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S Model Ice Machines S1400M Service Manual

1. 4 3 General decur ee ei be ee ed Lh d ua UNE 4 3 Cleaning Procedure 4 3 Sanitizing Procedure 2 1 4 4 Removal of Parts For Cleaning Sanitizing 4 5 Removing the Front Panels 4 11 Removal from Service Winterization 4 12 General je ed reae ete st emos ve s ob kam desees 4 12 Self Contained Water Cooled Ice Machines 4 12 AuCS ACCESSORY sesten hup bae ph de pad Ane PREDA Ru Ds mud ient 4 12 Section 5 Before Calling For Service Checklist 21 55 922 WE SURE ue UE ea BABIES EE BE RUE 5 1 Safety Limit Feature 5 2 2 Part No 80 1480 3 Table of Contents continued Section 6 Electrical System Energized Parts Charts 6 1 Self Contained Water Cooled Models 6 1 Wiring Diagram Sequence of Operation 6 2 Self Contained Models 6 2 Wiring Diagrams Yu MERE tie eS 6 9 Wiring Diagram Legend 6 9 Self Contained 1 Phase 6 10 Self Contained 3 Phase
2. Guardian Location 4 2 SACHET REPLACEMENT FREQUENCY Sachet packet s require replacement every thirty 30 days or whenever they come in direct contact with water Refer to chart below for requirements Ice Machine Sachet Use 51400 1 2 Although one sachet is recommended extreme conditions may necessitate using two sachet packets Guardian sachet packets are available through your local Manitowoc ice machine dealer SACHET REPLACEMENT PROCEDURE 1 Loosen the left screw and open the left front door The right front panel does not need to be removed 2 Remove and discard spent Guardian sachet packets 3 Remove the new sachet packet from foil package and install into holder Removing the foil package allows moisture in the air to activate the sachet contents 4 Close the left front door and tighten the screw 5 Discard the use sachet packet in the trash CLEAN UP PROCEDURE FOR DAMAGED PACKET 1 Remove all ice from bin dispenser and discard 2 Initiate a cleaning and sanitizing sequence on the ice machine see next pages 3 Clean the bin dispenser Flush the drain thoroughly to prevent future drain blockage 4 Sanitize the bin dispenser 5 Install a replacement sachet packet and reinstall all panels Part Number 80 1632 3 Section 4 Interior Cleaning and Sanitizing GENERAL Clean and sanitize the ice machine every six months for ef
3. Section 6 L2 or N Water Valve 99 20 21 61 22 Harvest Valve Mp E 1 7 e gt 1 He F 2E Dump Valve 75 HC ES gt t Cam OL NS 4 SE Water Pump IAE A en Trans Z 1 FIM 7 Ga N 58 Terminates at Pin Connection gt i L Contactor Co 25 56 10 Air Compressor 2 mo 74 Bin Switch 6 _ _ Voltage i ean Plug m ICE Red KO Compressor Overloa Yellow 46 Run Capacitor Black 51 85 86 IPIER bu Fan Motor Fan Cycle Fr Control C Run Capacitor 5 3137 1 Self Contained Automatic Shut Off Table 6 7 Self Contained Models 7 Automatic Shut Off Until Bin Switch Closes Toggle Switch ICE Bin Switch Open Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed 6 8 Part Number 80 1632 3 Section 6 Electrical System Wiring
4. bees 2S Hg a same COE Lg IL 7 ae B 4 E P F 4 74 42 i Trans Hh H Fuse 7a Terminates at Pin Connection 10 TT o L Contactor Coi 1 1 25 56 Air Compressor 26 Ice Thickness H 1 Water Level Probe 1 1 0 _ _ Voltage Plug Red KO Compressor Run Capacitor Contactor Overloa Yellow 46 Contacts ENG 0 Black ly 7 5 e 86 oni 2 X Fan Motor Fan Cycle wo Control C Run Capacitor V3137 2 Self Contained Water Purge 1 Water Purge 45 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor 35 sec OFF 10 sec ON 5 Water Inlet Valve OFF 6 Water Dump Valve ON 7 Contactor Coil Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed 6 2 Part Number 80 1632 3 Section 6 Electrical System 2 REFRIGERATION SYSTEM START UP The compressor starts after the 45 second water purge and it remains on throughout the Freeze and Harvest cycles The water fill valve is energized at the same time as the compressor The harvest valve s remains on for the first 5 seconds of the ini
5. 6 11 Component Specifications and Diagnostics 6 12 Maint FUSS ds 1 Eder EE Poe PR Ded pe A ROLL 6 12 Biri SWitChi iaces e Tue e Deb ble CREE Rec 6 12 Compressor Electrical Diagnostics 6 14 PTCR Diagnostics 6 15 Diagnosing Start Components 6 18 Harvest Assist Air Compressor 6 18 ICE OFF CLEAN Toggle Switch 6 19 Electronic Control Board 6 20 Ice Thickness Probe Harvest Initiation 6 22 How The Probe Works 6 22 Harvest Light Iw iss aot Eti e OR eaae VNDE Cu a eRe 6 22 Freeze Time Lock In Feature 6 22 Maximum Freeze Time 6 22 Ice Thickness 6 22 Diagnosing Ice Thickness Control Circuitry 6 23 Water Level Control Circuitry 6 24 Water Level Probe Light 6 24 Water Inlet Valve Safety 6 24 Freeze Cycle 6 24 Harvest Cycle Circuitry 6
6. SIS Ie teen AUXILLARY BASE DRAIN 1 2 CPVC SOCKET w DRAIN 1 2 NPTF Width Depth and Height Dimensions Dimension W Dimension D Dimension H 48 in 121 9 cm 24 5 in 62 2 cm 29 5 in 74 9 cm Electrical and AuCS Dimensions Electrical AuCS Dimension A Dimension B Dimension C Dimension E Dimension F 22 75 in 57 8 cm 22 25 in 56 5 cm 14 0 in 35 6 cm 9 5 in 24 1 cm 7 5 in 19 1 cm Part Number 80 1632 3 Installation Instructions Location of Ice Machine The location selected for the ice machine must meet the following criteria If any of these criteria are not met select another location The location must be free of airborne and other contaminants The air temperature must be at least 35 F 1 6 C but must not exceed 110 F 43 4 The location must not be near heat generating equipment or in direct sunlight and must be protected from weather The location must not obstruct air flow through or around the ice machine Refer to the chart below for clearance requirements Section 2 Ice Machine Heat of Rejection 1400M Water Cooled Top Sides 8 20 3 cm Back 5 12 7 cm There is no minimum clearance required for water cooled or remote ice machines This value is recommended for efficient operation and servicing only Caution The ice machine must be protected if it will be subjected to temperatures below 32 F 0 C
7. S Model Ice Machines 51400 Service Manual Thank you for selecting a Manitowoc Ice Machine the dependability leader in ice making equipment and related products With proper installation care and maintenance your new Manitowoc Ice Machine will provide you with many years of reliable and economical performance This manual is updated as new information and models are released Visit our website for the latest manual Part Number 80 1632 3 www manitowocice com 10 2004 Safety Notices As you work on a S Series Ice Machine be sure to pay close attention to the safety notices in this manual Disregarding the notices may lead to serious injury and or damage to the ice machine Throughout this manual you will see the following types of safety notices Procedural Notices As you work on a S Series Ice Machine be sure to read the procedural notices in this manual These notices supply helpful information which may assist you as you work Throughout this manual you will see the following types of procedural notices A Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications A Warning Text in a Warning box alerts you to a potential personal injury situation Be sure to read the Warning statement before proceeding and work carefully Caution Text in a Caution box aler
8. 2 Feel the inlet of the harvest valve s Refrigeration System 3 Feel the compressor discharge line A Warning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand Just touch them momentarily 4 Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line Findings Comments The inlet of the harvest valve is cool enough to touch and the compressor discharge line is hot This is normal as the discharge line should always be too hot to touch and the harvest valve inlet although too hot to touch during harvest should be cool enough to touch after 5 minutes into the freeze cycle The inlet of the harvest valve is hot and approaches the temperature of a hot compressor discharge line This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest valve and the compressor discharge line are cool enough to touch This is an indication something is wrong causing the compressor discharge line to be cool to the touch This is not caused by a harvest valve leaking Important Feeling the harvest valve outlet or across the h
9. Failure caused by exposure to freezing temperatures is not covered by the warranty See Removal from Service Winterization Series Heat of Rejection Ice Machine Air Conditioning Peak 51400 19000 28000 B T U Hour Because the heat of rejection varies during the ice making cycle the figure shown is an average Ice machines like other refrigeration equipment reject heat through the condenser It is helpful to know the amount of heat rejected by the ice machine when sizing air conditioning equipment where self contained air cooled ice machines are installed This information is also necessary when evaluating the benefits of using water cooled or remote condensers to reduce air conditioning loads The amount of heat added to an air conditioned environment by an ice machine using a water cooled or remote condenser is negligible Knowing the amount of heat rejected is also important when sizing a cooling tower for a water cooled condenser Use the peak figure for sizing the cooling tower Part Number 80 1632 3 Section 2 Electrical Service GENERAL A Warning All wiring must conform to local state and national codes VOLTAGE The maximum allowable voltage variation is 10 of the rated voltage at ice machine start up when the electrical load is highest A Warning The ice machine must be grounded in accordance with national and local electrical codes S Series Ice Machines
10. Installation Instructions Important Observe correct polarity of incoming line voltage Fuse Circuit Breaker A separate fuse circuit breaker must be provided for each ice machine Circuit breakers must be H A C R rated does not apply in Canada MINIMUM CIRCUIT AMPACITY The minimum circuit ampacity is used to help select the wire size of the electrical supply Minimum circuit ampacity is not the ice machine s running amp load The wire size or gauge is also dependent upon location materials used length of run etc so it must be determined by a qualified electrician ELECTRICAL REQUIREMENTS Refer to Ice Machine Model Serial Plate for voltage amperage specifications Air Cooled Water Cooled Remote Voltage Ice Machine Phase Maximum Minimum Maximum Minimum Maximum Minimum Cycle Fuse Circuit Circuit Amps Fuse Circuit Circuit Amps Fuse Circuit Circuit Amps Breaker Breaker Breaker 208 230 1 60 30 17 5 30 16 1 30 17 1 51400 208 230 3 60 20 13 2 20 11 8 20 12 8 230 1 50 30 15 1 30 13 7 30 14 7 Part Number 80 1632 3 2 3 Installation Instructions Section 2 Self Contained Electrical Wiring Connections A Warning SELF CONTAINED ICE MACHINE 208 230 3 60 These diagrams are not intended to show proper wire routing wire sizing disconnects etc only the correct wire connections electrical work including wire routing and grounding must conf
11. to carefully clean the parts A Warning Disconnect electric power to the ice machine and dispenser if applicable at the electric switch box before proceeding Caution Do not mix Cleaner and Sanitizer solutions together It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling 2 Remove all ice from the bin 3 Remove the water curtain and the components you want to clean or sanitize See the following pages for removal procedures for these parts Caution Do not immerse the water pump motor in the cleaning or sanitizing solution A Warning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner or Sanitizer 4 Soak the removed part s in a properly mixed solution Solution Type Water Mixed With Cleaner 1 gal 4 I 16 oz 500 ml cleaner Sanitizer 4 gal 15 1 3 oz 90 ml sanitizer Part Number 80 1632 3 6 Use the sanitizing solution and a sponge or cloth to sanitize wipe the interior of the ice machine and the entire inside of the bin dispenser 7 Thoroughly rinse all of the parts and surfaces with clear water 8 Install the removed parts NOTE Incomplete rinsing of the ice thickness probe or water level probe may leave a residue This could cause the ice machine to malfunction For best results brush or wipe the probes off while rinsing
12. 3 The current passing through the PTCR causes it to rapidly heat up and after approximately 25 1 second it abruptly switches to a very high resistance virtually stopping current flow through it 4 At this point the motor is up to speed and all current going through the start winding will now pass through the run capacitor 5 The PTCR remains hot and at a high resistance as long as voltage remains on the circuit 6 It is important to provide time between compressor restarts to allow the PTCR to cool down to near its initial temperature low resistance When th 3158 6 contactor opens to stop the compressor the PTCR cools down to its initial low resistance and is again ready to provide starting torque assistance To assure the PTCR has cooled down during an automatic shut off the S model ice machines have a built in 3 minute off time before it can restart 6 15 Electrical System S Model Automatic Shut Off and Restart When the storage bin is full at the end of a harvest cycle the sheet of cubes fails to clear the water curtain and will hold it open After the water curtain is held open for 30 seconds the ice machine shuts off To assure the PTCR has cooled the ice machine remains off for 3 minutes before it can automatically restart The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain As the water curtain swings back to operating posi
13. 6 No water or air flowing through the condenser will cause the HPCO control to open because of excessive pressure Watch the pressure gauge and record the cut out pressure A Warning If discharge pressure exceeds 460 psig 2068 kPa 20 68 Bar and the HPCO control does not cut out set ICE OFF CLEAN switch to OFF to stop ice machine operation Replace the HPCO control if it Will not reset below 300 psig 2068 kPa 20 68 Bar Does not open at the specified cut out point Part Number 80 1632 3 Refrigeration System 7 19 Refrigeration System Cycle Time 24 Hour Ice Production Refrigerant Pressure Charts These charts are used as guidelines to verify correct ice machine operation Accurate collection of data is essential to obtain the correct diagnosis Refer to OPERATIONAL ANALYSIS TABLE for the list of data that must be collected for refrigeration diagnostics This list includes before beginning service ice production check installation visual inspection water system checklist ice formation pattern safety limits comparing evaporator inlet outlet temperatures discharge and suction pressure analysis Ice production checks that are within 10 of the chart are considered normal This is due to variances in water and air temperature Actual temperatures will seldom match the chart exactly Zero out manifold gauge set before obtaining pressure readings to avoid misdiagnosis Disc
14. Automatic Cleaning System This optional accessory monitors ice making cycles and initiates cleaning procedures automatically The AuCS amp accessory can be set to automatically clean or sanitize the ice machine every 2 4 or 12 weeks Refer to the AuCS Installation Use and Care Manual for details Part Number 80 1632 3 Section 3 Ice Machine Operation Section 3 Ice Machine Operation Component Identification Water Distribution Tube Toggle Switch Water Curtain L _ LE 1 Dump Valve 1 Check Valve RAM Ice Thickness Probe Bin Switch Water Level Probe Water Inlet Location Water Pump Water Inlet Valve Located in Refrigeration Compartment sv3150 Part Number 80 1632 3 3 1 Ice Machine Operation Sequence Of Operation NOTE The toggle switch must be in the ice position and the water curtain must be in place on the evaporator before the ice machine will start INITIAL START UP OR START UP AFTER AUTOMATIC SHUT OFF 1 Water Purge Before the compressor starts the water pump and water dump solenoid are energized for 45 seconds to completely purge the ice machine of old water This feature ensures that the ice making cycle starts with fresh water The harvest valve s is also energized during water purge although it stays on for an additional 5 seconds 50 seconds total on time during the initial refrigeratio
15. Diagrams The following pages contain electrical wiring diagrams Be sure you are referring to the correct diagram for the ice machine which you are servicing A Warning Always disconnect power before working on electrical circuitry WIRING DIAGRAM LEGEND The following symbols are used on all of the wiring diagrams i Internal Compressor Overload Some models have external compressor overloads Fan Motor Run Capacitor Some models do not incorporate fan motor run capacitor TB Terminal Board Connection Terminal board numbers are printed on the actual terminal board Wire Number Designation The number is marked at each end of the wire gt gt Multi Pin Connection Electrical Box Side gt gt Compressor Compartment Side Part Number 80 1632 3 6 9 Electrical System SELF CONTAINED 1 PHASE L1 20 4 89 55 HIGH PRESSURE CONTROL BOARD CUTOUT T 121 inate E 88 TRANS W FUSE 7 58 EF ir O CLEAN 1 O LEFT BIN O RIGHT BIN 42 O RMT BIN WTR PROBE O ICE PROBE O HARVEST 5 1 51 2 ICE THICKNESS PROBE 7d a I WATER LEVEL AC PROBE LOWD VOLTAGE PLUG CONTACTOR CONTACTS Section 6 WATER VALVE L2 ORN 21 22 LH HARVEST 77 na 88 RH 99 SOLENOID 80 76 DUMP 81 87 SOLENOID WATER S PUMP TERMINATES AT PIN CO
16. MAXIMUM FREEZE TIME The control system includes a built in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle 6 22 Section 6 ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 32 cm NOTE Make sure the water curtain is in place when performing this check It prevents water from splashing out of the water trough 1 Inspect the bridge connecting the cubes It should be about 1 8 32 cm thick 2 If adjustment is necessary turn the ice thickness probe adjustment screw clockwise to increase bridge thickness or counterclockwise to decrease bridge thickness Set a 1 4 gap between the ice thickness probe and evaporator as a starting point Then adjust to achieve a 1 8 bridge thickness NOTE The starting point before final adjustment is approximately a 3 16 inch gap ADJUSTING SCREW Nc o 1 8 ICE BRIDGE THICKNESS B Ice Thickness Check 5 3132 Make sure the thickness probe wire and the bracket do not restrict movement of the probe Ice Thickness Probe Cleaning 1 Mix a solution of Manitowoc ice machine cleaner and water 2 ounces of cleaner to 16 ounces of water in a container 2 Soak ice thickness probe in container of cleaner water solution while disassembling and cleaning water circuit components soak ice thickness probe for 10 minutes or longer 3
17. Refer to Safety Limit Feature on the next page Ice machine does not release ice or is slow to harvest Ice machine is dirty Clean and sanitize the ice machine See Section 4 Ice machine is not level Level the ice machine See Section 2 Low air temperature around ice machine head section Air temperature must be at least 35 F 1 6 C Ice machine does not cycle into harvest mode The six minute freeze time lock in has not expired yet Wait for the freeze lock in to expire Ice thickness probe is dirty Clean and sanitize the ice machine See Section 4 Ice thickness probe is disconnected Connect the wire Ice thickness probe is out of adjustment Adjust the ice thickness probe See Section 3 Uneven ice fill thin at the top of evaporator Verify sufficient water level in sump trough Contact a qualified service company to check refrigeration system Ice quality is poor soft or not clear Poor incoming water quality Contact a qualified service company to test the quality of the incoming water and make appropriate filter recommendations Water filtration is poor Replace the filter Ice machine is dirty Clean and sanitize the ice machine See Section 4 Water dump valve is not working Disassemble and clean the water dump valve See Section 4 Water softener is working improperly if applicable Repair
