GEA Geneglace F15 User manual

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1
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
Table of contents
Table of contents
1. General ..................................................................................4
1.1 Introduction to this notice ................................................................4
1.2 Warning ............................................................................................4
1.3 Where can you find the information you need? ...............................4
2. Safety rules............................................................................5
2.1 Meaning of the danger pictograms...................................................5
2.2 Qualification and training of personnel ............................................5
2.3 Danger in the event of non-observance of the safety rules..............5
2.4 Operating range................................................................................5
3. Safety and Environmental Instructions .............................6
3.1 Safety rules.......................................................................................6
3.2 Protection of the Environment..........................................................6
4. Safety of pressure vessel.....................................................7
5. Installation and Handling of the F15 and F30.....................8
6. Dimensions and Connections of the F15 and F30.............9
6.1 Positioning the machine .................................................................10
6.2 Mountings.......................................................................................10
6.3 Ice level safety detection................................................................11
7. Connections .......................................................................12
7.1 Specifications .................................................................................12
7.2 Hydraulic connections ....................................................................13
7.3 Electrical connection.......................................................................13
7.4 Connections to the refrigerating circuit...........................................15
8. Initial start up.......................................................................16
8.1 Checks and adjustments................................................................16
8.2 Recommended uses.......................................................................18
8.3 Start-up report ................................................................................18
9. Operation............................................................................. 19
9.1 Principle of operation......................................................................19
9.2 Electrical sequences.......................................................................20
9.3 Refrigeration operation...................................................................22

2
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
Table of contents
10. Addition of salt..................................................................23
10.1 The salt dosing tube ....................................................................23
10.2 The dosing pump .........................................................................24
11. Options...............................................................................26
11.1 Electrical terminal box...................................................................26
11.2 «ILD» Ice level detector (regulation).............................................26
11.3 Remote Control.............................................................................26
12. Maintenance .....................................................................27
12.1 Maintenance schedule..................................................................27
12.2 Routine maintenance....................................................................28
12.3 Replacement of worn parts ..........................................................29
13. F15 and F30 Refrigeration Diagrams ..............................30
14. Troubleshooting................................................................31
15. Exploded view................................................................... 32
15.1 F15 Generator..............................................................................32
15.2 F30 Generator..............................................................................33
16. Commissioning Check List..............................................34
17. Operational Measurement sheet......................................36
17.1 Measurement Points for F15 or F30 Generator............................37
18. Adjustment of torque limiter............................................38
19. Adaptating of Water Pump...............................................39
20. Adjustment of Rubber Wipers Blade............................... 40
21. Electrical connexion of the ILD........................................41
22. Adjusting the Reamer.......................................................42

3
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
Type / Model
Pression de service Max. (PS)
Max. working
Intensité maxi. / max.
Charge fluide maxi
Max. refrigerant
N° construction / Serial
Puissance installée
Installed
Fluide / Fluid
Tension (V) - Phases
Voltage (V) - Phases
Fréquence / Frequency
GEA Geneglace s.a.s.
9 rue des orfèvres
44840 Les Sorinières - France
+33(0)2.51.19.10.51
Kg
A
Bar
kVA
Date
Hz
IDENTIFICATION
Introduction
Your GENEGLACE ice machine has been designed and manufactured in accordance with current regulations; built
with the greatest care, it has been subjected to a test for long-lasting quality. Nevertheless, if you discover a manu-
facturing fault and in order to protect your GENEGLACE machine, please do not attempt a repair but contact us as
soon as possible.
Any reproduction of all or part of this notice is subject to prior permission.
The information contained in this notice is subject to modification without prior notice.
In order to update the present notice, please advise us by return of any errors or misunderstandings that may have
slipped in.
GENEGLACEcannotbeheldresponsiblefordamageorproblemsinoperationoccurringwithGENEGLACEmachines
as a result of use outside the operating or safety limits or even the use of options or consumable items other than
those approved by GENEGLACE.
IDENTIFICATION
Manufacturer Plaque

