Koolaire KDT0300A User manual

Part Number STH063 9/17
Koolaire
KT Model Ice Machines
Technician’s Handbook

Safety Notices
Read these precautions to prevent personal injury:
• Read this manual thoroughly before operating,
installing or performing maintenance on the
equipment. Failure to follow instructions in this
manual can cause property damage, injury or death.
• Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
• Proper installation, care and maintenance are essential
for maximum performance and trouble-free operation
of your equipment.
• Visit our website www.manitowocice.com for manual
updates, translations, or contact information for
service agents in your area.
• This equipment contains high voltage electricity and
refrigerant charge. Installation and repairs are to be
performed by properly trained technicians aware of
the dangers of dealing with high voltage electricity
and refrigerant under pressure. The technician
must also be certified in proper refrigerant handling
and servicing procedures. All lockout and tag out
procedures must be followed when working on this
equipment.
• This equipment is intended for indoor use only. Do not
install or operate this equipment in outdoor areas.
• As you work on this equipment, be sure to pay close
attention to the safety notices in this handbook.
Disregarding the notices may lead to serious injury
and/or damage to the equipment.

nWarning
Follow these electrical requirements during
installation of this equipment.
• All field wiring must conform to all applicable
codes of the authority having jurisdiction. It is
the responsibility of the end user to provide the
disconnect means to satisfy local codes. Refer to
rating plate for proper voltage.
• This appliance must be grounded.
• This equipment must be positioned so that the plug
is accessible unless other means for disconnection
from the power supply (e.g., circuit breaker or
disconnect switch) is provided.
• Check all wiring connections, including factory
terminals, before operation. Connections can
become loose during shipment and installation.

nWarning
Follow these precautions to prevent personal injury
during installation of this equipment:
• Installation must comply with all applicable
equipment fire and health codes with the authority
having jurisdiction.
• To avoid instability the installation area must be
capable of supporting the combined weight of the
equipment and product. Additionally the equipment
must be level side to side and front to back.
• Remove all removable panels before lifting and
installing and use appropriate safety equipment
during installation and servicing. Two or more
people are required to lift or move this appliance to
prevent tipping and/or injury.
• Do not damage the refrigeration circuit when
installing, maintaining or servicing the unit.
• Connect to a potable water supply only.
• This equipment contains refrigerant charge.

nWarning
Follow these precautions to prevent personal injury
while operating or maintaining this equipment.
• Refer to nameplate to identify the type of refrigerant
in your equipment.
• Only trained and qualified personnel aware of the
dangers are allowed to work on the equipment.
• Read this manual thoroughly before operating,
installing or performing maintenance on the
equipment. Failure to follow instructions in this
manual can cause property damage, injury or death.
• Crush/Pinch Hazard. Keep hands clear of moving
components. Components can move without
warning unless power is disconnected and all
potential energy is removed.
• Moisture collecting on the floor will create a
slippery surface. Clean up any water on the floor
immediately to prevent a slip hazard.

nWarning
Follow these precautions to prevent personal injury
while operating or maintaining this equipment.
• Objects placed or dropped in the bin can affect
human health and safety. Locate and remove any
objects immediately.
• Never use sharp objects or tools to remove ice or
frost.
• Do not use mechanical devices or other means to
accelerate the defrosting process.
• When using cleaning fluids or chemicals, rubber
gloves and eye protection (and/or face shield) must
be worn.
DANGER
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications. This
appliance is not intended for use by persons (including
children) with reduced physical, sensory or mental
capabilities, or lack of experience and knowledge,
unless they have been given supervision concerning
use of the appliance by a person responsible for their
safety. Do not allow children to play with, clean or
maintain this appliance without proper supervision.

nWarning
Follow these precautions to prevent personal injury
during use and maintenance of this equipment:
• It is the responsibility of the equipment owner to
perform a Personal Protective Equipment Hazard
Assessment to ensure adequate protection during
maintenance procedures.
• Do Not Store Or Use Gasoline Or Other Flammable
Vapors Or Liquids In The Vicinity Of This Or Any
Other Appliance. Never use flammable oil soaked
cloths or combustible cleaning solutions for
cleaning.
• All covers and access panels must be in place and
properly secured when operating this equipment.
• Risk of fire/shock. All minimum clearances must be
maintained. Do not obstruct vents or openings.
• Failure to disconnect power at the main power
supply disconnect could result in serious injury or
death. The power switch DOES NOT disconnect all
incoming power.
• All utility connections and fixtures must be
maintained in accordance with the authority having
jurisdiction.
• Turn off and lockout all utilities (gas, electric, water)
according to approved practices during maintenance
or servicing.

