IOM GEMD270A 2.vp - Ice-O
Contents
1. Hi evap temp when Blinking 00600 N N b Bin empty e T 2505 Wo Hi cond temp when Steady NN 3 minute wait when Blinking X No water Auger Motor when Steady N Power Page 8 INITIAL START UP CONTINUED NOTE If the evaporating temperature has not dropped lower than 30 F within ten minutes of compressor start up the evaporating temperature sensor will detect the abnormal temperature and stop the unit operation In this circumstance the 3rd warning YELLOW LED will blink Fig 3 After diagnosing and eliminating the cause of the poor evaporating temperature insufficient refrigerant in the system inoperative compressor or inoperative evaporator sensor push the RESET BUTTON on the control board Before resuming operation the unit will go through the usual 3 minute STAND BY period GEMD270A OPERATION CHECKS UPON THE UNIT START UP D Remove the service panels and if needed connect the refrigerant service gauges to the corresponding service valves to check both the HI and LO refrigerant pressures NOTE The condenser temperature sensor which is located within the condenser fins keeps the head condensing pressure between two preset valves If proper flow of cooling are is prevented by a clogged condenser or inoperative fan motor the condenser temperature rises When it reaches 158 F the condenser temperature sensor shuts off the ice machine and turns on2. Bin empty Hi cond temp when Steady 3 minute wait when Blinking Auger Motor when Steady Hi evap temp when Blinking Bin full No water Power Page 16 DESCRIPTION G FRONT DISPENSING SELECTOR DISPLAY BLACK SIX POLE CONNECTOR Placed in the upper front part of the dispensing area it is used to select varies by machine model a Ice first switch or a Ice first switch b Ice and water second switch c Water not chilled third switch It is also possible to set up for continuous dispensing operation just by pushing the fourth switch before or after the selection of the dispensed product Once completed the dispensing selector display resumes its original dispensing setting mode NOTE It is possible to modify the original resume mode default by pushing the corresponding switch for 5 seconds all machines are factory set to the ICE dispensing mode It is also possible to modify the dispensing time controlled by the PC Board to 5 10 or 15 seconds by a Push and hold the 4th switch continuous for approximately 10 seconds till the first 3 lights start to blink b Pushing the 1st switch ICE is equivalent to 5 seconds Pushing the 2nd switch ICE WATER is equivalent to 10 seconds Pushing the 3rd switch WATER is equivalent to 15 seconds H PC BOARD Data processor The PC BOARD in a plastic box on the right side of the un
3. Remove your hand to allow the electronic eye to resume normal operation After about 6 seconds the flaker will resume the ice making process and the YELLOW LED will turn off after the 3 minute STAND BY period NOTE The ICE LEVEL CONTROL INFRARED SYSTEM is independent of the temperature However the reliability of its detection can be affected by dirt and scale sediment that may deposit directly on the light source and on the receiver To prevent ice machine malfunction due to sediment build up be sure to follow the instructions for the periodic cleaning of the light sensor elements as detailed in the MAINTENANCE AND CLEANING INSTRUCTIONS section of this manual CAUTION The use of de mineralized water water Fig 5 with no salt content having an electrical conductivity lower than 30mS will cause the water sensors to stop working properly which will CUT OUT the flaker operations and turn on the YELLOW LED that indicates a shortage of water even though water is indeed in the reservoir Reset button 6 After this is done open the water supply line shutoff valve to refill the float reservoir the 5th YELLOW LED goes off and the 2nd RED LED starts blinking The gear motor will start up immediately 2 seconds later the compressor will start and after the 3 minutes the unit resumes normal operation F To check for the correct operation of the electronic eye that
4. inner freezer walls and inner walls of freezer barrel using emery paper Low suction pressure Add refrigerant to increase suction pressure Water feed line to freezer clogged Vent and clean it Low water level into freezer Adjust to approx 20 mm below ice spout Gear motor noise Worn rotor bearings Check and replace Shortage or poor lubricant in gear case Check for proper lubricant level by opening gear case Top of gears must be covered with lubricant Gear case bearings and gear racers worn Out Check and replace worn parts Shortage of water Strainer at water inlet fitting clogged Remove strainer and clean Float reservoir water nozzle clogged up nozzle Remove float valve and clean Page 20 GEMD270A MAINTENANCE AND CLEANING INSTRUCTION GENERAL The times and the procedures for maintenance and cleaning are given as guides and are not to be construed as absolute or invariable Cleaning especially will vary depending upon local water and ambient conditions and the ice volume produced Each ice machine must be maintained individually in accordance with its particular location requirements B Ice machine The following maintenance should be scheduled at least two times per year on these ice machines 1 Check and clean the water line strainer or filter 2 Remove the cover from the float reservoir be careful to not damage the two wate
5. RESET button to or turning the power line main switch OFF and ON NOTE Any time the machine stops with a problem the front 4 LED s start to blink REFRIGERANT METERING DEVICE e Capillary tube OPERATING PRESSURES With 70 F ambient temperature e Discharge pressure 130 to 145 psig e Suction pressure 14 5 psig eREFRIGERANT CHARGE R134 A 13 oz NOTE Before charging the refrigerant system always check the type of refrigerant and quantity as specified on the individual ice machine data plate The refrigerant charges indicated are relatives to averages operating conditions Fig 7 eeceoo Reset button A Bin empty 7 Hi cond temp when Steady 3 minute wait when Blinking Auger Motor when Steady Hi evap temp when Blinking M Bin full X _No water N Power Page 14 DESCRIPTION TEMPERATURE SENSOR BLUE 2 POLE CONNECTOR MANUAL RESET The evaporator sensor probe is inserted into its tube well which is welded on the evaporator outlet line It detects the temperature of the refrigerant on the way out of the evaporator and signals it by supplying a low voltage current flow to the PC Board microprocessor According to the current received the microprocessor lets the ice machine to continue its operations or not If within 10 minutes of startup the evaporating temperature does not go below 30 F
