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Howe 1000-RLE, Installation & Service Manual

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Howe 1000-RLE Installation & Service Manual Download Page 1

Howe

 

Corporation

 

Phone:

  

1

‐

773

‐

235

‐

0200

Fax:

  

1

‐

773

‐

235

‐

0269

1650

 

North

 

Elston

 

Avenue

 

Website:

  

www.howecorp.com

Chicago,

 

IL

 

60642

‐

1585

 

Email:

  

[email protected]

 

 

Rapid Freeze

®

 

Ice

 

Flaker

 

 

Installation

 

&

 

Service

 

Manual

 

For

 

Use

 

with

 

Remote

 

Single

 

Condensing

 

Unit

 

1000

‐

RLE

 

2000

‐

RLE

 

3000

‐

RLE

 

 

 

 

Summary of Contents for 1000-RLE

Page 1: ...Fax 1 773 235 0269 1650 North Elston Avenue Website www howecorp com Chicago IL 60642 1585 Email howeinfo howecorp com Rapid Freeze Ice Flaker Installation Service Manual For Use with Remote Single Condensing Unit 1000 RLE 2000 RLE 3000 RLE ...

Page 2: ...n and Guidelines 8 Inspection 8 Condensing Unit Rigging and Mounting 8 Piping 9 Leak Testing 9 Evacuation 10 Field Wiring 10 Refrigerant Charging Instructions 11 Installation Checklist 12 START UP AND OPERATION 13 Water Operation 13 Refrigeration Operation 16 Electrical Operation 21 Mechanical Operation 26 Start Up Checklist 30 MAINTENANCE 31 Preventative Maintenance Schedule 31 Cleaning Procedure...

Page 3: ...never be supplied to the Ice Flaker RO system treated water is aggressive toward metals and plated surfaces In addition RO water will affect the life and integrity of rubber and plastic material Ice Flaker components If only RO water is available Post RO treatment must be provided to raise pH and mineral content Generally filtration of cold supply water is recommended Howe offers a complete line o...

Page 4: ...diction may dictate other indirect water connection requirements The figure depicts two separate drain lines which are required to ensure the Ice Flaker does not inadvertently flow Water Sump Drain water into the Ice Bin or Carts in the event of a backup or any other malfunction Electrical Requirements A dedicated 15 amp 2 pole 208 230 volt power supply from a field furnished and installed disconn...

Page 5: ...ed with the following accessories Liquid Line Filter Drier and Sight Glass Suction Filter Suction Accumulator Oil Separator Refrigerant Pump Down Cycle Heated and Insulated Receiver except for high ambient applications Discus Compressor Condenser Fan Cycling control Non Adjustable Head Pressure Control Valve Field Furnished Condensing Units Howe is not responsible for the performance of field furn...

Page 6: ...6 Engineering Guidelines Figure 1 ...

Page 7: ...erant piping should be joined with a suitable silver brazing alloy while purging nitrogen through the piping to prevent copper oxidation scale from forming inside the tubing For close coupling Ice Flaker to Condensing Unit use a minimum of ten feet total straight length of pipe Minimize bends and fittings Suction Line to include EPR and Heat Exchanger Refrigerant Pipework Insulation Requirements F...

Page 8: ...ed when moving these units To prevent damage to the unit housing during rigging cables or chains used must be held apart by spacer bars The mounting platform or base should be level and located so as to permit free access of supply air Ground Mounting Concrete slab raised six inches above ground level provides a suitable base Raising the base above ground level provides some protection from ground...

Page 9: ...piping open to the atmosphere any longer than is absolutely necessary 2 Use only refrigeration grade copper tubing properly sealed against contamination 3 Suction lines should slope 1 4 per 10 feet towards the compressor 4 Refer to the Suggested Refrigerant Piping Diagram p 6 for suitable P type oil trap locations to enhance oil return to the compressor 5 When brazing refrigerant lines Dry Nitroge...

Page 10: ...ich time the vacuum should be broken with the refrigerant to be used in the system through a drier until the system pressure rises above 0 psig Refrigerant used during evacuation cannot be vented Reclaim all used refrigerant Repeat this operation a second time Open the compressor service valves and evacuate the entire system to 500 microns absolute pressure Raise the pressure to 2 psig with the re...

Page 11: ...iquid refrigerant can be added directly into the receiver tank 3 The approximate refrigerant charge is listed in the table below Do not over charge Model System Charge1 Piping Charge2 1000 RLE 9 3 4 2000 RLE 14 6 4 3000 RLE 20 6 4 1 System Charge is approximate pounds of R 404a for Ice Flaker and Condensing Unit only 2 Piping Charge is approximate additional pounds refrigerant per 100 linear feet ...

