Zamboni FastICE DK - 11000 User manual

FastICE®is a registered trademark of Frank J. Zamboni & Co., Inc. © Zamboni Company
Zamboni FastICE®Ice Making System
Operating Manual

Table of Contents
................................................................................Chapter 1 – System Description 5
.........................................................................................................Switch Bank 1 7
.........................................................................................................Switch Bank 2 7
.........................................................................................................Switch Bank 1 8
..................................................................................................Test Mode OFF-ON 8
..................................................................................Test Speed (DEC)-HOLD-(INC) 8
............................................Malfunction Indicator Lamp (MIL) (lighted blank plate): 8
.........................................................................................................Switch Bank 2 9
................................................................................Upper Boom Control (OFF-ON) 9
................................................................................Lower Boom Control (OFF-ON) 9
..............................................................Application Rate Scaling (DEC)-HOLD-(INC) 9
..............................................................................................Board Spray (OFF-ON) 9
.......................................................................................................Blast (OFF-ON) 10
..............................................................................................DISPLAY CONTROLS 11
...................................................................................SCREEN NAVIGATION MAP 12
....................................................................................................MACHINE MODES 14
.............................................................................................................Test Mode 14
...................................................................................................Automatic Mode 14
......................................................................................Automatic Boom Shut-off 14
.............................................................................Safety and Functional Interlocks 15
............................................................................................OPERATOR INTERFACE 16
...........................................................................................................Boot Screen 16
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...........................................................................................................Load Screen 17
.................................................................................................Dashboard Screen 17
...................................................................................................Summary Screen 18
........................................................................................................Set-up Screen 19
................................................................................................Diagnostics Screen 19
..............................Machine Parameters Screen (Technical Set-up, Hidden Screen) 20
.................................................................Function Lockout on Parameters Screen 21
..................................................Fault Notification Pop-Ups on the Fast Ice Display 22
..................................................................Display Pop-Up System Fault Messages 23
................................................System Fault: Water Pressure Out Of Range: High! 23
..................................................System Fault: Water Pressure Out of Range: Low! 24
.......................................................System Fault: Water Flow Out of Range: Low! 24
...................................System Fault: Water Flow and Pressure Out of Range: Low! 25
....................................................System Fault: Water Level Sensor Disconnected! 26
..............................................................System Fault: Water Valve Disconnected! 26
.........................................................System Fault: Hydraulic Valve Disconnected! 27
.......................................................Chapter 2 - System Subassembly Description 28
.....................................................................................Water Pump Subassembly 28
............................................................................Water Valve Manifold Assembly 29
......................................................................................Spray Boom Subassembly 30
.............................Chapter 3 – Operating Procedures: Standard Ice Resurfacing 32
....................................................Chapter 4 – Operating Procedures: Ice Building 34
...................................Chapter 5 – Recommended Regular System Maintenance 35
......................................................................Chapter 6 - System Troubleshooting 36
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......................................Water flow and pressure fault criteria reference diagrams 40
...............................................................Lower Boom ONLY Alarm Limit Diagram 40
...............................................................Operating Region Identification Diagram 41
...............................................................Upper Boom ONLY Alarm Limit Diagram 42
....................................................................Both Booms ON Alarm Limit Diagram 43
...............................................................................................................Revisions 44
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Chapter 1 – System Description
The FastICE®system is offered in two versions – a base package and a pro package. The pro package will
be offered as an upgrade to the base package.
The FastICE base package consists of the following components;
• System master Off-On switch
• Electronic control module
• (2x) Programmable 4-switch CAN rocker switch panels • Dedicated hydraulic pump section
added to main pump stack
• Hydraulically-driven centrifugal water pump
• Proportional hydraulic flow control valve for water pump motor control
• Ice-making water flow sensor
• Speed sensor
• Ice-making water level sensor
• Upper and lower spray booms
• Board spray valve
• Electrically controlled, diaphragm type water control valves
(1 each for the Upper boom, Lower boom, and Board Spray Valve)
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Figure 1: FastICE Pro package with switch banks and display
Master Power Switch
USB Data Port
ON
OFF
SWITCH BANK 1 SWITCH BANK 2
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Switch Bank 1
TEST MODE
TEST SPEED ((DECREASE) – HOLD – (INCREASE))
MALFUNCTION INDICATOR LAMP
(MIL, LEFT GREEN, RIGHT YELLOW)
BOARD SPRAY VALVE CONTROL (ON-OFF)
Figure 2: FastICE Switch Bank 1 switch and LED identification
Switch Bank 2
UPPER BOOM WATER CONTROL (ON-OFF)
LOWER BOOM WATER CONTROL (ON-OFF)
WATER APPLICATION RATE SCALING
(DECREASE – HOLD – INCREASE)
WATER BLAST FUNCTION
Figure 3: FastICE Switch Bank 2 switch and LED identification
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The FastICE base package uses two dash-mounted rocker switch panels to control the system.