6. bearing out of the evaporator from the top down To remove gear reducer 1 Disconnect power leads and sensor wires from motor 2 Perform steps to remove bottom bearing 3 Use a 10 mm socket or box wrench to remove the 5 bolts holding the gear reducer to the unit Page 23 GEMD270A TOP BEARING REPLACEMENT Replacement of the top bearing CAUTION The GEMD270A top bearing is a unique design It is two bearings in one a flat thrust bearing and a roller bearing The bearing will separate if not installed properly Do attempt to install it unless it is 5 16 bolt secured as described in these instructions 4 ets 111111111111111111111111111111111 11 4 34 copper 1 Carefully clean out the breaker removing any PN coupling debris or dirt If using a new breaker skip this step 2 Separate the flat bearing amp thrust washer from the new roller bearing Flat bearing Flat Washer Thrust Washer Not Shown l 4 J T Vi Roller Large Flat l Bearing Washer Nut for centering i Roller Bearing Flat Nut for washer tightening 3 The bearing s inner race must be supported during installation Make an insertion tool Use a Construction of Bearing Insertion Tool 5 16 18 x 3 bolt copper coupling two or three washers one must be less than OD to go inside the breaker and two
7. current to the PC Board to cause a temporary stop of the Fan Motor NOTE If the condenser temperature probe senses a rise in temperature to 158 F for one of the following abnormal reasons e CLOGGED CONDENSER e FAN MOTOR OUT OF OPERATION e AMBIENT TEMPERATURE HIGHER THAN 109 4 F It will cause the total and immediate SHUT OFF of the machine in order to prevent the unit from operating in abnormal and dangerous conditions When the probe stops the ice machine the RED LED will turn on warning the user of the Hi Temperature situation After eliminating the cause of the increase in temperature push the RESET button PC Board to restart the ice machine The 2 RED LED starts blinking and three minutes later the flaker unit resumes normal operation The refrigerant suction or Lo pressure will be in normal ambient conditions about 70 F about 14 5 PSIG within a few minutes from the unit s start up This value can vary by 1 5 to 2 9 psig in relation to the water temperature variations influencing the freezer cylinder NOTE If no ice is made within ten minutes of unit start up and the evaporating temperature detected by the evaporator sensor is higher than 30 F the ice machine stops and the 3rd WARNING YELLOW LED blinks Page 13 GEMD270A MECHANICAL SYSTEM The mechanical system of the Ice O Matic Ice Dispenser consists of a gear motor assembly that drives through a ratchet coupling a worn shaft or auger pla
8. icebreaker houses the top bearing which is made of two roller bearings positioned to withstand the auger axial and radial loads This bearing is lubricated with a food grade water resistant grease NOTE Check the conditions of both the lubricant grease and the bearings every six months L DRIVE GEAR MOTOR This motor reducer is made of a single phase electric motor with a permanent capacitor directly fitted on a gearbox The drive motor rotor is kept aligned on its vertical axis by two permanently lubricated ball bearings The gear case contains a train of three spur gears the first of which is fiber to limit the noise level All three gears are encased in case bearings and are covered by lubricant grease MOBILPLEX IP 44 Two seal rings one fitted on the rotor shaft and the other on the output shaft keep the gear case sealed However the interior can be inspected and serviced by unbolting the two halves of the aluminum gear case housing The gear reducer output shaft is connected to the freezer auger by a ratchet coupling which is made of two toothed halves that engage only if turned in the correct direction counter clockwise M FAN MOTOR Air cooled version The fan motor is controlled through the PC Board and the TRIAC by the condenser temperature sensor Normally it operates to draw cooling air through the condenser fins In a cold ambient situation the fan motor can run intermittently as the condenser pres
9. most important single ingredient in producing ice these three items are very important Low water pressure below 20 psi may cause malfunction of the ice machine unit Water containing excessive minerals will tend to produce scale build up on the interior parts of the water system while water that s too soft water contains too few mineral salts will produce a very hard flaked ice PLUMBING CONNECTIONS MUST CONFORM TO ALL APPLICABLE CODES CONNECT TO POTABLE WATER ONLY The model GEMD270A is capable of having water connections through the bottom base or through the rear bottom side of the machine In this second case it is necessary to remove the small panel at the bottom rear WATER SUPPLY Connect to the 34 male water inlet fitting using the supplied fitting to the cold water supply line A shut off valve should be installed in an accessible position between the water supply line and the unit If the water contains a high level of impurities consider installing a water filter or conditioner WATER DRAIN The recommended drain tube is a copper rigid plastic or reinforced flexible tubing supplied with 75 19mm I D which runs to an open trapped and vented drain When the drain is a long run allow1 4 drop per foot Note Although soft easily kinked vinyl tubing is not recommended for a drain a short length of 34 ID vinyl tubing is required to connect a rigid drain tube to the 20 mm 25 32 fitting on