18. Section 7 ICE FORMATION PATTERN Evaporator ice formation pattern analysis is helpful in ice machine diagnostics Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction However when this analysis is used along with Manitowoc s Refrigeration System Operational Analysis Table it can help diagnose an ice machine malfunction Improper ice formation can be caused by any number of problems Important Keep the water curtain in place while checking the ice formation pattern to ensure no water is lost 1 Normal Ice Formation Ice forms across the entire evaporator surface At the beginning of the freeze cycle it may appear that more ice is forming at the inlet of the evaporator than at the outlet At the end of the freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet of the evaporator may be more pronounced than those at the inlet This is normal The ice thickness probe must be set to maintain the ice bridge thickness at approximately 1 8 If ice forms uniformly across the evaporator surface but does not reach 1 8 in the proper amount of time this is still considered normal Part Number 80 1632 3 Refrigeration System 2 Extremely Thin at Evaporator Outlet There is no ice or a considerable lack of ice formation at the outlet of the evaporator Examples No ice at all at th
19. Use sanitizer to remove algae or slime Do not use it to remove lime scale or other mineral deposits Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle Or set the switch to the OFF position and allow the ice to melt off the evaporator Caution Never use anything to force ice from the evaporator Damage may result A Warning Disconnect electric power to the ice machine and dispenser if applicable at the electric switch box before proceeding Step 2 Refer to Removal of Parts For Cleaning Sanitizing and remove ice machine parts Step 3 Mix a solution of water and sanitizer Solution Type Water Mixed With Sanitizer 4 gal 15 1 3 oz 90 ml sanitizer 4 4 Section 4 Step 4 Use the sanitizing solution and a sponge or cloth to sanitize wipe all parts and interior surfaces of the ice machine Sanitize the following areas A Side walls B Base area above water trough C Evaporator plastic parts D Bin or dispenser Step 5 Rinse all sanitized areas with clear water Step 6 Install the removed parts restore power and place toggle switch in the ice position Part Number 80 1632 3 Section 4 REMOVAL OF PARTS FOR CLEANING SANITIZING 1 Turn off the electrical and water supply to the ice machine and dispenser when applicable Maintenance 5 Use a soft bristle brush or sponge NOT a wire brush
20. causes Water inlet valve water pump starving expansion valve low refrigerant charge compressor etc OUTLET INLET Figure 7 6 No Ice Formation Important The S1400M model machines have left and right expansion valves and separate evaporator circuits These circuits operate independently from each other Therefore one may operate properly while the other is malfunctioning Example If the left expansion valve is starving it may not affect the ice formation pattern on the entire right side of the evaporator OUTLET INLET Figure 7 7 51400 Evaporator Tubing Part Number 80 1632 3 Section 7 SAFETY LIMITS General In addition to standard safety controls such as high pressure cut out the control board has two built in safety limit controls which protect the ice machine from major component failures Safety Limit 1 If the freeze time reaches 60 minutes the control board automatically initiates a harvest cycle If 6 consecutive 60 minute freeze cycles occur the ice machine stops Safety Limit 2 If the harvest time reaches 3 5 minutes the control board automatically returns the ice machine to the freeze cycle If 500 consecutive 3 5 minute harvest cycles occur the ice machine stops Safety Limit Indication When a safety limit condition is exceeded Six consecutive cycles for safety limit 1 the control board enters the limit into memory Three consecutiv
21. is improperly installed Reinstall according to the Installation Manual 7 6 Section 7 WATER SYSTEM CHECKLIST A water related problem often causes the same symptoms as a refrigeration system component malfunction Water system problems must be identified and eliminated prior to replacing refrigeration components Possible Problem Corrective Action Water area evaporator is dirty Clean as needed Water inlet pressure not between 20 and 80 psi 1 5 Bar 138 552 kPa Install a water regulator valve or increase the water pressure Incoming water temperature is not between 35 F 1 6 C and 90 F 32 2 If too hot check the hot water line check valves in other store equipment Water filtration is plugged if used Water dump valve leaking during the freeze cycle Vent tube is not installed on water outlet drain Hoses fittings etc are leaking water Water fill valve is stuck open Water is spraying out of the sump trough area Uneven water flow across the evaporator Install a new water filter Clean replace dump valve as needed See Installation Instructions Repair replace as needed Clean replace as needed Stop the water spray Clean the ice machine Water is freezing behind the evaporator Correct the water flow Plastic extrusions and gaskets are not secured to the evaporator Remount replace as needed Part Number 80 1632 3
22. it Thoroughly dry the probes before installing them 9 Turn on the water and electrical supply 4 5 Maintenance 1 Water Curtain A Gently flex the curtain in the center and remove it from the right side B Slide the left pin out SV3153 Water Curtain Removal 4 6 Section 4 2 Ice Thickness Probe A Compress the hinge pin on the top of the ice thickness probe COMPRESS HINGE PIN TO REMOVE SV3135 Ice Thickness Probe Removal B Pivot the ice thickness probe to disengage one pin then the other The ice thickness probe can be cleaned at this point without complete removal Follow Step C for complete removal A Warning Disconnect the electric power to the ice machine at the electric service switch box C Disconnect the ice thickness control wiring from the control board Part Number 80 1632 3 Section 4 3 Water Distribution Tube A Warning Removing the distribution tube while the water pump is running will allow water to spray from ice machine Disconnect the electrical power to the ice machine and dispenser at the electric service switch box and turn off the water supply NOTE Distribution tube thumbscrews are retained by o rings to prevent loss Loosen thumbscrews but do not pull thumbscrews out of distribution tube Water Distribution Tube Removal A Remove outer half of distribution tube by loosening the four 4 thumbscrews o rings retain t
23. neta RR Nr NER E Aa E Rad 1 2 Bin Caster x o utente idi wee aea ec as Ete es 1 2 dco 1 2 Guardian Sachet Packets 1 2 Arctic Pure Water Filter System 1 2 Manitowoc Cleaner and Sanitizer 1 2 AuCS Automatic Cleaning System 1 2 DISPENSER iun p Ee en C eret Gig ce e de RR A eR E obe D 1 2 Model Serial Number Location 1 3 Owner Warranty Registration Card 1 4 si E Met eos rd duret EU HUM eR c 1 4 Warranty Coverage 14 General cnp er Mu MeL E atin eS 1 4 lt 4 eat lode dion s teles Dare a d ed sl deae Poe e dele 1 4 Labor uci o Ret eas TUE he cael dels E NEA 1 4 Tcu 1 4 Authorized Warranty Service 1 4 Section 2 Installation Instructions General ES 2 1 Ice Machine Dimensions 2 1 51400 Water Cooled Ice Machines 2 1 Location of Ice Machine 2 2 Ice Machine Heat of Rejection 2 2 Electrical Service 2 E eR RR RE Ra MER ROI AE 2 3 General narrar hen ER B
24. switch in the CLEAN position The water will flow through the water dump valve and down the drain The Clean light will turn on to indicate the ice machine is in the Cleaning mode Step 3 Wait about two minutes or until water starts to flow over the evaporator Step 4 Add the proper amount of Manitowoc Ice Machine Cleaner to the water trough Model 51400 Amount of Cleaner 9 ounces 266 ml Step 5 The ice machine will automatically time out a ten minute cleaning cycle followed by six rinse cycles and stop The Clean light will turn off to indicate the Cleaning cycle is completed This entire cycle lasts approximately 30 minutes Step 6 When the cleaning process stops move the toggle switch to OFF position Refer to Sanitizing Procedure on the next page Step 7 A The ice machine may be set to start and finish a self cleaning procedure then automatically start ice making again B You must wait about one minute into the cleaning cycle until water starts to flow over the evaporator then move the switch from CLEAN to ICE position C When the self cleaning cycle is completed an ice making sequence will start automatically Important After the toggle switch is moved to the ICE position opening the curtain switch will interrupt the cleaning sequence The sequence will resume from the point of interruption when the curtain switch closes 4 3 Maintenance SANITIZING PROCEDURE
25. the ice machine This may be difficult to diagnose as many external problems occur intermittently Example An ice machine stops intermittently on safety limit 1 long freeze times The problem could be a low ambient temperature at night a water pressure drop the water is turned off one night a week etc Refrigeration and electrical component failures may also trip a safety limit Eliminate all electrical components and external causes first If it appears that the refrigeration system is causing the problem use Manitowoc s Refrigeration System Operational Analysis Table along with detailed charts checklists and other references to determine the cause The following checklists are designed to assist the service technician in analysis However because there are many possible external problems do not limit your diagnosis to only the items listed 7 9 Refrigeration System Safety Limit 1 Refer to previous page for safety limit operation Section 7 Freeze time exceeds 60 minutes for 6 consecutive freeze cycles Possible Cause Check Correct Improper installation Water system See Installation Visual Inspection Checklist Low water pressure 20 psi 138 kPa min High water pressure 80 psi 552 kPa max High water temperature 90 F 32 2 C max Clogged water distribution tube Dirty defective water fill valve Dirty defective water dump valve Defective water pump Loss of water from sump are
26. to OFF and then back to ICE In addition to the standard safety controls such as the high pressure cutout your Manitowoc ice machine A features built in safety limits which will stop the ice machine if conditions arise which could cause a major component failure Before calling for service re start the ice machine using the following procedure 5 2 If the safety limit feature has stopped the ice machine it will restart after a short delay Proceed to step 2 B If the ice machine does not restart see Ice page machine does not operate on the previous 2 Allow the ice machine to run to determine if the condition is recurring A Ifthe ice machine stops again the condition has recurred Call for service B Ifthe ice machine continues to run the condition has corrected itself Allow the ice machine to continue running Part Number 80 1632 3 Section 6 Electrical System Section 6 Electrical System Energized Parts Charts SELF CONTAINED WATER COOLED MODELS Control Board Relays Contactor Ice Making 1 2 3 4 5 6 7 7A 7B Sequence Of H H W Cond Length ti Water arvest arvest Air ater Dump Contactor one Of Time peration Pum Valve Valve omoa Inlet Valve Coil Comp Fan Left Right Valve Motor 35 sec START UP On x On On when Off On Off Off Off 45 Seconds 1 Water Purge used 10 sec On 2 Refrigeration
27. top of the coil 3 Note the position of the coil assembly on the valve for assembly later Leaving the wires attached lift the coil assembly off the valve body and the enclosing tube 4 Press down on the plastic nut on the enclosing tube and rotate it 1 4 turn Remove the enclosing tube plunger and plastic gasket from the valve body NOTE At this point the water dump valve can easily be cleaned If complete removal is desired continue with step 5 Part Number 80 1632 3 NOTE During cleaning do not stretch damage or remove the spring from the plunger If it is removed slide the spring s flared end into the plunger s slotted top opening until the spring contacts the plunger spring stop 5 Remove the valve body 6 Remove the tubing from the dump valve by twisting the clamps off 7 Remove the two screws securing the dump valve and the mounting bracket PLUNGER SPRING STOP CAP E COIL SPRING ae PLUNGER e DIAPHRAM ENCLOSING TUBE Dump Valve Disassembly VALVE BODY 4 9 Maintenance Section 4 Evaporator Tray Removal Drain Line Check Valve 1 Remove the water trough The drain line check valve normally does not require removal for cleaning Water loss from the sump trough will indicate removal and cleaning are required A Po 1 5 3154 2 Remove thumbscrew on left side of tray 3 Allow left side of tray to drop as you pull the tray to the left side Continu
28. with HFC refrigerant The same as R 502 Manitowoc recommends charging only liquid refrigerant into the high side of the system Part Number 80 1632 3 Attend A Manitowoc Factory Service School Improve Your Service Techniques Network with Your Peers 4 1 2 Days of Intensive Training on Manitowoc Ice Machines Extensive Hands Training on a Variety of Equipment Breakfast Lunch and Hotel Room Included with Tuition Contact Your Distributor or Manitowoc Ice Inc for Details OR Visit Our Website at www manitowocice com for School Dates MANITOWOC ICE INC 2110 South 26th Street Box 1720 Manitowoc WI 54221 1720 Phone 920 682 0161 Service Fax 920 683 7585 Web Site www manitowocice com 2004 Manitowoc lce Inc
29. 096 7 25 Refrigeration System Section 7 FIG A PINCHING OFF TUBING TYPICAL PRESSURE CONTROL SHOWN PINCH OFF TOOL USED HERE SEE FIG A AND FIG FIG B RE ROUNDING TUBING SV1406 Figure 7 10 Using Pinch Off Tool 7 26 Part Number 80 1632 3 Section 7 FILTER DRIERS The filter driers used on Manitowoc ice machines are manufactured to Manitowoc specifications The difference between Manitowoc driers and off the shelf driers is in filtration Manitowoc driers have dirt retaining filtration with fiberglass filters on both the inlet and outlet ends This is very important because ice machines have a back flushing action which takes place during every harvest cycle These filter driers have a very high moisture removal capability and a good acid removal capability The size of the filter drier is important The refrigerant charge is critical Using an improperly sized filter drier will cause the ice machine to be improperly charged with refrigerant Important Driers are covered as a warranty part The drier must be replaced any time the system is opened for repairs Listed below are the recommended O E M field replacement driers Drier Part Model Connection Size Number Size 51400 0535 3 8 82 5333 3 Suction Filter UK 165S 5 8 89 3028 3 Suction Filter used when cleaning up severely contaminated syste
30. 24 Diagnosing Water Level Control Circuitry 6 25 Diagnosing An Ice Machine That Will Not Run 6 27 Section 7 Refrigeration System Sequence of Operation 7 1 Self Contained Water Cooled Models 7 1 1400 Self Contained Tubing Schematic 7 4 Operational Analysis Diagnostics 7 5 cv EE HET eon Saud ba ac 7 5 Before Beginning Service 7 6 Ice Production Check 7 6 Installation Visual Inspection Checklist 7 7 Water System Checklist 7 7 Ice Formation Pattern 7 8 Safety LIMIS ve swale ice ood Riese 7 10 Analyzing Discharge Pressure During Freeze or Harvest Cycle 7 13 Analyzing Suction Pressure During Freeze 7 14 Harvest Valve Temperature 7 16 Discharge Line Temperature Analysis 7 17 How to Use the Refrigeration System Operational Analysis Tables 7 18 Refrigeration System Operational Analysis 7 19 Pressure Control Spe
31. 245 40 28 160 175 70 90 70 21 1 235 245 42 29 160 175 75 100 80 26 7 235 260 42 30 170 195 80 105 90 32 2 240 270 42 30 180 200 85 110 100 37 8 250 280 43 30 185 200 90 110 110 43 3 250 285 44 31 190 205 90 115 Suction pressure drops gradually throughout the freeze cycle Part Number 80 1632 3 Section 7 Refrigeration System Refrigerant Recovery Evacuation and Recharging NORMAL SELF CONTAINED MODEL PROCEDURES Refrigerant Recovery Evacuation Do not purge refrigerant to the atmosphere Capture refrigerant using recovery equipment Follow the manufacturer s recommendations Important Manitowoc Ice Inc assumes no responsibility for the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company Important Replace the liquid line drier before evacuating and recharging Use only a Manitowoc O E M liquid line filter drier to prevent voiding the warranty CONNECTIONS Manifold gauge sets must utilize low loss fittings to comply with U S Government rules and regulations Make these connections 1 Suction side of the compressor through the suction service valve 2 Discharge side of the compressor through the discharge service valve Part Number 80 1632 3 SELF CONTAINED RECOVERY EVACUATION 1 Place the toggle switch in the OFF position 2 Install manifold gauges scale and recovery unit or two stage
32. 7 6 Harvest Until Bin Switch Activation Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF May Cycle ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Part Number 80 1632 3 6 7 Electrical System Automatic Shut Off 7 AUTOMATIC SHUT OFF When the storage bin is full at the end of a harvest cycle the sheet of cubes fails to clear the water curtain and holds it open After the water curtain is held open for 30 seconds the ice machine shuts off L1 Ground 89 High Cutout 55 88 The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain As the water curtain swings back to the operating position the bin switch closes and the ice machine restarts steps 1 2 provided the 3 minute delay period is complete 42 Ice Thickness Probe NOTE The ice machine must remain off for 3 minutes before it can automatically restart Contactor Contacts
33. 80 1632 3 If the toggle switch is moved to the OFF position and then back to the ICE position prior to reaching the 100 harvest point the last safety limit exceeded will be indicated e Ifa Safety Limit light did not flash prior to the ice machine restarting then the ice machine did not stop because it exceeded a safety limit 7 11 Refrigeration System ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE Procedure 1 Determine the ice machine operating conditions Air temp entering condenser Air temp around ice machine Water temp entering sump trough being checked Use the operating conditions determined in step find the published normal discharge pressures Freeze Cycle Harvest Cycle Refer to Operating Pressure Chart for ice machine Section 7 3 Perform an actual discharge pressure check Freeze Cycle PSIG kPa Harvest Cycle PSIG kPa Beginning of Cycle Middle of Cycle End of Cycle 4 Compare the actual discharge pressure step 3 with the published discharge pressure step 2 The discharge pressure is normal when the actual pressure falls within the published pressure range for the ice machine s operating conditions 1 to Freeze Cycle Discharge Pressure High Checklist Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Restricted condenser water flow water cooled models Low water pressur
