Welbilt Koolaire KDF0150A User manual

Part Number STH047 Rev01 10/18
Undercounter Ice Machines
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

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.kool-aire.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.
• Ice machines require a deflector when installed on
an ice storage bin. Prior to using a non-OEM ice
storage system with this ice machine, contact the
bin manufacturer to assure their ice deflector is
compatible.
• 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.
• Installation of the line sets must be performed by
a properly trained and EPA certified refrigeration
technician aware of the dangers of dealing with
refrigerant charged equipment.

nWarning
Follow these precautions to prevent personal injury
while operating or maintaining this equipment.
• Legs or casters must be installed and the legs/casters
must be screwed in completely. When casters
are installed the mass of this unit will allow it to
move uncontrolled on an inclined surface. These
units must be tethered/secured to comply with all
applicable codes. Swivel casters must be mounted
on the front and rigid casters must be mounted on
the rear. Lock the front casters after installation is
complete.
• Some 50 Hz models may contain up to 150 grams
of R290 (propane) refrigerant. R290 (propane)
is flammable in concentrations of air between
approximately 2.1% and 9.5% by volume (LEL lower
explosion limit and UEL upper explosion limit). An
ignition source at a temperature higher than 470°C
is needed for a combustion to occur.
• 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.

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.
• Units with two power cords must be plugged
into individual branch circuits. During movement,
cleaning or repair it is necessary to unplug both
power cords.
We reserve the right to make product improvements at
any time. Specifications and design are subject to change
without notice.

Table of Contents
Part Number STH047 Rev01 10/18 9
General Information
Model Numbers............................... 13
How to Read a Model Number ................ 14
Accessories ................................... 14
Bin Caster ................................. 14
Cleaner and Sanitizer ...................... 14
Model/Serial Number Location ............... 15
Ice Machine Warranty Information............ 15
Installation
Location of Ice Machine....................... 17
Ice Machine Clearance Requirements......... 18
Ice Machine Heat of Rejection ................ 18
Leveling the Ice Machine...................... 19
Electrical Requirements....................... 20
Voltage ................................... 20
Fuse/Circuit Breaker ....................... 20
Total Circuit Ampacity ..................... 20
Electrical Specifications....................... 21
Air-cooled Ice Machine .................... 21
Water-cooled Ice Machines ................ 21
Water Service/Drains ......................... 22
Water Supply.............................. 22
Water Inlet Lines .......................... 22
Drain Connections ........................ 22
Water Supply and Drain Line Sizing/
Connections .............................. 23
Cooling Tower Applications................ 24
Component Identification
Evaporator Compartment .................... 25

10 Part Number STH047 Rev01 10/18
Maintenance
Ice Machine Inspection .................... 27
Exterior Cleaning .......................... 27
Cleaning the Condenser ................... 27
Interior Cleaning and Sanitizing............ 29
Removal from Service/Winterization ......... 42
Operation
Initial Start-up or Start-up After Automatic
Shut-off ................................... 45
Freeze Sequence .......................... 45
Harvest Sequence ......................... 46
Automatic Shut-off ........................ 46
Energized Parts Chart...................... 47
Operational Checks ........................... 49
Troubleshooting
Diagnosing an Ice Machine that Will Not Run ..
........................................... 53
Diagnosing Ice Thickness Control Circuitry . 54
Ice Production Check ...................... 57
Installation and Visual Inspection Checklist. 59
Water System Checklist .................... 60
Ice Formation Pattern...................... 61
Safety Limit Feature ....................... 63
Analyzing Discharge Pressure ............. 70
Analyzing Suction Pressure ................ 72
Harvest Valve.............................. 76
Comparing Evaporator Inlet/Outlet
Temperatures ............................. 80
Discharge Line Temperature Analysis....... 81
Refrigeration Component Diagnostic Chart 83
Procedure................................. 84
Final Analysis.............................. 85
Refrigeration Component Diagnostic Chart 86
Ice Quality Is Poor — Cubes are Shallow,
Incomplete or White....................... 89
Freeze Cycle Is Long, Low Ice Production ... 90
Ice Machine Runs and No Ice Is Produced... 91

Part Number STH047 Rev01 10/18 11
Component Check Procedures
Main Fuse ..................................... 93
Bin Switch..................................... 94
Diagnosing Start Components................ 97
Capacitor ................................. 97
Relay...................................... 97
ON/OFF/WASH Toggle Switch ................. 98
Ice Thickness Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Ice Thickness Check ......................100
Compressor Electrical Diagnostics...........101
Fan Cycle Control ............................103
High Pressure Cutout (HPCO) Control........104
Filter-Driers ..................................105
Refrigerant Recovery/Evacuation............106
Refrigerant Re-use Policy .................107
Recovery and Recharging Procedures ....109
System Contamination Cleanup .............112
Mild System Contamination Cleanup
Procedure................................114
Severe System Contamination Cleanup
Procedure................................115
Replacing Pressure Controls without
Removing Refrigerant Charge.............117
KF250/K270 Condenser Fan Motor Access ...119

