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Ice-O-Matic GEM1256R manual

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  • Page 1

    Ice-O-Matic 11100 East 45th Ave Denver, Colorado 80239 Part Number 9081350-02 17-3144-01 Date 10/08 SERVICE AND INSTALLATION MANUAL GEM Models: Remote GEM0650R, GEM0956R, GEM1256R Pearl Ice ™ Series By Ice-O-Matic[...]

  • Page 2

    8[...]

  • Page 3

    GEM0650/0956/1256 Remote Introduction Page i How To Use This Manual Ice-O-Matic provides this manual as an aid to the end user and service technician in installation and maintenance of the Pearl Ice™ Series ice machines. Do not attempt to perform installation, start-up or maintenance unless you have read and fully understand this manual. If, at a[...]

  • Page 4

    GEM0650/0956/1256 Remote Table Of Contents Page ii Table of Contents Introduction ................................................................................................................... ............... Page i Table Of Contents.............................................................................................................. .[...]

  • Page 5

    GEM0650/0956/1256Remote Freight Claim Procedure Page iii Important! Inspect Promptly This merchandise has been carefully inspected and packed in accordance with the carrier’s packing specifications. Responsibility for safe delivery has been assumed by the carrier. If loss or damage occurs, you as the consignee must file a claim with the carrier a[...]

  • Page 6

    GEM0650/0956/1256 Remote Warranty Page iv Ice-O-Matic Parts and Labor Domestic & International L imited Warrant y Mile High Equipment LLC (the “Company”) warr ants Ice-O-Matic brand ice machines, ice di spensers, remote conde nsers, water filters, and ice storage bins to the end customer against defects in mate rial and factory workmanship [...]

  • Page 7

    GEM0650/0956/1256 Remote For the Installer Page 1 Installation Guidelines: For proper operation of the Ice-O-Matic ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties. Ambient Operating Temperatures: (Not including remot[...]

  • Page 8

    GEM0650/0956/1256 Remote For The Installer Page 2 GEM0650/0956R[...]

  • Page 9

    GEM0650/0956/1256 Remote For The Installer Page 3 GEM1256R[...]

  • Page 10

    GEM0650/0956/1256 Remote For the Installer Page 4 Bin Application The Pearl Ice™ Series are designed to fit the following Ice-O-Matic Bins ● B42, using Bin Top KBT 24 (Note: GEM0650 and GEM0956 ONLY) ● B25, B40 B55 using Bin Top KBT 19. ● B100 using Bin Top KBT 23 (one unit) or KBT 22 (two units). ● B120, B150, B170 Not designed for Pearl[...]

  • Page 11

    GEM0650/0956/1256 Remote For the Installer Page 5 Location: Ice-O-Matic ice machines are designed to be installed indoors in a contro lled environment. Install the ice machine in a location where it has enough space around it t o be accessible for service. A minimum of 6 inches must be allowed at the back for air circulation on air cooled models. T[...]

  • Page 12

    GEM0650/0956/1256 Remote Remote Condenser Page 6 ERC Dimensions (Inches) GRC1001 GRC1061 GCR2061 A 33.36 33.36 33.36 B 10.75 10.75 10.75 C 23.81 23.81 23.81 D 2.04 2.04 2.04 E 6.12 6.12 6.12 F 16.73 16.73 16.73 G 11.65 11.65 11.65 H 19.57 19.57 19.57 Pearl Ice™ Number GEM0650 R GEM0956 R GEM1256 R Line Sets RT325404 25 Foot Precharged Line Set RT[...]

  • Page 13

    GEM0650/0956/1256 Remote Remote Condenser Location Page 7 Use the following for planning the placement of the remote condenser relative to the ice machine. Location Limits: Remote condenser location must not exceed ANY of the following: ● Maximum rise from the ice machine to the remote condenser is 35 physical feet. ● Maximum drop from the ice [...]

  • Page 14

    GEM0650/0956/1256 Remote For the Installer Remote Condenser Location: Limited to a 25 foot or a 40 foot length of precharged refriger ant tubing connecting the ice machine to the remote condenser. The remote condenser must be above or level with the ice machine. Select the best available location, protecting the remote condenser from extremes of di[...]

