. The diagnostic chart will direct you to a procedure to correct the problem.

  • Page 67: Symptom #1 - Self-Contained Air, Water-Cooled Traditional Remote

    SYMPTOM #1 - SELF-CONTAINED AIR, WATER-COOLED TRADITIONAL REMOTE Ice Machine stops running or has history of shutting down Part Number 000017439 Rev 01 4/24 Modular - 67...
  • Page 68 68 - Modular Part Number 000017439 Rev 01 4/24...

  • Page 69: Low Production, Long Freeze Cycle

    #2 - LOW PRODUCTION, LONG FREEZE CYCLE Ice Machine has a Long Freeze Cycle Ice Formation is Thick Thin on Inlet or Outlet of Evaporator Low Production How to Use the Freeze Cycle Refrigeration System Operational Analysis Table GENERAL These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear...
  • Page 70 Step 2 Enter Checkmarks (√). Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a Checkmark. Example: Freeze cycle suction pressure is determined to be low. Enter a Checkmark in the “low” column. Step 3 Add the Checkmarks listed under each of the four columns.

  • Page 71: Symptom #2 - Refrigeration Component Diagnostic Chart

    Part Number 000017439 Rev 01 4/24 Modular - 71...
  • Page 72 72 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 73 Part Number 000017439 Rev 01 4/24 Modular - 73...
  • Page 74 74 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 75 Ice Machine Does Not Cycle Into Harvest when the Harvest Float Is Down/Closed 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 76 Step 1 Disconnect power to the ice machine, remove 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. Step 2 Bypass the freeze time lock-in feature by moving the toggle switch Off/On to cycle the ice machine...
  • Page 77 Ice Machine Cycles Into Harvest Before the Harvest Float Is Down/Closed Step 1 Disconnect power to the ice machine, remove the electrical panel to allow viewing of the control board lights and disconnect the float switch harness from the control board. Ice Thickness Float Switch Harvest Float Switch Step 2...
  • Page 78 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 79 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 80 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 81 Water is spraying out of the sump trough area • Stop the water spray Uneven water flow across the evaporator • Clean the ice machine Water is freezing behind the evaporator • Correct the water flow Plastic extrusions and gaskets are not secured to the evaporator •...
  • Page 82 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 83 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 84 One Evaporator, Two TXV 48" Models Tubing routing for one evaporator with two TXV’s is different. The evaporator has two inlets and outlets. Fill pattern varies depending on which circuit is affected, Extremely Thin at the Evaporator Outlet Will first be visible 1/3 of the way down the evaporator. Only one side of the evaporator may be affected depending on failure.
  • Page 85 Analyzing Suction Pressure The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times. To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time.
  • Page 86 Procedure Step 1. Determine the ice machine operating conditions. Example: Air temp. entering condenser: 90°F/32.2°C Air temp. around ice machine: 80°F/26.7°C Water temp. entering water fill valve: 70°F/21.1°C 2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice machine model being checked. Using operating conditions from Step 1, determine published freeze cycle time and published freeze cycle suction pressure.

  • Page 87: Suction Pressure High Checklist

    SUCTION PRESSURE HIGH CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 79. Discharge Pressure • Discharge pressure is too high and is affecting suction pressure, refer to “Discharge Pressure High Checklist” on page 91. Improper Refrigerant Charge •...

  • Page 88: Suction Pressure Low Checklist

    SUCTION PRESSURE LOW CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 79. Discharge Pressure • Discharge pressure is too low, and is affecting suction pressure, refer to “Freeze Cycle Discharge Pressure Low Checklist” on page 91 Improper Refrigerant Charge •...
  • Page 89 Comparing Evaporator Inlet and 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 90 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 145 for ice machine being checked.

  • Page 91: Discharge Pressure High Checklist

    DISCHARGE PRESSURE HIGH CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 79. 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 92 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 93 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 94 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). Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison.
  • Page 95 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 &...
  • Page 96 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 97 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 98 Final Analysis - Self-contained Air, Water & Remote Condenser Models The column with the highest number of check marks identifies the refrigeration problem. COLUMN 1 - HARVEST VALVE LEAKING Replace the valve as required. COLUMN 2 - LOW CHARGE/TXV STARVING Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures.
  • Page 99 COLUMN 3 - TXV FLOODING OR REFRIGERANT OVERCHARGE A loose or improperly mounted expansion valve bulb causes the expansion valve to flood. Check bulb mounting, insulation, etc, before changing the valve. Verify refrigerant amount is correct by weighing recovered refrigerant before replacing a TXV.

  • Page 100: Symptom #3 - Remote Condenser

    SYMPTOM #3 - REMOTE CONDENSER Traditional Remote Ice Machine – Long Harvest/Low Production/Intermittent Safety Limit 2 100 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 101 Part Number 000017439 Rev 01 4/24 Modular - 101...

  • Page 102: Symptom #3 - Self-Contained Air Or

    SYMPTOM #3 - SELF-CONTAINED AIR OR WATER-COOLED Ice Machine Will Not Harvest – Freeze Cycle is Normal and ice Cubes Are Not Melted After Harvest 102 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 103 Part Number 000017439 Rev 01 4/24 Modular - 103...

  • Page 104: Symptom #4

    SYMPTOM #4 Ice Machine Will Not Harvest – Freeze Cycle Is Normal and Ice Cubes Are Not Melted After Harvest 104 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 105 Part Number 000017439 Rev 01 4/24 Modular - 105...
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  • Page 107: 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 108: 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 109 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 110: 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 111 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 112: 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 113 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 114 PTCR The PTCR allows current to flow through the start winding at compressor startup. Current flow heats the ceramic discs in the PTCR. The electrical resistance increases with temperature and stops all except a trickle of current flow through the start winding. The small flow of current keeps the PTCR hot (260°F/127°C) and the start winding out of the circuit.
  • Page 115 PTCR Operation Check 1. Visually inspect the PTCR. Check for signs of physical damage. NOTE: The PTCR case temperature may reach 210°F (100°C) while the compressor is running. This is normal. Do not change a PTCR just because it is hot. 2.