4
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
1. General
1.1 Introduction to this notice
Your GENEGLACE ice machine has been designed and
manufacturedinaccordancewith current regulations; built
with the greatest care, it has been subjected to a test for
long-lastingquality. Nevertheless, if you discover a manu-
facturing fault and in order to protect your GENEGLACE
machine, please do not attempt a repair but contact us
as soon as possible.
1.2 Warning
-Any reproduction of all or part of this notice is subject to
prior permission.
- The information contained in this notice is subject to
modification without prior notice.
- In order to update the present notice, please advise us
by return of any errors or misunderstandings that may
have slipped in.
- GENEGLACE cannot be held responsible for damage
or problems in operation occurring with GENEGLACE
machinesasaresult of use outside theoperatingorsafety
limitsoreven theuseofoptions or consumableitemsother
than those approved by GENEGLACE.
1.3 Where can you find the informa-
tion you need?
After reading the safety instructions, the «Handling»
sectiongivesalistoftheitemsthatshouldcomewithyour
GENEGLACE,aswell as instructionsconcerninghandling
with complete safety.
The layout will tell you about : the overall dimensions of
your GENEGLACE, the procedure to follow for choosing
the best location for it in relation to its environment and
finally all information concerning accessibility for future
service and maintenance.
«Connections»:In order to makeall the hydraulic,elec-
trical and cooling connections correctly, this section will
give you some useful advice regarding the procedures
for the connections.
To ensure that your GENEGLACE starts successfully the
firsttimeandnothandling it incorrectly, referto the «Initial
Start Up Sheets»as well as this section 8.
The «Operation»: section describes in detail all the
operational features, factory settings and adjustments to
be carried out.
The«“Service,MaintenanceandFaultRectification»:
section will help you, by following its advice, to keep your
GENEGLACE in optimum working condition for as long
as possible.
Throughout this notice, you will find boxes such as :
Note
A note provides certain general information
relevant to the subject treated.
Tip
Thetipsuggests proceduresenablingyouto surmount
or get round any difficulties that may arise.
Important
This inset is intended to draw the attention of the
reader to particular points that could be relevant
to the safety of the operator or the machine.
General
Read the safety instructions carefully before
working on the ice machine.
Important

5
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
2. Safety rules
This notice contains important rules to be observed con-
cerningsafety, installation, operationand maintenance of
ice machines and their scrapping. And for this reason it
must be read before any handling. In addition, a copy of
the«NoticeforUsers»,includingthesafetyrules,mustbe
continuouslyavailabletothe user at the place of operation
of the GENEGLACE.
An information board, indicating the type, identification
number and certain operating and safety features of your
GENEGLACEmachine must always be visible and under
no circumstances must it be removed.
The safety rules contained in this notice, as well as the
national or local requirements for the prevention of ac-
cidents must also be observed.
2.1 Meaning of the danger pictograms
Thesafety rulesappearinginGENEGLACE noticeswhich,
if not observed, could result in body injury, are preceded
by the following symbols :
These symbols are also placed directly on the machine
(or on certain spare parts), as well as arrows indicating
the direction of rotation which must be observed.
You must ensure that all these markings remain legible.
Non-observance of these safety or operating instructions
can result in equipment damage or incorrect operation of
the machine, this instruction must be taken seriously.
2.3 Danger in the event of non-
observance of the safety rules
Non-observance of the safety rules can also result in
physical danger, equipment danger or pollution of the
environment.
Failuretoobservethesafetyruleswillresultin the loss
of rights to damages or compensation.
2.4 Operating range
Electrical supply : as indicated on the manufacturer’s
rating plate and in accordance with current standards.
Safety rules
General danger
Risk of burning
Electrical danger
Chemical danger
Danger of damage
due to pressure
Escape of gas
Important
Your GENEGLACE is designed to operate within the
following limits :
Type of fluid : R22 & R 404A
(for other fluids : consult us)
Maximum working pressure (MWR) See page 7
Ambient air temperature : + 5 to + 35°C
(dry bulb)
Minimum evaporating temperature : - 25°C
Temperature of water to be frozen : + 5 to + 25°C
Mains water pressure : 2 to 4 bar
Hardness of mains water: TH 15 to 20° French°
Acidity of mains water : PH 7/8
Sodium chloride content : about 100 g/m³.
Electrical protection : IP 44
Any use of the GENEGLACE machine outside these
limits could result in malfunctions, or even damage.
Altitude : if greater than 500 m, consult us.
All installation and servicing is to be performed by qua-
lified personnel in compliance with all relevant practices
and safety procedures.
Note that all local and regional regulations and safety
standards, such as EN378, must be taken into account
when designing, connecting and running the system.
Concerningaccessibilityto the machine by the public, the
operator is responsible for protecting himself against any
accident that may occur associated with its mechanical,
electrical or chemical operation.
2.2 Qualification and training of
personnel

6
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
3.1 Safety rules
Starting and stopping a GENEGLACE.
Use the switch provided for this purpose on the electrical
terminal box.
CAUTION
When stopping, the rotating part of the generator
maintains a residual rotation that may cause an
accident.
If it is difficult to reach the Start/Stop switch (machine
mounted high up), request a remote control at a more
convenient height.
Ifitis necessarytoswitchthe machine off,use theisolating
switch on the electrical terminal box (three phase). Lock
the equipment with a padlock on the isolating switch to
prevent inadvertent starting of the machine.
Theprincipal area ofdangeris located insidetheice maker
itself, enclosed by an upper cover and a base cover.
It is dangerous to place the hands or any object into this
area while the rotating part is turning, for example during
a normal cleaning operation of the water system.
It is recommended that the machine be stopped and
switched off for cleaning or that the emergency switch on
the upper part is used.
If the rotating part is driven by a reduction gear and a
motor through a belt, a guard that can removed by using
tools is provided. Operation of the machine without this
guard is prohibited.
The operation of manual valves is strictly reserved for
maintenance personnel with the necessary skills (risk of
spurting of fluids under pressure).
In the event of a general power failure, protect yourself
againstanyrisk when the power returns(unintendedstart-
ing): keep personnel away from dangerous areas.
Operationofthe machine without theoriginalsafetyequip-
ment is prohibited: torque limiter, electrical protection,
pressostats,thermostats,transmission guards, etc.These
devices must be maintained in working condition and the
pictograms indicating the dangers must remain visible.
The drawing below indicates the principal dangerous
areas of the GENEGLACE.
3. Safety and Environmental Instructions
3.2 Protection of the Environment
Materials and fluids resulting from the disposal of ma-
chines must be treated via the approved channels in
accordance with current regulations.
Safety and Environmental Instructions
Within the directives of the “MONTREAL PROTOCOL”,
any service work that might place the cooling system in
communication with the atmosphere must be performed
by skilled personnel.
Theuseofamainssocketoranupstreamisolatingswitch
is prohibited.
Before operating, switch off the installation Before operating, switch off the installation.All other
maintenance, if required, shall be done by a qualified
engineer.

