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1. sexoq Jo Jequunu e 0 J93U3 sisAjeuy 05 do OU JO pue je JO pue je JO pue y je 9z99JJ JO pue JO pue je JeuBiu 10 2 1714 3 091 JeuBiu 10 JeuDiu 10 eBjeuosip Dob LZ 3 091 uey 5501 2 1 4091 Dob LZ 3 091 2994 eui eur eBueuosigq v L s s jeuy AATVA TAGOW f 107 PRESSURE CONTROL SPECIFICATIONS AND DIAGNOSTICS Harvest Pressure Regulating HPR System Remotes Only GENERAL The harvest pressure regulating H P R system includes Harvest pressure regulating solenoid valve H P R solenoid This is an electrically operated which opens when energized and closes when de energized OUTLET HPR SOLENOID SV3074 108 Harvest pressure regulating valve H P R valve This is a pressure regulating valve which modulates open and closed based on the refrigerant pressure at the outlet of the valve The valve closes completely and stops refriger
2. 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 and harvest pressure regulating HPR solenoid valves also energize during water purge although they stay on for an additional 5 seconds 50 seconds total on time during the initial refrigeration system start up 2 Refrigeration System Start Up The compressor and liquid line solenoid valve energize after the 45 second water purge and remain on throughout the entire Freeze and Harvest Sequences The water fill valve is energized at the same time as the compressor It remains on until the water level sensor closes for 3 continuous seconds or until a six minute time period has expired The harvest valve and HPR solenoid valves remain on for 5 seconds during initial compressor start up and then shut off The remote condenser fan motor starts at the same time the compressor starts and remains on throughout the entire Freeze and Harvest Sequences 19 Freeze Sequence 3 Prechill The compressor is on for 30 seconds prior to water flow to prechill the evaporator 4 Freeze The water pump restarts after the 30 second prechill An even flow of water is directed across the
3. Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 20 28 9 to 235 245 48 24 145 170 70 90 50 10 0 70 21 1 235 265 52 26 150 175 70 90 80 26 7 235 270 52 26 150 175 75 95 90 32 2 235 280 52 28 155 180 75 95 100 37 8 240 285 52 28 155 180 80 100 110 43 3 240 290 54 28 155 185 80 100 Suction pressure drops gradually throughout the freeze cycle 143 01600 Series Remote Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 20 to 70 7 5 8 4 8 2 9 2 9 0 10 1 29 to 21 1 90 32 2 8 0 8 9 8 6 9 6 9 2 10 3 100 37 8 8 4 9 3 9 2 10 2 9 7 10 8 110 43 3 9 2 10 3 10 0 11 2 10 4 11 6 1 2 5 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 201070 1600 1478 1370 29 to 21 1 90 32 2 1523 1425 1340 100 37 8 1460 1350 1290 110 43 3 1343 1250 1213 Based on average ice slab weight of 13 0 14 12 Ib Ratings with JC1895 condenser dice or half dice cubes OPERATING PRESSURES
4. HARVEST LIGHT yh SAFETY LIMIT CODE LIGHT VIEW FOR n q E OFF INTERNAL WORKING CLEAN FAN CYCLE CONTROL RUN CAPACITOR COMPRESSOR 3008 2365 Q450 Q600 Q800 Q1000 Remote 1 Phase With Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING N ELECTRICAL CIRCUITRY SEE SERIAL PLATE FOR VOLTAGE DIAGRAM SHOWN DURING FREEZE CYCLE L2 N TB35 HIGH PRES CUTOUT CLEAN LIGHT WATER LEVEL PROBE 46 LOW D C NOT USED MERGE WATER LEVEL LIGHT HARVEST LIGHT _______ SAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING 59 65 E 62 CLEAN 75 49 CONTACTOR CONTACTS TB35 