  • Page 116: 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 Cut-In Cut-Out Model (Close) (Open) KT0300 K0350 KT0400 KT0420 K0420 KT0500 335 psig ±5...

  • Page 117: 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 118: Refrigeration Components

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

  • Page 119: 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 120 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 121 Undercharge Symptoms • Safety limit #1 or Safety limit #2 in control board memory. • Harvest cycle suction pressure is low. • Harvest cycle discharge pressure is low. • Liquid line entering receiver feels warm to hot in the freeze cycle. Overcharge Symptoms •...

  • Page 122: Harvest Pressure Regulating Valve (Hpr) System Remote Condenser Only

    HARVEST PRESSURE REGULATING VALVE (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).
  • Page 123 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 head pressure control valve diagnostics.
  • Page 124 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 & harvest cycle times. (Refer to “Freeze Cycle Refrigeration System Operational Analysis Tables” for data collection detail). 7.

  • Page 125: 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 126: 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 127: 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 128 4. Recovered refrigerant must come from a “contaminant-free” system. To decide whether the system is contaminant free, consider: • Type(s) of previous failure(s) • Whether the system was cleaned, evacuated and recharged properly following failure(s) • Whether the system has been contaminated by this failure •...

  • Page 129: Recovery And Recharging Procedures

    RECOVERY AND RECHARGING PROCEDURES Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important 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 130 SELF-CONTAINED RECOVERY/EVACUATION 1. Cycle the toggle switch Off. 2. Install manifold gauge, scale and recovery unit or two- stage vacuum pump and open high, low and charging ports. 3. Perform recovery or evacuation: Recovery: Operate the recovery unit as directed by the manufacturer’s instructions.

  • Page 131: Charging Procedures

    CHARGING PROCEDURES Important 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. Isolate the vacuum pump valve, low side and high side access valves from the refrigeration system.
  • Page 132 7. Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses. Run the ice machine in freeze cycle. Remove the high side low loss fitting from the liquid line filter drier. Open the high and low side valves on the manifold gauge set.

  • Page 133: Remote Condenser Model Procedure

    REMOTE CONDENSER MODEL PROCEDURE Refrigerant Recovery/Evacuation Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important 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 134 • Access valve on the discharge line quick-connect fitting, located on the outside of the compressor/ evaporator compartment. This connection evacuates the condenser. Without it, the magnetic check valves would close when the pressure drops during evacuation, preventing complete evacuation of the condenser.

  • Page 135: Remote Charging Procedures

    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/liquid line drier and/or liquid line quick-connect fitting).

  • Page 136: System Contamination Cleanup

    System Contamination Cleanup This section describes the basic requirements for restoring contaminated systems to reliable service. Important 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. DETERMINING SEVERITY OF CONTAMINATION System contamination is generally caused by either moisture or residue from compressor burnout entering the...
  • Page 137 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 138: Cleanup 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. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation.

  • Page 139: Severe System Contamination Cleanup Procedure

    SEVERE SYSTEM CONTAMINATION CLEANUP PROCEDURE 1. Remove the refrigerant charge. 2. 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. 3. Wipe away any burnout deposits from suction and discharge lines at compressor.

  • Page 140: Liquid Line Filter Driers

    10. Charge the system with the proper refrigerant to the nameplate charge. 11. Operate the ice machine for one hour. Then, check the pressure drop across the suction line filter-drier. If the pressure drop is less than 1 psig the filter- drier should be adequate for complete cleanup.

  • Page 141: 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 • High pressure cut-out control •...

  • Page 142: Refrigerant Amount

    Refrigerant Amount KT MODELS NOTE: All models charged with R410A refrigerant. Nameplate information overrides all data in this chart. 51' to 100' Model Air-Cooled Water-Cooled Remote Line sets* KT0300 15 oz 60 Hz 425 g KT0300 17 oz 50 Hz 482 g KT0400 18 oz 14 oz...

  • Page 143: K Models

    K MODELS NOTE: All models charged with R410A refrigerant. Nameplate information overrides all data in this chart. 51' to 100' Model Air-Cooled Water-Cooled Remote Line sets* K0250 15 oz 60 Hz 425 g K0250 17 oz 50 Hz 482 g K0350 18 oz 14 oz 60 Hz 510 g...
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  • Page 145: Cycle Times, 24 Hr. Ice Production And Refrigerant Pressure Charts

    Charts Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts These charts are used as guidelines to verify correct ice machine operation. Accurate collection of data is essential to obtain the correct diagnosis. • 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 146: K0250A Self-Contained Air-Cooled

    K0250A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 9.3-11.5 10.8-12.9 12.3-14.6 80/27...

  • Page 147: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 148: K0350A Self-Contained Air-Cooled

    K0350A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 11.6-13.5 12.7-14.8 14.0-16.3 80/27...

  • Page 149: K0350W Self-Contained Water-Cooled

    K0350W 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 11.4-13.3 12.3-14.3 13.1-15.3...

  • Page 150: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 151: 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 10.0-11.7 9.9-11.6 11.7-13.7...

  • Page 152: K0420A Self-Contained Air-Cooled

    K0420A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 11.7-13.7 12.5-14.5 13.6-15.8 80/27...

  • Page 153: K0420W Self-Contained Water-Cooled

    K0420W 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 11.7-13.7 11.2-15.2 12.7-13.5...

  • Page 154: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 155: 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 10.0-11.7 9.9-11.6 11.7-13.7...

  • Page 156: K0500A Self-Contained Air-Cooled

    K0500A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 11.9-13.6 14.1-16.1 15.7-17.9 80/27...

  • Page 157: K0500W Self-Contained Water-Cooled

    K0500W 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 10.7-13.7 13.6-15.5 15.7-17.7...

  • Page 158: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 159: Kt0500W Self-Contained Water-Cooled

    KT0500W SELF-CONTAINED WATER-COOLED CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Air Temp. Freeze Time Around Ice Water Temperature °F/°C Harvest Machine Time 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 160: K0600A Self-Contained Air-Cooled

    K0600A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 8.5-11.0 11.5-13.2 12.4-14.3 80/27...

