Fulgi de Gheata Funk FRV 120 6000

Übersetzung der Originalbetriebsanleitung

Translation of the original Operating Instructions

Scale- Ice- Machine Funk EasyClean®

Model / Type F / FV / FRV 120 - 6000

• Read prior to operation

• Adhere to safety instructions

• Keep for future use. This device is not intended to be used by persons (including children) with limited physical, sensory or mental aptitude or lack of experience and/or knowledge unless they are supervised by a person responsible for their safety or have received instruction from this person as to how the device is used

FUNK GmbH – Kälte mit System, Zunftstrasse 8, D-77694 Kehl Fon: 07854 / 7077-78 Fax: 07854 / 7566 E-Mail: [email protected]

Operating Instructions Scale Ice Machine Funk EasyClean® type F/FV/FRV

Ausgabe /Rev. 05/2011 page 2 of 18

Contents

1 Safety

1.1 dangers/hazards 3

1.2 symbols used 3

1.3 correct use/operation 4

1.4 sources of danger 4

1.5 operator/ skilled person 4

1.6 actions to be taken on job-site 5

1.7 safety devices 5

1.8 noise emission/hearing protection 5

2 Transport/ Installation/ Storage 6

2.1 transport/ storage 6

2.2 set-up/ installation/ connection 6

2.3 initial operation 7

2.4 functional principle 8

3 Operation/ Use 8

3.1 construction/ controls 8

3.2 operation/ use 9

4 Troubleshooting 10

4.1 general 10

4.2 fault repair 10

4.3 refrigerant injection valve 11

4.3.1 automatic refrigerant injection valve 11

4.3.2 thermostatic refrigerant injection valve 11

5 Cleaning /Maintenance/ Taking out of operation 12

5.1 cleaning and care 12

5.1.1 cleaning of water basin 12

5.1.2 cleaning of evaporator drum, ice scraper and ice chute 13

5.1.3 cleaning of strainers 13

5.1.4 cleaning of condenser 14

5.1.5 cleaning schedule 14

5.2 maintenance 15

5.3 disposal 15

6 Exploded drawing 16

7 Type FV 17

8 Type FRV 18

9 Declaration of conformity

10 Technical data

11 Wiring diagram

12 Parts list



1 Safety 1.1 Dangers/Hazards The scale-ice-machine type F/FV/FRV is constructed according to recognized safety regulations and is equipped with safety devices. All parts which may come in contact with ice/water are made of stainless steel or food compatible plastic. Moving parts (ventilator, motor and compressor) are covered for protection. Electrical equipment complies with DIN EN 60335-2-89. Prior to delivery function and safety are tested. However, in case of faulty operation, non-observance of operating instructions or improper use the following is endangered:

• health of operator

• scale-ice-machine and other material values of the user

• effective operation of the scale-ice-machine All personnel engaged with set-up, operation and maintenance of the machine therefore have to:

• be accordingly qualified

• follow the specific directions of these instructions It’s about YOUR safety!!!

1.2 Symbols used These operating instructions use the following symbols for special references (safety and operating instructions).

DANGER

� imminent danger to life and limb, failure to

comply with instructions could result in death or serious injury

ATTENTION

� potentially dangerous situation for machine

or environment, failure to comply with instructions could result in damage to property

Advice

� information and employment advice, e.g. for

assistance

�

� functional advice= requested for correct use of scale-ice-machine (control, use, operation)



1.3 Correct Use/Operation Scale-ice-machines FUNK are exclusively designed for production of scale-ice made from drinking water. Application: mainly in food production (sausage production, bakeries, meat and fish markets, hotels and restaurants) as well as in laboratories/hospitals or the chemical industry. The scale-ice-machines shall only be set-up and operated in a frost-free room at a temperature between +5°C and +32°C. Humidity shall not exceed a maximum of 95%. The water intake shall only be connected to the drinking water supply (cold water). The temperature of the water shall be of +7 °C or higher. The machine shall only be connected to the ground three-pole-three-phase 230V and/or 400V (depending on machine type) network. Please pay attention to the correct rotation of the evaporator drum when taking into operation and after maintenance; it has to rotate forward towards the ice scraper/ejection opening. For safety and hygienic reasons reconstruction and/or alterations are only permitted after consulting the manufacturer. Defective parts shall only be replaced by original spare parts or standard parts. All other use is considered as improper use!!! The manufacturer is not liable for damage caused by improper use. E.g. improper use would be the installation/operation of the machine with ambient temperatures below +5°C as well as inappropriate cleaning with high-pressure cleaner/steam jet or cleaners which are not food compatible.

