GEMD790 - Ice-O
Contents
1. Page 30 E p PUWER SUPPLY nm NTC THERMISTIR UY 4 MATER Hi A TI iii Ss VITAE KEY LUCK J WITE AIGH CUNTACI WLU OD EN REO D u BIN DRIVE E o COOLED o NLY DC BOARD NAL CONTA R H i O 4 i AM i A i f j RX CL 7 j RX VATER ff RX BIN IX CE TX WATER Te BIN LOMPRESSUR l Ch START CAP pt TENTA Ji i i RELAY s IUN CAP ME v2. Bl H DHG SE HAE Ni ar JUNCTION BOX IY WATER O na SFE NANEPLATE FOR Es SUPPLY VOLTAGE II i i ANT MA FUSE SIZE VN FY V VAEN R cahin RK ni fi a ae E EN WITH AGIR DRIVE MOTOR KM MASTER CNT PIN LOCATION DETAIL Lhe ua I 306050 RODO E lU a L a iso O POTENTIAL NEE Se O all PUN CAP min Ko R I S ms io ES i Q ADI d TERMINAL AU S am FY S E Gl as ga L ul METER ps Is i LINPRESSUR i HT PRESSURE Lil N card HU n l iN ET E E Ma USE COPPER CONDUCTORS ONLY ND TALS UNIT MUST BE GROUNDED EX I NO A r IR n WN A y ay IA RUNI WAKING MODE WITH ALL DISPENSING TAIT SYSTEMS TN OPERA Page 29 GEMD790 Wiring Diagram 115 60 1 e
3. 4 Inspect the interior of the machine for loose screws or wires Check that no refrigerant lines are rubbing each other Check that the fan blade on air cooled models turns freely 9 Check that the machine is installed correctly according to the final check list Start Up 1 Go through the pre start inspection 2 Open the water hand valve observe that water enters the water reservoir fills the tube from the reservoir to the evaporator and then shuts off Check for leaks 3 Switch the mode switch to ON The auger drive motor and compressor start beginning the ice making process 4 On air cooled models warm air will begin to flow from the condenser Water cooled models will begin to discharge warm water down the drain 9 The unit should soon be making ice If desired the low side pressure may be checked it should be 38 PSIG or 4 PSIG The air cooled discharge pressure will depend upon air and water temperatures but should be between 200 PSIG and 300 PSIG Water cooled discharge pressure should be about 245 PSIG If needed adjust the water regulating valve The above numbers are for new clean machines Field values may be somewhat higher or lower 6 There are no adjustments to make so replace the panels GEMD790 7 Check ice dispensing by pushing in on the glass filler lever lce dispenses are portion controlled by turning a knob the length of time the unit dispenses when the glass filler lever
4. Minimum circuit ampacity is used to determine wire size and type per National Electric Code Options Machine stand GEMD5 or GEMD7 Page 2 FOR THE INSTALLER Location This ice system is designed to be installed indoors in a controlled environment Minimum Maximum Air Temp 50 F 100 F Water Temp 40 F 100 F Water Pressure 20 psi 80 psi Voltage 104 126 Operating the machine outside of the above limitations or outdoors is potentially damaging to the machine also it is misuse of the machine which may void the warranty Service Limitations Do not install in a location where the top of the machine is within 6 of a fixed ceiling Air cooled models require a minimum of 6 inches to the left and right of the machine for air circulation It is important that the machine be installed in a location where it has enough space above and behind it for service After uncrating and inspection the unit is ready for installation Machine Stand Installation Tip the stand on its back and install the legs return the stand to the upright position Adjust leg levelers so that the stand does not rock Counter Top or Machine Stand Installation The base of the icemaker dispenser must be sealed to the object it rests upon Food grade silastic sealant is recommended Place a bead of the sealant on the machine stand or counter top to match the outside edge of the cabinet base and sink The icemaker dispenser is hea
5. ICE SWEEP BREAKER COVER BEARING GEMD790 TO REMOVE AND REPAIR THE GEARMOTOR ASSEMBLY Assuming that the procedures through removal of the water seal have been performed 1 Remove the electrical wires from the gear drive motor AWARNING Electrical Shock Hazard Disconnect electrical power to the icemaker dispenser before beginning 2 Unscrew the 4 cap screws holding the gearmotor to the gearmotor plate 3 Remove the gearmotor from the icemaker To Inspect the gearmotor A Remove the cap screws holding the gearmotor case halves together and pry the two cases apart B To lift off the cover lift up until you can feel internal contact then pull the cover towards the output GEARCASE gear end and then lift the cover COVER with drive motor attached up and away from the gear motor case Note The case cover output gear bearings and shaft are one pressed together assembly Replace as a unit C Inspect the oil gears and bearings If the oil level and condition is acceptable quickly check the gears and bearings They are likely to be fine if the oil is If there is evidence of water in the oil rusty bearings and gears the oil having a creamy white appearance oil level too high carefully inspect the bearings and gears If in doubt about the condition of a part replace it The oil guantity is 14 fluid ounces do not overfill Note The gears and bearings are availabl
6. ce atic Installation and Service Manual GEMD790 fee DOMoatic WATER E ii Ice O Matic 11100 East 45th Ave Denver Colorado 80239 Part Number 9081424 01 Date 2 11 Ice O Matic Parts and Labor Domestic amp International Limited Warranty Mile High Equipment LLC the Company warrants Ice O Matic brand ice machines ice dispensers remote condensers water filters and ice storage bins to the end customer against defects in material and factory workmanship for the following e Cube ice machines GEM model compressed ice machines e Ice storage bins Twenty four 24 month parts and labor MFI model flake ice machines and remote condensers Thirty six 36 months parts and labor e EF model flake ice machines and GEMD maker dispensers e OD model dispensers Twenty four 24 months parts Twelve 12 months Twenty four 24 months parts and labor labor e CD model dispensers Thirty six 86 months parts and labor e Waiter filter systems Twelve 12 months parts and labor not including filter cartridges An additional twenty four 24 month warranty on parts excluding labor will be extended to all cube ice machine evaporator plates and compressors GEM model compressed ice machine compressors and MFI model flake ice machine compressors from the date of original installation An additional thirty six 86 month warranty on parts excluding labor will be extended to all EF