  • Page 161: K0600W Self-Contained Water-Cooled

    K0600W 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 9.5-11.0 10.9-12.5 11.5-13.2...

  • Page 162: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 163: 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 7.5-8.9 8.2-9.7 9.6-11.3...

  • Page 164: K1000A Self-Contained Air-Cooled

    K1000A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 8.5-10.1 9.9-11.7 11.6-12.6 80/27...

  • Page 165: K1000W Self-Contained Water-Cooled

    K1000W 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 8.3-9.8 8.8-10.4 9.7-11.5...

  • Page 166: K1000N Remote Air-Cooled

    K1000N 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 8.2-9.7 8.5-10.1 9.4-11.1 80/27...

  • Page 167: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 168: 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 11.0-11.9 11.6-12.5 13.4-14.4...

  • Page 169: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 170: K1350A Self-Contained Air-Cooled

    K1350A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 10.7-12.6 12.1-14.2 13.8-16.2 80/27...

  • Page 171: K1350W Self-Contained Water-Cooled

    K1350W 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 10.7-12.7 11.2-13.1 11.6-13.7...

  • Page 172: K1350N Remote Air-Cooled

    K1350N 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 10.6-12.5 12.0-14.2 12.2-14.3 80/27...

  • Page 173: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 174: 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 Around Ice Water Temperature °F/°C Harvest Machine Time 50/10 70/21 90/32 °F/°C 70/21 9.3-10.6 9.6-10.9 11.3-12.6...

  • Page 175: 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 Entering Water Temperature °F/°C Harvest Condenser Time 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 176: K1800A Self-Contained Air-Cooled

    K1800A 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 9.1-10.5 9.8-11.2 10.6-12.1 80/27...

  • Page 177: K1800N Remote Air-Cooled

    K1800N 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 Entering Water Temperature °F/°C Harvest Condenser Time 50/10 70/21 90/32 °F/°C 70/21 9.5-10.8 10.1-11.5 10.7-12.2 80/27...
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  • Page 179: 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. 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 180: K0250, Kt0300, K0350, Kt400, K0420, Kt0420, K0500, K0600, Kt0700, K1000

    K0250, KT0300, K0350, KT400, K0420, KT0420, K0500, K0600, KT0700, K1000, KT1000 WITHOUT PTCR 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)
  • Page 181 K0250, KT0300, K0350, KT400, K0420, KT0420, K0500, K0600, KT0700, K1000, KT1000 Without PTCR 1 Ph Self-contained Air/Water-cooled Number Component Bin Switch Compressor Compressor Overload Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch...

  • Page 182: K0250, Kt0300, K0350, Kt400, K0420, Kt0420, K0500, Kt0500, Kt0700, K1000

    K0250, KT0300, K0350, KT400, K0420, KT0420, K0500, KT0500, KT0700, K1000, KT1000 WITH PTCR 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)
  • Page 183 K0250, KT0300, K0350, KT400, K0420, KT0420, K0500, KT0500, KT0700, K1000, KT1000 WITH PTCR 1 Ph Self-contained Air/Water-cooled Number Component Bin Switch Compressor Compressor Overload Compressor PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch...

  • Page 184: K1000, Kt1000

    K1000, 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)
  • Page 185 K1000, KT1000 1Ph Remote Air-cooled Condenser Number Component Bin Switch Compressor Compressor Overload Compressor Potential Relay - When Used Compressor PTCR - When Used Compressor Run Capacitor Compressor Start Capacitor - When Used Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board...

  • Page 186: K1350, Kt1700, K1800

    K1350, KT1700, K1800 1 PH SELF-CONTAINED AIR/WATER-COOLED (21) BLU (20) BLU (80) (22) (87) (88) RED (77) RED (61) RED (26) (60) BLK (76) BLK (81 ) (99) (57) GRY (98) GRY (83) ORG (59) (58) (88) PRPL PRPL (89) (42) PRPL (56) WHT...

  • Page 187: K1350, Kt1700, K1800

    K1350, KT1700, K1800 1 Ph Self-contained Air/Water-cooled Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload Compressor PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse...

  • Page 188: Ph Self-Contained Air/Water-Cooled

    K1350, KT1700, K1800 3 PH SELF-CONTAINED AIR/WATER-COOLED (22) WHT (21) BLU (20) BLU (80) (87) (88) RED (61) RED (77) RED (26) (60) BLK (76) BLK (81) (99) (57) GRY (98) GRY (59) (58) (88) PRPL PRPL (89) (42) PRPL (56) WHT (74) (55)
  • Page 189 K1350, KT1700, K1800 3 Ph Self-contained Air/Water-cooled Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout On/Off/Clean Switch...

  • Page 190: K1350, Kt1700, K1800 1Ph Remote Air-Cooled Condenser

    K1350, KT1700, K1800 1PH REMOTE AIR-COOLED CONDENSER 000012161_04 190 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 191 K1350, KT1700, K1800 1Ph Remote Air-cooled Condenser Number Component Air Pump Harvest Assist Bin Switch Compressor Compressor Overload Compressor PTCR Compressor Run Capacitor Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse...

  • Page 192: Ph Remote Air-Cooled Condenser

    K1350, KT1700, K1800 3 PH REMOTE AIR-COOLED CONDENSER (22) WHT (21) BLU (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)
  • Page 193 K1350, KT1700, K1800 3 Ph Remote Air-cooled Condenser Number Component Air Pump Harvest Assist Bin Switch Compressor Condenser Fan Motor Condenser Fan Motor Run Capacitor Contactor Coil Contactor Contacts Control Board Fan Cycle Control Harvest Float Switch Water Level Float Switch Fuse High Pressure Cutout On/Off/Clean Switch...

  • Page 194: Electronic Control Board

    Electronic Control Board KT MODELS 194 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 195 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 196: K Models

    K MODELS 196 - Modular Part Number 000017439 Rev 01 4/24...
  • Page 197 Electronic Control Board Number Component LED Water Pump Relay LED Compressor Relay LED Water Dump Valve Relay LED Harvest Solenoid Valve LED Clean LED Water Fill Valve LED Harvest Float LED Water Level Float LED Bin Switch LED Safety Limit 2 LED Safety Limit 1 LED Harvest LED Test Mode...

