AF 80 AF 100 AF 200 AF 20 AF 30 - ndustrio.com · ISO 9001 - Cert. n. 0080 SERVICE MANUAL AF 80 AF 100 AF 200 AF 20 AF 30 S Electronic flakers with storage MS 1000.73 REV. 05/2009

Page 1Page 1

SCOTSMAN EUROPE - FRIMONT SPAVia Puccini, 22 - 20010 Pogliano M.se - Milano - ItalyTel. +39-02-93960.1 (Aut. Sel.)- Telefax +39-02-93550500Direct Line to Service & Parts:Phone +39-02-93960350 - Fax +39-02-93540449Website: www.scotsman-ice.comE-Mail: [email protected]

ISO 9001 - Cert. n. 0080

SERVICE MANUAL

AF 80AF 100AF 200

AF 20AF 30

S

Electronic flakerswith storage

MS 1000.73 REV. 05/2009

Page 2Page 2

TABLE OFCONTENTS

Table of contents page 2Specifications AF 80 3Specifications AF 100 5Specifications AF 200 7Specifications AF 20 9Specifications AF 30 11

GENERAL INFORMATION AND INSTALLATION

Introduction 13Unpacking and Inspection 13Location and levelling 13Electrical connections 14Water supply and drain connections 14Final check list 14Installation practice 15

OPERATING INSTRUCTIONS

Start up 16Operational checks 18

PRINCIPLE OF OPERATION (How it works)

Water circuit 21Refrigerant circuit 21Mechanical system 23Operating pressures 24Components description 25

ADJUSTMENT, REMOVAL AND REPLACEMENT PROCEDURES

Adjustment of the evaporator water level 28Replacement of evaporator temperature sensor 28Replacement of condenser temperature sensor 28Replacement of ice level light control 28Replacement of the gear motor rotation and speed sensor 28Replacement of the reservoir water level sensor 29Replacement of P.C. Board 29Replacement of the ice spout 29Replacement of the auger, water seal, bearings and coupling 29Replacement of the gear motor assy 30Replacement of fan motor 30Replacement of drier 30Replacement of the freezing cylinder 30Replacement of air cooled condenser 31Replacement of water cooled condenser 31Replacement of water regulating valve (water cooled models) 31Replacement of compressor 32Wiring diagram 33Service diagnosis 34

MAINTENANCE AND CLEANING INSTRUCTIONS

General 36Icemaker 36Cleaning instructions of water system 36

Page 3Page 3

SPECIFICATIONS

ice making capacity

ELECTRONIC FLAKER MODEL AF 80

NOTE. With the unit in “built-in” conditions, the ice production is gradually reduced in respect to thelevels shown in the graph, up to a maximum of 10% at room temperatures higher than 32°C.The daily ice-making capacity is directly related to the condenser air inlet temperature, watertemperature and age of the machine.To keep your SCOTSMAN FLAKER at peak performance levels, periodic maintenance checksmust be carried out as indicated on page 36 of this manual.

Important operating requirements:

MIN MAX- Air temperature 10°C (50°F) 40°C (100°F)- Water temperature 5°C (40°F) 40°C (100°F)- Water pressure 1 bar (14 psi) 5 bars (70 psi)- Electr. voltagevariations fromvoltagerating specifiedon nameplate -10% +10%

32

38

10

21

7 5

7 0

6 5

6 0

5 5

5 0

4 5

K g .

32 °C21 15

°Co

o

AIR COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

3238

10

21

7 5

7 0

6 5

6 0

5 5

5 0

4 5

K g .

32 °C21 15

°Co

o

WATER COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

Page 4Page 4

Start Electric power cons.Amps Kwh per 24 HRBasic electr. Amps Watts Nr. of wires Amps fuse

SPECIFICATIONS

Model Cond. unit Finish Comp. HPIce bin

capWater req.lt/24 HR

AF80 - MACHINE SPECIFICATIONS

Dimensions:

HEIGHT (less legs) 813 mm.HEIGHT (with legs) 933 mm.WIDTH 535 mm.DEPTH 621 mm.WEIGHT 72 Kg.

230/50/1 2.2 11 330 7.5 3 x 1.5 mm2 10

S. Steel 1/4 25 Kg.AF80 AS Air 53**AF80 WS Water 300*

* A 15°C water temperature

Page 5Page 5

SPECIFICATIONS

ice making capacity




NOTE. The daily ice-making capacity is directly related to the condenser air inlet temperature, watertemperature and age of the machine.To keep your SCOTSMAN FLAKER at peak performance levels, periodic maintenance checksmust be carried out as indicated on page 36 of this manual.

32

38

10

21

120

115

110

105

100

95

90

85

80

K g .

10 °C27 21 15

°Co

o

AIR COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

Page 6Page 6


SPECIFICATIONS




Dimensions:



230/50/1 2.2 11 400 9 3 x 1.5 mm2 10

S. Steel 1/4 32 Kg.AF 100 AS Air 85**AF 100 WS Water 600*

Page 7Page 7

SPECIFICATIONS

ice making capacity





32

38

10

21

120

115

110

105

100

95

90

85

80

K g .

32 10 °C27 21 15

°Co

o

AIR COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

3238

10

21

120

115

110

105

100

95

90

85

80

K g .

°C

°Co

o

WATER COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

Page 8Page 8

AF 200 AS Air 100*AF 200 WS Water 580*S. Steel 3/8 32 Kg.


SPECIFICATIONS



AF 200 - MACHINE SPECIFICATIONS

Dimensions:



230/50/1 3.5 18 760 12 3 x 1.5 mm2 10

Page 9Page 9

SPECIFICATIONS

ice making capacity




32

38

10

21

120

115

110

105

100

95

90

85

80

K g .

32 10 °C27 21 15

°Co

o

AIR COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

32

38

10

21

120

115

110

105

100

95

90

85

80

K g .

32 10 °C27 21 15

°Co

o

WATERCOOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.


Page 10Page 10


SPECIFICATIONS




Dimensions:



230/50/1 3.2 17 500 11 3 x 1 mm2 10

S. Steel 3/8 70 Kg.AF 20 AS Air 120**AF 20 WS Water 600*

Page 11Page 11

SPECIFICATIONS

ice making capacity




32

38

10

21

190

180

170

160

150

140

130

120

110

K g .

32 10 °C27 21 15

°Co

o

AIR COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.

32

38

10

21

190

180

170

160

150

140

130

120

110

K g .

32 10 °C27 21 15

°Co

o

WATER COOLED MODELS

WATER TEMPERATURE

AM

BIE

NT

TE

MP

ER

AT

UR

E

ICE

PR

OD

UC

ED

PE

R 2

4 H

RS

.


Page 12Page 12

S. Steel 1/2 70 Kg.


SPECIFICATIONS




Dimensions:



230/50/1 3.8 20 600 14 3 x 1 mm2 10

AF 30 AS Air 185*AF 30 WS Water 840*

Page 13Page 13

GENERAL INFORMATION AND INSTALLATION

A. INTRODUCTION

This manual provides the specifications and thestep-by-step procedures for the installation, start-up and operation, maintenance and cleaning forthe SCOTSMAN AF series icemakers.The Electronic Flakers are quality designed,engineered and manufactured.Their ice making systems are thoroughly testedproviding the utmost in flexibility to fit the needsof a particular user.

NOTE. To retain the safety and performancebuilt into this icemaker, it is important thatinstallation and maintenance be conductedin the manner outlined in this manual.

B. UNPACKING AND INSPECTION

1. Call your authorized SCOTSMAN Distributoror Dealer for proper installation.

2. Visually inspect the exterior of the packingand skid. Any severe damage noted should bereported to the delivering carrier and a concealeddamage claim form filled in subjet to inspection ofthe contents with the carrier’s representativepresent.

3. a) Cut and remove the plastic strip securingthe carton box to the skid.

b) Cut open the top of the carton and removethe polystyre protection sheet.

c) Pull out the polystyre posts from thecorners and then remove the carton.

4. Remove the front and the rear panels of theunit and inspect for any concealed damage.Notify carrier of your claim for the concealeddamage as stated in step 2 above.

5. Remove all internal support packing andmasking tape. (Leg package and water inlet andoutlet hoses are located in the storage bincompartment).