10. nuts to hold it together Place copper coupling onto top of bearing Place large washers over coupling and small washer under bottom of bearing Insert bolt through large washers coupling and bearing Run one nut into bearing to center the bolt Add small washer and nuit Tighten nut finger tight Page 24 GEMD270A BEARING REPLACEMENT CONTINUED Tighten finger tight e before inserting into breaker Bearing and Tool 4 Add food grade lube to the edges of the breaker where the bearing will be inserted 5 Tap the new roller bearing into the breaker using a plastic mallet Tap Bearing amp Tool into Breaker 6 Remove coupling bolt washers and nuts 7 The roller bearing is fully seated when it is 13 16 from the top edge of the breaker 8 Thoroughly lubricate the thrust bearing and place it on top of the roller bearing The inner race of the roller bearing must project through the center of the flat thrust bearing 9 Install the flat washer provided with the new bearing on top of the flat thrust bearing 10 Return the snap ring to its normal position 11 Add food grade water resistant grease to the top of the bearing area 12 Assemble onto auger and secure with the original bolt Page 25 GEMD270A WATER SEAL Stationary Half 1 Insert new water seal into bottom of evaporator 2 Insert new bearing under the water seal push or tap both in until the bottom of the bearing is flush
11. off the light beam for at least 6 seconds This should cause the 1st RED LED on the front of the PC board to turn off and 6 seconds later the ice machine will cease operation and the 6th YELLOW LED will turn on Once you remove your hand the ice machine should resume normal operation within a few seconds NOTE The ice level control uses a device that senses light therefore they must be kept clean enough so they can see Every month clean wipe the sensing eyes with a clean soft cloth 10 Check for refrigerant leaks and for proper frost line approx 8 inches from the compressor When in doubt of refrigerant charge connect refrigerant gauges to corresponding Schrader valves and check for correct refrigerant pressures See Operating Pressure on page 19 of this manual 11 Check that fan blades move freely and are not touching any surfaces 12 Remove the ice spout cover loosen the bolt securing the casting ice sweep and remove it then inspect the top bearing Wipe away existing grease and apply a coating of food grade waterproof grease NOTE Use of food grade waterproof grease to lubricate the top bearing is recommended 13 Turn the ice dispensing spout and remove it Wash and sanitize it 14 Remove the sink grill for washing and sanitizing Page 21 GEMD270A CLEANING INSTRUCTIONS OF WATER SYSTEM 1 Switch OFF the power supply to the GEMD270A 2 Remove the top panel and the top cover of
12. the back of the GEMD270A Install a vertical open vent on the drain line high point at the drain connection to ensure good draining The ideal drain receptacle is a trapped and vented floor drain NOTE The water supply and the water drain must be installed to conform with the local code In some case a licensed plumber and or a plumbing permit is required Page 6 FINAL CHECK LIST 1 Is the unit in a room where the ambient temperatures are within a minimum of 50 F even in winter months 2 Is there at least 6 clearance around the unit for proper air circulation 3 Is the unit level 4 Have all the electrical and plumbing connections been made and is the water supply shut off valve open 5 Has the voltage been tested and checked against the data plate rating 6 Has the water supply pressure been checked to ensure a flowing water pressure of at least 20 psi 7 Check all refrigerant lines and conduit lines to guard against vibrations and possible failure 8 Has the unit been sealed to the counter top 9 Has the owner user been given the Users Manual and been instructed on the importance of periodic maintenance checks 10 Has the Manufacturer s registration card been filled in properly Check the model and serial number against the serial plate and mail the registration card to Ice O Matic 11 Has the owner been given the name and the phone number of the authorized Ice O Matic Service Agency s
13. week Page 22 REMOVAL AND REPLACEMENT Bearings Auger Water Seal Note Metric tools are required for this procedure Disconnect electrical power 1 Remove all panels and the sink assembly 2 Remove the spout cover 3 Use a 17mm socket to remove the top bolt holding the ice sweep to the auger 4 Use a 13mm socket to remove the four bolts holding the breaker to the auger 5 Lift up to remove breaker To remove top bearing 6 Remove snap ring from the top of the breaker GEMD270A 4 Remove the gear reducer from the unit Reverse all individual sections to reassemble that section except for the top bearing and water seal See the next page 7 Turn breaker over and using punch or bolt tap the bearing out from the bottom To remove auger 8 After removing breaker pull up on the auger to remove it To remove water seal or bottom bearing 9 Remove bin cover 10 Disconnect drain and water line from bin 11 Remove nut holding bin to chassis 12 Pull bin out of machine 13 Remove screws holding air deflector to chassis and pull deflector out of the unit 14 Remove screws holding reservoir to bulkhead panel 15 Remove screws holding bulkhead panel to chassis frame push panel back several inches 16 Use a 13 mm open end or box wrench and remove the three bolts holding the adapter stand to the evaporator 17 Lift evaporator up and off the stand 18 Tap water seal and bottom
14. 0A If the temperature rises to 158 F or above the current sent to the microprocessor causes the machine to cease operation and turns on the 2nd RED WARNING LED NOTE After fixing the problem that caused the high condenser temperature press the RESET button or turn the power line main disconnect switch OFF and ON to restart the unit after the shut down The fan motor will cycle on an off to maintain the discharge pressure D GEAR MOTOR ROTATION AND SPEED SENSOR RED FOUR POLE CONNECTOR MANUAL RESET This safety device is housed on top of the Drive Motor and detects based on the Hall Effect principle the rotating speed and rotating direction of the drive Motor Should the rotating speed drop below 1300 rpm the magnitude measured by this device signals the microprocessor to stop the unit and turns on the 3rd YELLOW LED The same reaction occurs when the drive motor rotates in the wrong direction counterclockwise or it doesn t rotate at all NOTE After diagnosing and eliminating the problem that caused the intervention of the safety device press the RESET button or turn the power line main disconnect switch OFF and ON to restart the unit after the shut down Page 15 GEMD270A COMPONENT DESCRIPTION E ICE BIN LEVEL LIGHT CONTROL BLACK FOUR POLE CONNECTOR AUTOMATIC RESET The electronic ice bin level control located on the ice spout stops the operation of the ice machine when the light beam between the lig
