Nordcap SP 125 L User manual

User Manual
Electronic Modular Flaker SP 125 L / W
[Art. 41321100001] / [Art. 41321100002]
2020-01

Page 3
SPECIFICATIONS
ice making capacity
ELECTRONIC MODULAR FLAKER MODEL SPN 125
Important operating requirements:
MIN MAX
• Air temperature 10°C (50°F) 40°C (100°F)
• Water temperature 5°C (40°F) 35°C (90°F)
• Water pressure 1 bar (14 psi) 5 bars (70 psi)
• Electr. voltage
• variations from voltage
• rating specified
• on nameplate -10% +10%
NOTE. The daily ice-making capacity is directly related to the condenser air inlet temperature, water
temperature and age of the machine.
To keep your S IMA G FLAKER at peak performance levels, periodic maintenance checks
must be carried out as indicated on maintenance section of this manual.
Kg.
32 °C27 21 15 10
°C
10
21
o
o
32
38
120
115
110
105
100
95
90
85
80
Kg.
32 °C27 21 15 10
°C
10
21
o
o
32
38
120
115
110
105
100
95
90
85
80
ICE PRODUCED PER 24 HRS.
AIR COOLED MODELS
WATER TEMPERATURE
AMBIENT TEMPERATURE
ICE PRODUCED PER 24 HRS.
WATER COOLED MODELS
WATER TEMPERATURE
AMBIENT TEMPERATURE
2

Page 4
SPN 125 AS Air 120*
SPN 125 WS Water 480*
Start Electric power cons.
Amps Kwh per 24 HR
SPECIFICATIONS
Water req.
lt/24 HR
Model Finish
Cond. unit Comp. HP
* A 15°C water temperature
S. Steel 3/8
Basic electr. Amps Watts Nr. of wires Amps fuse
230/50/1 3.2 17 500 11 3 x 1.5 mm210
SPN 125 - MACHINE SPECIFICATIONS (R134A version)
Dimensions:
HEIGHT (less legs) 525 mm.
HEIGHT (with legs) 542 mm.
WIDTH 563 mm.
DEPTH 536 mm.
WEIGHT 49 Kg.
3

Page 21
OPERATING INSTRUCTIONS
START UP
After having correctly installed the ice maker and
completed the plumbing and electrical
connections, perform the following “Start-up” pro-
cedure.
A. Open the water supply line shutoff valve
and put the unit under electrical power by moving
the main switch, on the power supply line, to the
ON position.
The first LED - GREEN - will glow to signal that
unit is under power.
NOTE. Every time the unit is put under power,
after being kept for sometime in shut-off
conditions (electrically disconnected) the
RED LED will blink for 3 minutes (60' on MF
66 only) after which the unit will start up with
the immediate operation of the gear motor
assembly and, after few seconds, of the
compressor (Fig.1).
B. Elapsed the stand by period the unit starts
operating with the activation in sequence of the
following assemblies:
GEAR MOTOR/S
COMPRESSOR
FAN MOTOR/S (if unit is an air cooled version)
kept under control by the condenser temperatu-
re sensor which has its probe within the condenser
fins (Fig.2).
C. After 2 or 3 minutes from the compressor
start up, observe that flaker ice begins dropping
off the ice spout to fall through the ice chute into
the storage bin.
NOTE. The first ice bits that drop into the ice
storage bin are not so hard as the evaporating
temperature has not yet reached the correct
operating value. It is necessary to allow the
ice - just made - to cure itself and wait for
about ten minutes for the evaporating tem-
perature to reach the correct value so to
make more hard bits of ice.
FIG. 1
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
DATA PROCESSOR
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T>1°C
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
4

Page 22
FIG. 3
FIG. 2
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T 40÷50°C
DATA PROCESSOR
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
DATA PROCESSOR
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T>-1°C
11
10
9
1
2
L
N
8
7
6
5
4
3
10
9
1
2
L
N
8
7
6
5
4
3
12
11
13
13
12
5

Page 23
NOTE. If, after ten minutes from the
compressor start-up, the evaporating tem-
perature has not dropped down to a value
lower than -1
°
C (30
°
F) the evaporating tem-
perature sensor detects such an abnormal
situation and stops consequently the unit
operation (first the compressor and 3' later
the gear reducer).
In this circustance, the 5th warning YELLOW
LED will blink.
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
After having diagnosed and eliminated the
cause of the too hi evaporating temperature
(insufficient refrigerant in the system or
compressor not running) it is necessary to
unplug and plug in again to restart the
machine. The unit, before resuming the
normal operation, will go through the usual
3 minutes STAND-BY period.
OPERATION CHECKS UPON THE UNIT
START UP
D. Remove front service panel and, if
necessary, install the refrigerant service gauges
on the corresponding service valves to check
both the HI and LO refrigerant pressures.
NOTE. On air cooled models, the condenser
temperature sensor, which is located within
the condenser fins, keeps the head
(condensing) pressure between preset
values.