6. Check that refrigerant lines do not rub againstor touch other lines or surfaces, and that the fanblades move freely.

7. Check that the compressor fits snugly ontoall its mounting pads.

8. Use clean damp cloth to wipe the surfacesinside the storage bin and the outside of thecabinet.

9. See data plate on the rear side of the unitand check that local main voltage correspondswith the voltage specified on it.

CAUTION. Incorrect voltage supplied tothe icemaker will void your partsreplacement program.

10. Remove the manufacturer’s registration cardfrom the inside of the User Manual and fill-in allparts including: Model and Serial Number takenfrom the data plate.Forward the completed self-addressedregistration card to SCOTSMAN EUROPEfactory.

11. If necessary fit the four legs into their seatson the machine base and adjust them to thedesired level.

C. LOCATION AND LEVELLING

WARNING. This Ice Flaker is designed forindoor installation only. Extended periodsof operation at temperature exceedingthe following limitations will constitutemisuse under the terms of the SCOTSMANManufacturer’s Limited Warrantyresulting in LOSS of warranty coverage.

1. Position the unit in the selected permanentlocation.Criteria for selection of location include:a) Minimum room temperature 10°C (50°F)and maximum room temperature 40°C (100°F).b) Water inlet temperatures: minimum 5°C(40°F) and maximum 35°C (90°F).c) Well ventilated location for air cooled models(Clean the air cooled condenser at frequentintervals).d) Service access: adequate space must beleft for all service connections through the rear ofthe ice maker. A minimum clearance of 15 cm(6") must be left at the sides of the unit for routingcooling air drawn into and exhausted out of thecompartment to maintain proper condensingoperation of air cooled models.

2. Level the unit in both the left to right and frontto rear directions.

D. ELECTRICAL CONNECTIONS

See data plate for current requirements todetermine wire size to be used for electricalconnections. All SCOTSMAN icemakers requirea solid earth wire.

Page 14Page 14

All SCOTSMAN ice machines are supplied fromthe factory completely pre-wired and require onlyelectrical power connections to the wire cordprovided at the rear of the unit.Make sure that the ice machine is connected toits own circuit and individually fused (see dataplate for fuse size).The maximum allowable voltage variation shouldnot exceed -10% and +10% of the data platerating. Low voltage can cause faulty functioningand may be responsible for serious damage tothe overload switch and motor windings.

NOTE. All external wiring should conform tonational, state and local standards andregulations.

Check voltage on the line and the ice maker’sdata plate before connecting the unit.

E. WATER SUPPLY AND DRAINCONNECTIONS

GENERAL

When choosing the water supply for the ice flakerconsideration should be given to:a) Length of runb) Water clarity and purityc) Adequate water supply pressure

Since water is the most important single ingredientin producting ice you cannot emphasize toomuch the three items listed above.Low water pressure, below 1 bar may causemalfunction of the ice maker unit.Water containing excessive minerals will tend toproduce scale build-up on the interior parts of thewater system while too soft water (with too locontents of mineral salts), will produce a veryhard flaker ice.

WATER SUPPLY

Connect the 3/4" GAS male of the water inletfitting, using the flexible hose supplied to the coldwater supply line with regular plumbing fittingand a shut-off valve installed in an accessibleposition between the water supply line and theunit.If water contains a high level of impurities, it isadvisable to consider the installation of anappropriate water filter or conditioner.

WATER SUPPLY - WATER COOLED MODELS

The water cooled versions of SCOTSMAN IceMakers require two separate inlet water supplies,one for the water making the flaker ice and theother for the water cooled condenser.

Connect the 3/4" GAS male fitting of the waterinlet, using the flexible hose supplied to the coldwater supply line with regular plumbing fittingand a shut-off valve installed in an accessibleposition between the water supply line and theunit.

WATER DRAIN

The recommended drain tube is a plastic orflexible hose with 18 mm (3/4") I.D. which runs toan open trapped and vented drain. When thedrain is a long run, allow 3 cm pitch per meter(1/4" pitch per foot).Install a vertical open vent on drain line high pointat the unit drain connection to ensure gooddraining.The ideal drain receptacle is a trapped andvented floor drain.

WATER DRAIN - WATER COOLED MODELS

Connect the 3/4" GAS male fitting of thecondenser water drain, utilizing a second flexiblehose to the open trapped and vented drain.This additional drain line must not interconnect toany other of the units drains.

NOTE. The water supply and the water drainmust be installed to conform with the localcode. In some case a licensed plumber and/or a plumbing permit is required.

F. FINAL CHECK LIST

1. Is the unit in a room where ambienttemperatures are within a minimum of 10°C(50°F) even in winter months?

2. Is there at least a 15 cm (6") clearancearound the unit for proper air circulation?

3. Is the unit level? (IMPORTANT)

4. Have all the electrical and plumbingconnections been made, and is the water supplyshut-off valve open?

5. Has the voltage been tested and checkedagainst the data plate rating?

6. Has the water supply pressure been checkedto ensure a water pressure of at least 1 bar(14 psi).

7. Have the bolts holding the compressor downbeen checked to ensure that the compressor issnugly fitted onto the mounting pads?

Page 15Page 15

11. Has the Manufacturer’s registration cardbeen filled in properly? Check for correct modeland serial number against the serial plate andmail the registration card to the factory.

12. Has the owner been given the name and thephone number of the authorized SCOTSMANService Agency serving him?

8. Check all refrigerant lines and conduit linesto guard against vibrations and possible failure.

9. Have the bin liner and cabinet been wipedclean?

10. Has the owner/user been given the UserManual and been instructed on the importance ofperiodic maintenance checks?

G. INSTALLATION PRACTICE

1. Hand shut-off valve

2. Water filter

3. Water supply line

(flexible hose)

4. 3/4" GAS male fitting

5. Power line

6. Main switch

7. Drain fitting

8. Vented drain

9. Open trapped vented

drain

WARNING. This icemaker is not designed for outdoor installation and will not function inambient temperatures below 10 °C (50°F) or above 40 °C (100°F).This icemaker will malfunction with water temperatures below 5 °C (40°F) or above 35 °C(90°F).

Page 16Page 16

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

DATA

PRO

CESS

OR

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

T>1°C

OPERATING INSTRUCTIONS

B. Elapsed the 3 minutes - stand by period - theunit starts operating with the activation insequence of the following assemblies:GEAR MOTORCOMPRESSORFAN MOTOR (if unit is an air cooled version)kept under control by the condenser temperatu-re sensor which has its probe within the condenserfins (Fig.2).

C. After 2 or 3 minutes from the compressorstart up, observe that flaker ice begins droppingoff the ice spout to fall into the storage bin.

NOTE. The first ice bits that drop into the icestorage bin are not so hard as the evaporatingtemperature has not yet reached the correctoperating value. It is necessary to allow theice - just made - to cure itself and wait forabout ten minutes for the evaporating tem-perature to reach the correct value so tomake more hard bits of ice.

L

N

11

10

9

1

2

7

8

6

5

4

3

13

12

FIG. 1

START UP

After having correctly installed the ice maker andcompleted the plumbing and electricalconnections, perform the following “Start-up”procedure.

A. Open the water supply line shutoff valve andput the unit under electrical power by moving themain switch, on the power supply line, to the ONposition.The first LED - GREEN - will glow to signal thatunit is under power.

NOTE. Every time the unit is put underpower, after being kept for sometime in shut-off conditions (electrically disconnected) theRED LED will blink for 3 minutes after whichthe unit will start up with the immediateoperation of the gear motor assembly and,after few seconds, of the compressor assy(Fig.1).

Page 17Page 17

FIG. 2

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

T 40÷50°C

DATA

PRO

CESS

ORL

N

11

10

9

1

2

7

8

6

5

4

3

13

12

FIG. 3

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

T>75°C

DATA

PRO

CESS

OR

L

N

11

10

9

1

2

7

8

6

5

4

3

13

12

Page 18Page 18

FIG. 4

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

DATA

PRO

CESS

OR

L

N

11

10

9

1

2

7

8

6

5

4

3

12

13

NOTE. If, after ten minutes from thecompressor start-up, the evaporating tem-perature has not dropped down to a valuelower than -1°C (30°F) due to an insufficientquantity of refrigerant in the system, theevaporating temperature sensor detects suchan abnormal situation and stops consequentlythe unit operation (drive motor keeps onworking for 3' delay then stops).In this circustance, the 5th warning YELLOWLED will blink.

