Koolaire STH045 8/15 User manual

Technician’s
Handbook
This manual is updated as new information and models are
released. Visit our website for the latest manual. www.kool-aire.com
KOOLAIRE
Ice Machines
Part Number STH045 8/15
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Safety Notices
As you work on Koolaire 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.
Throughout this handbook, you will see the following
types of safety notices:
!Warning
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
!Caution
Text in a Caution box alerts you to a situation in
which you could damage the equipment. Be sure
to read the Caution statement before proceeding,
and work carefully.
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Procedural Notices
As you work on Koolaire equipment, be sure to read
the procedural notices in this handbook. These notices
supply helpful information which may assist you as
you work.
Throughout this handbook, you will see the following
types of procedural notices:
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about the procedure you
are performing.
Important
Text in an Important box provides you with
information that may help you perform a
procedure more efficiently. Disregarding this
information will not cause damage or injury, but it
may slow you down as you work.
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Read These Before Proceeding:
!Caution
Proper installation, care and maintenance are
essential for maximum performance and trouble-
free operation of your equipment. Visit our
website www.kool-aire.com for manual updates,
translations, or contact information for service
agents in your area.
Important
Routine adjustments and maintenance
procedures outlined in this handbook are not
covered by the warranty.
!Warning
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.
!Warning
Do not use electrical appliances or accessories
other than those supplied by Koolaire for your ice
machine model.
!Warning
Two or more people or a lifting device are
required to lift this appliance.
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!Warning
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.
!Warning
Do not damage the refrigeration circuit when
installing, maintaining or servicing the unit.
!Warning
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 this appliance.
!Warning
All covers and access panels must be in place
and properly secured, before operating this
equipment.
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!Warning
Do not obstruct machine vents or openings.
!Warning
Do not store gasoline or other flammable vapors
or liquids in the vicinity of this or any other
appliance.
!Warning
Do not clean with water jet.
!Warning
It is the responsibility of the equipment owner to
perform a Personal Protective Equipment Hazard
Assessment to ensure adequate protection
during maintenance procedures.
!Warning
Two or more people are required to move this
equipment to prevent tipping.
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!Warning
When using electric appliances, basic
precautions must always be followed, including
the following:
a. Read all the instructions before using
the appliance.
b. To reduce the risk of injury, close
supervision is necessary when an
appliance is used near children.
c. Do not contact moving parts.
d. Only use attachments recommended or
sold by the manufacturer.
e. Do not use outdoors.
f. For a cord-connected appliance, the
following must be included:
• Do not unplug by pulling on cord. To
unplug, grasp the plug, not the cord.
• Unplug from outlet when not in use
and before servicing or cleaning.
• Do not operate any appliance with a
damaged cord or plug, or after the
appliance malfunctions or is dropped
or damaged in any manner. Contact
the nearest authorized service facility
for examination, repair, or electrical
or mechanical adjustment.
g. Follow applicable lock out tag out
procedures before working on
equipment.
h. Connect to a properly grounded outlet
only.
We reserve the right to make product
improvements at any time. Specifications and
design are subject to change without notice.
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Part Number STH045 8/15 9
Table of Contents
GENERAL INFORMATION
Model Numbers . . . . . . . . . . . . . . . . . . . . .13
How to Read a Model Number . . . . . . . . .14
Ice Machine Warranty Information . . . . .15
Commercial Warranty Coverage . . . . .15
Residential Warranty Coverage . . . . .18
Limited Warranty for Ice Storage Bins . .21
Limited Warranty . . . . . . . . . . . . . . . . .21
INSTALLATION
Location of Ice Machine . . . . . . . . . . . . . .25
Ice Machine Clearance Requirements . .26
Clearance Requirements . . . . . . . . . . . . .26
Ice Machine Heat of Rejection . . . . . . . . .27
Leveling the Ice Machine . . . . . . . . . . . . .27
Electrical Requirements . . . . . . . . . . . . . .28
Water Service/Drains . . . . . . . . . . . . . . . .29
Water Supply . . . . . . . . . . . . . . . . . . . .29
Water Inlet Lines . . . . . . . . . . . . . . . . .29
Drain Connections . . . . . . . . . . . . . . . .30
Cooling Tower Applications . . . . . . . . .30
MAINTENANCE
Interior Cleaning and Sanitizing . . . . . . .33