  • Page 198: Refrigeration Tubing Schematics

    Refrigeration Tubing Schematics SELF-CONTAINED AIR OR WATER-COOLED K0250, KT0300, K0350, KT400, K0420, KT0420, K0500, K0600, KT0700, K1000, KT1000 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 198 - Modular...

  • Page 199: K1350, Kt1700,K1800 Self-Contained Air Or Water-Cooled

    K1350, KT1700, K1800 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 000017439 Rev 01 4/24 Modular - 199...
  • Page 200 K1000, KT1000 REMOTE AIR-COOLED CONDENSER Number Component Compressor Discharge Check Valve 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 Harvest Pressure Solenoid Valve...

  • Page 201: Remote Air-Cooled Condenser

    K1350, KT1700, K1800 REMOTE AIR-COOLED CONDENSER Number Component Compressor Discharge Check Valve 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...
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  • Page 203 K & KF Models UnderCounter Ice Machines Technician’s Handbook Part Number 000017439 Rev 01 4/24...

  • Page 205: Koolaire Undercounter Cover

    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 206: Definitions

    Definitions DANGER Indicates a hazardous situation that, if not avoided, will result in death or serious injury. This applies to the most extreme situations. Warning Indicates a hazardous situation that, if not avoided, could result in death or serious injury. Caution Indicates a hazardous situation that, if not avoided, could result in minor or moderate injury.
  • Page 207 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 208 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 209 Warning Follow these precautions to prevent personal injury while operating or maintaining this equipment. • Legs or casters must be installed and the legs/casters must be screwed in completely. When casters are installed the mass of this unit will allow it to move uncontrolled on an inclined surface.
  • Page 210 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 211 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.
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  • Page 213: Table Of Contents - Undercounter

    Table of Contents - UnderCounter Table of Contents - Modular ..........13 Safety Notices ......205 Definitions .
  • Page 214 Maintenance Ice Machine Inspection ....231 Exterior Cleaning ......231 Cleaning the Condenser .
  • Page 215 Refrigerant Recovery/Evacuation ...316 Refrigerant Re-use Policy ....317 Recovery and Recharging Procedures ..319 System Contamination Cleanup .
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  • Page 217: General Information

    General Information Model Numbers This manual covers the following models: Self-contained Air-cooled Self-contained Water-cooled KDF0150A KYF0150A KD0172A KY0174A KDF0250A KYF0250A KR0270A KR0271W KD0272A KD0273W KY0274A KY0275W Warning An ice machine contains high voltage electricity and refrigerant charge. Repairs are to be performed by properly trained refrigeration technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.

  • Page 218: How To Read A Model Number

    BIN CASTER Replaces standard legs. DE-SCALER AND SANITIZER Manitowoc Ice Machine De-scaler and Sanitizer are available in convenient 16 oz. (473 ml) and 1 gal (3.78 l) bottles. These are the only cleaner and sanitizer approved for use with Koolaire® products.

  • Page 219: Ice Machine Warranty Information

    Ice Machine Warranty Information Warranty For warranty information visit: www.kool-aire.com/Service/Warranty • Warranty Coverage Information • Warranty Registration • Warranty Verification Warranty coverage begins the day the ice machine is installed. Warranty Registration Completing the warranty registration process is a quick and easy way to protect your investment.
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  • Page 221: 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 222: Ice Machine Clearance Requirements

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

  • Page 223: Leveling The Ice Machine

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

  • Page 224: Electrical Requirements

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

  • Page 225: Electrical Specifications

    Electrical Specifications AIR-COOLED ICE MACHINE Voltage Phase Max. Fuse/ Total Ice Machine Cycle Circuit Breaker Amps KF0150 115/60/1 15 amp 115/1/60 15 amp K0170 208/1/60 15 amp 230/1/50 15 amp KF0250 115/60/1 15 amp 11.8 115/1/60 15 amp 10.7 K0270 208-230/1/60 15 amp 230/1/50...

  • Page 226: Water Service/Drains

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

  • Page 227: Water Supply And Drain Line Sizing/Connections

    WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS Part Number 000017439 Rev 01 4/24 UnderCounter - 227...

  • Page 228: Cooling Tower Applications

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

  • Page 229: Component Identification

    Component Identification Evaporator Compartment ICE THICKNESS PROBE DISTRIBUTION TUBE ICE DAMPER WATER PUMP WATER TROUGH SV1694A FLOAT VALVE SIPHON CAP BIN SWITCH MAGNET SV1695A Evaporator Compartment Part Number 000017439 Rev 01 4/24 UnderCounter - 229...
  • Page 230 ON/OFF/ WASH TOGGLE SWITCH COMPRESSOR CONDENSED AIR COMPARTMENT FILTER ACCESS SCREWS KF0150/K0170 Ice Machines ON/OFF/ WASH TOGGLE SWITCH CONDENSED AIR FILTER COMPRESSOR COMPARTMENT ACCESS SCREWS KF0250/K0270 Ice Machines 230 - UnderCounter Part Number 000017439 Rev 01 4/24...

  • Page 231: Maintenance

    Maintenance ICE MACHINE INSPECTION Check all water fittings and lines for leaks. Also, make sure the refrigeration tubing is not rubbing or vibrating against other tubing, panels, etc. Do not put anything (boxes, etc.) in front of the ice machine. There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life.
  • Page 232 Air-cooled Condenser A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces ice production and shortens component life. Clean the condenser at least every six months. Follow the steps below. Warning The condenser fins are sharp. Use care when cleaning them.

