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Welcome to the Windshield Chronicles, a mental sequence of operation.

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This episode brought to you by Dennis Sukup and Sunrise Refrigeration.

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Learn more about Sunrise Refrigeration at SunriseRef.com.

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Well thank you all for joining us once again.

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We're hanging out with Dennis Sukup.

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Dennis, thanks for joining us.

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Glad to be here today, Cliffin.

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Now a lot of people know Dennis from the HVAC excellence side of the business, but they

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don't know him from the contractor side of the business.

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So Dennis, tell us a little bit about your history in the business.

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Well okay, my history in the business goes back to when my time in the Air Force was

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ending and I realized I couldn't continue to do what I did in the Air Force because

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the war was ending.

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And I was able to have the Air Force send me to a night school as an adult in uniform

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and I selected then an air conditioning program in Las Vegas that was at that time being taught

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through the college but being taught at a local high school.

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And from that I actually left there with basic skills of an air conditioning technician.

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And as an air conditioning technician, I worked for a couple companies.

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By 1981, I took the contractor's test, got my license, opened up my company as a carrier

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dealer if you will, because that's what I was doing the most with.

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And a lot of people ask me, well, how did you get so much into commercial refrigeration

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and ice machines?

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And my answer was I lied.

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I was working on a rooftop at a Carl's Jr. and I came down the ladder after fixing the

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air conditioner and the manager was in a panic going into lunch and said, can you fix my

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milkshake machine?

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And I just said, yeah, of course.

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Sure, why not?

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I'm here.

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I took the book off their shelf in their office.

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I went out to my truck and hurried up and sped through a few pages and I got lucky.

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I fixed that milkshake machine and the next thing you know, they wanted me to be their

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service company for at that time there were only four stores in Las Vegas.

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Now there are 28.

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And that led into a long history of becoming an ice machine distributor and a walk-in box

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company in Las Vegas, which my company still does today.

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And as a matter of fact, I too was in a training yesterday morning on a brand new type of ice

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machine that is coming out.

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So my entire company was in school yesterday morning for about four hours.

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Oh man, I love it.

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So you've been around and seen many changes in ice machines.

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Well, let's talk about a sequence of operation of an ice machine.

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So we're in our van, we're heading out to a job.

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All we know is that we have a call for an ice machine.

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Patch has no more information than that.

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So let's mentally prepare ourselves before we get to this job.

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And that takes me back a lot of years because it makes me think of when the first time I

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took the cover off an ice machine, I had no idea what I was going to see or what to expect.

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So yes, so now there, I don't know, probably a good seven major manufacturers of ice machines

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out there today.

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I'd say so.

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And there's some slight variances between how they do things.

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But the basic sequence of operation is going to be identical in all.

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So if I were to start with that, the first thing I'm going to say is we're going to have

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to take on some water.

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Right now, some machines are going to use a float, which is a lot like a swamp cooler

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or a toilet, if you will.

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Sure.

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Mechanical device.

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Triple in until float says we're full.

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Some machines are going to use electronic probes.

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Probes being that when the water comes in touch with them, it sends a signal through

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the water and there's an electronic board that will be involved in that machine.

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It says I now have a batch of water.

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And from that batch of water, I'm going to make a batch of ice.

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So there the first step has been set up.

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Now we're going to machine will turn on and it doesn't know sometimes how long it's been

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off.

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So that water that could be laying in there could be contaminated.

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Right.

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Who knows what's in there?

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So a lot of machines will actually dump.

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We call dump that or purge that.

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Let that water go down the drain so we start with a brand new fresh fill cycle again.

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So now we know we're hopefully taking on fresh and filtered water because there must be a

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filter hopefully attached to that machine.

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Now we begin the startup process.

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So as the machine starts up, once the fill process is going, today's modern machines

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are very clever.

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We'll actually start with opening the hot gas valve.

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Things going on right now, but by opening the hot gas valve, I've relieved the pressures

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on both sides of the machine.

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The high side is now dumped over and the high and low sides become equal.

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Well, the neat part about that is it makes the compressor start without a big load already

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on it.

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So the start becomes soft.

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I call that start and then again for five seconds, that compressor will come on and

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that valve will still remain open.

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Letting that compressor get up to RPM before it switches and starts to freeze process.

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I want to explain that because a lot of technicians miss that.

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They think there's something wrong right away.

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So after that sounds a little different on startup.

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It does.

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It does.

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It makes a big difference.

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So now when that valve finally does close and it's only a matter of seconds, we begin

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the actual freeze process.

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My evaporator plate is going to start getting very cold.

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My condenser is going to start getting very warm.

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So the one thing we know about water is we freeze the purest of water at 32 degrees.

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So this is now a cascade principle.

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We have a sump.

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We have that batch of water we talked about.