General . . . . . . . . . . . . . . . . . . . . . . . .33
Cleaning and Sanitizing Procedure . . .33
Toggle switch Operation . . . . . . . . . . .34
Remove Parts for Cleaning . . . . . . . . .38
Preventative Maintenance Cleaning . . . .40
Ice Machine Inspection . . . . . . . . . . . . . .41
Cleaning the Condenser . . . . . . . . . . . . .42
Removal from Service/Winterization . . .43
Air-cooled Models . . . . . . . . . . . . . . . .43
Water-cooled Models . . . . . . . . . . . . .43
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10 Part Number STH045 8/15
OPERATION
Ice Making Sequence of Operation . . . . 45
Control Board Timers . . . . . . . . . . . . 46
Energized Parts Chart . . . . . . . . . . . . 48
Operational Checks . . . . . . . . . . . . . . . . . 50
Ice Thickness Check . . . . . . . . . . . . . 50
TROUBLESHOOTING
Control Board Test Mode . . . . . . . . . . . . 51
Diagnosing an Ice Machine that Will Not Run
52
Ice Machine Does Not Cycle Into Harvest
when Water Loses Contact with the Harvest
Float Switch . . . . . . . . . . . . . . . . . . . . . . . 53
IceMachineCyclesInto Harvest BeforeWater
loses Contact with the Harvest Float Switch
55
Ice Production Check . . . . . . . . . . . . . . . 56
Installation/Visual Inspection Checklist 57
Water System Checklist . . . . . . . . . . . . . 58
Ice Formation Pattern . . . . . . . . . . . . . . . 59
Safety Limits . . . . . . . . . . . . . . . . . . . . 61
Analyzing Discharge Pressure . . . . . . . . 68
Analyzing Suction Pressure . . . . . . . . . . 70
Harvest Valve . . . . . . . . . . . . . . . . . . . . . . 74
Comparing Evaporator Inlet/Outlet
Temperatures . . . . . . . . . . . . . . . . . . . . . . 78
Discharge Line Temperature Analysis . 79
Refrigeration Component Diagnostics . 81
Final Analysis . . . . . . . . . . . . . . . . . . . 83
Refrigeration Component Diagnostic Chart
84
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Part Number STH045 8/15 11
COMPONENT CHECK PROCEDURES
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . .87
Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . .88
Float Switch . . . . . . . . . . . . . . . . . . . . . . .90
Compressor Electrical Diagnostics . . . .92
Fan Cycle Control . . . . . . . . . . . . . . . . . . .94
High Pressure Cutout (HPCO) Control . .95
Refrigeration Components . . . . . . . . . . .96
Head Pressure Control Valve . . . . . . .96
HarvestPressure Regulating (HPR) System
Remote Condenser Only . . . . . . . . . . .100
Water Regulating Valve . . . . . . . . . . .103
Refrigerant Recovery/Evacuation . . . . . .104
Definitions . . . . . . . . . . . . . . . . . . . . . .104
Refrigerant Re-use Policy . . . . . . . . . .105
Recovery and Recharging Procedures 107
Remote Condenser Model Procedure .110
System Contamination Cleanup . . . . . . .113
Determining Severity of Contamination 113
Mild System Contamination Cleanup
Procedure . . . . . . . . . . . . . . . . . . . . . .115
Severe System Contamination Cleanup
Procedure . . . . . . . . . . . . . . . . . . . . . .116
Replacing Pressure Controls without
Removing Refrigerant Charge . . . . . . .117
Refrigerant Amount . . . . . . . . . . . . . . . . .119
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12 Part Number STH045 8/15
YCHARTS
Cycle Times, 24 Hr. Ice Production and
Refrigerant Pressure Charts . . . . . . . . . . 121
K0250A Self-contained Air-cooled . . . 122
K0350A Self-contained Air-cooled . . . 123
K0350W Self-contained Water-cooled 124
K0420A Self-contained Air-cooled . . . 125
K0420W Self-contained Water-cooled 126
K0500A Self-contained Air-cooled . . . 127
K0500W Self-contained Water-cooled 128
K0600A Self-contained Air-cooled . . . 129
K0600W Self-contained Water-cooled 130
K1000A Self-contained Air-cooled . . . 131
K1000W Self-contained Water-cooled 132
K1000N Remote Air-cooled . . . . . . . . 133
K1350A Self-contained Air-cooled . . . 134
K1350W Self-contained Water-cooled 135
K1350N Remote Air-cooled . . . . . . . . 136
DIAGRAMS
Wiring Diagrams . . . . . . . . . . . . . . . . . . . 137
Wiring Diagram Legend . . . . . . . . . . . 137
K0250, K0350, K0420, K0500, K0600,
K1000 
Self contained Air OR Water-cooled . . 138
K1000 Remote Air-cooled . . . . . . . . . 139
K13500 - K1800 Air or Water-cooled . 140
K13500 - K1800 Air or Water-cooled . 141
K13500 - K1800 remote Air-cooled . . 142
K13500 - K1800 remote Air-cooled . . 143
Electronic Control Board . . . . . . . . . . . 144
Refrigeration Tubing Schematics . . . . . 145
Self-contained Air or Water-cooled . . . 145
Remote Air-cooled . . . . . . . . . . . . . . . 146
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Part Number STH045 8/15 13
General Information
Model Numbers
This manual covers the following models:
Self-Contained
Air-Cooled Self-Contained Water-Cooled Remote
KD0250A
KY0250A ---- ---- ---- ----
KD0350A
KY0350A KD0350W KY0350W ---- ----
KD0420A
KY0420A KD0420W KY0420W ---- ----
KD0500A
KY0500A KD0500W KY0500W ---- ----
KD0600A
KY0600A KD0600W KY0600W ---- ----
KD1000A
KY1000A KD1000W KY1000W KY1000N KD1000N
KD1350A
KY1350A KD1350W KY1350W KY1350N KD1350N
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14 Part Number STH045 8/15
How to Read a Model Number
!Warning
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.