  • Page 233: Interior De-Scaling And Sanitizing

    The ice machine must be taken apart for de-scaling and sanitizing. Caution Use only Manitowoc Ice Machine De-scaler (part number 9505463) and Sanitizer (part number 9405653). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.
  • Page 234 Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle. Or, set the switch to the OFF position and allow the ice to melt off the evaporator. Caution Never use anything to force ice from the evaporator.
  • Page 235 Step 6 Remove parts for de-scaling. Remove Two Thumbscrews and Water Pump Cover (When Used). Remove the Vinyl Hose Connecting the Water Pump and Water Distribution Tube Remove Water Pump • Disconnect the water pump power cord • Loosen the screws securing the pump- mounting bracket to the bulkhead •...
  • Page 236 Remove the Ice Thickness Probe • Compress the side of the ice thickness probe near the top hinge pin and remove it from the bracket. THICKNESS PROBE COMPRESS SIDES OF ICE THICKNESS PROBE SV1138A Ice Thickness Probe Removal NOTE: At this point, the ice thickness probe can easily be de-scaled.
  • Page 237 Remove the Water Distribution Tube 1. LIFT UP 2. SLIDE BACK 3. SLIDE TO RIGHT DISTRIBUTION TUBE THUMBSCREW THUMBSCREW SV1630 Water Distribution Tube Removal • Loosen the two thumbscrews, which secure the distribution tube. • Lift the right side of the distribution tube up off the locating pin, then slide it back and to the right.
  • Page 238 Disassembly • Twist both of the inner tube ends until the tabs line up with the keyway. • Pull the inner tube ends outward. INNER TUBE INNER TUBE KEYWAY SV1211 Water Distribution Tube Disassembly 238 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 239 Remove the Float Valve • Turn the splash shield counterclockwise one or two turns. FLOAT VALVE BRACKET COMPRESSION FITTING SHUT-OFF VALVE CAP AND FILTER SCREEN SPLASH SHIELD FLOAT SV1695-2 Float Valve Removal • Pull the float valve forward and off the mounting bracket.
  • Page 240 Remove the Water Trough • Apply downward pressure on the siphon tube and remove from the bottom of the water trough. • Remove the upper thumbscrew. • While supporting the water trough remove the two thumbscrews from beneath the water trough. •...
  • Page 241 Remove the ice damper • Grasp ice damper and apply pressure toward the left- hand mounting bracket. • Apply pressure to the right-hand mounting bracket with thumb. • Pull ice damper forward when the right-hand ice damper pin disengages. STEP 3 STEP 2 STEP 1 SV1742A...
  • Page 242 Remove the Bin Door • Grasp the rear of the bin door and pull bin door forward approximately 5". • Slide bin door to the rear while applying upward pressure (The rear door pins will ride up into the track slot and slide backward to the stop tab).
  • Page 243 Step 7 Mix a solution of de-scaler and warm water. Depending on the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly de-scale all parts. Solution Type Water Mixed with...
  • Page 244 Step 11 Use 1/2 of the sanitizer/water solution to sanitize all removed components. Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution. Do not rinse parts after sanitizing. Step 12 Use 1/2 of the sanitizer/water solution to sanitize all foodzone surfaces of the ice machine and bin.
  • Page 245 Step 17 Mix a solution of sanitizer and warm water. Solution Type Water Mixed With Sanitizer 6 gal. (23 l) 4 oz (120 ml) sanitizer Step 18 Use 1/2 of the sanitizer/water solution to sanitize all removed components. Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution.

  • Page 246: Removal From Service/Winterization

    Removal from Service/Winterization General Special precautions must be taken if the ice machine is to be removed from service for an extended period of time or exposed to ambient temperatures of 32°F (0°C) or below. Caution If water is allowed to remain in the ice machine in freezing temperatures, severe damage to some components could result.
  • Page 247 Water-cooled Ice Machines 1. Perform steps 1-6 under “Self-contained Air-cooled Models” on page 246. 2. Disconnect the incoming water and drain lines from the water-cooled condenser. 3. Insert a large screwdriver between the bottom spring coils of the water regulating valve. Pry upward to open the valve.
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  • Page 249: Operation

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

  • Page 250: Harvest Sequence

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

  • Page 251: Energized Parts Chart

    ENERGIZED PARTS CHART * Condenser Fan Motor: The fan motor is wired through a fan cycle pressure control; therefore, it may cycle on and off. Part Number 000017439 Rev 01 4/24 UnderCounter - 251...

  • Page 252: Operational Checks

    Operational Checks Siphon System To reduce mineral build-up and de-scaling frequency, the water in the sump trough must be purged during each harvest cycle. When the water pump de-energizes, the level in the water trough rises above the standpipe, starting a siphon action. The siphon action stops when the water level in the sump trough drops.
  • Page 253 Water Level Check The float valve is factory-set for the proper water level. If adjustments are necessary: 1. Verify the ice machine is level. 2. Remove the siphon cap from the standpipe. 3. Place the main ON/OFF/WASH toggle switch to the ON position, and wait until the float valve stops adding water.
  • Page 254 Ice Thickness Check After a harvest cycle, inspect the ice cubes in the ice storage bin. The ice thickness probe is set to maintain an ice bridge of 1/8" (3.2 mm). If an adjustment is needed, follow the steps below. 1.

  • Page 255: Troubleshooting

    Troubleshooting SAFETY LIMIT FEATURE In addition to the standard safety controls, your Koolaire® ice machine features built-in safety limits that will stop the ice machine if conditions arise which could cause a major component failure. Before calling for service, re-start the ice machine using the following procedure: 1.
  • Page 256 Safety Limits In addition to standard safety controls, the control board has two built in safety limit controls which protect the ice machine from major component failures. Safety Limit #1: If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle. 3 cycles outside the time limit = 1 hour Stand-by Mode.
  • Page 257 Safety Limit Notes • A safety limit indication is completed before the water pump starts. Water contacting the ice thickness probe in the freeze cycle will cause the harvest light to flash. Do not mistake a harvest light flashing in the freeze cycle with a safety limit indication.
  • Page 258 ANALYZING WHY SAFETY LIMITS MAY STOP THE ICE MACHINE According to the refrigeration industry, a high percentage of compressor failure is a result of external causes. These can include flooding or starving expansion valves, dirty condensers, water loss to the ice machine, etc. The safety limits protect the ice machine (primarily the compressor) from external failures by stopping ice machine operation before major component damage occurs.