7
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
4. Safety of pressure vessel
Safety of pressure vessel
4.1.1 Service instructions
The GENEGLACE ice generators are pressure vessels, to be incorporated into refrigeration systems
complying with EC Machines Directive 98/79/EEC. Their use is only permitted if they have been incorporated
in refrigeration systems complying with the present instruction and if the refrigeration systems fully comply
with current local regulations.
F15 and F30 generators are designed and built using good engineering practice in
accordance with article 3§3 of Directive 97/23/EC relating to the construction of pressure
vessels.
4.1.1.1 Residual Danger
Pressure vessels can be a source of unavoidable residual danger. Anyone working on such equipment must
therefore carefully read this service instruction and must take into consideration:the precautions to be taken
against accidents, generally recognised safety rules, EU directives and any special requirements of the
country concerned.
4.1.1.2 Location
When used in extreme conditions (for example, in an aggressive atmosphere, in extreme outside
temperatures, etc.) take adequate protective measures. Where appropriate, it is advisable to consult
Geneglace.
Warning !
x Geneglace ice generators are designed to be installed in the “low pressure” sides of refrigeration
systems.
x Geneglace equipment must not be used as a storage reservoir for coolant.
4.1.2 Protection against exceeding permissible limits
xPermissible limits for GENEGLACE « generator only » type pressure vessels
Type (bar)
MWP
Group
of
Refrigerant
T°
Min
°C / °F
T°
Max
°C / °F
Maximum
charge
Kg
F15 1,5
F30 15 2 -30 / -22 +45 / +113 2,5
4.1.3 Pressure relief valve
All systems must be designed and operated so that the maximum working pressure (MWP) in pressure
vessels cannot be exceeded. Pressure relief valves are obligatory and must be correctly rated and installed
by installer (not inclued in the standard scope of supply).
4.1.4 Safety cut-out device
In accordance with current local regulations, safety cut-out devices must be fitted to limit the pressure or
temperature (thermostats and safety pressure regulators).

8
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
5. Installation and Handling of the F15 and F30
Installation and Handling of the F15 and F30
50 kg
B
AC
H1
I
L
H2/H3
D2
DEF
D1
Ea
c
K,Øi
ØG
12
a
b
3
ØG
K,Øi
Net weight
Installation
Minimum clearance for service
Handling
Tightness seal around the boring
1
Raising of the floor to avoid accidental water leaks in the storage
2
Provision should be made in the insulation to enable fixing the ice level detector
3
Dimensions of the base without insulation
B,E
Minimum clearance for reducer removal
D1
Minimum clearance for reamer removal
D2
Ice chute
G
Two fixation screws 8 x 40 mm
K
We advise to foresee enough space around the system for its inspection and maintenance
* Dimensions in mm
A300
C500
D600
F300
D1 300
D2 460
H1 430
H2 600
H3 600
L
I
GB
E
b
a
c
i
240
50
50
80
8
400
520
360
390
GENEGLACE s.a.s.
Tél. [phone]
Installation and handling GTI.001A
Fax [phone]
ZAC de la Forêt - 9, rue des Orfèvres
44840 Les Sorinières - France
COMMERCIAL LAND-BASED
Generator F15
Edition date
GENEGLACE may change this document whitout prior notice
29/01/2009 JPM 0.0
V
90 kg
B
AC
H1
I
L
H2/H3
D2
DEF
D1
a
c
K,Øi
ØG
12
b
3
a
Net weight
Installation
Minimum clearance for service
Handling
Tightness seal around the boring
1
Raising of the floor to avoid accidental water leaks in the storage
2
Provision should be made in the insulation to enable fixing the ice level detector
3
Dimensions of the base without insulation
B,E
Minimum clearance for reducer removal
D1
Minimum clearance for reamer removal
D2
Ice chute
G
Two fixation screws 8 x 40 mm
K
We advise to foresee enough space around the system for its inspection and maintenance
* Dimensions in mm
A500
C300
D700
F500
D1 300
D2 500
H1 500
H2 690
H3 700
L
I
GB
E
b
a
c
i
340
20
20
20
8
500
650
470
470
GENEGLACE s.a.s.
Tél. [phone]
Installation and handling GTI.001A
Fax [phone]
ZAC de la Forêt - 9, rue des Orfèvres
44840 Les Sorinières - France
COMMERCIAL LAND-BASED
Generator F30
Edition date
GENEGLACE may change this document whitout prior notice
29/01/2009 JPM 0.0
V

