Ziegra UBE 1.500 User manual

Operating Instructions
www.ziegra.com
Index
Page
Working method and ideal Ice Temperature 1
Start-up 2
Control elements and safety devices 3
Maintenance and Hygiene 4
Trouble shooting:
Water - Leakage 5
Machine does not work 5 - 6
No ice production 7
Ice quality - Miscellaneous 7
Cleaning of freezing unit 8
Wiring diagram attached
Cooling circuit "
General installation advice "
Assembly Instruction Freezing Unit "
Spare parts list "
Subject to technical modifications 6.07
ZIEGRA - EISMASCHINEN
Germany 30901 Isernhagen
www.ziegra.com
Service:
Tel. +49 - 511 - 90244 - 0
Tel. +49 - 511 -
90244 - 14
Fax. 90244 - 90
Fax.
90244 - 92
ice @ ziegra.com
[email protected]
UBE ZBE SWE SI TW
1.500 1.750 2.500 3.000 3.500 5.000 7.500 10.000

Working method
The ZIEGRA chip-ice machine is delivered ready for operation and has only to be connected to power and water supply.
No operating personnel is required.
The machine works fully automatically.
Water flows by gravity from the water chamber in the ice-
machine into the freezing cylinder. An evaporating coil
(e.g. R404) surrounds the cylinder, freezing the water inside
at an evaporation temperature of -20°C up to - 30°C.
An auger continuously scrapes thin layers of ice from the
inner cylinder wall and conveys it upwards. There the ice
is compacted, frozen further and subsequently broken off.
By this procedure the refrigeration energy can freeze the followig water without loss.
If the ice layer would become 1 or 2 mm thick, an unnecessary amount of energy would have to be used for freezing
due to the high insulating capacity of ice.
The ideal ice thickness of 6 - 9 mm at low energy consumption can be achieved thanks to the idea of subsequently
compacting the ice.
The ice being frozen on the inner wall of the cylinder, the refrigeration system of ZIEGRA Chip Ice Machines
is completely sealed. The rotating auger does not form part of the refrigeration circuit.
Therefore leakages in the refrigeration system caused by rotating parts cannot occur.
The ideal ice temperature is -0,5°C
ZIEGRA Chip-ice has the ideal temperature of - 0,5°C .
It is irregular and crystalline in structure and always stays loose.
In contrast with other types of ice it can be stored without being sub-cooled and never freezes up.
ZIEGRA-Cip-Ice is frozen within the patented freezing cylinder at an evaporation temperature of -20°C up to -30°C.
Due to the special procedure maximum refrigeration capacity is obtained at a very low energy consumption.
Cooling energy:
The uninterupted line shows the accumulated energy per kg of ice
(refrigeration energy).
Only when ice having a temperature of 0°C
melts to water of 0°C, the considerable
Refrigeration Capacity of 80 Kcal / kg
is released (vertical line)
The cooling capacity of water per °C is
(left line) 1 Kcal / kg,
Ice tempeartures below 0°C give only 0,5 Kcal / kg.
Energy consumption:
The broken line shows the minimum electric energy consumption
necessary for every ice production.
For an ice temperature of 0°C energy input and the
refrigeration capacity produced are closely correlated.
Only when ice is unnecessarily cooled to temperatures below 0°C,
the energy required rises disproportionately.
1