  • Page 259: Improper Installation

    Safety Limit Checklist The following checklists are designed to assist the service technician in analysis. However, because there are many possible external problems, do not limit your diagnosis to only the items listed. Safety Limit #1 Freeze time exceeds 60 minutes for 6 consecutive freeze cycles.
  • Page 260 Refrigeration System • Restricted condenser air flow • Condenser discharge air re-circulation • Dirty condenser fins • Non-OEM components • Improper refrigerant charge • Defective compressor • TXV starving or flooding (check bulb mounting) • Non-condensible in refrigeration system • Plugged or restricted high side refrigerant lines or component •...
  • Page 261 Safety Limit #2 Harvest time exceeds 3.5 minutes for 6 Consecutive harvest cycles. Possible Cause Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 277. Water System • Water area (evaporator) dirty • Dirty/defective water dump valve •...

  • Page 262: 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 (terminals #2 and #4) at all times. Removing control board fuse or moving the toggle switch to OFF will not remove the power supplied to the control board. 1.

  • Page 263: Troubleshooting By Symptom

    Troubleshooting By Symptom The troubleshooting procedures follow diagnostic charts. There are four symptoms, the symptom that you are experiencing will determine which diagnostic chart to use. The chart asks yes and no questions to determine the problem. The diagnostic chart will direct you to a procedure to correct the problem.

  • Page 264: Symptom #1

    SYMPTOM #1 Ice Machine stops running or has history of shutting down 264 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 265 Part Number 000017439 Rev 01 4/24 UnderCounter - 265...
  • Page 266 #2 - LOW PRODUCTION, LONG FREEZE CYCLE Ice Machine has a Long Freeze Cycle Ice Formation is Thick Thin on Inlet or Outlet of Evaporator Low Production How to Use the Freeze Cycle Refrigeration System Operational Analysis Table GENERAL These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear...
  • Page 267 Step 2 Enter Checkmarks (√). Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a Checkmark. Example: Freeze cycle suction pressure is determined to be low. Enter a Checkmark in the “low” column. Step 3 Add the Checkmarks listed under each of the four columns.

  • Page 268: Symptom #2 - Refrigeration Component Diagnostic Chart

    268 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 269 Part Number 000017439 Rev 01 4/24 UnderCounter - 269...
  • Page 270 270 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 271 Part Number 000017439 Rev 01 4/24 UnderCounter - 271...
  • Page 272 Diagnosing Ice Thickness Control Circuitry Ice Machine Does Not Cycle Into Harvest when Water Contacts the Ice Thickness Control Probe Step 1 Bypass the freeze time lock-in feature by moving the ON/OFF/WASH switch to OFF and back to ON. Wait until the water starts to flow over the evaporator. Step 2 Clip the jumper wire to the ice thickness probe and any cabinet ground.
  • Page 273 Step 3 Disconnect the ice thickness probe from the control board terminal. Clip the jumper wire to the terminal on the control board and any cabinet ground. Monitor the harvest light. PROBE CONNECTION ICE THICKNESS JUMPER WIRE PROBE GROUND BIN SWITCH EVAPORATOR HARVEST LIGHT LIGHT...
  • Page 274 Ice Machine Cycles Into Harvest Before Water Contact with the Ice Thickness Probe Step 1 Bypass the freeze time lock-in feature by moving the ON/OFF/WASH switch to OFF and back to ON. Wait until the water starts to flow over the evaporator, then monitor the harvest light.
  • Page 275 Ice Production Check The amount of ice a machine produces directly relates to the operating water and air temperatures. This means an ice machine with a 70°F (21.2°C) ambient temperature and 50°F (10.0°C) water produces more ice than the same ice machine with 90°F (32.2°C) ambient and 70°F (21.2°C) water.
  • Page 276 Weighing the ice is the only 100% accurate check. However, if the ice pattern is normal and the 1/8" (3.2 mm) thickness is maintained, the ice slab weights listed with the 24-Hour Ice Production Charts may be used. 4. Compare the results of step 3 with step 2. Ice production is normal when these numbers match closely.
  • Page 277 Installation and Visual Inspection Checklist Ice machine is not level Level the ice machine Condenser is dirty • Clean the condenser Water filtration is plugged (if used) • Install a new water filter Water drains are not run separately and/or are not vented •...
  • Page 278 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 279 Vent tube is not installed on water outlet drain • See Installation Instructions Hoses, fittings, etc., are leaking water • Repair/replace as needed Water float valve is stuck open or closed • Clean/replace as needed Water is spraying out of the sump trough area •...
  • Page 280 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 281 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 282 Analyzing Suction Pressure The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times. To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time.
  • Page 283 Procedure Step 1. Determine the ice machine operating conditions. Example: Air temp. entering condenser: 90°F/32.2°C Air temp. around ice machine: 80°F/26.7°C Water temp. entering water fill valve: 70°F/21.1°C 2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice machine model being checked. Using operating conditions from Step 1, determine published freeze cycle time and published freeze cycle suction pressure.