A - Air-cooled
W - Water-cooled
N - Remote Air-cooled
Series Condenser
Type
Model
K D 0350 A E
D - Dice
Y - Half-dice
Cube Size
E - WRAS 50Hz
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Part Number STH045 8/15 15
Ice Machine Warranty Information
Owner Warranty Registration Card
General
Warranty coverage begins the day the ice machine is
installed.
If the OWNER WARRANTY REGISTRATION CARD is
not returned, we will use the date of sale to the
Distributor as the first day of warranty coverage for
your new ice machine.
COMMERCIAL WARRANTY COVERAGE
The Koolaire brand warranty is administered through
Manitowoc Ice (hereinafter referred to as the
“COMPANY”) warrants for a period of 36 months from
the installation date (except as limited below) that new
ice machines manufactured by the COMPANY shall be
free of defects in material or workmanship under
normal and proper use and maintenance as specified
by the COMPANY and upon proper installation and
start-up in accordance with the instruction manual
supplied with the ice machine. The COMPANY’s
warranty hereunder with respect to the compressor
and evaporator shall apply for an additional tenty four
months, excluding all labor charges.
The obligation of the COMPANY under this warranty is
limited to the repair or replacement of parts,
components, or assemblies that in the opinion of the
COMPANY are defective. This warranty is further
limited to the cost of parts, components or assemblies
and standard straight time labor charges at the
servicing location.
Important
Complete and mail the OWNER WARRANTY-
REGISTRATION CARD as soon as possible to
validate the installation date.
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16 Part Number STH045 8/15
Time and hourly rate schedules, as published from
time to time by the COMPANY, apply to all service
procedures. Additional expenses including without
limitation, travel time, overtime premium, material cost,
accessing or removal of the ice machine, or shipping
are the responsibility of the owner, along with all
maintenance, adjustments, cleaning, and ice
purchases. Labor covered under this warranty must be
performed by a COMPANY Factory Authorized
Service Company or a refrigeration service agency as
qualified and authorized by the COMPANY’s local
Distributor. The COMPANY’s liability under this
warranty shall in no event be greater than the actual
purchase price paid by customer for the ice machine.
The foregoing warranty shall not apply to (1) any part
or assembly that has been altered, modified, or
changed; (2) any part or assembly that has been
subjected to misuse, abuse, neglect, or accidents; (3)
any ice machine that has been installed and/or
maintained inconsistent with the technical instructions
provided by the COMPANY; or (4) any ice machine
initially installed more than five years from the serial
number production date. This warranty shall not apply
if the Ice Machine’s refrigeration system is modified
with a condenser, heat reclaim device, or parts and
assemblies other than those manufactured by the
COMPANY, unless the COMPANY approves these
modifications for specific locations in writing.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES OR GUARANTEES OF ANY
KIND, EXPRESSED OR IMPLIED, INCLUDING
ANY IMPLIED WARRANTY OF
MERCHANTABILITY OR FITNESS FOR A
PARTICULAR PURPOSE. In no event shall the
COMPANY be liable for any special, indirect,
incidental or consequential damages. Upon the
expiration of the warranty period, the COMPANY’s
liability under this warranty shall terminate. The
foregoing warranty shall constitute the sole liability of
the COMPANY and the exclusive remedy of the
customer or user.
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Part Number STH045 8/15 17
To secure prompt and continuing warranty
service, the warranty registration card must be
completed and sent to the COMPANY within five
(5) days from the installation date.Authorized
Warranty Service
To comply with the provisions of the warranty, a
refrigeration service company qualified and authorized
by your Koolaire distributor, or a Factory Authorized
Servicer must perform the warranty repair.
