Kastel KP 21/5 User manual

All rights reserved. No part of this publication may be reproduced without the written authorisation of the manufacturer
KASTEL s.r.l. - Via Fusina, 1/A- 31033
Castelfranco Veneto - Treviso - Italy
AUTOMATIC ICE MAKER
USER MANUAL
I GB

2
ENGLISH
INDEX
1.INTRODUCTION TOMACHINEOPERATION Page 3
Operatingcycledescription Page 3
Operationaldiagram Page 3
2.TECHNICALDATA Page 4
Icemakertechnical features Page 4
Dimensionstable Page 5
Ice cube size Page5
3.MALFUNCTIONS-CAUSES-ACTIONS TOBETAKEN Page 6
4. PARTS SECTION Page 8
Casing Page8
Water system Page10
Refrigeratingsystem Page 12
5.ATTACHMENTS Page 14
Instructionsbooklet Page14
Icelevel thermostat adjustmentdiagram Page23
Evaporatorthermostat adjustmentdiagram Page24
Timeroperationaldiagram Page25
Drainfitting diagram Page26
Electrical diagram KP21 - KP25 Page27
Electrical diagram KP28 - KP50 Page28
Electrical diagram KP75 - KP130 Page29
ElectricaldiagramKP160 Page 30
Refrigeratingsystem diagram Page31
IDENTIFICATION PLATE

3
ENGLISH
1INTRODUCTION TO MACHINE OPERATION
OPERATING CYCLE DESCRIPTION
Correctly connect the ice maker to power and water mains, fill up the water tank and bring the machine
switch to position “I”. Power will get to the compressor, water pump and fan motors, switching them on to
start the freezing cycle. The nozzles will begin spraying water into the caps.
Astheevaporatorthermostat bulb reaches the right temperature, the freezing cycletimerstartsoff.
At the set time, the water pump stops and the water load (to top up the tank) and cycle reversal solenoid
valvesareopened. Heat is pumped to theevaporatorand, as a result, the icecubesare dropped from the
copper caps into the ice storage bin. When the bin is full, the ice level thermostat stops ice production.
As the evaporator thermostat reaches the preset temperature, the cycle reversal timer starts off.At the set
time,thewater load and cycle reversal solenoid valvesareclosedand the machine starts a newfreezing
cycle.
OPERATIONALDIAGRAM

4
ENGLISH
2TECHNICAL DATA
ICE MAKERS - TECHNICAL DETAILS
Mod. Production Storage Cooling Gas Cubesin Voltage Power
24h capacity system refrigerant a cycle max.
(Kg) (Kg) (N°) (W)
KP 21/5 21 5 A R404A 24 230V~50Hz 420
21 5 W R404A 24 230V~50Hz 420
KP 22/5 22 5 A R404A 24 230V~50Hz 420
22 5 W R404A 24 230V~50Hz 420
KP 25/6 25 6 A R404A 24 230V~50Hz 420
25 6 W R404A 24 230V~50Hz 420
KP 28/7 28 7 A R404A 24 230V~50Hz 530
28 7 W R404A 24 230V~50Hz 530
KP 30/10 30 10 A R404A 24 230V~50Hz 530
30 10 W R404A 24 230V~50Hz 530
KP 44/15 44 15 A R404A 36 230V~50Hz 700
44 15 W R404A 36 230V~50Hz 700
KP 50/26 50 26 A R404A 36 230V~50Hz 800
50 26 W R404A 36 230V~50Hz 800
KP 75/40 75 40 A R404A 60 230V~50Hz 950
75 40 W R404A 60 230V~50Hz 950
KP 100/60 100 60 A R404A 60 230V~50Hz 1200
100 60 W R404A 60 230V~50Hz 1200
KP 130/75 130 75 A R404A 108 230V~50Hz 1350
130 75 W R404A 108 230V~50Hz 1350
KP 160/75 160 75 A R404A 108 230V~50Hz 1700
160 75 W R404A 108 230V~50Hz 1700
KP 150 MOD. 150 - A R404A 108 230V~50Hz 1700
150 - W R404A 108 230V~50Hz 1700
KP 300 MOD. 300 - A R404A 216 230V~50Hz 3500
300 - W R404A 216 230V~50Hz 3500