The machine will remain in OFF mode forone hour then it will restart automatically.In case the unit trips OFF again in alarm for3 times in 3 hours, the machine SHUTS OFFDEFINITIVELY. After having diagnosed andeliminated the cause of the poor evaporatingtemperature (insufficient refrigerant in thesystem, etc.) it is necessary to unplug andplug in again to restart the machine.The unit, before resuming the total operation,will go through the usual 3 minutes STAND-BY period.

OPERATION CHECKS UPON THE UNITSTART UP

D. Remove front service panel and if necessaryinstall the refrigerant service gauges on thecorresponding Service valves to check both theHI and LO refrigerant pressures.

NOTE. On air cooled models, the condensertemperature sensor, which is located withinthe condenser fins, keep the head (conden-sing) pressure between 8.5 and 9.5 bar(120÷135 psig) - (17 and 18 bar on AF 30 only).In case of condenser clogging such to preventthe proper flow of the cooling air or, in casethe fan motor is out of operation or shortageof water in the water cooled condenser, thecondenser temperature rises and when itreaches 70°C (160°F) - for air cooled version- and 60°C (140°F) - for water cooled version- the condenser temperature sensor shuts-off the ice maker (drive motor keeps onworking for 3' delay then stops) with theconsequent light-up of the RED WARNINGLIGHT (Fig.3).

The machine will remain in OFF mode forone hour then it will restart automatically.In case the unit trips OFF again in alarm for3 times in 3 hours, the machine SHUTS OFFDEFINITIVELY.After having diagnosed the reason of thetemperature rise and removed its cause, it isnecessary to proceed as per the previous“NOTE” to start up again the operation of theice maker.

E. Check for the correct CUT-OUT andCUT-IN of the float reservoir water levelsensors by first shutting closed the water shutoffvalve on the water supply line.

Page 19Page 19

FIG. 5

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

DATA

PRO

CESS

OR

L

N

11

10

9

1

2

7

8

6

5

4

3

12

13

This will cause a gradual decrease of the waterlevel in the float reservoir and as soon as the levelgets below the sensors, the flaker stops to ope-rate (drive motor keeps on working by 3' delaythen stops) and the YELLOW warning LED willglow to signal the shortage of water (Fig. 4).

NOTE. The water level sensor detects thepresence of sufficient water in the floatreservoir and confirms it to the microprocessor by maintaining a low voltagecurrent flow between the two sensors usingthe water as conductor.

WARNING. The use of de-mineralizedwater (water with no salt content) havingan electrical conductivity lower than 30µS, will cause the ability of the watersensors to vanish with the consequentCUT-OUT of the flaker operations and theglowing of the YELLOW LED of shortageof water, even though that water is indeedin the reservoir.

After this, open the water supply line shutoffvalve to fill up again the float reservoir, the

YELLOW LED goes off while the RED LEDstarts blinking .After 3 minutes the unit resumes its total operationwith the immediate start-up of the gear motorand, 2 seconds later, of the compressor.

F. Check for correct operation of the ice levelcontrol, by clogging ice spout opening and waituntil ice, which built up inside the spout, cuts thelight beam of the sensing eyes.Wait the built up of the ice into the ice chute till itcuts the light beam of the sensing "eyes".This interruption will cause an immediate blinkingof the Bin Full YELLOW LED located on the frontof the P.C. Board and after about 6 secondscauses the shutoff of the unit (compressor firstand 3' later the gear reducer) with the simulta-neous lighting (steady) of the Same LEDsignalling the full bin situation (Fig. 5).

Remove the hand to discharge the ice into thestorage bin so to allow the resumption of the lightbeam previously interrupted. After about 6seconds the flaker will resume - through the 3minutes STAND-BY period - the ice makingprocess with the extinguishing of the YELLOWLED.

Page 20Page 20

NOTE. The ICE LEVEL CONTROL(INFRA-RED SYSTEM) is independent ofthe temperature however, the reliability ofits detection can be affected by externallight radiations or by any sort of dirt andscale sediment which may depositdirectly on the light source and on thereceiver.To prevent any possible ice makermalfunction, due to negative affection ofthe light detector, it is advisable to locatethe unit where it is not reached by anydirect light beam or light radiation, alsoit is recommended to keep the bin doorconstantly closed .

NOTE. In the front of the PC Board is locateda small I/R Trimmer directly connected withthe optical Ice level control. By means of itsscrew it is possible to modify the signalreceived from the Ice Level control so toovercame some problem caused by dirt and/or low power supply.When adjusted it is very important to checkfor its correct operation using ice (NOTHAND) to break the Infrared Beam. In casethe machine doesn't stop it means that thenew setting is too much powerfull and need tobe reduced always by means of the I/R Trimmer.

M. If previously installed, remove the refrigerantservice gauges and re-fit the unit service panelspreviously removed.

N. Instruct the owner/user on the generaloperation of the ice machine and about thecleaning and care it requires.

Page 21Page 21

WATER CIRCUITThe water enter in the machine through the waterinlet fitting which incorporates a strainer and it islocated at the rear side of the cabinet and then itgoes to the water reservoir flowing through a floatvalve.

NOTE. The presence of the water in the floatreservoir is detected by a system of twosensors which operates in conjunction withthe P.C. Board. The two sensors use thewater as a conductor to maintain a low voltagecurrent flow between them signalling in thisway to the P.C. Board the presence of thewater in the reservoir. In case the water usedis very soft (de-mineralized) or the floatreservoir gets empty the current flow betweenthe sensors become so weak or is no longermaintained that, as consequence, the P.C.Board shutoff the flaker operation (drive motorkeeps on working by 3' delay then stops) withthe simultaneous glowing of the YELLOWLED signalling “Shortage of water”.

The float reservoir is positioned at the side of thefreezing cylinder at such an height to be able tomaintain a constant water level around the freezerauger.In fact, the water flows from the reservoir into thebottom inlet of the freezing cylinder to sorroundthe stainless steel auger which is vertically fittedin the center of the freezer.In the freezer the incoming water gets chilled intosoft (slush) ice which is moved upward by therotating action of the auger. The stainless steelauger that rotates counter-clockwise within thefreezer, is powered by a direct drive gear motorand carries the ice upward along the refrigeratedfreezer inner walls and by doing so the ice getsprogressively thicker and harder.

The ice, being costantly lifted up, meet the toothedpoint of the ice breaker which is fitted on the topend of the auger, where it gets compacted,cracked and forced to change from vertical into

PRINCIPLE OF OPERATION

horizontal motion to be discharged out, throughthe ice spout, into the storage bin.By running the ice maker, i.e. by putting the unitunder power, starts the automatic and continuousicemaking process which would not stop until theice storage bin gets filled-up to the level of thecontrol “eyes” located on the sides of the ice spout.As the ice level raises to interrupt the light beamrunning between the two infrared Leds, the unitstops after six seconds (compressor first and 3'later the gear reducer), with the simulteneousglowing of the YELLOW LED signalling the “FullBin” situation.

NOTE. The interruption of the light beambetween the two light sensors is immediatelysignalled by the blinking of the BIN FULLYELLOW LED located on the front of theP.C. Board.After about 6" of steady interruption of thelight beam the unit stops (drive motor keepson working by 3' delay then stops) and the“Full Bin” YELLOW LED glows steady.The six seconds of delay prevent the unitfrom stopping for any undue reason like themomentarily interruption of the light beamcaused by the flakes that slides along the icespout before dropping into the bin.

As some ice gets scooped out from the storagebin, the light beam between the two sensorsresumes (fast blinking of YELLOW LED) and sixseconds later the ice machine restarts the icemaking process - going always through the 3'stand by - and the YELLOW LED goes off.