Table of Contents
Part Number STH063 9/17 9
General Information
Model Numbers................................ 13
How to Read a Model Number.................. 14
Ice Machine Warranty Information ............. 14
Installation
Location of Ice Machine ........................ 15
Ice Machine Clearance Requirements ........... 16
Ice Machine Heat of Rejection .................. 17
Leveling the Ice Machine ....................... 17
Electrical Requirements ........................ 18
Water Service/Drains........................... 19
Water Supply ...........................19
Water Inlet Lines ........................19
Drain Connections.......................20
Cooling Tower Applications ...............20
Water Supply and Drain Line Sizing/
Connections ...........................21
Remote Condenser ......................22
Maximum Line Set Distance Formula ......... 25
Operation
Ice Making Sequence of Operation.............. 27
Control Board Timers ....................28
Safety Limits............................29
Energized Parts Chart ....................31
Operational Checks............................. 33
Ice Thickness Check......................33
Minimum/Maximum Slab Weights .........34

10 Part Number STH063 9/17
Maintenance
Interior Cleaning and Sanitizing ................. 35
General................................35
Cleaning and Sanitizing Procedure .........35
Toggle Switch Operation..................36
Remove Parts for Cleaning ................40
Preventative Maintenance Cleaning ............ 42
Ice Machine Inspection ......................... 43
Cleaning the Condenser ........................ 44
Removal from Service/Winterization............ 45
Air-cooled Models .......................45
Water-cooled Models ....................45
Troubleshooting
Control Board Test Mode ....................... 47
Diagnosing an Ice Machine that Will Not Run ... 48
Ice Machine Does Not Cycle Into Harvest when
Water Loses Contact with the Harvest Float Switch
................................................ 49
Ice Machine Cycles Into Harvest Before Water Loses
Contact with the Harvest Float Switch .......... 51
Ice Production Check ........................... 52
Installation/Visual Inspection Checklist ......... 53
Water System Checklist......................... 54
Ice Formation Pattern .......................... 55
Safety Limits............................58
Analyzing Discharge Pressure .................. 65
Analyzing Suction Pressure ..................... 67
Harvest Valve .................................. 71
Comparing Evaporator Inlet/Outlet Temperatures ..
................................................ 75
Discharge Line Temperature Analysis............ 76
Refrigeration Component Diagnostics........... 78
Procedure..............................79
Final Analysis ...........................80
Refrigeration Component Diagnostic Chart...... 81

Part Number STH063 9/17 11
Component Check Procedures
Main Fuse ..................................... 85
Bin Switch ..................................... 86
Float Switch.................................... 88
Compressor Electrical Diagnostics............... 90
Fan Cycle Control............................... 92
High Pressure Cutout (HPCO) Control ........... 93
Refrigeration Components...................... 94
Head Pressure Control Valve ..............94
Freeze Cycle Operation All Models .........95
Harvest Cycle Operation..................95
Harvest Pressure Regulating (Hpr) System
Remote Condenser Only..................98
Water Regulating Valve..................101
Refrigerant Recovery/Evacuation ..............102
Definitions ............................102
Refrigerant Re-use Policy ................103
Recovery and Recharging Procedures .....105
System Contamination Cleanup ...........107
Determining Severity of Contamination ....107
Mild System Contamination Cleanup Procedure
.....................................109
Severe System Contamination Cleanup
Procedure.............................110
Replacing Pressure Controls without Removing
Refrigerant Charge .....................111
Refrigerant Amount ...........................113

