Ice-O-Matic GEM0650R Service And Installation Manual
Pearl ice series
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- Service and installation manual (64 pages) ,
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Summary of Contents for Ice-O-Matic GEM0650R
- Page 1 SERVICE AND INSTALLATION MANUAL GEM Models: Remote GEM0650R, GEM0956R, GEM1256R Pearl Ice Series ™ Ice-O-Matic By Ice-O-Matic 11100 East 45th Ave Denver, Colorado 80239 Part Number 9081350-02 17-3144-01 Date 10/08...
- Page 3 GEM0650/0956/1256 Remote How To Use This Manual Ice-O-Matic provides this manual as an aid to the end user and service technician in installation and maintenance of the Pearl Ice™ Series ice machines. Do not attempt to perform installation, start-up or maintenance unless you have read and fully understand this manual.
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Page 4: Table Of Contents
Removal and Replacement: Gear Motor ... Page 38 Removal and Replacement: Fan Blade and Fan Motor... Page 39 Refrigeration System Service ... Page 40 Wiring Diagram: GEM0650R ... Page 41 Wiring Diagram: GEM0956R ... Page 42 Wiring Diagram: GEM1256R ... Page 43 Service History... -
Page 5: Freight Claim Procedure
If loss or damage does not appear until merchandise has been unpacked, make a written request for inspection by the carrier within 15 days of the delivery date. Then file a claim on a form from the carrier. File Claim Without Delay Do Not Return Damaged Merchandise to Ice-O-Matic Page iii... -
Page 6: Warranty
Customer, that part of any such machine that becomes defective. In the event that the Warranty Registration Card indicating the installation date has not been returned to Ice-O-Matic, the warranty period will begin on the date of shipment from the Company. Irrespective of the actual installation date, the product will be warranted for a maximum of seventy-two (72) months from date of shipment from the Company. -
Page 7: For The Installer (Guidelines)
For the Installer Installation Guidelines: For proper operation of the Ice-O-Matic ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties. Ambient Operating Temperatures: (Not including remote condenser) Minimum Operating Temperature: 50°F (10°C) - Page 8 GEM0650/0956/1256 Remote For The Installer GEM0650/0956R Page 2...
- Page 9 GEM0650/0956/1256 Remote For The Installer GEM1256R Page 3...
- Page 10 GEM0650/0956/1256 Remote Bin Application The Pearl Ice™ Series are designed to fit the following Ice-O-Matic Bins ●B42, using Bin Top KBT 24 (Note: GEM0650 and GEM0956 ONLY) ●B25, B40 B55 using Bin Top KBT 19. ●B100 using Bin Top KBT 23 (one unit) or KBT 22 (two units).
- Page 11 If the ice machine is to be mounted on a bin or dispenser other than an Ice-O-Matic, refer to the manufacturer’s instructions for machine mounting. Ice-O-Matic will not be responsible for damage or injury that results from unexpected closing of the bin door as a result of the ice machine being too far forward on the bin.
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Page 12: Remote Condenser
RT360404 60 Foot Precharged Line Set GRC1001 GRC1061 33.36 33.36 10.75 10.75 23.81 23.81 2.04 2.04 6.12 6.12 16.73 16.73 11.65 11.65 19.57 19.57 GEM0650R GEM0956R Page 6 Remote Condenser GCR2061 33.36 10.75 23.81 2.04 6.12 16.73 11.65 19.57 GEM1256R... -
Page 13: For The Installer (Remote Condenser Location)
● Calculation: Drop(s) + Rise(s) + Horizontal Run = dd+rd+hd=Calculated Line Length Configurations that do NOT meet these requirements must receive written authorization from Ice-O-Matic. This includes multipass or rack system remote condensers. Do NOT: ● Route a line set that rises, then falls, then rises. - Page 14 GEM0650/0956/1256 Remote Remote Condenser Location: Limited to a 25 foot or a 40 foot length of precharged refrigerant tubing connecting the ice machine to the remote condenser. The remote condenser must be above or level with the ice machine. Select the best available location, protecting the remote condenser from extremes of dirt, dust and sun.