34. 9 89 55 amp High Pressure The harvest valve s opens at the beginning of the water purge to divert hot refrigerant gas into the 8j Cutout rE evaporator er The water pump continues to run the water dump valve energizes for 45 seconds to purge the water in the sump trough The water fill valve energizes and de energizes strictly by time The water fill valve energizes for the last 15 seconds of the 45 second water purge r L i Ice Thickness Probe After the 45 second water purge the water fill valve water pump and dump valve de energize eg Water Purge Adjustment for details The air compressor when used will energize after 35 seconds Contactor Overload Contacts 51 85 C Fan Cycle Control 86 Section 6 L2 or N Water Valve 99 20 Terminates at Pin Connection Air Compressor 2 Bin Switch 6 Run Capacitor Fan Motor R it un Capacitor SV31 37 6 Self Contained Water Purge Table 6 5 Self Contained Models 5 Water Purge 45 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON after 35 seconds 30 seconds OFF 5 Water Inlet Valve 15 seconds ON 6 Water
35. AINED TUBING SCHEMATIC HEAT EXCHANGER i W EXPANSION VALVE HARVEST SOLENOID VALVE COMPRESSOR RECEIVER NOTE The refrigeration sequence for self contained dual expansion valve ice machines is identical to self contained single expansion valve ice machines See Pages 7 1 and 7 2 for sequence of operation Part Number 80 1632 3 Refrigeration System EXPANSION VALVE HARVEST SOLENOID VALVE AIR OR WATER COOLED CONDENSER Section 7 Refrigeration System Operational Analysis Diagnostics GENERAL When analyzing the refrigeration system it is important to understand that different refrigeration component malfunctions may cause very similar symptoms Also many external factors can make good refrigeration components appear bad These factors can include improper installation or water system malfunctions such as hot incoming water supply or water loss The following two examples illustrate how similar symptoms can result in a misdiagnosis 1 An expansion valve bulb that is not securely fastened to the suction line and or not insulated will cause a good expansion valve to flood If a service technician fails to check for proper expansion valve bulb mounting he may replace the expansion valve in error The ice machine now functions normally The technician erroneously thinks that the problem was properly diagnosed and corrected by replacing the expansio
36. Clean all ice thickness probe surfaces including all plastic parts do not use abrasives Verify the ice thickness probe cavity is clean Thoroughly rinse ice thickness probe including cavity with clean water then dry completely Incomplete rinsing and drying of the ice thickness probe can cause premature harvest 4 Reinstall ice thickness probe then sanitize all ice machine and bin dispenser interior surfaces Part Number 80 1632 3 Section 6 DIAGNOSING ICE THICKNESS CONTROL CIRCUITRY Electrical System Ice Machine Does Not Cycle Into Harvest When Water Contacts The Ice Thickness Control Probe Step 1 Bypass the freeze time lock in feature by moving the ICE OFF CLEAN switch to OFF and back to ICE Step 2 Wait until the water starts to flow over the evaporator freeze cycle Step 3 Disconnect the ice thickness control from the control board then connect a jumper wire from the control board to any cabinet ground and monitor the harvest light Monitoring of Harvest Light Correction The harvest light comes on and 10 seconds later ice machine cycles from freeze to harvest The ice thickness probe is causing the malfunction The harvest light comes on but the ice machine stays in the freeze sequence The harvest light does not come on The control circuitry is functioning properly The ice machine is in a six minute freeze time lock in verify step 1 of this procedure was followed correctly The co
37. Dump Valve ON 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF May Cycle ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed 6 6 Part Number 80 1632 3 Section 6 6 HARVEST The harvest valve s remains open and the refrigerant gas warms the evaporator This causes the cubes to slide as a sheet off the evaporator and into the storage bin The sliding sheet of cubes swings the water curtain out opening the bin switch This momentary opening and closing of the bin switch terminates the Harvest Cycle and returns the ice machine to the Freeze Cycle steps 3 4 The air compressor when used remains energized throughout the entire harvest cycle The air compressor will automatically energize after 60 seconds when the harvest cycle time exceeded 75 seconds in the previous cycle Table 6 6 Self Contained Models L1 Ground 55 89 amp High Pressure 88 Cutout Ice Thickness Control Board Probe Contactor Contacts 51 Overload 85 C Fan Cycle 86 Control Electrical System L2 or N Water Valve 21 C Ca 22 Harvest Valve AN 99 Qo Terminates at Pin Connection Air Compressor 2 Bin Switch 6 Run Capacitor Fan Motor p Run Capacitor SV3137
38. HE PROBE WORKS Manitowoc s electronic sensing circuit does not rely on refrigerant pressure evaporator temperature water levels or timers to produce consistent ice formation As ice forms on the evaporator water not ice contacts the ice thickness probe After the water completes this circuit across the probe continuously for 6 10 seconds a harvest cycle is initiated SV3135 Ice Thickness Probe HARVEST LIGHT This light s function is to be on as water contacts the ice thickness probe during the freeze cycle and remain on throughout the entire harvest cycle The light will flicker as water splashes on the probes FREEZE TIME LOCK IN FEATURE The ice machine control system incorporates a freeze time lock in feature This prevents the ice machine from short cycling in and out of harvest The control board locks the ice machine in the freeze cycle for six minutes If water contacts the ice thickness probe during these six minutes the harvest light will come on to indicate that water is in contact with the probe but the ice machine will stay in the freeze cycle After the six minutes are up a harvest cycle is initiated This is important to remember when performing diagnostic procedures on the ice thickness control circuitry To allow the service technician to initiate a harvest cycle without delay this feature is not used on the first cycle after moving the toggle switch OFF and back to ICE
39. Line Temperature Record freeze cycle discharge line temperature at the end of the freeze cycle oF C Discharge line temperature 160 F 71 1 C or higher at the end of the freeze cycle Discharge line temperature 160 F 71 1 C or higher at the end of the freeze cycle Discharge line temperature less than 160 F 71 1 C at the end of the freeze cycle Discharge line temperature 160 F 71 1 C or higher at the end of the freeze cycle Final Analysis Enter total number of boxes checked in each column Harvest Valve Leaking Low On Charge Or TXV Starving TXV Flooding Compressor 7 18 Part Number 80 1632 3 Section 7 Pressure Control Specifications and Diagnostics HIGH PRESSURE CUT OUT HPCO CONTROL Function Stops the ice machine if subjected to excessive high side pressure The HPCO control is normally closed and opens on a rise in discharge pressure Specifications Cut out 450 psig 10 3103 kPa 69 31 Bar 69 Cut in Manual or automatic reset Must be below 300 psig 2068 kPa 20 68 Bar 69 to reset Check Procedure 1 Set ICE OFF CLEAN switch to OFF 2 Connect manifold gauges 3 Hook voltmeter in parallel across the HPCO leaving wires attached 4 On water cooled models close the water service valve to the water condenser inlet On self contained air cooled and remote models disconnect the fan motor 5 Set ICE OFF CLEAN switch to ICE
40. NNECTION AIR COMPRESSOR WHEN USED 74 75 OVERLOAD C 46 50 BLACK PTCR oye e FAN MOTOR AIR COOLED ONLY FAN CYCLE CONTROL 4 RUN CAPACITOR 6 10 Part Number 80 1632 3 Section 6 SELF CONTAINED 3 PHASE L3 L2 L _ 41 CONTACTS COMPRESSOR Part Number 80 1632 3 Electrical System WATER VALVE 20 21 22 LH HARVEST SOLENOID 61 77 87 CONTROL BOARD of 99 ees EMS 60 SOLENOID pcm ier E I a w 17 7 DUMP 81 acl 57 SOLENOID Lo 7 1 1 F 98 _ i 1 WATER Loto aM S PUMP C FUSE 7A 58 REM ASQ i TERMINATES AT EXP ove PIN CONNECTION 59 CLEAN A f LEFT BIN e CONTACTOR 55 HIGH PRESSURE Lor CUTOUT 88 27 1 42 ICE THICKNESS PROBE WATER LEVEL C__ c PROBE nal vol ua i LS 2 CONTACTOR FAN CYCLE CONTROL 86 RIGHT BIN COIL RMT BIN WTR PROBE ICE PROBE HARV SL 1 SL 2 AIR COMPRESSOR 75 WHEN USED 74 LOW D C VOLTAGE PLUG FAN MOTOR AIR COOLED ONLY RUN 6 11 Electrical System Component Specifications and Diagnostics MAIN FUSE Function The control board fuse stops ice machine operation if electrical components fail causing high amp draw Specifications The main fuse
41. RVING Normally a starving expansion valve only affects the freeze cycle pressures not the harvest cycle pressures A low refrigerant charge normally affects both pressures Verify the ice machine is not low on charge before replacing an expansion valve 1 Add refrigerant charge in 2 to 4 oz increments as a diagnostic procedure to verify a low charge If the problem is corrected the ice machine is low on charge Find the refrigerant leak The ice machine must operate with the nameplate charge If the leak cannot be found proper refrigerant procedures must still be followed Change the liquid line drier Then evacuate and weigh in the proper charge 2 If the problem is not corrected by adding charge the expansion valve is faulty On dual expansion valve ice machines change only the TXV that is starving If both TXV s are starving they are probably good and they are being affected by some other malfunction such as low charge COLUMN 3 TXV FLOODING A loose or improperly mounted expansion valve bulb causes the expansion valve to flood Check bulb mounting insulation etc before changing the valve On dual expansion valve machines the service technician should be able to tell which TXV is flooding by analyzing ice formation patterns Change only the flooding expansion valve COLUMN 4 COMPRESSOR Replace the compressor and start components To receive warranty credit the compressor ports must be properly sealed by
42. System Start Up Off On Off Off On Off On On Off 5 Seconds FREEZE td May Cycle E Ooo SEQUENCE Off Off Off Off On off Off On On On Off 30 Seconds 3 Pre Chill during thereafter the first 45 sec Until 10 sec water contact 4 Freeze On Off Off Off Cycles MayCycle with ice Off then On Off thick On ONG ickness probe more time 30 sec HARVEST SEQUENCE On On On On after Off On On On May Cycle Factory set at 35 sec 15 sec On Off 45 Seconds 5 Water Purge On 6 Harvest Off On On On Off Off On On Mey Cycle Bin satin On Off activation Until bin 7 AUTOMATIC switch SHUT OFF Off Off Off Off Off Off Off Off Off 3 min delay 1 Initial Start Up or Start Up After Automatic Shut Off Not Used on all Models Condenser Fan Motor Safety Timers The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off Harvest Water Purge The circuit board has an adjustable water purge in the harvest cycle This permits a 0 or 45 second purge cycle Auto Shut Off The ice machine remains off for 3 minutes before it can automatically restart The ice machine restarts steps 1 2 immediately after the delay period if the bin switch re closes prior to 3 minutes Part Number 80 1632 3 The control board has the following non adjustable safety timers The ice machine is locked into the freeze cycle for 6 minutes before a harvest sequence can be initiated The freeze loc
43. The contacts remain open until the compressor is de energized Relay Operation Check 1 Disconnect wires from relay terminals 2 Verify the contacts are closed Measure the resistance between terminals 1 and 2 No continuity indicates open contacts Replace the relay 3 Check the relay coil Measure the resistance between terminals 2 and 5 No resistance indicates an open coil Replace the relay 6 18 Section 6 HARVEST ASSIST AIR COMPRESSOR Function The air compressor breaks the vacuum between the sheet of ice and the evaporator which results in shorter harvest cycles Specifications 115 Volt or 230 Volt matches the ice machine voltage Check Procedure 1 Verify when the air compressor should be running in the sequence of operation 2 If the compressor is not running when it should be check voltage at the control board 3 If there is no voltage present at the control board replace the control board 4 If there is voltage present at the control board check for voltage at the air compressor connector 5 If there is no voltage present at the air compressor connector replace wire 6 If there is voltage at the air compressor connector use a volt ohm meter to verify there is no continuity through the motor windings then replace motor Part Number 80 1632 3 Section 6 ICE OFF CLEAN TOGGLE SWITCH Function The switch is used to place the ice machine in ICE OFF or CLEAN mode of operation Specific
44. UG ELECTRICAL PLUG PROBE 3 16 NUMBERS MARKED ON CONNECTION WIRES WATER LEVEL PROBE REMOTE BIN 5 3129 Control Board 6 20 Part Number 80 1632 3 Section 6 S Model control boards use dual voltage transformer This means only one control board is needed for both 115V and 208 230V use Safety Limits In addition to standard safety controls such as the high pressure cut out the control board has built in safety limits These safety limits protect the ice machine from major component failures For more information see Safety Limits in Section 7 Part Number 80 1632 3 Electrical System Inputs The control board along with inputs controls all electrical components including the ice machine sequence of operation Prior to diagnosing you must understand how the inputs affect the control board operation Refer to specific component specifications inputs wiring diagrams and ice machine sequence of operation sections for details As an example refer to Ice Thickness Probe on the next page for information relating to how the probe and control board function together This section will include items such as How a harvest cycle is initiated How the harvest light functions with the probe Freeze time lock in feature Maximum freeze time Diagnosing ice thickness control circuitry 6 21 Electrical System Ice Thickness Probe Harvest Initiation HOW T
45. a Electrical system Low incoming voltage Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operational Miscellaneous Restricted condenser airflow High inlet air temperature 110 F 43 3 C max Condenser discharge air recirculation Dirty condenser filter Dirty condenser Restricted condenser water flow Low water pressure 20 psi 138 kPa min High water temperature 90 F 32 2 C max Dirty defective water regulating valve Water regulating valve out of adjustment Refrigeration system Improper refrigerant charge Non Manitowoc components Defective harvest valve Defective compressor starving or flooding check bulb mounting Non condensables in refrigeration system Plugged or restricted high side refrigerant lines or component SAFETY LIMIT NOTES Because there are many possible external problems do not limit your diagnosis to only the items listed in this chart Acontinuous run of 100 harvests automatically erases the safety limit code The control board will store and indicate only one safety limit the last one exceeded 7 10 If the toggle switch is moved to the OFF position and then back to the ICE position prior to reaching the 100 harvest point the last safety limit exceeded will be indicated fa Safety Limit light did not flash prior to the ice machine restarting then
46. all ice machine panels before lifting and installing Part Number 80 1632 3 How to Read a Model Number CUBESIZE CONDENSER TYPE 3 DICE WATER COOLED 5 HALF DICE WATER COOLED MARINE MODEL MODEL SERIES ICE CUBE SIZE CONDENSER D DICE Y W SELF CONTAINEDWATER COOLED Ice Cube Sizes Gg Regular Dice Half Dice 1 1 8 x 1 1 8 x 7 8 7 8 x 7 8 x 7 8 3 8 x 1 1 8 x 7 8 2 86 x 2 86 x 2 22 cm 2 22 x 2 22 2 22 cm 0 95 x 2 86 x 2 22 cm 1 1 General Information Accessories Contact your Manitowoc distributor for these optional accessories BIN CASTER Replaces standard legs ICE BAGGER Maximize profits from bagged ice sales with this convenient accessory This sturdy unit rests on the bin door frame and adapts for left or right side filling GUARDIAN SACHET PACKETS Guardian sachet packets release chlorine dioxide on a controlled basis to inhibit the growth of bacteria and slime Guardian sachet packets are available through your local Manitowoc Ice Machine dealer ARCTIC PURE WATER FILTER SYSTEM Engineered specifically for Manitowoc ice machines This water filter is an efficient dependable and affordable method of inhibiting scale formation filtering sediment and removing chlorine taste and odor Section 1 MANITOWOC CLEANER AND SANITIZER Manitowoc Ice Machine Cleaner and Sanitizer are available in convenient 16 oz 473 ml bottles These are th
47. ance with the instructions in this manual Maintenance procedures are not covered by the warranty A Warning If you do not understand the procedures or the safety precautions that must be followed call your local Manitowoc service representative to perform the maintenance procedures for you We recommend that you perform the following maintenance procedures a minimum of once every six months to ensure reliable trouble free operation and maximum ice production Ice Machine Inspection A Warning Disconnect electric power to the ice machine and the remote condensing unit at the electric service switch before cleaning the condenser Check all water fittings and lines for leaks Also make sure the refrigeration tubing is not rubbing or vibrating against other tubing panels etc Do not put anything boxes etc on the sides or back of the ice machine There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life Exterior Cleaning Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation Use cleaners designed for use with stainless steel products Sponge any dust and dirt off the outside of the ice machine with mild soap and water Wipe dry with a clean soft cloth Heavy stains should be removed with stainless steel wool Never use plain steel wool or abrasive pads They will scratch
48. arting GREEN WATER LEVEL LIGHT OOOOOOOOO DISCONNECT WATER LEVEL PROBE FROM CONTROL BOARD Section 6 Step 2 Wait until the freeze cycle starts approximately 45 seconds the freeze cycle starts when the compressor energizes Step 3 Disconnect the water level probe from the water level probe terminal on the control board Important For the test to work properly you must wait until the freeze cycle starts prior to disconnecting the water level probe If you restart the test you must reconnect the water level probe restart the ice machine step 1 and then disconnect the water level probe after the compressor starts TERMINAL ool ooooo SV3135 Step 3 Step 3 Disconnect water level probe from control board terminal Is water flowing into The Water Level The Water Inlet Valve Caus the water trough Light is Solenoid Coil is YES OFF Energized The water level probe is causing the problem Clean or replace the water level probe NO OFF Energized The water inlet valve is causing the problem NO ON OR OFF De Energized The control board is causing the problem 6 26 Part Number 80 1632 3 Section 6 Electrical System Diagnosing An Ice Machine That Will Not Run A Warning High line voltage is applied to the control board terminals 55 and 56 at all times Removing control board fuse or moving the toggle switch to OFF will not remove the po
49. arvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking Part Number 80 1632 3 7 15 Refrigeration System DISCHARGE LINE TEMPERATURE ANALYSIS General Knowing if the discharge line temperature is increasing decreasing or remaining constant can be an important diagnostic tool Maximum compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle Comparing the temperatures over several cycles will result in a consistent maximum discharge line temperature Ambient air temperatures affect the maximum discharge line temperature Higher ambient air temperatures at the condenser and or higher inlet water temperature higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser and or lower supply water temperature lower discharge line temperatures at the compressor Regardless of ambient and water temperatures the freeze cycle discharge line temperature will be higher than 160 F 71 1 C on a normally operating ice machine 7 16 Section 7 Procedure Connect a temperature probe on the compressor discharge line with in 6 of the compressor and insulate Observe the discharge line temperature for the last three minutes of the freeze cycle and record the maximum discharge line temp
50. atically energize for 60 seconds when the harvest cycle time exceeded 75 seconds in the previous cycle AUTOMATIC SHUT OFF 7 Automatic Shut Off When the storage bin is full at the end of a harvest sequence the sheet of cubes fails to clear the water curtain and will hold it open After the water curtain is held open for 30 seconds the ice machine shuts off The ice machine remains off for 3 minutes before it can automatically restart The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain As the water curtain swings back to the operating position the bin switch re closes and the ice machine restarts steps 1 2 provided the 3 minute delay period is complete Part Number 80 1632 3 Ice Machine Operation SAFETY TIMERS The control board has the following non adjustable safety timers The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated Freeze lock is bypassed after moving the toggle switch from OFF to ICE position for the first cycle only The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence steps 5 amp 6 The maximum harvest time is 3 5 minutes at which time the control board automatically initiates a freeze sequence steps 3 amp 4 WARM WATER RINSE CYCLE Closing the back of the evaporator allows ice to build up o
51. ations Single pole single throw switch The switch is connected into a varying low D C voltage circuit Check Procedure NOTE Because of a wide variation in D C voltage it is not recommended that a volt meter be used to check toggle switch operation 1 Inspect the toggle switch for correct wiring 2 Isolate the toggle switch by disconnecting the Molex connector 3 Check continuity across the toggle switch terminals Note where the wire numbers are connected to the switch terminals or refer to the wiring diagram to take proper readings Switch Setting Terminals Ohm Reading 1 6 Open ICE 1 2 Closed 2 6 Open 1 6 Closed CLEAN 1 2 Open 2 6 Open 1 6 Open OFF 1 2 Open 2 6 Open 4 Replace the toggle switch if ohm readings do not match all three switch settings Part Number 80 1632 3 Electrical System 6 19 Electrical System Section 6 ELECTRONIC CONTROL BOARD 115V L2 208 230V PRIMARY POWER SUPPLY AC LINE VOLTAGE ELECTRICAL PLUG NUMBERS MARKED ON WIRES MAIN FUSE 7A AIR COMPRESSOR NOT USED ON ALL MODELS WATER PURGE O CLEAN LIGHT YELLOW ADJUSTMENT O LEFT BIN LIGHT GREEN O RIGHT BIN LIGHT GREEN O REMOTE BIN LIGHT GREEN WATER PROBE LIGHT GREEN O ICE PROBE LIGHT GREEN O HARVEST LIGHT RED O SAFETY LIMIT 1 LIGHT RED O SAFETY LIMIT 2 LIGHT RED AUTOMATIC CLEANING DC LOW VOLTAGE ICE THICKNESS SYSTEM AuCS PL
52. cedure Refrigeration System NOTE Analyze discharge pressure before analyzing suction pressure High or low discharge pressure may be causing high or low suction pressure Step Example Using SY1004A Model Ice Machine 1 Determine the ice machine operating conditions 2A Refer to Cycle Time and Operating Pressure charts for ice machine model being checked Using operating conditions from Step 1 determine published freeze cycle time and published freeze cycle suction pressure Air temp entering condenser Air temp around ice machine Water temp entering water fill valve Published freeze cycle time 8 5 9 8 minutes 90 F 32 2 C 80 F 26 7 C 70 21 1 Published freeze cycle suction pressure 58 28 PSIG 2B Compare the published freeze cycle time and published freeze cycle suction pressure Develop a chart Published Freeze Cycle Suction Pressure psig Published Freeze Cycle Time minutes 10 28 3 Perform an actual suction pressure check at the beginning middle and end of the freeze cycle Note the times at which the readings are Beginning of freeze cycle Middle of freeze cycle End of freeze cycle 70 PSIG at 1 minute 57 PSIG at 7 minutes 40 PSIG at 14 minutes taken 4 Compare the actual freeze cycle suction Time Into pressure Step 3 to the published freeze cycle Freeze Cycle time and pressure comparison Step 2B 1 minutes Determine if the suctio
53. cifications and Diagnostics 7 20 High Pressure Cut Out HPCO Control 7 20 Cycle Time 24 Hour Ice Production Refrigerant Pressure Charts 7 21 Part No 80 1480 3 3 Table of Contents continued Refrigerant Recovery Evacuation and Recharging 7 23 Normal Self Contained Model Procedures 7 23 System Contamination Clean Up 7 25 Replacing Pressure Controls Without Removing Refrigerant Charge 7 27 Eilter Driers ives ne fiver ee I Dose ital de 7 29 Total System Refrigerant Charges 7 29 Refrigerant Definitions 7 30 Refrigerant Re Use 7 31 HFC Refrigerant Questions and Answers 7 32 Part No 80 1480 3 Section 1 General Information Section 1 General Information Model Numbers This manual covers the following models Self Contained Water Cooled SD1403WM SY1405WM NOTE Model numbers ending in 3 indicate a 3 phase unit Example SY1403WM3 A Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications A Warning PERSONAL INJURY POTENTIAL Remove
54. crimping and soldering them closed Old start components must be returned with the faulty compressor Refrigeration System REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES S Models Dual Expansion Valve Ice Machine Model Number 3 Manitowoc This table must be used with charts checklists and other references to eliminate refrigeration components not listed on the table and external items and problems which can cause good refrigeration components to appear defective Section 7 Operational Analysis 1 2 Ice Production Air Temperature Entering Condenser Water Temperature Entering Ice Machine Published 24 hour ice production Calculated actual ice production NOTE The ice machine is operating properly if the ice fill pat capacity erns is normal and ice production is within 10 of charted Installation and Water System All installation and water related problems must be corrected before proceeding with chart Ice Formation Pattern Ice formation is extremely thin on outlet of evaporator Ice formation is extremely thin on outlet of one side of Ice formation normal or Ice formation normal or Refer to Analyzing Safety Limits to eliminate all non refrigeration problems Stops on safety limit 1or2 Stops on safety limit 1or2 Stops on safety limit 1or2 or evaporator Ice formation is extremely No ice formation on entire Le
55. e 20 psi 138 kPa min High inlet water temperature 90 F 32 2 C max Dirty condenser Dirty defective water regulating valve Water regulating valve out of adjustment Improper refrigerant charge Overcharged Non condensables in system Wrong type of refrigerant Other Non Manitowoc components in system High side refrigerant lines component restricted before mid condenser Freeze Cycle Discharge Pressure Low Checklist Possible Cause Improper installation Improper refrigerant charge Check Correct See Installation Visual Inspection Checklist Undercharged Wrong type of refrigerant Water regulating valve water cooled condensers Out of adjustment Defective Other NOTE Do not limit your diagnosis to only the items 7 12 Non Manitowoc components in system Defective fan cycle control listed in the checklists Part Number 80 1632 3 Section 7 ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE The suction pressure gradually drops throughout the freeze cycle The actual suction pressure and drop rate changes as the air and water temperatures entering the ice machine change This affects freeze cycle times To analyze and identify the proper suction pressure drop throughout the freeze cycle compare the published suction pressure to the published freeze cycle time Operating Pressure and Freeze Cycle Time charts can be found later in this section Pro
56. e cycles for safety limit 2 the control board enters the limit into memory and the ice machine continues to run Use the following procedures to determine if the control board contains a safety limit indication 1 Move the toggle switch to OFF 2 Move the toggle switch back to ICE 3 Watch the safety limit lights SL 1 and SL 2 If a safety limit has been recorded either the SL 1 light will flash once or the SL 2 light will flash twice corresponding to safety limit 1 or 2 to indicate which safety limit stopped the ice machine Part Number 80 1632 3 Refrigeration System Analyzing Why Safety Limits May Stop the Ice Machine According to the refrigeration industry a high percentage of compressors fail as a result of external causes These can include flooding or starving expansion valves dirty condensers water loss to the ice machine etc The safety limits protect the ice machine primarily the compressor from external failures by stopping ice machine operation before major component damage occurs The safety limit system is similar to a high pressure cut out control It stops the ice machine but does not tell what is wrong The service technician must analyze the system to determine what caused the high pressure cut out or a particular safety limit to stop the ice machine The safety limits are designed to stop the ice machine prior to major component failures most often a minor problem or something external to
57. e ein dta Eee en Ede s 2 3 Voltage Se LI Roe M be 2 3 Minimum Circuit Ampacity 2 3 Electrical Requirements 2 3 Self Contained Electrical Wiring Connections 2 4 Self Contained Ice Machine 115 1 60 or 208 230 1 60 2 4 Self Contained Ice Machine 208 230 3 60 2225 pas A Rat Pee sla ERR Sess uad Sd 2 4 Self Contained Ice Machine 230 1 50 i Ri Lies D Rata cate een heh lees Rae LEAL 2 4 For United Kingdom Only 2 4 Water Supply and Drain Requirements 2 5 Water Supply 4 4 peeled tee repa en deest vei Pato ve ped 2 5 Water Inlet Lines 2 5 Drain Connections 2 22 Cas eta ea 2 5 Cooling Tower Applications Water Cooled Models 2 5 Water Supply and Drain Line Sizing Connections 2 6 Installation Check 2 7 Before Starting the Ice Machine 2 8 AuCS Automatic Cleaning System 2 8 Part No 80 1480 3 1 Table of Contents continued Section 3 Ice Machine Operation Component Identification 3 1 Se
58. e only cleaner and sanitizer approved for use with Manitowoc products Sanitizer Part Number 16 ounce Bottle 94 0565 3 AuCS SO 94 0565 3 AuCS Sl 40 1327 3 Cleaner Part Number 16 ounce Bottle 94 0546 3 AuCS SO 94 0546 3 AuCS S 40 1326 3 AUCS AUTOMATIC CLEANING SYSTEM This accessory reduces equipment cleaning expense The AuCS accessory monitors ice making cycles and initiates cleaning procedures automatically DISPENSER A counter top dispenser is ideal for cafeterias and many types of self service facilities Manitowoc auto fill floor standing ice dispensers meet the strict sanitary requirements of the food service lodging and health care industries Part Number 80 1632 3 Section 1 General Information Model Serial Number Location These numbers are required when requesting The model and serial number are listed on the MODEL information from your local Manitowoc distributor or SERIAL NUMBER DECAL affixed to the ice machine Manitowoc Ice Inc remote condenser and storage bin h 5 13147 MODEL SERIAL DECAL LOCATION Model Serial Number Location Part Number 80 1632 3 1 3 General Information Owner Warranty Registration Card GENERAL The packet containing this manual also includes warranty information Warranty co
59. e outlet half of the evaporator but ice forms at the inlet half of the evaporator Or the ice at the outlet of the evaporator reaches 1 8 to initiate a harvest but the inlet of the evaporator already has 1 2 to 1 of ice formation Possible cause Water loss low on refrigerant starving TXV faulty water fill valve etc NO ICE or THIN ICE OUTLET INLET 7 Figure 7 3 Extremely Thin Ice Formation at Evaporator Outlet Refrigeration System 3 Extremely Thin at Evaporator Inlet There is no ice or a considerable lack of ice formation at the inlet of the evaporator Examples The ice at the outlet of the evaporator reaches 1 8 to initiate a harvest but there is no ice formation at all at the inlet of the evaporator Possible causes Insufficient water flow flooding TXV etc OUTLET INLET d Figure 7 4 Extremely Thin Ice Formation at Evaporator Inlet 4 Spotty Ice Formation There are small sections on the evaporator where there is no ice formation This could be a single corner or a single spot in the middle of the evaporator This is generally caused by loss of heat transfer from the tubing on the back side of the evaporator OUTLET INLET Figure 7 5 Spotty Ice Formation Section 7 5 No Ice Formation The ice machine operates for an extended period but there is no ice formation at all on the evaporator Possible
60. e sole responsibility of the servicing company Determining Severity Of Contamination System contamination is generally caused by either moisture or residue from compressor burnout entering the refrigeration system Inspection of the refrigerant usually provides the first indication of system contamination Obvious moisture or an acrid odor in the refrigerant indicates contamination Refrigeration System If either condition is found or if contamination is suspected use a Total Test Kit from Totaline or a similar diagnostic tool These devices sample refrigerant eliminating the need to take an oil sample Follow the manufacturer s directions If a refrigerant test kit indicates harmful levels of contamination or if a test kit is not available inspect the compressor oil 1 Remove the refrigerant charge from the ice machine 2 Remove the compressor from the system 3 Check the odor and appearance of the oil 4 Inspect open suction and discharge lines at the compressor for burnout deposits 5 If no signs of contamination are present perform an acid oil test Check the chart below to determine the type of cleanup required Contamination Cleanup Chart Symptoms Findings Required Cleanup Procedure No symptoms or suspicion of contamination Normal evacuation recharging procedure Moisture Air Contamination symptoms Refrigeration system open to atmosphere for longer than 15 minutes Refrig
61. e the three minute delay has expired Important The water curtain must be ON bin switch s closed to start ice making Specifications The bin switch is a magnetically operated reed switch The magnet is attached to the lower right corner of the water curtain The switch is attached to the right bulkhead wall The bin switch is connected to a varying D C voltage circuit Voltage does not remain constant NOTE Because of a wide variation in D C voltage it is not recommended that a voltmeter be used to check bin switch operation Part Number 80 1632 3 Section 6 Electrical System Symptoms Bin Switch Fails Open The ice machine will not start with the toggle switch in the ice position but runs normally with the toggle switch in the clean position Bin Switch Fails Closed Safety limit 2 is recorded in the control board memory and the harvest cycle continues after the ice opens and closes the water curtain harvest cycle is 3 5 minutes long Diagnostic Aids Always use the water curtain magnet to cycle the Switch a larger or smaller magnet will affect switch operation Readings are affected by your test lead connection and VOM battery strength Verify you have solid connections and a correctly functioning VOM before testing bin switch Open the curtain for 3 seconds then close the curtain for 3 seconds This will allow your VOM display to settle With the bin switch closed
62. e until the outlet tube disengages from the right side 1 Remove check valve and tube assembly A Tip assembly to right until tubing disengages B Lift up on assembly to remove 2 Remove insulation from check valve assembly 3 Remove vinyl tubing from top of check valve 4 Soak in cleaner solution 10 minutes and then flush with water to remove debris 4 10 Part Number 80 1632 3 Section 4 Water Inlet Valve The water inlet valve normally does not require removal for cleaning Refer to Section 5 for a list of causes for No Water Entering Water Trough or Water Overflows Water Trough 1 When the ice machine is off the water inlet valve must completely stop water flow into the machine 2 When the ice machine is on the water inlet valve must allow the proper water flow through it Set the toggle switch to ON Watch for water flow into the ice machine If the water flow is slow or only trickles into the ice machine refer to Section 5 Follow the procedure below to remove the water inlet valve A Warning Disconnect the electric power to the ice machine and dispenser at the electric service switch box and turn off the water supply before proceeding 1 Remove the 1 4 hex head screws 2 Remove clean and install the filter screen FILTER ACCESS SCREWS WATER ees 5 INLET VALVE SV1622 Part Number 80 1632 3 Maintenance Removing the Front Panels NOTE The fron
63. e water purge the water fill valve energizes and de energizes by time The water purge must be at the factory setting of 45 seconds for the water fill valve to energize during the last 15 seconds of the water purge If it is set to less than 45 seconds the water fill valve will not energize during the water purge Important The harvest sequence water purge is factory set at 45 seconds A shorter purge setting with standard water supplies such as city water is not recommended This can increase water system cleaning and sanitizing requirements The harvest sequence water purge is factory set for 45 seconds Repositioning the jumper will set the harvest water purge to 0 seconds This setting does not affect the SeCs or AuCs cleaning sequences OG ese DOO DOO xol OOC 45 second Ju setting Gu 74 0 second e o setting o SV3139 B 99 99999 uA Water Purge Adjustment Part Number 80 1632 3 For your safety and to eliminate errors we recommend that a qualified service technician make the harvest water purge adjustment 3 5 Ice Machine Operation Section 3 THIS PAGE INTENTIONALLY LEFT BLANK 3 6 Part Number 80 1632 3 Section 4 Maintenance Section 4 Maintenance General You are responsible for maintaining the ice machine in accord
64. eration test kit and or acid oil test shows contamination Leak in water cooled condenser No burnout deposits in open compressor lines Mild contamination cleanup procedure Mild Compressor Burnout symptoms Oil appears clean but smells acrid Refrigeration test kit or acid oil test shows harmful acid content No burnout deposits in open compressor lines Mild contamination cleanup procedure Severe Compressor Burnout symptoms Oil is discolored acidic and smells acrid Burnout deposits found in the compressor and lines and in other components Severe contamination cleanup procedure Part Number 80 1632 3 7 23 Refrigeration System Mild System Contamination Cleanup Procedure 1 Replace any failed components 2 If the compressor is good change the oil 3 Replace the liquid line drier NOTE If the contamination is from moisture use heat lamps during evacuation Position them at the compressor condenser and evaporator prior to evacuation Do not position heat lamps too close to plastic components or they may melt or warp Important Dry nitrogen is recommended for this procedure This will prevent CFC release Section 7 Severe System Contamination Cleanup Procedure 1 Remove the refrigerant charge 2 Remove the compressor 3 Disassemble the harvest solenoid valve If burnout deposits are found inside the valve install a new harvest valve and replace manifold strainer TXV and harvest pr