REFRIGERANT CIRCUITThe hot gas refrigerant discharged out from thecompressor reaches the condenser where, beingcooled down, condenses into liquid.Flowing into the liquid line it passes through thedrier filter, then it goes all the way through thecapillary tube where it looses some of its pressureso that its pressure and temperature are lowered.Next, the refrigerant enters into the evaporatorcoil wrapped around the freezer inner tube.The water being constantly fed at the interior ofthe freezer inner tube, exchange heat with therefrigerant circulating into the evaporator coil,this cause the refrigerant to boil-off and evapora-te, thereby it changes from liquid into vapor.The vapor refrigerant then passes through thesuction accumulator and through the suction linewhere the refrigerant exchanges heat with theone flowing into the capillary tube (warmer) beforebeing sucked into the compressor to be recirculated.The refrigerant heat pressure is kept betweentwo pre-set values (8.5÷10 bar - 120÷140 psig)- (17÷18 bar - 245÷260 psig on AF 30 only) bythe condenser temperature sensor which has itsprobe located within the condenser fins - in aircooled versions.This condenser temperature sensor, whensenses a rising of the condenser temperaturebeyond the pre-fixed limit, changes its electricalresistance and send a low voltage power flow to

ICE SPOUT

FLOAT TANKFLOAT VALVE

FREEZER

FREEZER WATERFEED LINE

WA

TE

R IN

LET

LIN

E

Page 22Page 22

FIG. 6

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

T<1°C

DATA

PRO

CESS

OR

the MICRO-PROCESSOR of the P.C. Boardwhich energizes, through a TRIAC, the FanMotor in ON-OFF mode.When the opposite situation occures, i.e. thecondenser temperature gets below the pre-fixed

NOTE. In case the condenser temperature probesenses that the condenser temperature hasrised to 70°C (160°F) - on air cooled versions- or 60°C (140°F) - on water cooled versions -for one of the following abnormal reasons:CLOGGED CONDENSER (Air cooled version)INSUFFICIENT FLOW OF COOLINGWATER (Water cooled version)FAN MOTOR OUT OF OPERATION (Aircooled version)AMBIENT TEMPERATURE HIGHER THEN43°C (110°F)it causes the total and immediate SHUT-OFFof the machine (drive motor keeps on workingby 3' delay then stops) in order to prevent theunit from operating in abnormal and dangerousconditions. When the ice maker stops onaccount of this protective device, there is asimultaneous glowing of the RED LED, warningthe user of the Hi Temperature situation. Themachine will remain in OFF mode for one hourthen it will restart automatically. In case the unittrips OFF again in alarm for 3 times in 3 hours,the machine SHUTS OFF DEFINITIVELY.After having eliminated the source of theexcessive con-denser temperature, to restartthe ice machine it is necessary to unplug andplug in again. The RED LED starts blinkingand three minutes later the flaker unit resumeits normal operating mode. The condensertemperature sensor has a further safetyfunction which consist in preventing the unitfrom operating in Lo-ambient conditions i.e.when the condenser body temperature -equivalent to the ambient temperature - islower then 1 °C 34°F (Fig.6). As soon as theambient temperature rises up to 5°C (40°F)the PC Board will automatically restarts themachine through the three minutes delay time.

L

N

11

10

9

1

2

7

8

6

5

4

3

12

13

limit, the temperature sensor changes again itselectrical resistance reducing therefore thecurrent flow to the P.C. Board to cause atemporary stop of the Fan Motor.On the water cooled versions, the refrigeranthead pressure is kept at the constant value of9.5 bars (138 psig) - 17 bar (245 psig) on AF 30only by the metered amount of water passingthrough the condenser which is regulated by theaction of the Water Regulating Valve that has itscapillary tube connected to the liquid refrigerantline. As pressure increases, the water regulatingvalve opens to increase the flow of cooling waterto the condenser.

ACCUMULATOR

CAPILLARY TUBE

COMPRESSOR

DISCHARGE LINE

CO

ND

EN

SE

R

SU

CT

ION

LIN

E

FAN MOTOR

EVAPORATOR

Page 23Page 23

directly fitted in the gear case through which itdrives - in counter clockwise rotation at a speedof 9.5 r.p.m. - the freezer auger being linked to itby the ratched coupling.

NOTE. In the event the gear motor will tendto rotate in the wrong direction (counter-clockwise) or not rotating at all or rotating atlower speed the unit will stop immediatelywith the glowing of the WARNING YELLOWLED on account of the intervention of theElectromagnetic Safety Device - based onHall Effect principle.

The machine will remain in OFF mode forone hour then it will restart automatically.In case the unit trips OFF again in alarm for3 times in 3 hours, the machine SHUTS OFFDEFINITIVELY.After having diagnosed and eliminated thesource of the failure, to restart the unit it isnecessary to switch OFF and ON the powerline main disconnnect switch (Fig. 7).The RED LED will start blinking and after3 minutes the ice maker will resume its totaloperations by running first the gear motorand then the compressor.

FIG. 7

2

1L

N

COM

PRES

SOR

9

10

11

12

13

3

4

5

6

7

8

CONTACTOR COIL

GEAR MOTOR

FAN MOTOR

ELECTRONICCARD

RELAYS

TRIAC

RESET

S E

N S

O R

S

WATERLEVEL

GEAR MOTOR ROTATION

CONDENSER TEMP.

EVAPORATOR TEMP.

ICE LEVEL CONTROL

TRANSF.

DATA

PRO

CESS

OR

L

N

11

10

9

1

2

7

8

6

5

4

3

12

13

The refrigerant suction or Lo-pressure sets - innormal ambient conditions (21 °C) - on the valueof 0.4÷0.5 bar (6÷7 psig) - 2.5 bar (36 psig) onAF 30 only after few minutes from the unit start-up.This value can vary of 0.1 or 0.2 bar (1.5 ÷3 psig)in relation to the water temperture variationsinfluencing the freezer cylinder.

NOTE. If, after ten minutes from the unit startup, no ice is made and the evaporatingtemperature detected by the evaporatorsensor results to be higher than -1°C (30°F)the ice maker stops (compressor first and 3'later the gear reducer) and the 5THWARNING YELLOW LED blinks.The machine will remain in OFF mode forone hour then it will restart automatically.In case the unit trips OFF again in alarm for3 times in 3 hours, the machine SHUTS OFFDEFINITIVELY.

MECHANICAL SYSTEM

The mechanical system of the SCOTSMANFlaker machines consists basically of a gearmotor assembly which drives, through a ratchedcoupling, a worn shaft or auger placed on itsvertical axis within the freezing cylinder.The gear motor is made of a single phase electricmotor with a permanent capacitor. This motor is

Page 24Page 24

REFRIGERANT METERING DEVICE:

capillary tube

REFRIGERANT CHARGE (R 134 A)air cooled water cooled

AF 80 310 gr 310 grAF 100 420 gr xxxxxAF 200 420 gr 420 grAF 20 420 gr xxxxx

REFRIGERANT CHARGE (R 404 A)air cooled water cooled

AF 30 660 gr 520 gr

NOTE. Before charging the refrigerant systemalways check the type of refrigerant andquantity as specified on the individual icemachine dataplate.The refrigerant charges indicated are relativesto averages operating conditions.

OPERATING PRESSURES(With 21 °C ambient temperature)

Discharge pressure: AF 80 - 100 - 200 - 20

Air cooled version 8.5 ÷ 10 bar123 ÷ 145 psig

Water cooled version 9.5 bar140 psig

Suction pressure: 0.4 ÷ 0.8 bar6 ÷ 12 psig

Discharge pressure: AF 30

Air cooled version 17 ÷ 18 bar245 ÷ 260 psig

Water cooled version 17 bar245 psig

Suction pressure: 2.5 bar36 psig

Page 25Page 25

A. EVAPORATOR TEMPERATURE SENSORThe evaporator sensor probe is inserted into itstube well, which is welded on the evaporatoroutlet line, it detects the temperature of therefrigerant on the way out from the evaporatorand signals it by suppying a low voltage currentflow to the P.C. Board Micro-Processor.According to the current received, the micro-processor let the ice maker to continue itsoperations. In case the evaporating temperatu-re, after 10 minutes from the unit start-up, doesnot go below -1°C (30°F) due to shortage ofrefrigerant in the system the evaporator sensorsignal reaching the microprocessor is such tostop immediately the unit operation (drive motorkeeps on working by 3' delay then stops), with the5th Warning YELLOW LED that blinks.

NOTE. The machine will remain in OFF modefor one hour then it will restart automatically.In case the unit trips OFF again in alarm for3 times in 3 hours, the machine SHUTS OFFDEFINITIVELY.To restart the unit after the shutoff caused bythe hi evaporating temperature, it is neces-sary to switch OFF and ON the power linemain disconnect Switch.

B. WATER LEVEL SENSOR

This sensor system consist of two small stainlesssteel rods vertically fitted on the inner face of thereservoir cover and electrically connected to thelow voltage circuit of the P.C. Board. When thecover of the reservoir is positioned in its place thetips of both the rods dip into the reservoir waterand detects and signals its presence by makinguse of its electrical resistance.

