Operation & Installation Manual 03/2004
Contents
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3. PUMP DEFROST SWITCH ON Y vy o B G ONG R PUMP Be SBCA S SOLENOID B G N O N C R oe Fe K coL BK W ONLY RELAY 2 MOTOR awa BU COLD WARM Y ey M IZ COLD R O N O T TIMER EXD WATER H gt 0 Haz i THERMO N C 256 PK PK l PK Sy a WATER PLATE MA Y 8U BU a HoT po p sing pi CLOSED OPENING E ARM E LEVER OPENED CLOSING RELAY Y 8U THERMOSTAT a orae TEN Y O MASTER ae R gin SWIG RELAY 4 x B G NEERI SLAVE ACT Y O rO SWITCH RELAY 2 Y BU R ONLY LI RELAY 3A WATER 2 BK Y O R NC gy R B G RY B G J RELAY 3B G N O cap MASTER DELAY BK ACT COLOR CODE So NC Y MOTOR TIMER BK BLACK po NO O 0 kK RELAY 1 B G BLACK GREEN Y O PDT 8 W BLACK WHITE nO 422 DPDT BR BROWN IR og BU BLUE RELAY 1A N C GY GRAY N C o ORANGE R BK ly OR PK PINK Y O RELAY A R RED B G ELAY 4 N O CAP 1 R W RED WHITE are B G E MW w WAITE RELAY 1B RELAY 4B _ ONC SLAV Y YELLOW N C O O se ACT Y BU YELLOW BLUE N O 0 BK ole L MOTOR ICE CUBER Y OR YELLOW ORANGE N O WIRING DIAGRAM R BK RED BLACK GB1258 O BK ORANGE BLACK 508 1057 02 SCHEMATIC WIRING DIAGRAM 508 1069 01 New 5 19 03 11 NVEHOVIG ONISIM IVIYOLOId LO 4901 80G
4. GB1258W KOLD DRAFT CLASSIC Installation amp Operation Instructions KOLD DRAFTEYA Ice Machine Products 1525 East Lake Road Erie PA 16511 1088 814 453 6761 FAX 814 455 6336 A Tradition of Excellence In Ice Equipment 2004 KDIndustries Inc Erie PA U S A i i 3 04 Printed in U S A 508 1069 01 INSTALLATION AND OPERATION INSTRUCTIONS FOR KOLD DRAFT CLASSIC GB1258W SERIES ICE CUBERS CHECK FOR FREIGHT DAMAGE BEFORE PROCEEDING Even though damage to the carton may not have been evident check for hidden damage and contact freight carrier immediately if necessary to file a claim THIS EQUIPMENT MUST BE INSTALLED IN COMPLIANCE WITH THE APPLICABLE FEDERAL STATE PROVINCE AND OR LOCAL PLUMBING ELECTRICAL AND HEALTH SANITATION CODES AND REQUIREMENTS CAUTION RISK OF PERSONAL INJURY PROPERTY DAMAGE EQUIPMENT FAILURE OR FIRE Refer all maintenance to qualified personnel Never operate this equipment with covers panels or other parts removed or not properly secured Warn all users to clean up spillage immediately keep storage bin doors closed and report any apparent leakage or unusual sounds to responsible maintenance personnel INSTALLATION NOTE For Multiplex installations please refer to Multiplex specific instructions before proceeding 1 Position the ice storage bin so that the following minimum clearances will be available around the ice maker for ventilation and uti
5. L INJURY NOTICE ON THE FRONT PAGE and the importance of the PREVENTATIVE MAINTENANCE recommendations below PREVENTATIVE MAINTENANCE CLEANING Usually at 3 to 6 month intervals depending on water conditions INSPECTIONS During cleaning at least twice a year SERVICE All such equipment will require service at some time Service requirements will be minimized with faithful preventative maintenance including good housekeeping at the installation site A CALL FOR SERVICE AS SOON AS A POSSIBLE PROBLEM IS NOTICED MAY AVOID EXTENSIVE REPAIRS CAUTION RISK OF PERSONAL INJURY OR PROPERTY DAMAGE Do not use ammonia solutions in cleaning any part of the ice maker Do not mix ice machine cleaner and sanitizer together Use rubber gloves eye protection and an apron Clean up splashes or spillage immediately Follow these instructions exactly 9 EAS 508 1069 01 New 5 19 03 ICE CUBER CLEANING INSTRUCTIONS 1 Mix one bag of KOLD DRAFT ice machine cleaner 29T 0 1090 in two 2 quarts of clean warm water 180 F MAX for each evaporator water plate assembly to be cleaned 2 If the cuber is operating wait until a harvest cycle occurs then trip the ICE OFF WASH switch to WASH as soon as the water plate begins to close 3 ee all ice from the storage bin and shut off other ice makers on the same in 4 After the water fill is completed switch the ICE OFF WASH to OFF While pinening water level c