1.4 Sources of Danger Break-down of isolating/separating safety devices (main and motor protective circuit breaker): damage to machine caused by overheating is generally possible.

DANGER

Do not touch hot compressor parts during operation and maintenance; allow time for cooling off. Danger of injuries when touching refrigeration aggregate, rotating fan blade or hot compressor parts during maintenance. Do not remove or avoid safety devices. Immediately remedy deficiencies.

1.5 Operator/Skilled person Only briefed personnel should work on a scale-ice-machine. The operator is responsible for all other persons within his work area. Therefore the management is obliged to:

• make these operating instructions accessible to everyone concerned

• make sure that they are read, understood and followed Set-up and maintenance shall only be done by electrically skilled persons. Intervention on the refrigeration equipment is reserved to refrigeration technicians authorized by the manufacturer.



1.6 Actions to be taken on job-site Ensure adequate ventilation for cooling of condenser. Minimum distance between back of machine and adjoining wall is 40 cm. Follow terms according to point 2.2. Air grid must always be kept free.

1.7 Safety Devices Shut-down of machine:

• release green button “ON” (F/FV/FRV 120 – 160)

• push red button “OFF” (F/FV/FRV 300 – 6000)

• close down water intake

• push white button “LEEREN”

• disconnect power plug

DANGER

On each short or long term shut-down the complete evaporating unit has to be: drained from water, disinfected and thoroughly cleaned (see point 5 et seqq.)

All moving parts (ventilator, motors and compressor) are covered against accidental contact. The safety devices are to protect the operator and should therefore not be removed, altered or bridged:

• protective covers, motor protecting switch

• micro-fuse/fuse in switch case

• floater switch (water level)

• icing controller and pressure control device (thickness of ice/water shortage)

1.8 Noise-Emission/Hearing Protection The constant sound pressure level (at 1m distance, height 1,6m) is between 70 and 75 dB(A).

Advice

When working close to the machine wear hearing protection.



2 Transport/Installation/Storage 2.1 Transport/Storage Scale-Ice-Machines type F and FV are delivered on pallet in cardboard, ready for installation, i.e. with power cable and plug. Scale-Ice-Machines type FRV are delivered on pallet in cardboard without refrigeration aggregate and have to be connected to an existing aggregate or one to be ordered. When transported/moved with pallet truck/ fork lift place forks between feet and machine frame. (Distance between floor and machine frame 100mm)

2.2 Set-Up/Installation/Connection Place machine stable. Check for sufficient bearing capacity of floor or console respectively. Consider floor load (see technical data for weight of machine)

ATTENTION

Respect minimum distance of 40cm between back of machine and adjoining wall. Mains supply must be secured sufficiently and power socket is to be mounted close to the machine and easy accessible (length of power cable: 2m).

At the back of the machine the hoses “drain” and “condensation water” are attached for discharge

• fix drain hose to sewage

or

• place suitable container below hose to collect water. The drain of the machine must be higher than the entry of the sewage

• Connect water intake hose to inlet water valve with an R ¾” threaded connection.

ATTENTION

Only connection to drinking water supply is allowed. Depending on the quality of the water it may be necessary to install a filter. Water and electrical installation shall be done by skilled persons.



2.3 Initial operation

ATTENTION

Let machine stand still at least one hour prior to first operation. Oil may have dispersed in tubes during transport and must flow back into its container first.

• insert main plug

• open water tap • turn main switch “ON” (only F 1200-6000, oil will be heated automatically)

• push button “ON” Machine only starts after achievement of required water level in water basin (controlled by float switch). It then starts automatically.

ATTENTION

Check correct rotation of evaporator drum (see pointing arrow). Drum must always rotate towards the ice chute.

1 ice chute 2 ice-scraper 3 evaporator drum

4 floater 5 icing controller

Machine starts ice production after reaching the correct temperature (approx 5 minutes).

DANGER




2.4 Functional principle The evaporator drum is rotated by a worm geared engine which is directly connected to the evaporator shaft. Being

cooled from the inside the drum creates a thin layer of ice on its surface by rotating in a level-controlled water basin. The

drum then rotates towards an ice scraper which produces the scales of ice by touching the ice layer.