In the event of condenser clogged - such to
prevent the proper flow of the cooling air - or,
in case the fan motor is out of operation, the
condenser temperature rises and when it
reaches 70
°
C (160
°
F) for air cooled version -
and 60
°
C (140
°
F) - for water cooled version -
the condenser temperature sensor shuts-off
the ice maker (first the compressor and 3'
later the gear reducer) with the consequent
light-up of the RED WARNING LIGHT (Fig.3).
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
After having diagnosed the reason of the
temperature rise and removed its cause, it is
necessary to proceed as per the previous
“NOTE” to start up again the operation of the
ice maker.
E. Check for the correct CUT-OUT and
CUT-IN of the water level sensor by first shutting
closed the water shutoff valve on the water
supply line.
FIG. 4
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T>75°C
DATA PROCESSOR
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
6

Page 24
After 3 minutes the unit resumes its total operation
with the immediate start-up of the gear motor
and, few seconds later, of the compressor.
F. Check for the correct operation of the
electronic eye (one per each ice chute on model
1205) of the optical ice level control, by closing
the bottom opening of the vertical ice chute.
Wait the built up of the ice into the ice chute till it
cuts the light beam of the sensing "eyes".
This interruption will cause an immediate blinking
of the Bin Full YELLOW LED located on the front
of the P.C. Board and after about 10 seconds
causes the shutoff of the unit (compressor first
and 3' later the gear reducer) with the
simultaneous lighting (steady) of the Same LED
signalling the full bin situation (Fig.5).
Discharge the ice from the ice chute so to resume
the light beam previously interrupted (YELLOW
LED blinking fast) and after about 10 seconds the
flaker will re-start - through the 3 minutes STAND-
BY period - with the extinguishing of the YELLOW
LED.
This will cause a gradual decrease of the water
level in the float reservoir and as soon as the
level gets below the two vertical metal pins, the
flaker stops to operate (compressor first and 3'
later the gear reducer) and the YELLOW warning
LED will glow to signal the shortage of water
(Fig. 4)
NOTE. The water level sensor detects the
presence of water in the float reservoir and
confirms it to the micro processor by
maintaining a low voltage current flow
between the two metal pins using the water
as conductor.
WARNING. The use of de-mineralized
water (water with no salt content) having
an electrical conductivity lower than 30
µS, will cause break with the consequent
CUT-OUT of the flaker and the glowing of
the YELLOW LED of water shortage, even
with water in the reservoir.
Opening the water supply line shutoff valve to fill
up again the float reservoir, the YELLOW LED
goes off while the RED LED starts blinking.
FIG. 5
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
DATA PROCESSOR
L
N
11
10
9
1
2
7
8
6
5
4
3
12
13
7

Page 25
NOTE. The ICE LEVEL CONTROL
(INFRARED SYSTEM) is independent of the
temperature however, the reliability of its
detection can be affected by external light
radiations or by any sort of dirt and scale
sediment which may deposit directly on the
light source and on the receiver.
To prevent any possible ice maker
malfunction, it is advisable to locate the unit
where it can't be reached by any direct light
beam or light radiation and to follow the
instructions for the periodical cleaning of the
light sensor elements as detailed in the
MAINTENANCE AND CLEANING PROCE-
DURES.
M. If previously installed, remove the refrigerant
service gauges and re-fit the unit service panels
previously removed.
N. Instruct the owner/user on the general
operation of the ice machine and about the
cleaning and care it requires.
8

Page 26
WATER CIRCUIT
The water enter in the machine through the
water inlet fitting which incorporates a strainer -
located at the rear side of the cabinet - then it
goes to the water reservoir flowing through a
float valve.
NOTE. The presence of the water in the float
reservoir is detected by a system of two
sensors which operates in conjunction with
the P.C. Board. The two sensors use the
water as a conductor to maintain a low
voltage current flow between them. In case
the water used is very soft (de-mineralized)
or the float reservoir gets empty the current
flow between the sensors become so weak
or is no longer maintained that, as
consequence, the P.C. Board shutoff the
flaker operation with the simultaneous
glowing of the YELLOW LED signalling
“Shortage of water”.
The float reservoir is positioned at the side of the
freezing at such an height to be able to maintain
a constant water level. The water flows from the
reservoir into the bottom inlet of the freezer to
sorround the stainless steel auger which is
vertically fitted in the center of the freezer.
In the freezer the incoming water gets chilled into
soft (slush) ice which is moved upward by the
rotating action of the auger. The auger rotates
counter-clockwise within the freezer powered by
a direct drive gear motor and carries the ice
upward along the refrigerated freezer inner walls
and by doing so the ice gets progressively thicker
and harder.
The ice, being costantly lifted up, meet the teeth
of the ice breaker which is fitted on the top end of
the auger, where it gets compacted, cracked and
forced to change from vertical into horizontal
motion to be discharged out, through the ice
spout and chute, into the storage bin.