Service Calls
Normal maintenance, adjustments and cleaning as
outlined in this manual are not covered by the
warranty.
For factory assistance Contact:
Manitowoc Foodservice Ice Machine Division
2110 South 26th Street, PO Box 1720,
Manitowoc WI, 54221-1720 Telephone: [phone]
Fax: [phone]
Website: www.kool-aire.com
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18 Part Number STH045 8/15
RESIDENTIAL WARRANTY COVERAGE
WHAT DOES THIS LIMITED WARRANTY COVER?
Subject to the exclusions and limitations below,
Manitowoc Foodservice (“Manitowoc”) warrants to the
original consumer that any new ice machine
manufactured by Manitowoc (the “Product”) shall be
free of defects in material or workmanship for the
warranty period outlined below under normal use and
maintenance, and upon proper installation and start-
up in accordance with the instruction manual supplied
with the Product.
HOW LONG DOES THIS LIMITED WARRANTY
LAST?
Product CoveredWarranty Period
Ice MachineTwelve (12) months from the sale date
WHO IS COVERED BY THIS LIMITED WARRANTY?
This limited warranty only applies to the original
consumer of the Product and is not transferable.
WHAT ARE MANITOWOC’S OBLIGATIONS UNDER
THIS LIMITED WARRANTY?
If a defect arises and Manitowoc receives a valid
warranty claim prior to the expiration of the warranty
period, Manitowoc shall, at its option: (1) repair the
Product at Manitowoc’s cost, including standard
straight time labor charges, (2) replace the Product
with one that is new or at least as functionally
equivalent as the original, or (3) refund the purchase
price for the Product. Replacement parts are
warranted for 90 days or the balance of the original
warranty period, whichever is longer. The foregoing
constitutes Manitowoc’s sole obligation and the
consumer’s exclusive remedy for any breach of this
limited warranty. Manitowoc’s liability under this limited
warranty is limited to the purchase price of Product.
Additional expenses including, without limitation,
service travel time, overtime or premium labor
charges, accessing or removing the Product, or
shipping are the responsibility of the consumer.
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Part Number STH045 8/15 19
HOW TO OBTAIN WARRANTY SERVICE
To obtain warranty service or information regarding
your Koolaire product, please contact:
MANITOWOC ICE
2110 So. 26th St.
P.O. Box 1720,
Manitowoc, WI 54221-1720
Telephone: [phone] Fax: [phone]
www.kool-aire.com
WHAT IS NOT COVERED?
This limited warranty does not cover, and you are
solely responsible for the costs of: (1) periodic or
routine maintenance, (2) repair or replacement of the
Product or parts due to normal wear and tear, (3)
defects or damage to the Product or parts resulting
from misuse, abuse, neglect, or accidents, (4) defects
or damage to the Product or parts resulting from
improper or unauthorized alterations, modifications, or
changes; and (5) defects or damage to any Product
that has not been installed and/or maintained in
accordance with the instruction manual or technical
instructions provided by Manitowoc. To the extent that
warranty exclusions are not permitted under some
state laws, these exclusions may not apply to you.
Except As Stated In The Following Sentence, This
Limited Warranty Is The Sole And Exclusive Warranty
Of Manitowoc With Regard To The Product. All Implied
Warranties Are Strictly Limited To The Duration Of The
Limited Warranty Applicable To The Products As
Stated Above, Including But Not Limited To, Any
Warranty Of Merchantability Or Of Fitness For A
Particular Purpose.
Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not
apply to you. Continued on next page …
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20 Part Number STH045 8/15
In No Event Shall Manitowoc Or Any Of Its Affiliates
Be Liable To The Consumer Or Any Other Person For
Any Incidental, Consequential Or Special Damages Of
Any Kind (Including, Without Limitation, Loss Profits,
Revenue Or Business) Arising From Or In Any Manner
Connected With The Product, Any Breach Of This
Limited Warranty, Or Any Other Cause Whatsoever,
Whether Based On Contract, Tort Or Any Other
Theory Of Liability.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
HOW STATE LAW APPLIES
This limited warranty gives you specific legal rights,
and you may also have rights that vary from state to
state or from one jurisdiction to another.
REGISTRATION CARD
To secure prompt and continuing warranty service, this
warranty registration card must be completed and sent
to Manitowoc within thirty (30) days from the sale date.
Complete the following registration card and send it to
Manitowoc.
For factory assistance Contact:
Manitowoc Foodservice Ice Machine Division
2110 South 26th Street, PO Box 1720,
Manitowoc WI, 54221-1720 Telephone: [phone]
Fax: [phone]
Website: www.kool-aire.com
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