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ELECTRONIC MODULAR
FLAKERS

SERVICE MANUAL

104409

F

80

104436

F

125

71503

135-0-000

service Flakers GB

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2
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Summary of Contents for F 120

Page 1: ...ELECTRONIC MODULAR FLAKERS SERVICE MANUAL 104409 F80 104436 F125 71503135 0 000 service Flakers GB ...

Page 2: ......

Page 3: ...3 Installation pratice 14 OPERATING INSTRUCTIONS Start up 15 Operations checks 17 PRINCIPLE OF OPERATION how it works Water circuit 20 Refrigerant circuit 21 Mechanical system 23 Operating pressures 24 Components description 25 ADJUSTMENT REMOVAL AND REPLACEMENT PROCEDURES Adjustment of the evaporator water level 29 Replace of the gear motor magnetic sensor 29 Replace of auger water seal bearing a...

Page 4: ...iales según pedido Capacità deposito Storage bin capacity Inhalt des Vorrats Eisbehänders Capacité de la réserve Capacidad del deposito Carrozzeria External structure Ausfühnrung inox Carrosserie Carroceria Peso netto Net weight Netto Gewcht Poids net Peso neto PRODUZIONE DI GHIACCIO ICE PRODUCTION EIS PRODUKTION PRODUCTION DE GLACE PRODUCICON DE HIELO RAFFR AD ACQUA WATER COOLED WASSERGEKÜHLT REF...

Page 5: ...gún pedido Capacità deposito Storage bin capacity Inhalt des Vorrats Eisbehänders Capacité de la réserve Capacidad del deposito Carrozzeria External structure Ausfühnrung inox Carrosserie Carroceria Peso netto Net weight Netto Gewcht Poids net Peso neto PRODUZIONE DI GHIACCIO ICE PRODUCTION EIS PRODUKTION PRODUCTION DE GLACE PRODUCICON DE HIELO RAFFR AD ACQUA WATER COOLED WASSERGEKÜHLT REFR A EAU ...

Page 6: ...he carton box to the skid b Cut open the top of the carton and remove the polystyre protection sheet c Pull out the polystyre posts from the cor ners and then remove the carton d Lift the whole carton and pull it out from the device 4 Remove top and sides panels of the unit and inspect for any concealed damage Notify carrier of your claim for the concealed damage as stated in step 2 above 5 Remove...

Page 7: ...ections All icemakers require a solid earth wire All ice machines are supplied from the factory completely pre wired and require only electrical power connections to the wire cord provided at the rear of the unit Make sure that the ice machine is connected to its own circuit and individually fused see data plate for fuse size The maximum allowable voltage variation should not exceed 10 and 10 of t...

Page 8: ...and the other for the water cooled condenser Connect the 3 4 GAS male fitting of the water inlet using the flexible hose supplied to the cold water supply linewith regular plumbing fitting and a shut off valve installed in an accessible position between the water supply line and the unit WATER DRAIN The recommended drain tube is a plastic or fle xible hose with 18mm 3 4 I D which runs to an open t...

Page 9: ...ted on the importan ce of periodic maintenance checks 11 Has the Manufacturer s registration card been filled in properly Check for correct model and serial number against the serial plate and mail the registra tion card to the factory 12 Has the owner been given the name and the phone number of the authorized Service Agency serving him G INSTALLATION PRACTICE WARNING This icemaker is not designed...

Page 10: ...on in sequence of the following assemblies GEAR MOTOR S COMPRESSOR FAN MOTOR S if unit is an air cooled version kept under control by the condenser temperatu resensorwhichhasitsprobewithinthecondenser fins Fig 2 C After 2 or 3 minutes from the compressor start up observe that flaker ice begins dropping off the ice spout to fall through the ice chute into the storage bin NOTE The first ice bits tha...