65. erature Discharge Line Temperature Above 160 F 71 1 C At End Of Freeze Cycle Ice machines that are operating normally will have consistent maximum discharge line temperatures above 160 F 71 1 C Discharge Line Temperature Below 160 F 71 1 C At End Of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that decreases each cycle Verify the expansion valve sensing bulb is 100 insulated and sealed airtight Condenser air contacting an incorrectly insulated sensing bulb will cause overfeeding of the expansion valve Verify the expansion valve sensing bulb is positioned and secured correctly Part Number 80 1632 3 Section 7 HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES General These tables must be used with charts checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear defective The tables list five different defects that may affect the ice machine s operation NOTE A low on charge ice machine and a starving expansion valve have very similar characteristics and are listed under the same column NOTE Before starting see Before Beginning Service for a few questions to ask when talking to the ice machine owner Procedure Step 1 Record the ice machine model number Step 2 Complete the Operati
66. essure regulating valve 4 Wipe away any burnout deposits from suction and discharge lines at compressor 5 Sweep through the open system with dry nitrogen 4 Follow the normal evacuation procedure except replace the evacuation step with the following A Pull vacuum to 1000 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psi 35 kPa B Pull vacuum to 500 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psi 35 kPa C Change the vacuum pump oil D Pull vacuum to 500 microns Run the vacuum pump for 1 2 hour on self contained models 1 hour on remotes NOTE You may perform a standing vacuum test to make a preliminary leak check You should use an electronic leak detector after system charging to be sure there is no leak 5 Charge the system with the proper refrigerant to the nameplate charge 6 Operate the ice machine 7 24 Important Refrigerant sweeps are not recommended as they release CFC s into the atmosphere 6 Install a new compressor and new start components 7 Install a suction line filter drier with acid and moisture removal capability P N 89 3028 3 Place the filter drier as close to the compressor as possible 8 Install an access valve at the inlet of the suction line drier 9 Install a new liquid line drier Continued on next page Part Number 80 1632 3 Sec
67. ficient operation If the ice machine requires more frequent cleaning and sanitizing consult a qualified service company to test the water quality and recommend appropriate water treatment An extremely dirty ice machine must be taken apart for cleaning and sanitizing Caution Use only Manitowoc approved Ice Machine Cleaner part number 94 0546 3 and Sanitizer part number 94 0565 3 It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Read and understand all labels printed on bottles before use CLEANING PROCEDURE Caution Do not mix Cleaner and Sanitizer solutions together It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling A Warning Wear rubber gloves and safety goggles and or face shield when handling ice machine Cleaner or Sanitizer Ice machine cleaner is used to remove lime scale or other mineral deposits It is not used to remove algae or slime Refer to the section on Sanitizing for removal of algae and slime Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle Or set the switch to the OFF position and allow the ice to melt off the evaporator Part Number 80 1632 3 Maintenance Caution Never use anything to force ice from the evaporator Damage may result Step 2 start cleaning place the toggle
68. ft Side No ice formation on the one or thin at inlet of one side of evaporator side of evaporator No ice formation on entire evaporator evaporator or Right Side No ice formation on entire evaporator Safety Limits Stops on safety limit 1or2 Freeze Cycle Discharge Pressure If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist to eliminate problems and or components not listed on this table before proceeding 1 minute Middle End into cycle Freeze Cycle If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist to eliminate Suction Pressure problems and or components not listed on this table before proceeding Suction pressure is Suction pressure is Suction pressure is Suction pressure is High Low or Normal High High 1 minute Middle End Wait 5 minutes into the freeze cycle Compare temperatures of compressor discharge line and both harvest valve inlets One harvest valve inlet is Hot and approaches the temperature of a Hot compressor discharge line Both harvest valve inlets are Cool enough to hold hand on and the compressor discharge line is Hot Both harvest valve inlets are Cool enough to hold hand on and the compressor discharge line is Cool enough to hold hand on Both harvest valve inlets are Cool enough to hold hand on and the compressor discharge line is Hot Discharge
69. groscopic than mineral oils Once moisture is absorbed into the oil it is difficult to remove even with heat and vacuum POE oils are also excellent solvents and tend to solvent clean everything inside the system depositing material where it is not wanted pressure assume that moisture has entered the POE oil After the leak is found and repaired the compressor oil must be changed The compressor must be removed and at least 95 of the oil drained from the suction port of the compressor Use a measuring cup to replace the old oil with exactly the same amount of new POE oil such as Mobil EAL22A Remember care must be taken to prevent moisture from getting into the refrigeration system during refrigeration repairs 7 30 5 How do leak check a system containing HFC refrigerant Use equipment designed for HFC detection Do not use equipment designed for CFC detection Consult leak detection equipment manufacturers for their recommendations Also standard soap bubbles will work with HFC refrigerants Does Manitowoc use a special liquid line filter drier with HFC refrigerants Yes Manitowoc uses an ALCO UK series filter drier for increased filtration and moisture removal During a repair Manitowoc recommends installing the drier just before hooking up a vacuum pump 7 15 other special equipment required to service HFC What do these POE oil characteristics mean to me refrigerants You must be m
70. harge and suction pressure are highest at the beginning of the cycle Suction pressure will drop throughout the cycle Verify the pressures are within the range indicated Record beginning of freeze cycle suction pressure one minute after water pump energizes Regular cube production derate is 796 50Hz production derate is 7 50Hz regular cube total production derate is 14 7 20 Section 7 1400 SERIES Self Contained Water Cooled NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 8 9 10 0 9 8 10 9 11 2 12 5 80 26 7 8 9 10 0 9 8 10 9 11 4 12 6 90 32 2 8 9 10 0 9 6 10 7 11 6 12 9 42 100 37 8 9 0 10 1 10 0 11 2 11 7 13 0 Times in minutes 24 Hour Ice Production Air Temp Water Temperature F C Around Ice Machine 50 10 0 70 21 1 90 32 2 70 21 1 1380 1280 1130 80 26 7 1380 1280 1120 90 32 2 1380 1300 1100 100 37 8 1370 1250 1090 Based on average ice slab weight of 10 11 Ib Operating Pressures Air Temp Freeze Cycle Harvest Cycle Aroundlce Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure F C PSIG PSIG PSIG PSIG 50 10 0 235
71. he water pump normally does not require removal for cleaning The water pump base can be wiped and cleaned in place or proceed to step 4 4 Grasp pump and pull straight down on pump assembly until water pump disengages and electrical connector is visible 5 Disconnect the electrical connector 6 Remove the water pump assembly from ice machine 7 Do not soak the water pump in cleaner or sanitizer Wipe the pump and ice machine base clean Part Number 80 1632 3 Section 4 Water Dump Valve The water dump valve normally does not require removal for cleaning To determine if removal is necessary 1 Locate the water dump valve 2 Set the toggle switch to ICE 3 While the ice machine is in the freeze mode check the dump valve s clear plastic outlet drain hose for leakage A If the dump valve is leaking remove disassemble and clean it B If the dump valve is not leaking do not remove it Instead follow the Ice Machine Cleaning Procedure Follow the procedure below to remove the dump valve Maintenance Important The plunger and the inside of the enclosing tube must be completely dry before assembly A Warning Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply before proceeding 1 If so equipped remove the water dump valve shield from its mounting bracket 2 Lift and slide the coil retainer cap from the
72. humbscrews to distribution tube B Pull inner half of water distribution tube forward to release slip joint from water pump tubing connection lt a 36 26 2 Q o eT Part Number 80 1632 3 Maintenance 4 Water Trough A Depress tabs on right and left side of the water trough B Allow front of water trough to drop as you pull forward to disengage the rear pins DEPRESS TABS 4 7 Maintenance Water Level Probe 1 Remove the water trough A Warning Disconnect the electrical power to the ice machine at the electrical disconnect before proceeding Section 4 Water Pump A Warning Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply before proceeding 2 The water level probe normally does not require removal for cleaning The probe can be wiped and cleaned in place or proceed to step 3 3 Pull the water level probe straight down to disengage 4 Lower the water level probe until the wiring connector is visible Disconnect the wire lead from the water level probe 5 Remove the water level probe from the ice machine WATER LEVEL PROBE SV3141 4 8 1 Empty the water trough A Move the toggle switch from OFF to ICE B Wait 45 seconds C Place toggle switch in OFF position 5 3091 WATER PUMP BASE Water Pump Removal 2 Remove the water trough 3 T
73. ice valve Open the charging cylinder and add the proper refrigerant charge shown on nameplate through the discharge service valve Let the system settle for 2 to 3 minutes Place the toggle switch in the ICE position Close the high side on the manifold gauge set Add any remaining vapor charge through the suction service valve if necessary NOTE Manifold gauges must be removed properly to ensure that no refrigerant contamination or loss occurs 8 Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses A Run the ice machine in freeze cycle B Close the high side service valve at the ice machine C Open the low side service valve at the ice machine D Open the high and low side valves on the manifold gauge set Any refrigerant in the lines will be pulled into the low side of the system E Allow the pressures to equalize while the ice machine is in the freeze cycle F Close the low side service valve at the ice machine G Remove the hoses from the ice machine and install the caps Part Number 80 1632 3 Section 7 SYSTEM CONTAMINATION CLEAN UP General This section describes the basic requirements for restoring contaminated systems to reliable service Important Manitowoc Ice Inc assumes no responsibility for the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is th
74. is 250 Volt 7 amp Check Procedure A Warning High line voltage is applied to the control board terminals 55 and 56 at all times Removing the control board fuse or moving the toggle switch to OFF will not remove the power supplied to the control board 1 If the bin switch light is on with the water curtain closed the fuse is good A Warning Disconnect electrical power to the entire ice machine before proceeding 2 Remove the fuse Check the resistance across the fuse with an ohm meter Reading Result Open OL Replace fuse Closed O Fuse is good 6 12 Section 6 BIN SWITCH Function Movement of the water curtain controls bin switch operation The bin switch has two main functions 1 Terminating the harvest cycle and returning the ice machine to the freeze cycle This occurs when the bin switch is opened and closed again within 30 seconds during the harvest cycle 2 Automatic ice machine shut off If the storage bin is full at the end of a harvest cycle the sheet of cubes fails to clear the water curtain and holds it open After the water curtain is held open for 30 seconds the ice machine shuts off The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain As the water curtain swings back to the operating position the bin switch closes and the ice machine restarts provid
75. ition or replace the probe as necessary WATER INLET VALVE SAFETY SHUT OFF In the event of a water level probe failure this feature limits the water inlet valve to a 6 minute on time Regardless of the water level probe input the control board automatically shuts off the water inlet valve if it remains on for 6 continuous minutes 6 24 Section 6 FREEZE CYCLE CIRCUITRY Manitowoc s electronic sensing circuit does not rely on float switches or timers to maintain consistent water level control During the freeze cycle the water inlet valve energizes turns on and de energizes turns off in conjunction with the water level probe located in the water trough During the first 45 seconds of the Freeze Cycle The water inlet valve is on when there is no water in contact with the water level probe The water inlet valve turns off after water contacts the water level probe for 3 continuous seconds The water inlet valve will cycle on and off as many times as needed to fill the water trough After 45 seconds into the Freeze Cycle The water inlet valve will cycle on and then off one more time to refill the water trough The water inlet valve is now off for the duration of the freeze sequence HARVEST CYCLE CIRCUITRY The water level probe does not control the water inlet valve during the harvest cycle During the harvest cycle water purge the water inlet valve energizes and de energizes strictly by time The harves
76. k is bypassed when the toggle switch is moved from the OFF to ICE position on the first cycle only The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence steps 5 6 maximum harvest time is 3 1 2 minutes at which time the control board automatically terminates the harvest sequence If the bin switch is open the ice machine will go to automatic shut off step 7 If the bin switch is closed the ice machine will go to the freeze sequence steps 3 4 Electrical System Wiring Diagram Sequence of Operation SELF CONTAINED MODELS Initial Start Up or Start Up After Automatic Shut Off 1 WATER PURGE Before the compressor starts the water pump and water dump solenoid are energized for 45 seconds to purge old water from the ice machine This ensures that the ice making cycle starts with fresh water The harvest valve s is also energized during the water purge In the case of an initial refrigeration start up or auto shut off it stays on for an additional 5 seconds 50 seconds total When Used The air compressor energizes for the last 10 seconds of the cycle Table 6 1 Self Contained Models Section 6 L1 L2 or N 9 Ground Water Valve ag 55 05 61 amp High Pressure Control Board Harvest Valve Cutout tei yr
77. ly calibrated meter Perform the resistance test after the compressor cools The compressor dome should be cool enough to touch below 120 F 49 C to assure that the overload is closed and the resistance readings will be accurate SINGLE PHASE COMPRESSORS 1 Disconnect power from the cuber and remove the wires from the compressor terminals 2 The resistance values between C and S and between C and R when added together should equal the resistance value between S and 3 If the overload is open there will be a resistance reading between S and R and open readings between C and S and between C and R Allow the compressor to cool then check the readings again THREE PHASE COMPRESSORS 1 Disconnect power from the cuber and remove the wires from the compressor terminals 2 The resistance values between L1 and L2 between L2 and L3 and between L3 and L1 should all be equal 3 If the overload is open there will be open readings between L1 and L2 between L2 and L3 and between L3 and L1 Allow the compressor to cool then check the readings again Check Motor Windings to Ground Check continuity between all three terminals and the compressor shell or copper refrigeration line Scrape metal surface to get good contact If continuity is present the compressor windings are grounded and the compressor should be replaced 6 14 Section 6 Determine if the Compressor is Seized Check the amp draw while the compress
78. ment screw clockwise to increase after cleaning and sanitizing bridge thickness counterclockwise to decrease bridge thickness Set at 1 4 gap between ice machine and evaporator as starting point then adjust to achieve a 1 8 bridge thickness when starting the ice machine for the first time after a prolonged out of service period NOTE Routine adjustments and maintenance procedures are not covered by the warranty WATER LEVEL The water level sensor is set to maintain the proper water level above the water pump housing The water ADJUSTING SCREW level is not adjustable If the water level is incorrect check the water level probe for damage probe bent etc Clean the water level probe with ice machine cleaner rinse thoroughly and re check operation Repair or replace the probe as necessary 1 8 ICE BRIDGE THICKNESS SV3132 Ice Thickness Check 3 Make sure the ice thickness probe wire and the bracket do not restrict movement of the probe Water Level Probe Location 3 4 Part Number 80 1632 3 Section 3 HARVEST SEQUENCE WATER PURGE The harvest sequence water purge adjustment may be used when the ice machine is hooked up to special water systems such as a de ionized water treatment system A Warning Disconnect electric power to the ice machine at the electrical disconnect before proceeding Ice Machine Operation During the harvest sequenc
79. ms Part Number 80 1632 3 Refrigeration System TOTAL SYSTEM REFRIGERANT CHARGES Important This information is for reference only Refer to the ice machine serial number tag to verify the system charge Serial plate information overrides information listed on this page Series Version Charge 51400 Water Cooled 40 oz NOTE All ice machines are charged using R 404A refrigerant 7 27 Refrigeration System REFRIGERANT DEFINITIONS Recover To remove refrigerant in any condition from a system and store it in an external container without necessarily testing or processing it in any way Recycle To clean refrigerant for re use by oil separation and single or multiple passes through devices such as replaceable core filter driers which reduce moisture acidity and particulate matter This term usually applies to procedures implemented at the field job site or ata local service shop 7 28 Section 7 Reclaim To reprocess refrigerant to new product specifications see below by means which may include distillation A chemical analysis of the refrigerant is required after processing to be sure that product specifications are met This term usually implies the use of processes and procedures available only at a reprocessing or manufacturing facility Chemical analysis is the key requirement in this definition Regardless of the purity levels reached by a reprocessing method refrige