5
DIMENSION TABLE
ENGLISH
ICE CUBE DIMENSIONS
Ice cube weigh = 17 g
MACHINE MACHINE WITH PACKAGE
Mod. L P H Foot Net L P H Volume Gross
weight weight
(mm) (mm) (mm) (mm) (Kg) (mm) (mm) (mm) (m3) (Kg)
KP21/5
KP22/5 430 530 680 0,154
KP25/6 360 450 585 0÷10 35 38
KP28/7 605 38 710 0,18 42
KP30/10 685 40 790 0,2 44
KP44/15 685 52 820 0,31 57
KP50/26 795 55 930 0,35 61
KP75/40 915 72 1050 0,58 80
KP100/60 1015 87 1150 0,64 96
KP130/75 108 118
KP160/75 113 123
KP150 870 560 730 - 97 925 640 860 0,51 109
KP300 1255 595 860 - 153 1310 640 1015 0,9 170
350 450 575 34 37
390 465 466 536
500 585 0÷20 576 656
740 605 816 676
55÷85
840 740 1070 916 816 1210 0,9

6
ENGLISH
PROBLEM - REASON - SOLUTION
3
PROBLEM REASON SOLUTION
No water supply Check the water system
Switching on the machine, it
doesn’t start No power supply Check the electrical system
No refrigerant in the ice maker Probable gas leak from the cooling
system. Repear the leak
The condensation cycle is not
correctly effected
Air cooled system:
- possible faulty fan motor
- possible faulty pressure switch
Water cooled system:
- no water in the cooling system
(see “ the safety thermostat
operates”)
Blow-by of the freon from the gas
valve Change gas valve
Blow-by of water throught the
water inlet valve Change water inlet valve
The ice maker effects the cycle
but it doesn’t produce ice
Low performance of the
compressor Change compressor
Dirty or faulty water pump First clean water pump, eventually
change it
Obstructed suntion filter of the
pump Check and clean the filter
Faulty or obstructed water inlet
valve First clean the valve, eventually change it
Faulty timer: it doesn’t open the
valve Change timer
Dirty or obstructed sprayers Check the sparyers and clean
them
Water leak fromthe bin Check bin seal
No water spraid during spaying
period
The overflow gasket is damaged Check and eventually change the
gasket
The hot gas valve doesn’t open
when operated Check electrical system
Check the valva and eventually
change it
Faulty evaporator thermostat Change the thermostat
No water filled up in the bin Check water flow in the evaporator
The thermostat operates or it is
faulty Check if the bin thermostat has operated and eventually change it
The defrost is not correctly
effected
Blocked timer Change the timer
Faulty evaporator thermostat Change the evaporator thermostat
Sheet of ice under the
evaporator Faulty or blocked timer Change the timer

7
ENGLISH
PROBLEM REASON SOLUTION
Faulty bin thermostat Check and eventually change the
bin thermostat
The ice makers works also when
the bin is full Bin thermostat not calibrated Check the thermostat and
eventually calibrate it
No electrical supply Check water system
Blocked water valve Check and eventually change the
water valve
Faulty pressure switch Check and eventually change the
pressure switch
The safety thermostat operates
Scale in the water condenser Clean the condenser with apposite
anti scale products
Low water level in the bin See ” no water spraid from
sprayers”
Evaporator thermostat not
calibrated Calibrate thermostat
Not standard water jets Check that each jet sprays directly without obstacles the center of the
copper cups
The ice maker is not in the correct
horizontal position Check the feet and place in the right horizontal position
Small quantity of refrigerant in the
cooling system Repear eventula leaks and recharge the refrigerant
The ice cubes are not complete
See also “decreasing of production”
High ambient temperature and/or
small air circulation
Change place of installation of the
ice maker or change ambient
temperature
Obstracted position of the machine
(e.g. inside a furniture) Change place of installation or permit air circulation
Dirty air condenser Clean the condenser with
compressed air
High water temperature Check water temperature and
change place of installation
Bin full of water Check drain pipe of the bin
Decreasing of production
Small quantity of refrigerant in the
cooling system Repear eventula leaks and recharge the refrigerant
The compressor is short-circuited
and/or grounded Check and change the compressor
The pump is short-circuited and/or
grounded Check and change the pump
The hot gas valve is short-circuited
and/or grounded Check and change the hot gas valve
The thermostats are grounded Check and change the thermostat
Other electrical componets are
short-circuited and/or grounded Check and change the component
The circuit breaker operates
Circuit breaker differential is faulty Check and change the component

