ICE MAker Service manual Models RF15I 1
CONTENTS 1. Introduction 1.1 Unit Specifications 1.2 Serial Nameplate 1.3 Before Servicing 1.4 After Servicing 1.5 Basic Refrigeration Tools 1.6 Installation 1.7 Electrical Requirements 1.8 Water Requirements 1.9 Gravity Drain 1.10 Drain Pump 1.11 Operation in “ON” Position 1.12 Operation in “CLEAN” Position 2. Sealed System 2.1 Introduction 2.2 Low Side Leaks 2.3 High Side Leaks 2.4 Restricted Capillary Tube 2.5 Access Valves 2.6 Pressure and Temperature 2.
Introduction 1.1 Unit Specifications Table A: Ice Maker Unit Specifications Exterior Cabinet Dimensions (in) Height Width Depth 34-1/4 14-7/8 21-1/4 Shipping Weight (lbs) Electrical Requirements 100 120VAC/ 60 Hz Power Cord Length (ft) Compressor R-134a Refrigerant Charge (oz) Equalized Pressure System Refrigerant Control Temperature Control Condenser Fan Motor Controller UL 7 Piston type 5 72 psi at 77 degrees F Capillary tube Electronic Control with thermistor input 2.
Introduction 1.4 After Servicing After servicing the unit, whether at a site or service center, check the following: • • • MAKE CERTAIN THERE ARE NO LEAKS IN THE DRAIN OR WATER LINES. Check the water line, water valve, drain valve, and drain tubing for leaks. Make certain the Ice Maker functions properly by observing ice production and ice harvest cycles. Check for hollow ice slabs or ice slabs that will not release. Make certain the bin thermostat will turn the unit off.
Introduction • • • Properly grounded outlet is required for this unit. It is recommended or your building code may require that a single circuit GFCI receptacle or breaker be used for this unit only. DO NOT USE AN EXTENSION CORD. Outdoor models must use a GFCI receptacle. 1.8 Water Requirements • • • • • • Use supplied water line fitting for water connection to the rear of the unit. Use cold, potable water supply only with pressure between 20 to 120 psi. Use 1/4 inch OD soft copper tubing.
Introduction 1.10 Drain Pump DCS Drain Pump can be used to drain water when a gravity drain is not practical. Refer to drain pump instructions supplied with the drain pump for installation. As with the gravity drain, it may be necessary to wrap the drain tubing from the Ice Maker to the inlet of the drain pump with wrap-type insulation. CONDENSATION CAN FORM ON THE DRAIN TUBING AND CAUSE SURROUNDING WATER DAMAGE. 1.
Introduction harvest cycle in process will continue until the harvest cycle is complete. Once complete, all loads will de-energize and remain so until the bin thermistor senses a temperature at or above the “start production” setpoint. A new production cycle will then begin. During the first production cycle only (the switch was previously in the “OFF” or “CLEAN” position), the evaporator thermistor temperature will be ignored until the circulation pump has run for two minutes.
Sealed System 2.1 Introduction The following should always be practiced with any sealed system that has been opened. ONLY OPEN THE SEALED SYSTEM AS A LAST RESORT AND AS A FINAL DIAGNOSIS. Always check other areas of operation such as wiring, water supply, drain setup, proper air flow, etc. before opening up the sealed system. Many times these areas can resemble sealed system problems. The diagnosis of a sealed system can be determined by accurate pressure and temperature measurements. 1. 2. 3. 4. 5. 6.
Sealed System 2.5 Access Valves A temporary access valve can be used to service or evaluate the system. The access valve can be installed on the compressor’s process tube (this will also be a low pressure side). Be sure to cap off access valve while servicing. This will prevent contamination of the system and/or refrigerant from leaking. AFTER SERVICING, THE ACCESS VALVE SHOULD BE REMOVED.
Sealed System During production cycle, low side pressures will vary anywhere from 140 psi to 2 psi, depending at what point measurements are taken. High side pressures can range from 481 psi to 25 psi also depending at what point measurements are taken. In evaluating this system, the best point to determine if pressures are correct is at the end of the production cycle. This is the point where there is a thick slab formed on the evaporator and the evaporator thermostat is near cut-out temperature.
