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Welbilt KOOLAIRE K0170 Series Installation Manual Download Page 160

© Welbilt, Inc.

Remote:  Harvest Cycle

160

Koolaire Modular Ice Machines:  Sequence of Operation Refrigeration System

EVAPORATOR

x

x

X

HEAT 

EXCHANGER 

THERMOSTATIC 

EXPANSION 

VALVE

HARVEST VALVE

REMOTE CONDENSER

PRESSURE 

REGULATOR

COMPRESSOR

HPR SYSTEM

CHECK VALVE

CHECK VALVE

D

R

C

RECEIVER

RECEIVER 

SERVICE 

VALVE

DRIER

LIQUID 

LINE 

SOLENOI

D VALVE 

STRAINER

HIGH PRESSURE VAPOR

HIGH PRESSURE LIQUID

LOW PRESSURE LIQUID

LOW PRESSURE VAPOR

The purpose of the HPR 

System is to recharge 

the hot gas loop

Summary of Contents for KOOLAIRE K0170 Series

Page 1: ...Welbilt Inc Koolaire Ice Machines Course ID ICE2114 Koolaire Ice Machine Training 4 Hour duration...

Page 2: ...Introduction Overview Installation Interior Cleaning and Sanitizing Disassembly Removal Sequence of Operation Troubleshooting Modular Product Introduction Overview Installation Interior Cleaning and...

Page 3: ...Welbilt Inc Welbilt Inc Overview Koolaire UnderCounter Ice Machines 3...

Page 4: ...Welbilt Inc Component Identification 4 Koolaire UnderCounter Ice Machines Overview Ice making and Bin compartment Data Plate Removable Front Cover Washable Air Filter 2ea Front Cover Screws...

Page 5: ...mponent Identification 5 Koolaire UnderCounter Ice Machines Overview Data Plate Condenser Control Box Ice Off Clean Switch Compressor Compartment Service Valves Hot Gas Valve Fan Cycling Switch High P...

Page 6: ...Welbilt Inc Component Identification 6 Koolaire UnderCounter Ice Machines Overview Evaporator Ice Thickness Probe Damper Door Water Trough Overflow Drain...

Page 7: ...onent Identification Water Pump Cover Removed 7 Koolaire UnderCounter Ice Machines Overview Ice Thickness Probe Discharge Hose Water Pump Bin Switch Magnet Damper Door Float Valve Siphon Cap Overflow...

Page 8: ...12 MFG DT 1501 600 P S I G DESIGN PRESSURE LOW SIDE 250 P S I G 17 BAR DESIGN PRESSURE HIGH SIDE 500 P S I G 34 BAR VOLTS CYCLE115 V 60 Hz AMPS 7 0 REFRIG TYPE R 404A PHASE 1 REFRIG CHARGE 14OZ 0 397K...

Page 9: ...nt type identifier has been added to model numbers KYF 150 A 161 ICE MACHINE MODEL ICE CUBE SIZE D DICE Y HALF DICE ICE MACHINE SERIES CONDENSER TYPE A SELF CONTAINED AIR COOLED W SELF CONTAINED WATER...

Page 10: ...Welbilt Inc Review 10 Koolaire UnderCounter Ice Machines Overview Overview o Component Identification Compressor Compartment Evaporator Compartment o Model Number...

Page 11: ...Welbilt Inc Welbilt Inc Installation Koolaire UnderCounter 11...

Page 12: ...Welbilt Inc Installation Operation and Maintenance Manual 12 UnderCounter Installation...

Page 13: ...a full bin of ice Enough clearance for water drain and electrical connections in the rear of the ice machine The location selected for the ice machine must meet the following criteria If any of these...

Page 14: ...reject heat through the condenser It is helpful to know the amount of heat rejected by the ice machine when sizing air conditioning equipment where self contained air cooled ice machines are installe...

Page 15: ...15 UnderCounter Installation 1 Screw the leveling legs onto the bottom of the ice machine 2 Screw the foot of each leg in as far as possible 3 Move into position 4 Level the ice machine to ensure that...

Page 16: ...codes If a power cord is used the wire size to the receptacle is dependent upon location materials used length of run etc so it must be determined by a qualified electrician Local state or national re...

Page 17: ...Machine Fitting Tubing Size Up to Ice Machine Fitting Ice Making Water Inlet 35 F 2 C Min 90 F 32 C Max 20 psi 140 kPa Min 80 psi 552 kPa Max 3 8 95 cm Female Pipe Thread 3 8 95 cm min inside diamete...

Page 18: ...Welbilt Inc Review 18 Koolaire UnderCounter Ice Machines Overview Location of Ice Machine Clearance Requirements Heat of Rejection Leveling Electrical Requirements Water Service Drains...

Page 19: ...Welbilt Inc Welbilt Inc Cleaning Sanitizing Koolaire UnderCounter Ice Machines 19...

Page 20: ...e area around the ice machine as often as necessary to maintain cleanliness and efficient operation Sponge any dust and dirt off the outside of the ice machine with mild soap and water Wipe dry with a...

Page 21: ...ter Cleaning The washable aluminum filter on self contained air cooled ice machines is designed to catch dust dirt lint and grease This helps keep the condenser clean Remove by sliding out the left si...