NOTE. In the event of shortage of water inthe reservoir or, in case the water used is toosoft (de-mineralized) to cause greaterresistence to the current flow (conductivitylower than 30 µS) this sensor system causesthe shutoff of the machine (drive motorkeeps on working by 3' delay then stops), toprotect it from running with an interrupted orinadequate water supply. In this situation theYELLOW LED will glow to warn of themachine shutoff and the reason why.

C. CONDENSER TEMPERATURE SENSOR

The condenser temperature sensor probe,located within the condenser fins (air cooledversion) or in contact with the tube coil (watercooled version) detects the condenser tempera-ture variations and signals them by supplyingcurrent, at low voltage, to the P.C. BOARD.In case the condenser temperature sensor detectsa temperature at the condenser lower than +1°C(33°F) that signify that the ambient temperatureis at the same value, therefore it is too low for thecorrect unit operation, the sensor signals to themicroprocessor to stop immediately or to do not

COMPONENTS DESCRIPTION start the unit operations up to the moment thatthe ambient temperature will rise to moreacceptables conditions (5°C).In the air cooled versions, in relation to thedifferent current received, the micro processor ofthe P.C. BOARD supplies, through a TRIAC, thepower at high voltage to the fan motor so that itcan cool the condenser and reduce its temperature.In the event the condenser temperature risesand reaches 70°C or 60°C the current arriving tothe micro processor is such to cause an immediateand total stop of the machine operation (drivemotor keeps on working by 3' delay then stops).

NOTE. The machine will remain in OFFmode for one hour then it will restart automa-tically. In case the unit trips OFF again inalarm for 3 times in 3 hours, the machineSHUTS OFF DEFINITIVELY.To restart the unit after the shutoff caused bythe hi condenser temperature, it is necessaryto switch OFF and ON the power line maindisconnect Switch.

D. GEAR MOTOR ROTATION AND SPEEDSENSOR

This safety device is housed on top of the DriveMotor and detects - based on Hall Effect principle- the rotating speed and rotating direction of thedrive Motor.Should the rotating speed drop below1300 r.p.m. the magnitude measured by thisdevice is such to signal to the microprocessor tostop the unit and light-up the YELLOW LED.About the same reaction occures when the drivemotor will tend to rotate in the wrong direction(counterclockwise) situation that, if it occures,will greatly affect all the freezer and gear reducercomponents.

NOTE. The machine will remain in OFFmode for one hour then it will restart automa-tically. In case the unit trips OFF again inalarm for 3 times in 3 hours, the machineSHUTS OFF DEFINITIVELY. To restart theunit after the shutoff caused by this safetydevice, it is necessary first to eliminate thecause that has generated the intervention ofthe device and then switch OFF and ON thepower line main disconnect switch.

E. ICE BIN LEVEL LIGHT CONTROL

The electronic ice bin level control, located intothe ice spout, has the function to stop the operationof the ice machine when the light beam betweenthe light source and the sensor gets interruptedby the flake ice which accumulates in the spout.When the light beam is interrupted the Bin FullYELLOW LED located in the front of the P.C.BOARD blinks; in case the light beam getsinterrupted for as long as 6 seconds, the icemachine stops (drive motor keeps on working by3' delay then stops) with the glowing-up of the2nd YELLOW LED to monitor the full ice binsituation. The 6 seconds of delay prevents thatany minimum interruption of the light beam dueto the regular ice chuting through the ice spoutmay stop the operation of the unit.

Page 26Page 26

JP3

JP260/70°C

TESTJP1

SYEN

TRANSFORMERTRANSFORMER

EVAPORATOR SENSOR SOCKETCONDENSER SENSOR SOCKET

DRIVE MOTOR SENSOR SOCKET

WATER SENSORSOCKET OPTICAL ICE LEVELOPTICAL ICE LEVEL

CONTROLSENSOR SOCKET

TERMINALBOARD

TERMINALBOARD

FUSEFUSE

TRIACTRIAC

RELAY

COMPRESSORRELAY

RELAY

DRIVE MOTORRELAY

MICROPR. EPROMREMOTESOCKET

3’ STAND BY BY-PASS JUMPER

POWERPOWER

BIN FULL

NO WATER

TEMP.3’ STAND

TO HI/LOW COND.TEMP.

3’ STANDBYPOWER

ROTATION

TO HI EVAP. TEMP.WRONG OR SLOW

DRIVE MOTORROTATION

60-70°CJUMPER

60-70°CJUMPER

RESISTANCERESISTANCE

I/R ADJUSTER

As soon as the ice is scooped out (with theresumption of the light beam between the twoinfrared sensor of ice level control) 6 seconds later theice machine resumes its operation with the simul-taneous extinguishing the 2nd YELLOW LED.

F. P.C. BOARD (Data processor)

The P.C. BOARD , fitted in its plastic box locatedin the front of the unit, consists of two separatedprinted circuits one at high and the other at lowvoltage and protected by fuses. Also it consists offive aligned LEDS monitoring the operation of themachine of three jumpers (TEST used only in thefactory, 60/70°C used to set up the PC Board atproper safety cut out condensing temperatureand 3' to by pass the 3 minutes Stand By) and ofinput terminals for the leads of the sensor probesas well as input and output terminals for the leadsof the ice maker electrical wires.The P.C. BOARD is the brain of the system andit elaborates, through its micro processor, thesignals received from the sensors in order tocontrol the operation of the different electricalcomponents of the ice maker (compressor, gearmotor, etc.).The five LEDS, placed in a row in the front of theP.C. BOARD, monitor the following situations:

GREEN LEDUnit under electricalpower

YELLOW LED- Blinking: I/R beam cut

out- Steady: unit shut-off at

storage bin full- Blinking fast: I/R beam resumed

YELLOW LEDUnit shut-off due to atoo lo-water level intofloat tank

RED LEDON all the time- Unit shut-off due to a

too hi-condensingtemperature

- Unit shut-off due to atoo lo-ambient temperature<+1°C

Blinking3 minutes start up delay time

YELLOW LEDON all the time- Unit shut-off due to the

wrong rotation directionof gear motor

- Unit shut-off due to thetoo lo speed of gear motor

Blinking- Unit shut-off due to a too hi-evaporating temp.>-1°C after 10 min of operation

YELLOW ANDRED LED

- Blinking: Evaporator sensorout of order

- Steady: Condenser sensorout of order

TO BY-PASS THE 3'/60' STAND BY TIME, SYMPLY JUMP "TEST" CONTACTS WITH PCB ENERGIZED

Page 27Page 27

In the ice breaker it is housed the top bearingwhich is made of two rolls bearings positioned towithstand the auger axial and radial loads. Thisbearing is lubricated with a food grade - waterresistant grease.

NOTE. It is advisable to check the conditionsof both the lubricant grease and the topbearing every six months.

K. DRIVE GEAR MOTOR

This motoreducer is made of a single phaseelectric motor with permanent capacitor directlyfitted on a gear box.The drive motor rotor is kept aligned on its verticalaxis by two ball bearings permanently lubricated.The gear case contains a train of three spur gearsthe first one of which is in fiber to limit the noiselevel. All the three gears are encased in casebearings and are covered by lubricant grease(MOBILPLEX IP 44).Two seal rings, one fitted on the rotor shaft andthe other on the output shaft keep the gear casesealed.Hovewer, the interior can be inspected andserviced by unbolting the two halves of thealuminium gear case housing.The gear reducer output shaft is connected to thefreezer auger by a ratched coupling which ismade of two toothed halves that engagesthemselves only if turned in the correct directionnamely, conterclockwise.

L. FAN MOTOR (Air cooled version)

The fan motor is controlled through the P.C.BOARD and the TRIAC by the condenser tempe-rature sensor. Normally it operates to draw coolingair through the condenser fins.In cold ambient situation, the fan motor can run atintermittance as the condenser pressure must bekept between two corresponding head pressurevalues (8.5÷9.5 bars-120÷135 psig) - (17÷18 bar-245÷260 psig on AF 30 only).

M. WATER REGULATING VALVE(Water cooled version)

This valve controls the head pressure in therefrigerant system by regulating the flow of watergoing to the condenser.As pressure increases, the water regulating val-ve opens to increase the flow of cooling water.

N. COMPRESSOR

The hermetic compressor is the heart of therefrigerant system and it is used to circulate andretrieve the refrigerant throughout the entiresystem. It compresses the low pressure refrigerantvapor causing its temperature to rise and becomehigh pressure hot vapor which is then releasedthrough the discharge valve.

