Introduction This technical manual covers the Prodigy line, excluding the Eclipse remote low side models. All models except Eclipse are shipped with an Installation and User's manual, which can be referred to separately. General installation information is included in this manual. Table of Contents Model Number Description . . . . . . . . . page 2 Diagnostics - Water Cooled . . . . . . . . page 47 Water . . . . . . . . . . . . . . . . . . . . page 3 Low ice Making Capacity - Water Cooled .
Model Number Description Example: • • • • • • • C0530SA-1A C= cuber 05= nominal ice capacity in 100s of pounds 30= nominal width of cabinet. Other sizes are 22 and 48. S= Cube size. S=small or half dice cube. M=medium or full dice cube A=Condenser type. A=air cooled. W=water cooled. R = Remote -1=Electrical code. -1=115 volts. -32=208-230 single phase. -3=208-230 three phase. -6=230 50 Hz • A=Series revision code.
Water The quality of the water supplied to the ice machine will have an impact on the time between cleanings and ultimately on the life of the product. There are two ways water can contain impurities: in suspension or in solution. Suspended solids can be filtered out. In solution or dissolved solids cannot be filtered, they must be diluted or treated. Water filters are recommended to remove suspended solids. Some filters have treatment in them for suspended solids.
General Installation - Air or Water Cooled Location Limitations: The product is designed to be installed indoors, in a controlled environment. Air cooled models discharge very warm air into the room out the back. Space must be allowed at the left side and back for air intake and discharge. Water cooled models discharge warm water into the building’s drain. Space needs to be provided on both sides and above for service access.
General Installation - Air or Water Cooled Plumbing Requirements All models require connection to cold, potable water. A hand actuated valve within site of the machine is required. Air cooled models have a single 3/8” FPT inlet water connection; a 3/8” FPT to 3/8” male flare adapter is supplied with the machine and can be used if desired. Water cooled models have the same inlet fitting plus an additional 3/8” FPT condenser inlet water connection.
General Installation - Air or Water Cooled Electrical See the spec sheet or User's Manual for Minimum Circuit Ampacity or Maximum Fuse Size ratings. The machine is not supplied with a power cord, one must either be field installed or the machine hard-wired. The dataplate on the back of the cabinet details the power requirements, including voltage, phase, minimum circuit ampacity and maximum fuse size. HACR type circuit breakers may be used in place of fuses. Extension cords are not permitted.
General Installation - Air or Water Cooled Note: Indentations may be deeper on C0322 and C0330 Adjustments 1/8" indentation Ice Bridge Thickness Caution: Do not make the bridge too thin or the machine will not harvest properly. Bridge thickness adjustments are not covered by warranty. 1/8-3/16" bridge Shut machine off. Access the ice thickness sensor. Too Big Check gap between metal tip and evaporator grid. Small cube standard gap is 3/16 inch, medium cube standard gap is 7/32 inch.
Water purge setting The water purge is factory set to the Automatic setting. The setting can be changed to one of 5 manual settings or placed on automatic. The purge setting shows in the Code Display.
General Installation - Remote Location Limitations This ice system is made up of three parts, the ice making machine, or head; the remote condenser; and the interconnecting tubing. The ice making machine must be installed indoors, in a controlled environment. Space must be provided near the machine for service access. The remote condenser may be installed above or below the ice machine, per the limits stated later in this manual.
General Installation - Remote Product Description and Electrical Requirements - See spec sheet or User's Manual for Minimum Circuit Ampacity or Maximum Fuse SIze Dimensions w” x d” x h” Model Electrical Use condenser 22 x 24 x 23 C0522SR-1 115/60/1 ERC111-1 same same same ERC211-1** 30 x 24 x 23 C0530SR-1 115/60/1 ERC111-1 same same same ERC211-1** same C0630SR-32 208-230/60/1 ERC311-32 30 x 24 x 29 C0830SR-32 208-230/60/1 ERC311-32 same C0830SR-3 208-230/60/3 ERC311-32 same
General Installation - Remote Central Condenser Coils The ice machine may be connected to a central condenser coil. The requirements are: • Coil – not previously used with mineral oil system. Virgin coil preferred. • Correct size (internal volume) and capacity (BTUH). • Includes a headmaster valve for discharge pressure control. Headmaster kit available for certain MAC condensers, kit number is RCKCME6GX. • Fan motor on all the time or controlled to be on whenever the ice machine is operating.
General Installation - Remote Water The quality of the water supplied to the ice machine will have an impact on the time between cleanings and ultimately on the life of the product. There are two ways water can contain impurities: in suspension or in solution. Suspended solids can be filtered out. In solution or dissolved solids cannot be filtered, they must be diluted or treated. Water filters are recommended to remove suspended solids. Some filters have treatment in them for suspended solids.
General Installation - Remote Remote Condenser Location Use the following for planning the placement of the condenser relative to the ice machine - see illustration on the following page. Location Limits - condenser location must not exceed ANY of the following limits: • • • • Maximum rise from the ice machine to the condenser is 35 physical feet Maximum drop from the ice machine to the condenser is 15 physical feet Physical line set maximum length is 100 feet. Calculated line set length maximum is 150.
General Installation - Remote For The Installer: Remote Condenser Locate the condenser as near as possible to the interior location of the ice machine. Note: The location of the condenser is relative to the ice machine is LIMITED by the specification on the prior page. Meet all applicable building codes.
General Installation - Remote Precharged Line Routing Do not connect the precharged tubing until all routing and forming of the tubing is complete. See the Coupling Instructions for final connections. 1. Each set of pre-charged tubing lines contains a 3/8” diameter liquid line, and a 1/2” diameter discharge line. Both ends of each line have quick connect couplings, the end without access valves goes to the ice maker.