12 Part Number STH063 9/17
Charts
Cycle Times, 24 Hr. Ice Production and Refrigerant
Pressure Charts ...............................115
KT0300A Self-contained Air-cooled ........116
KT0400A Self-contained Air-cooled ........117
KT0400W Self-contained Water-cooled ....118
KT0420A Self-contained Air-cooled ........119
KT0420W Self-contained Water-cooled ....120
KT0500A Self-contained Air-cooled ........121
KT0500W Self-contained Water-cooled ....122
KT0700A Self-contained Air-cooled ........123
KT0700W Self-contained Water-cooled ....124
KT1000A Self-contained Air-cooled ........125
KT1000W Self-contained Water-cooled ....126
KT1000N Remote Air-cooled .............127
Kt1700A Self-contained Air-cooled ........128
KT1700W Self-contained Water-cooled ....129
KT1700N Remote Air-cooled .............130
Diagrams
Wiring Diagrams ..............................131
KT0300, KT0500, KT0700, KT1000 1 Ph
Self-contained Air/Water-cooled .........132
KT0420 1Ph Self-contained Air/Water-cooled ..
.....................................134
KT1000 1Ph Remote Air-cooled Condenser .136
KT1700 1Ph Self-contained Air/Water-cooled ..
.....................................138
KT1700 3Ph Self-contained Air/Water-cooled ..
.....................................140
KT1700 1Ph Remote Air-cooled Condenser .142
KT1700 3Ph Remote Air-cooled Condenser .144
Electronic Control Board.................146
Refrigeration Tubing Schematics ...............148
Self-contained Air or Water-cooled ........148
Remote Air-Cooled Condenser ...........149

Part Number STH063 9/17 13
Model Numbers
This manual covers the following models:
Self-Contained
Air-Cooled
Self-Contained
Water-Cooled
Remote
KDT0300A ---- ----
KYT0300A ---- ----
KDT0400A KDT0400W ----
KYT0400A KYT0400W ----
KDT0420A KDT0420W ----
KYT0420A KYT0420W ----
KDT0500A KDT0500W ----
KYT0500A KYT0500W ----
KDT0700A KDT0700W ----
KYT0700A KYT0700W ----
KDT1000A KDT1000W KYT1000N
KYT1000A KYT1000W KDT1000N
KDT1700A KDT1700W KYT1700N
KYT1700A KYT1700W KDT1700N
General Information

14 Part Number STH063 9/17
How to Read a Model Number

Cube Size
Series
Capacity
Condenser
Type
E - WRAS 50Hz
A - Air-cooled
W - Water-cooled
R - Regular
D - Dice
Y - Half-dice
nWarning
An ice machine contains high voltage electricity and
refrigerant charge. Repairs are to be performed by
properly trained refrigeration technicians aware of the
dangers of dealing with high voltage electricity and
refrigerant under pressure.
Ice Machine Warranty Information
For warranty information visit:
http://www.manitowocice.com/Service/Warranty
• Warranty Verification
• Warranty Registration
• View and download a copy of the warranty Owner
Warranty Registration Card
Warranty coverage begins the day the ice machine is
installed.
T - R410A
Refrigerant

Part Number STH063 9/17 15
Location of Ice Machine
The location selected for the ice machine must meet the
following criteria. If any of these criteria are not met,
select another location.
• The location must be indoors.
• The location must be free of airborne and other
contaminants.
• Air temperature: Must be at least 40°F (4°C) but must
not exceed 110°F (43.4°C).
• The location must not be near heat-generating
equipment or in direct sunlight.
• The location must be capable of supporting the weight
of the ice machine and a full bin of ice.
• The location must allow enough clearance for water,
drain, and electrical connections in the rear of the ice
machine.
• The location must not obstruct airflow through or
around the ice machine (condenser air flow is in
the back and out the sides). Refer to the chart for
clearance requirements.
• The ice machine must be protected if it will be
subjected to temperatures below 32°F (0°C). Failure
caused by exposure to freezing temperatures is not
covered by the warranty.
Installation

16 Part Number STH063 9/17
Ice Machine Clearance Requirements
nWarning
Do not obstruct ice machine vents or openings.
 Self-Contained
Air-Cooled
Self-Contained
Water-Cooled
Top/Sides 12" (30.5 cm) n/a
Back 5" (12.7 cm)* n/a



Self-Contained
Air-Cooled
Water-Cooled
and Remote
Top/Sides 8" (20.3 cm) 8" (20.3 cm)
Back 5" (12.7 cm) 5" (12.7 cm)
,Caution
The ice machine must be protected if it will be
subjected to temperatures below 32°F (0°C). Failure
caused by exposure to freezing temperatures is not
covered by the warranty.