Page 12: ...ed near a floor sanitary sewer drain see Drain Water Piping Requirements p 4 6 Have the EPR and Suction Line Heat Exchanger been installed correctly see Suggested Refrigerant Piping Diagram p 6 7 Have all the refrigeration lines been sufficiently insulated see Refrigerant Pipework Insulation Requirements p 7 8 Has the Condensing Unit been mounted properly see Condensing Unit Rigging and Mounting p...

Page 13: ...rt Up and Operation Water Operation 1 Water Inlet Connection 2 Float Valve 3 Water Pump 4 Water Regulating Valve 5 Water Distribution Pan Side Spout 6 Sump Connections 7 Stop Valve 8 Condensate Drain Outlet 9 Sump Drain Outlet ...

Page 14: ...the Float Valve Rotate clockwise to raise the water level and counterclockwise to lower the water level Water Pump The Water Pump drives the water in a continuous flow through the system The Water Pump inlet should be submerged at all times Air should never be pulled into the intake Overflow Drain The higher of the two drain connections on the Water Sump is the Overflow Drain If water is exiting t...

Page 15: ...r level in the Water Distribution Pan should be about halfway full The Side Spouts should never be starved of water Water Regulating Valve Adjust the water level in the Water Distribution Pan by opening or closing the Water Regulating Valve located directly above the Water Sump Only adjust the Water Regulating Valve after the Ice Flaker has been producing ice for at least 10 minutes Condensate Dra...

Page 16: ...p Operation Refrigeration Operation Piping insulation not shown 1 Evaporator Pressure Regulator EPR 2 Solenoid Valve 3 Sight Glass 4 Thermostatic Expansion Valve TXV 5 TXV Sensing Bulb 6 Evaporator 7 Pressure Tap ...

Page 17: ... and must be field installed The EPR should ideally be located within 2 feet of the Ice Flaker To read EPR setting install service manifold at the Pressure Tap of the Evaporator or at the inlet of the EPR For Angle Style EPR remove end cap and adjust using a 1 4 hex wrench To increase the pressure setting rotate clockwise To decrease the pressure setting rotate counter clockwise If EPR fails to re...

Page 18: ...rigeration to the Ice Flaker 1 Visually inspect the frost pattern on the freezing surface of the Evaporator If the TXV is underfeeding the top of the frost pattern will be a milky white color and the bottom will be clear soft and not harvest properly TXV Underfeeding 2 If the TXV is not underfeeding close the TXV by 1 4 of a turn and wait 5 minutes 3 Visually inspect the frost pattern of the Evapo...

Page 19: ...d The moisture indicator in the middle of the Sight Glass should always be green Green Dry Yellow Wet Fan Cycling Control On Dual Fan Condensing Units 1000 RLE 2000 RLE the lead fan is always on when the Condensing Unit is operating The Second Fan is controlled by an ambient switch which should be set at 50 F On Single Fan Condensing Units 3000 RLE the fan is always on when the Condensing Unit is ...

Page 20: ... falling ice in the container for exactly 15 minutes Be sure that the container catches all of the ice 5 Weigh the ice and the container together in pounds using an accurate scale Do not drain before weighing Measured Weight Lbs 6 Subtract the weight of the container Measured Weight from 5 Container Weight from 1 Calculated Weight Lbs 7 Calculate the capacity by multiplying the calculated weight b...

Page 21: ...or Overload Indicator Light 1 Term 1 24V Input Power 2 Term 2 24V Input Power 3 Term 3 Control Signal 4 Term 4 Motor Overload Reset 5 Term 5 Motor Overload Switch Leg 6 Term 6 Ice Flaker Run Switch Leg 7 Term 7 Solenoid Valve Contact 8 Term 8 Solenoid Valve Contact 9 Off Delay Setting 10 Motor Overload Setting 11 Overcurrent Condition Indicator Light 12 Overload Sensing Coil ...

Page 22: ...ing light It operates in one of three main modes Normal Operation Off Delay Cycle Overload Condition Normal Operation Normal Operation begins when the Control Module senses voltage at the Control Signal Term 3 During Normal Operation voltage is present at Ice Flaker Run Switch Leg Term 6 and the Solenoid Valve Contacts Term 7 8 are closed Off Delay Cycle The Off Delay Cycle begins when voltage is ...

Page 23: ...hanges are made to the Drive Motor or Main Shaft Motor Overload Setting The proper adjustment of Motor Overload Setting will protect the Ice Flaker and help avoid nuisance service calls To set the Motor Overload correctly 1 Mark the location of the setscrew before an adjustment is made as a point of reference 2 Place a small flat blade screwdriver in the adjustment screw while the Ice Flaker is op...