80. n system start up The air compressor energizes for the last 10 seconds of the cycle 2 Refrigeration System Start Up The compressor starts after the 45 second water purge and it remains on throughout the entire Freeze and Harvest Sequences The water fill valve is energized at the same time as the compressor The harvest valve s remains on for 5 seconds during initial compressor start up and then shuts off At the same time the compressor starts the condenser fan motor air cooled models is supplied with power throughout the entire Freeze and Harvest Sequences The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off The compressor and condenser fan motor are wired through the contactor As a result anytime the contactor coil is energized the compressor and fan motor are supplied with power 3 2 Section 3 FREEZE SEQUENCE 3 Prechill The compressor is on for 30 seconds 60 seconds initial cycle prior to water flow to prechill the evaporator The water fill valve remains on until the water level probe is satisfied 4 Freeze The water pump restarts after the prechill An even flow of water is directed across the evaporator and into each cube cell where it freezes The water fill valve will cycle on and then off one more time to refill the water trough When sufficient ice has formed the water flow not the ice contacts the ice thickness probe After approximately 10
81. n pressure is high low 5 minutes or acceptable 10 minutes Published Actual Result Pressure Pressure 58 PSIG 70 PSIG High 43 PSIG 48 PSIG High 28 PSIG 40 PSIG High Part Number 80 1632 3 7 13 Refrigeration System Section 7 Freeze Cycle Suction Pressure High Checklist Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Discharge pressure Improper refrigerant charge Discharge pressure is too high and is affecting low side See Freeze Cycle Discharge Pressure High Checklist Overcharged Wrong type of refrigerant Other Non Manitowoc components in system H P R solenoid leaking Harvest valve stuck open TXV flooding check bulb mounting Defective compressor Freeze Cycle Suction Pressure Low Checklist Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Discharge pressure Discharge pressure is too low and is affecting low side See Freeze Cycle Discharge Pressure Low Checklist Improper refrigerant charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Improper water supply over evaporator See Water System Checklist Loss of heat transfer from tubing on back side of evaporator Restricted plugged liquid line drier Restricted plugged tubing in suction side of refrigera
82. n the rear of the evaporator and the plastic evaporator frame parts After 200 freeze harvest cycles have been complete the control board will initiate a warm water rinse After the 200th harvest cycle ends The Clean and Harvest LED s energize to indicate the ice machine is in a warm water rinse The compressor and harvest valve remain energized The water pump energizes The water inlet valve energizes until water contacts the water level probe The compressor and harvest valve warm the water for 5 minutes then de energize The water pump remains energized for an additional 5 minutes 10 minute total on time then de energizes NOTE The warm water rinse cycle can be terminated by moving the toggle switch to the OFF position then back to ICE 3 3 Ice Machine Operation Section 3 Operational Checks ICE THICKNESS CHECK GENERAL The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 32 cm Manitowoc ice machines are factory operated and mE adjusted before shipment Normally new installations do NOTE Make sure the water curtain is in place when not require any adjustment performing this check It prevents water from splashing out of the water trough To ensure proper operation always follow the 9 Operational Checks 1 Inspect the bridge connecting the cubes It should be about 1 8 32 cm thick 2 If adjustment is necessary turn the ice thickness probe adjust
83. n valve Actually the problem loose bulb was corrected when the technician properly mounted the bulb of the replacement expansion valve The service technician s failure to check the expansion valve bulb for proper mounting an external check resulted in a misdiagnosis and the needless replacement of a good expansion valve 2 An ice machine that is low on charge may cause a good expansion valve to starve If a service technician fails to verify the system charge he may replace the expansion valve in error During the replacement procedure recovery evacuation and recharging are performed correctly The ice machine now functions normally The technician erroneously thinks that the problem was properly diagnosed and corrected by replacing the expansion valve The service technician s failure to check the ice machine for a low charge condition resulted in a misdiagnosis and the needless replacement of a good expansion valve When analyzing the refrigeration system use the Refrigeration System Operational Analysis Table This table along with detailed checklists and references will help prevent replacing good refrigeration components due to external problems Part Number 80 1632 3 Section 7 BEFORE BEGINNING SERVICE Ice machines may experience operational problems only during certain times of the day or night A machine may function properly while it is being serviced but malfunctions later Information provided by
84. nnect a jumper from the control board terminal and any cabinet ground then refer to chart Important For the test to work properly you must wait until the freeze cycle starts prior to connecting the jumper wire If you restart the test you must disconnect the jumper wire restart the ice machine step 1 and then reinstall the jumper wire after the compressor starts 53135 Step 3 Step 3 Jumper wire connected from control board terminal to ground Is water flowing into The Water Level The Water Inlet Valve Cause the water trough Light is Solenoid Coil is NO ON De Energized The water level probe is causing the problem Clean or replace the water level probe YES ON Energized The control board is causing the problem YES OFF De Energized The water fill valve is causing the problem Part Number 80 1632 3 6 25 Electrical System Problem Water Will Not Run Into The Sump Trough During The Freeze Cycle Step 1 Verify water is supplied to the ice machine and then start a new freeze sequence by moving the ICE OFF CLEAN toggle switch to OFF then back to ICE Important This restart must be done prior to performing diagnostic procedures This assures the ice machine is not in a freeze cycle water inlet valve safety shut off mode You must complete the entire diagnostic procedure within 6 minutes of st
85. nside diameter Bin Drain u u 3 Female 3 4 1 91 cm minimum Pipe Thread inside diameter 3 8 FPT ICE MAKING WATER INLET FITTING ELECTRICAL ENTRANCE PLASTIC FITTING ON OPPOSITE SIDE DO NOT APPLY HEAT 2 18 46 VENT TUBE 2 2 3 8 CONDENSER WATER INLET E WATER COOLED UNITS ONLY 1 2 DRAIN CONNECTION 2 PLASTIC FITTING ON OPPOSITE jo gt Ae SIDE DO NOT APPLY HEAT EB cum 2d 1 2 CONDENSER WATER DRAIN WATER COOLED UNITS ONLY 1 2 1 3 CM MIN DRAIN ID 1 2 CPVC SOCKET AUXILLARY BASE DRAIN AIR GAP na A DO NOT TRAP DRAIN LINE OPEN TRAPPED AND LEAVE AIR GAP BETWEEN VENTED DRAIN DRAIN TUBE AND DRAIN 5 3142 Typical Water Supply Drain Installation 2 6 Part Number 80 1632 3 Section 2 Installation Check List ey abs abes Se Is the Ice Machine level Has all of the internal packing been removed Have all of the electrical and water connections been made Has the supply voltage been tested and checked against the rating on the nameplate Is there proper clearance around the ice machine for air circulation Has the ice machine been installed where ambient temperatures will remain in the range of 35 110 F 1 6 43 3 C Has the ice machine been installed where the incoming water temperature will remain in the range of 35 90 F 1 6 32 2 C Is there a separate drain for the water co
86. ntrol board is causing the malfunction HARVEST LIGHT ICE THICKNESS PROBE CONNECTION Ice Machine Cycles Into Harvest Before Water Contact With The Ice Thickness Probe Step 1 Disconnect the ice thickness probe from the control board Step 2 Wait until water starts to flow over the evaporator then monitor the harvest light Monitoring of Harvest Light Correction The harvest light stays off and the ice machine remains in the freeze sequence The harvest light comes on and 10 seconds later the ice machine cycles from freeze to harvest The ice thickness probe is causing the malfunction Verify that the Ice Thickness probe is adjusted correctly The control board is causing the malfunction Part Number 80 1632 3 6 23 Electrical System Water Level Control Circuitry WATER LEVEL PROBE LIGHT The water level probe circuit can be monitored by watching the water level light The water level light is on when water contacts the probe and off when no water is in contact with the probe The water level light functions any time power is applied to the ice machine regardless of toggle switch position During the freeze cycle the water level probe is set to maintain the proper water level above the water pump housing The water level is not adjustable If the water level is incorrect check the water level probe position Repos
87. oled condenser Is there a separate drain for the bin Part Number 80 1632 3 ae Installation Instructions Are the ice machine and bin drains vented Are all electrical leads free from contact with refrigeration lines and moving equipment Has the owner operator been instructed regarding maintenance and the use of Manitowoc Cleaner and Sanitizer Has the owner operator completed the warranty registration card Has the ice machine and bin been sanitized Is the toggle switch set to ice The toggle switch is located directly behind the front panel Is the ice thickness control set correctly Refer to Operational Checks to check set the correct ice bridge thickness 2 7 Installation Instructions Before Starting the Ice Machine All Manitowoc ice machines are factory operated and adjusted before shipment Normally new installations do not require any adjustment To ensure proper operation follow the Operational Checks in Section 3 of this manual Starting the ice machine and completing the Operational Checks are the responsibilities of the owner operator Adjustments and maintenance procedures outlined in this manual are not covered by the warranty A Warning Potential Personal Injury Situation Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications 2 8 Section 2 AuCS
88. on Analysis column Read down the left Operational Analysis column Perform all procedures and check all information listed Each item in this column has supporting reference material to help analyze each step While analyzing each item separately you may find an external problem causing a good refrigerant component to appear bad Correct problems as they are found If the operational problem is found it is not necessary to complete the remaining procedures NOTE Discharge Line Temperature will vary by model Refer to the model number to verify the correct temperature to analyze Step 3 Enter check marks the small boxes Each time the actual findings of an item in the Operational Analysis column matches the published findings on the table enter a check mark Example Freeze cycle suction pressure is determined to be low Enter a check mark in the low box Step 4 Add the check marks listed under each of the four columns Note the column number with the highest total and proceed to Final Analysis NOTE If two columns have matching high numbers a procedure was not performed properly and or supporting material was not analyzed correctly Part Number 80 1632 3 Refrigeration System Final Analysis The column with the highest number of check marks identifies the refrigeration problem COLUMN 1 HARVEST VALVE LEAKING A leaking harvest valve must be replaced COLUMN 2 LOW CHARGE TXV STA
89. onger off time to allow the PTCR to cool The compressor has short cycled or the compressor overload has opened Move the toggle switch to OFF and allow the compressor and PTCR to cool Continued on next page Part Number 80 1632 3 Section 6 There are other problems that may cause compressor start up failure with a good PTCR in a new properly wired ice machine The voltage at the compressor during start up is too low Manitowoc ice machines are rated at 10 of nameplate voltage at compressor start up Ex An ice machine rated at 208 230 should have a compressor start up voltage between 187 and 253 volts The compressor discharge and suction pressures are not matched closely enough or equalized These two pressures must be somewhat equalized before attempting to start the compressor The harvest valve and HPR valve on remotes energizes for 45 seconds before the compressor starts and remains on 5 seconds after the compressor starts Make sure this is occurring and the harvest valve and HPR solenoid coil is functional before assuming that the PTCR is bad CHECKING THE PTCR Electrical System Model Manitowoc Cera Mite i M Part Number Part Number p Resistance 51400 8504913 305 9 8 22 Ohms A Warning Disconnect electrical power to the entire ice machine at the building electrical disconnect box before proceeding 1 Visually inspect the PTCR Check for signs of
90. oo 60555553 HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR SV1569 Figure 7 1 Self Contained Prechill and Freeze Cycle Prechill Refrigeration Sequence Freeze Cycle Refrigeration Sequence No water flows over the evaporator during the prechill The refrigerant absorbs heat from water running over the The refrigerant absorbs heat picked up during the evaporator surface The suction pressure gradually harvest cycle from the evaporator The suction pressure drops as ice forms decreases during the prechill Part Number 80 1632 3 7 1 Refrigeration System Section 7 EVAPORATOR HEAT EXCHANGER NS EXPANSION VALVE GAS SOLENOID VALVE IFT IZ SS SSS AIR OR WATER STRAINER CONDENSER COMPRESSOR 227227 RECEIVER WATER COOLED ONLY BEE 55 52 59 0255553 HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR SV1570 Figure 7 2 Self Contained Harvest Cycle Harvest Cycle Refrigeration Sequence Hot gas flows through the energized harvest valve heating the evaporator The harvest valve is sized to allow the proper amount of refrigerant into the evaporator This specific sizing along with the proper system refrigerant charge assures proper heat transfer without the refrigerant condensing and slugging the compressor 7 2 Part Number 80 1632 3 Section 7 1400 SELF CONT
91. or is trying to start COMPRESSOR DRAWING LOCKED ROTOR The two likely causes of this are Defective starting component Mechanically seized compressor To determine which you have 1 Install high and low side gauges 2 Try to start the compressor 3 Watch the pressures closely A If the pressures do not move the compressor is seized Replace the compressor B Ifthe pressures move the compressor is turning slowly and is not seized Check the capacitors and start relay COMPRESSOR DRAWING HIGH AMPS The continuous amperage draw on start up should not be near the maximum fuse size indicated on the serial tag Diagnosing Capacitors fthe compressor attempts to start or hums and trips the overload protector check the starting components before replacing the compressor e Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane Do not assume a capacitor is good if no visual evidence is present A good test is to install a known good substitute capacitor Use a capacitor tester when checking a suspect capacitor Clip the bleed resistor off the capacitor terminals before testing Part Number 80 1632 3 Section 6 PTCR DIAGNOSTICS What is a PTCR APTCR or Positive Temperature Coefficient Resistor is made from high purity semi conducting ceramics A PTCR is useful because of its resistance versus temperature characteristic The PTCR has a low resistance over a
92. ore exacting in your procedures Take No Standard refrigeration equipment such as utmost care to prevent moisture from entering the gauges hoses recovery systems vacuum pumps refrigeration system Refrigeration systems and etc are generally compatible with HFC refrigerants compressors should not be left open to the Consult your equipment manufacturer for specific atmosphere for more than 15 minutes Keep oil recommendations for converting existing equipment containers and compressors capped at all times to to HFC usage Once designated and calibrated if minimize moisture entry Before removing the needed for HFC use this equipment should be system charge to replace a faulty component be used specifically with HFC refrigerants only sure you have all of the needed components at the 8 Do have to recover HEC refrigerants site Remove new system component plugs and _ caps just prior to brazing Be prepared to connect Yes Like other refrigerants government regulations vacuum pump immediately after brazing require recovering HFC refrigerants Are there any special procedures required ifa POE 9 Will R 404A or R 134A separate if there is a leak in system is diagnosed with a refrigerant leak the system For systems found with positive refrigerant system No Like R 502 the degree of separation is too small pressure no special procedures are required to detect For systems found without any positive refrigerant 10 How do charge a system
93. orm to local state and national electrical codes Though wire nuts are shown in the drawings the ice machine field wiring connections may use either wire nuts or screw terminals SELF CONTAINED ICE MACHINE GROUND 115 1 60 OR 208 230 1 60 GROUND ICE MACHINE TO SEPARATE SV1190 CONNECTIONS FUSE BREAKER L4 Ly N 115V SELF CONTAINED ICE MACHINE OR 230 1 50 L2 208 230V I GROUND GROUND Ly ICE MACHINE TO SEPARATE SV1258 CONNECTIONS FUSE BREAKER I N I GROUND TO SEPARATE JCE MACHINE lt FUSE BREAKER DISCONNECT ALL 5 1191 For United Kingdom Only As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings identifying the terminals in your plug proceed as follows The wire which is colored green and yellow must be connected to the terminal in the plug which is marked with the letter E or by the earth ground symbol _ colored green or green and yellow The wire colored blue must be connected to the terminal which is marked with the letter N or colored black The wire colored brown must be connected to the terminal which is marked with the letter L or colored red 2 4 Part Number 80 1632 3 Section 2 Water Supply and Drain Requirements WATER SUPPLY Local water conditions may require treatment of the water to inhibit scale formation filter sediment and remove chlorine odor and taste Impo