9
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
6. Dimensions and Connections of the F15 and F30
Dimensions and Connections of the F15 and F30
Generator F15
Minimal clearance for disassembly: See Installation and handling section
mmLength
Item Description Qty.Dimensions Overall Open crate Full crate
Dimensions Item
Width
Height
Volume
Net weight
Gross weigh
Max. water flow 19 l/h Water pressure 2 -> 4 bar
Maximum working pressure 2 MPa (PED 97/23 CE)
mm
mm
m3
kg
kg
0,12 0,72 0,99
Electrical connections
Other specifications
Refrigerating connections
Hydraulic connections
400
520
600
900
800
1000
1000
900
1100
50
115 12550
50 50
EHorizontal heat exchanger
(loose)
1
FIce detection flag (safety) 1
Connections
Item Description Qty. Type MaterialDimensions
AGenerator water supply 1Plain ends tube Chromed brass10/12 mm
A, or 1Threated Chromed brass1/2 " gaz
BOverflow 1Plain ends tube Plastic pipe20/22 mm
Connections
Item Description Qty. Type MaterialDimensions
E1 Heat exchanger-suction line 1O.D.F. Copper7/8 "
E2 Heat exchanger-liquid line 1O.D.F. Copper3/8 "
HSuction 1Plain ends tube Steel26,7 x 2,9 mm
JLiquid inlet 1Flare Brass3/8 "
Item Description Qty. Nominal power Nominal
amperage
Power supply
1 x 90 W 1 x 0,62 AReamer motor 1F1 400 V - 3 - 50 Hz
1 x 70 W 1 x 0,35 APump 1F2 230 V - 1 - 50 Hz
Torque limitor switch 1F3 -
Ice level safety switch (supplied) 1F4 -
* Dimensions in mm
L
I
H1 430
H2 600
600
400
520
H3
Dimensions GENEGLACE s.a.s.
Tél. [phone]
Dimensions and connections GTE.001A
Fax [phone]
ZAC de la Forêt - 9, rue des Orfèvres
44840 Les Sorinières - France COMMERCIAL LAND-BASED
Generator F15
Edition date
Cancels and re
p
laces the document of 20/08/200
4
GENEGLACE may change this document whitout prior notice
29/01/2009 JPM 0.0
V
Generator F30
Minimal clearance for disassembly: See Installation and handling section!
mmLength
Item Description Qty.Dimensions Overall Open crate Full crate
Dimensions Item
Width
Height
Volume
Net weight
Gross weigh
Max. water flow 50 l/h Water pressure 2 -> 4 bar
Maximum working pressure 1,5 MPa (PED 97/23 CE)
mm
mm
m3
kg
kg
0,23 0,72 0,99
Electrical connections
Other specifications
Refrigerating connections
Hydraulic connections
500
650
700
900
800
1000
1000
900
1100
90
155 16590
90 90
EHorizontal heat exchanger
(loose)
1
FIce detection flag (safety) 1
Connections
Item Description Qty. Type MaterialDimensions
AGenerator water supply 1Plain ends tube Chromed brass10/12 mm
A, or 1Threated Chromed brass1/2 " gaz
BOverflow 1Plain ends tube Plastic pipe20/22 mm
Connections
Item Description Qty. Type MaterialDimensions
E1 Heat exchanger-suction line 1O.D.F. Copper7/8 "
E2 Heat exchanger-liquid line 1O.D.F. Copper3/8 "
HSuction 1Plain ends tube Steel26,7 x 2,9 mm
JLiquid inlet 1Flare Brass3/8 "
Item Description Qty. Nominal power Nominal
amperage
Power supply
1 x 90 W 1 x 0,62 AReamer motor 1F1 400 V - 3 - 50 Hz
1 x 70 W 1 x 0,35 APump 1F2 230 V - 1 - 50 Hz
Torque limitor switch 1F3 -
Ice level safety switch (supplied) 1F4 -
* Dimensions in mm
L
I
H1 500
H2 690
700
500
650
H3
Dimensions GENEGLACE s.a.s.
Tél. [phone]
Dimensions and connections GTE.001A
Fax [phone]
ZAC de la Forêt - 9, rue des Orfèvres
44840 Les Sorinières - France COMMERCIAL LAND-BASED
Generator F30
Edition date
Cancels and re
p
laces the document of 20/08/200
4
GENEGLACE may change this document whitout prior notice
29/01/2009 JPM 0.0
V

