Cracked ice makers have simple controllers which are considered reliable but once you start monitoring their function a number of hidden issues start appearing.
For example, the micro switches on the timer will intermittently make and break contact. While this is not detectable I believe it is responsible for nuisance high pressure trips. Proven by the implementation of an early version of our control system which monitored the operation of the timer. Part of that system bypassed the 9'o'clock switch and we found that there were almost no high pressure trips even at 100+ degrees across 30 plus machines.
The mechanical bin control transformer and relay are also prone to failure due to the unnecessarily complex conversion of an intermittent 220VAC voltage energizing a transformer which goes through a series of switches in parallel to energize a relay which switches a 220vac signal. The relay is wired to common and NC so if either fails your ice machine will not stop running until it backs up into the chute and trips out on low pressure because it's jammed with ice.
The PHC switch and it's relay are also prone to failure causing freeze ups the minute it's not blazing hot outside.
My biggest issue with the system was the crank case heater. It is critical in cold weather because without it the oil becomes sludge and your compressor will fail if you have to run it in cold temperatures. No one ever checks it until it's too late and it sucks to find out that an $80 part just cost me a $6,000 compressor.
Anyway, I set out to solve these issues and built a new control panel, the BinLogic a solid state, microprocessor based controller.
The BinLogic monitors the state of the crankcase heater, contactor, oil pressure, low and high pressure, positive harvest control, water flow and crusher rpm.
Replaces complex wiring with simple and safe 24vdc signals.
Indicator LEDs display the state of all inputs and outputs.
Response to faults is specific to the fault e.g. water flow fault will cause the system to harvest the ice and then shut down. Pressure faults response is to stop the compressor but run the pump for 90 minutes to flush any ice of the tubes.
Cold start or anytime the compressor stops there is an automatic 3 minute delay before the compressor is allowed to start up again.
Self test of water flow and crusher rotation before starting the compressor.
Cold start always begins in the harvest cycle for 30 seconds reducing the load on the compressor on startup.
Status indicator shows you what fault occurred for quick diagnosis.
Remote monitoring as status data is transmitted via serial to the PLC.