Sealed System Components 3.1 Hot Gas Valve The hot gas valve is used to bypass the capillary tube and send warm vapor to the evaporator when opened during the harvest cycle. The valve is actuated by a solenoid that opens the valve when energized and closes when de-energized. The valve seats using gravity so the valve must remain vertical to fully close. The valve can fail by either being stuck in the open or stuck in the closed position.
Sealed System Components Black with white stripe wire Back panel Black with red stripe wire Black (hot) wire Figure 3.4 Lower shroud Figure 3.3 Remove the six screws on the bottom of the unit to slide out the mechanical assembly. Remove these two screws for the electrical bracket to slide out the mechanical assembly. Figure 3.5 Figure 3.6 Installing the Hot Gas Valve: Figure 3.7 1. 2. 3. Bend hot gas valve tubing similar to the one being replaced.
Sealed System Components 3.2 Evaporator The evaporator uses evaporating refrigerant to remove heat from the water that flows over the evaporator plate to form an ice slab. The ice slab will simply slide down the evaporator plate onto the cutter-grid during harvest. The evaporator plate will over time have a build-up of mineral deposits. The evaporator will NOT need to be replaced due to the mineral deposits. However, these deposits must be removed periodically for proper Ice Maker performance.
Sealed System Components 26. Unbraze the hot gas discharge line at the compressor (see Figure 3.8). 27. Remove the compressor by removing the two lock-nuts on the mounting plate of the compressor. Lift the compressor off of the carriage bolts (see Figure 3.8). 28. Install the four rubber grommets in the bottom of the new compressor and install the two sleeves where the carriage bolts will be located. Mount the new compressor and install the two washers and lock-nuts and tighten to 4 in-lbs.
Sealed System Components 3.3 Compressor The compressor is the heart of the refrigeration system. However, it also relies on other parts of the system to function. Make certain that the other parts of the system are functioning correctly before determining that the compressor is faulty. IMPORTANT The compressor is protected from power interruption with a start delay built into the control to prevent high pressure startup (see Section 1.11, Operation - Selector Switch in the “ON” Position).
Sealed System Components Installation: 1. 2. 3. 4. 5. 6. 7. 8. 9. Install the four rubber grommets in the bottom of the new compressor and install the two sleeves where the carriage bolts will be located. Mount the new compressor and install the three washers and lock nuts and tighten to 45 in-lbs. DO NOT REMOVE THE RUBBER PLUGS AT THE TUBE STUBS ON THE COMPRESSOR AT THIS TIME. Install and braze new drier assembly to condenser. Then install and braze the capillary tube and the hot gas valve tube.
System Components 4.1 Drain Valve The drain valve drains water that is left in the reservoir after ice production. The valve will only be open for a fixed time of 45 seconds during the beginning of the harvest cycle. The drain valve fails by allowing water to flow into the drain during the ice production cycle (leak-by). This can be caused by a foreign particle(s) or build-up of mineral deposits that will not allow the valve to fully seat or has caused damage to the seat of the valve.
Sealed System Components 4.2 Water Valve The water valve supplies water to the reservoir for producing ice. The valve opens for one and a half minutes during initial start up or power up of the unit and opens for two minutes at each harvest cycle after the drain valve has closed. The valve has a built-in screen in the water supply fitting. This screen will filter out any large particles and, over time, these particles will accumulate and restrict water supply.
System Components 5.1 Condenser Fan The condenser fan is used to force air over the condenser coil. The fan will only run during ice production cycle and turn off in ice harvest cycle. To check the condenser fan: • • • • Make sure motor shaft turns freely. This can be done by rotating the fan blade by hand and observing any excessive resistance. Axial motor shaft movement (thrust) is typical. Check for resistance between terminals. If no resistance found, replace the condenser fan.
System Components The following will happen in the event of a thermistor failure: 1. 2. 3. If the evaporator thermistor fails, all loads will be shut off and the unit will not run. If the evaporator thermistor senses temperature outside of 0-140 degrees F, all loads will be shut off and the unit will not run. The control LED will blink three times every five seconds. The thermistor can be checked by use of a multimeter with the ability to read resistance. To check the thermistor: 1. 2. 3.
