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Technician’s
Handbook
This manual is updated as new information and models are
released. Visit our website for the latest manual.
http://www.welbilt.cn
America’s #1 Selling Ice Machine
Part Number04000702304/19
ES60/ES90/ES130/
ES170/ES210/ES270
Undercounter
Ice machine
Safety Notices
As you work on KOOLAIRE equipment, be sure to pay
close attention to the safety notices in this handbook.
Disregarding the notices may lead to serious injury
and/or damage to the equipment.
Throughout this handbook, you will see the following
types of safety notices:
Text in a Warning box alerts you to a potential
personal
injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
Text in a Caution box alerts you to a situation in
which you could damage the equipment. Be sure
to read the Caution statement before proceeding,
and work carefully.
Procedural Notices
As you work on KOOLAIRE equipment, be sure to
read the procedural notices in this handbook. These
notices suppl helpful information which may assist you
as you work.
Throughout this handbook, you will see the following
types of procedural notices:
Text in an important box provides you with
information
that may help you perform a
procedure more efficiently. Disregarding this
information will not cause damage or injury, but it
may slow you down as you work.
!
Warning
!
Caution
Important
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about the procedure you
are performing.
Read These Before Proceeding:
Proper installation, care and maintenance are
essential for maximum performance and trouble-
free operation of your Ice Machine.If you
encounter problems not covered by this
handbook, do not proceed, contact us. We will be
happy to provide assistance.
Routine adjustments and maintenance
procedures
outlined in this handbook are not
covered by the warranty.
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
We reserve the right to make product
improvements at any time. Specifications and
design are subject to change without notice.
!
Caution
Important
!
Warning
POTENTIAL PERSONAL INJURY
SITUATION
This ice machine contains refrigerant charge.
Installation and brazing of the line sets must be
performed by a properly trained refrigeration
technician aware of the Dangers of dealing with
refrigerant charged equipment. The technician
must also be US Government Environmental
Protection Agency (EPA) certified in proper
refrigerant handling and servicing procedures.
!
Warning
Part Number04000702304/19 7
Contents
GENERAL INFORMATION
Model Numbers . . . . . . . . . . . . . . . . . . . . . 1
How to Read a Model Number . . . . . . . . . 2
Accessories . . . . . . . . . . . . . . . . . . . . . . . 2
Cleaner and sanitizer . . . . . . . . . . . . . . . . 2
Model/Serial Number Location . . . . . . . . 3
OWNER WARRANTY REGISTRATION CARD
4
General . . . . . . . . . . . . . . . . . . . . . . . . 4
Commercial Warranty Coverage . . . . . 4
INSTALLATION
General . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Location of Ice Machine . . . . . . . . . . . . . . 7
Ice Machine Heat of Rejection . . . . . . . . . 8
Leveling the Ice Machine . . . . . . . . . . . . . 9
ES60/ES90 . . . . . . . . . . . . . . . . . . . . . 9
ES130/ES170/ES210/ES270 . . . . . . . 10
Electrical Requirements . . . . . . . . . . . . . . 12
General . . . . . . . . . . . . . . . . . . . . . . . . 12
Voltage . . . . . . . . . . . . . . . . . . . . . . . . 12
Fuse/Circuit Breaker . . . . . . . . . . . . . . 12
Total Circuit Ampacity . . . . . . . . . . . . . 12
Electical rating . . . . . . . . . . . . . . . . . . . 13
Water Service/Drains . . . . . . . . . . . . . . . . 14
Water Supply . . . . . . . . . . . . . . . . . . . . 14
Water Inlet Lines . . . . . . . . . . . . . . . . . 14
Drain connections . . . . . . . . . . . . . . . . 14
COMPONENT IDENTIFICATION
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
ES90 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
ES130/170/210/270 . . . . . . . . . . . . . . . . . . 19
MAINTENANCE
Ice Machine Inspection . . . . . . . . . . . . . . 21