- Page 15 GEM0650/0956/1256 Remote For the Installer Typical Installation REMOTE CONDENSER ICE MACHINE Page 9...
- Page 16 GEM0650/0956/1256 Remote Coupling Instructions: Initial Connections: 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them. 2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil. 3.
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Page 17: For The Plumber
GEM0650/0956/1256 Remote For the Plumber Water Inlet: The recommended water supply is cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 inch male flare on the back of the cabinet. Install a hand valve near the machine to control the water supply. Drains: Ice Machine: There is one 3/4 inch FPT drain at the back of the cabinet;... -
Page 18: For The Electrician
GEM0650/0956/1256 Remote For the Electrician INSTALLATION MUST CONFORM TO ALL APPLICABLE CODES. Connect the electrical power to the unit to the wires in the junction box at the rear of the machine. Check the nameplate (located on the back panel) for the voltage requirements, and for the minimum circuit ampacity. The machine requires a solid chassis to earth ground wire. -
Page 19: For The Installer (Completed Installation)
GEM0650/0956/1256 Remote Completed Installation Roof Cut-A-Way A typical installation should generally appear as illustrated below. The best place for the remote condenser is above the ice machine, although other locations are permissible. Page 13 For the Installer... -
Page 20: For The Installer (Final Check List)
___11.Have the remote condenser and pre-charged lines been properly installed? ___12. Has the electrical connection between the ice maker and condenser been made? ___13. Verify that the master switch is in the OFF position. ___14. Switch ON the electrical power. -
Page 21: Start Up
9. Give the owner/user the service manual, instruct him/her in the operation of the unit, and make sure they know who to call for service. 10. Fill out the manufacturer’s registration and mail it to Ice-O-Matic. Page 15 Start Up... -
Page 22: Component Description
GEM0650/0956/1256 Remote ●Control Box: Contains the electrical controls that operate the machine. ●High Pressure Cut Out Switch: An auto-reset switch sensing the high side refrigeration pressure. It will shut the machine off if the discharge pressure exceeds 450 psig. ●Pump Down Control: A switch to control the compressor, depending upon low side pressure: closes at 30 PSIG and opens at 15 PSIG. - Page 23 GEM0650/0956/1256 Remote ●Contactor: A definite purpose contactor connecting the compressor and the fan motor to the power supply. ●Circuit Board: Controls the operation of the ice machine using input from the sensors and pressure controls. Switches loads on and off thru relays. (Reference Photo Below) ●Potential Relay: The compressor start relay.
- Page 24 GEM0650/0956/1256 Remote ●Evaporator: A refrigerated vertical tube filled with water and containing a water seal and auger. ●Auger: A solid stainless steel double spiral auger, it pushes the ice crystals up to the top of the evaporator. ●Water Seal: A two part “face” seal, the top half rotating with the auger, the bottom half stationary, the sealing action being where the two “faces”...
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Page 25: Electrical Sequence
GEM0650/0956/1256 Remote Electrical Sequence: There are 7 indicator lights on the control board: ●WTR-OK: (Water OK) Green. Normal=Glowing. Glow when there is water in the reservoir. ●PWR-OK: (Power OK) Green. Normal=Glowing. Glows when the power board has power and is functional. ●Service: Red. -
Page 26: Operation: Water
GEM0650/0956/1256 Remote Operation: Water Water Water enters the machine through the 3/8 inch male flare at the rear of the cabinet, goes to the water reservoir which it enters through the float valve. The water then goes out the bottom of the reservoir tank to the bottom of the evaporator. -
Page 27: Operation: Refrigeration
GEM0650/0956/1256 Remote Beginning at the compressor, the refrigerant is compressed into a high temperature gas. The discharge line directs this gas to the condenser and to the head pressure control. At the remote condenser the gas is cooled by air and it then condenses into a liquid. This high pressure liquid then goes through the liquid line connection at the head pressure control. - Page 28 GEM0650/0956/1256 Remote Low Condensing Temperature The refrigeration system under low condenser air temperatures is much the same as it is under higher temperatures, with the exception that the resulting low head pressures cause the head pressure control to close off the liquid line between the condenser and the receiver. This forces more refrigerant into the condenser (with a small amount of discharge gas going into the receiver to maintain pressure until the head pressure is built back up to 180 PSIG).