Page 22: ...UnderCounter Cleaning Sanitizing Cleaner for Lime or Mineral Build up Sanitizer for Disinfecting KOOLAIRE Approved Manitowoc Ice Cleaner 000005163 Manitowoc Ice Sanitizer 000005165 Use only Manitowoc...

Page 23: ...unter Cleaning Sanitizing 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...

Page 24: ...Welbilt Inc Interior Cleaning Sanitizing 24 UnderCounter Cleaning Sanitizing Step 2 Remove all ice from the bin No ice in the Bin...

Page 25: ...Welbilt Inc Interior Cleaning Sanitizing 25 UnderCounter Cleaning Sanitizing Step 3 To start a cleaning cycle move the toggle switch to the WASH position...

Page 26: ...Welbilt Inc Interior Cleaning Sanitizing 26 UnderCounter Cleaning Sanitizing Step 4 Add the proper amount of Manitowoc Ice Machine Cleaner to the water Trough...

Page 27: ...tion disconnect Power and water supplies to the ice machine Water Pump Hot Gas Solenoid Contactor Coil Compressor Condenser Fan Motor 1 Clean or Sanitize 10 Minutes Rinse Sequence 2 Water Purge 45 Sec...

Page 28: ...Welbilt Inc Interior Cleaning Sanitizing 28 UnderCounter Cleaning Sanitizing Step 6 Remove parts for cleaning...

Page 29: ...Welbilt Inc Interior Cleaning Sanitizing 29 UnderCounter Cleaning Sanitizing Step 6 Remove parts for cleaning...

Page 30: ...Welbilt Inc Removable parts for Cleaning Sanitizing 30 UnderCounter Cleaning Sanitizing UPPER THUMBSCREW LOWER THUMBSCREWS TAB KEYWAY INNER TUBE INNER TUBE...

Page 31: ...r Cleaning Sanitizing 31 UnderCounter Cleaning Sanitizing Step 7 Mix a solution of cleaner and warm water Solution Type Water Mixed with Cleaner 1 gal 4L 16oz 500 ml cleaner NOTE Never mix cleaner and...

Page 32: ...ng Sanitizing Step 8 Use of the solution to clean all components Step 9 Use of the solution to clean all food zone surfaces of the ice machine and bin After Cleaning Rinse all areas thoroughly with cl...

Page 33: ...Welbilt Inc Review 33 Koolaire UnderCounter Ice Machines Cleaning Sanitizing Exterior Cleaning Cleaning Sanitizing procedure Removable parts for cleaning...

Page 34: ...Welbilt Inc Welbilt Inc Sequence of Operation Koolaire UnderCounter Ice Machines 34...

Page 35: ...tell it to do 15 CONTACTOR CONTACTS HIGH PRES CUTOUT 14 FUSE TRANS 1 2 3 3 HARVEST LIGHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13 F...

Page 36: ...cuits to ground 15 CONTACTOR CONTACTS HIGH PRES CUTOUT 14 FUSE TRANS 1 2 3 3 HARVEST LIGHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13...

Page 37: ...WITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13 FAN CYCLE CONTROL COMPRESSOR START START CAPACITOR OVERLOAD PROTECTOR FAN MOTOR AIR COOLED ONLY...

Page 38: ...GHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13 FAN CYCLE CONTROL COMPRESSOR START START CAPACITOR OVERLOAD PROTECTOR FAN MOTOR AIR COO...

Page 39: ...0 21 10 11 7 8 6 5 9 4 12 13 FAN CYCLE CONTROL COMPRESSOR START START CAPACITOR OVERLOAD PROTECTOR FAN MOTOR AIR COOLED ONLY WATER PUMP HOT GAS SOLENOID CONTACTOR COIL ICE THICKNESS PROBE R 11 13 10 S...

Page 40: ...erCounter Ice Machines Sequence of Operation 40 Initial Start Push Toggle Switch to start making ice The toggle switch must be in the Ice On Position Bin Switch must be closed not sensing ice before t...

Page 41: ...CONTACTOR CONTACTS HIGH PRES CUTOUT 14 FUSE TRANS 1 2 3 3 HARVEST LIGHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13 FAN CYCLE CONTROL...

Page 42: ...e Contactor Coil 15 CONTACTOR CONTACTS HIGH PRES CUTOUT 14 FUSE TRANS 1 2 3 3 HARVEST LIGHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13...

Page 43: ...2 3 3 HARVEST LIGHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12 13 FAN CYCLE CONTROL COMPRESSOR START START CAPACITOR OVERLOAD PROTECTOR F...

Page 44: ...of Operation 44 4 Freeze 2 Start 5 Sec 1 Equal 15 Sec Energized Components Contactor Coil o Compressor o Fan motor potential to run Water Pump 4 Freeze Ice Thickness Probe 3 Pre chill 30 Sec NOTE Wat...

Page 45: ...of contact signals the control board to start a harvest cycle Water contact with the ITP will cause the red light on the control board to come on during freeze cycle Goal is a 1 8 Bridge thickness Se...

Page 46: ...Switch 3 5 Min Max 15 CONTACTOR CONTACTS HIGH PRES CUTOUT 14 FUSE TRANS 1 2 3 3 HARVEST LIGHT BIN SWITCH LIGHT CONTROL BOARD 2 TOGGLE SWITCH BIN SWITCH WASH OFF ON 22 24 23 20 21 10 11 7 8 6 5 9 4 12...