10
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
10 cm mini
1
2
3
4
5
6.1 Positioning the machine
- Place the generator on a level, flat surface.
- The generator must be located in a position protected
from bad weather, water spray or any other liquid
and in a non-aggressive environment.
- Position the generator so as to maintain adequate ac-
cess for upkeep and maintenance (see Installation
Handling - free access)
- The generator must be mounted sufficiently high, in order
to permit suitable storage for its daily production of ice
(e.g. cold chamber, static or orbital silo, etc.).
- Avoid locating the ice output in the air flow from an
evaporator.
- Do not reduce the cross section of the ice output.
Note
In order to facilitate all upkeep and maintenance
workonthegenerator,(such as regular greasing of
the bearings of the shaft and the reamer), provide
accessibility below and above the machine.
Fig 512. Optional chute, easily removable for mainte
-nance of generator.
Important
Risks of freezing during machine downtime :
protect the base of the pump and valve float by
means of a heater housed in the base.
This device will only be effective for an air tem-
peratureof- 10°C to + 5°Cmaximum for a period
of12to24 h.Beyondthat,itispreferable to drain
themachineif it is stopped.Also protect thewater
supply pipework
Note
When fitting a heater resistance, provide a
circuitbreakerforprotection and a thermostat
to monitor the ambient air temperature.
6.2 Mountings
The opening in the generator mounting must be at least
equal to the diameter «G» of the ice chute.
Important
Do not forget to add a silicone seal all round the
base of the generator to prevent water entering the
ice storage area.
The unit is mounted by the bottom of the base using the
two holes provided for the purpose. Fibre seals ensure
the mountings are watertight.
Positioning the machine
Ice
overflow
area
Access to
emergency
switch
Maxi 45°
Chute
PVC
1 Cap
2 Lag screw
3 Fibre seal
4 Pin
5 Silicone seal
Mounting
In concrete
In woodf

11
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
6.3 Ice level safety detection
The ice level safety detection, consisting of a blade and a probe, is delivered not fitted with your GENEGLACE.
Important
This safety system does not control the ice maker. The ice maker does not re-start automatically after the bin is emplied.
It must be associated with a manual reset device in accordance with electrical diagram 534004.
In order to prevent direct action due to ice flakes falling
on the switch “finger” :
- the blade must be screwed into the lower end of the
central shaft and positioned opposite the reamer,
(see drawing opposite).
- the switch and its end must be positioned in line nith
and underneath on of the supporting arm of the cen-
tral bearing of the generator.
In the case of an insulated wall, we recommend the following method of fixing :
Positioning the machine
Stainless steel
threaded rod
Stainless steel
lock nut
Stainless steel
washer
3 mm - 1/27 inch Ice level
safety switch

12
Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
7. Connections
7.1 Specifications
Connections - Specifications
Specifications
Units
F15 F30
Dimensions
Length x width x height mm 520 x 400 x 600 650 x 500 x 700
Net weight Kg 50 90
Sound level dBa < 70 < 70
Fluid load of R22 or R404A
kg 1.5 2,5
Conditions of operation R22 R404a R22 R404a R22 R404a
Frequency of power supply Hz 50 60 50 60 50 60 50 60 50 60 50 60
Production of temperature
of water to be frozen of +15°C kg/24h 450 450 450 450 650 650 650 650 950 950 950 950
Reamer Speed r.p.h 62 75 62 75 70 75 70 75 98 83 98 83
Thickness of ice flakes mm 1.9 1.8 1.9 1.8 1.9 1.7 1.9 1.7 1.8 2 1.8 2
Evaporation temperature at the
generator °C -18 -17 -20 -19 -20 -18 -22 -20 -23 -21 -23 -23
Required refrigeration power KW 2.33 2.33 2.33 2.33 3.4 3.4 3.4 3.4 4.9 4.9 4.9 4.9
Thermostatic expansion valve Type TX2 TS2 TX2 TS2 TX2 TS2
Orifice No. 2 3 2 3 2 4
Electrical supply V 400V 3 phase + N - 50 Hz / 60 Hz
Power of reducer motor W 90 Three 90 Three
Pump power (single phase) W 70 70
Switches Torque limiter
I S L (supplied not fitted)
Electrical diagrams Power + control, Part no.: 535003
Electrical diagrams for ice level
detection With manual resetting, Part no.: 535004 With automatic resetting, Part no.: 535005
Refrigerant connections
Liquid supply inches 3/8’’ brass nut
Inlet mm
26.9 x 2.65 smooth
steel 26.9 x 2.65 smooth steel
Exchanger (supplied not fitted) inches Inlet 7/8’’ Inlet 1 7/8’’
inches Liquid 3/8’’ Liquid 1/2’’
Hydraulic
Water supply connection mm 15/21 threaded connector or 10 x 12 smooth brass
Overflow connection mm 20 x 22 smooth steel
Water flow rate required (Max)
L/h 21 50
Water pressure required bar 2 to 4

