Installation and Service Manual GEM-MFI Series Ice-O-Matic 11100 East 45th Ave Denver, Colorado 80239 Part Number 9081350-04 9081350 04 Date 2/10
8
GEM-MFI SERIES Introduction How To Use This Manual Ice-O-Matic provides this manual as an aid to the end user and service technician in installation and maintenance of the GEM-MFI Series ice machines. Do not attempt to perform installation, start-up or maintenance unless you have read and fully understand this manual. If, at any time, you encounter conditions that are not addressed in this manual, call, E-mail or write the Ice-O-Matic Service Department: Ice-O-Matic 11100 E. 45th Ave. Denver, Co.
GEM-MFI SERIES Table Of Contents Table of Contents Introduction .................................................................................................................................. Table Of Contents........................................................................................................................ Freight Claim Procedure .............................................................................................................. Warranty .................................
GEM-MFI SERIES Freight Claim Procedure Important! Inspect Promptly This merchandise has been carefully inspected and packed in accordance with the carrier’s packing specifications. Responsibility for safe delivery has been assumed by the carrier. If loss or damage occurs, you as the consignee must file a claim with the carrier and hold the container for carrier’s inspection.
GEM-MFI SERIES Warranty Ice-O-Matic Parts and Labor Domestic & 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: Cube ice machines,”GEM” model compressed ice machines ,” MFI” model flake ice machines and remote condensers.
GEM-MFI SERIES For the Installer Installation Guidelines: For proper operation of the Ice-O-Matic ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties.
GEM-MFI SERIES For The Installer Air and Water Cooled Page 2
GEM-MFI SERIES For The Installer Remote Page 3
GEM-MFI SERIES For the Installer Bin Application The GEM Series are designed to fit the following Ice-O-Matic Bins ●B42, using Bin Top KBT 24 (Note: 21 inch wide cabinet ONLY) ●B25, B40 B55 using Bin Top KBT 19. ●B100-B120 using Bin Top KBT 23 (one unit) or KBT 22 (two units). ● B150, B170 Not designed for GEM-MFI Series. Dispenser Application The GEM Series can be placed on and used with certain ice and beverage dispensers. Kits are required for proper operation.
GEM-MFI SERIES For the Installer Location: Ice-O-Matic ice machines are designed to be installed indoors in a controlled environment. Install the ice machine in a location where it has enough space around it to be accessible for service. A minimum of 6 inches must be allowed at the back for air circulation on air cooled models. Try to avoid hot, dirty and crowded locations. Be sure that the location of the machine is within the environmental limitations. Storage Bin: Remove the bin packaging.
GEM-MFI SERIES For the Installer Allow 6 “Clearance for Air Circulation Allow 6 “Clearance for Air Circulation A proper installation locates the ice machine indoors, but in a place where the heat and noise it produces are not objectionable. Two Units on One Bin Air cooled machines discharge hot air out the back and must have a minimum of 6 inches of clearance behind the ice machine. Space for maintenance access is also important.
GEM-MFI SERIES ERC Dimensions (Inches) A B C D E F G H GEM-MFI Model Number Line Sets RT325404 RT340404 RT345404 RT360404 Remote Condenser GRC1001 33.36 10.75 23.81 2.04 6.12 16.73 11.65 19.57 GEM0650R 25 Foot Precharged Line Set 40 Foot Precharged Line Set 45 Foot Precharged Line Set 60 Foot Precharged Line Set Page 7 GRC1061 33.36 10.75 23.81 2.04 6.12 16.73 11.65 19.
GEM-MFI SERIES Remote Condenser Location Use the following for planning the placement of the remote condenser relative to the ice machine. Location Limits: Remote condenser location must not exceed ANY of the following: ● Maximum rise from the ice machine to the remote condenser is 35 physical feet. ● Maximum drop from the ice machine to the remote condenser is 15 physical feet. ● Physical line set maximum length is 100 feet. ● Calculated line set length maximum is 150 feet.
GEM-MFI SERIES For the Installer Remote Condenser Location: Limited to a 25 foot or a 40 foot length of precharged refrigerant tubing connecting the ice machine to the remote condenser. The remote condenser must be above or level with the ice machine. Select the best available location, protecting the remote condenser from extremes of dirt, dust and sun. Meet all applicable building codes. Usually the services of a licensed electrician are required. Roof Attachment: 1.