Start - up
1. Ambient temperature: Design max. min. 4. Electrical connection 400V - 3 - 50 Hz
Standard version. 20 °C 42 °C + 5 °C Or according to order, type plate, wiring -
Tropical version: 35 °C 45 °C + 5 °C diagram
Water temperature Check voltage:
Standard version. 15 °C > 5 °C Max. deviation is +5% / -10%
Tropical version: 25 °C > 5 °C
Check phase sequence:
When the phases are not in the correct order,
2. Installation place: the direction of the auger is reversed.
The distance between condenser (air outlet) and wall The ice then is pressed down onto the bearing
or ceiling respectively shall at least be 75 cm, instead upwards, damaging the seal.
see data sheet. (Phase sequence relay: see page 3, point 10)
Provide sufficient room ventilation. Observe the arrow indicating the
direction of rotation
Prevent any heat build-up.
Especially the air outlet of the condenser must be free Provide at site:
and at least 1,5 to 2,5 times larger in diameter than the Provide main switch and fuses according to
condenser itself. wiring diagram. Make firm installation to mains
power supply, do not use a plug-and-socket
connection in order to avoid later erroneous
At higher air temperatures (above 20°C resp. 35°C), interchange of phases.
or insufficient ventilation of the machine, Tighten all electrical connections in the control
and at water temperatures above 15°C resp. 25°C panel, as they may have loosened during.
the production capacity may decrease. transport
Crankcase heater:
3. Water connection After connecting the machine to electricity
the start-up is possible only after abt. 1 hr.
The machine works with normal potable water. (Preheating - see page 3 point 9)
With harder water above 20°d.H. install a water-
softener. 5. Cut-Out of machine when storage bin
If the water is slightly saline, or comes from a well or ice car is full:
or is outside 6,5 - 9,5 pH consult ZIEGRA
See page 3 point 2 .
for accordingly advice. and contact our service department
Provide at site: Rigid piping or high-pressure hose. 6. Start:
If long supply lines necessary, Ice production starts after approx. 2 min.
insulate, if possible.
Water pressure 2 - 4 bar 7. V-Belt:
Provide water overflow hose Check after 2-8 days and tighten, if necessary.
8 Ice discharge
Fasten tube to the ice discharge slightly with the clamp. Put on the insulation.
The ice must leave the outlet freely and without clogging.
Otherwise the freezing unit and gearbox will be overloaded.
Extension of ice discharge tube.
Enlargen diameter, no sharp curbs. Only use tubes
with smooth inner surface, without edges or ridges.
Ice must slide downwards only,
not horizontically or upwards.
Further advice in the extra folder "Installation Ice discharge"
2

Control Elements and Safety Devices
Operation Only by
of ice machine operating switch
1. When switching off the machine by the operating 6. Safety Device for the Compressor:
switch, the drive motor of the freezing unit continues A built-in or external motor protection guards the
to run for further 3 minutes. Thus the new ice compressor motor against overheating
produced by the re-evaporation will still will be removed,
and excessive drawing of current.
preventing a possible freeze-up of the machine.
When the machine is switched off by the 7. Overload cut-out
emergency cut-out or the main switch All other motors are also protected against
provided at site, the after running is out of overload by overload cut-out devices or
operation. Therefore a period of approx. motor protection switches.
30 minutes should elapse for safety reasons,
before the machine is switched on again.
8. Capacity control
The capacity control protects the evaporator and
2. Cut-out of machine when storage is full: the compressor against over burdeninhg by too
low ambient- or water temperature.
a) Light barrier in the ice hose:
The light barrier switches the machine off, when the
storage is full and the ice mounts into the ice hose. 9. Crankcase Heating
Automatic restart after removal of ice. As a crankcase heater is installed, the machine
must be switched on by the main switch
b) Heated light barrier: at least 1 hour in advance to allow pre heating.
For larger cold rooms we recommend a heated light-
barrier to switch the machine off when the bin is full.
This light barrier has been chosen by us for these 10. Phase sequence Relay
particular conditions. Please contact us. The phase sequence relay switches off the
machine,if the phases are not connected in the
c) Other cut-off devices: correct order. (see electrical connection)
Also when the ice is produced directly in an ice car,
a cut-off device should be installed. 11. Low voltage relay
Please contact our service department. The relay cuts the machine off, if the voltage
drops under the tolerated 10% low voltage.
3. Control lamps:
white: Machine operates and produces ice 12. Automatic water drain
yellow: The ice bin is full or the Compressor In order to reduce nucleation in stagnant water,
is switched off and the freezing a solenoid valve closes the water inlet as soon
units run for further 3 minutes. See above. as the machine is out of operation.
red: The lamps indicate, where a failure Another opens the water drain thus emtying the
has occured. water chamber and the freezing unit.
4.
Water-Level Control
The water-level control switches the machine off
13.
Ice jam switch on the ice outlet
in case of water shortage. After-running as This security switch switches off the machine,
described under 1 (Control lamp lights up). should the ice jam in the ice hose.
Automatic reset, when the water supply has been (e.g. if the light barrier fails)
restored. After the failure has been found and the ice outlet.
has been reinstalled, the machine switches on
again automatically.
5. High/Low pressure switch
The machine is switched off, if there is e.g.
excess pressure in the refrigeartion system
caused by too high ambient temperature or soiled
condenser, or if the pressure is insufficient
due to refrigerant loss. (Control lamp lights on)
3