TERMINATES AT lt 53 PIN CONNECTIONS 7924 ITB30 REMOTE CONDENSER RUN CAPACITOR RUN 1648 37 Q450 Q600 Q800 Q1000 Remote 1 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY u DIAGRAM SHOWN DURING FREEZE CYCLE 120 SEE SERIAL PLATE FOR VOLTAGE HIGH PRES CUTOUT WATER LEVEL LIGHT BIN SWITCH LIGHT HARVEST LIGHT SAFETY LIMIT CODE LIGHT INTERNAL WORKING OFF CLEAN 42 CONTACTOR CONTACTS 2073 38 Q800 Q1000 Remote 3 Phase With Terminal Board SEE SERIAL PLATE FOR VOLTAGE CAUTION DISCONNECT POWER BEFORE WORKING L3 L2 L1 ON ELECTRICAL CIRCUITRY e DIAGRAM SHOWN DURING FREE
5. 22 Electrical System Wiring 2 112 25 Wiring Diagram 25 Q200 Q280 Q320 Self Contained 1 Phase With Terminal Board 26 Q280 Q370 Self Contained 1 Phase Without Terminal Board 27 0320 Self Contained 1 Phase Without Terminal Board 28 Q420 Q450 Q600 Q800 Q1000 Self Contained 1 Phase With Terminal Board 29 Q420 Q450 Q600 Q800 Q1000 Self Contained 1 Phase Without Terminal Board 30 Q800 Q1000 Self Contained 3 Phase With Terminal 31 Q800 Q1000 Self Contained 3 Phase Without Terminal 32 01300 01800 Self Contained 1 Phase With Terminal Board 33 01300 01600 01800 Self Contained 1 Phase Without Terminal Board 34 01300 01800 Self Contained 3 Phase With Terminal 35 01300 01600 01800 Self Contained 3 Phase Without Terminal Board 36 Q450 Q600 Q800 Q1000 Remote 1 Phase With Terminal Board 37 Q450 Q600 Q800 Q1000 Remote 1 Phase Without Terminal Board 38 Q800 Q1000 Remote 3 Phase With Terminal 39 Q800 Q1000 Remote 3
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8. Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F PC PSIG PSIG PSIG PSIG 20 to 50 29 220 255 52 26 100 120 70 85 to 10 0 70 21 1 250 270 56 28 110 120 75 90 80 26 7 250 275 56 28 110 120 75 90 90 32 2 255 285 56 28 110 120 80 90 100 37 8 270 310 56 30 115 130 80 95 110 43 3 305 350 58 32 120 135 80 100 Suction pressure drops gradually throughout the freeze cycle 144 91800 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 8 5 9 3 9 4 10 3 9 9 10 9 80 26 7 9 0 9 9 9 8 10 8 10 5 11 5 90 32 2 9 6 10 5 10 4 11 5 11 1 12 2 3 100 37 8 10 6 11 6 11 5 12 6 12 4 13 6 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 70 21 1 1880 1720 1640 80 26 7 1780 1650 1560 90 32 2 1690 1570 1480 100 37 8 1550 1440 1350 Based on average ice slab weight of 13 0 14 12 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suc
9. 148 Normal Self Contained Model Procedures 148 Normal Remote Model Procedures 152 System Contamination Clean Up 157 Gerieral ettet eese 157 Determining Severity Of Contamination 157 Cleanup Procedure 159 Replacing Pressure Controls Without Removing Refrigerant 162 Filter Driers iere 164 Total System Refrigerant Charge 165 Additional Refrigerant Charges 166 For Line Sets Between 50 100 166 THIS PAGE INTENTIONALLY LEFT BLANK General Information HOW TO READ A MODEL NUMBER CUBESIZE CONDENSER TYPE 0 REGULAR AIR COOLED 1 REGULAR WATER COOLED 9 REMOTE AIR COOLED 2 DICE AIR COOLED 3 DICE WATER COOLED 4 HALF DICE AIR COOLED 5 HALF DICE WATER COOLED zT ICE MACHINE ICE MACHINE MODEL SERIES CUBE SIAE CONDENSER TYPE R REGULAR D DICE SELF CONTAINED AIR COOLED Y HALF DICE W SELF CONTAINED WATER COOLED N REMOTE AIR COOLED ICE CUBE SIZES 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 x 2 22 x 0 95 x 2 86 x 2 22 cm 2 22 2 22 4 MODEL SERIAL NUMBER LOCATION These numbers are required when requesting information from your local Manitowoc Distributor service representative