General Installation - Remote Coupling Instructions The couplings on the ends of the pre-charged line sets are self-sealing when installed properly. Follow these instructions carefully. These steps must be performed by an EPA Certified Type II or higher technician. Initial Connections 1. Remove the protector caps and plugs. Wipe the seats and threaded surfaces with a clean cloth to remove any possible foreign matter. 2. Lubricate the inside of the couplings, especially the O-rings, with refrigerant oil. 3.
Pre-Charged Tubing Coupling Connections Inspect couplings, wipe clean and lubricate both parts with polyolester refrigerant oil. Hand tighten to be sure threads are properly engaged. Use two wrenches and continue tightening the couplings. As the diaphragms being to pierce, the couplings will be harder to turn. Be sure only the swivel nut is rotated. Continue tightening until the swivel nut feels like it is tight, then go to the next step. No threads will be seen when the couplings are tight.
General Installation - Remote Plumbing Requirements All models require connection to cold, potable water. A hand actuated valve within site of the machine is required. There is a single 3/8” FPT inlet water connection, a 3/8” FPT to 3/8” male flare adapter is supplied with the machine and can be used if desired. Water Filters Install a new cartridge if the filters were used with a prior machine. All models require drain tubing to be attached to them.
General Installation - Remote Electrical The machine is not supplied with a power cord, one must either be field installed or the machine hard-wired. The dataplate on the back of the cabinet details the power requirements, including voltage, phase, minimum circuit ampacity and maximum fuse size. HACR type circuit breakers may be used in place of fuses. Extension cords are not permitted. Use of a licensed electrician is recommended.
Adjustments Bridge Thickness - For the Service Tech Only Push and hold Off till the machine stops. Adjustment Screw Access ice thickness sensor. Check gap between metal tip and evaporator grid. Small cube standard gap is 3/16 inch, medium cube standard gap is 7/32 inch. To set, place a 3/16" (small cube) or 7/32" (medium cube) drill bit between sensor tip and evaporator to check. Adjust gap using adjustment screw. Gap Restart unit and check ice bridge.
Prodigy Cuber System Information Overall System Type: • Refrigeration: Mechanical, either air cooled, water cooled or remote cooled. • Water System: Inlet water solenoid valve fills reservoir once per cycle. Purge solenoid valve opens to discharge some reservoir water once per cycle.
Controller Information Machine Indicator Lights • • • • Power Status Water Clean Code Display Main codes - automatically displayed F F H H b C L d O E 1 1 2 2 3 4 5 7 8 8 . . . . . flashes . . . . . flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . flashes . . . . . flashes . . . . . . . . . . . . . . . . . . . . . . . . . flashes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Controller Information Component Indicator Lights • • • • • • • • • • • Condenser Fan / Aux (Aux = liquid line solenoid when a remote condenser model) Water Pump Purge Valve Water Solenoid Hot Gas Compressor Ready to Harvest Sump Empty Sump Full Curtain SW1 Curtain SW2 Component Indicator Lights September 2006 Page 23
How It Works - Air Cooled Freeze Cycle. At start up the controller drains and refills the reservoir. The reservoir refills when the mid length water level sensor probe is uncovered and continues to fill until the top probe is in contact with water. When the reservoir has filled, the compressor and water pump start. After the discharge pressure has increased past the cut in point of the fan pressure control, the fan motor(s) will begin to operate and warm air will be discharged out the back of the cabinet.
How It Works - Water Cooled Freeze Cycle. At start up the controller drains and refills the reservoir. The reservoir refills when the mid length water level sensor probe is uncovered and continues to fill until the top probe is in contact with water. When the reservoir has filled, the compressor and water pump start. After the discharge pressure has increased past the set point of the water regulating valve, the water regulating valve will open and warm water will be discharged out the condenser drain.
How It Works - Remote Freeze Cycle. At start up the controller drains and refills the reservoir. The reservoir refills when the mid length water level sensor probe is uncovered and continues to fill until the top probe is in contact with water. When the reservoir has filled, the liquid line valve, compressor and water pump are switched on.
Electrical Sequence - Air or Water Cooled Power connected, unit previously switched Off. Control board does a self check. If the self check fails, the unit displays an E and no further action will occur. If the self check passes, the controller will display a 0, the curtain light(s) will be ON and the Power and Sump Empty lights will be ON. Pushing and releasing the On button will start the ice making process. The display will begin to blink F.
Electrical Sequence - Air or Water Cooled Indicator Information: The display shows a non-blinking H. The Power and Status Lights will be Green. The compressor, hot gas valve and one or two curtain switch lights will be ON. After a few seconds the water pump, purge valve and inlet water valve lights will come on. The fan motor(s) shut off and remain off throughout the harvest cycle. The harvest assist solenoid is connected in parallel with the hot gas valve.
Electrical Sequence - Remote Cooled Power connected, unit previously switched Off. Control board does a self check. If the self check fails, the unit displays an E and no further action will occur. If the self check passes, the controller will display a 0, the curtain light(s) will be ON and the Power and Sump Empty lights will be ON. Pushing and releasing the On button will start the ice making process. The display will begin to blink F.
Electrical Sequence - Remote Cooled The harvest assist solenoid is connected in parallel with the hot gas valve. Although it is energized throughout the harvest cycle, its piston does not move until the ice has become partially loosened from the evaporator plate by the action of the hot refrigerant gas passing through the evaporator serpentine. The remote condenser fan motor is powered by the compressor contactor, so it will be operating during the harvest cycle.