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I got a water pump that's picking it up and if you will, it's running over a dam and that's

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cascading down in and out through all the cells that make the ice.

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And think about if we're freezing the purest of the water at 32 degrees, then all the garbage

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in the water, I like to say the blood, guts and rocks, all of our impurities, minerals

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to the sump.

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Sure.

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It's in the sump and it's now allowed to be in greater concentration because that's all

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the filter does for us.

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We can't filter out scale.

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We can play with it.

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We can change its molecular structure, keep it happier in a greater concentration.

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So now that as I'm freezing that purest of ice, I have those concentrated minerals ready

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to go down the drain and start the process again.

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All right.

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So that's what's happening.

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The purest of the water is freezing in and out of these cells.

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The garbage of the water is continuing to fall to the bottom and I'm finishing filling

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in the cells.

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Here's where we need the next device.

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Something that has to tell us that ice is now present on the plate and is ready to be

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harvested.

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We like to see that the cells are filled in.

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There could be a dimple there.

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That's normal.

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We want a bridge thickness of about an eighth of an inch.

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In between each individual cell.

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Right.

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It's a webbing, if you will, connecting the cells together.

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And that's only there so that when we harvest the ice, we can harvest it in a full sheet.

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It should be an eighth of an inch because an eighth is just enough to keep it together,

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but enough so you don't need a hammer to break it apart.

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To break it apart.

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Absolutely.

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It should fall apart easily when it hits.

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An ice scoop with a bartender should be able to break it up and use that ice without a

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great difficulty.

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And when people start to adjust and play with that thickness, well then there's a lot of

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problems that occur with the machine and you start to lose production.

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So as we build that ice, we now have either, we could have an ice thickness probe, a temperature

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pressure control, or simply a sonar control that senses that the ice is there.

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It's present, it's thick enough, it's ready to be harvested.

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So boom, now we switch again, either a board or a relay and we're going to ask it to go

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into hot gas, kind of like a heat pump.

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We're going to reverse the cycle, start pumping the hot gas into the evaporator plate.

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While that's going on, don't forget about that concentrated water.

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We're sending that down the drain.

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That's going down the drain now and we're flushing.

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Getting out that debris.

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To bring on some fresh water.

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So the plate's getting warm, garbage water's going out and then pretty soon that capillary

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action on the back of that ice will let go and it's going to fall into the bin.

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Now when it falls into the bin, older machines will have a mechanical thermostat.

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If the ice lays on that stat and gets cold, it's going to shut it off.

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Newer machines will have just a damper, a damper that'll have incorporated a magnetic

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switch so when the ice hits the damper, one, it's set up the stage for another cycle.

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Or if the damper should stay open, then it's going to say, I must be a full bin and I'll

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turn it off.

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Right.

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Okay.

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So let's just assume that the bin is not full and we finally have harvested the ice.

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We'll go ahead and that damper will go down, setting up the cycle.

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It'll come right back up and go back into the free cycle.

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Now in that case, we don't have to do that beginning part where we did the soft start

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and we pre-chilled the evaporator.

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That's another important step that a lot of machines are doing today.

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We're pre-chilling the evaporator and that's what we call to prevent from slushing.

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Slushing ice can be damaging to the pump and so forth.

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But anyway, once we do that and that damper resets, we're ready to start with the free

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cycle again and then move all the way forward to a harvest.

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And if the damper should stay open, let's say for a number of minutes, 30 minutes or

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whatever, it's telling us that ice is laying there.

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It can't fall in the bin because the bin is full and it's waiting for someone to scoop

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that ice, knock it loose.

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And then the damper will start and we'll go back to that first step.

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The first step where we purge the water, bring on the fresh water, soft start, and then recycle

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again through the cascading principle, bringing the ice back to the plate to another harvest.

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Fantastic.

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Complete cycle.

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Complete cycle.

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One of the things that's, and some of the things that's kind of unique and I see as

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test questions all the time is, you know, people will say what temperature is the evaporator

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when ice is formed and they right away want to say 32 degrees.

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Right.

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Well, no, that's not true.

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It has to be colder than 32.

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It has to be colder.

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It's got to have that saturated suction temperature.

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Actually it's unique.

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It started back in the old days of R12s when I used to log it in at 18 degrees Fahrenheit.

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That was precisely the point when 32 degree water became 32 degree ice or the latent heat

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of fusion took place.

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So the evaporator was at 18 and if you looked at your charts of R12, there was your saturated

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temperature where 32 degree water became 32 degrees ice.

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And as we've migrated these years now into R290, those principles are coming back.

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That R290 is a lot like the performance of R12.

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For a while there, those pressures went way up in the years of 404.

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Especially 404.

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Yeah.

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Right.

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Now they're coming back down again to the R290s or is bringing it back down to where

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at 18 degrees, we see that latent heat of fusion.

