This document is a service manual for SIMAG Electronic Modular Flakers and Superflakers, covering models SP 125, SP 255, SPN 405, SPN 605, and SPN 1205. These devices are designed to produce flake ice and are available in both air-cooled and water-cooled versions, utilizing R134A or R404A refrigerants.
Function Description
The SIMAG ice makers are designed for automatic and continuous ice production. The core of the ice-making process involves a freezing cylinder where incoming water is chilled into soft (slush) ice. A rotating auger then moves this slush ice upward along the refrigerated inner walls, progressively thickening and hardening it. At the top of the auger, the ice meets an ice breaker, where it is compacted, cracked, and forced from a vertical to a horizontal motion, discharging through an ice spout into a storage bin.
The system incorporates several sensors and a P.C. Board (Data Processor) to monitor and control operations. These include:
- Water Level Sensor: Detects the presence of water in the float reservoir, ensuring sufficient water for ice production. A low voltage current flows between two metal pins in the reservoir, using water as a conductor. If the water level drops too low or the water conductivity is insufficient (e.g., de-mineralized water), the unit shuts off, and a YELLOW LED signals "Shortage of water."
- Evaporator Temperature Sensor: Monitors the refrigerant temperature exiting the evaporator. If this temperature does not drop below -1°C (30°F) within 10 minutes of compressor start-up, it indicates an abnormal situation, causing the unit to stop, and a YELLOW LED blinks.
- Condenser Temperature Sensor: Located within the condenser fins (air-cooled models) or in contact with the tube coil (water-cooled models), this sensor detects condenser temperature variations. It helps maintain head pressure within preset values. If the condenser temperature rises too high (70°C/160°F for air-cooled or 60°C/140°F for water-cooled) due to issues like a clogged condenser, insufficient cooling water flow, or a faulty fan motor, the unit shuts off, and a RED WARNING LIGHT illuminates. Conversely, if the ambient temperature is too low (below 1°C/34°F), the sensor prevents the unit from starting until the temperature rises to 5°C.
- Electromagnetic Sensor (SPN 1205 only): Housed on top of the drive motor, this safety device uses the Hall Effect principle to detect the rotating speed and direction of the drive motor. If the speed drops below 1300 r.p.m. or the motor rotates in the wrong direction, the unit stops, and a YELLOW LED lights up.
- Optical Ice Level Control (SPN 1205 only): Located in the ice chute, this control stops the machine when flake ice accumulates and interrupts a light beam between a light source and receiver. A blinking YELLOW LED indicates a "Bin Full" situation, followed by a steady YELLOW LED and unit shut-off after 6 seconds of continuous interruption.
Important Technical Specifications
The ice makers are modular, meaning they require an auxiliary storage bin. Recommended bins include R 85 (for SP 125, SP 255), R 155 (for SP 125, SP 255, SPN 405, SPN 605), and R 250 (for SPN 405, SPN 605), each with a corresponding top cover.
Operating Requirements:
- Air Temperature: MIN 10°C (50°F), MAX 40°C (100°F)
- Water Temperature: MIN 5°C (40°F), MAX 35°C (90°F)
- Water Pressure: 1 bar (14 psi) to 5 bars (70 psi)
- Electrical Voltage Variations: -10% to +10% from nameplate rating.
Refrigerant Charges (R134A):
- SP 125: 440 gr (air-cooled), 400 gr (water-cooled)
Refrigerant Charges (R404A):
- SP 255: 660 gr (air-cooled), 520 gr (water-cooled)
- SPN 405: 750 gr (air-cooled), 600 gr (water-cooled)
- SPN 605: 880 gr (air-cooled), 820 gr (water-cooled)
- SPN 1205: 2400 gr (air-cooled), 1200 gr (water-cooled)
Operating Pressures (at 21°C ambient temperature):
- SP 125:
- Discharge pressure: 8 ÷ 9 bar (air-cooled), 8.5 bar (water-cooled)
- Suction pressure: 0.5 bar
- SP 255/SPN405-605:
- Discharge pressure: 17 ÷ 18 bar (air-cooled), 17 bar (water-cooled)
- Suction pressure: 2.5 bar
- SPN 1205:
- Discharge pressure: 17 ÷ 18 bar (air-cooled), 17 bar (water-cooled)
- Suction pressure: 2.4 bar
Specific Model Specifications:
- SP 125:
- Ice-making capacity: 80-120 kg/24 hrs (air-cooled), 80-120 kg/24 hrs (water-cooled)
- Dimensions (less legs): 525 mm (H), 560 mm (W), 533 mm (D)
- Weight: 49 Kg
- Compressor HP: 3/8
- Electrical: 230/50/1, 3.2 Amps (run), 17 Amps (start), 500 Watts, 11 Kwh/24 HR
- SP 255:
- Ice-making capacity: 120-200 kg/24 hrs (air-cooled), 150-190 kg/24 hrs (water-cooled)
- Dimensions (less legs): 525 mm (H), 533 mm (W), 533 mm (D)
- Weight: 49 Kg
- Compressor HP: 3/4
- Electrical: 230/50/1, 4 Amps (run), 20 Amps (start), 760 Watts, 17 Kwh/24 HR
- SPN 405:
- Ice-making capacity: 190-310 kg/24 hrs (air-cooled), 200-360 kg/24 hrs (water-cooled)
- Dimensions (less legs): 645 mm (H), 538 mm (W), 663 mm (D)
- Weight: 77 Kg
- Compressor HP: 1
- Electrical: 230/50/1, 5.2 Amps (run), 29 Amps (start), 1200 Watts, 26 Kwh/24 HR
- SPN 605:
- Ice-making capacity: 300-700 kg/24 hrs (air-cooled), 400-600 kg/24 hrs (water-cooled)
- Dimensions (less legs): 785 mm (H), 538 mm (W), 663 mm (D)
- Weight: 93 Kg
- Compressor HP: 1.5
- Electrical: 230/50/1 (10 Amps run, 34 Amps start, 2000 Watts, 45 Kwh/24 HR) or 400/50/3+N (4 Amps run, 22 Amps start, 2000 Watts, 40 Kwh/24 HR)
- SPN 1205:
- Ice-making capacity: 700-1150 kg/24 hrs (air-cooled), 500-1400 kg/24 hrs (water-cooled)
- Dimensions (less legs): 850 mm (H), 1065 mm (W), 698 mm (D)
- Weight: 179 Kg
- Compressor HP: 2.5
- Electrical: 230/50/3 (7.1 Amps run, 56 Amps start, 3600 Watts, 80 Kwh/24 HR) or 400/50/3+N (3.4 Amps run, 28 Amps start, 3600 Watts, 70 Kwh/24 HR)
Usage Features
- Installation: Designed for indoor installation only. Proper location requires minimum room temperature of 10°C (50°F), maximum 40°C (100°F), water inlet temperatures between 5°C (40°F) and 35°C (90°F), and good ventilation for air-cooled models. Adequate service access (minimum 15 cm/6" clearance on sides) is also crucial.