Page 47: ...Welbilt Inc Koolaire UnderCounter Ice Machines Sequence of Operation 47 5 Harvest Water Drain System Water inlet Float Siphon Cap Overflow drain Water Level Line Water Pump Discharge Hose...

Page 48: ...of Operation 48 5 Harvest Water Drain System Siphon Cap Over Flow Tube Water Trough Water Level Freeze Cycle Float Valve maintains water level during Harvest Cycle Water Pump stops and water overflow...

Page 49: ...Start 5 Sec 1 Equal 15 Sec Energized Components Contactor Coil o Compressor o Fan motor potential to run 4 Freeze Ice Thickness Probe 3 Pre chill 30 Sec 5 Harvest Bin Switch Bin Switch Opens Closes W...

Page 50: ...Sec 4 Freeze Ice Thickness Probe 3 Pre chill 30 Sec 5 Harvest Bin Switch Bin Switch Opens Stays open for more than 30 Seconds NOTE As the bin fills up the ice falling from the evaporator doesn t have...

Page 51: ...s Probe 3 Pre chill 30 Sec 5 Harvest Bin Switch The Ice machine remains off until enough ice has been removed Ice Damper swings back into the upright position Bin Switch Re Closes Ice Machine Restarts...

Page 52: ...Welbilt Inc Welbilt Inc Sequence of Operation Refrigeration System Koolaire UnderCounter Ice Machines 52...

Page 53: ...tion 53 Refrigeration System Freeze Cycle X Condenser Heat Exchanger Compressor Drier Hot Gas Solenoid Valve Thermostatic Expansion Valve Receiver Water Cooled Only HIGH PRESSURE VAPOR HIGH PRESSURE L...

Page 54: ...tion 54 Refrigeration System Harvest Cycle Condenser Heat Exchanger Compressor Drier Hot Gas Solenoid Valve Thermostatic Expansion Valve Receiver Water Cooled Only HIGH PRESSURE VAPOR HIGH PRESSURE LI...

Page 55: ...Counter Ice Machines Overview Sequence Of Operation o Control System o Pressure Equalization o Refrigeration System Start Up o Pre Chill o Freeze ITP Operation o Harvest Bin Switch Water Drain System...

Page 56: ...Welbilt Inc Welbilt Inc Troubleshooting Koolaire UnderCounter 56...

Page 57: ...Welbilt Inc 57 DIAGNOSING AN ICE MACHINE THAT WILL NOT RUN Koolaire UnderCounter Troubleshooting...

Page 58: ...n Ice Machine that will not run 58 Koolaire UnderCounter Ice Machines Troubleshooting 1 Verify primary voltage is supplied to ice machine and the fuse circuit breaker is closed Wire 4 L1 and 2 L2 120...

Page 59: ...l not run 59 Koolaire UnderCounter Ice Machines Troubleshooting 1 Verify primary voltage is supplied to ice machine and the fuse circuit breaker is closed 2 Verify control board fuse is okay NOTE If a...

Page 60: ...erify primary voltage is supplied to ice machine and the fuse circuit breaker is closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin sw...

Page 61: ...he fuse circuit breaker is closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin switch functions properly A defective bin switch can fal...

Page 62: ...Ice Machines Troubleshooting 5 Be sure Steps 1 4 were followed thoroughly Intermittent problems are not usually related to the control board Replace control board if user interface board does not corr...

Page 63: ...Welbilt Inc 63 DIAGNOSING AN ICE THICKNESS CONTROL NOT CYCLING INTO HARVEST Koolaire UnderCounter Troubleshooting...

Page 64: ...est 64 Koolaire UnderCounter Ice Machines Troubleshooting 1 Bypass the freeze time lock in by moving the ON OFF WASH switch to OFF and back to ON Wait until the water starts to flow over the evaporato...

Page 65: ...rom the ITP to any cabinet Ground o The harvest light comes on and 6 10 seconds later the ice machine cycles from freeze to harvest o The harvest light comes on but the ice machine stays in the freeze...

Page 66: ...not Cycle into Harvest 66 Koolaire UnderCounter Ice Machines Troubleshooting 3 Disconnect the ITP from the control board terminal Clip the jumper wire to the terminal on the control board and to any c...

Page 67: ...est light o The harvest light comes on and 6 10 seconds later the ice machine cycles from freeze to harvest o The harvest light comes on but the ice machine stays in the freeze sequence o The harvest...

Page 68: ...Welbilt Inc 68 DIAGNOSING AN ICE THICKNESS CONTROL CYCLES INTO PREMATURE HARVEST Koolaire UnderCounter Troubleshooting...

Page 69: ...Wait until the water starts to flow over the evaporator then monitor the harvest light Step 2 Disconnect the ice thickness probe from the control board terminal o The harvest light stays off and the i...

Page 70: ...Welbilt Inc 70 SAFETY LIMITS Koolaire UnderCounter Troubleshooting...

Page 71: ...mers that will shut the ice machine off to protect itself if there is a problem before causing further damage If a Safety Limit has shut down the ice machine the red Harvest light on the control board...