  • Page 284: Improper Installation

    Suction Pressure High Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 277. Discharge Pressure • Discharge pressure is too high, and is affecting suction pressure, refer to “Discharge Pressure High Checklist” on page 288. Improper Refrigerant Charge •...
  • Page 285 Suction Pressure Low Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 277. Discharge Pressure • Discharge pressure is too low, and is affecting suction pressure, refer to “Freeze Cycle Discharge Pressure Low Checklist” Improper Refrigerant Charge •...
  • Page 286 Comparing Evaporator Inlet and Outlet Temperatures The temperatures of the suction lines entering and leaving the evaporator alone cannot diagnose an ice machine. However, comparing these temperatures during the freeze cycle, along with using the Refrigeration System Operational Analysis Table, can help diagnose an ice machine malfunction.
  • Page 287 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 333 for ice machine being checked.
  • Page 288 Discharge Pressure High Checklist Improper Installation • Refer to “Installation and Visual Inspection Checklist” on page 277. Restricted Condenser Air Flow • High inlet air temperature • Condenser discharge air re-circulation • Dirty condenser fins • Defective fan cycling control •...
  • Page 289 Harvest Valve General The harvest valve is an electrically operated valve that opens when energized, and closes when de-energized. Normal Operation The valve is de-energized (closed) during the freeze cycle and energized (open) during the harvest cycle. The valve is positioned between the receiver and the evaporator and performs two functions: 1.
  • Page 290 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 291 Use the following procedure and table to help determine if a harvest valve is remaining partially open during the freeze cycle. 1. Wait five minutes into the freeze cycle. 2. Feel the inlet of the harvest valve. Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison.
  • Page 292 Findings Comments The inlet of the harvest valve is This is normal as the cool enough to touch and the discharge line should always compressor discharge line is hot. be too hot to touch and the harvest valve inlet, Cool & Hot although too hot to touch during harvest, should be cool enough to touch after 5...
  • Page 293 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 294 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 295 Ice Quality Is Poor — Cubes are Shallow, Incomplete or White Ice machine is dirty • Clean and sanitize the ice machine Water filtration is poor • Replace the filter Water softener is working improperly (if applicable) • Repair the water softener Poor incoming water quality •...
  • Page 296 Freeze Cycle Is Long, Low Ice Production Water temperature is too high • Connect to a cold water supply, verify check valves in faucets and other equipment are functioning correctly Dirty Condenser • Clean condenser High air temperature entering condenser •...
  • Page 297 Ice Machine Runs and No Ice Is Produced No water to ice machine • Correct water supply Incorrect incoming water pressure • Water pressure must be 20-80 psi (1.4-5.5 bar) Excessive mineral buildup • De-scale and sanitize the ice machine Ambient temperature is too high or low •...
  • Page 298 Final Analysis The column with the highest number of check marks identifies the refrigeration problem. Column 1 – Harvest Valve Leaking A leaking harvest valve must be replaced. Column 2 – Low Charge/TXV Starving Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures.

  • Page 299: Symptom #3

    SYMPTOM #3 Ice Machine Will Not Harvest – Freeze Cycle Is Normal and Ice Cubes Are Not Melted After Harvest Part Number 000017439 Rev 01 4/24 UnderCounter - 299...
  • Page 300 300 - UnderCounter Part Number 000017439 Rev 01 4/24...

  • Page 301: Symptom #4

    SYMPTOM #4 Ice Machine Will Not Harvest – Freeze Cycle is Normal and Ice Cubes Are Not Melted After Harvest Part Number 000017439 Rev 01 4/24 UnderCounter - 301...
  • Page 302 302 - UnderCounter Part Number 000017439 Rev 01 4/24...

  • Page 303: Component Check Procedures

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

  • Page 304: Bin Switch

    Bin Switch Function Bin switch operation is controlled by the movement of the ice damper. The bin switch has two main functions: 1. Terminating the harvest cycle and returning the ice machine to the freeze cycle. This occurs when the bin switch is opened and closed again within 7 seconds of opening during the harvest cycle.
  • Page 305 Ohm Test 1. Disconnect the bin switch wires to isolate the bin switch from the control board. 2. Connect an ohmmeter to the disconnected bin switch wires. 3. Cycle the bin switch open and closed numerous times by opening and closing the ice damper. NOTE: To prevent mis-diagnosis: •...
  • Page 306 Bin Switch Removal 1. Disconnect power to the ice machine at service disconnect. 2. Disconnect bin switch wires in control box. 3. Insert a small screwdriver through the hole located in the top of the bin switch, and depress mounting tab slightly.

  • Page 307: 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 308: On/Off/Wash Toggle Switch

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

  • Page 309: Ice Thickness Probe

    Ice Thickness Probe How the Probe Works The Koolaire® electronic sensing circuit does not rely on refrigerant pressure, evaporator temperature, water levels or timers to produce consistent ice formation. As ice forms on the evaporator, water (not ice) contacts the ice thickness probe.

  • Page 310: Ice Thickness Check

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

  • Page 311: 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 312 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 set. 2. Try to start the compressor. 3. Watch the pressures closely. •...

  • Page 313: 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 (Close) Cut-Out (Open) KF0150 K0170 275 psig ±5 225 psig ±5 KF0250 K0270...

  • Page 314: High Pressure Cutout (Hpco) Control

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

  • Page 315: Filter-Driers

    Filter-Driers Liquid Line Filter Drier The filter-drier used on Koolaire® ice machines are manufactured to Koolaire® specifications. The difference between a Koolaire® drier and an off- the-shelf drier is in filtration. A Koolaire® drier has dirt-retaining filtration, with fiberglass filters on both the inlet and outlet ends.

  • Page 316: 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 317: Refrigerant Re-Use Policy

    REFRIGERANT RE-USE POLICY Koolaire® recognizes and supports the need for proper handling, re-use, and disposal of CFC and HCFC refrigerants. Koolaire® service procedures require recapturing refrigerants, not venting them to the atmosphere. It is not necessary, in or out of warranty, to reduce or compromise the quality and reliability of your customers’...
  • Page 318 4. Recovered refrigerant must come from a “contaminant-free” system. To decide whether the system is contaminant free, consider: • Type(s) of previous failure(s) • Whether the system was cleaned, evacuated and recharged properly following failure(s) • Whether the system has been contaminated by this failure •...

  • Page 319: Recovery And Recharging Procedures

    RECOVERY AND RECHARGING PROCEDURES Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important 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 320 SELF-CONTAINED RECOVERY/EVACUATION 1. Place the toggle switch in the OFF position. 2. Install manifold gauge set, charging cylinder/scale, and recovery unit or two-stage vacuum pump. 3. Open (backseat) the high and low side ice machine service valves, and open high and low side on manifold gauge set.
  • Page 321 7. Close the high side on the manifold gauge set. Add any remaining vapor charge through the suction service valve (if necessary). NOTE: Manifold gauge set must be removed properly to ensure that no refrigerant contamination or loss occurs. 8. Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses.