GEM-MFI SERIES For the Installer Typical Installation REMOTE CONDENSER ICE MACHINE Page 10
GEM-MFI SERIES For the Installer Coupling Instructions: Initial Connections: 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to be certain that no foreign matter remains on them. 2. Lubricate the inside of the couplings, especially the O-Rings with refrigerant oil. 3. Position the fittings on the correct connections on the remote condenser and ice machine.
GEM-MFI SERIES For the Plumber Water Inlet: ●Air Cooled Models: The recommended water supply is clean, cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 FPT at the back of the cabinet. Install a hand valve near the machine to control the water supply. ●Water Cooled Models: A separate 3/8 inch O.D. copper line is recommended, with a separate hand valve to control it. Connect to the 3/8 inch FPT condenser inlet at the back of the cabinet.
GEM-MFI SERIES For the Plumber Water Inlet: ●Remote Cooled Models: The recommended water supply is cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 inch FPT on the back of the cabinet. Install a hand valve near the machine to control the water supply. Drains: ●Remote Cooled Models: There is one 3/4 inch FPT drain at the back of the cabinet; the drain line is of the gravity type, and 1/4 inch per foot fall is an acceptable pitch for the drain tubing.
GEM-MFI SERIES For the Electrician Electrical Connections: Check the ice machine nameplate (located on the back panel) for the voltage requirements, and minimum circuit ampacity. The ice machine requires a solid chassis to earth ground. Connect the ice machine to its own electrical circuit so it is individually fused. Voltage variation must remain within the limitations, even under starting conditions. Note: All external wiring must conform to national, state and local electrical codes.
GEM-MFI SERIES For the Electrician INSTALLATION MUST CONFORM TO ALL APPLICABLE CODES. Connect the electrical power to 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 requirements, and for the minimum circuit ampacity. The machine requires a solid chassis to earth ground wire. Connect the ice machine to its own electrical circuit so it is individually fused.
GEM-MFI SERIES For the Installer Completed Installation A typical installation should generally appear as illustrated below. The best place for the remote condenser is above the ice machine, although other locations are permissible.
GEM-MFI SERIES For the Installer Final Check List: Air and Water Cooled _______1. Is the ice machine installed indoors in a location where the air and water temperatures are controlled and where they do not exceed the design limitations? _____2. Is there an electrical service disconnect within sight of the installed machine? _____3. Has the voltage been checked and compared to the nameplate requirements? _____4. Have all the plumbing connections been made and checked for leaks? _____5.
GEM-MFI SERIES For the Installer Final Check List: Remote ___1. Is the ice system installed indoors in a location where air and water temperatures are controlled, and where they do not exceed the design limitations? Condenser Leveled? ___2. Is there an electrical service within sight of the installed machine? Has the voltage been checked, and compared to nameplate requirements? Roof Holes Sealed? ___3. Have all the plumbing connections been made and checked for leaks? ___4.
GEM-MFI SERIES Start Up Pre-Start Inspection: Air and Water Cooled 1. Remove the front and side service panels. 2. Check that any shipping blocks have been removed. 3. Inspect the interior of the ice machine for loose screws or wires. 4. Check that no refrigerant lines are rubbing each other. 5. Check that the fan blades turn freely (Air Cooled). 6. Check that the unit is installed correctly according to the final check list. Start Up: 1. Go through the pre-start inspection. 2.
GEM-MFI SERIES Start Up Pre-Start Inspection: Remote 1. Remove the front and side service panels. 2. Check that any shipping blocks have been removed. 3. Inspect the interior of the ice machine for loose screws or wires. 4. Check that no refrigerant lines are rubbing each other. 5. Check that the fan blades turn freely (Remote Condenser). 6. Check that the refrigerant lines are properly installed. 7. Check that the electrical power has been on for at least 4 hours and that the compressor dome is warm. 8.
GEM-MFI SERIES Component Description ●Control Box: Contains the electrical controls that operate the machine. ●High Pressure Cut Out Switch: An auto-reset switch sensing the high side refrigeration pressure. It will shut the machine off if the discharge pressure exceeds 450 psig. ●Pump Down Control: A switch to control the compressor, depending upon low side pressure: closes at 30 PSIG and opens at 15 PSIG. ●Evaporator: A vertical stainless steel tube, refrigerated and water filled.