System Components Bin Thermistor: The bin thermistor is made up of a soft copper tube body and placed inside a plated copper sensing tube. This plated tube is then secured to the side of the Ice Maker ’s bin to detect the ice bin level. The bin thermistor gives voltage input to the electronic control. This input is processed through the electronic control to switch the Ice Maker into stop making ice or start making ice. THE THERMISTOR MUST BE FULLY INSERTED INTO THE PLATED SENSING TUBE FOR PROPER DETECTION.
System Components 5.3 Electronic Controller and Diagnostic LED The electronic control can be replaced without removal of the unit from the front of the unit. For electronic control functions, see Section 1.11, Operation - Selector Switch in the “ON” Position. Evaporator thermistor connector Power wire harness connector Bin thermistor connector Diagnostic LED Figure 5.1 Diagnostic LED: • • • • • No LED light: Operations are normal. LED on for 10 seconds then off: Start of the clean cycle.
System Components 5.4 Cutter-Grid Transformer The cutter-grid transformer is used to step down the voltage to the cutter-grid to 12VAC. The transformer is ON only from the start of a harvest cycle to 35 minutes from the start of the production cycle. The transformer remains off at all other times. The transformer itself can be checked by applying 120VAC to the marked 120V (for the hot lead) and COM (neutral lead) side of the transformer and reading the 12V side using a multimeter.
INTERIOR COMPONENTS 6.1 Cutter-Grid The cutter-grid is used to cut cubes from the ice slab formed on the evaporator. It uses low voltage, 12VAC from the transformer, to heat the wires. Wires are warm to the touch of a hand when not under the load of a slab of ice. The cutter-grid is on only from the start of a harvest cycle to 35 minutes from the start of the production cycle (see Section 1.1, Operation - Selector Switch in “ON” Position). There is no electrical repair for the cutter-grid.
INTERIOR COMPONENTS Removing the Reservoir: 1. 2. 3. 4. 5. 6. 7. Remove the escutcheon panel from the inside of the unit. Remove the cutter-grid (see Figure 6.1). Remove the four screws that secure the ice deflector. Remove the ice deflector. Drain the reservoir by removing the drain plug located on the bottom of the reservoir. Remove the two screws and spacers that secure the reservoir (see Figure 6.2).
INTERIOR COMPONENTS 6.3 Circulation Pump The circulation pump is used to circulate the water in the reservoir over the evaporator. The circulation pump will run only during ice production cycle and turn off in ice harvest cycle and also when called on for the clean cycle. The pump is a centrifugal impeller type pump. The pump and motor are an assembly that cannot be repaired separately. To check the circulation pump (with the pump removed): • • • • • Make sure motor shaft turns freely.
WIRING Figure 7.
Ordering Parts The following information will need to be given when inquiring about service parts: 1. 2. 3. 4. Model and serial number located on the serial nameplate (see Section 1.2, Serial Nameplate) Color of the model Metal or plastic grill Type of door To order parts, call or write: Fisher & Paykel Appliances, Inc. Attention: DCS Customer Care 5900 Skylab Road Huntington Beach, CA 92647 phone: 888.936.7872 www.dcsappliances.
Ice Maker Storage - Outdoor Models Storing the Ice Maker: If the Ice Maker is to be moved, not used for an extended period of time, or will be in an area that will be near freezing temperatures - below 37 degrees F, it is necessary to remove the remaining water in the icemaking system. CAUTION ALL WATER MUST BE DRAINED AND REMOVED TO PREVENT ICE MAKER DAMAGE AND POSSIBLE WATER DAMAGE TO THE SURROUNDING AREA IN FREEZING CONDITIONS. THESE DAMAGES ARE NOT COVERED UNDER WARRANTY.