8
4PARTS SECTION
ENGLISH
BODY

9
Pos. Description Note 21/5 22/5 25/6 28/7 30/10 44/15 50/26 75/40 100/60 130/75 160/75
1 Foamed body K00997 K00997 K00997 K00471 K00470 K00469 K00468 K00466 K00467 K00473
2a Right angle K00155 K00155 K00155 K00155 K00155 K00126 K00126 K00052 K00052 K00446
2b Left angle K00704 K00704 K00704 K00704 K00704 K00703 K00703 K00702 K00702 K00706
3 Base assembly K00803 K00803 K00803 K00154 K00154 K00123 K00123 K00550 K00550 K00549
4 Rightpanel K00832 K00805 K00995 K01613 K01615 K01618 K01620 K01623 K01625 K01628
5 Left panel K00831 K00804 K00996 K01614 K01616 K01619 K01621 K01624 K01626 K01629
6 Door K00828 K00816 K00816 K00241 K00241 K00245 K00245 K00249 K00249 K00456
7 Front panel K00830 K00811 K00811 K00182 K00165 K00136 K00194 K00063 K00214 K00455
8 Back grid K00844 K00844 K00844 K00173 K00173 K00195 K00195 K00065 K00065 K00450
9 Back panel K00810 K00810 K00810 K00178 K00163 K00134 K00191 K00059 K00211 K00448
10 Top assembly K01369 K01393 K01651 K01658 K01658 K01659 K01659 K01656 K01656 K01657
11 Door support K00834 K00834 K00834 K00273 K00273 K00274 K00274 K00275 K00275 K00224
12 Thermostat pocket K00896 K00896 K00896 K00895 K00895 K00043 K00043 K00043 K00043 K00043
13 Foot K01086 K01086 K01086 K01086 K01086 K01574 K01574 K01341 K01341 K01341
14 Bush K01148 K01148 K01148 K01148 K01148 K01148 K01148 K01148 K01148 K01148
ENGLISH
BODY

10
ENGLISH
Pos. Description Note 21/5 22/5 25/6 28/7 30/10 44/15 50/26 75/40 100/60 130/75 160/75
1 Tank K00800 K00800 K00800 K00149 K00149 K00144 K00144 K00045 K00045 K00300 K00300
2 Tank support / / / K00152 K00152 K00121 K00121 K00036 K00036 K00439 K00439
3 Evaporator support K00817 K00817 K00817 K00151 K00151 K00120 K00120 K00041 K00041 K00320 K00320
4 Flag support assembly K00826 K00826 K00826 K00225 K00225 K00653 K00653 K00556 K00556 K00227 K00227
5 Flag K00008 K00008 K00008 K00008 K00008 K00008 K00008 K00008 K00008 K00008 K00008
6 Pawl K00013 K00013 K00013 K00013 K00013 K00013 K00013 K00013 K00013 K00013 K00013
7 Suction filter K00012 K00012 K00012 K00012 K00012 K00012 K00012 K00012 K00012 K00012 K00012
8 Suction ring K00058 K00058 K00058 K00058 K00058 K00058 K00058 K00058 K00058 K00058 K00058
9 Suction pipe K00823 K00823 K00823 K00185 K00142 K00142 K00198 K00072 K00218 K00218 K00218
10 Pump assembly W K01530 K01530 K01530 K00553 K00553 K00553 K00553 K00553 K00553 K01164 K01164
A K01302 K01302
WATERWORKS