  • Page 322: System Contamination Cleanup

    System Contamination Cleanup General This section describes the basic requirements for restoring contaminated systems to reliable service. Important 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. Determining Severity of Contamination System contamination is generally caused by either moisture or residue from compressor burnout entering the...
  • Page 323 Contamination/Cleanup Chart Symptoms/Findings Required Cleanup Procedure No symptoms or suspicion of contamination Normal evacuation/ 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 324: 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 325: Severe System Contamination Cleanup

    SEVERE SYSTEM CONTAMINATION CLEANUP PROCEDURE 1. Remove the refrigerant charge. 2. Remove the compressor. 3. Disassemble the harvest solenoid valve. If burnout deposits are found inside the valve, install a rebuild kit, and replace the TXV and head pressure control valve.
  • Page 326 11. Operate the ice machine for one hour. Then, check the pressure drop across the suction line filter-drier. If the pressure drop is less than 2 psig, the filter- drier should be adequate for complete cleanup. If the pressure drop exceeds 2 psig, change the suction line filter-drier and the liquid line drier.

  • Page 327: Replacing Pressure Controls Without

    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 • High pressure cut-out control •...
  • Page 328 FIG. A - “PINCHING OFF” TUBING FIG. B - RE-ROUNDING TUBING SV1406 Using Pinch Off Tool 328 - UnderCounter Part Number 000017439 Rev 01 4/24...

  • Page 329: Kf0250/K0270 Condenser Fan Motor Access

    KF0250/K0270 Condenser Fan Motor Access Access to remove, clean or replace the condenser fan/ motor can be obtained by performing the following: 1. Disconnect electrical power to the ice machine at the electrical service disconnect. 2. Remove the screws that secure the condenser to the cabinet and the base to the cabinet.
  • Page 330 THIS PAGE INTENTIONALLY LEFT BLANK...

  • Page 331: Component Specifications

    Component Specifications Main Fuse Volt KF0150 K0170 KF0250 K0270 Bin Switch Bin switch operation is controlled by the movement of the ice damper. ON/OFF/WASH Toggle Switch Single-pole, double-throw switch. The switch is connected into a varying low D.C. voltage circuit. Fan Control Cycle Model Cut-in (Close)

  • Page 332: Total System Refrigerant Charge

    Total System Refrigerant Charge Important This information is for reference only. Refer to the ice machine serial number tag to verify the system charge. Serial plate information overrides information listed on this page. Model Air-Cooled Water-Cooled Refrigerant Type KF0150 14 oz (397 g) R404A K0170 14 oz (397 g)

  • Page 333: Cycle Times, 24 Hr. Ice Production And Refrigerant Pressure Charts

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

  • Page 334: Kf0150A Self-Contained Air-Cooled

    KF0150A 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 Water Temperature °F/°C Time Condenser 50/10 70/21 90/32 °F/°C 19.8-22.5 21.2-24.0 26.6-30.2 70/21 21.2-24.0...

  • Page 335: K0170A Self-Contained Air-Cooled

    K0170A 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 Water Temperature °F/°C Time Condenser 50/10 70/21 90/32 °F/°C 17.6-20-1 20.5y-23.3 24.5-28.0 70/21 19.8-22.5...

  • Page 336: Kf0250 Self-Contained Air-Cooled

    KF0250 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 Water Temperature °F/°C Time Condenser 50/10 70/21 90/32 °F/°C 12.3-14.0 14.5-16.5 16.5-18.8 70/21 13.1-15.5...

  • Page 337: K0270 Self-Contained Air-Cooled

    K0270 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 Water Temperature °F/°C Time Condenser 50/10 70/21 90/32 °F/°C 11.0-12.6 12.8-14.7 14.5-16.5 70/21 11.3-12.9...

  • Page 338: K0270 Self-Contained Water-Cooled

    K0270 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 Water Temperature °F/°C Time Machine 50/10 70/21 90/32 °F/°C 10.6-12.2 12.3-14.0 13.5-15.4 70/21...

  • Page 339: 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 340: Kf0150/K0170 Wiring Diagram

    KF0150/K0170 WIRING DIAGRAM NOTE: Diagram shown in the freeze cycle (22) (24) (23) (20) (10) (11) (21) (12) (14) (15) (13) 340 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 341 KF0150/K0170 WIRING DIAGRAM LEGEND Item Description Control Board Fuse Transformer On/Off /Clean Switch Bin Switch Bin Thermostat High Pressure Cut Out Harvest Solenoid Valve Contactor Coil Contactor Contacts Compressor Compressor Relay Compressor Start Capacitor Compressor Overload Condenser Fan Motor Fan Cycle Control Water Pump Ice Thickness Control Part Number 000017439 Rev 01 4/24...

  • Page 342: Kf0250/K0270 Wiring Diagram

    KF0250/K0270 WIRING DIAGRAM NOTE: Diagram shown in the freeze cycle (22) (24) (23) (20) (21) (14) (12) (47) (49) (10) (44) (48) (46) (45) 342 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 343 KF0250/K0270 WIRING DIAGRAM LEGEND Item Description Control Board Fuse Transformer On/Off /Clean Switch Bin Switch Bin Thermostat High Pressure Cut Out Harvest Solenoid Valve Contactor Coil Contactor Contacts Compressor Compressor Potential Relay Compressor Start Capacitor Compressor Overload - May be internal or external Condenser Fan Motor Fan Cycle Control Water Pump...

  • Page 344: Electronic Control Board

    Electronic Control Board ICE THICKNESS PROBE DC VOLTAGE ELECTRICAL PLUG BIN SWITCH LIGHT HARVEST LIGHT AC LINE VOLTAGE ELECTRICAL PLUG 10 AMP FUSE KF0150/K0170/KF0250/K0270 Tubing Schematic EVAPORATOR HEAT EXPANSION EXCHANGER VALVE HARVEST SOLENOID VALVE AIR OR WATER STRAINER CONDENSER DRIER COMPRESSOR RECEIVER (WATER COOLED ONLY)
  • Page 345 Notes Part Number 000017439 Rev 01 4/24 UnderCounter - 345...
  • Page 346 Notes 346 - UnderCounter Part Number 000017439 Rev 01 4/24...
  • Page 348 MANITOWOC ICE 2110 SOUTH 26TH STREET MANITOWOC, WI 54220 800-545-5720 WWW.KOOL-AIRE.COM ©2022 Manitowoc Ice except where explicitly stated otherwise. All rights reserved. Part Number 000017439 Rev 01 4/24...

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