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Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
7.2 Hydraulic connections
Recommendation
Risk of frost : fit the water supply and overflow pipes
withadevice (insulation and/orheater)toprotect them
against freezing.
7.2.1 Connection to the water supply
The water supply should preferably be connected by a
flexible hose to the 15/21 threaded connector + flange.
Rigidpipecan also be used soldered to the 10/12smooth
brass connector.
Note
It is a good idea to fit a shutoff valve in the water in
order to make maintenance operations easier.
Whentighteningthe flange connector, hold the float valve
so that its water outlet is perpendicular to the bottom of
the base and the rod and float valve can move freely up
and down.
Important
In order to prevent malfunctions of your
GENEGLACE and from a food hygiene point of
view, it is a good idea to fit a water filter or purifier
as required.
In fact, filtering the water supply may considerably slow
down the deposition of impurities in your GENEGLACE,
but not scale formation. For this reason, when the hard-
ness of the water is too high, the use of a softener is
required.
Important
In order to prevent malfunctions of your
GENEGLACE it is a good idea to fit a device for pro-
tection against falls in pressure or water flow rate.
7.2.2 Overflow connection
In the event of malfunction of the float valve, the ex-
cess water escapes through the overflow. The overflow
therefore prevents any overflow of water through the ice
descent hole and thus into the ice store.
The overflow water must flow into the drains as required
by the regulations.
The drain pipe must not have a rising portion that could
prevent the natural flow of water, and its slope must be
sufficient.
7.3 Electrical connection
The type of electrical power supply is stated on the rating
plate attached to the generator.
Ensure that the electrical supply for your GENEGLACE
complies with the regulations in force and in the following
respects :
 voltage (Volts)
 three phase or single phase + Earth
 frequency (Hz)
 installed power (KVA)
 nominal current (A)
Important
The cross section of the electrical supply cable
must be adequate for the installed power of the
machine (see rating plate) and comply with cur-
rent standards. An electrical protection device
complying with current standards must be fitted
to protect the various parts of the machine. Using
the electrical diagram of the machine, check the
polarityoftheelectricalconnectionofsingle phase
generators.
Hydraulic and Electrical connections
Anelectricalcontrol box is obligatory to control the opera-
tion of the generator. The electrical sequences and cur-
rent regulations must be followed (refer to the functional
diagram section).
The water consumption of your GENEGLACE is equal to
its ice production
the water supply pressure must be between 2 bar mini-
mum and 4 bar maximum. The water flow rate must al-
ways be constant and greater than that due to the water
consumptionofyour GENEGLACE. If this is not the case,
the installation of a pump and reservoir and/or an expan-
sion valve is essential.

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Contractor’s manual
F15 - F30 Generators
Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
W2U2V2
W1U1V1
U
1
V
1
W
1
10
P
f
13 21
14 22
13 21
14 22
7.3.1 Reamer motor
Inthe caseofathree phasesupply, connectasappropriate
for the characteristics of the electrical supply.
The motors are supplied connected in star.
Where the electrical supply is single phase, 220 Volt, the
reamer motor is fitted with a 10 μf capacitor.
Connect as follows :
If the moving parts assembly does not rotate in the direc-
tion indicated by the arrow on the top, connect the phase
to W1.
7.3.2 Water pump
The water pump operates from 220 Volts, single phase
and is fitted in advance with a 3 m cable.
However if the cable has to be changed, the connections
must be as follows :
7.3.3 Torque limiter switch
Thedrawingbelowshowstheposition of the torque limiter
switch when the generator is operating normally.
7.3.4 High level safety switch
The drawing below shows the position of the high level
safety switch when the generator is operating normally.
Note
In all the above cases, do not forget to connect
the earth terminals.
Electrical connection
Neutral Phase
Neutral (blue)
Phase (brown)
Earth (green /yellow)
Fault
indication
Action on safety
channel
Earth
Earth
Earth
Earth
Operate the switch for
manual resetting and
indication