Switch bank 1 controls system test mode, test speed increment up or down, malfunction indicator
lamp (MIL) and Board Spray Control Switch. These are infrequently used control functions.
Switch Bank 1
Test Mode OFF-ON
• Operation:
- Illuminates the left light Red when in the OFF position
- Illuminates the right light White when in the ON position, and blinks at 4 times per
second when ON
Test Speed (DEC)-HOLD-(INC)
• Operation:
- Off when in the HOLD position
- Illuminates Red when DEC pressed
- Illuminates Green when INC pressed
Malfunction Indicator Lamp (MIL) (lighted blank plate):
• Operation:
- Left-hand light illuminates Green when the system has no malfunctions are
detected
- Left light illuminates Red when there is a malfunction detected. The right-hand light
will be off when there is no fault active and flash the fault numeric code in a White
blinking light when the left hand light is Red. The details of the blink codes are
detailed in the “Troubleshooting” section of this manual.
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Switch Bank 2
Upper Boom Control (OFF-ON)
• This switch controls water flow to the upper boom.
• Operation:
- Left LED is illuminated Red when in the OFF position
- Right LED is illuminated White when the in the ON position
Lower Boom Control (OFF-ON)
• This switch controls water flow to the lower boom.
• Operation
- Left LED is illuminated Red when in the OFF position
- Right LED is illuminated White when the in the ON position
Application Rate Scaling (DEC)-HOLD-(INC)
• This function allows the operator to increase or decrease a scaling factor applied to the default
value of 100%, and allows for situations where a lesser or greater water application rate is
desirable.
• Operation:
- Off when in the HOLD position
- Blinks Blue once for each single press of DEC (decrement) on the left of the switch
- Blinks Green once for each single press of INC (increment) on the right of the
switch
- Each press of either DEC-INC switch will generate one blink for each press of the
switch.
- Each press of the switch will change the spray flow 5 percentage points to a
maximum of 50% (10 presses). The switch will only blink when pushed.
Board Spray (OFF-ON)
• This switch controls water flow out of the Board Spray Valve.
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• Operation:
- Illuminates the right light Red when in the OFF position
- Illuminates the left light White when in the ON position
Blast (OFF-ON)
• This switch will produce the maximum water flow rate possible from the system.
• Operation:
- Illuminates Red when in the OFF position
- Illuminates White when in the ON position (activates both upper and lower booms
and sets pump hydraulic control valve to Imax value for maximum water flow)
The FastICE system produces the best results with water at a temperature of 100 to 140 degrees F (40 to
60 degrees C).
The system uses (arena facilities sourced) warm water carried in a dedicated ice-making water tank on the
machine. The ice-making water is supplied to the spray nozzles by means of a hydraulically driven,
proportionally controlled centrifugal water pump. Hydraulic power is supplied by a dedicated single gear
pump section added to the standard pump stack as part of the FastICE system.
Solenoid-actuated, diaphragm-type water valves (one each for the upper and lower conditioner booms and
one for the board spray nozzle) are used to facilitate turning the water spray nozzles off/on, and are
selected manually by the operator via the boom control switches on Switch Bank 2. No throttling is
provided by the solenoid water valves. The water valves only provide off-on control. Nozzle flow is
controlled by pump speed (RPM).
When the system is active, water flow to the booms and/or board spray nozzle is monitored by a water
flow sensor located in the delivery piping between the centrifugal pump and the spray booms as well as a
pressure transducer located in the delivery piping after the pump.
Ground speed is monitored from a speed sensor over the output shaft of the gearbox of the machine. The
(speed) sensor signal is used to synchronize (adjust) water flow (water pump RPM) with the machine travel
speed automatically, providing a consistent application of water across the entire ice surface, regardless of
speed.
