ice cubes are coming out really small and thin, not the full square size

Diagnosis

The Newair AI-215SS produces "thin" or undersized cubes when the thickness sensor (the infrared probe located at the top of the freezing chamber) triggers the harvest cycle prematurely. This sensor is designed to detect the opacity and depth of the ice; if it perceives the ice has reached the target thickness, it signals the machine to dump the cubes. When the sensor is obstructed, misaligned, or fooled by air bubbles/impurities in the water, it cuts the freezing cycle short, resulting in thin, fragile sheets of ice rather than solid squares. Another primary cause is insufficient water volume during the filling phase. If the water intake valve is partially clogged or the external reservoir is too low, the water doesn't reach the intended fill line. Because the sensor measures the distance from the top down, a shallow pool of water will freeze quickly, but the sensor may misread the surface level as "full thickness" due to the way light refracts through a thinner layer of ice, triggering an early dump. You can confirm this by checking if the ice is consistently thin across all cubes or if only a few are undersized.

How to Fix It

To restore full-sized ice production, follow these precise steps to optimize water flow and sensor accuracy:

1. Optimize Reservoir Elevation: If using the external water bottle system, place the bottle on a shelf or stand at least 6 to 10 inches higher than the top of the AI-215SS unit. This utilizes gravity to ensure the intake valve is fully primed and the chamber fills to the maximum capacity.
2. Clear the Intake Valve: Locate the water intake port where the tubing connects to the machine. Disconnect the line and use a fine-bristled brush or a needle to clear any calcium buildup or sediment from the small filter screen. A restricted flow prevents the chamber from filling completely, leading to thin cubes.
3. Clean the Sensor Lens: Open the top lid and locate the infrared thickness probe (the small glass/plastic lens overlooking the freezing tray). Use a cotton swab dipped in a mixture of 50% isopropyl alcohol and 50% distilled water to gently wipe the lens. Any film, mineral deposits, or frost buildup on this lens will cause the sensor to misread the ice depth.
4. Reset the Thermal Cycle: Unplug the unit from the wall for 30 minutes to allow the internal evaporator plate to completely defrost. This removes any "ghost ice" or frost buildup on the sensor housing that may be triggering premature harvest cycles.
5. Water Quality Adjustment: Fill the reservoir with filtered or distilled water. High mineral content (hard water) creates air bubbles and cloudiness in the ice, which reflects the infrared sensor's beam prematurely, tricking the machine into thinking the ice is thicker than it actually is.

If That Didn't Work

• Recalibrate the Ambient Temperature: If the machine is placed in a hot environment (above 90°F) or directly in sunlight, the internal coolant cannot keep up, and the sensor may trigger a harvest based on a temperature threshold rather than thickness. Move the unit to a cool, ventilated area with at least 4 inches of clearance on all sides.
• Check the Pump Impeller: If the water is filling slowly, the internal pump impeller may be jammed with debris. Use a thin wire to gently clear the pump intake to ensure a rapid, full fill of the freezing tray.
• Inspect for Refrigerant Leaks: If the ice is thin and takes an unusually long time to form, the unit may have a slow refrigerant leak. Check for any oily residue around the compressor area at the bottom of the machine; if found, the unit requires professional servicing as the cooling capacity has dropped.
• Hard Reset the Logic Board: While the unit is unplugged, hold the "Power" button for 15 seconds to discharge the capacitors on the control board. Plug it back in and start a fresh cycle to clear any software glitches in the harvest timing.

Heads Up

• Avoid Tap Water: Always use filtered water to prevent scale buildup on the thickness sensor, which is the #1 cause of "thin ice" syndrome in the AI-215SS model.
• Monthly Descaling: Run a cleaning cycle with a mild citric acid solution once a month to keep the intake valves and sensors free of calcium carbonate.
• Avoid Overfilling: Do not force more water into the reservoir than the maximum fill line, as this can cause overflow into the electronics and trigger erratic sensor behavior.
• Ventilation is Key: Ensure the side vents are not blocked by curtains or walls; overheating the compressor leads to inconsistent ice thickness.