PRINCIPLE OF OPERATION
FLOAT TANK
FLOAT VALVE
FREEZER
SPN 1205
FREEZER WATER
FEED LINE
FREEZER
FLOAT VALVE
ICE SPOUT
FLOAT TANK
SPN 125-255
FREEZER
FLOAT TANK
FLOAT VALVE
SPN 405-605
WATER INLET LINE
WATER INLET LINE
ICE SPOUT
FREEZER
WATER
FEED LINE
WATER INLET LINE
FREEZER
WATER
FEED LINE
ICE SPOUT
9

Page 27
By running the ice maker, i.e. by putting the unit
under power, starts the automatic and continuous
icemaking process which would not stop until the
ice storage bin gets filled-up to the level of the
control “eyes” located on the ice chute. As the ice
level raises to interrupt the light beam running
between the two infrared leds (one or both on
model MF 66), the unit stops after six seconds
(compressor first and 3' later the gear reducer),
with the simulteneous glowing of the YELLOW
LED signalling the “Full Bin” situation.
NOTE. The interruption of the light beam
between the two light sensors is immediately
signalled by the blinking of the BIN FULL
YELLOW LED located on the front of the
P.C. Board.
After about 10" of steady interruption of the
light beam the unit stops and the “Full Bin”
YELLOW LED glows steady.
The ten seconds of delay prevent the unit
from stopping for any undue reason like the
momentarily interruption of the light beam
caused by the flakes that slides along the ice
spout before dropping into the bin.
As some ice gets scooped out from the storage
bin, the light beam between the two sensors
resumes (fast blinking of YELLOW LED) and
tenseconds later the ice machine restarts the ice
making process - going always through the 3'
stand by - and the YELLOW LED goes off.
REFRIGERANT CIRCUIT
The hot gas refrigerant discharged out
from the compressor reaches the
condenser where, being cooled down,
condenses into liquid.
Flowing into the liquid line it passes
through the drier filter, then it goes all
the way through the capillary tube where
it looses some of its pressure so that its
pressure and temperature are lowered.
Next, the refrigerant enters into the
evaporator coil wrapped around the
freezer inner tube.
The water being constantly fed at the
interior of the freezer inner tube, exchan-
ge heat with the refrigerant circulating
into the evaporator coil, this cause the
refrigerant to boil-off and evaporate,
thereby it changes from liquid into vapor.
The vapor refrigerant then passes
through the suction accumulator and
through the suction line where the
refrigerant exchanges heat with the one
flowing into the capillary tube (warmer)
before being sucked into the compressor
to be recirculated.
The refrigerant head pressure is kept
between two pre-set values by the
condenser temperature sensor which
has its probe located within the
condenser fins - in air cooled versions.
CAPILLARY TUBE
DISCHARGE LINE
COMPRESSOR
FAN MOTOR
EVAPORATOR
SPN 1205
ACCUMULATOR
This condenser temperature sensor, when
senses a rising of the condenser temperature
beyond the pre-fixed limit, changes its electrical
resistance and send a low voltage power flow to
the MICRO-PROCESSOR of the P.C. Board
which energizes, through a TRIAC, the Fan
Motor in ON-OFF mode.
On the water cooled versions, the refrigerant
head pressure is kept at the constant value by
the metered amount of water passing through
the condenser which is regulated by the action of
the Water Regulating Valve that has its capillary
SPN 125-255-405-605
ACCUMULATOR
CAPILLARY TUBE
DISCHARGE LINE
EVAPORATOR
FAN MOTOR
COMPRESSOR
CONDENSER
SUCTION LINE
SUCTION LINE
CONDENSER
DRIED
10

Page 28
tube connected to the liquid refrigerant line. As
pressure increases, the water regulating valve
opens to increase the flow of cooling water to the
condenser.
NOTE. In case the condenser temperature
probe senses that the condenser tempera-
ture has rised to 70 ° C on air cooled version
- or 60 ° C on water cooled version - for one of
the following abnormal reasons:
CLOGGED CONDENSER (Air cooled version)
INSUFFICIENT FLOW OF COOLING
WATER (Water cooled version)
FAN MOTOR OUT OF OPERATION (Air
cooled version)
AMBIENT TEMPERATURE HIGHER THEN
43
°
C (110
°
F)
it causes the total and immediate SHUT-OFF
of the machine (compressor first and gear
motor 3' later) in order to prevent the unit from
operating in abnormal and dangerous
conditions.
When the ice maker stops on account of this
protective device, there is a simultaneous
glowing of the RED LED, warning the user of
the Hi Temperature situation.
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
After having eliminated the source of the
excessive condenser temperature, to restart
the ice machine it is necessary to unplug and
plug in again.
The RED LED starts blinking and three
minutes later the flaker unit resume its normal
operating mode. The condenser temperatu-
re sensor has a further safety function which
consist in preventing the unit from operating
in Lo-ambient conditions i.e. when the
condenser temperature - equivalent to the
ambient temperature - is lower then 1
°
C
34
°
F (Fig.6).
As soon as the ambient temperature rises up
to 5 ° C the P.C. Board restarts automatically
the machine on the three minutes starting
time.