15. 3 Assemble adapter to evaporator Tightening the mounting bolts will correctly position the bottom bearing and bottom seal Rotating Half 1 Remove old rotating half from the auger Clean the mounting area 2 Place a bead of food grade sealant onto the shoulder of the auger where the rotating half of the water seal will be installed 3 Wash the new seal in water While wet slip it onto the bottom of the auger rubber side toward the auger Push up until seated against the sealant Do not allow any sealant to come into contact with the face of the seal R T V IN THIS GAP Bottom of Auger RUBBER ROTATING WATER SEAL BRASS Page 26
16. Ice O Matic SERVICE AND INSTALLATION MANUAL PEARL ICE WATER DISPENSER MODEL GEMD270A spense e disp er Ice O Matic 11100 East 45th Ave Denver Colorado 80239 Part Number 9081407 01 Print Date 9 09 GEMD270A INTRODUCTION This manual provides the specifications and the NOTE To retain the safety and performance built step by step procedures for the installation into this ice machine it is important that installation start up operation maintenance and cleaning for and maintenance be conducted in the manner the Ice O Matic GEMD270A counter top Pearl outlined in this manual Ice dispenser Ice O Matic 11100 East 45th Ave Denver CO 80239 800 423 3367 Table of Contents SPECIFICATIONS Page 2 CABINET DIAGRAMS Page 3 GENERAL INFORMATION AND INSTALLATION sss n t t es Page 4 ELECTRICAL CONNECTIONS re Page 5 WATER SUPPLY AND DRAIN CONNECTIONS 5 n n n n es Page 6 FINAL CHECK I ST ETT TUTTI DOCTI PO CU DULL TT P Page 7 OPERATING INSTRUCTIONS s ee Page 8 INITIAL START UP CONTINUED cooo o Page 9 SETTING THE DISPENSING SELECTOR Page 11 PRINCIPLE OF OPERATION s s Page 12 REFRIGERANT CIRCUIT ss es Page 13 MECHANICAL SYSTEM o hh s Page 14 COMPONENT DESCRIPTION s o o Page 15 COMPONENT DESCRIPTION s o Page 16 COMPONENT DESCRIPTION s Page 17 COMPONENT DESCRIPTION s e Page 18 SERVICE DIAGNOSIS lt 299 ard d odeur ee Ea S Wd OO ed qued RU V der as P
17. ND WATER or WATER for 5 seconds H CHECK OF THE DISPENSING OPERATING MECHANISM To check for the correct operation of the dispensing mechanism Note If all the dispensing selector lights are blinking the main control board on the right side of the unit has sensed a problem with the machine s operation Check the main board s diagnostic lights for further information a First select the Dispensing Mode by pushing the proper switch b Place a glass or a carafe in front of the two Optical Dispensing Devices c The dispensing drive motor and or the water solenoid valve starts Ice and or water is discharged through the bottom plastic spout The drive motor and or the water solenoid valve remains in operation per dispensing time settings unless the glass or carafe is removed Push the CONTINUOUS switch and check again for the dispensing mechanism operation per the steps above The drive motor and or the water solenoid valve will remain in operation until the glass or carafe is removed If connected remove the refrigerant service gauges and re attach the service panels J Instruct the owner user on the general operation of the ice machine and its required cleaning and care SELECT Page 11 GEMD270A PRINCIPLE OF OPERATION WATER CIRCUIT The water enters the machine through the water inlet fitting which has a strainer and is located at the rear side of the cabinet and goes to the wate
18. T 213 8 25 64 275 10 53 64 3 4 GAS WATER INLET Page 3 GEMD270A GENERAL INFORMATION AND INSTALLATION UNPACKING AND INSPECTION 1 Call your authorized Ice O Matic Distributor or Dealer for proper installation 2 Visually inspect the exterior of the packing and skid Any severe damage noted should be reported to the delivering carrier and a concealed damage claim form filled in subject to inspection of the contents with the carrier s representative present 3 a Cut and remove the plastic strip securing the carton box to the skid b Cut open the top of the carton and remove the polystyrene protection sheet Pull out the polystyrene posts from the corners and then remove the carton 4 Remove the top and sides panels of the unit and inspect for any concealed damage Notify carrier of your claim for the concealed damage as stated in step 2 above 5 Remove all internal support packing and masking tape 6 Check that refrigerant lines do not rub against or touch other lines or surfaces and that the fan blades move freely 7 Check that the compressor fits snugly onto all its mounting pads 8 Use clean damp cloth to wipe the surfaces outside of the cabinet 9 See data plate on the rear side of the unit and check that local main voltage corresponds with the voltage specified on it CAUTION Incorrect voltage supplied to the ice machine will void your parts replacement program 10 Remove
19. TION LINE CONDENSER Flowing into the liquid line it passes through the drier filter then it goes all the way through the capillary tube where it loses some of its pressure At this time the pressure and temperature are lowered and the refrigerant enters into the evaporator coil wrapped around the freezer inner tube The water being constantly fed into the freezer inner tube exchanges heat with the refrigerant circulating in the evaporator coil This causes the refrigerant to boil off and it evaporates thereby changing from liquid into vapor The vapor refrigerant then passes through the suction accumulator and the suction line where the refrigerant exchanges heat with the one flowing into the capillary tube warmer before being sucked into the compressor to be re circulated The refrigerant heat pressure is kept between two pre set values 131 145 psig by the condenser temperature sensor the probe is located within the condenser fins in air cooled versions When this condenser temperature sensor detects a rise in condenser temperature beyond the pre fixed limit it changes its electrical resistance and sends a low voltage power flow to the microprocessor on the PC Board that energizes through a TRIAC the Fan Motor in ON OFF mode GEMD270A When the condenser temperature goes below the pre fixed limit the temperature sensor changes its electrical resistance again by reducing the flow of