Page 72: ...es outside the time limit 1 hour Stand by Mode Safety 2 3 Consecutive 3 5 minute Harvest Cycles If the harvest time reaches 3 5 minutes the control board automatically returns the ice machine to the f...

Page 73: ...sure not between 20 and 80 psig 1 5 bar 138 552 kPa Incoming water temperature is not between 35 F 1 7 C and 90 F 32 2 C Water Filtration is plugged if used Vent tube is not installed on water outlet...

Page 74: ...ilt Inc Review 74 Koolaire UnderCounter Ice Machines Troubleshooting Ice Machine that will not run Ice Thickness Control o Not Cycling into Harvest o Premature Harvest Safety Limits Water System Check...

Page 75: ...Welbilt Inc Welbilt Inc Overview Koolaire Modular Ice Machines 75...

Page 76: ...e identifier has been added to upcoming model numbers KYT 500 A 261 ICE MACHINE MODEL ICE CUBE SIZE D DICE Y HALF DICE Ice Machine Series CONDENSER TYPE A SELF CONTAINED AIR COOLED W SELF CONTAINED WA...

Page 77: ...Welbilt Inc Component Identification 77 Koolaire Modular Ice Machines Overview Water Curtain Front View...

Page 78: ...Welbilt Inc Component Identification 78 Koolaire Modular Ice Machines Overview Control Box Evaporator Refrigeration Access Valves Toggle Switch Curtain Switch Float Switches Water Trough Front View...

Page 79: ...lt Inc Component Identification 79 Koolaire Modular Ice Machines Overview Control Box Evaporator Refrigeration Access Valves Toggle Switch Curtain Switch Float Switches Water Trough Front View Warning...

Page 80: ...ESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR Rotary Compressor Third Port Liquid Charging Damage may occur when charging liquid into the front discharge line service access port It is recommen...

Page 81: ...onent Identification 81 Koolaire Modular Ice Machines Overview R 410a Refrigeration Access Service Valves Control Board Compressor Run Capacitor Compressor Contactor On Off Clean Toggle Switch Front V...

Page 82: ...Welbilt Inc Component Identification 82 Koolaire Modular Ice Machines Overview Harvest Float Switch Ice Thickness Float Switch Water Pump Water Trough Compartment...

Page 83: ...should be about 1 8 3 mm thick 2 If adjustment is necessary turn the high water float clockwise to increase bridge thickness raising water level counterclockwise to decrease bridge thickness lowering...

Page 84: ...lt Inc Right Side 84 Koolaire Modular Ice Machines Overview Right Side Heat Exchanger High Pressure Cut out Discharge Manifold Strainer Water Inlet Solenoid Valve Water Dump Valve Curtain Switch Compr...

Page 85: ...Modular Ice Machines Overview Left Side Water pump Discharge hose TXV Bulb Evaporator Outlet TXV Evaporator Inlet Harvest Float Switch ITP Float Switch Cupra Nickel Water Cooled Condenser Water Regul...

Page 86: ...Overview Rear Water Cooled Electrical Connection Rear Data Plate 3 8 95cm Ice Making Water Inlet 1 27cm Ice Making Water Drain 1 27cm Condenser Water Drain 3 8 95cm Condenser Water Inlet Injection Mol...

Page 87: ...Traditional Remote Line sets 87 Koolaire Modular Ice Machines Overview Indigo NXT Koolaire Traditional Remote Ice machines have common Traditional Remote Line sets for stocking and ease of installatio...

Page 88: ...Welbilt Inc Review 88 Overview Component Identification o Front Control Box Ice Thickness Water Level Adjustment o Right Side o Left Side o Rear...

Page 89: ...Welbilt Inc Welbilt Inc Installation Koolaire Modular Ice Machines 89...

Page 90: ...Welbilt Inc Installation and Maintenance Manual 90 Koolaire Modular Installation...

Page 91: ...uit Amperage Chart 8 WaterSupply and Drain Requirements 9 Water Supply 9 Water Inlet Lines 9 Drain Connections 9 WaterSupply and Drain Line Sizing Connections 10 Water Cooled Condenser Water Pressure...

Page 92: ...not be near heat generating ovens dishwashers etc equipment or in direct sunlight and must be protected from weather The location must not obstruct air flow through or around the ice machine Refer to...

Page 93: ...0 6100 KT0700 12400 13700 KT1000 60 Hz 15400 17100 KT1000 50 Hz 14600 16200 KT1700 24700 29000 Ice Machine Heat of Rejection Ice machines like other refrigeration equipment reject heat through the con...

Page 94: ...rain fitting 2 Screw the leveling legs onto the bottom of the bin 3 Screw the foot of each leg in as far as possible 4 Move the ice machine into its final position 5 Level the ice machine by using a l...

Page 95: ...Modular Installation The air cooled baffle prevents condenser air from recirculating To Install 1 Loosen the back panel screws next to the condenser 2 Align the keyhole slots in the air baffle with th...

Page 96: ...Installation All Electrical work including wire routing and grounding must conform to all applicable national and local electrical codes If a power cord is used the wire size to the receptacle is depe...

Page 97: ...pe Thread 1 2 1 27 cm FPT I3300 Only 3 8 95 cm min inside diameter Ice Making Water Drain 1 2 1 27 cm Female Pipe Thread 1 2 1 27 cm min inside diameter Condenser Water Inlet 90 F 32 2 C Max Standard...

