Welbilt (China) Koolaire ES Undercounter User manual

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 Number04000702304/19

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 Number04000702304/19 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 Number04000702304/19

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

LEDdefinition . . . . . . . . . . . . . . . . . . 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 Number04000702304/19 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 systemES130/

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 Number04000702304/19

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 SwitchES90/Es130/ES170/ES210/ES270

131

Bin ThermostatES60 . . . . . . . . . . . . . . . 131

“ON/OFF/WASH” Toggle Switch . . . . . . 131

Fan Control Cycle . . . . . . . . . . . . . . . . . . 131

ES90/ES130/ES170/ES210/ES270 . . 131

Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . 132

Liquid Line ThermistorES60 . . . . . . . . . 132

Total System Refrigeration Charge . . . . 132

CHARTS

Part Number04000702304/19 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

ControlBoard . . . . . . . . . . . . . . . . . . . . . . 148

ES60 Tubing Schematics . . . . . . . . . . . . . 150

ES90/ES130 Tubing Schematics . . . . . . . 151

ES170/ES210/ES270 Tubing Schematics 152

12

Part Number04000702304/19 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 Number04000702304/19

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 KOOLAIREproducts.

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 oz94-0565-3

1 gal 94-0580-3 1 gal 94-0581-3

!

Caution

Part Number04000702304/19 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

MODELSERIAL

NUMBER PLATE

MODELSERIAL

NUMBER PLATE

ES60/90

MODELSERIAL

NUMBER PLATE

MODELSERIAL

NUMBER PLATE

4 Part Number04000702304/19

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 Number04000702304/19 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.

6 Part Number04000702304/19

This page is blank.

Part Number04000702304/19 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 32F (0C).

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 Number04000702304/19

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

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Welbilt (China) Koolaire ES Undercounter User manual

Welbilt (China) Koolaire ES Undercounter User manual

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