3 Operation/Use 3.1 Construction/Controls

1. ice ejection

2. button “drain” (F/FV/FRV 120 – 6000)

3. button “ON/OFF” (F/FV/FRV 120 – 160) or button “ON” (F/FV/FRV 300 – 6000)

4. button “OFF” (F/FV/FRV 300 – 6000)

5. geared engine

6. (ice) distance controller

7. switch box

8. float switch

9. tube leading to cooling unit

10. ice scraper

11. limit switch



3.2 Operation/Use

Turn on:

• open water supply/tab • push button “ON”

• place ice container beneath ice chute (respect approx. distance from ventilation grid of 5 cm) Turn off:

• open button “ON” ( F/FV/FRV 120 – 160)

• push button “OFF” (F/FV/FRV 300 – 6000)

• close water supply/tap

• push (white) button “DRAIN”

• water flows from water basin into drainage

• clean water basin (see point 5.1.1)

DANGER




4 Troubleshooting

4.1 General Prior to calling FUNK customer service in case of disturbance, please check the following table so you may perhaps solve the problem on your own. If the problem persists please feel free to contact us. Always consider the following:

DANGER

Prior to working at electrical or mechanical refrigeration appliances ALWAYS remove plug and secure against reconnection by accident.

4.2 Fault repair trouble possible cause procedure measure machine does not start • no electricity

• no water

• filter screens are blocked

• connect plug and check fuse

• open water supply/tap

• remove screens and clean them

no ice production • leak in refrigeration cycle

• call refrigeration technician: he has to search for leak and seal it, then fill up freezing mixture R404A; applicable environmental regulations are to be observed

ice production to low • leakage

• condenser dirty

• insufficient condenser ventilation

• injection valve displaced

• clean condenser (with brush not high pressure equipment)

• check distance from wall 40 cm air room. i.e. open window, clean ventilation grid of the machine

• call refrigeration technician

• call refrigeration technician

water overflow (next to chute at evaporator)

• floater switch defect

• water solenoid valve displace

• call electrician to replace float switch

• call electrician to replace the water solenoid valve

compressor covered with frost

• injection valve displaced

• call refrigeration technician to adjust injection valve



4.3 Refrigeration injection valve 4.3.1 Automatic refrigeration injection valve

F 120-800/ F5000/ F6000 Readjustment of injection valve The automatic injection valve is set at the works. After longer operation periods it may become necessary to readjust the valve. By turning the adjustment screw the injection of refrigerant increases or decreases. By pulling off the protective cap the adjustment screw becomes accessible (see drawing). Setting is correct when evaporator drum is evenly covered with ice. There should be no ice on the compressor.

4.3.2 Thermostatic refrigeration injection valve F 1200-3000

ATTENTION

Setting of valves must be done by refrigeration technicians. Incorrect setting may damage the compressor. In this case there is no warranty and no liability.



5 Cleaning/Maintenance/Taking out of operation

5.1 Cleaning and Care 5.1.1 Cleaning of water basin Water basin has to be cleaned daily!

DANGER


ATTENTION

Prior to emptying the water basin check whether hose “drain” is connected to sewage, otherwise place suitable container underneath.

figure 1

• Release green “ON” button on front ( F 120 – 160)

• push red “OFF” button on front ( F 300 – 6000)

• close water supply/tap

• push white “EMPTY” button on front

• remove plug

• remove top cover

• open the front flap (see figure 1)

• remove the ice chute

figure 2

open front flap

gripping levers

knurled head screw

plastic lid



• unscrew knurled head screws from plastic lid (see figure 2)

• remove the plastic lid

• open gripping levers

ATTENTION

To avoid dirt-collecting scratches in the surface do not use pointed and sharp-edged cleaning equipment. For disinfection use “Doyen F 40” cleaner which may be obtained from company Funk.

• remove water basin and clean thoroughly

• remove float switch and clean thoroughly

• clean distance rod and disinfect ends of rod

• clean side plates

• clean water intake on side plate

• replace float switch

• replace water basin and close gripping levers

• replace ice chute

• replace the plastic lid and fix it with knurled head screws

• close the front flap

ADVICE

If plastic lid is not replaced and fastened correctly, machine cannot be switched on.

• replace top cover

• open water supply/tap

• release white “EMPTY” button

• supply electric power • push green “ON” button

5.1.2 Cleaning evaporator drum, ice scraper and ice chute Evaporator drum, ice scraper and ice chute have to be cleaned daily.

ATTENTION

Do not use pointed and sharp-edged cleaning equipment.

5.1.3 Cleaning of strainers (filter screens) Strainers have to be cleaned weekly In each solenoid valve (water intake and drain) is a strainer which has to be cleaned thoroughly under running water once per week.



5.1.4 Cleaning of condenser Condenser has to be cleaned weekly.

ATTENTION

Danger of short circuit. Clean condenser only with dry brush; high pressure cleaners or steam jets may damage fan motor.