The refrigerant suction or Lo-pressure sets gets
to pre set value after few minutes from the unit
start-up.
This value can vary of 0.1 or 0.2 bar (1.5 ÷3
psig) in relation to the water temperture varia-
tions influencing the freezer cylinder.
NOTE. If, after ten minutes from the unit start
up, no ice is made and the evaporating
temperature detected by the evaporator
sensor results to be higher than -1 ° C (30 ° F)
the ice maker stops (compressor first and
gear motor 3' later) and the 5th WARNING
YELLOW LED blinks.
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
FIG. 6
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
T<1°C
DATA PROCESSOR
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
11

Page 29
MECHANICAL SYSTEM
The mechanical system of the SIMAG
Flaker machines consists basically of a gear
motor assembly (two on model 1205) which
drives, through a ratched coupling, a worn shaft
or auger placed on its vertical axis within the
freezing cylinder (two on model 1205).
The gear motor is made of a single phase electric
motor with a permanent capacitor. This motor is
directly fitted in the gear case through which it
drives - in counter clockwise rotation at a speed
of 9.5 r.p.m. - the freezer auger being linked to it
by the ratched coupling.
NOTE. In the event the gear motor (one of
the two on 1205) will tend to rotate in the
wrong direction (counterclockwise) or not
rotating at all or rotating at lower speed the
unit will stop immediately (compressor and
gear motor) with the glowing of the WARNING
YELLOW LED on account of the intervention
of the Electromagnetic Safety Device -
based on Hall Effect principle.
The machine will remain in OFF mode for
one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
After having diagnosed and eliminated the
source of the gear motor wrong rotation, to
restart the unit it is necessary switch OFF
and ON the power line main disconnnect
switch (Fig. 7).
The RED LED will start blinking and after 3
minutes the ice maker will resume its total
operations by running first the gear motor
and then the compressor.
Too low ambient and water temperature (well
below the limitations of respectively 10 °C and
5°C - 50°F and 40°F) or frequent interruptions of
the water supply to the freezing cylinder (clogging
of the water hose connecting the float reservoir to
the water inlet at the bottom of the freezer) may
cause the ice to get too hard and compact loosing
fluidity and thereby seizing the auger.
This situation will put under excessive strain
and load the entire drive system and freezer
bearings.
FIG. 7
2
1
L
N
COMPRESSOR
9
10
11
12
13
3
4
5
6
7
8
CONTACTOR COIL
GEAR MOTOR
FAN MOTOR
ELECTRONIC
CARD
RELAYS
TRIAC
RESET
S E N S O R S
WATER
LEVEL
GEAR MOTOR ROTATION
CONDENSER TEMP.
EVAPORATOR TEMP.
ICE LEVEL CONTROL
TRANSF.
DATA PROCESSOR
11
10
9
1
2
L
N
8
7
6
5
4
3
13
12
12

Page 30
REFRIGERANT METERING DEVICE:
capillary tube
.
REFRIGERANT TYPE
MODEL R134A R404A R452A
MF 26 A 440 gr *** ***
MF 26 W 400 gr *** ***
MF 36 A 700 gr 660 gr ***
MF 36 W 560 gr 520 gr ***
MF 46 A *** 750 gr 950 gr
MF 46 W *** 600 gr 650 gr
MF 56 A *** 980 gr 1000 gr
MF 56 W *** 700 gr 680 gr
MF 66 A *** 2400 gr 2600 gr
MF 66 W *** 1200 gr 2300 gr
MF 26-36 A R134A 8 ÷9 0,3
MF 26-36 W R134A 9,5 0,3
MF36-46-56-66 A R404A 17 ÷18 2,5
MF36-46-56-66 W R404A 17 2,5
MF 46 A R452A 18,5 2.1
MF 46 W R452A 16,1 1,9
MF 56 A R452A 18,5 1,8
MF 56 W R452A 17 1,8
MF 66 A-W R452A 17 1,9
OPERATING PRESSURE
21
°
C temp. amb./15
°
C temp. water
REFRIG.
TYPE
Discharge (bar)
MODEL
Suction (bar)
NOTE. Before charging the refrigerant system
always check the type of refrigerant and
quantity as specified on the individual ice
machine dataplate. The refrigerant charges
indicated are relatives to averages operating
conditions.
13
R134a R404A R452A
SPN125A 440gr *** ***
SPN125W 400gr *** ***
SPN255A 700gr 660gr ***
SPN255W 560gr 520gr ***
SPN405A *** 750gr 950gr
SPN405W *** 600gr 650gr
SPN605A *** 980gr 1000gr
SPN605W *** 700gr 680gr
SPN1205A *** 2400gr 2600gr
SPN1205W *** 1200gr 2300gr
REFRIGERANTTYPE
MODEL
REFRIGERANT CHARGES :
Discharge (bar) Suction (bar)
SPN 125-255 A R134a 8 ÷ 9 0,3
SPN 125-255 W R134a 9,5 0,3
SPN 255-405-605-1205 A R404A 17 ÷ 18 2,5
SPN 255-405-605-1205 W R404A 17 2,5
SPN 405 A R452A 18,5 2,1
SPN 405 W R452A 16,1 1,9
SPN 605 A R452A 18,5 1,8
SPN 605 W R452A 17 1,8
SPN 1205 A-W R452A 17 1,9
OPERATING PRESSURE
21°C Temp. Amb./15°C Temp. Water
REFRIG. TYPEMODEL

Page 31
ture variations and signals them by supplying
current, at low voltage, to the P.C. BOARD.