GEM-MFI SERIES Component Description ●Contactor: A definite purpose contactor connecting the compressor and the fan motor to the power supply. ●Circuit Board: Controls the operation of the ice machine using input from the sensors and pressure controls. Switches loads on and off thru relays. (Reference Photo Below) ●Potential Relay: The compressor start relay. ●Mode (ON/OFF) Switch: Manual control for the machine.
GEM-MFI SERIES Component Description ●Evaporator: A refrigerated vertical tube filled with water and containing a water seal and auger. ●Auger: A solid stainless steel double spiral auger, it pushes the ice crystals up to the top of the evaporator. ●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 “faces” meet. ●Ice Sweep: A plastic cap with “fingers”.
GEM-MFI SERIES Electrical Sequence Electrical Sequence: There are 7 indicator lights on the control board: ●WTR-OK: (Water OK) Green. Normal=Glowing. Glow when there is water in the reservoir. ●PWR-OK: (Power OK) Green. Normal=Glowing. Glows when the power board has power and is functional. ●Service: Red. Normally Off. ●Freeze: Red. Normally glowing when making ice. ●Bin Full: Red. Normally Off when making ice. ●LED1: White. Located next to the Control Board’s Compressor Relay.
GEM-MFI SERIES Operation: Water Water Water enters the machine through the 3/8 FPT 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 or evaporator condensation is routed to the drain. Water Level The correct water level should be checked when the machine is making ice.
GEM-MFI SERIES Operation: Refrigeration-Remote Beginning at the compressor, the refrigerant is compressed into a high temperature gas. The discharge line directs this gas to the condenser and to the head pressure control. At the remote condenser the gas is cooled by air and it then condenses into a liquid. This high pressure liquid then goes through the liquid line connection at the head pressure control.
GEM-MFI SERIES Operation: Refrigeration-Remote Low Condensing Temperature The refrigeration system under low condenser air temperatures is much the same as it is under higher temperatures, with the exception that the resulting low head pressures cause the head pressure control to close off the liquid line between the condenser and the receiver.
GEM-MFI SERIES Operation: Refrigeration-Remote Pump Down During the pump down cycle (usually initiated by the circuit board de-energizing the liquid line valve) the discharge gases flow through their normal path to the remote condenser, through the head pressure control and into the receiver. At this point the refrigerant flow is stopped by the closed liquid line valve. This action forces the refrigerant into the receiver and keeps it out of the compressor.
GEM-MFI SERIES Operation: Performance-A&W Beginning at the compressor, the refrigerant is compressed into a high temperature gas. The discharge line directs this gas to the condenser. At the condenser (air or water cooled) the gas is cooled by either air or water and then it condenses into a liquid. This high pressure liquid then goes through the liquid line to the expansion valve.
GEM-MFI SERIES Operation: Performance-Remote Typical Low Side Pressure: Remote: 28-35 PSIG Typical Discharge Pressure: Remote: 220-275 PSIG Typical Compressor Amp Draw: GEM0650 115/60/1 GEM0956/MFI 1256 208-230/60/1 11.9 Amps 7.0 Amps Typical Auger Drive Motor Amp Draw: GEM0650 115/60/1 GEM0956/MFI1256 208-230/60/1 4.6 Amps 2.
GEM-MFI SERIES Sanitizing and Cleaning 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 replacing 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. Maintenance and Cleaning should be scheduled at a minimum of twice a year.
GEM-MFI SERIES Condenser Maintenance: Remote ● Clean the condenser: the condenser may appear to be clean on the surface, but it can still be clogged internally. Check with a flashlight from the front to see if light can be seen through the condenser fins. Brush in direction of fins The condenser coil must be kept clean. The condenser can be cleaned with compressed air or by using a brush. If a brush is used, brush in the direction of the fins taking care not to bend or distort the fins.
GEM-MFI SERIES Maintenance: Air Cooled Clean the air cooled condenser: Air flow on this model is from front to back, so the inside of the ice machine will have to be available to clean the air cooled condenser. Use a vacuum cleaner or coil cleaner if needed. DO NOT use a wire brush. ● Disconnect electrical power, and remove the air filter if applicable. The filter may be cleaned or replaced. ● Clean the condenser: the condenser may appear to be clean on the surface, but it can still be clogged internally.
GEM-MFI SERIES Bearing Maintenance Bearing Maintenance: The bearing in the breaker should also be checked at least two (2) times per year. Switch the machine OFF and check the bearing. 1. Remove the chute cover. 2. Unscrew the ice sweep 3. Removing the water shed and unscrewing the breaker cover. Note: Left Hand Threads 5. 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.