Page 98: ...Welbilt Inc 98 Koolaire Modular REMOTE INSTALLATION Koolaire Modular Installation...

Page 99: ...e Circuit Condenser Line Set KT1000 JCT1200 RT 20R R410 RT 35R R410 RT 50R R410 KT1700 JCT1500 RL 20R R410 RL 35R R410 RL 50R R410 Line Set Discharge Line Liquid Line RT 1 2 1 27cm 5 16 79cm RL 1 2 1...

Page 100: ...0 lbs 3 2 kg 230 VOLT 60 Hz MIN CIRCUIT AMPS 16 3 COMP R L A FREEZE 12 1 COMP R L A HARVEST L R A 66 0 FAN MOTOR 0 7 PUMP 0 4 SOLENOID 0 1 GEAR MOTOR 20 MAX CIRCUIT FUSE OR HACR CIRCUIT BREAKER CANADA...

Page 101: ...the bottom for air intake The front coupling panel and one other panel back or side must also be unobstructed Remote condenser installations consist of vertical and horizontal line sets between the i...

Page 102: ...nser Distances 102 Koolaire Modular Installation Maximum Line Set Run H R D 100 feet 30 5 meters Maximum Rise 35 feet 10 7 meters Maximum Drop 15 feet 4 5 meters Maximum Calculated Distance 150 feet 4...

Page 103: ...___ Calculated Rise Measured Drop 15 4 5 m Maximum _______x 6 6 ______ Calculated Drop Measured Horizontal Distance ______ Horizontal Distance Total Calculated Distance 150 45 7 m Maximum ______ Total...

Page 104: ...er valves Use these valves to recover any vapor charge from the line set When lengthening or shortening lines follow good refrigeration practices purge with nitrogen and insulate all tubing Do not cha...

Page 105: ...of Traditional Remote Line sets 105 Koolaire Modular Installation Indigo NXT Koolaire Traditional Remote Ice machines have common Traditional Remote Line sets for stocking and ease of installation Ca...

Page 106: ...r operator completed the warranty registration card Has the ice machine and bin been sanitized Is the ice thickness control set correctly Refer to Operational Checks to check set the correct ice bridg...

Page 107: ...lbilt Inc Review 107 Installation Installation Manual Location of Ice Machine Heat of Rejection Bin Installation Air Baffle Electrical Service Water and Drain Connections Line Set Installation Checkli...

Page 108: ...Welbilt Inc Welbilt Inc Removal of Parts Koolaire Modular Ice Machines 108...

Page 109: ...Welbilt Inc Remove Front Panel 109 Koolaire Modular Removal of Parts Loosen Screws on the front panel Pull the bottom of the panel out 45 degrees Lift off...

Page 110: ...Welbilt Inc Water Curtain 110 Koolaire Modular Removal of Parts Gently flex the curtain in the center and remove it from the right side Slide the left pin out...

Page 111: ...arts Only on Self Contained Air Cooled Ice Machines The Purpose is to keep air from blowing from the Compressor compartment into the evaporator compartment thus keeping the ice machine cleaner longer...

Page 112: ...Welbilt Inc Water Trough 112 Koolaire Modular Removal of Parts Pull 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 suppor...

Page 113: ...Removal of Parts Remove the water trough Grasp pump and pull straight down on pump assembly until water pump disengages and electrical connector is visible Disconnect the electrical connector Remove...

Page 114: ...est Float Switches 114 Koolaire Modular Removal of Parts For removal pull the Float Switches straight down to disengage Lower the Float Switches until the wiring connector is visible Disconnect the wi...

Page 115: ...Inc Water Distribution Tube 115 Koolaire Modular Removal of Parts Remove distribution tube by loosening the 2 two outer thumbscrews Pull the tube forward to release slip joint from water pump tubing c...

Page 116: ...Inc Evaporator Top Filler Panel 116 Koolaire Modular Removal of Parts The evaporator top filler panel does not have to be removed for every cleaning Remove by Remove top cover Lift evaporator top fill...

Page 117: ...dular Removal of Parts The washable filter on self contained ice machines is designed to catch dust dirt lint and grease Clean the filter with a mild soap and water Remove by Disengage tab holding air...

Page 118: ...Welbilt Inc Review 118 Removal of Parts o Panels o Water Curtain o Top Evaporator Cover o Water Trough o Water Pump o Float Switches o Water Distribution Tube o Evaporator Top Filler Panel o Air Filte...

Page 119: ...Welbilt Inc Welbilt Inc Cleaning Sanitizing Koolaire Modular Ice Machines 119...

Page 120: ...Cleaner or Sanitizer 120 Koolaire Modular Cleaning Sanitizing Cleaner for Lime and or Mineral Build up Sanitizer for Disinfecting KOOLAIRE Approved Manitowoc Ice Cleaner 000005163 Manitowoc Ice Saniti...

Page 121: ...ing Sanitizing 121 Koolaire Modular Cleaning Sanitizing Disassemble Clean and Sanitize Ice Machine and Bin Upon Installation and Minimum of Once Every Six Months Refer to Installation Use and Care Man...

Page 122: ...Welbilt Inc Water Curtain 122 Koolaire Modular Cleaning Sanitizing Clean and Sanitize All Surfaces...