7. does not remove the container ice will be dispensed for 60 seconds and then stop Page 11 GEMD790 OPERATION Water Water enters the machine through the 3 8 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 bottom of the reservoir tank to the bottom of the evaporator Reservoir overflow evaporator condensation and water in the sink are all routed to the drain Water cooled models have a separate water circuit for the cooling water it enters the fitting at the rear goes to the water regulating valve then to the water cooled condenser and down the drain The water dispensing station adds an additional water circuit When the water station sensor detects a container in front of it the control board closes a circuit to an electric water valve and water is dispensed RESERVOIR RESERVOIR OVERFLOW DRAIN WATER INLET gt WATER VALV SINK DRAIN Note The correct water level is determined when the machine is operating Check the water level and compare it to the line molded into the side of the reservoir The water level should be between 4 above and 4 below the line If needed adjust the water level by bending the float arm WATER LEVEL BIN DRAIN WATER SCHEMATIC Page 12 OPERATION Refrigeration Beginning at the compressor the refrigerant is compressed into a high temperature gas The discharge line direc
8. model flake ice machine and GEMD maker dispenser compressors from the date of original installation The company will replace EXW Incoterms 2000 the Company plant or EXW Incoterms 2000 the Company authorized distributor without cost to the Customer that part of any such machine that becomes defective In the event that the Warranty Registration Card indicating the installation date has not been returned to lce O Matic the warranty period will begin on the date of shipment from the Company Irrespective of the actual installation date the product will be warranted for a maximum of seventy two 72 months from date of shipment from the Company ICE model cube ice machines which are registered in the Water Filter Extended Warranty Program will receive a total of eighty four 84 months parts and labor coverage on the evaporator plate from the date of original installation Water filters must be installed at the time of installation and registered with the Company at that time Water filter cartridges must be changed every six 6 months and that change reported to the Company to maintain the extended evaporator warranty No replacement will be made for any part or assembly which I has been subject to an alteration or accident ll was used in any way which in the Company s opinion adversely affects the machine s performance lll is from a machine on which the serial number has been altered or removed or IV uses any replacement part not
9. As the ice maker begins to use water from the reservoir continue to add more cleaning solution to maintain a full reservoir 10 After all of the cleaning solution has been added to the reservoir and the reservoir is nearly empty switch the master switch to OFF 11 After draining the reservoir as in step 6 wash and rinse the water reservoir To Sanitize Repeat steps 8 11 except substitute sanitizer solution for the cleaning solution A possible sanitizer solution may be made by mixing 1 ounce of household bleach and 2 gallons of warm 95 F 1157F potable water 12 Remove the block from the float in the water reservoir 13 Switch the master switch to ON 14 Continue ice making for at least 15 minutes to flush out any cleaning solution Check ice for acid taste continue icemaking until ice tastes sweet DO NOT USE any ice produced from the cleaning solution Be sure no ice remains in the bin 15 Remove all ice from the storage bin 16 Add warm water to the ice storage bin and thoroughly wash and rinse all surfaces within the bin 17 Sanitize the bin interior cover door and agitator with an approved sanitizer using the directions for that sanitizer 18 Replace the ice storage bin cover and the front panel Page 16 GEMD790 SENSOR MAINTENANCE 1 The ice machine senses water level by a probe 2 The bin control uses devices that sense light located in the water reservoir At least twice a ye
10. Remove evaporator inlet hose from reservoir 7 Remove water level sensor probe 8 Remove mounting screws from reservoir bracket and remove reservoir from icemaker 9 Reverse to reassemble FLOAT ASSEMBLY LOCKING TABS BIN CONTROLS Ice Level Sensors 1 Disconnect electrical power 2 Remove front panel 3 Remove control box cover 4 Locate bin top in front of and behind it are two rubber bin control grommets 5 Pull each bin control out and in the control box disconnect the electrical leads connecting the bin control to the circuit board 6 Reverse to reassemble be certain that the bin controls are aligned so that the ice level sensors are visible centered through the holes in the ice chute Page 22 GEMD790 REMOVAL AND REPLACEMENT Bearing And Breaker Note Removal of the auger water seal evaporator and gearmotor must begin at the top of the assembly To Remove the Breaker Bearing Assembly AWARNING Moving Parts Hazard Disconnect electrical power to the icemaker dispenser before beginning 1 Remove panels and disconnect electrical power 2 Unscrew three studs and remove ice chute cover 3 Unscrew and remove ice sweep 4 Lift up and remove ice chute 9 The breaker may be removed from the auger and evaporator without disturbing the auger a Unscrew breaker cover from breaker left hand threads b Unscrew auger stud from top of auger c Unscrew 4 allen head c