11
ENGLISH
11 Fan W / / / K01023 K01023 K01023 K01023 K01023 K01023 K01023 K01023
A K01301 K01301
12 Inlet pipe K00824 K00824 K00824 K00184 K00141 K00141 K00197 K00109 K00217 K00217 K00217
13 Inlet ring K00057 K00057 K00057 K00057 K00057 K00057 K00057 K00057 K00057 K00057 K00057
14 Bar pipe K00048 K00048 K00048 K00048 K00048 K00048 K00048 K00048 K00048 / /
15 Sprayers bar assembly K00825 K00825 K00825 K00171 K00171 K00133 K00133 K00047 K00047 K00316 K00316
16 Sprayers K00220 K00220 K00220 K00220 K00220 K00220 K00220 K00220 K00220 K00220 K00220
17 Plug K00527 K00527 K00527 K00527 K00527 K00527 K00527 K00527 K00527 K00527 K00527
18 Chute K00820 K00820 K00820 K00157 K00157 K00124 K00124 K00024 K00024 K00334 K00334
19 Fan motor assembly W K01083 K01083 K01083 / / / / K01083 K01083 K01083 K01083
A K01380 K01380 K01380 / / / / / / / /
20 Overflow assembly K01317 K01317 K01317 K01317 K01317 K01317 K01317 K01317 K01317 K01317 K01317
21 Gasket K01125 K01125 K01125 K01125 K01125 K01125 K01125 K01125 K01125 K01125 K01125
22 Overflow drain K00006 K00006 K00006 K00006 K00006 K00006 K00006 K00006 K00006 K00006 K00006
23 Gasket K00536 K00536 K00536 K00536 K00536 K00536 K00536 K00536 K00536 K00536 K00536
24 Ring nut K01126 K01126 K01126 K01126 K01126 K01126 K01126 K01126 K01126 K01126 K01126
25 Overflow pipe / / / / K00541 K00542 K00543 K00540 K00544 K00545 K00545
26 Drain screw nut K00004 K00004 K00004 K00004 K00004 K00004 K00004 K00004 K00004 K00004 K00004
27 Gasket K00003 K00003 K00003 K00003 K00003 K00003 K00003 K00003 K00003 K00003 K00003
28 Drain stub pipe K00039 K00039 K00039 K00039 K00039 K00039 K00039 K00039 K00039 K00039 K00039
29 Drain pipe K00110 K00110 K00110 K00110 K00110 K00110 K00110 K00110 K00110 K00110 K00110
30 Nipple water outlet W K00578 K00578 K00578 K00578 K00578 K00578 K00578 K00578 K00578 K00578 K00578
A K00001 K00001 K00001 K00001 K00001 K00001 K00001 K00001 K00001 K00001 K00001
31 Watervalve W K01045 K01045 K01045 K01045 K01045 K00204 K00204 K01322 K01322 K01195 K01046
A K01212 K01212 K01212 K01212 K01212 K01213 K01213 K01213 K01213 K01214 K01214
32 Hydrohelectrical support K00822 K00822 K00822 K00030 K00030 K00030 K00030 K01146 K01146 K01146 K01146
33 Cable K01324 K01324 K01324 K01324 K01324 K01324 K01324 K01324 K01324 K01324 K01324
34 Wye / / / / / / / K00010 K00010 K00010 K00010
35 Valve support W //////////K00330
36 Nipple W //////////K01160
37 Pressure valve W //////////K00497
38 Union tee / / / / / / / / / K00230 K00230
39 Bar pipe / / / / / / / / / K00445 K00445
40 Bar pipe / / / / / / / / / K00444 K00444
41 Pipe / / / / / / / / / K00311 K00311
Pos. Description Note 21/5 22/5 25/6 28/7 30/10 44/15 50/26 75/40 100/60 130/75 160/75
WATERWORKS
W: WATER A: AIR

12
ENGLISH
COOLINGSYSTEM

13
1 Evaporator K00145 K00145 K00145 K00145 K00139 K00139 K00138 K00138 K00332 K00332
2 Hot gas valve K01531 K01531 K01531 K01531 K01531 K01531 K01531 K01531 K01532 K01532
3 Compressor K00200 K00200 K00200 K01186 K00202 K00085 K00085 K00206 K00475 K00476
4 Water condenser ass. W K00278 K00278 K00278 K00112 K00147 K00147 K00017 K00017 K00333 K00333
5 Condenser support W K00279 K00279 K00279 K00113 K00146 K00146 K00029 K00029 K00335 K00335
6 Gas filter K00199 K00199 K00199 K00199 K00199 K00199 K00081 K00081 K00478 K00478
7 Safety thermostat W K00076 K00076 K00076 K00076 K00076 K00076 K00076 K00076 K00076 K00076
8 Electric panel K00808 K00808 K00808 K00119 K00119 K00119 K00049 K00049 K00049 K00049
9 On-off switch K00082 K00082 K00082 K00082 K00082 K00082 K00082 K00082 K00082 K00082
10 Timer K00075 K00075 K00075 K00075 K00075 K00075 K00075 K00075 K00075 K00257
11 Evaporator thermostat K00080 K00080 K00080 K00080 K00080 K00080 K00080 K00080 K00080 K00080
12 Bin thermostat K00079 K00079 K00079 K00079 K00079 K00079 K00079 K00079 K00079 K00079
13 Pressure switch K00077 K00077 K00077 K00077 K00077 K00077 K00077 K00077 K00077 K00077
14 Contactor / / / / / / / / / K00500
15 Evaporator cover K00150 K00150 K00150 K00150 K00118 K00118 K00069 K00069 K00226 K00226
16 Air condenser ass. A K01223 K01223 K01223 K01665 K01225 K01225 K01313 K01314 K01314 K01315
Pos. Description Note 21/5 22/5 25/6 28/7 30/10 44/15 50/26 75/40 100/60 130/75 160/75
W: WATER
A: AIR
ENGLISH
COOLINGSYSTEM

14
5ATTACHMENTS
ENGLISH
USER MANUAL

15
ENGLISH
USER MANUAL

16
ENGLISH
USER MANUAL

17
ENGLISH
USER MANUAL

18
ENGLISH
USER MANUAL

19
ENGLISH
USER MANUAL

20
ENGLISH
USER MANUAL