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Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
3
4
2
1
7.4 Connections to the refrigerating
circuit
7.4.1 General topics concerning the liquid and
suction pipes
Important
Every precaution must be taken to ensure that the
refrigerant piping is clean and free from moisture
and enhances oil return to the compressor.
Concerningthesuctionpipe, as far as possible the loss of
pressurebetweenthe generator and thecompressormust
not exceed a value corresponding to a variation of about
1 to 2°C in the temperature of the saturated fluid.
7.4.2 Generator and refrigerating system
located at the same level
F15 and F30 generators are fitted with a thermostatic ex-
pansion valve.Aheat exchanger is supplied not mounted
with the generator. Install it according to the diagram
below, horizontally and close to the generator.
The diameters of pipes «section 7» can be retained for a
maximum developed length of 6 m.
7.4.3 Generator and refrigerant systems
located at different levels
In the case where the compressor and the generator are
mountedat differentlevels, certain precautionsconcerning
the piping must be taken into account.
7.4.3.1 Suction pipe
Thesuction pipe must bearranged with aslope descend-
ingtowardsthecompressorandany part of the piping that
could constitute a fluid trap must be avoided.
Wherever the suction piping has to rise, a siphon must be
providedtoformanoil trap at the output from the evapora-
tor. It is advisable to install a double siphon three metres
from the rising piping.
Regarding the section of suction piping sloping towards
the compressor, a reverse siphon must be placed at the
top in order to prevent any return behind of oil.
Where the suction piping is very long, it is recommended,
after a section of ascending piping of sufficient size to en-
sure the correct oil carry-over, that a change is made to a
larger cross section in order to minimise pressure drop.
The suction piping must be thermally insulated in accord-
ance with current technology.
Thethermalinsulation must haveathicknessofat least 13
mm and must tight to vapour migration (this is to prevent
rotting of the insulating material).
7.4.3.2 Liquid pipe
Any gas trap must be avoided, that is any section of pip-
ing in an inverted «U» so as not to interrupt the flow of
liquid.
Asolenoid valveon the liquidline must shutoffthe supply
ofrefrigerantfluidfromthegeneratorin order to avoid any
risk of liquid fluid flowing into the compressor.
Where the difference in level is greater than about 5 m, it
is recommended that the liquid pipe is increased in size.
In this case, it is possible that the selection of the expan-
sion valve may have to be reconsidered, no longer taking
into account the condensation pressure but the pressure
existing upstream of the expansion valve.
Connections to the refrigerating circuit
Refer to the section «Safety Concerning Pressu-
rised Equipment».
4 m/s or more
4 m/s or more
8 to 12 m/s
Max
3 m
Max
3 m
10 hour
bulb
Suction
HP Fluid
Insulation
0,5 %
0,5 %
–Supplied with the
generator - - - To be fitted on site
1Thermostatic
expansion valve 3Evaporating pressure
regulator (if required)
2Heat exchanger
F15 - 7/8 - 3/8
F30 - 1"1/8 - ½
4Liquid solenoide valve

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Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
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1 2 3 4 5 6
R
8. Initial start up
This section gives the chronological order of the checks
and actions to be carried out before, during and after the
initial start up of your GENEGLACE in complete safety.
This is why, before operation of your GENEGLACE, we
invite you to refer to the recommendations suggested in
this section, by ticking X the boxes corresponding to
the checks you carry out. (See section‘’Commissioning
Check List’’).
8.1 Checks and adjustments
8.1.1 Hydraulics
Ensure that the water flow rate is greater than the
quantity of water required for maximum production
of your GENEGLACE and that the water quality is
as required.
Check that the water supply pressure of your ma-
chine lies between 2 and 4 bar.
Check, by pressing on the valve float, that water is
reaching the base.
8.1.1.1 Presetting the float valve
The float valve has two basic settings.
The first setting is the level of water in the base.
The level must be sufficient to prevent cavitation of the
pumpthrough lack ofwateron theonehandand toprevent
overflow on the other hand.
The second setting is for the water flow rate, which must
correspond to the quantity of water necessary for the
maximum ice production rate of your GENEGLACE.
Fig. 7111. Illustration of the float valve in its closed and open
positions.
♦ Setting the level
By turning the screw 6, adjust the water level in the
base while observing the following dimensions :
Once the adjustment of the water level in the base has
been completed, lock the setting with the lock nut 5.
♦ Adjusting the flow rate
♦ Measure
Adjusting the flow rate of the float valve must be carried
out when its flow rate is not sufficient to provide the water
required for the production of ice in your GENEGLACE.
In this case :
shut-off the water supply and remove the inlet
connector of the machine.
Unlock the nut 2, (see fig. 7111)
Unscrew adjustment 1 in the housing 3 to increase
the flow rate.
Lock the setting by locking the nut 2 on the housing
3,thenormalsetting of dimension R varies from 1 to
3 mm.
Adjust the water level
To prevent flooding of the ice container if the float
valve sticks open, check, with the machine stopped,
that the flow rate of the valve when the float is
completelysubmergeddoesnotexceedthecapacity
of the overflow.
If, after 1 hour of operation, the level in the base is
lower than the minimum level, increase the flow rate
of the valve as described above
Tip
At the first start up, submerge the float to obtain a
water level close to the overflow, in order to assist
priming of the pump.
Initial start up
Water level in the ‘’Base’’ F15 / F30
Maximum shut-off level 50 mm
Minimum operating level 40 mm
Stroke