Page 11: ...DENSER TEMP EVAPORATOR TEMP ICE LEVEL CONTROL TRANSF T 40 50 C DATA PROCESSOR 2 1 L N COMPRESSOR 9 10 11 12 13 3 4 5 6 7 8 CONTACTOR COIL GEAR MOTOR FAN MOTOR ELECTRONIC CARD RELAYS TRIAC RESET S E N S O R S DATA PROCESSOR WATER LEVEL GEAR MOTOR ROTATION CONDENSER TEMP EVAPORATOR TEMP ICE LEVEL CONTROL TRANSF T 1 C 11 10 9 1 2 L N 8 7 6 5 4 3 10 9 1 2 L N 8 7 6 5 4 3 12 11 13 13 12 ...

Page 12: ...perature sensor which is located within the condenser fins keeps the head condensing pressure between preset values In the event of condenser clogged such to prevent the proper flow of the cooling air or in case the fan motor is out of operation the condenser temperature rises and when it reaches 70 C 160 F for air cooled version and 60 C 140 F for water cooled version the condenser temperature se...

Page 13: ...e a gradual decrease of the water level in the float reservoir and as soon as the level gets below the two vertical metal pins the flaker stops to operate compressor first and 3 laterthegearreducer andtheYELLOWwarning LED will glow to signal the shortage of water Fig 4 NOTE The water level sensor detects the presence of water in the float reservoir and confirms it to the micro processor by maintai...

Page 14: ...control By means of its screw it is possible to modify the signal received from the Ice Level control so to overcame some problem caused by dirt and or low power supply When adjusted it is very important to check for its correct operation using ice NOT HAND to break the Infrared Beam In case the machine doesn t stop it means that the new setting is too much powerfull and need to bereducedalwaysbym...

Page 15: ...of the auger The auger rotates counter clockwisewithin the freezer powered by a direct drive gear motor and carries the ice upward along the refrigerated freezer innerwalls andbydoingso theice gets progressively thicker and harder The ice being costantly lifted up meet the teeth of the ice breakerwhich is fitted on the top end of the auger where it gets compacted cracked and forced to change from ...

Page 16: ...ion accumulator and through the suction line where the refrigerant exchanges heatwith the one flowing into the capillary tube warmer befo rebeingsuckedinto thecompressor to be recircu lated The refrigerant head pressure is kept between two pre set values 8 9 bar 110 125 psig on F120 by the condenser temperature sensorwhi ch has its probe locatedwithin the condenser fins in air cooled versions This...

Page 17: ... it causes the total and immediateSHUT OFF of the machine compressor first and gear motor 3 later in order to prevent the unit from opera ting in abnormal and dangerous conditions When the ice maker stops on account of this protective device there is a simultaneous glowing of the RED LED warning the user of the Hi Temperature situation The machine will remain in OFF mode for one hour then it will ...

Page 18: ...f respectively 10 C and 5 C 50 F and 40 F or frequent interruptions of the water supply to the freezing cylinder clogging of thewater hose connecting the float reservoir to the water inlet at the bottom of the freezer may cause the ice to get too hard and compact loosing fluidity and the reby seizing the auger This situation will put under excessive strain and load the entire drive system and free...

Page 19: ...9 bar 8 5 bar Pression suction 0 5 bar 0 5 bar Working pression with 21 C ambient temperature Pression discharge 17 18 bar 17 bar Pression suction 2 5 bar 2 5 bar NOTE Before charging the refrigerant system always check thetypeof refrigerantandquan tity as specified on the individual ice machine dataplate The refrigerant charges indicated are relatives to averages operating condi tions GB 19 ...

Page 20: ...ation the sensor signals to the P C BOARD to do not start up the unit till the ambient temperature rises to 10 C In the air cooled versions in relation to the diffe rent current transmitted the micro processor of the P C BOARD supplies through a TRIAC the power at high voltage to the fan motor In the event the condenser temperature rises and reaches 60 C or 70 C according to the setting of DIP SWI...

Page 21: ...n of the light beam between the two infrared sensor of ice level control YELLOW LED blinks fast 6 seconds later the ice machi ne resumes its operation with the simultaneous extinguishing the 2nd YELLOW LED NOTE The machine will remain in OFF mode for one hour then itwill restart automatically In case the unit trips OFF again in alarm for 3 times in 3 hours the machine SHUTS OFF DEFINITIVELY To res...