Part Number STH063 9/17 17
Ice Machine Heat of Rejection
Series
Ice Machine
Heat of Rejection1
Air Conditioning2Peak
KT0300 4600 5450
KT0400 3800 6000
KT0420 5400 6300
KT0500 5300 6100
KT0700 9000 13900
KT1000 17000 20700
KT1700 24700 29000
1 B.T.U./Hour
2 Because the heat of rejection varies during the ice making cycle,
the figure shown is an average.
Ice machines, like other refrigeration equipment, reject heat
through the condenser. It is helpful to know the amount of
heat rejected by the ice machine when sizing air conditioning
equipment where self-contained air-cooled ice machines are
installed.
Leveling the Ice Machine
1. The leveling legs must be screwed into the bottom of
the bin as far as possible.
,Caution
The legs must be screwed in tightly to prevent them
from bending.
2. Move the bin into its final position.
3. Use a level on top of the bin. Adjust each foot as
necessary and level from front to back and side to
side.

18 Part Number STH063 9/17
Electrical Requirements
Voltage
The maximum allowable voltage variation is ±10% of the
rated voltage on the ice machine model/serial number
plate at start-up (when the electrical load is highest).
Fuse/Circuit Breaker
A separate fuse/circuit breaker must be provided for each
ice machine.
Total Circuit Ampacity
The total circuit ampacity is used to help select the wire
size of the electrical supply.
The wire size (or gauge) is also dependent upon location,
materials used, length of run, etc., so it must be
determined by a qualified electrician.
Refer to ice machine data plate, for electrical
requirements. The ice machine data plate information
overrides all other published data.
nWarning
All wiring must conform to local, state and national
codes.
nWarning
The ice machine must be grounded in accordance with
national and local electrical code.

Part Number STH063 9/17 19
Water Service/Drains
WATER SUPPLY
Local water conditions may require treatment of the water
to inhibit scale formation, filter sediment, and remove
chlorine odor and taste.
Important
If you are installing a water filter system, refer to the
Installation Instructions supplied with the filter system
for ice making water inlet connections.
nWarning
For ice making, connect to a potable water supply only.
WATER INLET LINES
Follow these guidelines to install water inlet lines:
• Do not connect the ice machine to a hot water supply.
Be sure all hot water restrictors installed for other
equipment are working. (Check valves on sink faucets,
dishwashers, etc.)
• If water pressure exceeds the maximum recommended
pressure, 80 psig (5.5 bar) obtain a water pressure
regulator from your Koolaire distributor.
• Install a water shut-off valve for ice making potable
water.
• Insulate water inlet lines to prevent condensation.

20 Part Number STH063 9/17
DRAIN CONNECTIONS
Follow these guidelines when installing drain lines to
prevent drain water from flowing back into the ice
machine and storage bin:
• Drain lines must have a 1.5-inch drop per 5 feet of run
(2.5 cm per meter), and must not create traps.
• The floor drain must be large enough to accommodate
drainage from all drains.
• Install a tee to vent the ice machine drain to the
atmosphere.
• Insulate drain lines to prevent condensation.
COOLING TOWER APPLICATIONS
Water Cooled Models Only
A water-cooling tower installation does not require
modification of the ice machine. The water regulator valve
for the condenser continues to control the refrigeration
discharge pressure.
It is necessary to know the amount of heat rejected, and
the pressure drop through the condenser and water valves
(inlet to outlet) when using a cooling tower on an ice
machine.
• Water entering the condenser must not exceed 90°F
(32.2°C).
• Water flow through the condenser must not exceed 5
gallons (19 liters) per minute.
• Allow for a pressure drop of 7 psig (.48 bar) between
the condenser water inlet and the outlet of the ice
machine.
• Water exiting the condenser must not exceed 110°F
(43.3°C).
,Caution
Plumbing must conform to state and local codes