10. 0600 0800 01000 8504993 305 19 18 40 01300 01600 01800 8504913 305 9 8 22 Ohms MEASURE OHMS BETWEEN END TABS Manitowoc PTCR s 8505003 amp 8504993 LEAVE JUMPER WIRE IN PLACE MEASURE OHMS BETWEEN CENTER TAB AND END TAB 68 Manitowoc PTCR s 8504913 THIS PAGE INTENTIONALLY LEFT BLANK 69 THIS PAGE INTENTIONALLY LEFT BLANK 70 Refrigeration System REFRIGERATION SYSTEM DIAGNOSTICS 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 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 e When does the ice machine malfunction night day all the time only during the Freeze cycle etc e When do you notice low ice production one day a week every day on weekends etc e Can you describe exactly what the ice machine seems to be doing e Has anyone been working on the ice machine e During store shutdown is the circuit breaker water supply or air temperature altered e Is there any reason why incoming water pressure might rise or drop substantially 71 Ice Production Check The amount of ice a machine produces directly relates t
11. 2 Warranty Coverage 3 Installation Location of Ice Machine 5 Ice Machine Head Section Clearance Requirements eren rete 5 Stacking Two Ice Machines on a Single Storage Bin 6 Calculating Remote Condenser Installation 2 2 7 Removal from Service Winterization Cepe 11 Self Contained Air Cooled Ice Machines 11 Water Cooled Ice Machines 11 Remote Ice 5 12 AUCS 12 Ice Making Sequence of Operation Self Contained Air and Water Cooled 13 Initial Start Up or Start Up After Automatic 13 Freeze 14 Harvest 15 Automatic 16 Energized Parts 17 Rermole s n nA eth 19 Initial Start Up or Start Up After Automatic 422 19 Freeze Sequence 20 Harvest 21 Automatic 21 Remote Energized Parts
12. Ice fill pattern normal Refer to Ice Formation Pattern if ice fill is not normal Freeze time normal Refer to Cycle Times Refrigerant Pressures 24 Hour Ice Production Charts Shorter freeze cycles Refer to headmaster diagnostics Longer freeze cycles Refer to water system checklist then refer to Refrigeration Diagnostic Procedures Harvest time is longer than normal and control board indicates safety limit 2 Refer to Cycle Times Refrigerant Pressures 24 Hour Ice Production Charts Connect refrigeration manifold gauge set to the access valves on the front of the ice machine and a thermometer thermocouple on the discharge line within 6 of the compressor insulate thermocouple Establish baseline by recording suction and discharge pressure discharge line temperature and freeze amp harvest cycle times Refer to Refrigeration System Operational Analysis Tables for data collection detail 110 Freeze cycle Head Pressure 220 psig 1517 kPa or higher If the head pressure is lower than 220 psig 1517 kPa refer to headmaster diagnostics Freeze cycle Suction Pressure normal Refer to analyzing suction pressure if suction pressure is high or low Discharge line temperature is 160 F 71 1 C or higher at end of freeze cycle If less than 160 F 71 1 C check expansion valve bulb mounting and insulation Harvest cycle suction and discharge pressures are lower than indica