G. JUMPERS

The Flaker PC Board is equipped by three jumpers:J1 · TEST: Used in the factory to energise all

the electrical components during theTesting Mode.Used to by-pass the 3' stand by time(just jump the contacts with PC Boardunder power).

J2 - SYENJ3 - Pro. El. Ind.· 60/70°C: Used to set up the Cut Out tempera-

ture of the condenser sensor:• Jump OUT = 60°C• Jump IN = 70°C

J3 - SYENJ2 - Pro. El. Ind.· 3'/60': Used to set up the start up delai time:

• Jump IN = 3'• Jump OUT = 60'

H. FLOAT RESERVOIR

The float reservoir consists of a plastic water panon which is fitted a float valve with its settingscrew. The float valve modulate the incomingwater flow to maintain a constant water level inthe reservoir, level that corresponds to the one inthe freezing cylinder to ensure proper iceformation and fluidity.On the inner side of the reservoir cover are fittedthe two water level sensors which detects thepresence or the shortage of water in the reservoir.

NOTE. It is very important to make sure ofthe correct fitting of the cover on the reservoirin order to enable the sensor to efficientlycontrol the water situation avoiding undueshutoff interventions.

I. FREEZING CYLINDER (EVAPORATOR)

The freezing cylinder is made of a stainless steelvertical tube on which exterior is wrapped aroundthe cooling coil with the evaporating chamberand in its interior is located the auger whichrotates on its vertical axis and it is maintainedaligned by the top and bottom bearings. A waterseal system is located in the bottom part of thefreezer while at the top end is fitted the icebreaker.The water constantly flowing into the cylinderbottom part, freezes into ice when in contact withthe cylinder inner walls. The ice is then lifted upby the rotating auger and compacted and forcedout by the ice breaker.

J. ICE BREAKER

The ice breaker is fitted in the freezer upper partit has two breaker teeth to break the ice and withits slanted shape from the rear tooth to the frontone it compacts and forces the ice out in anhorizontal way. By undergoing this, the ice loosesits excess of water content so it drops into the binin hard dry bits of ice.

Page 28Page 28

NOTE. Read the instructions thoroughlybefore performing any of the followingadjustment or removal and replacement pro-cedure.

A. ADJUSTEMENT OF THE EVAPORATORWATER LEVEL

The correct water level in the freezing cylinder isabout 25 mm. (1") below the ice dischargeopening. Low water level causes excessive straininside the freezer assembly due to a faster freezingrate.

When the water level is above or below thecorrect one, adjustment can be performed toRaise or Lower the water level by raising orlowering at the measure required, the waterreservoir and its mounting bracket.1. To Raise the water level:a. Loosen and remove the screw securing themounting bracket of the water reservoir to theunit cabinet and raise the water reservoir to thecorrect level.b. Thread the mounting screw in thecorresponding hole and tighten it.2. To Lower the water level follow the aboveindications to lower to the correct level the waterreservoir assembly.

WARNING. Be sure the electrical powersupply circuit breaker and the inlet watersupply are OFF, before starting any of thefollowing Removal and Replacementprocedures as a precaution to preventpossible personal injury or damage to theequipments.

ADJUSTMENT, REMOVAL AND REPLACEMENT PROCEDURES

B. REPLACEMENT OF EVAPORATORTEMPERATURE SENSOR

1. Remove the front, rear and top panels.

2. Remove the insulation from the refrigeranttubing, connecting the freezer to the accumulator,to gain access to the sensor probe well and beable to pull out from this well the sensor probe.

3. Trace the condenser sensor terminal plug(blue) on the left side of the control box andremove it from its socket by carefully pulling outthe terminal plug securing clip.

4. To install the replacement evaporator sensorfollow the above steps in reverse.

C. REPLACEMENT OF CONDENSERTEMPERATURE SENSOR

1. Remove the front panel.

2. Trace the condenser sensor probe locatedwithin the condenser fins on air cooled versionand withtrow it.On water cooled version remove it by openingthe plastic strap (reusable) securing the probe tothe refrigerant liquid line.

3. Trace the condenser sensor terminal plug(black) on the left side of the control box andremove it from its socket by carefully pulling outthe terminal plug securing clip.

4. To install the replacement condenser sensorfollow the above steps in reverse.

D. REPLACEMENT OF THE ICE LEVELLIGHT CONTROL

1. Remove the front , rear and top panels.

2. Trace the ice level light control terminal plug(black and with four terminal pins) on the left sideof the control box and draw it out from its socketby carefully slackening the fastening tie.

3. Unloose the two screws holding the opticalice level control to the upper side of the spout andremove it.

4. To install the replacement ice level lightcontrol follow the above steps in reverse.

E. REPLACEMENT OF THE GEAR MOTORROTATION AND SPEED SENSOR


Page 29Page 29

2. Unloose the three screws securing the plasticcover to the gear motor speed sensor housingand remove it.

3. Unloose the two screws securing the sensorto the plastic housing and withdraw it from itsseat.

4. Trace the gear motor speed sensor terminalplug (red with four pins) on the left side of thecontrol box and draw it out from its socket bycarefully slackening the fastening tie.

5. To install the replacement gear motor rotationand speed sensor follow the above steps inreverse.

F. REPLACEMENT OF THE RESERVOIRWATER LEVEL SENSOR


2. Unloose the two nuts securing the wireleads to the two water level sensor rods locatedon the water reservoir plastic cover.

3. Trace the water level sensor terminal plug(red) on the left side of the control box and drawit out from its socket by carefully slackening thefastening tie.

4. To install the replacement water level sensorfollow the above steps in reverse.

G. REPLACEMENT OF P.C. BOARD

1. Remove front panel.

2. Remove all sensor terminal plugs, locatedon the left side of P.C. Board, by carefully releasingthem out from their sockets clips.

3. Disconnect the terminal board connectionplug from the rear side of P.C. BOARD thenunloose the four screws holding the same to theplastic control box and remove it.

4. To install the replacement P.C. BOARDfollow the above steps on reverse.

NOTE. In case the TEST contacts are jumpedtogether (it is a possibility when PC Board isreplace as spare parts), the machine startsup immediately with all the electrical parts(compressor, drive motor and fan motor starttogether with no delay).This for 3 minutes then the machine stopswith all LEDs blinking.

H. REPLACEMENT OF THE ICE SPOUT

1. Remove the top and rear panels.

2. Slacken and remove the two metal strapsthat hold tight the polystyre insulations againstthe freezer upper part.

3. Remove the optical ice level control.

4. Unloose and remove the two screws and thespout from the freezer cylinder.

5. To install the replacement spout followprevious steps in reverse.

I. REPLACEMENT OF THE AUGER, WATERSEAL, BEARINGS AND COUPLING


2. Follow the steps at item H to remove the icespout.

3. Grasp the wire cap hook at the top of thefreezer and pull out the auger and attached cap,ice breaker, bearings and O rings, at the top ofthe auger, and the top half of the water seal at theauger bottom.

NOTE. If the auger cannot be pulled out,proceed to steps 9 and 10 of this paragraph,to gain access to the auger bottom. Then,with a rowhide mallet or placing a piece ofwood on the bottom end of the auger, tap thisbottom to break loose the auger and be ablethen to pull it out as in step 3 above.

4. With a circlip plier remove the retaining ringand cap hook from the ice breaker.

5. Unloose and remove cap screw and removethe ice breaker from the auger.

6. Clean away the old grease from the interiorof the ice breaker and inspect the conditions ofthe O ring; if torn or worn replace it.

7. Inspect the bearing pressed into the top ofthe ice breaker and if worn do not hesitate toreplace it.

WARNING. The top bearing assembly worksin critical conditions for what concern itslubrication status as it is haused in the icebreaker where the formation of a greatrate of condensation is usual. Therefore itis important to apply on it an ample coa-ting of Food grade Waterproof GreaseP/N 263612.00 before installing the breakerand cap hook in place.

8. Slide off from the auger bottom the upperhalf of the water seal.

NOTE. Any time the auger is removed forreplacement or inspection use extra care inhandling the water seal parts, so no dirt orforeign matters are deposited on the surfacesof the seal. If there is any doubt about theeffectiveness of the water seal or O ring donot hesitate to REPLACE THEM.

9. Unloose and remove the three bolts andlockwashers which attach the freezer assy to thealuminium adaptor.

10. Raise the freezer assy off the adaptor, secureit out of the way to allow room to work. Using asuitable lenght and size wooden dowel or stickinserted through the top of the open freezer, tapthe lower half of the water seal and the lowerbearing out the bottom of the freezer.