Remote Schematics Remote Condenser Head Pressure Control Valve Discharge Line Receiver Hot Gas Valve TXV Liquid Line Valve Heat Exchange Suction Evaporator Compressor C0522R, C0530R, C0630R and C1030R Remote Condenser Hot Gas Valve Head Pressure Control Valve TXV Discharge Line Suction Receiver Evaporator Hot Gas Valve Liquid Line Valve TXV Heat Exchange Suction Evaporator Accumulator Compressor C1448R, C1848R and C2148R September 2006 Page 31
Electrical Component Details Compressor • Operated by the compressor contactor. Single phase self contained models have PTCR and run capacitor. Contactor • Operated by the controller and the high pressure cut out switch. Line voltage coil. When energized the Compressor indicator light will be ON. Water Pump • Operated by the controller. When energized, the Water Pump indicator light will be ON. Inlet Water Solenoid Valve • Operated by the controller. Line voltage coil.
Electrical Component Details Liquid Line Valve • Remote only. Opened by the controller to start a freeze cycle. Closed to shut unit off. Line voltage coil. Hot Gas Valve(s) • Operated by the controller in parallel with the harvest assist solenoid. Cycles on and off at the beginning of a restart. Energized throughout the harvest cycle. Line voltage coil. Controller • Senses ice thickness, water level, water temperature, discharge temperature.
Electrical Component Details Discharge temperature sensor. • Thermistor attached to the discharge line near the compressor. Reported temperature used by the controller to determine end-of-cycle-fan-off-delay time. If discharge temperature exceeds a preset maximum, controller will shut the machine off. Note: Controller will operate machine in a default mode with thermistors disconnected from the controller. Diagnostic code #5 or 7 will be displayed during that time.
Refrigeration Refrigerant: R-404A Compressors: Copeland or Tecumseh hermetic by model Expansion valves: Non adjustable, internally equalized, one per evaporator. Hot gas valves: Pilot operated, line voltage coils. One per plate. Condensers: Forced draft air, counterflow water. All air cooled models have left side air inlet. 48” wide air cooled models also have front air inlet. All air cooled models exhaust air out the back. Air filters: Surface mounted to panels.
Water System Batch type. Insulated water reservoir contains full water charge for each ice making cycle. Water valve: Solenoid type. Opens to fill reservoir when mid sensor probe no longer makes a circuit to the bottom probe. Closes when reservoir is full and top probe makes circuit to mid probe. Pump: Unsealed pedestal type, twist-release mounting Water purge valve: Solenoid type. Opens to purge water during harvest cycle. Water Level Sensor: Three probe conductivity. Distributor: ABS plastic.
Control Operation Standard control: • Electronic controller operating from a 12 AC volt power supply. Will operate within a voltage range between 10 and 15.5. • User’s Indicator lights, four front visible: Power, Status, Water, De-scale/Sanitize. • Accessible On switch. • Accessible Off switch. • Code Display: Displays letters and numbers to indicate cycles and diagnostic codes. • Manual Harvest switch: Use to trigger harvest at any time.
Control Safeties Max freeze time – 45 minutes When exceeded, the controller will attempt another freeze cycle. If the next cycle's freeze time is less than maximum, the control will continue normal ice making. If the next freeze cycle was too long, the control will again attempt another freeze cycle. If the freeze cycle is too long three consecutive cycles, the controller will shut the unit off and it must be manually reset.
Restarts Power Interruption The controller will automatically restart the ice machine after adequate voltage has been restored. • • • • H blinks on code display Status indicator light blinks Reservoir is drained and refilled Default harvest is initiated. The curtain switch does not have to open to terminate harvest, harvest will continue until the default harvest time expires. Default harvest time is 3 minutes. The machine will then return to a normal freeze cycle.
Control Button Use (from standby) Set purge level, 1-5 (1 is minimum, 5 is maximum) or Automatic: • Hold off button in for 3 seconds. Release. • Press and release the On button to cycle through and select one of the five purge settings or to use the Automatic setting. Recall diagnostic code: • Hold off button in for 3 seconds. Release. • Press and release the Harvest button to cycle through each of the last 10 error codes from most recent to oldest.
Control Button Use - continued Change De-Scale Notification Interval Like the others, this feature is accessible only from standby (Status Light Off). 1. Press and hold harvest button for 3 seconds. Starts the Time to Clean Adjustment State and displays the current time to clean setting. 2.
Diagnostics – Air Cooled No ice Problem Likely Cause Probable Solution No power to unit Power disconnected Check breaker or fuse.
Diagnostics – Air Cooled Problem Likely Cause Probable Solution Pump hose disconnected Check hose Check compressor contactor, check controller using test mode Compressor not operating Check compressor start components, check PTCR resistance and temperature Check compressor voltage Check compressor windings Shut down on maximum freeze time Low refrigerant charge Add some refrigerant and restart unit. If cycle time improves, look for leak.
Diagnostics – Air Cooled Problem Shut down on maximum harvest time Shut down on minimum freeze time Likely Cause Probable Solution Ice bridge thickness too small, not enough ice to open curtain Check and adjust if needed Ice bridge thickness too large, ice frozen to evaporator frame Check and adjust if needed Purge valve does not open, water melts ice bridge, not enough ice to open curtain Check purge valve Incomplete ice formation Check water distributor for partially plugged holes Curtain out
Low Ice Making Capacity - Air Cooled Problem Likely Cause Probable Solution Dirty air filters Clean filters Dirty condenser Clean condenser Hot ambient Reduce room air temperature Water leak Check purge valve, check curtain Water inlet valve leaks through Check inlet valve Low on refrigerant Add refrigerant, if cycle time drops, check for leak Incorrect superheat Check evaporator superheat, if significantly low or high, replace TXV Fan(s) cycle on and off Check pressures fans cycle at.