13. Q1300 Q1600 Q1800 Self Contained 1 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY SEE SERIAL PLATE FOR VOLTAGE u DIAGRAM SHOWN DURING FREEZE CYCLE TERMINATES AT PIN CONNECTION CLEAN LIGHT WATER LEVEL LIGHT BIN SWITCH LIGHT HARVEST LIGHT SAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING 68 INTERNAL WORKING OFF CLEAN 47 RUN CAPACITQR CONTACTOR CONTACTS FAN MOTOR AIR COOLED ONLY RUN CAPACITOR 2075 34 Q1300 Q1800 Self Contained 3 Phase With Terminal Board SEE SERIAL PLATE FOR VOLTAGE CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY WATER 1 DIAGRAM SHOWN DURING FREEZE CYCLE 21 LH HARVES SOLENOID CLEAN LIGHT IATER LEVEL LIGHT BIN SWITCH LIGHT HARVEST LIGHT TISAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING 68 INTERNAL WORKING VIEW 66 62 CLEAN NOTE WIRE 96 IS NOT USED ON 50HZ 33 52 85 86 FAN CYCLE CONTROL COMPRESSOR RUN CAPACITOR SV1653 35 Q1300 Q1600 Q1800 Self Contained 3 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING Gert PEATEFORNOLTAGE ON ELECTRICAL CIRCUITRY wee re DIAGRAM SHOWN DURING FREEZE CYCLE 20 TERMINATES AT ICE THICKNESS PROBE PIN CONNECTION cLEAN WATER LeveL BW
14. The difference between a Manitowoc drier and an off the shelf drier is in filtration A Manitowoc drier has 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 that takes place during every harvest cycle A Manitowoc filter drier has a very high moisture removal capability and a good acid removal capacity 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 Listed below is the recommended OEM field replacement drier Liquid Line Driers End Drier Model Connection Size Size Part Number Self Contained Air and Water Cooled Q200 Q280 Q320 UK 032S 1 4 in 89 3025 3 Q370 Q420 Q450 Q600 Q800 Q1000 Remote Air Cooled Q450 Q600 UK 083S 3 8 in 89 3027 3 Q800 Q1000 All Condenser Type Q1300 Q1600 UK 083S 3 8 in 82 3027 3 Q1800 Suction Filter UK 165S 5 8 in 89 3028 3 Used when cleaning up severely contaminated systems Important Driers are covered as a warranty part The drier must be replaced any time the system is opened for repairs 164 Total System Refrigerant Charge Important This information is for referance only
15. to maintain 240 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Aroundlce Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 235 245 36 20 170 190 65 80 70 21 1 235 245 38 20 170 190 65 80 80 26 7 235 245 40 20 170 190 65 80 90 32 2 235 250 42 22 175 190 65 80 100 37 8 235 255 44 22 175 190 65 80 110 43 3 235 260 46 22 175 190 65 80 Suction pressure drops gradually throughout the freeze cycle 146 01800 Series Remo te These characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time F PC 50 10 0 70 21 1 90 32 2 eae 70 04 400 98 108 107 117 80 26 7 9 3 10 2 10 1 11 1 10 9 12 0 90 32 2 95 105 103 114 111 122 125 100 37 8 10 1 11 1 11 1 12 2 11 9 13 0 110 43 3 11 0 12 1 12 1 13 2 12 7 13 9 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 20 28 9 to 70 21 1 1770 1650 1540 80 26 7 1735 1615 1510 90 32 2 1700 1580 1480 100 37 8 1620 1480 1400 110 43 3 1500 1380 1320 Based on average ice slab weight of 13 0 14 12 Ib Regular cube d
16. 122 Self Contained 123 0320 5 Self Contained Air Cooled 124 Self Contained Water Cooled 125 Q370 Series Self Contained Air Cooled 126 Self Contained Water Cooled 127 Q420 450 Series Self Contained Air Cooled 128 Self Contained Water Cooled 129 Remote 130 0600 Series Self Contained Air Cooled 131 Self Contained Water Cooled 132 133 0800 Series Self Contained Air Cooled 134 Self Contained Water Cooled 135 Bos teu 136 01000 Series Self Contained Air Cooled 137 Self Contained Water Cooled 138 139 01300 Self Contained Air Cooled 140 Self Contained Water Cooled 141 ROMO ts Le tore 142 01600 Series Self Contained Water Cooled 143 Remote necant eter ao Eds 144 Q1800 Series Self Contained Air Cooled 145 Self Contained Water Cooled 146 Refrigerant Recovery Evacuation