Page 30Page 30

NOTE. It is good practice to replace the waterseal assy and both the top and the bottombearings any time the auger is removed.To facilitate this, SCOTSMAN EUROPEService makes available a service KitP/N 001028.07 which includes besides theabove mentioned parts, the ice breaker O ringand a can of food grade waterproof grease.

11. Reach through the adaptor and remove thecoupling parts.

12. Check both the coupling halves for chippingand wear and do not hesitate to replace them.

13. To install the ratched coupling, the waterseal, the bearings and auger follow previoussteps in reverse.

NOTE. It is very important to provide correct/proper lubrication of the inside bore of theupper semi-coupling as well as to the externalsurfaces of the teeth as shown on the herebelow photo.The correct lubrication allows the upper semi-coupling to move it down, by the load of theupper spring, in case of any rising up duringits rotation.

NOTE. Install the upper bearing into the icebreaker starting by the radial portion thatmust be fitted with the flat surface facing up.Apply some lubricant (grease) on the uppersurface then install the rollers cage with thesmaller openings of the same facing up so toleave a small gap between plastic cage andflat surface of the botton portion of the bearing(see drawing).

Apply some move lubricant then place theS.S. trust washer.

J. REPLACEMENT OF THE GEAR MOTORASSY

1. Remove the rear and top panel.

2. Remove the three bolts and washerssecuring the gear reducer base to the unit chassis,then remove bolts and lockwashers which attachthe bottom of the aluminium adaptor to the gearreducer case cover.

3. Disconnect the electrical leads from theelectromagnetic safety device located on top ofdrive motor.

4. Trace and disconnect the electric wires leadsof the drive motor. Lift and remove the entire gearmotor assembly.

5. To install the replacement gear motor assyfollow the above steps in reverse.

K. REPLACEMENT OF FAN MOTOR

1. Remove front and back panel.

2. Remove screws and yellow green groundwire. Trace the electrical leads of fan motor anddisconnect them.

3. Remove the bolts securing the fan motorbracket to the cabinet base and then remove theassembly.

4. To install the replacement fan motor followthe above steps in reverse.

NOTE. When installing a new fan motorcheck that the fan blades do not touch anysurface and move freely.

L. REPLACEMENT OF DRIER


2. Recover the refrigerant from the system andtransfer it in a container so to reclaim or recycleit.

3. Unsolder the capillary tube and the refrigerantline from the two ends of the drier.

4. To install the replacement drier removefactory seals and solder the refrigerant lines andthe capillary tube taking precautions to NOTOVERHEAT the drier body.

5. Thoroughly evacuate the system to removemoisture and non condensable after drierreplacement.

6. Charge the system with refrigerant 134 A byweight (see data plate of machine) and check forleaks.

7. Replace panels previously removed.

M. REPLACEMENT OF THE FREEZINGCYLINDER

1. Follow the steps at item H to remove the icespout.

Page 31Page 31

6. To install the replacement condenser followthe above steps in reverse.

NOTE. Thoroughly evacuate the system toremove moisture and non condensables aftercondenser replacement.

O. REPLACEMENT OF WATER COOLEDCONDENSER

1. Remove front and rear side panels.

2. Remove the condenser temperature sensorprobes from condenser.

3. Remove bolts which secure the condenserto the unit base.

4. Remove the corbin clamps and disconnectthe plastic hoses from the water cooledcondenser.


6. Unsolder the refrigerant lines from thecondenser and remove it from the unit.

NOTE. It is imperative to install a replace-ment drier whenever the sealed refrigerationsystem is open.Do not replace the drier until all other repairsor replacements have been completed.

7. To install the replacement condenser followthe above steps in reverse.

NOTE. Thoroughly evacuate the system toremove moisture and non condensables aftercondenser replacement.

P. REPLACEMENT OF WATERREGULATING VALVE(WATER COOLED MODELS)

1. Remove front and rear panels.

2 Close the shut-off valve on the water supplyline and disconnect it at the rear of the flaker.

3. Remove corbin clamp and disconnect thewater hose from the outlet of water regulatingvalve.

4. Unloose the nut securing the water regulatingvalve to the unit frame.


2. Remove the clamp fastening the water hoseto the water inlet port of the freezer assy. Placea water pan under this water inlet port thendisconnect the water hose and collect all waterflowing from freezer and from water hose.

3. Withdraw the evaporator sensor probe fromthe its holder as stated in item B.

4. Recover the refrigerant from the system andtransfer it in a container so to reclaim or recycle it.

5. Unsolder and disconnect the capillary tubeand the accumulator/suction line assy from theoutlet line of the freezing cylinder.

6. Remove the three bolts and washerssecuring the gear reducer base to the unit chassis,then remove bolts and lockwashers which attachthe bottom of the aluminium adaptor to the gearreducer case cover.

7. Lift the freezer up and off the gear motorassembly, then if necessary remove thealuminium adaptor by removing the threemounting screws and lockwashers.


8. To install the replacement evaporator followthe above steps in reverse.

NOTE. Thoroughly evacuate the system toremove moisture and non condensables afterevaporator replacement.

N. REPLACEMENT OF AIR COOLEDCONDENSER


2. Remove from the condenser fins thecondenser ambient temperature sensor probes.

3. Remove the two bolts attaching thecondenser to the base.


5. Unsolder the refrigerant lines from thecondenser and remove it from the unit.


Page 32Page 32

6. Trace the water regulating valve capillarytube and unsolder its end from the refrigerant linethen remove it from the unit.


7. To install the replacement water regulatingvalve follow the above steps in reverse.

NOTE. Thoroughly evacuate the system toremove moisture and non condensables afterwater regulating valve replacement.

NOTE. The water flow that passes throughthe valve can be adjusted by means of thevalve setting stem in order to have acondensing pressure of 9.5 bars (138 psig).

Q. REPLACEMENT OF COMPRESSOR

1. Remove back and front panels.

2. Remove the cover and disconnect theelectrical leads from the compressor junctionbox.


4. Unsolder and disconnect both the suctionline and the discharge line from the compressor.

5. Remove the four compressor mounting boltsand the compressor from the unit base.6. Unsolder suction and process header fromcompressor and retain it to be used on newcompressor.


7. To install the replacement compressor followthe above steps in reverse.

NOTE. Thoroughly evacuate the system toremove moisture and non condensables aftercompressor replacement.

R. REPLACEMENT OF THE GEAR MOTORMAGNETIC SENSOR

1. Remove top and back panel.

2. Unloose the three screws securing theplastic cover to the top of the gear motor andremove it.

3. Unloose the two screws securing themagnetic sensor to the plastic housing andwithdraw it from its seat.

4. Trace the gear motor magnetic sensorterminal plug on the rear side of the control box(red with four terminal pins) and draw it out fromits socket by carefully slackening the fasteningtie.

5. To install the replacement gear motormagnetic sensor follow the above steps inreverse.

0.5-1.0 mm

Page 33Page 33

WIRING DIAGRAMAIR AND WATER COOLED

230/50-60/1 GV - YELLOW GREENB - WHITEG - GREYN - BLACKA - BLUEM - BROWNV - GREEN

Page 34Page 34

SYMPTON POSSIBLE CAUSE SUGGESTED CORRECTION

Unit will not run Blown fuse in P.C.Board Replace fuse & check for cause ofNo LED lighted-up blown fuse

Master switch in OFF position Turn switch to ON position

Inoperative P.C.Board Replace P.C.Board

Loose electrical connections Check wiring

Bin full yellow LED glows with Inoperative or dirty ice level control Replace or clean ice level controlno ice in the bin

Water yellow LED glows Shortage or too soft water See remedies for shortage of wateror install a mineral salt meteringdevice

Red-alarm LED glows High head pressure Dirty condenser. CleanInoperative fan motor. Replace

Ambient temperature too low Move unit in warmer location

Reverse rotation yellow LED blinks Too hi evap. temperature Check and charge refrigerant systemShortage or lack of refrigerant

Reverse rotation yellow LED glows Gear motor turns on reverse Check gear motor capacitor

Too low gear motor rotating speed Check rotor bearings, freezerbearings and interior of freezer forscores. Replace whatever worn ordamaged.