6. ORMALLY BIN CAP TUBE 14 If start up will not occur immediately secure all cuber cabinet panels now READ THE FOLLOWING NOTES CAREFULLY PRIOR TO MAKING CONNECTIONS Electrical Requirements 220 V 380 V 10 50 HZ 3 PHASE N 1 5 A 7 0 A Minimum Ampacity Minimum ampacity does not indicate typical running current value Refer to equipment NAME PLATE data Use minimum ampacity value for sizing branch circuit conductors up to 25 feet length For conductor length over 25 feet up to 100 feet increase 1 AWG size Over 100 feet requires 2 or more AWG size increase Branch circuit protection Proper protection must be provided by either fuse s or HACR type circuit breaker s Each ice maker must be provided with a separately protected circuit with no other load s A fused disconnect installed adjacent to each ice maker is recommended must be supplied by the installer and may be required by local codes NORMAL protector size is based on rated voltage and operation at lower than extreme temperature limits When branch circuit conductors are sized to permit increasing the protector size up to the specified maximum may avoid nuisance protector opening under harsh operating conditions Water supply Minimum 30 psig supply pressure while the ice maker is filling is required Maximum supply pressure is 100 psig The water fill flow rate is 2 GPM for each GB1250 Backflow backsiphonage protection is provide
7. Remove the top and front cabinet panels 2 Be sure that the ICE OFF WASH switch is in the center OFF position 3 Turn on supply water and power Be sure that condenser liquid coolant lines are ready for use before turning power on Check for leaks in water liquid supply connections Be sure that pump hoses are connected then put about one pint of clean tap water into the circulation system to lubricate the pump seal 4 Move the ICE OFF WASH switch to the right WASH position and observe the water fill cycle and the pumps running If all water distributor holes do not produce full streams and the appearance of air is evident in the tube pinch the plastic tube connected to the water solenoid valve outlet while water is running until the streams are full all the way across the distributor tube Water fill is complete when the water in the liquid level control tube reaches the high level probe At this time observe that the water shuts off and that there are no water leaks dripping into the drain pan 508 1069 01 New 5 19 03 5 Pull the right end of either water plate down stretching the springs until the pump stops and hold until the pump does not re start when released The water plates will both open fully to dump the batch of water previously taken in then close immediately The water plates should stop when they are fully closed and the water fill cycle will repeat 6 After the water fill is complete move the ICE OFF WASH swi
8. ain opening and clamp the tubing to the drain pan nipples 10 Electrical water and drain locations are shown on the following drawing All dimensions are in inches See INSTALLER NOTE at the end of this section POTABLE WATER INLET 1 2 F P T 3 4 DIA OPENING FOR 7 8 DIA OPENING ICE MAKER DRAIN FOR ELECTRICAL MULTIPLEX ONLY SUPPLY LIQUID COOLE CONDENSER LIQUID IN L UPPER 3 8 F P T EVAPORATOR REMOTE PRAN DISCHARGE LINE MALE QUICK CONNECT COUPLING 1 2 0 D TUBING a el 1 LIQUID COOLE CONDENSER LI UID OUT S VAZ EPI 220748 REMOTE m 4 7 8 2 1 8 H LIQUID LINE MALE QUICK L 14 1 8 2 7 8 CONNECT COUPLING 3 8 O D TUBING LOWER EVAPORATOR DRAIN GB12XX WARNING RISK OF CONTAMINATION OF ICE IN THE BIN Provide separate unconnected drains for the ice maker and the bin Consult local codes for suitable connections to the building drains 11 Purge the potable water supply line 12 Remove the water plate shipping strap s 13 Route the bin thermostat capillary tube through the grommet in the compressor compartment wall and under the ice chute See the diagram and notes following for location and securing of the capillary tube The capillary tube clips will be toward the drain pan when properly installed 508 1069 01 New 5 19 03 WHEN BIN CAP TUBE IS PUSHED INTO PLACE Nw of N