94. physical damage NOTE The PTCR case temperature may reach 210 F 100 C while the compressor is running This is normal Do not change a PTCR just because it is hot 2 Wait at least 10 minutes for the PTCR to cool to room temperature 3 Remove the PTCR from the ice machine 4 Measure the resistance of the PTCR as shown below If the resistance falls outside of the acceptable range replace it Part Number 80 1632 3 LEAVE JUMPER WIRE IN PLACE MEASURE OHMS BETWEEN CENTER TAB AND END TAB Manitowoc PTCR 8504913 m T SV4541 6 17 Electrical System DIAGNOSING START COMPONENTS If the compressor attempts to start or hums and trips the overload protector check the start components before replacing the compressor Capacitor Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane Do not assume a capacitor is good if no visual evidence is present A good test is to install a known good substitute capacitor Use a capacitor tester when checking a suspect capacitor Clip the bleed resistor off the capacitor terminals before testing Relay The relay has a set of contacts that connect and disconnect the start capacitor from the compressor start winding The contacts on the relay are normally closed start capacitor in series with the start winding The relay senses the voltage generated by the start winding and opens the contacts as the compressor motor starts
95. quence Of Operation eae ees eaters xe x eRe 3 2 Initial Start Up or Start Up After Automatic Shut Off 3 2 Freeze Sequence 3 2 Harvest Sequence 3 3 Automatic ShutOft 3 2 reos et ives bes EE doe eerta 3 3 Safety TImers 3 3 Warm Water Rinse Cycle 3 3 Operational Checks sigran feted was wA Woes ied a eee Rae 3 4 General ete dE EN PD ee ate ae 3 4 Water Level sis da sh ead erga once pde pie guiness 3 4 Ice Thickness Check setae ra bo eet eo an a allied 3 4 Harvest Sequence Water Purge 3 5 Section 4 Maintenance General ue URN 4 1 Ice Machine Inspection 4 1 Exterior Cleaning 5 2 ker E UR EE EMEN wa a RR 4 1 Water Cooled Condenser and Water Regulating Valve 4 1 5 24 a 4 1 Guardian PUDE 4 2 Installation 4 2 Sachet Replacement Frequency 4 2 Sachet Replacement Procedure 4 2 Clean Up Procedure for Damaged Packet 4 2 Interior Cleaning and Sanitizing
96. r flow not the ice contacts the ice thickness probes After approximately 10 seconds of continual contact a harvest cycle is initiated NOTE The ice machine cannot initiate a harvest cycle until a 6 minute freeze lock has expired Table 6 4 Self Contained Models Electrical System L1 L2 Ground 89 55 High Cutout Control Board Terminates at Pin Connection Ice Thickness Probe Water Level Probe AIA Compressor 25 4 9 Run Capacitor Contactor Yellow 6 Contacts 4 Fan Motor Fan Cycle Control leno eio Run Capacitor V3137 5 Self Contained Freeze 4 Freeze Until 10 Seconds of Water Contact with Ice Thickness Probe Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve Cycles OFF then ON one more time 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Main Fuse On Control Board Closed Closed Part Number 80 1632 3 6 5 Electrical System Harvest Sequence 5 WATER PURGE
97. rant is not considered reclaimed unless it has been chemically analyzed and meets ARI Standard 700 latest edition New Product Specifications This means ARI Standard 700 latest edition Chemical analysis is required to assure that this standard is met Part Number 80 1632 3 Section 7 REFRIGERANT RE USE POLICY Manitowoc recognizes and supports the need for proper handling re use and disposal of CFC and HCFC refrigerants Manitowoc service procedures require recapturing refrigerants not venting them to the atmosphere It is not necessary in or out of warranty to reduce or compromise the quality and reliability of your customers products to achieve this Important Manitowoc Ice Inc assumes no responsibility for use of contaminated refrigerant Damage resulting from the use of contaminated recovered or recycled refrigerant is the sole responsibility of the servicing company Manitowoc approves the use of 1 New Refrigerant Must be of original nameplate type 2 Reclaimed Refrigerant Must be of original nameplate type Must meet ARI Standard 700 latest edition specifications Part Number 80 1632 3 Refrigeration System 3 Recovered or Recycled Refrigerant Must be recovered or recycled in accordance with current local state and federal laws Must be recovered from and re used in the same Manitowoc product Re use of recovered or recycled refrigerant from other produc
98. rtant If you are installing a Manitowoc Arctic Pure water filter system refer to the Installation Instructions supplied with the filter system for ice making water inlet connections WATER INLET LINES Follow these guidelines to install water inlet lines Do not connect the ice machine to a hot water supply Be sure all hot water restrictors installed for other equipment are working Check valves on sink faucets dishwashers etc f water pressure exceeds the maximum recommended pressure obtain a water pressure regulator from your Manitowoc distributor Install a water shut off valve for both the ice making and condenser water lines Insulate water inlet lines to prevent condensation Caution Do not apply heat to water valve inlet fitting This will damage plastic valve body Part Number 80 1632 3 Installation Instructions DRAIN CONNECTIONS Follow these guidelines when installing drain lines to prevent drain water from flowing back into the ice machine and storage bin Drain lines must have a 1 5 inch drop per 5 feet of run 2 5 cm per meter and must not create traps The floor drain must be large enough to accommodate drainage from all drains Run separate bin and ice machine drain lines Insulate them to prevent condensation Vent the bin and ice machine drain to the atmosphere Do not vent the condenser drain on water cooled models Cooling Tower Application
99. s Water Cooled Models A water cooling tower installation does not require modification of the ice machine The water regulator valve for the condenser continues to control the refrigeration discharge pressure Itis necessary to know the amount of heat rejection and the pressure drop through the condenser and water valves inlet and outlet when using a cooling tower on an ice machine Water entering the condenser must not exceed 90 F 32 2 C Water flow through the condenser must not exceed 5 gallons 19 liters per minute Allow for a pressure drop of 7 psi 48 between the condenser water inlet and the outlet of the ice machine Water exiting the condenser must not exceed 110 F 43 3 C 2 5 Installation Instructions Section 2 WATER SUPPLY AND DRAIN LINE SIZING CONNECTIONS Caution Plumbing must conform to state and local codes Location Water Temperature Water Pressure Ice Machine Fitting Tubing DES Up to Machine Fitting Ice Making 35 F 1 6 C Min 20 psi 137 9 KPA Min 3 8 Female Pipe 3 8 95 cm minimum Water Inlet 90 F 32 2 C Max 80 psi 551 5 Max Thread inside diameter Ice Making u 1 2 Female 1 2 1 27 cm minimum Water Drain Pipe Thread inside diameter Condenser 40 F 4 4 C Min 20 psi 137 9 KPA Min n Water Inlet 90 F os Max 150 i ee Max FEE Pipe te Condenser 1 2 Female 1 2 1 27 cm minimum Water Drain Pipe Thread i
100. seconds of continual water contact the harvest sequence is initiated The ice machine cannot initiate a harvest sequence until a 6 minute freeze lock has been surpassed NOTE Freeze lock is bypassed after moving the toggle switch from OFF to ICE position for the first cycle only Part Number 80 1632 3 Section 3 HARVEST SEQUENCE 5 Water Purge The harvest valve s opens at the beginning of the water purge to divert hot refrigerant gas into the evaporator The water pump continues to run and the water dump valve energizes for 45 seconds to purge the water in the sump trough The water fill valve energizes turns on and de energizes turns off strictly by time The water fill valve energizes for the last 15 seconds of the 45 second water purge After the 45 second water purge the water fill valve water pump and dump valve de energize Refer to Water Purge Adjustment for details 6 Harvest The harvest valve s remains open and the refrigerant gas warms the evaporator causing the cubes to slide as a sheet off the evaporator and into the storage bin The sliding sheet of cubes swings the water curtain out opening the bin switch The momentary opening and re closing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence Step 3 4 The air compressor energizes after 35 seconds and remains energized throughout the entire harvest cycle The air compressor will autom
101. t panels do not normally have to be removed If needed perform the following procedure 1 Loosen screws Do not remove they are retained by o rings to prevent loss 2 To remove right front door lift up and remove 22 inch machines have a single door proceed to step 3 Door Removal 3 Open left front door to 45 degrees 4 Support with left hand depress top pin tilt top of door forward and lift out of bottom pin to remove Maintenance Removal from Service Winterization GENERAL Special precautions must be taken if the ice machine is to be removed from service for an extended period of time or exposed to ambient temperatures of 32 F 0 C or below Caution If water is allowed to remain in the ice machine in freezing temperatures severe damage to some components could result Damage of this nature is not covered by the warranty Follow the applicable procedure below SELF CONTAINED WATER COOLED ICE MACHINES 1 Disconnect the electric power at the circuit breaker or the electric service switch 2 Turn off the water supply 3 Remove the water from the water trough 4 Disconnect and drain the incoming ice making water line at the rear of the ice machine 5 Blow compressed air in both the incoming water and the drain openings in the rear of the ice machine until no more water comes out of the inlet water lines or the drain 6 Make sure water is not trapped in any of the wa
102. t water purge jumper may be set at 45 seconds top and center terminals or 0 seconds center and bottom terminals Set the harvest water purge to 0 seconds when reverse osmosis or deionized water is used Use the factory setting of 45 seconds for all other types of water HARVEST WATER PURGE ADJUSTMENT 45 SECOND 522 JUMPER ood 0919 999 o_o Gl Tg o 9 9 m 2 gt 9 a o OSECOND 0 E JUMPER o POSITION 9 53139 2 59 99999 53140 80 1632 3 Section 6 DIAGNOSING WATER LEVEL CONTROL CIRCUITRY Problem Water Trough Overfilling During The Freeze Cycle Step 1 Start a new freeze sequence by moving the ICE OFF CLEAN toggle switch to OFF then back to ICE if water flows with the switch off check the water inlet valve Important This restart must be done prior to performing diagnostic procedures This assures the ice machine is not in a freeze cycle water inlet valve safety shut off mode You must complete the entire diagnostic procedure within 6 minutes of starting GREEN WATER LEVEL LIGHT WATER LEVEL PROBE CONNECTION Electrical System Step 2 Wait until the freeze cycle starts the freeze cycle starts when the water pump energizes Step 3 Disconnect water level probe wire from control board and co
103. tal Cycle Time 1440 2 Minutes in 24 Total Cycle Time Cycles Per Day Hours X 3 Weight of One Cycles Per Day Actual 24 Hour Ice Harvest Production Important Times are in minutes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights are in pounds Example 2 Ib 6 oz converts to 2 375 Ib 6 oz 16 oz 375 Ib Weighing the ice is the only 100 accurate check However if the ice pattern is normal and the 1 8 thickness is maintained the ice slab weights listed with the 24 Hour Ice Production Charts may be used 4 Compare the results of step 3 with step 2 Ice production checks that are within 1096 of the chart are considered normal If they match closely determine if another ice machine is required more storage capacity is required relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc distributor for information on available options and accessories 7 5 Refrigeration System INSTALLATION VISUAL INSPECTION CHECKLIST Possible Problem Corrective Action Ice machine is not level Level the ice machine Condenser is dirty Clean the condenser Water filtration is plugged if used Install a new water filter Water drains are not run separately and or are not vented Run and vent drains according to the Installation Manual Line set
104. ter lines drain lines distribution tubes etc 7 Disconnect the incoming water and drain lines from the water cooled condenser 8 Insert a large screwdriver between the bottom spring coils of the water regulating valve Pry upward to open the valve 9 Hold the valve open and blow compressed air through the condenser until no water remains 4 12 Section 4 SV1624 Pry Open the Water Regulating Valve AUCS Accessory Refer to the AuCS Accessory manual for winterization of the AuCS Accessory Part Number 80 1632 3 Section 5 Section 5 Before Calling For Service Before Calling For Service Checklist If a problem arises during operation of your ice machine follow the checklist below before calling service Routine adjustments and maintenance procedures are not covered by the warranty Problem Possible Cause To Correct Ice machine does not operate No electrical power to the ice machine and or condensing unit Replace the fuse reset the breaker turn on the main switch High pressure cutout tripping Clean condenser coil See Section 4 ICE OFF CLEAN toggle switch set improperly Move the toggle switch to the ICE position Water curtain stuck open Water curtain must be installed and swinging freely See Section 4 Ice machine stops and can be restarted by moving the toggle switch to OFF and back to ICE Safety limit feature stopping the ice machine
105. the ice machine did not stop because it exceeded a safety limit Part Number 80 1632 3 Section 7 Safety Limit 2 Refer to page 7 11 for safety limit operation Refrigeration System Harvest time exceeds 3 5 minutes for 500 consecutive harvest cycles Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Water system Water area evaporator dirty Dirty defective water dump valve Vent tube not installed on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Low water pressure 20 psi 138 kPa min Loss of water from sump area Clogged water distribution tube Dirty defective water fill valve Defective water pump Electrical system Ice thickness probe out of adjustment Ice thickness probe dirty Bin switch defective Premature harvest Refrigeration system Non Manitowoc components Water regulating valve dirty defective Improper refrigerant charge Defective harvest valve TXV flooding check bulb mounting Defective fan cycling control SAFETY LIMIT NOTES Because there are many possible external problems do not limit your diagnosis to only the items listed in this chart Acontinuous run of 100 harvests automatically erases the safety limit code The control board will store and indicate only one safety limit the last one exceeded Part Number
106. the original installation Section 1 EXCLUSIONS The following items are not included in the ice machine s warranty coverage 1 Normal maintenance adjustments and cleaning 2 Repairs due to unauthorized modifications to the ice machine or use of non standard parts without prior written approval from Manitowoc Ice Inc 3 Damage caused by improper installation of the ice machine electrical supply water supply or drainage or damage caused by floods storms or other acts of God 4 Premium labor rates due to holidays overtime etc travel time flat rate service call charges mileage and miscellaneous tools and material charges not listed on the payment schedule Additional labor charges resulting from the inaccessibility of equipment are also excluded 5 Parts or assemblies subjected to misuse abuse neglect or accidents 6 Damage or problems caused by installation cleaning and or maintenance procedures inconsistent with the technical instructions provided in this manual 7 This product is intended exclusively for commercial application No warranty is extended for personal family or household purposes AUTHORIZED WARRANTY SERVICE To comply with the provisions of the warranty a refrigeration service company qualified and authorized by a Manitowoc distributor or a Contracted Service Representative must perform the warranty repair NOTE If the dealer you purchased the ice machine from is not authori
107. the panels Part Number 80 1632 3 Water Cooled Condenser and Water Regulating Valve Symptoms of restrictions in the condenser water circuit include Low ice production High water consumption High operating temperatures High operating pressures If the ice machine is experiencing any of these symptoms the water cooled condenser and water regulating valve may require cleaning due to scale build up Because the cleaning procedures require special pumps and cleaning solutions qualified maintenance or service personnel must perform them AlphaSan The goal of AlphaSan is to keep the plastic surfaces of an ice machine cleaner by reducing or delaying the formation of bio film The active ingredient in AlphaSan is the element silver in the form of silver ions Ag AlphaSan slowly releases silver ions via an ion exchange mechanism When AlphaSan is compounded directly into a plastic part a controlled release of silver ions from the surface is regulated to maintain an effective concentration at or near the surface of the plastic ice machine part AlphaSan s unique ability to effectively control the release of silver not only protects against undesired discoloration of the plastic but also will last the life of the plastic part Although AlphaSan helps prevent bio film build up it does not eliminate the need for periodic cleaning and maintenance AlphaSan has no adverse effect on the taste of the ice or be
108. the user can help the technician start in the right direction and may be a determining factor in the final diagnosis Ask these questions before beginning service When does the ice machine malfunction night day all the time only during the freeze cycle etc When do you notice low ice production one day a week every day on weekends etc Can you describe exactly what the ice machine seems to be doing Has anyone been working on the ice machine During store shutdown is the circuit breaker water supply or air temperature altered Is there any reason why incoming water pressure might rise or drop substantially ICE PRODUCTION CHECK The amount of ice a machine produces directly relates to the operating water and air temperatures This means an ice machine in a 70 F 21 1 C room with 50 F 10 0 C water produces more ice than the same model condensing unit with a 90 F 32 2 C outdoor ambient temperature and 70 F 21 1 C water 1 Determine the ice machine operating conditions Air temp entering condenser Air temp around ice machine Water temp entering sump trough o o o Part Number 80 1632 3 Refrigeration System 2 Refer to the appropriate 24 Hour Ice Production Chart Use the operating conditions determined in Step 1 to find published 24 hour ice production 3 Perform an actual ice production check Use the formula below Freeze Time Harvest Time To
109. the water softener Part Number 80 1632 3 5 1 Before Calling For Service Section 5 Problem Possible Cause To Correct Ice machine produces shallow or incomplete cubes or the ice fill pattern on the evaporator is incomplete Low ice capacity Ice thickness probe is out of adjustment Adjust the ice thickness probe See Section 4 Water trough level is too low Check the water level probe for damage See Section 3 Water inlet valve filter screen is dirty Remove the water inlet valve and clean the filter screen See Section 4 Water filtration is poor Replace the filter Hot incoming water Connect the ice machine to a cold water supply See Section 2 Water inlet valve is not working Replace the water inlet valve Incorrect incoming water pressure Ice machine is not level Water inlet valve filter screen is dirty Incoming water supply is shut off Water pressure must be 20 80 psi 1 4 bar 5 5 bar Level the ice machine See Section 2 Remove the water inlet valve and clean the filter screen See Section 4 Open the water service valve Water inlet valve stuck open or leaking Place toggle switch in OFF position if water continues to enter water trough replace the water inlet valve The harvest assist air compressor is not functioning Call for service Safety Limit Feature 1 Move the ICE OFF CLEAN switch