In case the condenser temperature sensor
detects a temperature at the condenser lower
than +3°C (37°F) that means ambient tempera-
ture too low for the correct unit operation, the
sensor signals to the P.C. BOARD to do not start
up the unit till the ambient temperature rises to
10°C.
In the air cooled versions, in relation to the
different current transmitted, the micro processor
of the P.C. BOARD supplies, through a TRIAC,
the power at high voltage to the fan motor.
In the event the condenser temperature rises
and reaches 60°C or 70 °C according to the
setting of DIP SWITCH number 8 the current
arriving to the micro processor is such to cause an
immediate and total stop of the machine operation.
NOTE. The machine will remain in OFF
mode for one hour then it will restart
automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
To restart the unit after the shutoff caused by
the hi condenser temperature, it is neces-
sary to switch OFF and ON the power line
main disconnect Switch.
D. ELECTROMAGNETIC SENSOR
(Two on SPN 1205 Model)
This safety device is housed on top of the Drive
Motor (one per each motor on MF 66 model) and
detects - based on Hall Effect principle - the
rotating speed and rotating direction of the drive
Motor.
Should the rotating speed drop below 1300 r.p.m.
t he magnitude measured by this device is such
to signal to the microprocessor to stop the unit
and light-up the YELLOW LED. The same
reaction occures when the drive motor will tend
to rotate in the wrong direction (counterclockwise)
or when it doesn't rotate at all.
NOTE. The machine will remain in OFF
mode for one hour then it will restart automa-
tically. In case the unit trips OFF again in
alarm for 3 times in 3 hours, the machine
SHUTS OFF DEFINITIVELY. To restart the
unit after the shutoff caused by this safety
device, it is necessary first to eliminate the
cause that has generated the intervention of
the device and then switch OFF and ON the
power line main disconnect switch.
COMPONENTS DESCRIPTION
A. EVAPORATOR TEMPERATURE
SENSOR
The evaporator sensor probe is inserted into its
tube well, which is welded on the evaporator
outlet line, it detects the temperature of the
refrigerant on the way out from the evaporator
and signals it by suppling a low voltage current
flow to the P.C. Board.
According to the current received, the micro-
processor let the ice maker to continue its
operations or not. In case the evaporating tem-
perature, after 10 minutes from the unit start-up,
does not go below -1 °C (30°F) the evaporator
sensor signals to stop immediately the unit
operation, with the blinking of the 5th Warning
YELLOW LED.
NOTE. The machine will remain in OFF mode
for one hour then it will restart automatically.
In case the unit trips OFF again in alarm for
3 times in 3 hours, the machine SHUTS OFF
DEFINITIVELY.
To restart the unit after the shutoff caused by
the hi evaporating temperature, it is neces-
sary to switch OFF and ON the power line
main disconnect Switch.
B. WATER LEVEL SENSOR
This sensor consists of two small stainless steel
rods vertically fitted on the inner face of the
reservoir cover and electrically connected to the
low voltage circuit of the P.C. Board.
When the cover of the reservoir is positioned in
its place the tips of both the rods dip into the
reservoir water transmitting a low power current
throu the same.
NOTE. In the event of shortage of water in
the reservoir or, in case the water used is too
soft (de-mineralized) to cause greater
resistence to the current flow (electrical
conductivity lower than 30 µ S) this sensor
system causes the shutoff of the machine,
to protect it from running without water or
with an inadequate water quality. In this
situation the YELLOW LED will glow to warn
of the machine shutoff and the reason why.
C. CONDENSER TEMPERATURE SENSOR
The condenser temperature sensor probe,
located within the condenser fins (air cooled
version) or in contact with the tube coil (water
cooled version) detects the condenser tempera
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E. OPTICAL ICE LEVEL CONTROL
(Two on SPN 1205 Model)
The electronic optical ice level control, located
into the ice chute (one in each of the two ice
chutes on 1205 model), has the function to stop
the operation of the ice machine when the light
beam between the light source and the receiver
gets interrupted by the flake ice which
accumulates in the chute.
When the light beam is interrupted the Bin Full
YELLOW LED located in the front of the P.C.
BOARD blinks; in case the light beam gets
interrupted for as long as 6 seconds, the ice
machine stops (drive motor keeps on working by
3' delay then stops) with the glowing-up of the
2nd YELLOW LED to monitor the full ice bin
situation.
The 6 seconds of delay prevents that any minimum
interruption of the light beam due to the regular
ice chuting through the ice spout may stop the
operation of the unit.