Page 123: ...Welbilt Inc Interior 123 Koolaire Modular Cleaning Sanitizing Clean and Sanitize All Interior Surfaces...

Page 124: ...Welbilt Inc Clean Sanitize Float Switches 124 Koolaire Modular Cleaning Sanitizing Clean All Surfaces Rinse With Clean Water Dry Thoroughly Repeat with Sanitizer...

Page 125: ...Welbilt Inc Cleaning the Condenser 125 Koolaire Modular Cleaning Sanitizing Clean With Coil Cleaner and Water...

Page 126: ...Welbilt Inc Exterior Cleaning 126 Koolaire Modular Cleaning Sanitizing Wash with Mild soap and Water When Necessary...

Page 127: ...Welbilt Inc Review 127 Clean and Sanitize all Parts Cleaner or Sanitizer Water Curtain Interior Float Switches Condenser Exterior...

Page 128: ...Welbilt Inc Welbilt Inc Clean Sequence of Operation Koolaire Modular Ice Machines 128...

Page 129: ...tart up 1 Water Purge 2 Water Fill On Until water level float switch is satisfied 3 Clean or Sanitize 10 Minutes Rinse Sequence 4 Water Purge 45 Seconds 5 Water Fill On Until water level float switch...

Page 130: ...Welbilt Inc Review 130 Clean Sequence of Operation Purge Water Fill Circulation 6X Rinse and Flushes...

Page 131: ...Welbilt Inc Welbilt Inc Sequence of Operation Koolaire Modular Ice Machines 131...

Page 132: ...ubes It should be about 1 8 3 mm thick 2 If adjustment is necessary turn the high water float clockwise to increase bridge thickness raising water level counterclockwise to decrease bridge thickness l...

Page 133: ...Welbilt Inc Control System 133 Koolaire Modular Ice Machines Sequence of Operation Outputs Inputs...

Page 134: ...ay Clean LED Light Yellow Test Button Harvest Float Switch Connection Ice Thickness Float Switch Connection Bin Level Switch Connection 3 15 Amp Fuse Water Fill Relay Low Level Float LED Green Hight L...

Page 135: ...t 135 Koolaire Modular Ice Machines Sequence of Operation The toggle switch must be in the Ice Position Water curtain must be in place on the evaporator before the ice machine will start Push Toggle S...

Page 136: ...Welbilt Inc Purge 136 Koolaire Modular Ice Machines Sequence of Operation Water Pump Dump Valve Energized Parts 45 Sec Purge 1 Start Up...

Page 137: ...Welbilt Inc Delay 137 Koolaire Modular Ice Machines Sequence of Operation Nothing is energized Energized Parts 45 Sec Purge 5 Sec Delay 1 Start Up...

Page 138: ...ondenser Expansion Device Compressor Hot Gas Solenoid Valve High Side Pressure Decrease Hot Gas Solenoid Valve Energized Parts 45 Sec Purge Refrigeration Start 5 Sec Delay 5 Sec Equalize 1 2 Start Up...

Page 139: ...Start Contactor Coil Compressor and Fan Energized Parts 5 Sec Delay 5 Sec Equalize 1 2 Start Up Hot Gas Solenoid Valve Evaporator Condenser Expansion Device Compressor Hot Gas Solenoid Valve High Sid...

Page 140: ...ve Evaporator Condenser Expansion Device Compressor Hot Gas Solenoid Valve 120 Sec first cycle 30 Sec thereafter 3 Pre Chill 45 Sec Purge 5 Sec Compressor Refrigeration Start Contactor Coil Compressor...

Page 141: ...peration Harvest Float Switch Ice Thickness Float Switch Adding Water During the Pre Chill cycle the water inlet Solenoid Valve is energized filling the water trough Ice Thickness float switch gives i...

Page 142: ...hereafter 3 Pre Chill 45 Sec Purge 5 Sec Compressor Refrigeration Start Contactor Coil Compressor and Fan Water Pump Water Inlet Float Switch Activation Energized Parts 5 Sec Delay 5 Sec Equalize 1 2...

Page 143: ...Float Switch Ice Thickness Float Switch Adding Water During the freeze cycle the water pump energizes dropping the water in the sump trough and circulating the water over the evaporator Ice Thickness...

Page 144: ...nergizes dropping the water in the sump trough and circulating the water over the evaporator Ice Thickness float switch gives input to control board for water fill Maximum Water fill time limit is 6 M...

Page 145: ...e evaporator Ice Thickness float switch gives input to control board for water fill Maximum Water fill time limit is 6 Minutes Water level raises float switch 5 seconds and control board de energizes...

Page 146: ...ion and Open contacts in the up position During the freeze cycle the water in the trough freezes onto the evaporator surface dropping the water level When the Harvest Float Switch drops to its lowest...

Page 147: ...vaporator Condenser Expansion Device Compressor Hot Gas Solenoid Valve 120 Sec first cycle 30 Sec thereafter 3 Pre Chill 45 Sec Purge 5 Sec Compressor Refrigeration Start Contactor Coil Compressor and...

Page 148: ...Sec Compressor Refrigeration Start Hot Gas Solenoid Valve Contactor Coil Compressor and Fan Energized Parts 5 Sec Delay 5 Sec Equalize 1 2 Start Up 4 Freeze Ice Thickness Float Switch 5 Purge 45 Sec 6...