- Page 29 GEM0650/0956/1256 Remote Pump Down During the pump down cycle (usually initiated by the circuit board de-energizing the liquid line valve) the discharge gases flow through their normal path to the remote condenser, through the head pressure control and into the receiver. At this point the refrigerant flow is stopped by the closed liquid line valve. This action forces the refrigerant into the receiver and keeps it out of the compressor.
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Page 30: Operation: Performance
GEM0650/0956/1256 Remote Typical Low Side Pressure: Remote: Typical Discharge Pressure: Remote: Typical Compressor Amp Draw: GEM0650 115/60/1 GEM0956 208-230/60/1 GEM1256 208-230/60/1 Typical Auger Drive Motor Amp Draw: GEM0650 115/60/1 GEM0956 208-230/60/1 GEM1256 208-230/60/1 Expansion Valve Superheat: High Pressure Cut Out- Automatic Reset: Pump Down Cut Out- Automatic Reset: Refrigerant Charge: R404A GEM0650 Remote... -
Page 31: Sanitizing And Cleaning
GEM0650/0956/1256 Remote It is the USER’S RESPONSIBILITY to keep the ice machine and ice storage bin in a sanitary condition. Without human intervention, sanitation will not be maintained. Ice machines also require occasional cleaning of their water systems with a specifically designed chemical. That chemical dissolves mineral build up that forms during the ice making process. -
Page 32: Remote Condenser Maintenance
GEM0650/0956/1256 Remote Brush in direction of fins will restrict the airflow through the condenser and the fins will need to be straightened with a fin comb. When cleaning the condenser check the fan blade for cleanliness and for balance. Balance is checked by spinning the blade by hand and looking for any wobble. -
Page 33: Bearing Maintenance
GEM0650/0956/1256 Remote Bearing Maintenance: The bearing in the breaker should also be checked at least two (2) times per year. Switch the machine OFF and check the bearing. 1. Remove the chute cover. 2. Unscrew the ice sweep 3. Removing the water shed and unscrewing the breaker cover. -
Page 34: Sensor Maintenance
GEM0650/0956/1256 Remote Bin Control Sensor: The bin control uses devices that sense light, therefore they must be kept clean enough so that they can “see”. At least twice a year, remove the bin control sensors from the base of the chute, and wipe the inside clean, as illustrated. -
Page 35: Auger Maintenance
GEM0650/0956/1256 Remote Auger: In some areas, the water supply to the ice machine will contain a high concentration of minerals, and that will result in an evaporator and auger becoming coated with these minerals, requiring a more frequent removal than twice per year. If in doubt about the condition of the evaporator and auger, the auger can be removed so the parts can be inspected. -
Page 36: Service Diagnosis
GEM0650/0956/1256 Remote Symptom No ice is made nothing operates. No ice, auger motor is turning. Possible Cause •Unit off due to no power •Unit off due to master switch in OFF position •Unit off due to low water level •Unit off due to ice level sensors. (Photo Eyes ) blocked. - Page 37 GEM0650/0956/1256 Remote Symptom Unit makes ice, but very slowly Water leak. Excessive water use. Excessive ice meltage. Machine makes too much noise. Possible Cause •High discharge pressure because of a dirty condenser. •Low capacity because the auger and evaporator are coated with mineral scale.