Makes Excessive Noise - Air Cooled Problem Likely Cause Probable Solution Blade is bent Replace fan blade Fan motor mount is broken Replace motor mount Compressor vibrates Mounting bolts loose Tighten bolts Water pump vibrates Pump bearings worn Replace pump Panels vibrate Mounting screws loose Tighten screws Fan blade vibrates September 2006 Page 46
Diagnostics - Water Cooled No Ice Problem Likely Cause Probable Solution No power to unit Power disconnected Check breaker or fuse.
Diagnostics - Water Cooled Problem Shut down on maximum freeze time Shut down on maximum harvest time Likely Cause Probable Solution Low refrigerant charge Add some refrigerant and restart unit. If cycle time improves, look for leak.
Diagnostics - Water Cooled Problem Likely Cause Probable Solution Shut down on minimum freeze time Grounded ice thickness sensor Check sensor for dirt and position. Clean and check gap.
Low ice Making Capacity - Water Cooled Problem Long freeze cycle Long Harvest Cycle False bin full signal Likely Cause Probable Solution Water leak Check purge valve, check curtain Water inlet valve leaks through Check inlet valve Low on refrigerant Add refrigerant, if cycle time drops, check for leak Incorrect superheat Check evaporator superheat, if significantly low or high, replace TXV Dirty evaporator De-scale water system No harvest assist Check harvest assist solenoid Bridge thickne
Makes Excessive Noise - Water Cooled Problem Likely Cause Probable Solution Compressor vibrates Mounting bolts loose Tighten bolts Water pump vibrates Pump bearings worn Replace pump Panels vibrate Mounting screws loose Tighten screws September 2006 Page 51
Diagnostics - Remote Air Cooled No Ice Problem Likely Cause Probable Solution No power to unit Power disconnected Check breaker or fuse. Reset or replace, restart and check No power to controller Transformer open Replace transformer Shut down on max.
Diagnostics - Remote Air Cooled Problem Likely Cause Compressor not operating (continued) Probable Solution Check compressor start components, check PTCR resistance and temperature Check compressor voltage Check compressor windings Shut Down on Maximum Freeze Time (continued) Shut down on maximum harvest time Low refrigerant charge Add some refrigerant and restart unit. If cycle time improves, look for leak.
Diagnostics - Remote Air Cooled Problem Shut down on maximum harvest time (continued) Shut down on minimum freeze time Likely Cause Probable Solution Curtain switch does not open when curtain does Check switch with ohmmeter Machine in very cold ambient Move machine to a warmer location Hot gas valve does not open Check hot gas valve, check controller using test mode Harvest assist probe out of position – ejector pin not retracted Check harvest assist mechanism – spring should retract pin Damage
Low Ice Making Capacity - Remote Problem Long freeze cycle Long Harvest Cycle False bin full signal Likely Cause Probable Solution Dirty condenser Clean condenser Hot ambient Check condenser inlet temp.
Makes Excessive Noise - Remote Problem Likely Cause Probable Solution Blade is bent Replace fan blade Fan motor mount is broken Replace motor mount Compressor vibrates Mounting bolts loose Tighten bolts Water pump vibrates Pump bearings worn Replace pump Panels vibrate Mounting screws loose Tighten screws Fan blade vibrates Test Mode Sequence - Remote Test Time (seconds) On Off 0 WIV - 30 seconds WP, HGV, Comp, BV, PV 30 WP - 10 seconds WIV, HGV, Comp, BV, PV 40 WP, PV, HGV - 10 s
Test Procedures - Sensors All electrical components in this ice machine can be diagnosed with a volt-ohmmeter. Curtain Switch: 1. Test using the controller’s indicator lights. Observe SW1 and SW2. Open and close the curtain in question. When the curtain is opened, the SW light will be ON. When the curtain gets to within a half inch of closing (at the switch) the SW light will go OUT. 2. Test with an ohmmeter. Disconnect electrical power. Open the control box cover.
Ice Thickness Sensor 1. Test using the controller’s indicator light. Observe the Ready To Harvest light. Shut the machine off. Use a wire to connect the metal part of the Ice Thickness sensor to the evaporator or simply remove the Ice Thickness Sensor and touch its metal surface to the metal control box wall. The Ready for Harvest light should go ON. 2. Test with an Ohmmeter. Disconnect electrical power. Open the control box cover. Unplug the ice thickness sensor lead from the controller.
Water Level Sensor 1. Test using the controller’s indicator lights (sump empty and sump full). Unit must be powered up and there must be water in the sump. Add some manually if needed. Locate water level sensor. Release from sump cover and slowly lift up until the mid-length probe is out of the water. The sump empty light should come on, and if the unit is on the inlet water solenoid valve will open to fill the reservoir. Return the water level sensor to its normal position.
Temperature Sensors 1. Check controller. If the sensor calibration is completely out of range, the code display will read either 5 or 7. 2. Check with an ohmmeter. Open control box cover, unplug sensor from J6. Water temperature probe: Measure the temperature of the water. Push and release the clean button. Wait one minute. Measure the resistance of the water probe (two leads next to the open socket) and compare to the resistance in the chart for that temperature. Any reading within 1000 ohms is acceptable.