Page 149: ...5 Sec Compressor Refrigeration Start Contactor Coil Compressor and Fan Water Fill Valve Float Switch Activation Energized Parts 5 Sec Delay 5 Sec Equalize 1 2 Start Up 4 Freeze Ice Thickness Float Sw...

Page 150: ...Sec Purge 5 Sec Compressor Refrigeration Start 5 Sec Delay 5 Sec Equalize 1 2 Start Up 4 Freeze Ice Thickness Float Switch 5 Purge 45 Sec 6 Harvest Bin Switch Open for more than 30 seconds 7 Auto Shu...

Page 151: ...thereafter 3 Pre Chill 45 Sec Purge 5 Sec Compressor Refrigeration Start 5 Sec Delay 5 Sec Equalize 1 2 Start Up 4 Freeze Ice Thickness Float Switch 5 Purge 45 Sec 6 Harvest Bin Switch Reclose 7 Auto...

Page 152: ...OR Self contained Air cooled The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off y High Float is Satisfied for 5 continuous seconds Maximum Water fill during...

Page 153: ...Welbilt Inc Welbilt Inc Sequence of Operation Refrigeration System Koolaire Modular Ice Machines 153...

Page 154: ...ar Ice Machines Sequence of Operation Refrigeration System Discharge Valve Blade Spring Suction Hole Roller Shaft Cylinder Note The shell of the Rotary Compressor is part of the Discharge line as appo...

Page 155: ...t Inc Component Identification 155 Koolaire Modular Ice Machines Overview Control Box Evaporator Refrigeration Access Valves Toggle Switch Curtain Switch Float Switches Water Trough Front View Warning...

Page 156: ...APOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR Rotary Compressor Third Port Liquid Charging Damage may occur when charging liquid into the front discharge line service access port It...

Page 157: ...hines Sequence of Operation Refrigeration System X HEAT EXCHANGER THERMOSTATIC EXPANSION VALVE HARVEST VALVE CONDENSER COMPRESSOR DRIER EVAPORATOR Receiver Water Cooled Only HIGH PRESSURE VAPOR HIGH P...

Page 158: ...achines Sequence of Operation Refrigeration System HEAT EXCHANGER THERMOSTATIC EXPANSION VALVE HARVEST VALVE CONDENSER COMPRESSOR DRIER EVAPORATOR Receiver Water Cooled Only HIGH PRESSURE VAPOR HIGH P...

Page 159: ...ALVE HARVEST VALVE REMOTE CONDENSER HEADPRESSURE REGULATOR COMPRESSOR HPR SYSTEM CHECK VALVE CHECK VALVE D R C RECEIVER RECEIVER SERVICE VALVE DRIER LIQUID LINE SOLENOID VALVE STRAINER EVAPORATOR HIGH...

Page 160: ...ERMOSTATIC EXPANSION VALVE HARVEST VALVE REMOTE CONDENSER PRESSURE REGULATOR COMPRESSOR HPR SYSTEM CHECK VALVE CHECK VALVE D R C RECEIVER RECEIVER SERVICE VALVE DRIER LIQUID LINE SOLENOI D VALVE STRAI...

Page 161: ...ion System x x X Evaporator Condenser Heat Exchanger Drier Strainer Hot Gas Solenoid Valve Receiver HPR System Discharge Line Check Valve Head Pressure Regulating Valve R D C Liquid Line Check Valve R...

Page 162: ...Ice Machines Overview Component Identification Ice Making Sequence of Operation o Ice Thickness Adjustment o Initial Start Purge Refrigeration Start o Pre Chill o Freeze o Harvest Harvest Purge Harve...

Page 163: ...Welbilt Inc Welbilt Inc Troubleshooting Koolaire Modular Ice Machines 163...

Page 164: ...imit 2 Long Harvest 100 consecutive 7 minute Harvest cycles After 3 consecutive 7 minute Harvest cycles the control board records safety limit 2 in the memory Safety Limit 2 LED will flash on off and...

Page 165: ...off and on Upon restart the SL1 SL2 light will flash 3 times 120 Sec first cycle 30 Sec thereafter 3 Pre Chill 45 Sec Purge 5 Sec Compressor Refrigeration Start 5 Sec Delay 5 Sec Equalize 1 2 Start Up...

Page 166: ...lbilt Inc Safety Limit 166 Troubleshooting Description Board LED Control Board SL 1 Long Freeze After 3 Consecutive 60 minute Freeze cycles After 6 Consecutive 60 Minute Freeze Cycles Control Board LE...

Page 167: ...t Inc Description Board LED Control Board SL 2 Long Harvest After 3 Consecutive 3 5 Minute Harvest Cycles After 100 Consecutive 3 5 minute Harvest Cycles Safety Limit 167 Troubleshooting Control Board...

Page 168: ...Welbilt Inc Safety Limit 168 Troubleshooting Description Board LED Control Board SL 3 Water After 4 minutes energizing the water inlet valve with the Harvest Float Switch down Control Board LED s...

Page 169: ...arvest After 3 Consecutive 3 5 Minute Harvest Cycles After 100 Consecutive 3 5 minute Harvest Cycles SL 3 Water After 4 minutes energizing the water inlet valve with the Harvest Float Switch down To c...