20. age 19 SERVICE DIAGNOSIS UOS DTE to dore Page 20 MAINTENANCE AND CLEANING INSTRUCTION s n n t n n n n n n ne Page 21 CLEANING INSTRUCTIONS OF WATER SYSTEM 55 ttt tte Page 22 REMOVAL AND REPLACEMENT s es Page 23 TOP BEARING REPLACEMENT co cooo o s Page 24 BEARING REPLACEMENT CONTINUED s n n n n t n ns Page 25 ERA Ed be s Page 26 Page 1 GEMD270A SPECIFICATIONS GEMD270A Ice Maker Dispenser TouchFree 200 Ib ice making capacity Pearl Ice amp 12 Ib storage To keep your Ice O Matic Pearl Ice Dispenser at peak performance levels periodic maintenance checks must be carried out as indicated in this manual Important Operating Requirements Min Max Air Temperature 50 F 100 F Water Temperature 40 F 95 F Water Pressure 20 psi 70 psi Electrical voltage 10 10 variations from voltage rating specified on nameplate MACHINE SPECIFICATIONS Model Cond Cabinet Size Finish Comp Ice bin unit HP cap GEMD270A Air 34 13 32 high x 15 9 32 wide x 26 7 64 deep S Steel 3 8 12 Ib Basic Amps Watts Amps fuse electrical 115 60 1 6 550 15 Unit is equipped with leveling legs The unit has a power cord GEMD270A CABINET DIAGRAMS SPECIFICATIONS 388 5 9 32 12 15 35 653 26 7 64 BASE OPENING FOR HIDDEN CONNECTIONS 25 32 WATER OUTLE
21. ained auger surface Clean or replace auger Will not dispense Dispense motor open Check windings No power to dispense motor Check harness connections from touch free sensors to control board amp from board to motor Control board does not work Trace harness from touch free sensors to PC board jump the two center pins the disoense motor should turn If not replace the board Open harness Check the harness for continuity if any wire is open replace the harness Defective sensor If the above does not prove to be a problem replace the sensors Page 19 GEMD270A SERVICE DIAGNOSIS SYMPTOM POSSIBLE CAUSE SUGGESTED CORRECTION Wet ice Ambient temperature too high Move unit to cooler location High water level in the freezer Lower to approx 20mm below ice spout Faulty compressor Replace Machine runs but makes no ice Water not entering in the freezer Air lock in feed line to freezer Clogged feed line to freezer Clean it Gear stripped Check and repair Moisture in the system Purge replace drier and re charge Water leaks Water seal leaking Replace water seal Water feed line to freezer leaking Check and fasten hose clamp Float valve not closing Check and adjust float valve setting screw Excessive noise or chattering Mineral or scale deposit on auger Remove and manually polish auger and
22. all a mineral salt metering device 2nd LED glows High head pressure Dirty condenser Clean Inoperative fan motor Replace 3rd Yellow LED blinks Too high evap temperature Check and charge refrigerant system Shortage or lack of refrigerant 3rd Yellow LED glows Gear motor tends to run reverse Check gear motor capacitor Too low gear motor rotating speed Check rotor bearings freezer bearings and interior of freezer for scores Replace whatever is worn or damaged No rotation of gear motor Check for power to drive motor 16 A fuses Check for stator winding Gear motor starts and stops Check for correct operation of drive after a while motor magnetic sensor Check for correct magnetic capacity of magnetic cylinder Compressor cycles intermittently Low voltage Check circuit for overloading Check voltage at the supply to the building If low contact the power company Non condensable gas in system Purge the system Compressor starting device with loose wires Check for loose wires in starting device Low ice production Capillary tube partially restricted Blow charge add new gas amp drier after evacuating system with vacuum pump Moisture in the system Same as above Low water level in the freezer Adjust to approx 20mm below ice spout Shortage of refrigerant Check for leaks amp recharge Pitted or st
23. ced on its vertical axis within the freezing cylinder The gear motor is made of a single phase electric motor with a permanent capacitor This motor is directly fitted in the gear case through which it drives in a counter clockwise rotation at a speed of 9 5 rpm the freezer auger linked to it by the ratchet coupling NOTE If the gear motor rotates in the wrong direction counter clockwise or is not rotating at all the unit will stop immediately and the WARNING YELLOW LED will turn on showing the intervention of the Electromagnetic Safety Device based on Hall Effect principle After diagnosing and eliminating the source of the failure restart the unit by pressing the RESET button or turn the power switch OFF and ON Fig 7 RED LED will start blinking and after 3 minutes the ice machine will resume normal operations by running first the gear motor and then the compressor When the gear motor rotating speed is slowed below 1300 rpm normal speed is 1400 rpm the Electromagnetic Safety Device transmits an electrical signal to the MICROPROCESSOR to stop the unit operation immediately just as it does for the wrong rotation and the 3rd YELLOW WARNING LED turns on This is done to avoid overloading the electrical and mechanical components of the entire Drive System and extend their durability NOTE After diagnosing and eliminating the source of the gear motor slow rotation restart the unit by pushing the
24. controls ice bin level place one hand between the sensing eye located in the ice spout to interrupt the light beam This interruption will cause the 1st RED LED to go out After about 6 seconds the unit shuts off and the 6th YELLOW LED will light 000000 Bin empty_ 7 Hi cond temp when Steady 3 minute wait when Blinking Auger Motor when Steady temp when Blinking Bin full __No water N Power Fig 6 CY Reset button 74 PP PRR Bin N Bn ful Hi cond temp when Steady X x 3 minute wait when Blinking No water Auger Motor when Steady Power Hi temp when Blinking Page 10 GEMD270A SETTING THE DISPENSING SELECTOR Setting the dispensing time It s possible to modify the dispensing time to 5 10 or 15 seconds To modify the original setting time 5 seconds a Push and hold the 4 switch CONTINUOUS for 10 seconds until the first 3 lights start to blink b Push amp release the 15 switch ICE for a 5 second dispense Push amp release the 274 switch ICE AND WATER for a 10 second dispense d Push amp release the 3 switch WATER for a 15 second dispense The unit resumes a default dispense setting Ice Ice and Water or Water after each dispense To modify the resume mode from factory set to ICE push the desired switch ICE ICE A