Page 22: ... I T P O T E K C O S R O S N E S L O R T N O C L E V E L E C I L A C I T P O T E K C O S R O S N E S L O R T N O C L A N I M R E T D R A O B L A N I M R E T D R A O B E S U F E S U F C A I R T C A I R T R O S S E R P M O C Y A L E R R O S S E R P M O C Y A L E R R O T O M E V I R D Y A L E R R O T O M E V I R D Y A L E R M O R P E R P O R C I M M O R P E R P O R C I M E T O M E R T E K C O S E T O...

Page 23: ... auger which rotates on its vertical axis and it is maintained aligned by the top and bottom bearings A water seal system is located in the bottom part of the freezer while at the top end is fitted the ice breaker The water constantly flowing into the cylinder bottompart freezes into ice when in contact with the cylinder inner walls The ice is then lif ted up by the rotating auger and compacted an...

Page 24: ...version The fanmotor is controlled through the TRIAC of the P C BOARD by the condenser temperature sensor Normally it operates to draw cooling air through the condenser fins In cold ambient situation the fan motor can run at intermittance as the condenser pressuremust be kept between two corresponding head pres sure values M Water regulating valve This valve controls the head pressure in the refri...

Page 25: ...gearmotor magnetic sensor 1 On F80 F120 remove the front top and side rear panels top and left side panels 2 Unloose the three screws securing the pla stic cover to the top of the gear motor and remove it 3 Unloose the two screws securing the magne tic sensor to the plastic housing and with draw it from its seat 4 Trace the gear motor magnetic sensor termi nal plug on the rear side of the control ...

Page 26: ...2 Search for the terminal of the single sensor with two red mandrels in the back part of the switch box and pull them out of their position through pressing on the fastening strap 3 Pull off the terminals for the electrical con nections of the back part of the control card and then remove the whole control card by loosening the four screws with which it is fastened in the electrical switch box mad...

Page 27: ... the screw the remaining models of the steel ring must be pulled out with a spring 10Loosen and remove the three four bolts which are used to fasten the aluminum container underneath the evaporator 11Lift the evaporator and raise it from its contai ner After that push a wooden or plastic tool with a suitable knife and length in the upper part of the evaporator so that it can be pressed out from th...

Page 28: ...ar motor 1 For the F125 Model the front upper and the side back plate 2 Loosen the three four screws which are used to fasten the evaporator on the upper casing 3 Remove the sensors for the engine rotating direction according to the instructions in Point B Loosen the screws which are used to fasten the gear motor on the framework 4 Interruption of the supply of power of the motor through the elect...

Page 29: ...he collection sucking unit from the outflow pipe of the evaporator 6 Loosen the three four bolts which are used to fasten the evaporator on the upper casing of the gear motor 7 Remove the evaporator of the gear motor and if necessary remove the aluminum con tainer by loosening the three four bolts of the evaporator 8 For the installation of the new evaporator the process used in a reverse order M ...

Page 30: ...tion Then remove it from the device 7 For the installation of the new condensers use the process in reverse order P Change of the compressor 1 For the F 125 Model the front upper and the side back plate 2 Remove the cover and pull out the electrical cable from the terminals of the compressor 3 Remove the cooling agent from the system and let it flow into a particular container to be able to recycl...

Page 31: ...TE Carefully purged the refrigerant circuit to remove moisture and non condensable gases after the replacement of the condenser NOTE Replace the dryer filter whenever the refrigerant circuit is opened Do not apply the new filter dehumidifier until all repairs or repla cements have been made ...

Page 32: ...ITA POWER AUFGENOMME NE LEISTUNG ASS MARCIA AMPS AMP BETRIEB ASS AVVIAMENTO START AMPS AMP START CONSUMO ELETTRICO POWER CONS STROMVERBRAUCH ASSORBIMENTO MOTORIDUTTORE AMPS MOTOREDUCT AUFNAHME GETRIE BEMOTOR 3000mm F80 A W 230 50 1 ELECTROLUX R134a 300 300 gr D int 0 90 400W 2 6A 11A 0 200A 9 6 KWH 24 HR GL90TB R134A D 2 2mm 2500mm F125 A W 230 50 1 UNITE HERMETIQUE R134A 400 300gr D int 1 00 480W...