As soon as the ice is scooped out (with the
resumption of the light beam between the two
infrared sensor of ice level control) 6 seconds
later the ice machine resumes its operation with
the simul-taneous extinguishing the 2nd YELLOW
LED.
F. P.C. BOARD (Data processor)
The P.C. BOARD, fitted in its plastic box located
in the front of the unit, consists of two separated
printed circuits one at high and the other at low
voltage and protected by fuses.
Also it consists of five aligned LEDS monitoring
the operation of the machine of three jumpers
(TEST used only in the factory, 60/70°C used to
set up the PC Board at proper safety cut out
condensing temperature and 3' to by pass the 3
minutes Stand By) and of input terminals for the
leads of the sensor probes as well as input and
output terminals for the leads of the ice maker
electrical wires.
The P.C. BOARD is the brain of the system and
it elaborates, through its micro processor, the
signals received from the sensors in order to
control the operation of the different electrical
components of the ice maker (compressor, gear
motor, etc.).
The five LEDS, placed in a row in the front of the
P.C. BOARD, monitor the following situations:
GREEN LED
Unit under electrical
power
YELLOW LED
- Blinking: I/R beam cut
out
- Steady: unit shut-off at
storage bin full
- Blinking fast: I/R beam resumed
YELLOW LED
Unit shut-off due to a
too lo-water level into
float tank
RED LED
ON all the time
- Unit shut-off due to a too
hi-condensing temperature
- Unit shut-off due to a too
lo-ambient temperature <+1°C
Blinking
3 minutes start up delay time
YELLOW LED
ON all the time
- Unit shut-off due to the wrong
rotation direction of gear motor
- Unit shut-off due to the
too lo speed of gear motor
Blinking
- Unit shut-off due to a
too hi-evaporating temp.
>-1°C after 10 min of operation
YELLOW AND
RED LED
- Blinking: Evaporator sensor
out of order
- Steady: Condenser sensor
out of order
- Blinking alternatively: Ice level
control out of order
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60/70°C Set up of the Safety Condensing
Temperature Sensor
JUMP IN - 70°C
JUMP OUT - 60°C
H. INTERFACE P.C. BOARD
(Only on SPN 1205 Model)
Used only on 1205 model, it allows to elaborate
the signal received from both the electromagnetic
sensors as well as from both the optical ice level
controls transmitting it to the P.C. Board for the
control of the unit operation.
The Interface P.C. Board is equipped by four
INLET sockets (two for the electromagnetic
sensors and two for the optical ice level controls)
and two OUTLET plugs to be connected to the
sockets of the main P.C. Board.
I. FLOAT RESERVOIR
The float reservoir consist of a plastic water pan
on which is fitted a float valve with its setting
screw. The float valve modulate the incoming
water flow to maintain a constant water level in
the reservoir, level that corresponds to the one in
the freezing cylinder to ensure proper ice
formation and fluidity.
On the inner side of the reservoir cover are
fitted the two water level sensor pins which
detects the presence or the shortage of water
in the reservoir.
G. JUMPERS
The Flaker PC Board is equipped by six jumpers:
PURGE Used on machine equipped with Water
Purge Valve to purge out the water
from the water system every 12 hours
and when the machine restart from the
Bin Full
JUMP IN - Purge OFF
JUMP OUT - Purge ON
PWD Used to Pump Out the water by means
of the Progressive Water Pump
supplied as a kit
JUMP IN - No Progressive Water Pump
installed/in operation - MF Models
JUMP OUT - Progressive Water Pump
installed/in operation
3’/60’ Delay time at start up
JUMP IN - 3 minutes delay
JUMP OUT - 60 minutes delay - MF 66
TEST Factory use ONLY
6/12 M Cleaning remind for the water system -
Red Light blinks/flashes with machine
ON
JUMP IN - No remind
JUMP OUT - 12 months set up
NOTE. To restart the cleaning remind
countdown push and hold the PC Board
button for more of 5 seconds with machine in
operation till the switching OFF of the two
YELLOW Leds.
TO BY-PASS THE 3'/60' STAND BY TIME, SYMPLY JUMP "TEST" CONTACTS WITH PCB ENERGIZED
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NOTE. It is very important to make sure of the
correct fitting of the cover on the reservoir in
order to enable the sensor to efficiently control
the water situation avoiding undue shutoff
interventions.
J. FREEZING CYLINDER or EVAPORATOR
(Two on SPN 1205 Model)
The freezing cylinder is made of a stainless steel
vertical tube on which exterior is wrapped around
the cooling coil with the evaporating chamber
and in its interior is located the auger which
rotates on its vertical axis and it is maintained
aligned by the top and bottom bearings. A water
seal system is located in the bottom part of the
freezer while at the top end is fitted the ice
breaker.
The water constantly flowing into the cylinder
bottom part, freezes into ice when in contact with
the cylinder inner walls. The ice is then lifted up
by the rotating auger and compacted and forced
out by the ice breaker.