11. is pushed and the amount of ice dispensed is adjusted 8 Switch off the icemaker dispenser remove the top panel and the top of the ice storage bin Sanitize the interior of the ice storage bin with a locally approved sanitizer A possible sanitizer is a mixture of 1 ounce of household bleach to 2 gallons of water Wash the interior of the bin with the sanitizing solution Replace all covers and panels Switch the icemaker dispenser back on 9 Give the owner user the service manual instruct him her in the operation and maintenance reguirements of the unit Make sure they Know who to call for service 10 Fill out the Customer Evaluation and warranty Registration form and mail it in to Ice O Matic Page 7 GEMD790 COMPONENT DESCRIPTION RESERVOIR WATER ICE LEVEL SENSOR LEAR SENSOR ICE STORAGE BIN ES CONTROL BOX ad SS Qh DRAIN TUBE PRESSURE Ice Level Sensor An electronic eye it senses CUT OUT the presence of ice in the bottom of the ice discharge chute Operates to turn the ice machine on and off automatically as the level of ice in the bin changes Control Box Contains the electrical controls that Drain Tube When uncapped and lowered drains operate the machine the evaporator High Pressure Cut Out Switch An automatic Condenser Air or water cooled where the heat reset switch sensing the high side refrigeration removed in ice making is discharged pressure It is set to shut the machine off if the Ice Sto
12. S WARRANTY IS THE EXCLUSIVE REMEDY OF THE CUSTOMER MILE HIGH EQUIPMENT SHALL NOT BE LIABLE FOR ANY INCIDENTAL OR CONSEGUENTIAL DAMAGES FOR BREACH OF ANY EXPRESS OR IMPLIED WARRANTY ON THIS PRODUCT EXCEPT TO THE EXTENT PROHIBITED BY APPLICABLE LAW ANY IMPLIED WARRANTY OR MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE ON THIS PRODUCT IS LIMITED IN DURATION TO THE LENGTH OF THIS WARRANTY Filing a Claim All claims for reimbursement must be received at the factory within 90 days from date of service to be eligible for credit All claims outside this time period will be void The model the serial number and if necessary proof of installation must be included in the claim Claims for labor to replace defective parts must be included with the part claim to receive consideration Payment on claims for labor will be limited to the published labor time allowance hours in effect at the time of repair The Company may elect to reguire the return of components to validate a claim Any defective part returned must be shipped to the Company or the Company authorized distributor transportation charges pre paid and properly sealed and tagged The Company does not assume any responsibility for any expenses incurred in the field incidental to the repair of equipment covered by this warranty The decision of the Company with respect to repair or replacement of a part shall be final No person is authorized to give any other warranties or to assume any other liabilit
13. SENSOR MAINTENANCE ce aW ee ham R US er ee fF ee ao we ee ee WOW GW R ermimm Page 17 BEARING MAINTENANCE Mc dr ww Se ee ec a ee ee ee oe eo he a ow ee WOW OE mm mire Page 18 AUGER MAINTENANCE aa e My Se rn ee a ea dr Page 19 SERVICE DIAGNOSIS re mi ee ae OS ie ee ee Ha Page 20 CONTROL SYSTEM DIAGNOSTICS mm a k ehee re ide Ci na Im na Page 21 REMOVAL AND REPLACEMENT E EEE ERA RS Cia Page 22 REMOVAL AND REPLACEMENT Bearing And Breaker lt lt rn nn nn nn nn nn Page 23 REMOVAL AND REPLACEMENT Boo av Y ke Oe Uk ee Oe rum mi ee ae ee E Emis Page 24 REMOVAL AND REPLACEMENT Water Seal gt gt so so sos nn nn nn nn nn nn nr nn Page 25 REMOVAL AND REPLACEMENT ee oe GL h OR WM Wy we Se a Wy WM r Go GE E dw Y WM WW Page 26 TO REMOVE AND REPAIR THE GEARMOTOR ASSEMBLY nn nn nn nn nnr Page 27 REFRIGERATION SERVICE Mam WC dw we de We AW EW de R W a ee r OW ew ee we Oo NW Oe ii a Page 29 WIRING DIAGRAMS R a mm arr riam rm rhe CD Ed a Page 29 This manual was printed on recycled paper Note this symbol when it appears Keep it for future reference AWARNING It marks a possible hazard Page 1 GEMD790 FOR THE INSTALLER Specifications This ice maker dispenser is designed to be mounted on a machine stand or a countertop Before beginning the installation check that all the materials and kits required are available at the installation location Ice O Matic ice machines are designed and manufactur
14. UGER ASSEMBLY GEMD790 SERVICE DIAGNOSIS Symptom No ice is made nothing operates Possible Cause Unit off due to no power Probable Correction Restore Power Unit off due to master switch in OFF position Switch master switch to ON Unit off due to low water level Check water supply filter float valve Correct water supply Unit off due to ice level sensors photo electric eyes blocked Check clean ice level sensors Unit off due to scale on water level sensor Clean water level sensor Unit off due to high pressure control open Check for water interruption water cooled or fan motor failure air cooled Auger motor hums but does not turn Auger can t turn No power to circuit board Check harness HI pressure cut out open Circuit Board gear motor relay will not close Check replace board Water level or ice level sensor failed Check replace sensor No ice auger motor is turning Compressor contactor coil is open Check replace contactor Compressor will not start Check start capacitor Check start relay Check compressor windings Circuit board compressor relay will not close Check replace board Unit makes ice but very slowly High discharge pressure because of a dirty condenser Clean the condenser Low capacity because the auger and evaporator are coated with mineral scale Clean the water
15. ap screws holding breaker to evaporator STEP 5 A STEP 5 B ICE SWEEP 6 d Lift up and remove breaker bearing assembly from auger amp evaporator 6 Service the bearing Check for rust rough spots and damage a The bearing is pressed into the breaker to remove the bearing and replace it an arbor press is needed b Replace lower seals before installing new bearing in breaker Note seals must be pressed in with a tool pushing against the outer edge only they will not install by hand Replace parts as required Re grease bearing with Ice O Matic part no 6051062 01 bearing grease Replace top seal and check the o rings replace if cut or torn 7 Reverse to reassemble specific tools and materials are required to install properly a Add food grade grease such as Ice O Matic part number 6051036 01 to the seal area before installing on the auger b Check the seal to shaft areas for cuts or rough spots none are permitted STEPS 5 C BEARING AND 6 BREAKER Page 23 GEMD790 REMOVAL AND REPLACEMENT To Remove the Auger Turn off the water to the machine and unclip the evaporator drain hose pull it down and drain the evaporator into the bin or a container AWARNING Moving Parts Hazard Disconnect electrical power to the icemaker dispenser before beginning 1 The top panel must be removed 2 Remove ice chute cover 3 Unscrew ice sweep 4 Remove ice chute body 9 The aug