9. baking soda per gallon of warm water and a sanitizing solution of no less than 1 teaspoonful 5 ml 5 1 4 sodium hypochlorite per quart of clean water 11 After cleaning has been completed trip the ICE OFF WASH switch to ICE and check to be sure that the cuber is operating properly particularly the water level probes Then re assemble and secure all cabinet enclosure panels ICE BIN CLEANING INSTRUCTIONS The bin should be cleaned periodically If bin drain has any horizontal run remove ice from left side of bin and flush with two quarts of hot water monthly Long drain lines should be flushed weekly 508 1069 01 New 5 19 03 CAUTION RISK OF PERSONAL INJURY EQUIPMENT DAMAGE OR CONTAMINATION OF THE ICE BIN Do not use ammonia solutions or strong detergents in cleaning any part of the ice maker or bin Never use appliance polishers or other finish preservatives or cleaners in ice storage areas 1 Clean exterior of bin frequently 2 To clean the interior follow instructions provided with bin 3 Empty the storage area and disconnect the electrical power supply to the ice maker s 4 Remove the ice maker inspection panel top left and right end panels and drain pan Sliding bin doors may be removed by lifting them up then pulling out from the bottom 5 When cleaning the ice maker follow the ice maker cleaning instructions and clean the bin last 6 Replace all enclosure panels before
10. d by an internal air gap accepted by NSF If additional protection is required by local codes or authorities any device s and installation of the same including specification and cost are the responsibility of the installation specifier Ice maker drain The size of the gravity drain for the ice maker purge and rinse water must not be reduced Individual drains from stacked ice makers may be discharged into a standpipe or manifold with a minimum 1 1 2 inch air gap at each ice maker connection Liquid condenser coolant pressure drop Condenser coolant pressure drop may reach 20 psig during peak load with 85 F coolant temperature at recommended refrigerant high side pressure The condenser coolant water regulating valve may require adjustment due to variations in the coolant supply characteristics to provide optimum efficiency 508 1069 01 New 5 19 03 All models are intended FOR INDOOR USE ONLY with PERMANENT CONNECTION TO THE FIELD ELECTRICAL SUPPLY The remotely installed condensers supplied by KOLD DRAFT may be installed outdoors and they require a separate electrical supply CAUTION RISK OF PROPERTY DAMAGE EQUIPMENT FAILURE OR FIRE Failure to comply with all installation specifications and instructions may cause erratic operation and the risk of damage or fire Other operating condition requirements Ice maker ambient air temperature MINIMUM 45 F MAXIMUM 90 F Remote condenser ambient air t