Page 170: ...Welbilt Inc Welbilt Inc Troubleshooting Control Board Test Mode Koolaire Modular Ice Machine 170...

Page 171: ...Welbilt Inc 171 Troubleshooting CONTROL BOARD TEST MODE Koolaire Modular...

Page 172: ...Energizes all control board lights Energizes control board relays in one second interval Harvest Valve Solenoid Water Pump Dump Valve Water Inlet Valve Compressor Contactor Control Board Test Mode Pre...

Page 173: ...t mode the machine will start a new ice making sequence if the toggle switch is in the ice making position To Cancel a Test Cycle Press the test button a Second Time Control Board Test Mode Press and...

Page 174: ...Welbilt Inc 174 Troubleshooting DIAGNOSING AN ICE MACHINE THAT WILL NOT RUN Koolaire Modular...

Page 175: ...Inc Diagnosing an Ice Machine that will not run 175 Troubleshooting 1 Verify primary voltage is supplied to ice machine and the fuse circuit breaker is closed Wire 55 L1 and 56 L2 120 1 OFF COM VAC 0...

Page 176: ...Machine that will not run 176 Troubleshooting 1 Verify primary voltage is supplied to ice machine and the fuse circuit breaker is closed 2 Verify control board fuse is okay NOTE If any control board...

Page 177: ...tage is supplied to ice machine and the fuse circuit breaker is closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin switch functions pr...

Page 178: ...y primary voltage is supplied to ice machine and the fuse circuit breaker is closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin switch...

Page 179: ...reaker is closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin switch functions properly A defective bin switch can falsely indicate a f...

Page 180: ...ights are on the fuse is okay 3 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 4 Verify Toggle Switch functions properly A defective Toggle Swit...

Page 181: ...Welbilt Inc 181 Troubleshooting DIAGNOSING AN ICE MACHINE THAT WILL NOT CYCLE INTO HARVEST Koolaire Modular...

Page 182: ...minals connected to the control board Step 2 Bypass the freeze time lock in feature by cycling the toggle switch off and then back on Wait until water flows over the evaporator then refer to chart Res...

Page 183: ...Welbilt Inc Float Switch Diagnostics 183 Troubleshooting Float Down Closed Switch Float Up Open Switch NOTE Both Float Switch s operate and Ohm out the same...

Page 184: ...Welbilt Inc 184 Troubleshooting DIAGNOSING AN ICE MACHINE THAT CYCLES INTO PREMATURE HARVEST Koolaire Modular...

Page 185: ...s over the evaporator then refer to chart Result Correction The harvest light does not come on The Harvest float switch or wire is causing the malfunction Refer to Float Switch Diagnostics The harvest...

Page 186: ...Welbilt Inc Float Switch Diagnostics 186 Troubleshooting Float Down Closed Switch Float Up Open Switch NOTE Both Float Switch s operate and Ohm out the same...

Page 187: ...Welbilt Inc 187 Troubleshooting TROUBLESHOOTING REFRIGERATION SYSTEM Koolaire Modular...

Page 188: ...ore proceeding ________ _______ _______ 1 minute Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into the freeze...

Page 189: ...ne ___ Water temp entering sump trough ____ 2 Find Published 24 hr ice production ____ 3 Perform ice production check using the formula 4 Compare results of step 3 with step 2 Ice production is normal...

Page 190: ...he ice machine been installed where ambient temperatures will remain in the range of 40 110 F 4 43 C Has the ice machine been installed where the incoming water temperature will remain in the range of...

Page 191: ...Welbilt Inc Refrigeration Troubleshooting 191 Troubleshooting Ice Formation Normal Thin at Inlet Very Thin or No Ice at Outlet No Ice...

Page 192: ...s table before proceeding ________ _______ _______ 1 minute Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into...

Page 193: ...mponents not listed on this table before proceeding ________ _______ _______ 1 minute Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is...

Page 194: ...is High Suction pressure is High Wait 5 minutes into the freeze cycle Compare temperatures of evaporator inlet evaporator outlet Inlet______ F C Outlet ______ F C Difference______ F C Inlet and outlet...

Page 195: ...Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into the freeze cycle Compare temperatures of evaporator inlet ev...

Page 196: ..._______ 1 minute Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into the freeze cycle Compare temperatures of e...

Page 197: ...before proceeding ________ _______ _______ 1 minute Middle End Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into the fre...

Page 198: ...Welbilt Inc Review 198 Troubleshooting Safety Limits Control Board Test Mode Will not Run Not Cycling into Harvest Prematurely Harvesting Float Switch Diagnostics Refrigeration System...

Page 199: ...Inc Welbilt Inc Manitowoc Ice Training videos 199 Service Training Update Indigo NXT Firmware Upgrade Manitowoc Ice Technical Training Videos Indigo NXT PM Cleaning RN RF Cleaning Indigo NXT Detailed...

Page 200: ...Welbilt Inc CLEVELAND CONVOTHERM DELFIELD FITKITCHENSM FRYMASTER GARLAND KOLPAK LINCOLN MANITOWOC MERCO MERRYCHEF MULTIPLEX SUPPORTED BY KITCHENCARE Thank You For Attending...

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