16. ar therefore they must be kept clean enough so that the probe should be removed from the reservoir they can see At least twice a year remove the and the tip wiped clean of mineral build up bin control sensors from the ice chute and wipe them clean SLIDE SENSORS UP TO REMOVE Clean the Probe s Tip with ice machine cleaner and a clean soft cloth Page 17 GEMD790 BEARING MAINTENANCE The bearing in the breaker should also be checked at least two times per year A Check the bearing by eremoving the ice chute cover lce Sweep eunscrewing the ice sweep eremoving the water shed Breaker Cover eunscrewing the breaker cover Auger Stud Cap Screw eunscrewing the auger stud Inspect the bearing There should be plenty of grease in sight If grease is needed the bearing and breaker should be removed to check the action of the bearing It should rotate smoothly To remove the breaker remove the lower ice chute then take out all four allen head cap screws and pull the breaker off the auger and evaporator If the bearing only needs grease inject grease into the bearing using lce O Matic grease needle pn 1011380 230 and Ice O Matic bearing grease pn 6051062 01 Be sure to inject grease evenly and thoroughly See Removal and Replacement section to replace bearing or seals Needle pn Bearin g 1011380 230 Reverse to reassemble Page 18 AUGER MAINTENANCE In some area
17. auger to sweep the ice into the ice chute Breaker Where the ice is compressed and much of the extra water is sgueezed out of it before it is discharged into the bin ICE SWEEP BEARING BREAKER ICE CHUTE Ei AFR AU E EVAPORATOR a eae SAS n pr 7 Fri s LE DA LT ia Tal wt AUGER aM per ry tee Hydd a fal 1m E ad Em ERC F Fi Aa a y mb u n i Fd ST Un MM um ace T a ae ZA Apre i en E ca pd A Py a Aire at v a e n ES A y NT na y Mr An bhia I Ha Wr HU Un Wn EF pr dm i Piy mi VN w 1 Lar i FE er ha 3 al Te WATER SEAL a e ua Yr Fn F Tale Tat ita Lgl 4 we Cre iN ao T Ms ja i Yn e t r ii Pini Ac E ae oie Fn O if ity Se ara yd WATER INLET GEAR MOTOR Page 9 GEMD790 CONTROL BOX Circuit Board The circuit board receives input signals from several sensors and translates them to control the electrical power supply to the various loads The sensors include e Touch Free ice or water e ce level in the bin eWater level in the reservoir The loads include e Compressor contactor eFan motor e Bin drive motor e Auger drive motor eWater solenoid In addition a Clean switch is available to temporarily disable the Touch Free sensors for cleaning of the splash panel On Off Switch Manual contr
18. authorized by the Company This warranty does not apply to destruction or damage caused by unauthorized service using other than Ice O Matic authorized replacements risks of transportation damage resulting from adverse environmental or water conditions accidents misuse abuse improper drainage interruption in the electrical or water supply charges related to the replacement of non defective parts or components damage by fire flood or acts of God This warranty is valid only when installation service and preventive maintenance are performed by a Company authorized distributor a Company authorized service agency or a Company Regional Manager The Company reserves the right to refuse claims made for ice machines or bins used in more than one location This Limited Warranty does not cover ice bills normal maintenance after install adjustments and cleaning Limitation of Warranty This warranty is valid only for products produced and shipped from the Company after March 2011 A product produced or installed before that date shall be covered by the Limited Warranty in effect at the date of its shipment The liability of the Company for breach of this warranty shall in any case be limited to the cost of a new part to replace any part which proves to be defective The Company makes no representations or warranties of any character as to accessories or auxiliary eguipment not manufactured by the Company REPAIR OR REPLACEMENT AS PROVIDED UNDER THI
19. chute Table of Contents FOR THE INSTALLER Specifications gt gt ed ta Vr ere eo MR ee en MD RW O ho ho ho 8 Page 2 FOR THE INSTALLER z dd I Y amp amp i r owe we L Aiii ee id Eu OR we Oe Oe a Page 3 FOR THE PLUMBER r e Y Tr z EF e E a a o a a Page 4 FOR THE ELECTRICIAN R R Rd e Bom cb dn amp de RR JR ee oe di de R RR oe we du dn RR BR ww a Page 5 FOR THE INSTALLER Final Check List 5 5 s s s s s s s a ie eo eh he nn Page 6 INITIAL START UP IR d Ce S CE RE et d eM WW Ok ek Oe CE 8 GE a oe eR ae rW eH ee ee r Page T COMPONENT DESCRIPTION za tk NW Y OR GW RE Gr ee O RE eo a WR OR ee r SRL RE we e Ww om ow Page 8 COMPONENT DESCRIPTION E OR OW ge BL AM GR Bh GH Me R RE do O OR KH rn wok RE ee Gr Oe BH OW Page 9 CONTROL BOX kw w CBL amp W ER we k WU ek BL we WR eH ee ee we ee ek GW OUR ee WR amp H a Page 10 ELECTRICAL SEQUENCE ca ek W R RR Se oe ee ee ee Bw GW aa ee ee ee eh ee eR HW B amp B WCW Page 11 OPERATION Water amp Gb wc A OW OW wT oe cw WO Oe OA ew E o Sw me O ee ke oe WW MW Oe O WW GW me AR Page 12 OPERATION Refrigeration Wd oW cee kee eh ew S GR ew eS ES Re eS mm mam mm RW W Page 13 OPERATION Ice Vending POE we Se rr ima Ia Wr WW NW GW WOW Oe a Oe WW OW a Page 14 DISPENSE AREA SANITATION i 2 oe ee Ewe we Se Gn ee ee O O mar HY Ow ee OK nn Page 15 CLEANING and SANITIZING R W WW W W Oe em OO GW CW a yW WE OW GW EW Wen OO ee ce OO OR Page 16