  • Page 15

    GEM0650/0956/1256 Remote For the Installer Page 9 Typical Installation REMOTE CONDENSER ICE MACHINE[...]

  • Page 16

    GEM0650/0956/1256 Remote For the Installer Page 10 Coupling Instructions: Initial Connections: 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them. 2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil. 3. Position the fi[...]

  • Page 17

    GEM0650/0956/1256 Remote For the Plumber Page 11 Water Inlet: The recommended water supply is cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 inch male flare on the back of the cabinet. Install a hand valve near the machine to control the water supply. Drains: Ice Machine: There is one 3/4 inch FPT drain at the back of the cabinet; [...]

  • Page 18

    GEM0650/0956/1256 Remote For the Electrician Page 12 INSTALLATION MUST CONFORM TO ALL APPLICABLE CODES. Connect the electrical power to the unit to the wires in the junction box at the rear of the machine. Check the nameplate (located on the back panel) for the voltage requirements, and for the minimum circuit am pacity. The machine requires a soli[...]

  • Page 19

    GEM0650/0956/1256 Remote For the Installer Page 13 Completed Installation A typical installation should generally appear as illustrated below . The best place for the remote condenser is above the ice machine, although other locations are permissible. Roof Cut-A-Way[...]

  • Page 20

    GEM0650/0956/1256 Remote For the Installer Page 14 Final Check List Roof Holes Sealed? Condenser Leveled? ___1. Is the ice system installed indoors in a location where air and water temperatures are controlle d, and where they do not exceed the design limitations? ___2. Is there an electrical service within sight of the installed machine? Ha s the [...]

  • Page 21

    GEM0650/0956/1256 Remote Start Up Page 15 Pre-Start Inspection: 1. Remove the front and side service panels. 2. Check that any shipping blocks have been removed. 3. Inspect the interior of the ice machine for loose screws or wires. 4. Check that no refrigerant lines are rubbing each other. 5. Check that the fan blades turn freely (Remote Condenser)[...]

  • Page 22

    GEM0650/0956/1256 Remote Component Description Page 16 ● Control Box: Contains the electrical controls that operate the machine. ● High Pressure Cut Out Switch: An auto-reset switch sensing the high side refrigeration pressure. It will shut the machine off if the discharge pressure e xceeds 450 psig. ● Pump Down Control: A switch to control t[...]

  • Page 23

    GEM0650/0956/1256 Remote Component Description Page 17 ● Contactor: A definite purpose contactor connecting the compressor and the fan motor to the po wer supply. ● Circuit Board: Controls the operation of the ice machine using input from the sensors and pressure controls. Switches loads on and off thru relays. (Reference Photo Below) ● Poten[...]

  • Page 24

    GEM0650/0956/1256 Remote Component Description Page 18 ● Evaporator: A refrigerated vertical tube filled with water and containing a water seal and auger. ● Auger: A solid stainless steel double spiral auger, it pushes the ice crystals up to the top of the evaporator. ● Water Seal: A two part “face” seal, the top half rotating with the au[...]

  • Page 25

    GEM0650/0956/1256 Remote Electrical Sequence Page 19 Electrical Sequence: There are 7 indicator lights on the control board: ● WTR-OK: (Water OK) Green . Normal=Glowing. Glow when there is water in the reservoir. ● PWR-OK: (Power OK) Green . Normal=Glowing. Glows when the power board has power and is functional. ● Service: Red . Normally Off.[...]

  • Page 26

    GEM0650/0956/1256 Remote Operation: Water Page 20 Water Water enters the machine through the 3/8 inch male flare at the rear of the cabinet, goes to the water reservoir which it enters through the float valve. The water then goes out the botto m of the reservoir tank to the bottom of the evaporator. Reservoir overflow or ev aporator condensation is[...]

  • Page 27

    GEM0650/0956/1256 Remote Operation: Refrigeration Page 21 Beginning at the compressor, the refrigerant is compressed into a high temperature gas. The discharge line directs this gas to the condenser and to the head pressure control. At the remote condenser the gas is cooled by air and it then condenses into a liquid. This high pr essure liquid then[...]