K. ICE BREAKER (Two on SPN 1205 Model)
The ice breaker is fitted in the freezer upper part
it has, on SPN 125-255 Models, two breaker teeth
to break the ice and with its slanted shape from the
rear tooth to the front one it compacts and forces
the ice out in an horizontal way.
On the other models the ice breaker is made by
several rectangular openings where the ice is
forced to pass through.
By undergoing this, the ice looses its excess of
water content so it drops into the bin in hard dry
bits of ice.
In the ice breaker it is housed the top bearing
which is made of two rolls bearings positioned to
withstand the auger axial and radial loads. This
bearing is lubricated with a food grade - water
resistant grease.
NOTE. It is advisable to check the conditions
of both the lubricant grease and the top
bearing every six months.
L. GEAR MOTOR
(Two on SPN 1205 Model)
The gear motor is made of a single phase electric
motor with permanent capacitor directly fitted on
a gear box.
The drive motor rotor is kept aligned on its
vertical axis by two ball bearings permanently
lubricated. The gear case contains a train of
three spur gears with the first one in fiber to limit
the noise level. All the three gears are encased
in case roller bearings and are covered by
lubricant grease (MOBILPLEX IP 44).
Two seal rings, one fitted on the rotor shaft and
the other on the output shaft keep the gear case
sealed.
The interior can be inspected and serviced by
unbolting the two halves of the aluminium gear
case housing.
M. FAN MOTOR (Air cooled version)
The fan motor is controlled through the TRIAC of
the P.C. BOARD by the condenser temperature
sensor. Normally it operates to draw cooling air
through the condenser fins.
In cold ambient situation, the fan motor can run
at intermittance as the condenser pressure must
be kept between two corresponding head
pressure values.
N. WATER REGULATING VALVE
(Water cooled version)
This valve controls the head pressure in the
refrigerant system by regulating the flow of water
going to the condenser.
As pressure increases, the water regulating
valve opens to increase the flow of cooling
water.
O. COMPRESSOR
The hermetic compressor is the heart of the
refrigerant system and it is used to circulate and
retrieve the refrigerant throughout the entire
system.
It compresses the low pressure refrigerant vapor
causing its temperature to rise and become high
pressure hot vapor which is then released through
the discharge valve.
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ADJUSTMENT, REMOVAL AND REPLACEMENT PROCEDURES
NOTE. Read the instructions throughly
before performing any of the following
adjustment or removal and replacement pro-
cedure.
A. ADJUSTEMENT OF THE EVAPORATOR
WATER LEVEL
The correct water level in the freezing cylinder is
about 20 mm. (1") below the ice discharge
opening. Low water level causes excessive strain
inside the freezer assembly due to a faster
freezing rate.
When the water level is above or below the
correct one, adjustment can be performed by
raising or lowering at the measure required, the
water reservoir and its mounting bracket.
To Raise or Lower the water level:
a. Loosen and remove the screw securing the
mounting bracket of the water reservoir to the
unit cabinet and raise the water reservoir to the
correct level.
b. Thread the mounting screw in the
corresponding hole and tighten it.
WARNING. Be sure the electrical power
supply circuit breaker and the inlet water
supply are OFF, before starting any of the
following Removal and Replacement
procedures as a precaution to prevent
possible personal injury or damage to the
equipments.
B. REPLACEMENT OF THE GEAR MOTOR
MAGNETIC SENSOR
1. On SPN 125-255-405 and SPN 605
remove the front/top and side/rear panels and
on 1205 remove the front, top and left side
panels.
2. Unloose the three screws securing the
plastic cover to the top of the gear motor and
remove it.
3. Unloose the two screws securing the
magnetic sensor to the plastic housing and
withdraw it from its seat.
4. Trace the gear motor magnetic sensor
terminal plug on the rear side of the control box
(red with four terminal pins) and draw it out from
its socket by carefully slackening the fastening
tie.
5. To install the replacement gear motor
magnetic sensor follow the above steps in
reverse.
C. REPLACEMENT OF THE AUGER,
WATER SEAL, BEARINGS AND
COUPLING
1. Remove thepanels.
2. Follow the steps at item H to remove the ice
spout.
3. On model SPN 125-255 unloose and remove
two screws and washers holding tight the spout
bracket to the freezing cylinder.
On models SPN 405-605-1205 unloose
and remove the four bolts securing the ice breaker
to the upper flange of the evaporator.
4. On model SPN 125-255 grasp the wire cap
hook at the top of the freezer and pull out the
auger, attached cap and ice breaker from the top
of the freezer.
On models SPN 405-605-1205 with two flat
screwdrivers insert then on the space between
the icebreaker and the upper flange and by tilting
them lift the icebreaker and auger assembly.
0.5-1.0 mm
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Grasp the icebreaker and remove the icebreaker
and auger assembly by lifting them from the
evaporator.
NOTE. If the auger cannot be pulled out,
proceed to steps 10 and 11 of this paragraph,
to gain access to the auger bottom. Then,
with a rowhide mallet or placing a piece of
wood on the bottom end of the auger, tap this
bottom to break loose the auger and be able
then to pull it out as per step 4 above.