Clean condenser weekly with a brush to avoid loss of performance.

5.1.5 Cleaning Schedule cleaning when who how

water basin daily operator see 5.1.1

evaporator drum daily operator see 5.1.2

ice scraper daily operator see 5.1.2

float switch (incl. fastener) daily operator

distance rod daily operator

side plates daily operator

water intake on side plate daily operator

ice chute daily operator see 5.1.2

strainers weekly operator see 5.1.3

condenser weekly operator see 5.1.4



5.2 Maintenance For hygienic reasons the following parts have to be cleaned daily:

• water basin

• evaporator drum

• ice scraper

• ice chute

• float switch (incl. fastener)

• distance rods (+ disinfection of the ends)

• side plates

• water intake on side plate

ADVICE

For optimal function and conservation of value a yearly maintenance inspection through the manufacturer or an authorized refrigeration company should be carried out.

WHAT WHEN WHO HOW

maintenance inspection annual Funk- Service

injection valve semi-annual refrigeration technician see 4.3.1 see 4.3.2

5.3 Disposal Drain oil from compressor and freezing mixture prior to disposal and dispose of both liquids separately in accordance to applicable official regulations. Metal parts may be given to scrap processing.

Advice

To avoid environmental pollution it may be advisable to charter an authorized contractor with the disposal of the entire machine.



6. Exploded drawing Evaporator F

position quantity name position quantity position

1 4 scraper collar 11 1 support bracket for gripping lever

2 1 ice scraper 12 1 tensioning lever

3 1 traverse 13 1 water basin

4 1 holding rod front/back

14 1 blocking flap

5 3 distance washer 15 1 side plate motor-side

6 1 evaporator drum 16 1 coupling

7 2 distance shaft 17 1 geared engine

8 2 axial bearing 18 2 support bracket

9 1 rotation insertion 19 1 ice chute

10 1 side plate arrive 20 1 feed shaft



7. Scale Ice Machine Funk EasyClean® type FV with storage container By default types FV 120, 160, 300 and 400 are delivered with storage container.

figure 1 figure 2

type approx. capacity storage container

FV 120 (figure 1) 60-70 kg

FV 160 (figure 1) 60-70 kg

FV 160 (figure 2) 160 kg



Standard containers available with capacities of 600 kg, 975 kg and 1300 kg. Larger containers available on request. FUNK storage containers are made of stainless steel on the in- and outside. The containers come double-walled and have an insulation of approx. 30 mm. Ice can easily be taken out as there’s only one flap to be opened. Please use a shovel or similar made out of plastic as other materials may damage the containers surface. All FV-type machines come with the mounted container and ready to use. For installation and set-up please refer to the instructions of the F-type machines. Ice-container should always be emptied completely and then cleaned thoroughly.

DANGER




8. Scale-Ice Machines Funk EasyClean® - type FRV without cooling unit

FRV types are ice machines without refrigeration aggregate which may be connected to an existing aggregate or one to be ordered. FRV types can be set-up in different ways, either individually, on a pad or with an ice chute into another room. FRV machines are delivered including wired switch box for the ice machines which should be connected according to the enclosed wiring diagram. The pipe cross sections have to correspond with the diameter of the pressure and suction pipe - see „Technical Data“. Please Note! 1. The electrical, refrigeration technical and sanitary installation must be done by respective technicians. 2. When using FRV types check the respective refrigeration load (see section „technical data“) 3. The data on pipe cross-section and other recommended parts for FRV types may also be taken from the

technical data sheet 4. The liquid line generally has to be connected via a solenoid valve. The solenoid valve is to be connected to

clamps 1, N and PE of the switch box. 5. Please use shielding gas when soldering the copper pipes on site to avoid impurities inside copper tubing. 6. Please observe electrical supply data for connection. 7. Regulations issued by the local energy supply agencies are to be observed. 8. Electrical connection of power supply has to permit an all-polar disconnection at any time. 9. The external control of the refrigeration aggregate or the multicompressor refrigeration system has to comply

to the protection category of IP 54. 10. Filling quantity of cooling agent depends on compressor-type and distance between compressor and ice-

machine and should be taken from technical data sheet of the compressor. 11. Heat exchanger (type Danfoss HE or similar) must be connected between suction and liquid line.

Attention! The ice machine has a slowing-down-relay for the drum. After turning off the machine the system voltage still has to be connected with clamps L1-L2-L3. The drum must be free of ice when it stops! Shut-off valves have to be installed in the fluid and suction pipes to allow the cut-off of the scale ice machine for maintenance or reparation.

Fulgi de Gheata Funk FRV 120 6000

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