SERVICE AND INSTALLATION MANUAL GEM Models: Remote GEM0650R, GEM0956R, GEM1256R Ice-O-Matic 11100 East 45th Ave Denver, Colorado 80239 Part Number 9081350-02 17-3144-01 Pearl Ice™ Series By Ice-O-Matic Date 10/08
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GEM0650/0956/1256 Remote 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 Pearl Ice™ 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.
GEM0650/0956/1256 Remote Table Of Contents Table of Contents Introduction .................................................................................................................................. Table Of Contents........................................................................................................................ Freight Claim Procedure.............................................................................................................. Warranty ........................
GEM0650/0956/1256Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote For The Installer GEM0650/0956R Page 2
GEM0650/0956/1256 Remote For The Installer GEM1256R Page 3
GEM0650/0956/1256 Remote For the Installer Bin Application The Pearl Ice™ Series are designed to fit the following Ice-O-Matic Bins ●B42, using Bin Top KBT 24 (Note: GEM0650 and GEM0956 ONLY) ●B25, B40 B55 using Bin Top KBT 19. ●B100 using Bin Top KBT 23 (one unit) or KBT 22 (two units). ●B120, B150, B170 Not designed for Pearl Ice™ Series. Dispenser Application The Pearl Ice™ Series can be placed on and used with certain ice and beverage dispensers. Kits are required for proper operation.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote Remote Condenser ERC Dimensions (Inches) GRC1001 GRC1061 GCR2061 A B C D E F G H Pearl Ice™ Number 33.36 10.75 23.81 2.04 6.12 16.73 11.65 19.57 GEM0650R 33.36 10.75 23.81 2.04 6.12 16.73 11.65 19.57 GEM0956R 33.36 10.75 23.81 2.04 6.12 16.73 11.65 19.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote For the Installer Typical Installation REMOTE CONDENSER ICE MACHINE Page 9
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote For the Plumber Water Inlet: The recommended water supply is cold water. Use 3/8 inch O.D. copper tubing, connect to the 3/8 inch male flare on the back of the cabinet. Install a hand valve near the machine to control the water supply. Drains: Ice Machine: 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote For the Installer Final Check List ___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.
GEM0650/0956/1256 Remote Start Up Pre-Start Inspection: 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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”.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote Operation: Water Water Water enters the machine through the 3/8 inch 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 or evaporator condensation is routed to the drain. Water Level The correct water level should be checked when the machine is making ice.
GEM0650/0956/1256 Remote Operation: Refrigeration 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.
GEM0650/0956/1256 Remote Operation: Refrigeration 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.
GEM0650/0956/1256 Remote Operation: Refrigeration 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.
GEM0650/0956/1256 Remote Operation: Performance Typical Low Side Pressure: Remote: 34-38 PSIG Typical Discharge Pressure: Remote: 220-275 PSIG Typical Compressor Amp Draw: GEM0650 115/60/1 GEM0956 208-230/60/1 GEM1256 208-230/60/1 8-9 Amps 4-5 Amps 5-6 Amps Typical Auger Drive Motor Amp Draw: GEM0650 115/60/1 GEM0956 208-230/60/1 GEM1256 208-230/60/1 3.1 to 3.5 Amps 1.6 to 1.8 Amps 1.6 to 1.
GEM0650/0956/1256 Remote Sanitizing and Cleaning It is the USER’S RESPONSIBILITY to keep the ice machine and ice storage bin in a sanitary condition. Without human intervention, sanitation will not be maintained. Ice machines also require occasional cleaning of their water systems with a specifically designed chemical. That chemical dissolves mineral build up that forms during the ice making process.
GEM0650/0956/1256 Remote Condenser Maintenance ● 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/0956/1256 Remote 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.
GEM0650/09561256 Remote 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.
GEM0650/0956/1256 Remote R&R-Fan Blade and Motor To Remove the 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.
GEM0650/0956/1256 Remote Refrigeration System Service Refrigeration Service: 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.
GEM0650/0956/1256 Remote GEM0650R Wiring Diagram Wiring Diagram GEM0650R Page 41
GEM0650/0956/1256 Remote GEM0956R Wiring Diagram Wiring Diagram GEM0956R Page 42
GEM0650/0956/1256 Remote GEM1256R Wiring Diagram Wiring Diagram GEM1256R Page 43
GEM0650/0956/1256 Remote 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.