If the upper (spray) boom is active, automatic control of the boom valve will turn off water flow to the
upper boom if ground speed drops below a preset value, which is adjustable within the SETUP screen,
which will be discussed in a later section. The boom which turns off when the speed drops below the
specified value can also be changed.
The target water flow rate for a given driving speed can be increased or decreased by up to 50% by
turning the adjustment knob on the display or by depressing the rocker switch for flow scaling.
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The “blast” function provides the opportunity for the operator to “blast” (apply water at the maximum
application rate) water where needed. It is a momentary function that is activated when the switch is
depressed, and can be activated for up to 10 seconds, after which time it will turn off and reset.
The FastICE display will provide for operator monitoring of the operational parameters, including ground
speed, water flow, water usage, water spray pressure and water temperature. It will record operational
data for later download (for record keeping or analysis) and provide troubleshooting diagnostic
information. The display has four operational display screens: Dashboard, Summary, Set-up, and
Diagnostic screens.
Navigation through the screens will be by button pushes of the Function key. An additional hidden
screen(s) may be accessed only from the Set-up screen (by pressing the Function key for (5) seconds and
releasing) and will be used for advanced technical set-up purposes.
The encoder knob of the display will be used to enter/adjust screen based operational settings. The
encoder knob will also provide alternate control of the Spray DEC-INC setting in conjunction with the Spray
switch in Switch bank 2 (only when the display is on the Dashboard screen). Either the knob or switch may
be used to make the adjustment based on the operator’s preference.
DISPLAY CONTROLS
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SCREEN NAVIGATION MAP
The BOOT screen will display when power is initially turned on.
The LOAD screen will display while the unit is loading display software.
The DASHBOARD screen (home screen) will display (as passive read-out) when the unit is fully booted:
• Scaling - Water flow percentage sliding scale (+/- 10) of water flow
• Spray thickness – based on program algorithm
• Water Used – total amount of water used during the current application (US or Metric units)
• Speed – actual ground speed of the ice resurfacing machine
• Water Flow – total water flow being sprayed each minute (US or Metric units)
• Water Level – level of ice-making water in the tank
• Water Pressure – water pressure as indicated by the pressure transducer
• Ice Water Temperature – as indicated by the ice-making water temperature sensor
Active adjustment of the Scaling function using the encoder knob will be provided to the operator as an
alternate means of adjustment to the switch panel. Either method may be used at any time during
operation at the operator’s discretion.
The SUMMARY screen will display average readings (passive read-out):
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• Average Spray Thickness
• Average Ground Speed (calculated only when one or more nozzles are active)
• Average Water Temperature – average ice-making water temperature
And active fields to:
• Reset Summary Statistics – this button is the only means of resetting the summary information.
• Download Summary
The SET-UP screen will display and allow selection of (using encoder knob):
• Units of Measure selection – US or Metric
• Spray thickness - US = Inches, Metric = mm
• Ground speed - US = MPH, Metric = km/h
• Water Flow – US = GPM, Metric = L/min
• Water Used – US = Gallons, Metric = Liters
• Upper Boom Shut-off Speed
The DIAGNOSTICS screen will display (passive read-out only):
• Hydraulic Valve Status – coil fault indication – open / short / okay
• Communication Status – okay or display to controller communication fault
• Supply Voltage (VDC) – system voltage
• Upper Boom Valve Status – coil fault indication – open / short / OK
• Lower Boom Valve Status – coil fault indication – open / short / OK
• Board Spray Valve Status – coil fault indication – open / short / OK
• Display Software Version
• Controller Software Version
The HIDDEN screen may be accessed only from the Set-Up screen and when the Function key is pressed for
5-seconds and released. When active, it will display and allow selection (using encoder knob) of:
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• Ground Speed Scaling – sensor pulses per 10 meters
• Flow Meter Scaling – sensor pulses per 10 Liters
• Proportional Valve IMin (mA)
• Proportional Valve IMax (mA)
• Reset To Default Values – resets all parameters to factory values
MACHINE MODES
There will be two operational modes with both allowing full system functionality. No functional lock-outs
are required other than pump flow interlock (defined in the Safety and Functional Interlocks section
below).