No rotation of gear motor Check for power to drive motor(16 A fuses)Check for stator winding

Gear motor starts and stop Check for correct operation of driveafter a while motor magnetic sensor

Check for correct magnetic capacityof magnetic cylinder

Water yellow LED and red LED Inoperative Condenser Sensor Replace it.ON (steady) together

Water yellow LED and red LED Inoperative Evaporator Sensor Replace it.blink together

Compressor cycles intermittently Low voltage Check circuit for overloadingCheck voltage at the supply to thebuilding. If low, contact the powercompany

Non-condensable gas in system Purge the system

Compressor starting device with Check for loose wires in startingloose wires device

Low ice production Capillary tube partially restricted Blow charge, add new gas & drier,after evacuating system with vacuumpump

Moisture in the system Same as above

Low water level in the freezer Adjust to approx 20 mm below icespout

Shortage of refrigerant Check for leaks & recharge

Pitted or stained auger surface Clean or replace auger

SERVICE DIAGNOSIS

Page 35Page 35

SYMPTON POSSIBLE CAUSE SUGGESTED CORRECTION

Wet ice Ambinet temperature too high Move unit to cooler location

High water level in the freezer Lower to approx. 20 mm belowice spout

Faulty compressor Replace

Machine runs but makes no ice Water not entering in the freezer Air look in feed line to freezer.Clogged feed line to freezer. Clean it

Gear stripped Check and repair

Moisture in the system Purge, replace drier and re-charge

Water leaks Water seal leaking Replace water seal

Water feed line to freezer leaking Check and fasten hose clamp

Float valve not closing Check and adjust float valvesetting screw

Spout leaking Tighten screws holding the spout

Excessive noise or chattering Mineral or scale deposit on auger Remove and manually polish augerand inner freezer walls and inner walls of freezer barrel

using emery paper

Low suction pressure Add refrigerant to rise suction pressure

Water feed line to freezer clogged Vent and clean it

Low water level into freezer Adjust to approx. 20 mm belowice spout

Gear motor noise Worn rotor bearings Check and replace

Shortage or poor lubricant in gear Check for proper lubricant openingcase gear case.

Top of gears must be coveredwith lubricant

Gear case bearings and gear Check and replace worn partsracers worn out

Shortage of water Strainer at water inlet fitting clogged Remove strainer and clean

Float reservoir water nozzle Remove float valve and cleanclogged-up nozzle

SERVICE DIAGNOSIS

Page 36Page 36

MAINTENANCE AND CLEANING INSTRUCTION

A. GENERAL

The periods and the procedures for maintenanceand cleaning are given as guides and are not tobe construed as absolute or invariable.Cleaning, especially, will vary depending uponlocal water and ambient conditions and the icevolume produced; and, each icemaker must bemaintened individually, in accordance with itsparticular location requirements.

B. ICEMAKER

The following maintenance should be scheduledat least two times per year on these icemakers.

1. Check and clean the water line strainer.

2. Remove the cover from the float reservoir -care to do not damage the two water sensors -and depress the float to make sure that a fullstream of water enters into the reservoir.

3. Check that the icemaker is levelled in side toside and in front to rear directions.

4. Check that the water level in the waterreservoir is below the overflow but high enoughthat it does not run out of the spout opening.

NOTE. The float must close positively theincoming water flow when its fulcrum, housingthe setting screw, is perpendicular to thewater nozzle.

5. Clean the water system, water reservoirand the interior of freezing cylinder using asolution of SCOTSMAN Ice Machine Cleaner.Refer to procedure C cleaning instructions andafter cleaning will indicate frequency and proce-dure to be followed in local areas.

NOTE. Cleaning requirements varyaccording to the local water conditions andindividual user operation.

6. If required, polish the two sensor rodssecured to the float reservoir cover, heavy scalesediment on them can be removed with the helpof a bit of SCOTSMAN Cleaner plain.

7. With the ice machine and fan motor OFF onair cooled models, clean condenser using vacuumcleaner, whisk broom or non metallic brush takingcare to do not damage the condenser/ambienttemperature sensor.

8. Check for water leaks and tighten drain lineconnections. Pour water down bin drain line tobe sure that drain line is open and clear.

9. Check the ice level control sensor to testshut-off. Put your hand in front of the ice spoutand wait till it is completely full of ice so to cut offthe light beam for at least 6 seconds.This should cause the immediate blinking of theBin Full YELLOW LED located in the front of P.C.Board and, 6 seconds later, the total stopping ofthe ice maker with the simultaneous light up ofthe Full Bin Yellow LED (steady).

NOTE. Test the operation of the Ice LevelControl using ice NOT HAND.

Within few seconds from the removal of the icebetween the sensor lights the ice maker resumeits operation.

NOTE. The ice level control uses devicesthat sense light, therefore they must be keptclean enough so they can “see”.

10. Check for refrigerant leaks and for properfrost line, which should frost as far as approx. 20cm (8") from the compressor.When doubtful about refrigerant charge, installrefrigerant gauges on corresponding Schrädervalves and check for correct refrigerant pressures.(See Operating pressure at page 20 of thismanual).

11. Check that fan blades move freely and arenot touching any surfaces.

12. Remove the retaining ring and the hook andcap from the top of the freezer assembly theninspect the top bearing, wipe clean of all greaseand apply a coating of food grade water proofgrease P/N 263612.00

NOTE. It is recommended to use only foodgrade and waterproof grease to lubricate thefreezer top bearing.

13. Check the quality of ice. Ice flakes should bewet when formed, but will cure rapidily to normalhardness in the bin.

NOTE. It is not abnormal for some water toemerge from the ice spout with the flaker ice.

C. CLEANING INSTRUCTIONS OF WATERSYSTEM

1. Switch OFF the Master disconnect switchon the power line.

2. Remove all ice stored in the bin to prevent itfrom getting contaminated with the cleaningsolution.

Page 37Page 37

3. Shut close the water shutoff valve on waterline.

4. Remove the top panels to gain access to thewater reservoir.

5. Remove the float reservoir cover and with apiece of copper wire jump the two water levelsensors.

6. Place a water pan under the freezer waterinlet port, disconnect the water hose from thisport and allow the water from the freezer to flowinto the pan previously positioned.Then refit the water hose to the freezer waterinlet port.

7. Prepare the cleaning solution by diluting ina plastic container one or two liters of warmwater (45°-50°C) with a 0,1-0,2 liters ofSCOTSMAN Ice Machine Cleaner.

WARNING. The SCOTSMAN Ice MachineCleaner contains Phosphoric andHydroxyacetic acids. These compoundsare corrosive and may cause burns ifswallowed, DO NOT induce vomiting.Give large amounts of water or milk. CallPhysician immediately. In case of externalcontact flush with water. KEEP OUT OFTHE REACH OF CHILDREN

8. Switch ON the Master switch to start the unitthen pour the cleaning solution into the floatreservoir.

9. Wait for about three minutes for the unit tostart operating, then continue to slowly pour thecleaning solution into the water reservoir takingcare to maintain the level just below the overflow.

NOTE. The ice made with the cleaningsolution is slushy and coloured also, it maytend to loose fluidity creating some resistencein being elevated and extruded; this situationcan be heard by the creacking noise made bythe ice.Should this occure it is recommended to stopfor few minutes the ice machine in order toallow the ice in the freezer to partially melt.

10. When all the cleaning solution has beenused up, open the water shutoff valve to allownew fresh water to flow into the reservoir. Let theunit to continue to run until the ice resumes thenormal colour and hardness.

11. Stop the icemaker and pour warm water onthe ice deposited into the storage bin to melt it up.

NOTE. DO NOT use ice produced with thecleaning solution. Be sure none remains inthe bin.

12. Pour into the water reservoir 1 cc. (approx20 drops) of Scotsman Sanitiser (Antialgae P/N264000.00) then switch the unit ON.

13. Left the unit running for approx 10 minutesthen remove the copper wire used to jump thetwo sensors for the water level and place backcorrectly the cover on the float reservoir.

NOTE. DO NOT use ice produced with thesanitising solution.

14. With a sponge moisted with a sanitisingsolution, wipe clean all the bin interior surfaces.

REMEMBER. To prevent the accumulationof undesirable bacteria it is necessary tosanitise the interior of the storage bin with ananti-algae disinfectant solution every week.

Documents

AF 80 AF 100 AF 200 AF 20 AF 30 - ndustrio.com · ISO 9001 - Cert. n. 0080 SERVICE MANUAL AF 80 AF 100 AF 200 AF 20 AF 30 S Electronic flakers with storage MS 1000.73 REV. 05/2009