25. erving them Page 7 GEMD270A GEMD270A OPERATING INSTRUCTIONS INITIAL START UP After having correctly installed the ice machine completed the plumbing and electrical connections perform the following Start up procedure Remove the control board inspection panel and cover to view the lights on the control board A Open the water supply line shutoff valve and turn the main switch on the power supply line to the ON position The GREEN LED will glow to signal that unit is under power NOTE Every time the unit is turned on after being shut off for a period of time the 2nd RED LED will blink for 3 minutes B After 3 minutes have elapsed the stand by period the unit starts operating by activating systems in following sequence 1 GEAR MOTOR 2 COMPRESSOR 3 FAN MOTOR which is controlled by the condenser temperature sensor The probe is within the condenser fins 4 2 RED LED switches off Fig 2 C Two or three minutes after compressor start up cubelet ice should begin dropping off the ice spout into the storage bin Fig 1 BLINKING 3 MIN STAND BY PERIOD TOY Reset button Hi temp when Blinking Bin empty 2 7 X 17 cond temp when Steady_ NN S 3 minute wait when Blinking No water Auger Motor when Steady _ Power Fig 2 2 Reset button
26. ht source and the sensor gets interrupted by the ice which accumulates in the spout When the light beam is interrupted for 6 seconds the 1st RED LED on the front of the PC board goes off and the ice machine stops ice production and turns on the 6 YELLOW LED to show that there is a full storage bin The 6 second delay prevents interruption of machine operation in the case of minimal breaks in the light beam that can occur due to the ice dropping through the ice spout blocking the sensor As soon as ice is scooped out of the bin the light beam resumes contact with the two infrared sensors of ice level control The RED LED lights up and after 6 seconds the ice machine resume its operation and the 6 YELLOW LED turns off F ICE WATER OPTICAL DISPENSING DEVICE BLUE FOUR POLE CONNECTOR Located on the front of the dispensing area it consists of a combination of an infrared Transmitter and Receiver When a glass or a carafe is placed in front of the Infrared sources the optical device transmits a signal to the PC Board This activates the dispensing drive motor which in turn puts into rotation a dispensing vane that pushes the ice towards a rectangular opening located in the bottom of the storage bin After the glass carafe is removed or the dispensing time has elapsed 5 10 or 15 seconds according to the setting the infrared transmitter switches off the dispensing drive motor Fig 6 popecel Reset button
27. ir consists of a plastic water pan which has float valve with set screw on it The float valve modulates the incoming water flow to maintain a constant water level in the reservoir that corresponds to the one in the freezing cylinder to ensure proper ice formation and fluidity On the inside of the reservoir cover are two water level sensors that detect the presence or shortage of water in the reservoir NOTE It is very important to make sure that the cover on the reservoir is seated properly to enable the sensors to efficiently control the water level to avoid undue shutoff J FREEZING CYLINDER EVAPORATOR The freezing cylinder is made of a stainless steel vertical tube The cooling coil is wrapped around its exterior with the evaporating chamber In its interior is the auger which rotates on a vertical axis that is kept aligned by the top and bottom bearings A water seal system is located in the bottom part of the freezer and the ice breaker is fitted on top end The water constantly flows into the cylinder bottom and it freezes into ice when it comes into contact with the cylinder inner walls The ice is then lifted up by the rotating auger compacted and forced out by the icebreaker K ICE BREAKER The icebreaker is made up of several rectangular openings that the ice is forced to pass through By undergoing this process the ice loses its excess of water content and drops into the bin in hard dry bits of ice The
28. it consists of two separated printed circuit boards one at high voltage and the other at low voltage protected by three fuses integrated with a RESET button It also consists of six aligned LEDS monitoring machine operation input terminals for the leads of the sensor probes as well as input and output terminals for the leads of the ice machine electrical wires GEMD270A The PC BOARD is the brain of the system It relays through its microprocessor the signals received from the sensors to control the operation of the different electrical components of the ice machine compressor gear motor etc as well as the dispensing of the ice and water The six LEDS on the front of the PC BOARD indicate the following RED LIGHT Empty storage bin RED LIGHT ON all the time Unit shut off due to a Too high condensing temperature gt 158 F Blinking 3 minutes start up delay time YELLOW LIGHT ON all the time Unit shut off due to the wrong rotation direction of gear motor Unit shut off due to the too lo speed of gear motor Blinking Unit shut off due to a Too high evaporating temp gt 30 F after 10 min of operation GREEN LIGHT Unit under electrical power YELLOW LIGHT Unit shut off due to a too lo water level into float tank YELLOW LIGHT Unit shut off at full storage bin BLINKING 3 MINUTE STAND BY PERIOD Page 17 GEMD270A COMPONENT DESCRIPTION FLOAT RESERVOIR The float reservo
29. ker which is located on the top end of the auger where it gets compacted cracked and shifted horizontally to be discharged out through the ice spout into the storage bin Once the ice machine is turned on it starts the automatic ice making process which will continue until ice storage bin is full enough to trigger the control eye located on the sides of the ice spout As the ice level raises it interrupts the light beam running between the two infrared lamps The unit stops after six seconds and the YELLOW LED turns on to signal that there is a Full Storage Bin NOTE The interruption of the light beam between the two light sensors is signaled by the 1st RED LED located on the front of the PC Board turning off After about 6 seconds of steady interruption of the light beam the unit stops and the Full Storage Bin YELLOW LED glows The six second delay prevents the unit from stopping for small interruptions in the light beam such as is caused by flakes sliding along the ice spout before dropping into the bin As ice gets scooped out of the storage bin the light beam between the two sensors resumes The 1st RED LED lights up 6 seconds later the ice machine resumes making ice and the YELLOW LED goes off Page 12 REFRIGERANT CIRCUIT The hot gas refrigerant discharged from the compressor reaches the condenser where it is cooled down and condenses into liquid EVAPORATOR ACCUMULATOR SUC