11. emperature CONSULT SERVICE MANUAL Ice makar ambient temperatures less than 60 F may cause erratic bin thermostat operation Potable water and condenser liquid supply Temperature MINIMUM 45 F MAXIMUM 90 F Pressure MINIMUM 30 psig MAXIMUM 100 psig Potable water temperatures less than 50 F are likely to cause cold water thermostat operation see SERVICE MANUAL If regulator is used recommended setting is 30 to 50 psig 508 1069 01 New 5 19 03 START UP INSTRUCTIONS WATER LEVELS CYCLE TIMES AND REFRIGERANT CHARGES PARAMETER MODEL GB1258W K C HK Water fill level Top of tank to level in control tube 35 8 23 4 Approximate cycle time min 12 22 5 18 Approximate harvest weight Ib 8 15 4 14 2 Refrigerant Charge Oz R 404a Liq cooled 52 Values are for GB1258W model at 90 F air 70 F water temperatures with cuber adjusted to produce fully formed ice Greater capacity can be obtained by reducing the water fill level lowering the high level probe to produce ice with larger dimples A slight adjustment of the probe will result in a noticeable effect on dimple size The control stream will not rise over the dam with lower water fill levels than indicated above CAUTION REFRIGERANT CHARGES MUST BE ACCURATELY WEIGHED Consult the specification and troubleshooting guide if variations from the following description of operation are noticed 1
12. ified RTV sealant Dow Corning RTV 732 or equal 3 Remove the cuber cabinet TOP panel as follows Lift from the front and pull forward until the rear clip is disengaged from the chassis 4 CAREFULLY lift the cuber out of the carton and onto the floor CAUTION RISK OF PERSONAL INJURY OR EQUIPMENT DAMAGE Use a suitable lifting means and be careful of sharp edges 5 Remove the remaining cuber cabinet panels as follows FRONT Remove the 4 screws at the bottom and front sides pull forward SIDES Pull forward and lift to disengage the clips from the chassis NOTE When re installing the panels be sure that the screws engage the TOP panel 6 Remove the ice deflectors ice chutes and drain pans Drain tube assemblies are packed with the drain pans as shown below 7 Install gasketing on top of bin if required Gasket material must be positioned so that it extends to the outside edge of the perimeter of the cuber chassis when the cuber is in place 8 CAREFULLY place the cuber onto the gasketed bin noting the alignment of the mounting holes in the chassis if mounting means are provided on the bin Follow the bin installation instructions for securing the cuber to the bin 508 1069 01 New 5 19 03 9 Install the drain pans ice chutes and ice deflectors Route the Lower Evaporator Drain tube through the rear of the bin the Upper Evaporator drain tube through the Upper Evaporator Dr
13. lity connections REAR W 8 R 6 inches A 10 inches from left of rear cabinet panel TOP and LEFT SIDE 6 inches RIGHT SIDE 8 inches 7 8 DIA OPENING FOR ELECTRICAL SUPPLY 1 2 F PT LIQUID COOLED POTABLE WATER INLET CONDENSER oe IN 3 4 1 D FLEX FINER FILTER REQUIRED TUBING FIELD CONDUIT OUTLET BOX MULTIPLEX ONLY SIB DIA DISCHARGE LINE MALE QUICK CONNECT COUPLING 1 2 0 D TUBING 7 STAND PIPE FOR STAC ICE MAKER DRAINS UPPER PANEL FASTENERS EVAPORATOR DRAIN propdan LIQUID COOLED 7 SUPPLIED BY i CONDENSER LIQUID OUT 3 4 1 D FLEX TUBING INSTALLER Au pa EPT UPPER EVAPORATOR DRAIN 1 50 MIN vu MINE AIR GAPS a a E QUICK a CONNECT COUPLING FATE 3 8 0 D TUBING 3 4 1 D FLEX TUBIN Al LOWER LOWER EVAPORATOR DEAN A EVAPORATOR DRAIN SUPPLIED BY INSTALLER TO DRAIN SE J SUPPLIED BY rare BIN DRAIN SEE BIN INSTALLATION BIN INSTALLATION INSTRUCTIONS LEFT SIDE VIEW REAR VIEW INSTRUCTIONS FOR SIZE de LOCATION CLEARANCE REQUIREMENTS GB12XX ALLOW 6 MINIMUM CLEARANCE AT BACK AND TOP 4 LEFT SIDE amp 8 RIGHT SIDE FOR VENTILATION AND UTILITY CONNECTIONS 508 1069 01 New 5 19 03 2 Level the bin with adjusters on legs or by shimming if the bin is to be sealed to the floor If gaps due to shims are greater than 1 8 inch install a cove molding around the bin bottom Seal the bin or molding to the floor with NSF Cert