GEM-MFI SERIES Sensor Maintenance Bin Control Sensor: The bin control uses devices that sense light, therefore they must be kept clean enough so that they can “see”. At least twice a year, remove the bin control sensors from the base of the chute, and wipe the inside clean, as illustrated. Ice Discharge Chute Slide In and Out Ice Level Sensors Water Sensor: The ice machine uses a probe in the water reservoir to determine if there is water.
GEM-MFI SERIES Auger Maintenance Auger: In some areas, the water supply to the ice machine will contain a high concentration of minerals, and that will result in an evaporator and auger becoming coated with these minerals, requiring a more frequent 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.
GEM-MFI SERIES Service Diagnosis Symptom Possible Cause Probable Correction No ice is made nothing operates. •Unit off due to no power •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 strainer, float valve. Correct water supply. •Unit off due to ice level sensors. (Photo Eyes ) blocked. •Check/clean ice level sensors. •Unit off due to scale on water level sensor. •Clean water level sensor.
GEM-MFI SERIES Service Diagnosis Symptom Possible Cause Probable Correction Unit makes ice, but very slowly •High discharge pressure because of a dirty condenser. •Clean filter and condenser. •Low capacity because the auger and evaporator are coated with mineral scale. •Clean the water system. •Low suction pressure due to low refrigerant charge. •Locate leak. Recover the refrigerant, repair leak, replace drier, evacuate and weigh in the nameplate charge. •Drain plugged up. •Clean out drain.
GEM-MFI SERIES Control System Diagnostics The Control System consists of: ●Control Board ●Water Sensors ●Ice Sensors ●High Pressure Cut Out ●Low Pressure Cut Out If the unit is OFF, check the control board: 1. Is the Power OK light on? If not check power to the unit. If it has power, and the Power OK light is not on, check the high pressure and low pressure cut outs. If they are both closed, replace the board. If the POWER OK light is ON, go to the next step. 2.
GEM-MFI SERIES R&R- Water Reservoir, Bin Control Water Reservoir: 1. Disconnect electrical power supply. 2. Shut off water supply to the ice maker. 3. Remove the front panel. 4. Disconnect water inlet tube from reservoir inlet fitting. 5. To remove float valve, push in “locking tabs” as shown and pull float up. Note: The plunger/seat is available separately as a part. 6. To remove reservoir, pull up and remove water sensor. 7. Disconnect water outlet tubes. 8.
GEM-MFI SERIES R&R-Bearing and Breaker Note: Removal of the auger, water seal, evaporator and gear motor must begin at the top of the assembly. To Remove the Breaker Bearing Assembly: 1. Disconnect electrical power. 2. Remove panels. 3. Push back bail clamp and remove ice chute cover. 4. Unscrew and remove ice sweep. 5. Lift up and remove ice chute. 6. The breaker may be removed from the auger and evaporator without disturbing the auger. a. Unscrew breaker cover from breaker (Note: Left Hand Threads) b.
GEM-MFI SERIES R&R-Auger To Remove the Auger: 1. Disconnect electrical power. 2. Turn off the water to the machine. 3. Unclip the evaporator drain hose, pull it down and drain the evaporator into the bin or container. 4. Remove the top panel. 5. Swing bail clip down and remove the ice chute cover. 6. Unscrew ice sweep. 7. Remove ice chute body. 8. The auger and breaker/bearing may now be removed as an assembly. a. Unscrew four (4) Allen head cap screws holding breaker to evaporator. b.
GEM-MFI SERIES R&R-Water Seal To Remove the Water Seal: (Assuming all steps to remove the auger have been performed) 1. The gear motor/evaporator assembly will have to be exposed. 2. Remove the four (4) hex head cap screws holding the evaporator to the gear motor assembly. Lift the evaporator up and off the gear motor. 3. Remove the snap ring or wire retainer from the groove under the water seal. 4. Pull or drive out the lower half of the water seal.
GEM-MFI SERIES R&R-Evaporator To Replace the Evaporator: (Assuming all steps for removal of the thrust bearing, breaker, auger and water seal have been performed). 1. Recover the refrigerant from the ice machine. 2. Unsweat the refrigerant connections: a. At the thermostatic expansion valve outlet. b. At the suction line at the joint about three (3) inches from the evaporator. 3. Remove the evaporator. 4. Unsweat the drier from the liquid line. 5.