  • Page 28

    GEM0650/0956/1256 Remote Operation: Refrigeration Page 22 Low Condensing Temperature The refrigeration system under low condenser air temperatures is much the same as it is under higher temperatures, with the exception that the resulting low head pressures cause the head pressure control to close off the liquid line between the condenser and the re[...]

  • Page 29

    GEM0650/0956/1256 Remote Operation: Refrigeration Page 23 Pump Down During the pump down cycle (usually initiated by the circuit board de-energizing the liquid line valve) the discharge gases flow through their normal path to the remote condenser, through th e head pressure control and into the receiver. At this point the refrigerant flow is stoppe[...]

  • Page 30

    GEM0650/0956/1256 Remote Operation: Performance Page 24 Typical Low Side Pressure: Remote: 34-38 PSIG Typical Discharge Pressure: Remote: 220-275 PSIG Typical Compressor Amp Draw: GEM0650 115/60/1 8-9 Amps GEM0956 208-230/60/1 4-5 Amps GEM1256 208-230/60/1 5-6 Amps Typical Auger Drive Motor Amp Draw: GEM0650 115/60/1 3.1 to 3.5 Amps GEM0956 208-230[...]

  • Page 31

    GEM0650/0956/1256 Remote Sanitizing and Cleaning Page 25 It is the USER’S RESPONSIBILITY to keep the ice machine and ice storage bin in a sanitary condition. Without human intervention, sanitation will not be maintained. Ice machines also require occa sional cleaning of their water systems with a specifically designed chemical. That chemical diss[...]

  • Page 32

    GEM0650/0956/1256 Remote Condenser Maintenance Page 26 ● Clean the condenser: the condenser may appear to be clean on the surface, but it can still be clogged internally. Check with a flashlight from the front to see if light can be seen through the condenser fins. Brush in direction of fins The condenser coil must be kept clean. The condenser ca[...]

  • Page 33

    GEM0650/0956/1256 Remote Bearing Maintenance Page 27 Bearing Maintenance: The bearing in the breaker should also be checked at least two (2) times per year. Switch the machine OFF and check the bearing. 1. Remove the chute cover. 2. Unscrew the ice sweep 3. Removing the water shed and unscrewing the breaker cover. Note: Left Hand Threads 5. Inspect[...]

  • Page 34

    GEM0650/0956/1256 Remote Sensor Maintenance Page 28 Bin Control Sensor: Ice Discharge Chute The bin control uses devices that se nse light, therefore they must be kept clean enough so that they can “see”. At least twice a year, remove the bin control sensors from the base of the chute, and wipe the inside clean, as illustrated. Slide In and Out[...]

  • Page 35

    GEM0650/0956/1256 Remote Auger Maintenance Page 29 Auger: In some areas, the water supply to the ice machine will contain a high concentration of minerals, and that will result in an evaporator and auger becoming co ated with these minerals, requiring a more frequent removal than twice per year. If in doubt about the condition of the evaporator and[...]

  • Page 36

    GEM0650/0956/1256 Remote Service Diagnosis Page 30 Symptom Possible Cause Probable Correction No ice is made nothing operates. •Unit off due to no power •Restore Power •Unit off due to master switch in OFF •Switch master Switch to ON position •Unit off due to low water level •Check water supply, filter s t r a i n e r , f l o a t v a l [...]

  • Page 37

    GEM0650/0956/1256 Remote Service Diagnosis Page 31 Symptom Possible Cause Probable Correction Unit makes ice, but very slowly •High dischar ge pres su re because •Clean filter and co ndenser. of a dirty condenser. •Low capacity because the auger and •Clean the water sy stem. evaporator are coated with mineral s c a l e . •Low suction pres[...]

  • Page 38

    GEM0650/0956/1256 Remote Co ntrol System Diagnostics Page 32 The Control System consists of: ● Control Board ● Water Sensors ● Ice Sensors ● High Pressure Cut Out ● Low Pressure Cut Out If the unit is OFF , check the control board: 1. Is the Power OK light on? If not check power to the unit. If it has power, and the Power OK light is not [...]