Page 33: ...H SS ST SO CA CT F CS LEGENDE Ventilatoren Schrittmotor Verdichter Platine Led Schalter Wasserniveau Rotationfu h ler Kondensator Fu h ler Verdampfer Fu h ler Optischer Sensor Anschlusskabel Steckverbinder Verriegelung STart Kondensator LEGEND Fan Gearmotor Compressor Electronic card Led card Water level Rotation probe Condenser probe Evaporator probe Fotoswitch system Power cable Terminal for cab...

Page 34: ...E Wasser Ventil Pressostat Schrittmotor Verdichter Platine Led Schalter Wasserniveau Rotationfuühler Kondensator Fuühler Verdampfer Fuühler Optischer Sensor Anschlusskabel Steckverbinder Verriegelung Start Kondensator LEGEND Water solenoid valve Pressure control Gearmotor Compressor Electronic card Led card Water level Rotation probe Condenser probe Evaporator probe Fotoswitch system Power cable T...

Page 35: ...T SO CA CT F CS LEGENDE Ventilatoren Schrittmotor Verdichter Platine Led Schalter Wasserniveau Rotationfu h ler Kondensator Fu h ler Verdampfer Fu h ler Optischer Sensor Anschlusskabel Steckverbinder Verriegelung STart Kondensator LEGEND Fan Gearmotor Compressor Electronic card Led card Water level Rotation probe Condenser probe Evaporator probe Fotoswitch system Power cable Terminal for cables Lo...

Page 36: ...alarm water cooled J3 off Verspätung 3 Aus 3 delay off Verspätung 3 Aktiv 3 delay on LEGENDE Wasser Ventil Pressostat Schrittmotor Verdichter Platine Led Schalter Wasserniveau Rotationfuühler Kondensator Fuühler Verdampfer Fuühler Optischer Sensor Anschlusskabel Steckverbinder Verriegelung Start Kondensator LEGEND Water solenoid valve Pressure control Gearmotor Compressor Electronic card Led card ...

Page 37: ...d Check wiring Replace or clean ice level control See remedies for shortage of water Install a mineral salt metering device Dirty condenser Clean INOPERATIVE fan motor Replace Move unit in warmer location None Wait the elapsed of 3 Check and charge refrigerant system Replace Check stator winding and capacitor Check rotor bearings freezer bearings and interior of freezer for scores Replace whatever...

Page 38: ...nd fasten hose clamp Check and adjust float valve setting screw Tighten screws holding the spout Excessive noise or chatte ring Mineral or scale deposit on auger and inner freezer walls Low suction pressure Water feed line to freezer clogged Low water level into freezer Worn freezer bearings Remove and manually polish auger and inner walls of freezer barrel using emery paper Add refrigerant to ris...

Page 39: ... removed with the help of a bit of cleaner 7 With the ice machine and fan motor OFF on air cooled models clean condenser using vacuum cleaner whisk broom or non metallic brush taking care to do not damage the con denser ambient temperature sensor 8 Check for water leaks and tighten drain line connections Pourwater down bin drain line to be sure that drain line is open and clear 9 Check the ice lev...

Page 40: ...r level sensor 6 Place a water pan under the freezer water inlet port disconnect the water hose from this port and allow the water from the freezer to flow into the pan Then refit the water hose to the freezer water inlet port 7 Prepare the cleaning solution in a plastic container r 8 Pour the cleaning solution into the water reservoir 9 Wait till the machine starts to discharge ice then continue ...

Page 41: ...emove the copper wire used to jump the two sensors for the water level and place back correctly the cover on the float reser voir ATTENTION use ice produced with the cleaner solution Be sure none remains in the bin NOTE The ice produced with the decalcifi cation solution is yellowish and smooth In this phase there are loud noises from the freezer due to the rubbing between the rising ice and the e...

Page 42: ...71503135 0 000 service Flakers GB ...

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