Maintenance
For your safety and environmental protection:
Have repairs of electrical parts and refrigeration circuit
only carried out by a qualified technician!
2 - 8 days after installation
V - belts check tension tighten
Every 3 - 6 months
When machine is subject to heavy strain, in case of poor water quality or for hygienic reasons: at less frequent intervals
Water supply Strainer / Filter clean
water chamber incl valve clean
Condenser use soft brush or compressed air to clean
water-cooled machine open condenser and use pipe brush clean pipes
check seals replace, if necessary
Compressor oil level in sight glass check
refrigerant oil (consult ZIEGRA) refill, if necessary
V - belts check replace, if necessary
A loose V-belt does not transfers the
load correctly on the auger. This will
overload the freezing unit.
Ice hose and water retainer calcified? clean - or replace
Gearbox ATM NRV 90 Lifetime lubrication with synthetic oil 1 Litre check oil level
or Flender OT 80 Lifetime lubrication with synthetic oil 1,5 Litre detach drive-shaft cover
BP Energol SGXP 220 drain oil into fuel measure
Mobil Glygoyle 30 and refill up to the correct
Shell Tivela WB (SC 320 ) level.
Klüber Syntheso D 220 EP
or equivalent
Freezing unit see cleaning of freezing unit page 8
Bearing check, replace if necessary
The following are symptoms
of a defective bearing:
* Water leaks from bottom of freezing unit
* Noise during operation
* Overload cut out has switched off
Placement and insulation check, renew insulation
of sensor expansion valve
4

Repairs of electrical parts and refrigeraion circuit Trouble shooting
only by qualified technician
Malfunction Cause Remedial Action
Water - Leakage Hose connections loose fasten, insert new seals or replace
Water runs into machine
or defective
or onto floor
Water leaks from freezing cylinder Water seals or lower bearing replace
in cylinder defective
Water pressurestat No water in water chamber Check water supply
or water level control Water pressure: min. 2 bar - max 4 bar
has switched off Clean water filter and float valve.
o Control lamp shows red Check water solenoid valve.
Machine does not work
General electric faults * No current Check connection and fuses
*Fuses blow up Check
*Intermittent contact Check electrical connections,
also in control panel
*Water pressurestat or readjust or replace
*Water level control defective readjust or replace
*Ice jam switch has cut - off eliminate cause, reset switch,
manual reset of machine
*Light barrier does not work check, see page 6
*Voltage too low or too high Voltage as per type plate: max. + 5%
min. - 10 %
*Exchange or failure of phases Connect phases in correct order
Overload cut-out Motor overload caused by
has switched off
o Control lamp shows red
* gear box motor defective check / replace
* gear box defective check / replace
* cylinder bearing damaged check / replace
* freezing unit tends to freeze up see "machine freezes up"
* auger calcified see "cleaning of freezing unit" (page 8)
* compressor motor overloaded check / replace
(see also page 3 point 6)
5

Repairs of electrical parts and refrigeraion circuit Trouble shooting
only by qualified technician
Malfunction Cause Remedial Action
Highpressure switch Air in refrigeration circuit evacuate circuit, refill refrigerant
has switched off (insufficiently evacuated after repair)
o Control lamp shows red
Refrigeration circuit overfilled adjust
air-cooled machine: machine must not be placed in the sun or
*ambient temperature too high too warm ambience. Improve ventilation.
*condenser soiled clean with brush or compressed air,
never with wire brush
*ventilator motor or speed control check / replace
defective
water-cooled machine:
*insufficient water pressure increase water pressure to min 2 bar
*condenser soiled clean condenser with bottle brush,
hot water and antilime agent
clean water filter
*water or condensing pressure check / clean / replace
governor misadjusted, soiled
or defective
Cut - out by compressor * compressor overheated depending on ambient temperature let
machine cool for 3 hours, compressor
starts again automatically
*wrong electrical connection check
or defective protection switch
*compressor defective check / replace
Light barrier does not work * transmitter and receiver not in line adjust
*defective check manually at short distance
*dirty or lime scale clean
Ice jam switch has cut off switch defective check
Ice jams back into cylinder eliminate cause, readjust ice hose and
security switch. (page 3 point 13)
6