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Page 38: Control System Diagnostics
GEM0650/0956/1256 Remote The Control System consists of: ●Control Board ●Water Sensors ●Ice Sensors ●High Pressure Cut Out ●Low Pressure Cut Out If the unit is OFF, check the control board: 1. Is the Power OK light on? If not check power to the unit. If it has power, and the Power OK light is not on, check the high pressure and low pressure cut outs. -
Page 39: Removal And Replacement: Water Reservoir And Bin Controls
GEM0650/0956/1256 Remote Water Reservoir: 1. Disconnect electrical power supply. 2. Shut off water supply to the ice maker. 3. Remove the front panel. 4. Disconnect water inlet tube from reservoir inlet fitting. 5. To remove float valve, push in “locking tabs” as shown and pull float up. -
Page 40: Removal And Replacement: Bearing And Breaker
Replace top seal and check the O-Rings, replace if cut or torn. 8. Reverse to reassemble: Specific tools and materials are required to install properly. a. Add food grade grease such as Ice-O-Matic PN6051036-01 to the seal area before installing on the auger. -
Page 41: Removal And Replacement: Auger
GEM0650/0956/1256 Remote To Remove the Auger: 1. Disconnect electrical power. 2. Turn off the water to the machine. 3. Unclip the evaporator drain hose, pull it down and drain the evaporator into the bin or container. 4. Remove the top panel. 5. -
Page 42: Removal And Replacement: Water Seal
GEM0650/0956/1256 Remote To Remove the Water Seal: (Assuming all steps to remove the auger have been performed) 1. The gear motor/evaporator assembly will have to be exposed. 2. Remove the four (4) hex head cap screws holding the evaporator to the gear motor assembly. -
Page 43: Removal And Replacement: Evaporator
GEM0650/0956/1256 Remote To Replace the Evaporator: (Assuming all steps for removal of the thrust bearing, breaker, auger and water seal have been performed). 1. Recover the refrigerant from the ice machine. 2. Unsweat the refrigerant connections: a. At the thermostatic expansion valve outlet. -
Page 44: Removal And Replacement: Gear Motor
GEM0650/09561256 Remote To Check the Gear Motor: 1. Remove wires from terminals 1 and 2 2. Use an ohmeter to check for continuity. If there is none, replace only the motor. If there is continuity but the motor will not start, check the motor’s start switch. 3. -
Page 45: Removal And Replacement: Fan Blade And Fan Motor
GEM0650/0956/1256 Remote To Remove the Condenser Fan Motor Assembly: 1. Disconnect electrical power to the ice machine and/or remote condenser. 2. Remove fan guard. 3. Remove the fan blade. 4. Disconnect the electrical power lead to the fan motor. 5. Remove the four (4) bolts from the fan motor assembly. 6. -
Page 46: Refrigeration System Service
GEM0650/0956/1256 Remote Refrigeration Service: General: This ice machine uses R404A refrigerant and polyolester oil. Do NOT use mineral oil in this refrigeration system. ●When the refrigeration system is serviced, a special liquid line drier is required. It is included with replacement compressors. -
Page 47: Wiring Diagram Gem0650R
GEM0650/0956/1256 Remote GEM0650R Wiring Diagram Wiring Diagram GEM0650R Page 41... -
Page 48: Wiring Diagram Gem0956R
GEM0650/0956/1256 Remote GEM0956R Wiring Diagram Wiring Diagram GEM0956R Page 42... -
Page 49: Wiring Diagram Gem1256R
GEM0650/0956/1256 Remote GEM1256R Wiring Diagram Wiring Diagram GEM1256R Page 43... -
Page 50: Service History
GEM0650/0956/1256 Remote What to Do Before Calling for Service: ●Check the water supply to the ice machine. The ice machine is designed to shut off if there is no water to it. Check the water filters if there are any. ●Check the power supply to the ice machine.