GEM-MFI SERIES R&R-Gear Motor To Check the Gear Motor: 1. Remove wires from terminals 1 and 2 2. Use an ohmeter to check for continuity. If there is none, replace only the motor. If there is continuity but the motor will not start, check the motor’s start switch. 3. Remove motor end bell or motor stator. With ohnmeter wires attached to 1 and 2 move centrifugal switch actuator up and down to simulate motor rotation. If the ohnmeter does not show any change, replace the switch or motor.
GEM-MFI SERIES R&R-Fan Blade and Motor To Remove the Condenser Fan Motor Assembly: (GEM0956 Air Shown) 1. Disconnect electrical power to the ice machine 2. Remove top panel and the service panels. 3. Unplug the fan motor wire leadsfrom the fan motors. 4. Remove the two (2)head bolt from the top end of the fan motor assembly. (Fig 1) 5. Lift up the fan motors and bracket assembly about ½ inch and pull out the fan assembly out the right service access hole. (Fig 2) 6. Repair as needed. 7.
GEM-MFI SERIES R&R-Fan Blade and Motor To Remove the Remote Condenser Fan Motor Assembly: 1. Disconnect electrical power to the ice machine and/or remote condenser. 2. Remove fan guard. 3. Remove the fan blade. 4. Disconnect the electrical power lead to the fan motor. 5. Remove the four (4) bolts from the fan motor assembly. 6. Remove the fan motor assembly. 7. To Reassemble: Place the fan motor assembly on the condenser bracket and install the bolts.
GEM-MFI SERIES Refrigeration System Service Refrigeration Service: Air and Water Cooled General: This ice machine uses R404A refrigerant and polyolester oil. Do NOT use mineral oil in this refrigeration system. ●When the refrigeration system is serviced, a special liquid line drier is required. It is included with replacement compressor. ●R404A is not compatible with mineral oil so these ice machines use Polyolester oil. Polyolester oil absorbs water very easily.
GEM-MFI SERIES Refrigeration System Service Refrigeration Service: Remote General: This ice machine uses R404A refrigerant and polyolester oil. Do NOT use mineral oil in this refrigeration system. ●When the refrigeration system is serviced, a special liquid line drier is required. It is included with replacement compressors. ●R404A is not compatible with mineral oil so these ice machines use Polyolester oil. Polyolester oil absorbs water very easily.
GEM-MFI SERIES Wiring Diagram Wiring Diagram GEM0450A/W, MFI0500A/W Page 50
GEM-MFI SERIES Wiring Diagram Ladder Diagram GEM0450A/W, MFI0500A/W Page 51
GEM-MFI SERIES Wiring Diagram Wiring Diagram GEM0650A/W, MFI0800A/W Page 52
GEM-MFI SERIES Wiring Diagram Ladder Diagram GEM0650A/W, MFI0800A/W Page 53
GEM-MFI SERIES Wiring Diagram Wiring Diagram GEM0655A/W, MFI0805A/W GEM0955A/W, MFI1255A/W Page 54
GEM-MFI SERIES Wiring Diagram Ladder Diagram GEM0655A/W, MFI0805A/W GEM0955A/W, MFI1255A/W Page 55
GEM-MFI SERIES Wiring Diagram Wiring Diagram GEM0650R, MFI0800R Page 56
GEM-MFI SERIES Wiring Diagram Ladder Diagram GEM0650R, MFI0800R Page 57
GEM-MFI SERIES Wiring Diagram Wiring Diagram GEM0956A/W, MFI1256A/W Page 58
GEM-MFI SERIES Wiring Diagram Ladder Diagram GEM0956A/W, MFI1256A/W Page 59
GEM-MFI SERIES Wiring Diagram Wiring Diagram GEM0956R, MFI1256R Page 60
GEM-MFI SERIES Wiring Diagram Ladder Diagram GEM0956R, MFI1256R Page 61
GEM-MFI SERIES Service History What to Do Before Calling for Service: ●Check the water supply to the ice machine. The ice machine is designed to shut off if there is no water to it. Check the water filters if there are any. ●Check the power supply to the ice machine. Reset the breaker if it is tripped. ●If both water and power have been checked and are available, try switching the power OFF and then ON. After 2 minutes the machine should restart.