Test Procedures - Loads Compressor Failure to start. Single phase models. All have resistance start, capacitor run type motors. Check voltage to compressor at the contactor. Compare the idle voltage (compressor off) to the active voltage (compressor starting). The supply voltage must not be less than the lowest rated voltage for the ice machine. If the voltage is correct, proceed to the next step. Check starting components.
Compressor Electrical Chart Resistance reading tolerance is +- 10% Ice Machine Voltage/Hz/Phase Compressor C0330-1 115/60/1 AKA9438ZXA 4.22 .59 C0330-6 230/50 AKA9438ZXC 7.11 2.69 C0330-32 208-230/60/1 AKA9468ZXD 10.43 1.77 C0530-1 115/60/1 AKA9451ZXA 5.95 .69 C0530-6 230/50 AKA9451ZXC 7.11 2.69 C0530-32 208-230/60/1 AKA9451ZXD 10.43 1.77 C0630-32 208-230/60/1 AJA7490ZXD 2.74 1.52 C0630-6 230/50 AJA7490ZXC 2.23 2.02 C0830-32 208-230/60/1 CS10K6EPFV 3.10 1.
Test Procedures - Loads Fan motor 1. Test using the controller’s indicator lights. Note: Fan pressure control connection must be jumped to perform this test. Put the controller into test mode (depress Off for 3 seconds then depress Clean for 3 seconds). At the end of the test cycle, the fan motor will be powered and the Condenser Fan motor indicator light will be on. The fan motor should start and run at that time.
Test Procedures - Loads Water Pump 1. Test using the controller’s indicator lights. Check the indicator light during the freeze cycle. The light will be On for all but the 30 second anti-slush period, so observe the light for one minute. When it is On, check the water pump, it should be operating. If not, check voltage to the pump. If low check the voltage from the controller to ground. The water pump pin is number 6.
Test Procedures - Loads Purge valve 1. Test using the controller’s indicator lights. Shut unit off by holding the Off button for 3 seconds. Wait four minutes. Push and release the On button, observe the Purge Valve indicator light. As the unit drains the reservoir, the purge valve will be powered. When it gets power, the indicator light will be ON. If the purge valve does not open to drain the reservoir when its indicator light is on, do a voltage check.
Test Procedures - Loads Compressor contactor 1. Test using the controller’s indicator lights. When the unit is in ice making mode the compressor contactor will have power. Check the Compressor indicator light, when it is on the compressor contactor will have pulled in. If it is not, do a voltage check. Place voltmeter leads on the coil of the contactor. There should be full voltage . If there is full voltage present and the contactor has not pulled in, replace the contactor.
Test Procedures - Loads Pressure switches There are two pressure switches: Fan and High Pressure cut out. Fan. The fan pressure switch will open to shut the fan motor off at a certain pressure and re-close at a preset higher pressure. High pressure cut out. The high pressure cut out switch will open at a preset pressure, shutting off power to the compressor contactor. After the pressure has fallen to another preset level, the switch will re-close and the contactor coil will be engergized.
Test Procedures - Loads Liquid Line Solenoid (remote only) 1. Test using the controller’s indicator lights. Put the controller into test mode (depress Off for 3 seconds then depress Clean for 3 seconds). At the end of the test cycle, the liquid line valve will be powered and the Condenser Fan motor indicator light will be on. The liquid line valve should be open at that time.
Test Procedures - Loads Inlet Water Solenoid Valve 1. Test using the controller’s indicator lights. Shut unit off by holding the Off button for 3 seconds. Wait four minutes. Push and release the On button, observe the Water Solenoid indicator light. After the unit drains the reservoir, the inlet water valve will be powered to refill the reservoir. When it gets power, the indicator light will be ON. If the water valve does not open to fill the reservoir when its indicator light is on, do a voltage check.
Test Procedures - Loads Harvest assist solenoid 1. Test using the controller’s indicator lights. Push and release the Harvest button. The Hot Gas indicator light will be on. At the same time the Harvest Assist Solenoid will be powered. If the ice on the evaporator is thin, the solenoid will extend. If the ice is nearly full sized, the solenoid will press against the ice until it releases from the evaporator, then the solenoid probe will extend. If the probe extends, the solenoid is good.
Technical Information Pressure Switches Cut In, Cut Out Cut In (PSIG) Cut Out (PSIG Fan Pressure Control, 22" and 30" 240 190 Fan Pressure Control, 48" 280 220 High Pressure Cut Out AC 390 500 High Pressure Cut Out WC 300 400 High Pressure Cut Out, Remote 350 450 Compressor Amp Draws Voltage C0322 C0522 C0330 Base Model Freeze Harvest 115 AKA9438 7.3-4.8 6.2 230 same 115 AKA9451 7.9-6.5 7.2 230 same 6.2-4.8 5.7 8-6.5 9.
Heat Load & Condenser Water GPM Air Cooled - Average heat load for air conditioning unit sizing Model BTUH C0322 4000 C0522 6800 C0330 4000 C0530 6800 C0630 8800 C0803 10800 C1030 12000 C1448 17200 C1848 22000 Water Cooled Water Use - condenser only, Model GPM, 45oF. water inlet temp GPM, 70oF. water inlet temp C0322 .2 .3 C0522 .3 .7 C0330 .1 .3 C0530 .3 .5 C0630 .4 .7 C0803 .4 .8 C1030 .4 1.0 C1448 .6 1.1 C1848 1.0 1.8 C2148 1.0 2.
Controller Differences The controllers are programmed at the factory for the model they are installed on, they cannot be moved from one model to another due to differences in: • Water purge time per setting • Maximum harvest time • Number of evaporator plates The service controller has a selector switch that allows it to be used as a replacement part in any of the Prodigy models in production at the time the controller was manufactured.