20. e only as pressed together sets D After replacing parts as reguired if any reassemble the gearcase The two smaller gears and the oil should be in the lower case the output gear will be with the cover As you lower the cover onto the lower case cover will have to be moved closer to the second gear after the output gear has cleared the second gear top bearing E After the case is together and the locating pins are secure in both ends replace all cap screws 4 Bench test the gearmotor check for oil leaks noise and amp draw BEARING i BEARINGS aim BEARINGS GASKET GEAR CASE GEMD790 REFRIGERATION SERVICE General This ice machine uses R 404A refrigerant Instructions for Liguid Charging R 404A and polyolester oil Do NOT use mineral oil in this In preparation for charging the low side hose refrigeration system should have a sight glass and or a restricting eWhen the system is serviced a special liguid device such as a Charge Faster installed in it line drier is required It is included with for metering liquid into the low side of the system replacement compressors 1 After a thorough evacuation shut off the manifold valves and switch off the vacuum pump en renome nen 2 Place a drum of R 404A onto an electronic these ice machines use Polyolester oil Polyolester oil absorbs water very easily A Sa system opened for service must be re sealedas Attach the charging hose to t
21. ed with the highest regard for safety and performance They meet or exceed the Ice O Matic assumes no liability or responsibility of any kind for products manufactured by Ice O Matic that have been altered in any way including the use of any parts and or other components not specifically approved by Ice O Matic Ice O matic reserves the right to make design changes and or improvements at any time Specifications and designs are subject to change without notice BACK VIEW standards of U L N S F and C U L 3 8 FPT Cond Water Electrical Junction Inlet Box UE 3 8 Flare 1 2 FPT Water Inlet Cond Drain W C 6 63 A 3 4 FPT lo l 12 5 Drain mu q 4 63 e L 75 3 84 7 93 3 4 FPT Drain Water Limitations An ice machine is a food manufacturing plant it takes in a raw material water and turns it into a food product ice The purity of the water is very important in obtaining pure ice and in maximizing product life General recommendations are 1 Filter the water used to produce ice 2 Check with a water treatment specialist for a water test and any recommendations regarding filters and treatment Model Number Dimensions Condenser Refrigerant Basic Minimum Max w o stand Type Charge Electrical Circuit Fuse H x W x D R 404A Ampacity Size GEMD790 45 90 x 35 20 x 27 31 Air 32 115 60 1 18 1 25
22. er and breaker bearing may now be removed as an assembly BREAKER BEARING AUGER ASSEMBLY SHARP EDGES a Unscrew 4 allen head cap screws holding breaker to evaporator b Lift up on breaker and remove auger from evaporator Note If the auger is stuck the breaker must be removed from the auger The breaker may be removed from the auger and evaporator without disturbing the auger a Unscrew breaker cover from breaker left hand threads b Unscrew auger stud from top of auger c Unscrew 4 allen head cap screws holding breaker to evaporator d Lift up amp remove breaker from evaporator e If the auger is stuck use a slide hammer type puller to pull on the auger at the threaded hole The size of that hole is 5 8 18 Inspect the auger the critical areas of the auger are 1 The auger body It should be clean and shining Sometimes an auger will appear clean when wet but after it is dry it will be seen to be stained Scrub the auger with ice machine cleaner and hot water Ice machine cleaner is an acid Handle it with extreme care keep out of the reach of children 2 The water seal area Because the auger has been removed the water seal will have to be replaced Remove the water seal top half from the auger and inspect the auger for minerals clean as reguired SLIDE HAMMER PULLER THREAD INTO AUGER Page 24 REMOVAL AND REPLACEMENT Water Seal GEMD790 To Remove the Wa
23. g worn parts before they can cause failure The following is a list of recommended maintenance that will help Keep the machine running with a minimum of problems Cleaning should be scheduled at a minimum of twice per year Sanitizing of the ice storage bin should be scheduled for a minimum of 4 times a year Electrical power will be ON when doing in place cleaning ICEMAKING SYSTEM In place cleaning 1 Check and clean any water treatment devices if any are installed 2 Remove screws and remove the upper front panel 3 Move the ON OFF switch to OFF 4 Remove the cover to the ice storage bin and remove the ice 5 Remove the cover to the water reservoir and block the float up 6 Drain the water reservoir and freezer assembly using the drain tube attached to the freezer water inlet Return the drain tube to its normal upright position and replace the end cap 7 Prepare the cleaning solution Mix eight ounces of Ice Machine Cleaner with three quarts of hot water The water should be between 90 115 Ice Machine Cleaner contains acids These compounds may cause burns If swallowed DO NOT induce vomiting Give large amounts of water or milk Call Physician immediately In case of external contact flush with water Keep out of the reach of children AWARNING degrees F 8 Slowly pour the cleaning solution into the water reservoir until it is full Wait 15 minutes then switch the master switch to ON 9
24. he drum soon as possible 15 minutes maximum 4 Open the valve on the drum and purge the charging hose 5 Zero out the scale 6 Shut the low side access valve at the ice machine 7 Open the discharge manifold valve full open 8 Watch the scale when the correct charge is e Evacuate to 300 microns shown shut the manifold valve eLiguid charge the system Note If all of the charge will not go in the Access Valves To use the discharge side access valves A Shut the discharge access valve at the ice Torque stem machine db to 6 8 ft lb B Switch the machine on caps to 7 12 l i gt ft Ib C Open the low side access valve at the ice machine D Open the low side manifold valve and observe the sight glass to be certain that only gas is flowing into the system E When the proper charge is indicated on the scale shut off the manifold valve s e Special leak detection equipment is required to locate small refrigerant leaks Usually a leak detector capable of detecting a Halongenated refrigerant or HFC 134a will work Check with the leak detector manufacturer if in doubt e Remove the cap from the stem use a 3 16 allen wrench to check that the valve is CLOSED The remove the core cap e Close the valve and replace the caps when done The valve must be closed and the caps must be on or the valve will Eas 9 Shut off the valve on the refrigerant drum 10 Re ope