- Start-up Procedure: After installation, open the water supply valve and turn on the main switch. A GREEN LED indicates power. The unit undergoes a 3-minute stand-by period (RED LED blinks), then the gear motor and compressor (and fan motor for air-cooled units) activate. Ice production begins after 2-3 minutes of compressor start-up. The first ice bits may be softer until the evaporating temperature stabilizes.
- Safety Features:
- Automatic Shut-off: The unit stops if the ice storage bin is full (detected by the optical ice level control), if there's a water shortage, if the evaporator temperature is too high, if the condenser temperature is too high or too low, or if the gear motor experiences wrong rotation or low speed.
- Restart Mechanism: After an alarm shut-off, the machine typically remains in OFF mode for one hour before attempting an automatic restart. If the unit trips OFF three times in three hours, it shuts off definitively and requires manual intervention (unplugging/plugging or pressing the RE-SET button) to restart.
- Voltage Protection: The P.C. Board is protected by fuses, and the system is designed to handle voltage variations within -10% to +10% of the rated voltage. Incorrect voltage can damage the overload switch and motor windings.
- Water Quality: The quality of water significantly impacts ice production. Water with excessive minerals can cause scale build-up, while very soft water (low electrical conductivity) can cause the water level sensor to malfunction, leading to shut-off.
Maintenance Features
Regular maintenance is essential for optimal performance and to retain warranty coverage. It should be scheduled at least twice a year, with frequency adjusted based on local water conditions and usage.
- General Checks:
- Inspect and clean the water line strainer.
- Check and clean the float reservoir, ensuring the float valve operates correctly and the water level is appropriate (approx. 20 mm below the ice discharge opening).
- Verify the unit's level.
- Check for refrigerant leaks and proper frost line (approx. 20 cm/8" from the compressor).
- Ensure fan blades move freely and do not touch any surfaces.
- Inspect the top bearing of the freezer assembly, clean off old grease, and apply food-grade waterproof grease.
- Check the quality of ice; it should be wet when formed but cure rapidly to normal hardness.
- Cleaning Instructions for Water System:
- Switch off the main power and water supply.
- Remove all ice from the bin to prevent contamination.
- Remove top panels to access the water reservoir.
- Short the two metal pins of the water level sensor with a copper wire.
- Disconnect the water hose from the freezer water inlet port to drain water from the freezer.
- Prepare a cleaning solution by diluting SIMAG Ice Machine Cleaner in warm water (45°-50°C).
- Pour the solution into the water reservoir.
- After 15 minutes, switch ON the Master switch.
- Slowly pour the remaining cleaning solution into the reservoir while the machine produces ice, ensuring the level is just below the overflow.
- Once the cleaning solution is used, open the water shutoff valve to flush the system with fresh water until the ice resumes its normal color and hardness.
- Stop the icemaker and melt any remaining ice in the bin with warm water.
- WARNING: Do not use ice produced with the cleaning solution.
- Pour SIMAG Sanitiser (Antialgae) into the water reservoir and run the unit for 10 minutes.
- WARNING: Do not use ice produced with the sanitizing solution.
- Wipe interior bin surfaces with a sanitizing solution.
- REMEMBER: Sanitize the storage bin weekly to prevent bacteria accumulation.
- Optical Ice Level Control Maintenance: Every three months, remove the optical system and clean the sensing "eyes" with a soft cloth to ensure proper detection.
- Component Replacement Procedures: The manual provides detailed step-by-step instructions for replacing various components, including the evaporator temperature sensor, condenser temperature sensor, ice level light control, P.C. Board, ice spout, auger, water seal, bearings, coupling, gear motor assembly, fan motor, drier, freezing cylinder, air-cooled condenser, water-cooled condenser, water regulating valve, and compressor. Many of these procedures emphasize the need to install a replacement drier whenever the sealed refrigeration system is opened and to thoroughly evacuate the system to remove moisture and non-condensables after component replacement.
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