Thermistor Values Deg. F . . Ohms Deg. F . . Ohms Deg. F. . Ohms Deg. F. . Ohms Deg. F. . Ohms 0. . . . . . 85325 1. . . . . . 82661 2. . . . . . 80090 3. . . . . . 77607 4. . . . . . 75210 5. . . . . . 72896 6. . . . . . 70660 7. . . . . . 68501 8. . . . . . 66415 9. . . . . . 64400 10. . . . . 62453 11. . . . . 60571 12. . . . . 58752 13. . . . . 56995 14. . . . . 55296 15. . . . . 53653 16. . . . . 52065 17. . . . . 50529 18. . . . . 49043 19. . . . . 47607 20. . . . . 46217 21. . . . . 44872 22. .
Performance Data C0322A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 10-12 11-12 12-13 13-14 80 12-13 13-14 14+ 14-15 90 13-14 14-16 15-16 16-17 Suction Pressure End of Freeze (PSIG) Harvest 26 105 32 130 End of Freeze Harvest 235 150 250 200 Discharge Pressure (PSIG) C0322W Ambient Air Temp., Degrees F.
Performance Data C0522A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 11-13 13 14 15 80 13 14 15 16 90 16 16-18 18 19 Suction Pressure End of Freeze (PSIG) Harvest 32 105 34 120 End of Freeze Harvest 228 180 270 210 Discharge Pressure (PSIG) C0522W Ambient Air Temp., Degrees F.
Performance Data C0330A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 9-10 10-11 11-12 12-13 Suction Pressure End of Freeze (PSIG) Harvest 28 110 End of Freeze Harvest 200 150 Discharge Pressure (PSIG) 80 10-11 11-12 12-13 13-14 90 11-12 12-13 13-14 14-15 C0330W Ambient Air Temp., Degrees F.
Performance Data C0530A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 Suction Pressure End of Freeze (PSIG) Harvest Discharge Pressure (PSIG) End of Freeze Harvest 13 14 15 16 80 14 15 16 17 90 16 17 18 19 33 95 32 105 230 130 260 190 C0530W Ambient Air Temp., Degrees F.
Performance Data C0630A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 9-10 10-11 11-12 12-13 80 10-11 11-12 12-13 13-14 90 10-11 11-12 12-13 13-14 Suction Pressure (PSIG) End of Freeze Harvest 21 85 27 115 Discharge Pressure (PSIG) End of Freeze Harvest 200 160 255 200 C0630W Ambient Air Temp., Degrees F.
Performance Data C0830A Ambient Air Temp., Degrees F. 70 80 90 Water Temp 50 70 80 90 11 12 13 14 Suction Pressure (PSIG) End of Freeze Harvest 26 80 30 100 Discharge Pressure (PSIG) End of Freeze Harvest 204 160 260 195 Cycle Time (minutes) 12 13 14 15 13 14 15 16 C0830W Ambient Air Temp., Degrees F.
Performance Data C1030A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 9-10 10-11 11-12 10-13 80 10-11 11-12 12-13 13-14 90 11-12 12-13 13 14-15 Suction Pressure (PSIG) End of Freeze Harvest 26 80 30 90 Discharge Pressure (PSIG) End of Freeze Harvest 210 165 260 190 C1030W Ambient Air Temp., Degrees F.
Performance Data C1448A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 12-13 13-14 14-15 15-16 80 13-14 14-15 15-16 16-17 90 14-15 15-16 16-17 17-18 Suction Pressure (PSIG) End of Freeze Harvest 38 100 40 100 Discharge Pressure (PSIG) End of Freeze Harvest 250 150 270 160 C1448W Ambient Air Temp., Degrees F.
Performance Data C1848A Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 10-11 11-12 12-13 13-14 80 11-12 12-13 13-14 14-15 90 12-13 13-14 14-15 15-16 Suction Pressure (PSIG) End of Freeze Harvest 30 90 32 100 Discharge Pressure (PSIG) End of Freeze Harvest 227 170 285 195 C1848A Ambient Air Temp., Degrees F.
Performance Data C2148W Ambient Air Temp., Degrees F. 70 Cycle Time (minutes) Water Temp 50 70 80 90 9-10 10-11 11-12 11-12 80 10-11 11-12 11-12 11-12 90 11 11 12 13 Suction Pressure (PSIG) End of Freeze Harvest 27 75 27 75 Discharge Pressure (PSIG) End of Freeze Harvest 235 160 240 160 Ice weight per cycle: 14.
Performance Data - Remotes C0522R Condenser Intake Air Temp., Degrees F. -20 Cycle Time (minutes) Water Temp 50 70 80 90 10 Suction Pressure End of Freeze (PSIG) Harvest Discharge Pressure (PSIG) End of Freeze Harvest Min 205 70 80 90 12-13 13-14 14-15 15-16 13-14 13-14 14-15 17-18 14 14-15 15-16 18-19 35 85 35 90 230 215 245 225 Ice per cycle, 4.4 to 4.
Performance Data - Remotes C0530R Condenser Intake Air Temp., Degrees F.
Performance Data - Remotes C0630R Condenser Intake Air Temp., Degrees F.
Performance Data - Remotes C0830R Condenser Intake Air Temp., Degrees F.
Performance Data - Remotes C1030R Condenser Intake Air Temp., Degrees F.