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Manual For F15 and F30 - Mill.: 2008 - 11 / Mod. : JPM 05 Page
8.1.3.2 Levels in the distribution tank
The water level must be a minimum of 15mm and a
maximum of 1mm below the dent at the top of the
upper water tray.
Inthiscase,checkthatthewaterreachestheoverflowpipe
of the distribution tank and is continuously removed by it.
Correct level (minimum 15 mm)
If the water level in the distribution tank is too low, raise
the overflow pipe or refer to the section «Adapting of the
water pump».
If the water level in the distribution tray is much too high,
check that the holes in the tank are not blocked or file
down the base of the overflow pipe or refer to the section
« Adapting of the water pump».
8.1.2 Electrical system
Wechecked previously that the water pump was function-
ing correctly.
Adjust all the circuit breakers to the values corre-
sponding to the nominal current consumed by their
respective motors.
Adjust or preset the time delays.
Checking the reamer motor :
Check that the motor is correctly coupled.energise
the motor from a separate supply to check :
that the direction of rotation of the rotating parts is
the same as that shown by the arrow marked on the
top of the generator
that the speed of rotation of the reamer corresponds
to the production rate of the machine (see “Specifi
cations”)
Note
The speed of the reamer is the number of
complete revolutions made by all the rotating
parts in one hour.
At the same time, check the operation of the torque
limiter by causing it to trip.
Todothisit issufficienttotripthetorque limiterbymanually
moving the roller of its microswitch. To reset the limiter,
hold the reamer motor with both hands and turn it a few
degrees in a clockwise direction
Fig.712. Illustration of resetting the torque limiter after trip-
ping.
Check the operation of the high level safety switch
by tripping it.
8.1.3 Refrigerating checks
8.1.3.1Before initial start up
Check for leaks in the refrigerating system.
Ensure that the expansion bulb is correctly located
on the suction pipe, is held securely and is well
insulated.
In the case of an independent refrigerating system,
that is a generator connected to a compressor
alone,thefluidchargeofthegeneratorisindicatedin
the section (“Specifications” under “Connections”).
The installer must provide the charge for the remain-
der of the system.
Initial start up
For generators F15 and F30, the water level in the up-
per water distribution tray is obtained by the flow rate of
the water pump and the regulation of its over flow tube.
In order to check the water level, switch on the pump
alone after checking that the water level in the base is
sufficient.
Tripping the
torque limiter
Resetting the
torque limiter
Overflow pipe
Dent

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Manual For F15 and F30 - Mill.: 2008 - 11 / Mod.: JPM 05
Page
8.1.3.2 Starting your ice machine
Check that the starting procedure of your
GENEGLACE is carried out as described in the sec-
tion ‘’ Diagram of operation’’.
Check that the distribution tank is correctly filled with
water.
Adjust the back pressure valve to the reference
suction pressure for your GENEGLACE (in the case
of connection to central refrigeration plant).
Adjust the superheater 4 to 6 °K see section ‘’Adjus-
ting the expansion’’.
Check the correct oil carry-over to the compressor
(in thecaseof refrigerating system with a dedi-
cated compressor).
After a few minutes of operation, check that ice is
forming over the full height of the drum swept by the
reamer.
If this is not the case, see the section ‘’Faults’’.
8.1.4 Other checks
Check that the ice is stripped correctly.
If after a few minutes of operation the generator
makes a significant noise when the ice is stripped or
the ice has difficulty in releasing itself, see sections
‘’Faults and Addition of salt’’.
Check that the wipers are performing their function
(no water flowing into the ice store). To adjust the
wipers see section’’Adjusting the wipers’’.
Check, by simulating the presence of ice while
pressingontheswitch, that the ice safety detector is
operational.
If required, adjust the salt dosage. See section
‘’Addition of salt’’.
Important
The high ice safety detector is, as its name indi-
cates, a safety device for the generator and not a
control device. For this reason, it should never be
used for the purpose of controling the quantity of
ice in the bin.
8.1.4.1 Addition of salt
 Check that the salt addition system is operating correctly.
8.2 Recommended uses
In the case of an independent refrigerating system, leave
thepowersupply of thesystemswitchedon during periods
of stoppage : the crankase heater must remain live.
In the same case, after a long period without electrical
power, power on at least 3 hours before starting-up.
Avoid short duration run and stop periods. It is preferable
to leave the machine operating for 4 hours rather than
short-cycling it 4 times 1 hour on and 1 hour off.
During prolonged stoppages (more than a week), it is
advisable to run the machine for 1 hour without adding
salt and to drain and dry the base.
Management of a stock of ice :
The basis for calculating the effective volume is : 500 kg
about of freshly flaked ice for 1m3of storage.
To keep the ice fresh, do not keep it for more than 2
days.
The ice storage container must be emptied at least once
a week so that the user has no difficulty in extracting the
ice. There is also a risk of damage to the GENEGLACE,
by a build-up of ice in the generator.
8.3 Start-up report
A start-up report at the initial start up will :
- enable you to check the correct operation of your
installation by noting a few key points of operation.
- Open all right for warrantly.
You will find an initial start up report at the end of this
notice, it has four headings.
- Points to note : description of the inspection or check
to be carried out.
- Values : generally a physical quantity to be measured
and entered or a box to be ticked as checked.
- Where to note : the exact location of the note or check
tobemade in relation to the fluid diagramattached
to the note.
- How to note : for the purpose of helping you to make
themostaccurate note possible by means of a
precise procedure.
Initial start up