30. ored It may also loose fluidity creating some resistance in being elevated and extruded this situation can be heard by the creaking noise made by the ice If this should occur it is recommended that you stop the ice machine for few minutes in order to allow the ice in the freezer to partially melt 12 When all of the cleaning solution has been used up open the water shutoff valve to allow new fresh water to flow into the reservoir Let the unit continue to run until the ice resumes the normal color and hardness 13 Stop the ice machine and pour warm water on the ice deposited into the storage bin to melt it NOTE DO NOT use ice produced with the cleaning solution Be sure none remains in the bin SANITATION 14 Pour into the water reservoir locally approved sanitizer mixed according to the directions for that sanitizer A possible saniziter can be obtained by mixing 1 ounce of liquid household bleach with 2 gallons of warm water 15 Leave the unit running for approx 10 minutes then remove the copper wire used to jump the two sensors for the water level and place the cover back on the float reservoir NOTE DO NOT use ice produced with the sanitizing solution 16 With a sponge moistened with a sanitizing solution wipe clean all bin interior surfaces REMEMBER To prevent the accumulation of undesirable bacteria it is necessary to sanitize the interior of the storage bin with an anti algae disinfectant solution every
31. r reservoir through a float valve NOTE The presence of the water in the float reservoir is detected by a system of two sensors that operate in conjunction with the PC Board The two sensors use the water as a conductor to maintain a low voltage current flow between them If the water used is very soft de mineralized or the float reservoir is empty the current that flows between the sensors may become weak or cease If this happens the PC Board will shut off the flaker s operation and the YELLOW LED will light signaling a Shortage of water The float reservoir is positioned at the side of the freezing cylinder high enough to maintain a constant water level around the freezer auger In fact the water flows from the reservoir into the bottom inlet of the freezing cylinder to surround the stainless steel auger which is vertically fitted in the center of the freezer ICE SPOUT FLOAT VALVE FLOAT TANK FREEZER WATER FEED LINE WATER INLET LINE p 7 In the freezer the incoming water gets chilled into soft slush ice which is moved upward by the rotating action of the auger The stainless steel auger rotates counter clockwise within the freezer and is powered by a direct drive gear motor It carries the ice upward along the inner walls of the freezer and as it raises the ice gets progressively thicker and harder As the ice rises upward it moves toward the icebrea
32. r sensors depress the float to make sure that a full stream of water enters the reservoir 3 Check that the ice machine is level 4 Check that the water level in the water reservoir is below the overflow but high enough that it does not run out of the spout opening NOTE The float must stop the incoming water flow when the rubber housed in the setting screw is perpendicular to the water nozzle 5 Clean the water system water reservoir and the interior of freezing cylinder using a solution of ice machine cleaner Refer to section C CLEANING INSTRUCTIONS OF WATER SYSTEM for cleaning procedures and after cleaning will indicate frequency and procedure to be followed in local areas NOTE Cleaning requirements vary according to the local water conditions and individual user operation 6 If required polish the two sensor rods secured to the float reservoir cover Heavy scale sediment on them can be removed with the help of a bit of ice machine cleaner plain 7 With the ice machine and fan motor OFF clean condenser using vacuum cleaner whiskbroom or non metallic brush taking care to do not damage the condenser temperature sensor 8 Check for water leaks and tighten drain line connections Pour water into the sink to be sure that drain line is open and clear 9 Check the ice level control sensor to test shut off Put your hand between the light source and the receiver on the upper side of the storage bin to cut
33. sure must be kept between two corresponding head pressure values N ICE DISPENSER DRIVE MOTOR Located on the upper side of the storage bin it turns the dispensing vane by a milled shaft inside the round storage bin By rotating the dispensing vane pushes the ice towards the bottom rectangular opening to force the nugget ice to go through the bottom outlet spout O STORAGE BIN The storage bin is located in the front of the ice machine It main purpose is to store the cubelet ice produced by the evaporator until it reaches its maximum level In its bottom is placed the ice spout as well as the water drain hole Inside the ice spout opening is the water outlet tube connected to the solenoid valve P DISPENSING WATER SOLENOID VALVE Energized and controlled by the PC Board it allows a metered quantity of not chilled water to be dispensed through the same opening of the ice Page 18 SERVICE DIAGNOSIS GEMD270A SYMPTOM POSSIBLE CAUSE SUGGESTED CORRECTION Unit will not run Blown fuse in P C Board Replace fuse amp check for cause of blown fuse No LED lights Master switch in OFF position Turn switch to ON position Inoperative P C Board Replace P C Board Loose electrical connections Check wiring 6th Yellow LED glows Inoperative or dirty ice level control Replace or clean ice level control 5th Yellow LED glows Shortage or too soft water See remedies for shortage of water or inst