17. 2 Refer to Operating Pressure Chart for ice machine being checked Use the operating conditions determined in step 1 to find the published normal discharge pressures Freeze Cycle Harvest Cycle 3 Perform an actual discharge pressure check Freeze Harvest Cycle psig Cycle psig 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 It is normal for the discharge pressure to be higher at the beginning of the Freeze cycle when load is greatest then drop throughout the Freeze cycle 85 DISCHARGE PRESSURE HIGH CHECKLIST Problem e Cause Improper Installation e Refer to Installation Visual Inspection Checklist Restricted Condenser Air Flow e High inlet air temperature 110 F 43 3 C max e Condenser discharge air recirculation Dirty condenser filter Dirty condenser fins Defective fan cycling control Defective fan motor Restricted Condenser water flow e Low water pressure 20 psi min e High inlet water temperature 90 F 32 2 C max e Dirty condenser Dirty Defective water regulating valve e Water regulating valve out of adjustment Improper Refrigerant Charge e Overcharged e Non condensable in system e Wrong type of refrigerant Other Non Manito
18. 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 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 When a high pressure cut out or a safety limit stops the ice machine they are doing what they are supposed to do That is stopping the ice machine before a major component failure occurs Refrigeration and electrical component failures may also trip a safety limit Eliminate
19. Refer to the ice machine serial number tage to verify the system charge Serial plate information overrides information listed on this page Series Version Charge Air Cooled 18 oz Q200 Water Cooled 15 oz Air Cooled 18 oz Q280 Water Cooled 15 oz Air Cooled 20 oz Q320 Water Cooled 16 oz Air Cooled 20 oz Q370 Water Cooled 17 oz Air Cooled 24 oz Q420 Q450 Water Cooled 22 oz Remote 6 Ib Air Cooled 28 oz Q600 Water Cooled 22 oz Remote 8 Ib Air Cooled 36 oz 0800 Water Cooled 25 oz Remote 8 Ib Air Cooled 38 oz Q1000 Water Cooled 32 Remote 9 5 Ib Air Cooled 48 oz Q1300 Water Cooled 44 oz Remote 12 5 Ib Water Cooled 46 oz Q1600 Remote 15 Ib Air Cooled 56 oz Q1800 Water Cooled 46 oz Remote 15 Ib The ice machine serial number plate overrides any amounts listed on this chart 165 ADDITIONAL REFRIGERANT CHARGES For Line Sets Between 50 100 Refrigerant to be Maximum Nameplate System M Added for achine Charge 50 100 Charge Line Sets 6 Ib 6 Ib 9490 None 96 oz 8 Ib 8 Ib Q690 128 oz 128 8 Ib 8 Ib Q890 128 oz 128 9 5 Ib 9 5 Ib 01090 452 oz None 152 oz 12 5 Ib 1 5 Ib 14 Ib 91390 50002 2402 224 15 Ib 2 0 Ib 17 Ib Q1690 4002 3207 272 15 Ib 2 0 Ib 17 Ib 91890 24002 3202 2720
20. e Zero out manifold gauge set before obtaining pressure readings to avoid misdiagnosis e Discharge 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 119 0200 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Air Temp Freeze Time Entering Condenser Water Temperature F C Time 50 10 0 70 21 1 90 32 2 70 21 1 11 5 13 5 13 8 16 1 15 2 17 8 80 26 7 13 8 16 1 15 6 18 2 17 0 19 8 035 90 32 2 16 1 18 7 18 6 21 6 20 5 23 8 ie 100 37 8 19 8 23 0 23 6 27 4 25 5 29 6 Times in Minutes 24 HOUR ICE PRODUCTION Air Temp Water Temperature F C Entering Condenser 50 10 0 70 21 1 90 32 2 70 21 1 270 230 210 80 26 7 230 205 190 90 32 2 200 175 160 100 37 8 165 140 130 Based on average ice slab weight of 2 44 2 81 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure FP C PSIG PSIG 1 50 10 0 195 260 60 28 120 190 85 110 70 21 1 195 260 60 28 120 190 85 110 80 26 7 210 270 65 28 160 190 90 110 90 32 2 240 290 70 30 190 210 100 120 100 37 8 270 330 70 35 220 240 120 140 110