Exterior Cleaning . . . . . . . . . . . . . . . . . . . 21
Cleaning the Condenser . . . . . . . . . . . . . 21
Interior Cleaning and Sanitizing . . . . . . . 23
8 Part Number04000702304/19
Contents
General . . . . . . . . . . . . . . . . . . . . . . . . 23
Cleaning and sanitizing procedure . . . 23
Removal from Service/Winterization . . . 36
General . . . . . . . . . . . . . . . . . . . . . . . . 36
Self-contained air-cooled ice machines 36
OPERATION
Sequence of Operation . . . . . . . . . . . . . . 37
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Energized Parts Chart-ES60 . . . . . . . 39
ES90/ES130/ES170/ES210/ES270 . . 40
Initial start-up or start-up after automatic
shut-off . . . . . . . . . . . . . . . . . . . . . . . . 40
Freeze sequence . . . . . . . . . . . . . . . . 40
Harvest sequence . . . . . . . . . . . . . . . . 41
Automatic shut-off . . . . . . . . . . . . . . . . 41
Energized parts chart-ES90-270 . . . . 42
Operational Checks . . . . . . . . . . . . . . . . . 43
General . . . . . . . . . . . . . . . . . . . . . . . . 43
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 44
ES90/ES130/ES170/ES210/ES270 . . 46
TROUBLESHOOTING
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Diagnosing an ice machine that will not run
49
Diagnosing refrigeration system . . . . . 50
Ice formation pattern . . . . . . . . . . . . . . 52
Ice production check and ice thickness
adjust . . . . . . . . . . . . . . . . . . . . . . . . . 53
Safety limit checklist . . . . . . . . . . . . . . 55
LEDdefinition . . . . . . . . . . . . . . . . . . 55
ES90/ES130/ES170/ES210/ES270 . . . . . . 56
Diagnosing a ice machine that will not run
56
Diagnosing ice thickness control circuitry
57
Ice production check . . . . . . . . . . . . . . 60
Part Number04000702304/19 9
Contents
Installation and visual inspection checklist
62
Water system checklist . . . . . . . . . . . . 63
Ice Formation Pattern . . . . . . . . . . . . . 64
Safety limit feature . . . . . . . . . . . . . . . . 66
Flooding expansion valve . . . . . . . . . . 71
Starving Expansion Valve/Low refrigerant
charge . . . . . . . . . . . . . . . . . . . . . . . . . 71
Overcharged System . . . . . . . . . . . . . . 71
Hot Gas Valve . . . . . . . . . . . . . . . . . . . 72
Refrigeration diagnostics-ES90 . . . . . . 76
Diagnosing Refrigeration systemES130/
ES170/ES210/ES270 . . . . . . . . . . . . . 80
COMPONENT CHECK PROCEDURES
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 93
Function . . . . . . . . . . . . . . . . . . . . . . . . 93
Specifications . . . . . . . . . . . . . . . . . . . 93
Check Procedure . . . . . . . . . . . . . . . . . 93
Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . . 94
ES90/ES130/ES170/ES210/ES270 . . 94
Bin Thermostat . . . . . . . . . . . . . . . . . . . . . 97
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Liquid Line Thermistor . . . . . . . . . . . . . . . 99
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Diagnosing Start Components . . . . . . . . 102
Capacitor . . . . . . . . . . . . . . . . . . . . . . . 102
Relay . . . . . . . . . . . . . . . . . . . . . . . . . . 102
ON/OFF/WASH Toggle Switch . . . . . . . . . 103
Function . . . . . . . . . . . . . . . . . . . . . . . . 103
Specifications . . . . . . . . . . . . . . . . . . . 103
Check Procedure . . . . . . . . . . . . . . . . . 103
Ice Thickness Probe . . . . . . . . . . . . . . . . . 105
ES90/130/ES170/ES210/ES270 . . . . . 105
Ice Thickness Check . . . . . . . . . . . . . . 106
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Compressor Electrical Diagnostics . . . . 109
Check Resistance (Ohm) Values . . . . 109
Single Phase Compressors . . . . . . . . . 109
10 Part Number04000702304/19
Contents
Check Motor Windings to Ground . . . 109
Compressor Drawing Locked Rotor . . 110
Compressor Drawing High Amps . . . . 110
Fan Cycle Control . . . . . . . . . . . . . . . . . . 111
ES90/ES130ES170/ES210/ES270 . . . 111
Filter-driers . . . . . . . . . . . . . . . . . . . . . . . . 112
Liquid Line Filter Drier . . . . . . . . . . . . 112
Refrigerant Recovery/Evacuation . . . . . 113