RESTARTING THE ICE Maker 1. 2. 3. 4. 5. 6. With the rocker switch in the “OFF” position, plug the unit into an electrical outlet. Reconnect or turn on the water supply line. Reconnect the drain tubing if removed. Turn the rocker switch to the “ON” position. Check the water inlet, drain lines, and fittings for any water leaks. Check drain pump (if equipped) operation by pouring approximately two quarts of water into the ice storage bin.
Troubleshooting Guide PROBLEM Unit does not operate. POSSIBLE CAUSE CORRECTION 1. The unit is unplugged. Plug in the unit. 2. Breaker is tripped or fuse is blown. Reset breaker or replace fuse. Check to make sure there is not a short in the electrical circuit. 3. Ice Maker selector switch is in the “OFF” Set the rocker switch on the grill of the position. Ice Maker to the “ON” position. 4. The evaporator and/or bin thermistors are out of specification.
Troubleshooting Guide PROBLEM POSSIBLE CAUSE CORRECTION 10. Room and/or water temperature is too warm. Move the unit to an area where ambient temperature is below 90 degrees F. The unit should not be placed next to a heat source such as an oven. Check for cold water connection. 11. Leaking drain valve. See “Cleaning Your Ice Maker” section for cleaning the unit. This will also dissolve and flush out foreign material in the drain valve causing it to leak.
Troubleshooting Guide PROBLEM POSSIBLE CAUSE CORRECTION 7. Leaking drain valve See “Cleaning Your Ice Maker” section for cleaning the unit. This will also dissolve and flush out foreign material in the drain valve causing it to leak. 8. Room temperature is too cold. Move to an area where temperature is above 55 degrees F. 1. Ice slab not releasing. See “Cleaning Your Ice Maker” section for cleaning the unit for proper operation and cube size. 2. Condenser fan air flow is restricted.
Troubleshooting Guide PROBLEM POSSIBLE CAUSE CORRECTION 1. Low water level in reservoir. Make sure that the reservoir drain plug is installed properly. Check the water line to the unit to make sure there are no restrictions or kinks in the line. Check all filters to make sure they are not restricted or plugged. 2. Distributor tube is restricted. See “Cleaning Your Ice Maker” section for cleaning the unit for proper operation. 3. Build-up of deposits on evaporator plate.
Troubleshooting Guide PROBLEM Cutter-grid is not cutting the ice slab. POSSIBLE CAUSE 2. The grid-cutter is not plugged into the receptacle. Remove the escutcheon panel and plug cutter-grid into the receptacle on the side of the line. 3. Time to cut through the slab. It can take up to 35 minutes to cut through a harvested ice slab. This is normal operation. 1. Ice consumption is low. Use the ice in the bin frequently. Ice will stick together if left in an insulated bin over long periods of time. 2.
Troubleshooting Guide PROBLEM The drain pump cycles on and off erratically. POSSIBLE CAUSE CORRECTION 2. Discharge line is restricted or kinked. Check the discharge line and connection to the desired drain for any restrictions or kinks and repair as necessary. 3. The drain pump is not level. THE DRAIN PUMP MUST BE LEVEL. Check for level on the top of the drain pump case and adjust the tubing or use shims to level.
WARRANTY Limited Warranty When you purchase any new DCS Refrigeration Product, you automatically receive a One Year Limited Warranty covering parts and labor for servicing within the 48 mainland United States, Hawaii, Washington, D.C. and Canada. In Alaska the Limited Warranty is the same except that you must pay to ship the Product to the service shop or for the service technician’s travel to your home.
WARRANTY 7. Noise and vibration that is considered normal e.g. drain sounds, regeneration noises and user warning beeps. 8. Correcting damage caused by pests e.g. rats, cockroaches etc. 9. Used in commercial applications. B. Defects caused by factors other than: 1. Normal domestic use or 2. Use in accordance with the Product’s Use and Care Guide. C. Defects to the Product caused by accident, neglect, misuses, fire, flood or Act of God. D.
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Fisher & Paykel Appliances, Inc. 5900 Skylab Road, Huntington Beach, CA 92647 Customer Care: 888.936.7872 Fax: 714.372.7003 www.dcsappliances.com As product improvement is an ongoing process, we reserve the right to change specifications or design without notice. P/N 243198 Rev.