34. the machine Leave the upper louvers open for proper air exhaust The base of the GEMD270A must be sealed to the counter top 1 Place the unit in its final position 2 Place a bead of sealant on the counter top to match the outside edge of the cabinet base and sink Food grade silastic sealant is recommended Page 4 ELECTRICAL CONNECTIONS See data plate for current requirements to determine wire size to be used for electrical connections All Ice O Matic ice machines require a solid earth wire This Ice O Matic ice machine is supplied from the factory completely pre wired and only needs to be plugged into a nearby 115 volt outlet Make sure that the ice machine is connected to its own circuit and individually fused see data plate for fuse size The maximum allowable voltage variation should not exceed 10 and 10 of the data plate rating Low voltage can cause faulty functioning and may be responsible for serious damage to the overload switch and motor windings NOTE All external wiring should conform to national state and local standards and regulations Check voltage on the line and the ice machine s data plate before connecting the unit Page 5 GEMD270A GEMD270A WATER SUPPLY AND DRAIN CONNECTIONS GENERAL When choosing the water supply for the ice flaker consideration should be given to a Length of run b Water clarity and purity c Adequate water supply pressure Water is the
35. the storage bin with the dispensing drive motor 3 Remove all ice stored in the bin to prevent it from getting contaminated with the cleaning solution 4 Close the water shutoff valve on water line 5 Remove the left side panel to gain access to the water reservoir 6 Remove the float reservoir cover and jump the two water level sensors with a piece of copper wire 7 Remove the right service panel and loosen the drain plug from the water purge tube to drain all of water our of the freezer Then re plug the purge tube CLEANING 8 Prepare the cleaning solution by diluting it in a plastic container with 2 1 quarts 2 liters of warm water 113 122 F with 7 ounces 0 2 liters of machine cleaner WARNING Ice machine cleaner contains Phosphoric and Hydroxyacetic acids These compounds are corrosive and may cause burns if swallowed DO NOT induce vomiting Give large amounts of water or milk and call a Physician immediately In case of external contact flush with water KEEP OUT OF THE REACH OF CHILDREN 9 Pour the cleaning solution into the water reservoir until it reaches the proper level 10 After 15 minutes switch ON the Master switch to start the unit 11 Wait till the machine starts to discharge ice then continue to slowly pour the cleaning solution into the water reservoir taking care to maintain the level just below the overflow NOTE The ice made with the cleaning solution is slushy and col
36. the 2nd RED WARNING LIGHT Fig 4 Fig 3 ee O 776 Reset button Hi cond temp when Steady 3 minute wait when Blinking Auger Motor when Steady Hi evap temp when Blinking X 5 Bin full __No water Power Fig4 200000 __Reset button Bin empty 7 Hi cond temp when Steady 3 minute wait when Blinking Auger Motor when Steady Hi evap temp when Blinking Bin full X _No water Power Page 9 GEMD270A After diagnosing and fixing the cause of the temperature rise push the RESET BUTTON on the control board Before resuming operation the unit will go through the usual 3 minute STAND BY period E Check for the correct CUT OUT and CUT IN of the float reservoir water level sensors by shutting off the valve on the water supply line This will cause a gradual decrease of the water level in the float reservoir and as soon as the level gets below the sensors the flaker stops operating and the 5th YELLOW WARNING LED will glow to signal the shortage of water Fig 5 NOTE The water level sensor detects the presence of sufficient water in the float reservoir and confirms it to the microprocessor by maintaining a low voltage current flow between the two sensors using the water as conductor signaling that there is a full storage bin Fig 6
37. the evaporator sensor signals the microprocessor to stop the unit operation immediately and causes the 3rd WARNING YELLOW LED to blink B WATER LEVEL SENSOR RED TWO POLE CONNECTOR AUTOMATIC RESET This sensor system consists of two small stainless steel rods vertically fitted on the inner face of the reservoir cover and electrically connected to the low voltage circuit of the PC Board When the cover of the reservoir is positioned properly the tips of both rods dip into the reservoir water and signal its presence by supplying power to the PC Board NOTE In the event of shortage of water in the reservoir or if the water used is too soft de mineralized to cause greater resistance to the current flow conductivity lower than 30 5 this sensor system causes the machine to shutoff to protect it from running with an interrupted or inadequate water supply When this happens the YELLOW LED will turn on warn that the ice machine is off and why C CONDENSER TEMPERATURE SENSOR BLACK TWO POLE CONNECTOR MANUAL RESET The condenser temperature sensor probe located within the condenser fins detects condenser temperature variations and signals them by supplying current at low voltage to the PC BOARD Current to the microprocessor on the PC Board varies and as it does the microprocessor supplies through a TRIAC power at a high voltage to the fan motor so that it can cool the condenser and reduce its temperature GEMD27
38. the manufacturer s registration card from the inside of the Users Manual and fill in all parts including Model and Serial Number taken from the data plate Forward the completed self addressed registration card to Ice O Matic factory LOCATION AND LEVELING WARNING This Ice Dispenser is designed for indoor installation only If the machine is operated for extended periods at temperatures exceeding the following limitations it will constitute misuse under the terms of the Ice O Matic Manufacturer s Limited Warranty resulting in LOSS of warranty coverage Position the unit in the selected permanent location Criteria for selection of location include Min Max Air Temperature 50 F 100 F Water Temperature 40 F 95 F Water Pressure 20 psi 70 psi Electrical voltage 103 v 126 v Service access adequate space must be left for all service connections through the rear of the ice machine This machine is air cooled and sucks air through the left side panel and blows air out the rear side of the top panel Do not install the machine where the left and upper rear side air flows might be blocked A minimum clearance of 6 inches is required at the left and upper rear side for air circulation It is important that the machine be installed in a location where it has enough space around it to be accessible for service Avoid hot dirty and crowded locations NOTE Do NOT place anything on top of
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