Ziegra ZBE 30 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
No ice production 6
Ice quality - Miscellaneous 6
Freezing unit 7
Refrigerant and water cicuits 8
wiring diagram attached
General installation advice "
Assembly Instruction Freezing unit "
Spare parts list "
Subject to technical modifications - Edition 07/8.09
ZIEGRA - EISMASCHINEN
Germany 30901 Isernhagen
www.ziegra.com
Service:
Tel. [phone] - 0
Tel. (+49) 0511
90244 - 18
Fax. 90244 - 90
Fax.
90244 - 92
ice @ ziegra.com
[email protected]
ZBE 30 ZBE 70 ZBE 110 ZBE 150 ZBE 250 ZBE 350 ZBE 375

Working Method
The Ziegra chip-ice machine is delivered ready for operation and has only to be connected to power and water supply
(provide melt-water drain for machines including storage bin). No operating personnel is required.
The ice machine works fully automatically.
Water flows by gravity from the water chamber
in the ice machine into the freezing cylinder.
An evaporating coil (with ozone friendly refrigerant
R 404 A) surrounds the cylinder freezing the water
inside at an evaporation temperature
of -12°C up to -18°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 following 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 - 7 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 chip-ice is frozen within the patented freezing cylinder at an evaporation temperature of -12°C up to -18°C.
Due to the special procedure maximum refrigeration capacity is obtained at a very low energy consumption.
Cooling energy:
The uninterruped line shows the accumulated energy per kg of
ice (refrigerating energy). Only when ice having a temperature of
0°C melts to water of 0°C, the considerable refrigeration capacity
of ice is released (vertical line). The cooling capability of water
is lower (left line), ice of low temperatures does hardly cool at all
(right line).
The cooling capacity of water per °C is
(left line) 1 Kcal / kg,
Ice temperatures 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.
Up to an ice temperature of 0°C energy input and the
refrigerating energy produced are closly correlated.
Only when ice is unnecessarily cooled to temperatures
below 0°C, the energy required rises disproportionately.
1

Start-up
1. Temperatures:
Ambient: normal max. min.
ZBE 30 to ZBE 350 20 °C 42 °C + 5 °C
ZBE 375 35 °C 45 °C + 5 °C
Water:
ZBE 30 to ZBE 350 15 °C > 5 °C
ZBE 375 25 °C > 5 °C
2. Installation site
Distance from rear wall at least 10 cm
(ZBE 150-ZBE 375: 20 cm). The ventilation apertures
of the machine must not be covered.
Provide sufficient room ventilation.
The ice production capacity may decrease at high
ambient- or water temperature or insufficient
ventilation of the machine. At low temperatures the
machine may switch off or even freeze up. ZBE 30-10 ZBE 70-35 ZBE 110-35
ZBE 150 bis ZBE 375: see specification
3. Water connection:
4.
Electrical connection
The machine operates with normal potable water or fuses 16 A, slow
fully demineralized (destilled) water.
With harder water > 14°d.H.: install a water softener. 230V-1-50 Hz Machine incl. 2 m cable and plug
< 6°d.H.: consult Ziegra or on request for ZBE 350 und ZBE 375:
If the water is slightly saline, or comes from a well or
400V-3-50 Hz
Make firm installation to main
is outside 7,2 - 9,5 pH: consult Ziegra. power supply. Provide main switch.
3-phase machines have a
supplied with m/c: 2 m high-pressure hose an phase sequence relay.
3/4'' sleeve for water inlet Other voltage according to order, type plate, wiring
Provide at side: Water pressure: 1 - 5 bar diagram.
stop valve and strainer
If long supply lines necessary,
insulate, if possible.
5.
Storage bin:
Wash out thoroughly with warm water.
Melt-water drain
supplied with m/c: 2 m hose, 14 mm dia.
Provide at side: Mount hose and fasten with clamp.
6.
Start
Ice production starts after app. 2 min.
The drain pipe must be at a lower level than the
machine outlet. Otherwise the melt water will not
drain off from the storage bin. 7. Machines without bin only:
Fasten tube to the ice discharge by means of clamp.
The ice mus 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).
Ice must slide downwards only,
not horizontically or upwards.
Further advice in the extra folder "Installation Ice discharge"
2

Control Elements and Safety Devices
1. On-off switch at the front
2. Cut-out of machine when storage bin is full:
ZBE 30 - ZBE 110:
Thermostat in bin
The thermostat switches the machine off when the bin is full
and on again when ice has been removed.
The switch-off point is adjusted for longer ice contact,
not for a momentary contact.
The thermostat does not operate at temperatures below +5°C
For such applications ask for special execution.
ZBE 150 - ZBE 375:
switch the machine off, when ice dams up
in the ice discharge hose and when the bin is full.
Special models:
e.g. for sauna, on request
3. Water pressure switch or Water level control
switch the machine off in case of too low water
pressure or water shortage.
Automatic restart when the water supply
has been restored.
4. Compressor
Automatic motor cut-out in compressor connecting box.
5. High pressure switch
The machine is switched off, if there is e. g. excess
in the refrigeration system caused by too high
ambient temperature or soiled condenser.
6. Gear Motor
Overload cut-out in switch box.
7. Automatic water drain
(not provided in all machines)
In order to reduce nucleation in stagnant water, a solenoid
valve closes the water inlet as soon as the machine
is out of operation, another opens the water drain
thus emptying the water chamber and the freezing unit.
8. Capacity control (ZBE 350 and ZBE 375):
The capacity control protects the evaporator and
the compressor against overburdening by too
low ambient- or watertemperature.
3
Automatic restart after removal of ice.