12 Part Number STH047 Rev01 10/18
Component Specifications
Main Fuse ....................................121
Bin Switch....................................121
ON/OFF/WASH Toggle Switch ................121
Fan Control Cycle ............................121
High Pressure Cutout (HPCO) Control........121
Filter-Driers ..................................121
Total System Refrigerant Charge.............122
Charts
Cycle Times, 24 Hr. Ice Production and
Refrigerant Pressure Charts..................123
KF0150A self-contained Air-Cooled .......124
K170A Self-contained Air-cooled..........125
KF0250 Self-contained Air-cooled.........126
K270 Self-contained Air-cooled ...........127
Diagrams
Wiring Diagrams .............................129
KF150/K170 Wiring Diagram ..............130
KF250/K270 Wiring Diagram ..............132
Electronic Control Board.....................134
KF150/K170/KF250/K270 Tubing Schematic. 134

Part Number STH047 Rev01 10/18 13
Model Numbers
This manual covers the following models:
Self-contained Air-cooled Self-contained Water-cooled
KDF0150A N/A
KYF0150A N/A
KD0172A N/A
KY0174A N/A
KDF0250A N/A
KYF0250A N/A
KR0270A KR0271W
KD0272A KD0273W
KY0274A KY0275W
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.
General Information

14 Part Number STH047 Rev01 10/18
How to Read a Model Number
K D F 0172 A
Cube Size
A - Air-cooled
Series
Capacity
Condenser
Type
2 - Dice, Air-cooled
4 - Half-dice, Air-cooled
D - Dice
Y - Half-dice
Accessories
Contact your distributor for these optional accessories:
BIN CASTER
Replaces standard legs.
CLEANER AND SANITIZER
Manitowoc Ice Machine Cleaner and Sanitizer are available
in convenient 16 oz. (473 ml) and 1 gal (3.78 l) bottles.
These are the only cleaner and sanitizer approved for use
with Koolaire® products.
Cleaner Part Number Sanitizer Part Number
16 oz 94-0456-3 16 oz 94-0565-3
1 Gallon 4-0580-3 1 Gallon 94-0581-3
F - R404A Refrigerant

Part Number STH047 Rev01 10/18 15
Model/Serial Number Location
The model and serial numbers are required when
requesting information from your local distributor, service
representative, or Welbilt KitchenCare®. The model and
serial number are listed on the OWNER WARRANTY
REGISTRATION CARD. They are also listed on the MODEL/
SERIAL NUMBER DECAL affixed to the ice machine.
MODEL/SERIAL
NUMBER PLATE
MODEL/SERIAL
NUMBER PLATE
SV1687G
Model/Serial Number Location
Ice Machine Warranty Information
For warranty information visit:
http://www.kool-aire.com/Service/Warranty
• Warranty Verification
• Warranty Registration
• View and download a copy of the warranty

16 Part Number STH047 Rev01 10/18
THIS PAGE INTENTIONALLY LEFT BLANK

Part Number STH047 Rev01 10/18 17
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 airflow is in and
out the front). Refer to the chart below 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

18 Part Number STH047 Rev01 10/18
Ice Machine Clearance Requirements
Self-contained
Air-cooled
Top/Sides 5" (127 mm)*
Back 5" (127 mm)*
*NOTE: The ice machine may be built into a cabinet.
There is no minimum clearance requirement for the top or
left and right sides of the ice machine. The listed values are
recommended for efficient operation and servicing only.
Ice Machine Heat of Rejection
Series
Ice Machine
Heat of Rejection*
Air Conditioning** Peak
KF150 2200 2600
K170 2200 2600
KF250 3800 6000
K270 3800 6000
* B.T.U./Hour
** 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.

Part Number STH047 Rev01 10/18 19
Leveling the Ice Machine
1. Screw the leveling legs onto the bottom of the ice
machine.
2. Screw the foot of each leg in as far as possible.
,Caution
The legs must be screwed in tightly to prevent them
from bending.
3. Move the ice machine into its final position.
4. Level the ice machine to ensure that the siphon
system functions correctly. Use a level on top of the
ice machine. Turn each foot as necessary to level the
ice machine from front to back and side to side.
NOTE: An optional 2-1/2" (6.35 cm) caster assembly
is available for use in place of the legs. Installation
instructions are supplied with the casters.
THREAD
LEVELING LEG
INTO BASE OF
CABINET
THREAD “FOOT”
IN AS FAR AS
POSSIBLE
SV1606
Leg Installation

20 Part Number STH047 Rev01 10/18
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).
The 115/1/60 ice machines are factory pre-wired with a 6'
(1.8 m) power cord, and NEMA 5-15P-plug configuration.
The 208-230/1/60 and 230/1/50 ice machines are factory
pre-wired with a power cord only, no plug is supplied.
FUSE/CIRCUIT BREAKER
A separate fuse/circuit breaker must be provided for each
ice machine. Circuit breakers must be H.A.C.R. rated (does
not apply in Canada).
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.