110. tial compressor start up and then shuts off At the same time the compressor starts the condenser fan motor air cooled models is supplied with power throughout the entire freeze and harvest sequences The fan motor is wired through a fan cycle pressure control and may cycle on and off The compressor and the condenser fan motor are wired through the contactor Any time the contactor coil is energized the compressor and fan motor are supplied with power Table 6 2 Self Contained Models L1 9 Ground 89 55 amp High Pressure Cutout riMWE Control Board Ice Thickness Probe Contactor Overloag e Contacts Black C Fan Cycle Control Terminates at Pin Connection Air Compressor SV3137 4 Self Contained Refrigeration System Start Up Refrigeration System Start Up 5 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve ON 6 Water Dump Valve OFF 7 Contactor Coil Closed 7A Compressor ON 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Part Number 80 1632 3 6 3 Electrical System Free
111. tion the bin switch closes and the ice machine restarts provided the three minute delay period is complete L1 CONTACTOR CONTACTS RUN CAPACITOR SV1506 During Start Up First 25 1 0 Seconds CONTACTOR CONTACTS RUN CAPACITOR SV1507 After Start Up Current Flows Through Run Capacitor 6 16 Section 6 Troubleshooting PTCR s WHY A GOOD PTCR MAY FAIL TO START THE COMPRESSOR The PTCR must be cooled before attempting to start the compressor otherwise the high starting torque may not last long enough For example if the PTCR is properly cooled say 60 F 15 6 C when the compressor starts it will take 25 to 1 0 seconds before its temperature reaches 260 F 126 6 C and current flow is stopped If the PTCR is still warm say 160 F 71 1 C when the compressor starts it will take only 125 to 50 seconds before its temperature reaches 260 F 126 6 C and current flow is stopped This decreased time may be insufficient to start the compressor A good PTCR may be too hot to operate properly at start up because The ice machine s 3 minute delay has been overridden Opening and closing the service disconnect or cycling the toggle switch from OFF to ICE will override the delay period The control box temperature is too high Though rare very high air temperatures intense sunlight etc can greatly increase the temperature of the control box and its contents This may require a l
112. tion 7 10 Follow the normal evacuation procedure except replace the evacuation step with the following Important Dry nitrogen is recommended for this procedure This will prevent CFC release A Pull vacuum to 1000 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psi 35 kPa 35 bar B Change the vacuum pump oil C Pull vacuum to 500 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psi 35 kPa 35 bar D Change the vacuum pump oil E Pull vacuum to 500 microns Run the vacuum pump for 1 2 hour on self contained models 1 hour on remotes NOTE You may perform a standing vacuum test to make a preliminary leak check You should use an electronic leak detector after system charging to be sure there is no leak 11 Charge the system with the proper refrigerant to the nameplate charge 12 Operate the ice machine for one hour Then check the pressure drop across the suction line filter drier A Ifthe pressure drop is less than 1 psi 7 kPa 7 bar the filter drier should be adequate for complete cleanup B If the pressure drop exceeds 1 psi 7 kPa 7 bar change the suction line filter drier and the liquid line drier Repeat until the pressure drop is acceptable 13 Operate the ice machine for 48 72 hours Then remove the suction line drier and change the liquid line drier 14 Follow normal e
113. tion system TXV starving NOTE Do not limit your diagnosis to only the items listed in the checklists 7 14 Part Number 80 1632 3 Section 7 HARVEST VALVE TEMPERATURE CHECK General NOTE This procedure requires checking both harvest valves on dual expansion valve 51400 and 51800 ice machines A harvest valve requires a critical orifice size This meters the amount of hot gas flowing into the evaporator during the harvest cycle If the orifice is even slightly too large or too small long harvest cycles will result A too large orifice causes refrigerant to condense to liquid in the evaporator during the harvest cycle This liquid will cause compressor damage A too small orifice does not allow enough hot gas into the evaporator This causes low suction pressure and insufficient heat for a harvest cycle Refer to the Parts Manual for proper valve application If replacement is necessary Use only original Manitowoc replacement parts Harvest Valve Analysis Symptoms of a harvest valve remaining partially open during the freeze cycle can be similar to symptoms of either an expansion valve or compressor problem The best way to diagnose a harvest valve is by using Manitowoc s Ice Machine Refrigeration System Operational Analysis Table Use the following procedure and table to help determine if a harvest valve is remaining partially open during the freeze cycle 1 Wait five minutes into the freeze cycle
114. ts is not approved Recycling equipment must be certified to ARI Standard 740 latest edition and be maintained to consistently meet this standard e Recovered refrigerant must come from a contaminant free system To decide whether the system is contaminant free consider Type s of previous failure s Whether the system was cleaned evacuated and recharged properly following failure s Whether the system has been contaminated by this failure Compressor motor burnouts and improper past service prevent refrigerant re use Refer to System Contamination Cleanup to test for contamination 4 Substitute or Alternative Refrigerant Mustuse only Manitowoc approved alternative refrigerants Mustfollow Manitowoc published conversion procedures 7 29 Refrigeration System Section 7 HFC REFRIGERANT QUESTIONS AND ANSWERS Manitowoc uses R 404A and R 134A HFC refrigerants with ozone depletion potential ODP factors of zero 0 0 R 404A is used in ice machines and reach in freezers and R 134A is used in reach in refrigerators 1 What compressor oil does Manitowoc require for use with HFC refrigerants Manitowoc products use Polyol Ester POE type compressor oil It is the lubricant of choice among compressor manufacturers What are some of the characteristics of POE oils They are hygroscopic which means they have the ability to absorb moisture POE oils are 100 times more hy
115. ts you to a situation in which you could damage the ice machine Be sure to read the Caution statement before proceeding and work carefully Important Text in an Important box provides you with information that may help you perform a procedure more efficiently Disregarding this information will not cause damage or injury but it may slow you down as you work NOTE Text set off as a Note provides you with simple but useful extra information about the procedure you are performing Read These Before Proceeding Caution Proper installation care and maintenance are essential for maximum ice production and trouble free operation of you Manitowoc Ice Machine Read and understand this manual It contains valuable care and maintenance information If you encounter problems not covered by this manual do not proceed contact Manitowoc Ice Inc We will be happy to provide assistance Important Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty We reserve the right to make product improvements at any time Specifications and design are subject to change without notice Table of Contents Section 1 General Information Model Numbers s lE ERES dead d e dg E nan 1 1 How to Read a Model Number 1 1 lceCube Sizes ou ema e ada etica 1 1 Accessories i i2csaks mea
116. vacuation procedures Part Number 80 1632 3 Refrigeration System REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE This procedure reduces repair time and cost Use it when any of the following components require replacement and the refrigeration system is operational and leak free Water regulating valve water cooled only High pressure cut out control High side service valve Low side service valve Important This is a required in warranty repair procedure 1 Disconnect power to the ice machine 2 Follow all manufacturer s instructions supplied with the pinch off tool Position the pinch off tool around the tubing as far from the pressure control as feasible See the figure on next page Clamp down on the tubing until the pinch off is complete A Warning Do not unsolder a defective component Cut it out of the system Do not remove the pinch off tool until the new component is securely in place 3 Cut the tubing of the defective component with a small tubing cutter 4 Solder the replacement component in place Allow the solder joint to cool 5 Remove the pinch off tool 6 Re round the tubing Position the flattened tubing in the proper hole in the pinch off tool Tighten the wingnuts until the block is tight and the tubing is rounded See the drawing on next page NOTE The pressure controls will operate normally once the tubing is re rounded Tubing may not re round 10
117. vacuum pump MANIFOLD SET OPEN BACKSEATED BACKSEATED LOW SIDE SERVICE r VALVE HIGH SIDE SERVICE VALVE VACUUM PUMP RECOVERY UNIT 1 CLOSED LL SV1404A Figure 7 8 Recovery Evacuation Connections 3 Open backseat the high and low side ice machine service valves and open high and low side on manifold gauges 4 Perform recovery or evacuation A Recovery Operate the recovery unit as directed by the manufacturer s instructions B Evacuation prior to recharging Pull the system down to 500 microns Then allow the pump to run for an additional half hour Turn off the pump and perform a standing vacuum leak check 5 Follow the Charging Procedures 7 21 Refrigeration System Self Contained Charging Procedures Important The charge is critical on all Manitowoc ice machines Use a scale or a charging cylinder to ensure the proper charge is installed 1 Be sure the toggle switch is in the OFF position MANIFOLD SET FRONTSEATED BACKSEATED LOW SIDE HIGH SIDE SERVICE C O SERVICE VALVE VALVE CHARGING CYLINDER VACUUM PUMP RECOVERY UNIT CLOSED tt OPEN SV1404B Figure 7 9 Charging Connections 7 22 Section 7 Close the vacuum pump valve the low side service valve and the low side manifold gauge valve Open the high side manifold gauge valve and backseat the high side serv
118. verage 4 1 Maintenance Guardian Section 4 Slime is a leading cause of ice machine breakdowns and biological growth is a health concern The Guardian system releases chlorine dioxide on a controlled basis to inhibit the growth of bacteria and fungi that form slime and cause malodors in the food zone of ice machines The Guardian will not control mineral or other water borne buildup Your water quality will determine the length of time before mineral buildup affects ice machine performance Mineral buildup must be removed as often as necessary to ensure trouble free operation of the ice machine INSTALLATION If the Guardian system has been ordered install the sachet holder in the inside of the front panel 1 Loosen the left screw and open the left front door The right front panel does not need to be removed Loosen Screw Screw Location 2 Inside the front panel there are two thumbscrew holes covered by stickers pierce the sticker with a screwdriver 3 Attach the sachet holder to the front panel by inserting the thumbsrews through the holes in the sachet holder and tightening the thumbscrews 4 Remove the new sachet packet from foil package and install into holder Removing the foil package allows moisture in the air to activate the sachet contents 5 Close the left front door and tighten the screw Inside Left Front Door Guardian
119. verage begins the day your new ice machine is installed Important the OWNER WARRANTY REGISTARATION CARD as soon as possible to validate the installation date Complete and mail If you do not return your OWNER WARRANTY REGISTRATION CARD Manitowoc will use the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice machine Warranty Coverage GENERAL The following Warranty outline is provided for your convenience For a detailed explanation read the warranty bond shipped with each product Contact your local Manitowoc Distributor Manitowoc Ice Inc or visit our website at www manitowocice com if you need further warranty information Important This product is intended exclusively for commercial application No warranty is extended for personal family or household purposes PARTS 1 Manitowoc warrants the ice machine against defects in materials and workmanship under normal use and service for three 3 years from the date of original installation 2 The evaporator and compressor are covered by an additional two 2 year five years total warranty beginning on the date of the original installation LABOR 1 Labor required to repair or replace defective components is covered for three 3 years from the date of original installation 2 The evaporator is covered by an additional two 2 year five years total labor warranty beginning on the date of
120. wer supplied to the control board Step Check Notes 1 Verify primary voltage supply to ice Verify that the fuse or circuit breaker is closed machine 2 Verify the high pressure cutout is closed The H P C O is closed if primary power voltage is present at terminals 55 and 56 on the control board 3 Verify control board fuse is OK If the bin switch light functions the fuse is OK 4 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 5 Verify ICE OFF CLEAN toggle switch A defective toggle switch may keep the ice machine in the OFF mode functions properly 6 Verify low DC voltage is properly Loose DC wire connections may intermittently stop the ice machine grounded 7 Replace the control board Be sure Steps 1 6 were followed thoroughly Intermittent problems are not usually related to the control board Part Number 80 1632 3 6 27 Electrical System Section 6 SELF CONTAINED 1 PHASE WITH TERMINAL BOARD ee ee 1111 SV2071 6 28 Part Number 80 1632 3 Section 7 Refrigeration System Section 7 Refrigeration System Sequence of Operation SELF CONTAINED WATER COOLED MODELS EVAPORATOR HEAT o EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE GSSSSNSSSSSSSSSY X ee COMPRESSOR AIR OR WATER STRAINER CONDENSER WATER COOLED ONLY BEES o
121. wide low temperature range but upon reaching a certain higher temperature its resistance greatly increases virtually stopping current flow When the source of heat is removed the PTCR returns to its initial base resistance In severe duty cycles it can be used to repeatedly switch virtually stop large currents at line voltages PTCR s have been used for many years in millions of HVAC applications In place of using the conventional start relay start capacitor a simple PTCR provides the starting torque assistance to PSC Permanent Split Capacitor single phase compressors which can equalize pressures before starting Part Number 80 1632 3 Electrical System Compressor Start Sequence PTCR s provide additional starting torque by increasing the current in the auxiliary start winding during starting The PTCR is wired across the run capacitor in series with the start winding 1 It is important for the refrigerant discharge and suction pressures to be somewhat equalized prior to the compressor starting To assure equalization of pressures the harvest valve and HPR valve on remotes will energize for 45 seconds prior to compressor starting The harvest valve and HPR valve on remotes remains on for an additional 5 seconds while the compressor is starting 2 When starting the compressor the contactor closes and the PTCR which is at a low resistance value allows high starting current to flow in the start winding
122. your meter reading should be 0 0 to 10 is acceptable With the curtain open the reading must be infinity OL Continuity Test 1 Disconnect the bin switch wires to isolate the bin switch from the control board 2 Connect an ohmmeter to the disconnected bin switch wires 3 Cycle the bin switch open and closed 25 times by opening and closing the water curtain Watch for consistent readings each time the bin switch is cycled open and closed bin switch failure could be erratic Part Number 80 1632 3 Water Curtain Removal Notes The water curtain must be on bin switch closed to start ice making While a freeze cycle is in progress the water curtain can be removed and installed at any time without interfering with the electrical control sequence If the ice machine goes into harvest sequence while the water curtain is removed one of the following will happen Water curtain remains off When the harvest cycle time reaches 3 5 minutes and the bin switch is not closed the ice machine stops as though the bin were full e Water curtain is put back on If the bin switch closes prior to reaching the 3 5 minute point the ice machine immediately returns to another freeze sequence prechill 6 13 Electrical System COMPRESSOR ELECTRICAL DIAGNOSTICS The compressor will not start or will trip repeatedly on overload Check Resistance Ohm Values NOTE Compressor windings can have very low ohm values Use a proper
123. ze Sequence L1 3 PRE CHILL To pre chill the evaporator the compressor runs for 30 seconds 60 seconds initial cycle prior to water Cutout flow The water fill valve remains on until the water level probe is satisfied Ice Thickness Probe Contactor Contacts Table 6 3 Self Contained Models Section 6 L2 orN Water Valve Terminates at Pin Connection Air Compressor Bin Switch 6 Run Capacitor eic Run Capacitor 5 3137 3 Self Contained Pre Chill 6 4 3 Pre Chill 60 Seconds Initial Cycle 30 Seconds thereafter Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve On 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Part Number 80 1632 3 Section 6 4 FREEZE The water pump starts after the pre chill An even flow of water is directed across the evaporator and into each cube cell where it freezes The water fill valve will cycle off then on one more time to refill the water trough When sufficient ice has formed the wate
124. zed to perform warranty service contact your Manitowoc distributor or Manitowoc Ice Inc for the name of the nearest authorized service representative Service Calls Normal maintenance adjustments and cleaning as outlined in this manual are not covered by the warranty If you have followed the procedures listed on page 5 1 of this manual and the ice machine still does not perform properly call your authorized service company Part Number 80 1632 3 Section 2 These instructions are provided to assist the qualified installer Check your local Yellow Pages for the name of the nearest Manitowoc distributor or call Manitowoc Ice Section 2 Installation Instructions Installation Instructions Inc for information regarding start up services Ice Machine Dimensions S1400M WATER COOLED ICE MACHINES Important Failure to follow these installation guidelines may affect warranty coverage 3 250 6 35 END AuCS CONDENSER WATER E Connection eter Cooled Only WATER INLET 5 75 14 6cm 8 1 1 2 8 Y T CONDENSER WATER m INLET 3 8 FPT 10 2 Water Cooled Only 10 25 26 0cm 3 0 7 6cm 27 9cm pe gt

S Model Ice Machines S1400M Service Manual

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