25. ing takes place when the agitator sweeps the ice through the ice dispensing chute ice will ICE DISCHARGE CHUTE continue to discharge out this chute as long as the agitator is turning It stops when the agitator stops DOOR SOLENOID e di as ICE CHUTE STORAGE BIN it DOOR NO ICE CHUTE AGITATOR IT AGITATOR E DRIVE MOTOR Rr 3 e fae TOUCH FREE E SENSOR SINK Page 14 DISPENSE AREA SANITATION The dispense area spouts sink grill and splash panel will need periodic cleaning and maintenance 1 The ice chute may be pulled down to remove it from the ice dispenser Wash and sanitize it 2 The sink grill may be removed for washing and sanitizing 3 The sink should be flushed with hot water and wiped clean with sanitizer 4 The splash panel requires special attention to clean it e Push and release the Splash Panel Cleaning switch located to the left of the water spout This disables the Touch Free sensors so the splash panel may be cleaned without vending ice and or water eWash the splash panel and wipe with with sanitizer Re push the clean switch or allow 2 minutes to pass for the Touch Free system to reset GEMD790 Page 15 GEMD790 CLEANING and SANITIZING It is the USER S RESPONSIBILITY to see that the unit is properly maintained It is always preferable and less costly in the long run to avoid possible down time by keeping it clean adjusting it as needed and by replacin
26. l the steps for removal of the thrust bearing breaker auger and water seal have been performed 1 Recover the refrigerant from the ice maker 2 Unsweat the refrigerant connections a At the thermostatic expansion valve outlet Heat sink the TXV body when unsweating or resweating the adjacent tubing b At the suction line at the joint about 3 from the evaporator 3 Remove the evaporator 4 Unsweat the drier from the liguid line 5 After installing a new water seal in the new evaporator see To Replace the Water Seal sweat in the new evaporator at the old tubing connections 6 Install an new drier in the liguid line EVAPORATOR 7 Evacuate the system until dehydrated then weigh in the nameplate charge Check for leaks 8 Install auger breaker breaker bearing assembly and ice discharge chute in reverse order of disassembly RETAINING RING SEAL DRIP PAN To Reassemble the Evaporator and Auger 1 After the gearmotor has been inspected fasten the evaporator to the gear motor be sure that the number of shims indicated on the gear case cover is in place between the gearcase cover and the drip pan gasket Torque the bolts to 110 inch pounds 2 Lower the auger into the evaporator barrel slightly turning it to match up with the drive end Do Not Drop Into the Evaporator 3 Complete the reassembly by reversing the disassembly for the breaker amp thrust bearing assembly BREAKER
27. n the manifold valves until all liguid has a 7 flowed out of the hoses 11 Shut the low side access valve on the ice machine 12 Remove hoses from ice machine and replace all caps Sight Glass Hose Connection Schematic for Liquid Charging Page 28 GEMD790 Schematic Diagram
28. nal state and local electrical codes The use of a licensed electrician is required to perform the electrical installation POWER SUPPLY ELECTRICAL CONNECTION Page 5 N NN o E N NN W N FAN Ih GEMD790 N N GEMD790 FOR THE INSTALLER Final Check List 1 Is the icemaker dispenser installed indoors in a location where the air and water temperatures are controlled and where they do not go beyond design limitations 2 IS there an electrical service disconnect within sight of the installed machine Is the machine on a separate circuit Has the voltage been checked and compared to nameplate reguirements 3 Have all of the plumbing connections been made and checked for leaks 4 Has the machine been leveled 5 Is there a minimum of 6 inches of clearance at the left and right sides of an air cooled machine 6 Is there a minimum of 6 inches of clearance at the top and back of the machine for service and utility connections 7 Is there a water shut off valve installed near the machine 8 Have all of the shipping blocks been removed INLET DRAINS ELECTRICAL LEVELED T7 NN E Page 6 INITIAL START UP Pre Start Inspection 1 Remove the two front panels 2 Check that all shipping blocks have been removed 3 Remove any and all packing tape check inside the storage bin
29. ol for the machine Contactor A definite purpose contactor connecting the compressor to the power supply Potential Relay The compressor start relay F my Eta Em 7 to N t tu EEEF E sia iat 4 sb f Fa Apis o 2722720 j MW t TAERA so i i o iu A AS SS il misin THRE reer IPE TIDI DITT o MAA i Wn ivi Touch Free Control Board Page 10 ELECTRICAL SEOUENCE Refer the wiring diagram as needed The Power light on the board glows whenever there is power to the machine and the master switch is ON If the machine is switched off at the master switch but is otherwise ready to go switching the master switch to ON does the following e The bin empty and power lights on the circuit board glow e There is a 15 second delay el there is enough water in the reservoir the circuit board will allow the machine to start up Start up consists of e The compressor contactor coil receives power from the circuit board e The contactor is energized connecting power to the compressor and the compressor starts e The auger motor receives power from the circuit board and starts eAs ice goes past the ice level sensors the bin empty light will stay on and the machine will continue to run unless the ice stays between the sensors for more than 15 seconds bin full At that point the bin empty light goes out and