Definitions . . . . . . . . . . . . . . . . . . . . . . 113
Refrigerant Re-use Policy . . . . . . . . . . 114
Recovery and Recharging Procedures
ES130/ES170/ES210/ES270 . . . . . . . 116
Recovery and Recharging Procedures-
ES60/ES90 . . . . . . . . . . . . . . . . . . . . . 119
System Contamination Cleanup . . . . . . . 122
General . . . . . . . . . . . . . . . . . . . . . . . . 122
Determining Severity of Contamination 122
Mild System Contamination Cleanup
Procedure . . . . . . . . . . . . . . . . . . . . . . 124
Severe System Contamination Cleanup
Procedure . . . . . . . . . . . . . . . . . . . . . . 125
Replacing Pressure Controls without
Removing Refrigerant Charge . . . . . . 127
ES270Condenser Fan Motor Replacement
129
COMPONENT SPECIFICATIONS
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . 131
Bin SwitchES90/Es130/ES170/ES210/ES270
131
Bin ThermostatES60 . . . . . . . . . . . . . . . 131
“ON/OFF/WASH” Toggle Switch . . . . . . 131
Fan Control Cycle . . . . . . . . . . . . . . . . . . 131
ES90/ES130/ES170/ES210/ES270 . . 131
Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . 132
Liquid Line ThermistorES60 . . . . . . . . . 132
Total System Refrigeration Charge . . . . 132
CHARTS
Part Number04000702304/19 11
Contents
Cycle Times, 24 Hr. Ice Production and
Refrigerant Pressure Charts . . . . . . . . . . 133
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 134
ES90 . . . . . . . . . . . . . . . . . . . . . . . . . . 136
ES130 . . . . . . . . . . . . . . . . . . . . . . . . . 138
ES170 . . . . . . . . . . . . . . . . . . . . . . . . . 139
ES210 . . . . . . . . . . . . . . . . . . . . . . . . . 140
ES270 . . . . . . . . . . . . . . . . . . . . . . . . . 141
DIAGRAMS
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . 143
ES60 . . . . . . . . . . . . . . . . . . . . . . . . . . 144
ES90 . . . . . . . . . . . . . . . . . . . . . . . . . . 145
ES130/ES170 . . . . . . . . . . . . . . . . . . . 146
ES210/ES270 . . . . . . . . . . . . . . . . . . . 147
ControlBoard . . . . . . . . . . . . . . . . . . . . . . 148
ES60 Tubing Schematics . . . . . . . . . . . . . 150
ES90/ES130 Tubing Schematics . . . . . . . 151
ES170/ES210/ES270 Tubing Schematics 152
Part Number04000702304/19 1
General Information
Model Numbers
This manual covers the following models:
An ice machine contains high voltage electricity
and
refrigerant charge. repairs are to be
performed by properly trained refrigeration
technicians aware of the dangers of dealing with
high voltage electricity and refrigerant under
pressure.
ES60A Series, like ES60AC-251
ES90A Series, like ES90AC-251
ES130A Series, like ES0130AC-251
ES170A Series, like ES0170AC-251
ES210A Series, like ES0210AC-251
ES270A Series, like ES0270AC-251
Self-contained
Air-cooled
ES60A Series
ES90A Series
ES130A Series
ES170A Series
ES210A Series
ES270A Series
!
Warning
A-Air-cooled
Series
Condenser
Type
Capacity
E S 0130 A
2 Part Number04000702304/19
How to Read a Model Number
Accessories
Contact your distributor for these optional accessories:
Cleaner and sanitizer
KOOLAIRE Ice Machine Cleaner and Sanitizer are
available in convenient 16 oz.(473ml) and 1 gal
(3.78L) bottles.
These are the only cleaner and
sanitizer approved for use with KOOLAIREproducts.
Use only KOOLAIRE approved Ice Machine
Cleaner
(part number 94-0546-3 original green
ice machine cleaner or 000000084 clear metal
safe ice machine cleaner) and Sanitizer (part
number 94-0565-3). It is a violation of Federal
law to use these solutions in a manner
inconsistent with their labeling. Read and
understand all labels printed on bottles before
use.
Cleaner Part Number Sanitizer Part Number
16 oz 94-0546-3 16 oz94-0565-3
1 gal 94-0580-3 1 gal 94-0581-3
!
Caution
Part Number04000702304/19 3
Model/Serial Number Location
The model and serial numbers are required when
requesting information from your local KOOAIRE
distributor, service representative. The model and
serial number are listed on the OWNER WARRANTY
REGISTRATION CARD. They are also listed on the
MODEL/SERIAL NUMBER DECAL affixed to the ice
machine.