  • Page 39

    GEM0650/0956/1256 Remote R&R- Water Reservoir, Bin Control Page 33 Water Reservoir: 1. Disconnect electrical power supply. 2. Shut off water supply to the ice maker. 3. Remove the front panel. 4. Disconnect water inlet tube from reservoir inlet fitting. 5. To remove float valve, push in “locking tabs” as shown and pull float up. Note: The p[...]

  • Page 40

    GEM0650/0956/1256 Remote R&R-Bearing and Breaker Page 34 Note : Removal of the auger, water seal, evaporator and gear motor must begin at the top of the assembly. To Remove the Breaker Bearing Assembly: 1. Disconnect electrical power. 2. Remove panels. 3. Push back bail clamp and remove ice chute cover. 4. Unscrew and remove ice sweep. 5. Lift [...]

  • Page 41

    GEM0650/0956/1256 Remote R&R-Auger Page 35 To Remove the Auger: 1. Disconnect electrical power. 2. Turn off the water to the machine. 3. Unclip the evaporator drain hose, pull it down and drain the evaporator into the bin or container. 4. Remove the top panel. 5. Swing bail clip down and remove the ice chute cover. 6. Unscrew ice sweep. 7. Remo[...]

  • Page 42

    GEM0650/0956/1256 Remote R&R-Water Seal Page 36 To Remove the Water Seal: (Assuming all steps to remove the auger have been performed) 1. The gear motor/evaporator assembly will have to be exposed. 2. Remove the four (4) hex head cap screws holding the evaporator to the gear motor assembly. Lift the evaporator up and off the gear motor. 3. Remo[...]

  • Page 43

    GEM0650/0956/1256 Remote R&R-Evaporator Page 37 To Replace the Evaporator: (Assuming all steps for removal of the thrust be aring, breaker, auger and water seal have been performed). 1. Recover the refrigerant from the ice machine. 2. Unsweat the refrigerant connections: a. At the thermostatic expansion valve outlet. Evaporator Auger Ice Chute [...]

  • Page 44

    GEM0650/09561256 Remote R&R-Gear Motor To Check the Gear Motor: 1. Remove wires from terminals 1 and 2 2. Use an ohmeter to check for continuity. If there is none, replace only the motor. If there is continuity but the motor will not start, check the motor’s start switch. 3. Remove motor end bell or motor stator. With ohnmeter wires attached [...]

  • Page 45

    GEM0650/0956/1256 Remote R&R-Fan Blade and Motor Page 39 To Remove the Condenser Fan Motor Assembly: 1. Disconnect electrical power to the ice machine and/or remote condenser. 2. Remove fan guard. 3. Remove the fan blade. 4. Disconnect the electrical power lead to the fan motor. 5. Remove the four (4) bolts from the fan motor assembly. 6. Remov[...]

  • Page 46

    GEM0650/0956/1256 Remote R efrigeration System Service Page 40 Refrigeration Service: General: This ice machine uses R404A refrigerant and polyolester oil. Do NOT use mineral oil in this refrigeration system. ● When the refrigeration system is serviced, a special liquid line drier is re quired. It is included with replacement compressors. ● R40[...]

  • Page 47

    GEM0650/0956/1256 Remote GEM0650R Wiring Diagram Page 41 Wiring Diagram GEM0650R[...]

  • Page 48

    GEM0650/0956/1256 Remote GEM0956R Wiring Diagram Page 42 Wiring Diagram GEM0956R[...]

  • Page 49

    GEM0650/0956/1256 Remote GE M1256R Wiring Diagram Page 43 Wiring Diagram GEM1256R[...]

  • Page 50

    GEM0650/0956/1256 Remote Service History Page 44 What to Do Before Calling for Service: ● Check the water supply to the ice machine. The ice machine is design ed to shut off if there is no water to it. Check the water filters if there are any. ● Check the power supply to the ice machine. Reset the breaker if it is tripped. ● If both water and[...]