30. rage Bin Assembly A plastic lined discharge pressure should ever exceed 450 psig insulated cylinder that receives stores and Evaporator A vertical stainless steel tube dispenses the ice Fresh ice enters at the top and refrigerated and water filled In it there is a when the bin is full enough the ice will be between stainless steel auger the ice level sensors and the icemaking will stop Reservoir Float operated it maintains the water Ice Is dispensed through a chute at the bottom level in the evaporator at a constant level it also front when the agitator assembly sweeps the ice contains the water level sensor through the chute Water Level Sensor Senses if there is water in the reservoir to make ice out of Will shut the machine off it there is none Page 8 GEMD790 COMPONENT DESCRIPTION Evaporator A refrigerated vertical tube filled with Motor A split phase motor that drives the gear water and containing a water seal and auger reducer Auger A solid stainless steel double spiral auger Thrust Bearing As the ice is pushed up the it pushes the ice crystals up to the top of the evaporator the auger is thrust down and pressure evaporator from the auger thrust is taken up by this bearing Water Seal A two part face seal the top half rotating with the auger the bottom half stationary the sealing action being where the two seal faces meet Ice Sweep A plastic cap with fingers It revolves with the
31. s the water supply to the ice maker will contain a high concentration of minerals and that will result in an evaporator and auger becoming coated with these minerals reguiring a more freguent removal than twice per year If in doubt about the condition of the evaporator and auger the auger can be removed so the parts can be inspected Note Water filters can filter out suspended solids but not dissolved solids Soft water may not be the complete answer Check with a water treatment specialist regarding water treatment For more information on removal of these parts see REMOVAL AND REPLACEMENT AWARNING Moving Parts Hazard Disconnect electrical power to the icemaker dispenser before beginning Disconnect electrical power and shut off the water supply Use care when removing the auger it has sharp edges 1 To remove the auger remove the front and top panels 2 Drain evaporator using drain hose 3 Remove bail clamp from over ice chute cover and remove cover 4 Unscrew and remove ice sweep 5 Remove ice chute from evaporator 6 Remove 4 allen screws holding breaker to evaporator 7 Pull up to remove auger After the auger has been removed allow the auger to dry if the auger is not bright and shiny it must be cleaned Clean the auger and evaporator as reguired DO NOT HONE THE EVAPORATOR 8 Replace the water seal 9 Reverse to reassemble Page 19 GEMD790 BREAKER AND A
32. system Low suction pressure due to low refrigerant charge Locate leak Recover refrigerant repair leak replace dryer evacuate and weigh in the nameplate charge Page 20 CONTROL SYSTEM DIAGNOSTICS The control system consists of eControl Board eWater Sensor e ce Sensors eVending Sensors GEMD790 1 Power Light 2 Bin Empty Light 3 Delay Timer Light 4 No Water Light Explanation of Indicator Light Position On Name and Meaning of Board Light or Reset On at all times when the master switch is ON and machine is 1 Power connected to electrical power ON Normal On when ice level is low unit making ice 2 Bin Empty ON Needs Ice Normal 6 minute off delay start To prevent short cycling the 3 Off Timer machine will not restart after any shut off except power to the ON Unit cycling off board until 6 minutes have passed On when water level is low in the reservoir 4 No Water ON Trouble Page 21 GEMD790 REMOVAL AND REPLACEMENT WATER RESERVOIR 1 Shut off the water supply to the icemaker 2 Remove front panel and reservoir cover 3 To remove float only pry the mounting flanges apart enough to lift one float pivot pin out of the flange hole and pull float up and out of the reservoir 4 To remove reservoir disconnect water inlet compression fitting at reservoir inlet 5 Remove drain hose from reservoir 6
33. ter Seal 5 Carefully push the water seal rubber side Assuming all steps to remove the auger have against the auger shoulder and the silastic been performed sealant 1 The gearmotor evaporator assembly will have to Do not get any sealant onto the face of the seal be exposed See illustration next page 2 Remove the 4 hex head cap screws holding the evaporator to the gearmotor assembly Lift the evaporator up and off of the gearmotor 3 Remove the snap ring or wire retainer from the grove under the water seal 4 Pull or drive out the lower half of the water seal To Replace the Water Seal 1 Lubricate the water seal with water and push the water seal into the bottom of the evaporator slightly past the grove for the snap ring e WATER SEAL RETAINING RING 2 Replace the snap ring and pull the water seal down against it 3 The part of the water seal that rotates with the auger must also be replaced Remove the old part from the auger and clean the mounting area 4 Place a small bead of food grade silastic sealant such as 732 RTV on the area of the auger where the water seal is to be mounted Page 25 6 Allow the auger and seal to air dry until the sealant is dry on the surface 7 If the original water seal was leaking it would be a good idea to inspect the interior of the gearmotor FOOD GRADE GEMD790 REMOVAL AND REPLACEMENT To Replace the Evaporator Assuming al
34. the machine shuts down Other reasons for shut down eLow water level as sensed by the thermistor in the reservoir Shut Down consists of e The compressor contactor opens e The compressor stops e The auger motor is run by the circuit board for 2 more minutes clearing out ice in the evaporator and then e The auger motor no longer receives power from the circuit board and the auger motor stops GEMD790 After a 6 minute delay If the ice level sensor is clear bin empty for more than 15 seconds the machine will start up again Another purpose of the circuit board is to turn the machine off if there is not enough water in the machine eVWhen the water level in the reservoir falls below the tip of the water level sensor the machine will shut down e After a 6 minute delay if the water refills the reservoir the machine will start up again Separate from the circuit board elf the high pressure control cut out switch opens the compressor will stop immediately through the contactor It will automatically reset when the discharge pressure drops below 350 PSIG e The master switch is the manual control for the complete machine but it is not a service disconnect Ice Vending eWhen a user places a container in front of the Touch Free ice sensor and below the ice delivery chute the circuit board connects power to the bin drive motor and ice is dispensed for as long as the container is present If the user