21. 165 180 85 100 90 32 2 235 245 52 35 165 180 85 100 100 37 8 235 245 52 35 165 185 85 100 110 43 3 240 250 55 36 165 185 85 100 Suction pressure drops gradually throughout the freeze cycle 129 0450 Series Remote Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 166 125 12 0 14 0 13 3 15 6 80 26 7 10 9 12 8 12 3 14 4 13 7 16 0 90 32 2 11 1 13 1 12 6 14 8 14 1 16 5 1 25 100 37 8 12 0 14 0 13 7 16 0 15 5 18 0 110 43 3 13 3 15 6 15 5 18 0 17 6 20 6 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 20 28 9 to 70 21 1 490 440 400 80 26 7 480 430 390 90 32 2 470 420 380 100 37 8 440 390 350 110 43 3 400 350 310 Based on average ice slab weight of 4 12 4 75 Ib Regular cube derate is 7 Ratings with JC0495 condenser dice or half dice cubes OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F PC PSIG PSIG PSIG PSIG ADU 225 245 50 32 175 190 85 100 70 21 1 230 250 50 32 175 190 85 100 80 26 7 240
22. 180 70 80 70 21 1 235 245 40 18 150 180 70 80 80 26 7 235 245 40 20 150 180 70 80 90 32 2 235 250 42 20 150 180 70 80 100 37 8 235 255 44 20 150 180 70 80 110 43 3 240 265 46 20 150 180 70 80 Suction pressure drops gradually throughout the freeze cycle 141 01300 Series Remote Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 2028 9 t070 99 114 10 9 12 2 117 130 80 26 7 10 0 11 2 11 0 12 3 11 1 12 4 90 32 2 10 1 11 3 11 1 12 4 10 7 11 9 100 37 8 10 8 12 0 11 8 13 2 12 8 14 2 110 43 3 11 7 13 0 12 9 14 3 13 8 15 4 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 20 28 9 to 70 21 1 1260 1160 1090 80 26 7 1250 1150 1140 90 32 2 1240 1140 1180 100 37 8 1170 1080 1010 110 43 3 1090 1000 940 Based on average ice slab weight of 10 0 11 0 Ib Regular cube derate is 7 Ratings with JC1395 condenser dice or half dice cubes OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F PC PSIG PSIG PSIG PSIG 2028 81
23. 210 240 85 120 Suction pressure drops gradually throughout the freeze cycle 134 9800 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 8 7 10 1 9 5 11 0 10 9 12 5 80 26 7 8 9 10 2 9 7 11 1 11 0 12 7 155 90 32 2 9 0 10 3 9 8 11 3 11 2 12 9 100 37 8 9 1 10 5 10 0 11 5 11 4 13 1 Times minutes 24 HOUR ICE PRODUCTION Air Temp Around Ice Water Temperature F C Machine F C 50 10 0 70 21 1 90 32 2 70 21 1 810 750 670 80 26 7 800 740 660 90 32 2 790 730 650 100 37 8 780 720 640 Based on average ice slab weight of 5 75 6 50 10 Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Ice Machine 90 F 32 2 C Water Temperature F C 50 10 0 70 21 1 90 32 2 Gal 24 hours 640 1420 6000 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Around Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG FI C 50 10 0 225 235 33 20 160 185 65 85 70 21 1 22