Page 24: ...24 Start Up Operation Photo Eyes Level Control Emitter Part E20T104 Two Pins Blue Brown One LED Green Receiver Part E20T105 Three Pins Blue Black Brown Two LEDs Green Amber ...

Page 25: ... wires connected Correct Voltage With Level Control Relay plugged in and power to Ice Flaker on unplug Emitter and Receiver Use a voltmeter to verify 24 volts across blue and brown pins Alternatively you can check terminals 1 and 10 on the Level Control Relay If 24 volts is not present the Level Control Relay has likely failed and needs to be replaced Sequence of Operation There are Light Emitting...

Page 26: ...26 Start Up Operation Mechanical Operation 1 Ice Deflector 2 Ice Blade 3 Squeegee 4 Speed Reducer 5 Drive Motor ...

Page 27: ...or Scraper This plastic arm clears any excess buildup of ice on the Ice Deflector as it passes by the Ice Deflector Scraper The Ice Deflector should never touch the Ice Deflector Scraper or the Bottom Casting Ice Blade The Ice Blade shatters the ice formed on the Evaporator freezing surface as the Main Shaft rotates Ice harvesting problems are often caused by improper refrigeration settings Adjust...

Page 28: ... ice which causes drag on the Ice Blade This puts greater stress on the Sleeve Bearings and causes them to wear faster than normal The 1000 RLE does not feature a Squeegee However it has a longer drying time between Ice Blade passes With normal usage the Squeegee can wear over time Worn Squeegees need to be trimmed or replaced Gear Motor 1000 RLE The Gear Motor is a drive motor and speed reducer c...

Page 29: ...ol Module 1 time The Drive Motor and Speed Reducer will only fit in the enclosure in the orientation shown above Sleeve Bearings Ice Flakers have two Sleeve Bearings on the Main Shaft located in the Top Casting and the Bottom Casting Over time normal usage can cause these bearings to wear Worn bearings can result in ice harvesting problems and even damage to the Evaporator Improper refrigeration s...

Page 30: ...Control 1000 RLE 2000 RLE only see Fan Cycling Control p 19 7 Have you set the Low Pressure Control on the Condensing Unit see Low Pressure Control p 19 8 Have you run a Field Capacity Check see Field Capacity Check p 20 9 Have you set the Off Delay Setting on the Control Module see Off Delay Setting p 22 10 Have you set the Motor Overload Setting on the Control Module see Motor Overload Setting p...

Page 31: ... flowing freely 14 Verify correct Sequence of Operation of Photo Eye sensors 25 Clean and Sanitize Ice Flaker 32 Replace Water Filter Cartridge 36 Run a Field Capacity Check 19 Verify Ice Blade Clearance 27 Check Squeegee for excessive and uneven wear 28 Check Main Shaft for movement and Sleeve Bearing wear 29 Lubricate Sleeve Bearings 34 ...

Page 32: ... Turn the Power Switch Off at the Ice Flaker Control Panel 2 Open Ice Flaker Control Panel and turn Off Delay timer knob fully clockwise to 30 minutes run time 3 Remove all ice from Ice Bin 4 Close water supply at shut off valve 5 Open Ice Flaker Stop Valve to allow water to exit from Water Sump Afterwards close Stop Valve to prevent loss of solution 6 Prepare approved cleaning solution by followi...

Page 33: ...sh water until all cleaning solution is flushed out Sanitizing Procedure 1 Mix 16 oz of household bleach with 2 gallons of warm water 90 F 115 F 2 Pour solution into the Water Sump to the normal operating level then re circulated the sanitizing solution for approximately 20 minutes by turning on Drive Motor and Water Pump 3 Drain solution and rinse thoroughly with fresh water at least twice follow...

Page 34: ...educer Oil should drain out when setscrew is removed Add oil through top Allen head screw opening until oil seeps out of centered screw opening Do not overfill Sleeve Bearing Lubrication The bearings should be greased annually using USDA approved food grade edible grease Typically only one squirt of the grease gun is required or until you feel resistance on the pump Use caution to ensure the beari...

Page 35: ...d down time Scale forms on wetted surfaces accumulates in tubing and fittings and interferes with operation Sediment The formation of scale from dissolved minerals is made worse by sediment Sediment is suspended particles of dirt silt and other fine particulate matter that act as a catalyst for scale to form Sediment can be detrimental to the condition and performance of the Ice Flaker Particulate...

Page 36: ...g ball valve 2 Press the red button to release pressure 3 Remove housing s use filter wrench if necessary Clean housings with warm water If desired disinfect housings using 1 2 teaspoon of household bleach in a bowl of water Let stand 5 minutes and then discard 4 Insert new cartridges into filter housings Match cartridge model numbers to model numbers on bracket 5 Make certain the O ring is proper...