Repairs of electrical parts and refrigeraion circuit Trouble shooting
only by qualified technician
Malfunction Cause Remedial Action
Machine operates - but no ice production
Freezing unit and loss of refrigerant check refrigeration circuit (bubbles in
refrigeration unit work sight glass), eliminate leakage, evacuate
circuit, refill refrigerant
Freezing unit works, * no water in water chamber see water level control (page 5)
refrigeration unit does not * motor cut-out defective check / replace
*compressor defective check / replace
Ice jam in ice outlet Defective light barrier check (see page 6)
or ice hose consult ZIEGRA
Decrease of ice production * Condenser soiled or clean with brush or compressed air, never
poor ice quality insufficientcooling water flow with a wire brush. Watercooled machines:
bottle brush, antilime agent, clean water
filter. Open further the water control valve.
*ambient temperature too high machine must not be placed in the sun or
too warm ambience. Improve ventilation.
*expansion valve misadjusted adjust evaporation temperature as
indicated. Check thermal feeler pipe
and contact at evaporator outlet.
*insufficient amount of refrigerant, remove leak, evacuate circuit, refill
bubbles in sight glass with indicated quantity of refrigerant
*lime deposit on auger or cylinder clean freezing unit (see page 8)
*machine has switched off also consider possible water shortage
in between times or malfunction with a central refrigeration
plant.
*capacity control misplaced Shut the capacity control. Adjust over-
heating of the machine according to the
data sheet. Adjust capacity control at
1 K below evaporation temperature.
Cracking noise cylinder bearing defective replace
in freezing unit
Ice comes out of machine After leaving the cylinder, the ice check that there are no small edges or
in pressed form is pressed due to wrong installation bends. Amend.
("sausages") of the ice discharge tube, the see page 2
tube extension of the outlet
or due to sharp bends.
*V-belt loose or defective tighten / replace (see page 4 - V-belt)
loud squeaking noise * lime deposit on auger or cylinder Clean freezing unit (see page 8)
strong vibrations
freezing unit freezes up * air bubble in hose between remove air bubble
water chamber and freezing unit
7

Cleaning of Freezing Unit
Depending on the water quality a layer of solids may form after a while
in the freezing cylinder or on the auger.
Vibrations or noises in the freezing cylinder, e.g. "rumbling" and production of powdery ice may be a symptom
of such deposits.
As the freezing unit has to be completely clean inside in order to ensure proper freezing and an even upward
conveying of the ice on the auger, this layer has to be removed.
Remove tenacious deposits on the auger with steel wool.
However, these deposits often are of calcareous nature, which can be removed with an antilime
agent, e.g. ZIEGRA cleaning agent:
oSwitch the ice machine off, close the water tap and wait 1-2 hours
until the ice in the freezing unit has totally melted.
oDetach the water-inlet pipe at the bottom of the freezing unit, drain the water from the water chamber
and the freezing unit into a container.
oConnect a hose of appr. 80 cm with funnel at the water inlet of the freezing unit.
o Mix cleaning agent with hot water:
For each freezing unit: 1/2 bottle agent in 1 litre water of appr. 50°C
oFill the freezing unit with cleaning agent up to the ice discharge level.
oAllow the cleaner to react for 10 - 15 minutes.
This is mostly sufficient.
A maximum of 30 minutes must not be exceeded.
The cleaner first removes the lime deposit
and then may slightly effect the metal of the cylinder/auger, if having too long contact.
Do not apply the cleaning agent unnecessarily.
oDrain cleaning agent and flush freezing unit thoroughly with water.
oConnect water inlet pipe and switch the machine on.
As the ice may still contain residues of the cleaning agent, we recommend not to use the
ice production of the first minutes of operation,
though the cleaning agent is admissable for food machinery.
When deposits occur frequently, we recommend the installation of a filter system for the water.
We can offer a three stage filter system, please contact us.
8