5. On model SPN 125-255, with a circlip plier, re-
move the retaining ring and cap hook from the ice
breaker while, on the superflaker models, remove
the plastic cap using a screwdriver as a lever.
6. Unloose and remove cap screw and remove
the ice breaker from the auger.
7. Clean away the old grease from the interior
of the ice breaker and inspect the bearing pressed
into the top of the ice breaker and if worn do not
hesitate to replace it.
8. Inspect the conditions of the O ring; if torn or
worn replace it.
WARNING. The top bearing assembly
works in critical conditions for what
concern its lubrication as it is haused in
the ice breaker where the formation of
condensation is usual. Therefore it is
important to apply on it an ample coating
of Food grade Waterproof Grease before
installing the breaker and cap hook in
place .
9. Slide off from the auger bottom the upper
half of the water seal.
NOTE. Any time the auger is removed for
replacement or inspection use extra care in
handling the water seal parts, so no dirt or
foreign matters are deposited on the surfaces
of the seal. If there is any doubt about the
effectiveness of the water seal or O ring do
not hesitate to REPLACE THEM.
10. Unloose and remove the three/four bolts
which attach the freezer assy to the aluminium
adaptor.
11. Raise the freezer assy off the adaptor,
secure it out of the way to allow room to work. On
SPN 125-255 using a suitable lenght and size
wooden dowel or stick inserted through the top of the
open freezer, tap the lower half of the water seal
and the lower bearing out the bottom of the
freezer.
12. On the superflaker models, with two
screwdrivers as a lever, remove from the bottom
of the freezer assy the lo bearing brass holding
ring.
NOTE. It is good practice to replace the water
seal assy and both the top and the bottom
bearings any time the auger is removed.
To facilitate this it is available a service Kit
(P/N SC001028.07 for SPN 125-255 and
P/N SC060692.00 for 405-605-1205) which
includes besides the above mentioned parts,
the ice breaker O ring and a tube of food
grade waterproof grease.
13. Reach through the adaptor and remove the
coupling parts.
14. Check both the coupling halves for chipping
and wear and do not hesitate to replace them.
NOTE. It is very important to provide correct/
proper lubrication of the inside bore of the
upper semi-coupling as well as to the external
surfaces of the teeth as shown on the here
below photo.
The correct lubrication allows the upper semi-
coupling to move it down, by the load of the
upper spring, in case of any rising up during
its rotation.
15. Install bottom bearing and brass retainer
assy into the bottom of the freezer.
16. Install the upper bearing into the ice breaker
starting by the radial portion that must be fitted
with the flat surface facing up.
17. Apply some lubricant (grease) on the upper
surface then install the rollers cage with the
smaller openings of the same facing up so to
leave a small gap between plastic cage and flat
surface of the botton portion of the bearing (see
drawing).
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18. Apply some move lubricant then place the
S.S. trust washer.
19. After to have replace the O ring into the ice
breaker fit the same on top of the auger and
secure it with the top bolt.
20. Install the auger/icebreaker into the
evaporator following the previous steps in reverse.
D. REPLACEMENT OF THE GEAR MOTOR
ASSY
1. On SPN 125-255-405-605 remove the
front/top and side/rear panels and on 1205
remove the front, rear, top and left side panels.
2. Remove the three/four bolts and washers
securing the gear reducer base to the unit chassis,
then remove bolts and lockwashers which attach
the bottom of the aluminium adaptor to the gear
reducer case cover.
3. Follow the steps of item E to remove the
gear motor magnetic sensor.
4. Trace and disconnect the electric wires
leads of the drive motor. Lift and remove the
entire gear motor assembly.
5. To install the replacement gear motor assy
follow the above steps in reverse.
E. REPLACEMENT OF THE FREEZING
CYLINDER
1. Follow the steps at item H to remove the ice
spout.
2. Remove the clamp fastening the water hose
to the water inlet port of the freezer assy. Place
a water pan under this water inlet port then
disconnect the water hose and collect all water
flowing from freezer and from water hose.
3. Withdraw the evaporator sensor probe from
the its holder as stated in item B.
4. Recover the refrigerant from the system
and transfer it in a container so to reclaim or
recycle it.
5. Unsolder and disconnect the capillary tube
and the accumulator/suction line assy from the
outlet line of the freezing cylinder.
6. Remove the three/four bolts and washers
securing the gear reducer base to the unit chassis,
then remove bolts and lockwashers which attach
the bottom of the aluminium adaptor to the gear
reducer case cover.
7. Lift the freezer up and off the gear motor
assembly, then if necessary remove the
aluminium adaptor by removing the three
mounting screws and lockwashers.
NOTE. It is imperative to install a replacement
drier whenever the sealed refrigeration
system is open.
Do not replace the drier until all other repairs
or replacements have been completed.
8. To install the replacement evaporator follow
the above steps in reverse.
NOTE. Thoroughly evacuate the system to
remove moisture and non condensables after
evaporator replacement.
20