Page 37: ... Ice Bin is full 1 Defective Emitter Photo Eye 1 Unplug Emitter Photo Eye and wait longer than Off Delay setting If Ice Flaker stops Emitter Photo Eye may be defective and need to be replaced 2 Defective Receiver Photo Eye 2 Unplug Receiver Photo Eye and wait longer than Off Delay setting If Ice Flaker stops Receiver Photo Eye may be defective and need to be replaced 3 Level Control Relay LC1 is j...

Page 38: ...ose wiring 7 Check all wire terminals and tighten as necessary Water Pump will not run 1 Defective Control Module CM 1 Verify 24 VAC present across Term 1 purple and Term 3 red at Control Module CM Check voltage between Term 1 and Term 6 blue If no voltage present Control Module CM may be defective and need to be replaced 2 Defective Water Pump 2 Verify control voltage at Water Pump wire leads If ...

Page 39: ...surface of Evaporator 2 Clean spouts of any debris or blockages Make sure all spouts are perpendicular to and within reasonable distance from surface of Evaporator 3 Water is ramping off rings of ice formed on Evaporator 3 Adjust refrigeration to the Ice Flaker 4 Ice Bin is not draining properly 4 Check that all drains are flowing freely and pitched away from Ice Bin 5 Ice turnover is low and Ice ...

Page 40: ...40 Appendix Appendix Cut View 1000 RLE ...

Page 41: ...Appendix 41 Cut View 2000 RLE 3000 RLE ...

Page 42: ...42 Appendix Assembly Drawing 1000 RLE Ice Flaker CP750 Mobile Express Ice Bin ...

Page 43: ...Appendix 43 Assembly Drawing 2000 RLE Ice Flaker CP1500 Mobile Express Ice Bin ...

Page 44: ...44 Appendix Assembly Drawing 3000 RLE Ice Flaker CP2500 Mobile Express Ice Bin ...

Page 45: ...Appendix 45 Wiring Diagram Ice Flaker ...

Page 46: ...46 Appendix Wiring Diagram 230 3 60 Air Cooled Condensing Unit supplied by Howe Corporation ...

Page 47: ...Installation Service Manual For Use with Remote Single Condensing Unit RLE Rev Date 08 2014 ...

Page 48: ...Parts List 1000 RLE Non Replaceable Parts Item No Description Part No ...

Page 49: ... Compression Fitting Copper Water Tube Insulation Water Regulating Valve F5H11 KT 11 Water Sump Gasket F5H18 12 Water Sump Cover F5H25 4 13 Water Sump Kit Float Valve Water Pump Water Regulating Valve Water Sump Gasket Water Sump Water Sump Covers F5H26 P 14 Water Distribution Spout Kit Lead Spout Side Spouts F5H30 KT 15 Handhole Cover F5I2 16 Top Insulating Ring F5J4 17 Bottom Insulating Ring F5J...

Page 50: ...LRN 24 Overload Reset Button N O E20T23 Ice Level Control Emitter E20T104 Ice Level Control Receiver E20T105 Replacement Filter Cartridge E10H56 Replacement O Ring E10H74 Filter Wrench SW 1 R 404A R 507 Balance Port TXV Valve F5V20 KT R 404A R 507 Standard TXV Valve F5V18 KT R 22 R 407 Balance Port TXV Valve F5V17 KT R 22 R 407 Standard TXC Valve F5V19 KT Solenoid Valve B6S1 038 Ice Machine Cleane...

Page 51: ...Parts List 2000 RLE 3000 RLE ...

Page 52: ...r Scraper Kit Scraper Scraper Backing Plate E20G9 KT 14 Water Distribution Pan Kit Lead Spout Side Spouts Water Distribution Pan E10H51 15 Water Distribution Bottom Spout E10H17 16 Water Distribution Side Spout 6 Required E10H73 17 Water Sump Kit Float Valve Water Pump Water Regulating Valve Water Sump Water Sump Covers Water Sump Gasket E10H61 P 18 Water Float Valve E10H79 20 Water Pump E10Q7 P 2...

Page 53: ...0V24 KT R 22 R 407 Standard TXV Valve TXV Strainer E10V22 KT E15V5 KT Solenoid Valve B6S1 050 Parts List Control Panel Miscellaneous Replacement Parts Item No Description Part No 1 Ice Level Control Relay E20T68 2 Motor Relay F5T2 3 Control Module E20T48 4 Transformer E20T31 5 Power Switch E20T24 6 Ice Faker Run Indicator Light LGX 24 7 Motor Overload Indicator Light LRN 24 Overload Reset Button N...

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