ES130/ES170/ES210/ES270
MODELSERIAL
NUMBER PLATE
MODELSERIAL
NUMBER PLATE
ES60/90
MODELSERIAL
NUMBER PLATE
MODELSERIAL
NUMBER PLATE
4 Part Number04000702304/19
OWNER WARRANTY REGISTRATION
CARD
GENERAL
Warranty coverage begins the day the ice machine is
installed.
Complete and mail the OWNER WARRANTY
REGISTRA
TION CARD as soon as possible to
validate the installation date.
If the OWNER WARRANTY REGISTRATION CAERD
is not returned, we will use the date of sale to the
KOOLAIRE Distributor as the first day of warranty
coverage for your new ice machine.
COMMERCIAL WARRANTY COVERAGE
General
The following Warranty outline is provided for your
convenience. For a detailed explanation, read the
warranty bond shipped with each product.
Contact your local KOOLAIRE representative, if you
need further warranty information.
Parts
KOOLAIRE warrants the ice machine against defects
in materials and workmanship, under normal use and
service for two(2) years from the date of original
installation.
Labor
Labor required to repair or replace defective
components is covered for two(2) years from the date
of original installation.
Important
Part Number04000702304/19 5
Exclusions
The following items are not included in the ice
machine’s warranty coverage:
1. Normal maintenance, adjustments and cleaning
as outlined in this manual.
2. Repairs due to unauthorized modifications to the
ice machine or use of non-standard parts without
prior written approval from Welbitl.
3. Damage caused by improper installation of the ice
machine, electrical supply, water supply or
drainage, or damage caused by floods, storms, or
other acts of God.
4. Premium labor rates due to holidays, overtime,
etc.;travel time; flat rate service call
charges;mileage and miscellaneous tools and
material charges not listed on the payment
schedule. Additional labor charges resulting from
the inaccessibility of equipment are also
excluede.
5. Parts or ssemblies subjected to misuse,abuse,
neglect or accidents.
6. Damage or problems caused by installation,
cleaning and/or maintenance procedures
inconsistent with the technical instructions
provided in this manual.
Authorized Warranty Service
To comply with the provisions of the warranty, a
refrigeration service company qualified and authorized
by your KOOLAIRE distributor, or a Contracted
Service Representative must perform the warranty
repair.
Service Calls
Normal maintenance, adjustments and cleaning as
outlined in this manual are not covered by the
warranty.
Part Number04000702304/19 7
Installation
General
These instructions are provided to assist the qualified
installer.
Location of Ice Machine
The location selected for the ice machine must meet
the following criteria. If any of these criteria are not
met, select another location.
• The location must be indoors.
•
The location must be free of airborne and other
contaminants.
• Air temperature must be at least 40°F(4°C) but
must not exceed 110°F(43°C)
• The location must not be near heat-generating
equipment or in direct sunlight.
• The location must be capable of supporting the
weight of the ice machine and a full bin of ice.
• The location must allow enough clearance for
water, drain, and electrical connections in the rear
of the ice machine.
• The location must not obstruct airflow through or
around the ice machine( condenser airflow is in
and out the front). Refer to the chart below for
clearance requirements:
NOTE: The ice machine may be built into a cabinet.
There is no minimum clearance requirement for the
top or left and right sides of the ice machine. The listed
values are recommended for efficient operation and
servicing only.
The ice machine must be protected if it will be
subjected
to temperatures below 32F (0C).
Failure caused by exposure to freezing
temperatures is not covered by the warranty.
See “Removal from Service/Winterization”
Section 4.
60/90 130/170/210/270
Top/Sides 127 mm 203 mm
Back 127 mm 127 mm
!
Caution
8 Part Number04000702304/19
Ice Machine Heat of Rejection
* B.T.U./Hour
** Because the heat of rejection varies during the ice making cycle,
the figure shown is an average.
Ice machines ,like other refrigeration equipment, reject
heat through the condenser. It is helpful to know the
amount of heat rejected by the ice machine when
sizing air conditioning equipment where self-contained
air-cooled ice machines are installed.
Series
Ice Machine
Heat of Rejection*
Air Conditioning** Peak
ES60 1600 2350
ES90 1750 2600
ES130 2400 2900
ES170 2400 3200
ES210 2400 3400
ES270 3800 6000
/