Performance Data - Remotes C1448R Condenser Intake Air Temp., Degrees F. -20 Cycle Time (minutes) Water Temp 50 70 80 90 Suction Pressure (PSIG) End of Freeze Harvest Discharge Pressure (PSIG) End of Freeze Harvest 9 Min 207 70 80 90 11 11-12 13 14 11-12 11-12 13 15-16 14-15 14-15 16 18-19 40 100 40 125 240 150 270 200 Ice per cycle, 12 lb.
Performance Data - Remotes C1848R Condenser Intake Air Temp., Degrees F. -20 Cycle Time (minutes) Water Temp 50 70 80 90 8 End of Freeze Suction Pressure (PSIG) Harvest End of Freeze Discharge Pressure (PSIG) Harvest Min 210 70 80 90 9-10 10 11-12 12-13 10 10-11 11-12 14-15 10-11 11 12-13 14-15 32 85 33 105 240 170 245 205 Ice per cycle 12 lb.
Performance Data - Remotes C2148R Condenser Intake Air Temp., Degrees F -20 Cycle Time (minutes) Water Temp 50 70 80 90 Suction Pressure (PSIG) End of Freeze Harvest Discharge Pressure (PSIG) End of Freeze Harvest 9 Min 217 70 10 9-10 11-12 12-13 80 10 10 11 14 90 11 12 13 15-16 24 80 24 95 240 190 250 220 Ice per cycle, 14-15 lb.
W W BK R BK W J7 1 2 J8 1 2 12 3 J9 1 2 3 4 J1 J10 MOT PUMP BU BN MOT FAN W V W W BN SEE NOTE 4 HIGH PRESSURE CONTROL BK SOLENOID HOT GAS T1 BK W JUNCTION BOX 1 2 L2 1 3 Y W/R W GN/Y BK R TERMINAL BOX Y MORE THAN ONE DISCONNECT MEANS MAY BE REQUIRED TO DISCONNECT ALL POWER TO THIS UNIT.
September 2006 Page 94 W THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
BN W BK R THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
Wiring Diagram C0522R, C0530R, C0630R, C0830R, C1030R Single Phase after 9/09 September 2009 Page 96
BN THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
Wiring Diagram C0522R, C0530R, C0630R, C0830R, C1030R Three Phase after 9/09 September 2009 Page 98
THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP. SENSOR ICE THICKNESS PROBE WATER LEVEL SENSOR BN BK R FAN CYCLING PRESSURE CONTROL SWITCH (AIR COOLED ONLY) R DUMP VALVE BK W 17-3167-01 W W ELECTRONIC CONTROL W WATER SOLENOID CURTAIN SWITCH 1 1 2 3 4 J6 March 2007 Page 100 J7 1 2 R/W 1 2 3 4 J1 1 2 3 J9 CURTAIN SWITCH 2 BU CAUTION: BN MOT FAN BN W V W W MOT FAN MORE THAN ONE DISCONNECT MEANS MAY BE REQUIRED TO DISCONNECT ALL POWER TO THIS UNIT.
September 2006 Page 101 BN W W BK R THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
BN THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
BN THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
Repair Procedures Inlet Water Solenoid Valve 1 Disconnect electrical power 2 Shut off the water supply. 3 Remove front and left side panels. 4 Unplug wire from coil. 5 Disconnect water supply tube from the inlet of the valve. 6 Disconnect the water outlet tube. 7 Remove the two mounting screws holding the valve to the back panel. 8 Pull the valve forward and out of the machine. Electrical Shock Hazard. Disconnect electrical power before beginning.
Harvest Assist Solenoid 1 Remove front panel. 2 Push and release Manual Harvest button 3 Disconnect electrical supply Electrical Shock Hazard. Disconnect electrical power before beginning. 4 Remove sound shield 5 Unplug wires from solenoid 6 Remove two screws and solenoid from cabinet 7 Reverse to reassemble.
Repair Procedures Ice thickness sensor 1 Push and release the Off switch. 2 Remove front and top panels. 3 Push and release the Harvest switch 4 Remove the evaporator cover. 5 Remove the sound shield. 6 Disconnect electrical power. Electrical Shock Hazard. Disconnect electrical power before beginning. 7 Open the control box. 8 Remove curtain. 9 Locate sensor, squeeze mounting legs together to release it from the mounting bracket. 10 Remove sensor, follow wire back to control box.
Repair Procedures Capacitor (run) 1 Disconnect electrical power. 2 Remove front panel. 3 Open control box cover. 4 Remove right side of control box. 5 Remove metal barrier from control box 6 Remove screw holding strap to back of the control box. 7 Remove wires from capacitor 8 Connect wires to new capacitor, refer to wiring diagram as needed. 9 Reverse to reassemble. Electrical Shock Hazard. Contactor 1 Disconnect electrical power. 2 Remove front panel. 3 Open control box cover.
Repair Procedures Controller 1 Disconnect electrical power. Electrical Shock Hazard. Disconnect electrical power before beginning. 2 Remove front panel. 3 Open control box door. 4 Unplug all wires from controller. 5 Remove screws holding controller to door 6 Push controller snaps down and pull controller from mounting bracket. 7 Before touching new controller, discharge any static electricity by touching the metal surface of the ice machine cabinet.
Repair Procedures Curtain 1 Push and hold the Off button to shut the machine off. 2 Remove front panel. 3 Remove evaporator cover. 4 Push inside tab in to release front curtain pin from holder. 5 Pull curtain from machine. 6 Reverse to reassemble. 7 Push and release the ON button to restart the machine. Curtain switch 1 Push and hold the Off button to shut the machine off. 2 Disconnect electrical power Electrical Shock Hazard. Disconnect electrical power before beginning.