35. to the FPT condenser inlet at the back of the cabinet The water pressure to all lines must always be above 20 psig and below 120 psig Drains Air Cooled Models Connect a drain tube to the one 74 FPT drain fitting plastic at the back of the cabinet the drain line is of the gravity type and inch per foot fall is an acceptable pitch for the drain tubing There should be a vent at the highest point of the drain line and the ideal drain receptacle would be a trapped and vented floor drain Use only 74 rigid tubing WATER COOLED SHUT OFF VALVE CONDENSER WATER ME A m FLOOR DRAIN ad lt gt oo es 0000 Ath CONDENSER DRAIN Water Cooled Models In addition to the above mentioned drain a separate condenser drain line must be installed Connect it to the condenser drain connection at the back of the cabinet Page 4 FOR THE ELECTRICIAN CONFORM TO ALL APPLICABLE CODES Connect the electrical power supply for 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 reguirements and for the minimum circuit ampacity The machine requires a solid chassis to earth ground wire The ice maker should be connected to its own electrical circuit so it would be individually fused Voltage variation must remain within design limitations even under starting conditions All external wiring must conform to natio
36. ts this gas to the condenser At the condenser air or water cooled the gas is cooled by either air or water and it then condenses into a liguid This high pressure liguid then goes through the liguid line to the expansion valve The thermostatic expansion valve meters liguid refrigerant into the evaporator the volume of liguid refrigerant depending upon the temperature of the evaporator warmer evaporators get more refrigerant and colder evaporators get less GEMD790 At the evaporator the refrigerant enters an area of relatively low pressure where it can easily boil off or evaporate As it evaporates it absorbs heat from the evaporator and whatever is in contact with it such as the water inside it After the evaporator the refrigerant now a low pressure vapor goes through the suction line back to compressor where the cycle is repeated REFRIGERATION SCHEMATIC AIR COOLED SHOWN LIQUID LINE e ZL is FAN MOTOR f PTET AEE EPs ARTE JUTE DELA TIT CONDENSER SUCTION LINE THERMOSTATIC EXPANSION VALVE DISCHARGE LINE EVAPORATOR byf ia COMPRESSOR Page 13 GEMD790 OPERATION Ice Vending When the ice dispensing sensor detects a container in front of it the control board connects an electrical circuit to the ice chute door solenoid causing the ice chute door to open At the same time power is connected to the agitator drive motor Dispens
37. vy use of a mechanical hoist is recommended to lift it to the height required to install it The DMS machine stand has holes in the top that match up with threaded holes in the base of the machine Secure the machine stand to the base with 4 5 16 bolts ICEMAKER DISPENSER TO THE COUNTER TOP OR MACHINE STAND GEMD790 In both counter top and machine stand installations wipe off and neatly smooth any excess sealant Level the machine stand and cabinet Unpack and install the sink brackets Fit the sink assembly onto the two sink brackets and press onto the bead of sealant Wipe off and neatly smooth any excess sealant from under the sink edge Connect the sink drain to the dispenser drain system Airflow SEAL Page 3 GEMD790 FOR THE PLUMBER CONFORM TO ALL APPLICABLE CODES Water Inlet Air Cooled Models Connect a clean potable and cold water supply to the male flare at the back of the cabinet Install a hand valve near the machine to control the water supply Use 3 O D copper tubing Water Treatment In most areas a water filter of some type will be useful In areas where the water is highly concentrated with minerals the water should be tested by a water treatment specialist and the recommendations of the specialist regarding filtration and or treatment should be followed Water Cooled Models Connect a separate 3 O D copper line with a separate hand valve to INLET WATER control it
38. y on the Company s behalf unless done in writing by an officer of the Company GOVERNING LAW This Limited Warranty shall be governed by the laws of the state of Delaware U S A excluding their conflicts of law principles The United Nations Convention on Contracts for the International Sale of Goods is hereby excluded in its entirety from application to this Limited Warranty Mile High Eguipment LLC 11100 East 45th Avenue Denver Colorado 80239 303 371 3737 March 2011 N RE Le Oo Te Ice O Matic is devoted to sustainability in every aspect of our business So to help offset our carbon footprint we work with American Forests to plant a tree for every ice machine we sell Our ultimate goal is to plant 150 000 trees over the next several years GEMD790 INTRODUCTION To the owner or user The service manual you are The ice making section is eguipped with the reading is intended to provide you and the following features electronic controls for bin level maintenance or service technician with the and low water thermostatic expansion valve front information needed to install start up clean service for most components and R 404A maintain and service this ice maker dispenser refrigerant The ice dispensing section is a The GEMD790 is a combination GEM ice maker seamless plastic storage bin with a stainless steel and countertop dispenser A water station is ice agitator at the bottom to sweep the ice into the standard dispensing
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