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And if you're servicing an ice machine, it's fun to watch that exactly when it happens

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because everything will be circulating and cascading like I talked about it.

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And suddenly you can see that slush appear into your water sump.

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Some machines will do different things to combat that.

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They'll let maybe six minutes into the freeze cycle, they'll pause and pulse that incoming

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water valve and shoot some incoming tap water or warm water to counteract that slushing.

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Some machines have dampers or diverters in the trough to catch the slush before it gets

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to the pump.

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So the pump doesn't cavitate and pick up that slush.

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And then of course now most machines will pre-chill.

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Pre-chill meaning once we soft started that compressor, we'll let the evaporator freeze

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down a little bit with no pump running, no water, get it nice and cold, and then bring

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the water down and start that cascading principle.

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And it really is unique to watch that, to see it freeze the best of the water.

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That's what you have to think about.

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I'm freezing the best of that batch of water to the plate and letting the garbage cascade

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out.

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Those minerals and those deposits freeze at colder temperatures than 32.

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That's why we're able to almost purify the water during that cascading principle.

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So having an incoming filter is a good thing.

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It allows you to stay in solution and it's not going to prevent you from having to clean

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the machine, but it's going to help you.

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It won't stick to the sides and the parts as hard as it does without a filter.

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What about a general sequence of operation for cleaning a machine while we're talking

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about those heavy minerals?

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So a good cleaning process.

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The older machines, the other was absolutely not a mechanical type process.

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The new machines today are pretty simple.

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They got reminders in them.

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They're going to tell the owner and tell the technician, hey, I'm due for cleaning.

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And they're pretty much a plug and play.

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You can actually push the button and say, do you want to clean and sanitize?

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Yes.

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And then it's going to tell you, okay, now you add your chemical and basically you stand

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back and the machine will circulate.

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It'll flush, clean, flush, clean, and then it'll tell you it's time to add sanitizer.

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Now let's go beyond that.

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And this is a kind of a frustrating part for me when some people think you just pour a

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bottle of chemicals in it and you're done.

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That's not the case at all.

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So first off in effectively cleaning an ice machine and here in Las Vegas, we have some

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pretty tough water.

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People say, is it hard water in Las Vegas?

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We'll take a look at the Grand Canyon.

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Tell me what you think.

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We cut it.

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That's a lot of water.

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That's hard water.

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Okay.

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So I like to start off with you take a lot of the removable parts, take that splash

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curtain off, take that damper out, take the water sump tray out, get all that stuff to

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a three compartment sink if you can, and get it soaking in some solution to help you thoroughly

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get all of it.

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You know, then's the time I reassemble all of that and add some chemicals so that it

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can cascade over the evaporator plate.

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And you're going to need a brush.

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You need a little bit of a brush to make sure you're breaking that calcium deposits up and

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you're getting all of that off of there.

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But there's one important thing that people don't know about ice machine cleaners.

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There's a couple of grades.

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I recommend check the manufacturer because those plates are coated with certain materials.

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And if you can use the wrong ice machine cleaner, you'll damage the evaporator plate.

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But you're not done there.

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You're not done there because there is the problem of the, what we call pink slime or

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bacteria slime.

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All the ice machine cleaner in the world will not touch the slime and bacteria.

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You're not done until you've sanitized that machine.

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Sanitizer is a separate little bottle, a separate chemical.

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You put it in, let that circulate through the system inside and outside all of your

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tubes, through your cascading system, down the evaporator.

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And now you're sanitizing and killing bacteria.

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Very important in places that bake bread, throw beer cans down the drain because the

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soon as that yeast goes airborne, it's looking for the coldest, wettest place to live.

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Right.

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And where's that?

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In your ice machine.

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And the minute the health department comes in, they're going to lift the lid.

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They're going to slide a mirror underneath that water tray and they're going to see stalactites

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of slime.

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And where's that slime dripping and falling?

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On top of the ice.

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On top of the ice.

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Now again, you're not done because a lot of guys used to do this.

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In an ice machine with a bin full of ice.

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I'm sorry, but all that you're not going to contain that chemical.

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You have to do what we call in the trade, burn that ice.

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You're going to have to get rid of it.

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Think about what you're doing with it before you start.

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I usually tell the bartenders, let's fill up your station because you're going to be out

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of ice for a little while.

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Get that ice out of the bin because if you haven't taken sanitizer and sloshed and mopped

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it all around the internal liner of the bin, you have not completed your job.

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You have not sanitized.

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That's food and that's where the food is being stored.

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A lot of students used to ask me, well, Mr. Sukup, how do you know when the ice machine's

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actually clean?

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And my answer was when I let my grandkids have a drink.

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Very good point.

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Dennis Sukup, thank you so much for joining us today.

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We appreciate your time.

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You bet.

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Great.