Repair Procedures Purge valve 1 Push and hold the Off button to shut the machine off. 2 Disconnect electrical power. 3 Remove front panel. 4 Remove left side panel. 5 Unplug wires from valve coil. Electrical Shock Hazard. Disconnect electrical power before beginning. Note: The coil can be removed from the valve body by rotating it 1/8 turn CW. After removal of the coil the spring and plunger can be taken out. 6 Remove screws holding valve to mounting bracket.
Repair Procedures Water pump 1 Push and hold the Off button until the machine shuts off. Electrical Shock Hazard. Disconnect electrical power before beginning. 2 Remove the front panel. 3 Remove the sound shield. 4 Unplug the water pump 5 Rotate the pump CCW about 1/8 turn to release it. 6 Lift pump up and remove hose 7 Attach hose to new pump 8 Install in pump bracket. 9 Rotate CW about 1/8 turn to lock it in place.
Refrigeration Removal and Replacement Procedures Evaporator 1 Remove front panel. 2 Remove evaporator cover. 3 Remove right side panel. 4 Remove top panel. 5 If the machine was in operation, push and release the Harvest button to warm up the evaporator. 6 Disconnect electrical power. Electrical Shock Hazard. Disconnect electrical power before beginning. 7 Remove harvest assist solenoid 8 Recover refrigerant.
Refrigeration Removal and Replacement Procedures 17 Gain access to the right side of the unit. Remove mounting screws holding the evaporator to the freezing compartment wall. Note: fastener size is 5/16” hex. 18 Remove the evaporator from the ice machine. 19 Attach new evaporator to freezing compartment wall, but do not secure tightly at this time. 20 Install the harvest assist solenoid. Note location of ejector pin.
Refrigeration Removal and Replacement Procedures Compressor 1 Remove front panel. 2 Remove sound shield 3 If the machine was in operation, push and release the Harvest button to shut it down. Wait until the harvest cycle has ended so the evaporator has no ice on it. 4 Open the replacement compressor box. Check the compressor nameplate, be SURE that the replacement compressor is the correct one for the unit. 5 Disconnect electrical power. Electrical Shock Hazard.
Refrigeration Removal and Replacement Procedures 17 Open nitrogen bottle and braze compressor suction, discharge and process joints together. Braze new drier into system. 18 Shut off nitrogen, shut access valves. 19 Evacuate to at least 300 microns. 20 Replace PTCR and run capacitor. 21 Weigh in the nameplate charge. Check for leaks. 22 Reconnect electrical leads. 23 Attach compressor terminal cover. 24 Reconnect electrical power.
Refrigeration Removal and Replacement Procedures Thermostatic Expansion Valve 1 Remove front panel. 2 Remove sound shield (when used) 3 If the machine was in operation, push and release the Harvest button to shut it down. Wait until the harvest cycle has ended so the evaporator has no ice on it. 4 Disconnect electrical power. 5 Recover refrigerant. 6 Remove insulation covering expansion valve and bulb. 7 Remove strap securing bulb to suction line.
Optional add-on control information Vari-Smart™ Adjustable ice level option The adjustable ice level control is an optional add-on system consisting of an control board, label and sensor. The control board fits above the standard control and connects to it using connector J4. The sensor mounts to the base of the ice machine through a hole in the base. The control has an adjustment knob. Rotating the knob CW lowers the maximum ice level that the ice machine will maintain in the bin or dispenser.
Adjustable Ice Level System Information and Diagnosis The ultrasonic sensor in the base of the ice machine is located to take advantage of the natural slope of the ice as it builds up in the bin. The numbers of the settings are from the sensor to the top of the ice pile directly under the sensor. If the Vari-Smart system fails to shut off the machine and ice overfills the bin or dispenser, the curtain switch in the machine will switch the machine off, and will also restart the machine when ice is removed.
Prodigy's Smart-Board™ - an Advanced Feature Control An optional control is available that can provide users with more features. It is available either as a field installed option or as a data-logger that can be used by the service technician. The kit number for the add on option is: KSB The kit number for the data logger version is: TPDL1 The Smart-Board can be applied to most Prodigy models.
Scroll Up Button Select Button Escape Button SmartBoard™ Advanced Feature Control 34 SEL ESC ENTER 02-4293-01 Rev A. See Instructions for Available Features Display Area Scroll Down Button Enter Button USB Connection Scroll Up: Changes the display to a menu item higher on the menu list or goes up one number on a setting Scroll Down: Changes the display to a menu item lower on the menu list or goes down one number on a setting Select Button: Use to make changes to settings.
Remote SmartLock (KSL) The remote lock out feature can be added to any controller. The feature allows someone, using a special paging service and code to control the on and off operation of that ice machine. When a controller is locked out, the machine will finish a cycle and then stop. Switching the power off and on, pushing any amount or combination of switches will not restart the machine. It can only restart when it receives a clear signal from the remote lockout board.
BN THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
BN THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
THIS UNIT MUST BE GROUNDED. DISCHARGE TEMP. SENSOR SUMP TEMP.
Wiring Diagram C0630R-6, C0830R-6, C1030R-6 September 2009
Wiring Diagram C0830R-63, C1030R-63 September 2009
50 Hz Electrical Info, June 2008 Model MDT25A MDT25W MDT40A HD22 HD30 C1030MA C1030MW C1448MA C1448MW C1448SA C1448SR C1848MA C1848MR C1848MW C1848SA C2148MR C0322MA C0322MW C0522MA C0522MW C0522SA C0530MA C0530MW C0630MA C0630MW C0630SA C0830MA C0830MW NME654AS NME654WS NME954AS NME954WS Voltage 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50/1 230/50