Test Mode
Test mode will be used to test the spray nozzles prior to moving onto the ice surface and to purge cold
water from the plumbing of the FastICE system prior to on-ice application. Test mode runs the system at a
simulated ground speed while the machine is stationary (adjustable parameter within HF-Impulse),
generated by the control module. The FastICE system will operate as though in actual use allowing for
inspection of nozzle spray patterns will be carried out, identifying any plugged or partially plugged
nozzle(s) resulting in a poor, uneven spray pattern and correcting any defects found. The operator may
adjust the application amount setting according to ice conditions using the spray adjust rocker switch.
Automatic Mode
Automatic mode uses the ground speed sensor input to determine real-time ground speed of the ice
resurfacing machine.
This is the standard operating mode for this system.
This ‘live’ ground speed signal is used by the controller to proportionally adjust the speed of the
hydraulically driven ice making water pump, resulting in water flow (to the boom nozzles) delivered to the
boom nozzles being proportional to ground speed. The result is an automatically controlled spray system
providing uniform application thickness regardless of speed variations during the entire resurfacing event.
Automatic Boom Shut-off
Automated shut off of water flow to the upper spray boom (when it is ON) will occur when the ground
speed of the machine falls below a pre-set threshold. The threshold speed is labelled UPPER BOOM SHUT-
OFF SPEED and is set on the Set-up Screen. The boom will turn back on when ground speed exceeds the
set threshold speed.
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The boom that turns off when the speed setting is reached can be changed in either the hidden settings
screen, or with the FastICE system programming tool and software.
Safety and Functional Interlocks
The hydraulically driven water pump is interlocked to the ice-making water tank level sensor to prevent the
pump from running dry. When the level sensor indicates tank levels below 0% for 2 seconds, the ice
making water pump will automatically shut off.
Likewise, if the control system does not sense a water level greater than 0%, the water pump will not start.
A moving average calculation is performed on the water level sensor signal to prevent rapid off/on due to
water sloshing in the tank.
Re-filling the tank so the level holds above 0% for at least 5 seconds will reset this interlock and allow the
pump to start.
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OPERATOR INTERFACE
See Machine Functions section for general details of operator interface and operation.
Boot Screen
The Boot Screen is displayed while the display is booting up. It is the first screen displayed. When the
display program starts to load, the display will change to the Load Screen.
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Load Screen
The Load Screen is displayed while the display program is loading. It will remain displayed until the display
program has fully loaded, which takes 25 to 30 seconds). When the display program has fully loaded, the
display will change to the Dashboard Screen.
Dashboard Screen
The Dashboard Screen provides a read-out of real time operational performance.
This is a mostly passive display – interaction is allowed only for Scaling (Water Flow Adjustment), using the
encoder knob as an alternate to the control switch.
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Summary Screen
The Summary Screen provides a read-out of the average performance for the last refinishing event (since
the last reset). Average performance for spray thickness, ground speed and ice making water temperatures
are calculated and recorded during operation. These values are available to download via USB port
mounted on the machine’s dash.
Operator interaction is only allowed to reset summary statistics and to download summary information via
USB.
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Set-up Screen
The Set-up Screen allows the operator to select or set operational parameters of the control system. The
operator will use the encoder knob to select the desired parameter - rotate the knob to move the red
highlighted box to the desired parameter, press the encoder knob to make the selection (highlighting
around the box will change to white), rotate the knob to change the highlighted value and press the
encoder knob to enter the new value. Box highlighting will change back to red after entering the new
value. Rotating the knob will move the highlighted box to another parameter.
Diagnostics Screen
The Diagnostics Screen provides a read-out of the current state of the solenoid valves, communication
status (between the display and machine controller), supply voltage, display software version and controller
software version. The Diagnostics Screen will display the status of the hydraulic valve coil and the three
water valve coils regardless of whether or not the system is in use. Supply voltage will also be monitored
for troubleshooting purposes.
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Machine Parameters Screen (Technical Set-up, Hidden Screen)
The Machine Parameters Screen is used for factory set-up and tuning of the control system. It is accessible
only when the display is on the Set-up Screen and the Function key is held for a 5-second interval and
released.
Once accessed, the technician may adjust any of the control parameters using the encoder knob to select
the desired parameter - rotate the knob to move the red highlighted box to the desired parameter, press
the encoder knob to make the selection (highlighting around the box will change to white), rotate the
knob to change the highlighted value and press the encoder knob to enter the new value.
Box highlighting will change back to red after entering the new value and rotating the knob will move the
box to the next parameter.
Exit the Machine Parameters screen by pressing the Home key (returns to the Dashboard screen).
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