14. ontrol hose carefully remove the water level control tube rom the cap HOLD THE TUBE HIGH ENOUGH SO THAT THE TUBE DOES NOT OVERFLOW Release the hose and pour about half of the mixed cleaner into the tube Replace the tube on the cap while pinching water level control hose then pour the remaining cleaner into the control stream box 5 Switch the ICE OFF WASH to WASH and allow the cleaner to circulate for approximately 15 minutes then pal the right side of the water plate down until the pump stops and hold it until the pump will not re start when released 6 The water plate will open and dump the cleaner then close immediately and the water system will refill Repeat this dumping and refilling three 3 times to rinse out all of the cleaning solution 7 Mix a sanitizing solution of two 2 oz 5 1 4 sodium hypochlorite household bleach or equivalent and one 1 quart of clean water 8 As in step 4 pour about half of the sanitizing solution into the water level control tube and the remaining sanitizer into the control stream box 9 Allow the sanitizing solution to circulate AT LEAST 15 MINUTES then dump and rinse two 2 times as described above If necessary reset the water level probes to the proper levels 10 While the cleaning and sanitizing solutions are circulating clean rinse and sanitize all accessible parts of the een compartment of the cuber with clean cloths Use a cleaning solution of 8 tablespoons 1 2 cup
15. re connecting the electrical supply WINTER CONDITIONING Ice cubers that are idle in the winter months require preparation to prevent damage from freezing The following procedure should insure the safety of the machine so that it can be started easily the following year 1 Shut off and detach the water supply to the Ice Cuber 2 If the cuber contains a water cooled condenser the cuber must be running while air is introduced through the condenser water inlet connection to blow water out of the condenser coils 3 The machine should then be run into defrost to drain the water tank and the air blown into the water inlet to blow out the water solenoid 508 1069 01 New 5 19 03 10 CHASSIS L1 L3 NEUT GROUND L2 BU BK o BR BK n B G y BK y uo CIA N O NE CIB N O COMPRESSOR REMOTE CONDENSER MODELS ONLY R ZEN e oe T BK BU BU go AX BU PUMP DOWN HIGH PRESSURE CONTACTOR OPENS LOW OPENS HIGH BIN LIQUID COOLED MODELS ONLY W a THERMO eU BU e BU x BU an A XY HIGH PRESSURE ce ew Oo CONTACTOR R W BK BK BU A 19 B G s e L L C BOARD Y B W 277 R MODELS oo LIQUID LINE N C INPUT WASH la B G o o ICE OFF WASH an SWITCH PUMP DEFROST SWITCH EROBES Y Y B G 2 o Os E PUMP
16. tch to the left ICE position and observe that the compressor starts and the water pumps continue to run The refrigeration system operation should be checked during the first few cycles and any adjustments should be made at this time Consult the adjustments section in the service manual Initial ice making cycles may exhibit super cooling of the circulating water so that ice crystals form in the circulating water slush possibly stopping the flow momentarily If water goes over the control stream dam when circulation resumes after two 2 cycles AND with all skin panels installed consult the Factory 7 Test the bin thermostat s by holding some ice against the capillary tube s If necessary adjust the thermostat s so that the ice maker s shut off within 30 seconds after ice contacts the capillary tube s 8 Be sure that the drain pans ice chutes and deflectors are in place and that the electrical control box covers are secured then replace the cabinet panels skins Start with the SIDE panels then the FRONT panel secure the FRONT panel with 2 screws along the bottom edge replace the TOP panel and finally secure all the panels with 2 screws in the TOP SIDES of the machine 9 Discard ice from start up cycles then clean and sanitize the bin following the instructions provided with the bin 10 Complete and mail the Registration Certificate and leave this manual with the owner user Emphasize the CAUTION RISK OF PERSONA
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