Maintenance and hygiene
switch off machine
disconnect from power supply, close water supply
Maintenance Hygiene
For a failure-free operation:
For hygienic ice:
Every 3 - 6 months At frequent intervals
Clean the water chamber and float valve Clean all parts getting in contact with water or ice
thoroughly with a commercial cleaning agent:
Clean condenser with soft brush or Water-bearing parts,
vacuum cleaner small filter in the water hose, water chamber
and float valve
ZBE 30 - ZBE 110: lift grid
and take it off All parts getting in contact with ice:
ZBE 150 - ZBE 375: remove lid ice hose into storage
and front panel ice-discharge interior or exterior.
Ice-storage
melt water grid
General check Any water leaks? melt-water drain
The machine runs quite? ice scoop
Small parts
After being thorougly cleaned
Every 2 - 5 years
can also be given into dishwasher
check cylinder bearing. Scaled parts
clean mechanically and with antilime agent,
replace if required
Ask for further Options:
Water drainage
when machine stops
Automatic flushing system
e.g. once a day
Hygiene kit:
A set of all water bearing parts which cannot
be cleaned satisfactorly for replacement.
4

Repairs of electrical parts and refrigeration circuit only carried out Trouble Shooting
by a qualified technician!
Malfunction
Cause
Remedial Action
Melt-water in storage bin * Melt-water drain blocked Clean, rinse with water
does not flow off * Machine is sited below Raise machine or lower drain
drain level Install melt water pump
(ask Ziegra)
Water-Leakage
*
Hose connections loose or defective
Fasten, insert new seals or replace
Water runs into machine or * Lid of water chamber loose Reset correctly
onto floor * Melt-water drain loose Fasten clamp
* Fissure in water chamber Replace
Water leaks from the ice Shaft seal in cylinder defectiv Replace
maker
Water pressure switch or No water in water chamber Check water supply
Waterlevel control Water pressure: min 1 bar - max 5 bar
has switched off Clean water filter and float valve
High pressure switch * Air in refrigeration circuit Change filter drier
has switched off (insufficiently evacuated evacuate circuit
after repair) refill refrigerant
* ambient temperature too high Machine must not be placed in
the sun or too warm ambience.
Improve ventilation.
* condensor soiled Clean with brush or compressed air.
* ventilator motor
defective Check / replace
Machine does not work
General electrical faults * Absence of current Check socket and fuses
*Intermittent contact Check electrical connections,
also in control panel
*Water pressure switch defective replace
*Water level switch does not work Check, adjust metal tongue if necessary
*Ice switch does not work Check, see below
Overload cut-out Motor overload caused by
has switched off *electric capacitor of gear replace
motor defective
*gear defective replace
* cylinder bearing damaged replace
* machine freezes up see "machine freezes up"
* ice breaker misadjusted see "cleaning of freezing unit"
(ZBE 30 - ZBE 110)
* overload cut-out defective replace
Storage bin thermostat does not * Ambient temperature too low Choose different locations or increase
switch or switches too early ambient temperature. Instant remedy:
warm thermostat by hand.
* Thermostat defective or replace or Re-Set
setting incorrect off: approx. 1 min. after ice contact
on: at +5°C
Ice switch does not work jammed (or defect) adjust (or replace)
5

Trouble Shooting
Malfunction
Cause
Remedical Action
Machine operates, but no ice production
Drive motor and Loss of refrigerant
refrigeration unit work
(ventilator runs)
Refrigeration unit stopped * No water in water chamber See water pressure or water level switch
or works at intervals above
(drive motor runs) * Motor cut-out defective Check / replace
* Compressor defective Check / replace
Decreased ice production * Condenser soiled or insufficient Clean with brush or compressed air,
Poor ice quality cooling-water flow never with a wire brush. Water-cooled
machines: bottle brush, antilime agent
* Ambient temperature too high Provide better ventilation,
move maschine away from wall.
* Insufficient amount of refrigerant, Remove leak, evacuate circuit,
bubbles in sight glass replace filter drier, refill with
indicated quantity of refrigerant.
* Lime deposit on auger Clean freezing unit with hot water and
or cylinder antilime agent (Ziegra cleaning agent),
clean mechanically, if required.
* Ice breaker is misadjusted see istallation sheet freezing unit
-ZBE 30-110
* Machine runs in intervals see above (refrigeration unit stopped)
If Ice maker is connected * no sufficient refrigerant check the cooling system of the
to a central refrigeration unit: * Suction pressure too low central refrigeration unit
Machine runs in intervals * pressure fluctuation
Data must comply to the ZIEGRA prescription
(If not at hand, ask Ziegra)
Rumbling or loud squeaking
*
Air bubble in pipe between water Remove air bubble
noise chamber and freezing unit
Strong vibrations
Machine freezes up
*
Lime deposit on auger or Clean freezing unit with hot water and
cylinder antilime agent, clean mechanically,
if required.
Occasional gentle squeaking noises
are a typical sign for good and hard ice,
but do not indicate a failure.
Cracking noise in the Cylinder bearing defective Replace
freezing unit
Ice comes out of machine Even small edges or bends can be
in pressed form the cause (see page 2)
("sausages")
6
Repairs of electrical parts and refrigeration circuit only carried out by a
qualified technician!
Check refrigeration circuit (bubbles
in sight glass). Eliminate leakage,
replace filter drier, evacuate circuit,
refill refrigerant.
After leaving the cylinder the ice is
pressed due to wrong installation of the
ice discharge tube, the extension, or
due to sharp bends.

Cleaning of Freezing Unit
Depending on water quality a layer of solids may form 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:
1/3 bottle agent in 3/4 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.
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.
7

Refrigerant and Water Circuit
8

Wolf Laboratories Limited
www.wolflabs.co.uk
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