24. 260 52 32 180 195 85 100 90 32 2 245 270 54 35 185 200 85 100 100 37 8 280 310 57 37 190 205 90 105 110 43 3 290 325 64 39 190 205 95 110 Suction pressure drops gradually throughout the freeze cycle 130 9600 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 7 1 8 4 7 8 9 2 8 6 10 1 80 26 7 7 8 9 2 8 6 10 1 9 5 11 2 Duns 90 32 2 8 6 10 1 9 5 11 2 10 4 12 2 100 37 8 9 5 11 2 10 6 12 5 12 0 14 0 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 70 21 1 690 640 590 80 26 7 640 590 540 90 32 2 590 540 500 100 37 8 540 490 440 Based on average ice slab weight of 4 12 4 75 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG 50 10 0 195 260 42 22 155 180 75 95 70 21 1 220 290 44 22 160 185 85 100 80 26 7 220 305 52 22 160 190 90 110 90 32 2 250 325 52 23 175 195 95 115 100 37 8 280 355 54 30 195 210 95 125 110 43 3 300 385 56 32 200 225 100
25. Black Microprocessor Freeze Time exceeds 60 minutes for 3 consecutive freeze cycles or Control Board with Orange Label on Microprocessor Freeze time exceeds 60 minutes for 6 consecutive freeze cycles Possible Cause Checklist Improper Installation e Refer to Installation Visual Inspection Checklist Water System Low water pressure 20 psig min High water pressure 80 psig 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 Electrical System Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operational Restricted condenser airflow High inlet air temperature 110 F 43 3 C max Condenser discharge air recirculation Dirty condenser fins Dirty condenser filter Defective fan cycling control Defective fan motor Restricted condenser water flow Low water pressure 20 psig min High water temperature 90 F 32 2 C max Dirty condenser Dirty defective water regulating valve e Water regulating valve out of adjustment 82 Refrigeration System Non Manitowoc components Improper refrigerant charge Defective head pressure control remotes Defective harvest valve Defective compressor TXV starving or flooding check bulb mounting Non condensable in refrigeration system Plugged or restricted high
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27. Suction pressure drops gradually throughout the freeze cycle 122 0280 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time F C 50 10 0 70 21 1 90 32 2 70 21 1 10 6 12 5 12 0 14 1 12 3 14 4 80 26 7 10 8 12 7 12 3 14 4 13 8 16 1 90 32 2 11 0 13 0 12 6 14 7 14 1 16 5 Tos 100 37 8 11 3 13 2 12 8 15 0 14 5 16 9 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Around Water Temperature F C Machine 50 10 0 70 21 1 90 32 2 70 21 1 290 260 255 80 26 7 285 255 230 90 32 2 280 250 225 100 37 8 275 245 220 Based on average ice slab weight of 2 44 2 81 Ib Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Water Temperature F C Machine 90 F 32 2 C 50 10 0 70 21 1 90 32 2 Gal 24 hours 250 490 3400 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Aroundlce Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 225 235 60 28 190 200 75 90 70 21 1 225 235 60 28 190 200 80 90 80 26 7 225 240 60 28 190 200 80 90 90 32
28. TOE INTERNAL WORKING z orr 66 E CLEAN e COMPRESSOR KT 47 TB35 RUN CAPACITOR CONTACTOR OVERLOAD CONTACTS 48 1835 TERMINATES 53 2 PIN CONNECTION 7574 F1 1650 41 Q1300 Q1600 Q1800 Remote 1 Phase Without Terminal Board ON ELECTRICAL CIRCUITRY DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE CAUTION DISCONNECT POWER BEFORE WORKING VALVE C HIGH PRES CUTOUT IQUID LINE SOLENOID CLEAN LIGHT PLUG PATER LeveL BIN SWITCH LIGHT 3 19 SAFETY LIMIT CODE LIGHT TOGGLE SWITCH 68 INTERNAL WORKING VIEW OFF sh 62 CLEAN CONTACTOR CONTACTOR CONTACTS CONTACTS 5 2076 42 Q1300 Q1800 Remote 3 Phase With Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING VALVE ON ELECTRICAL CIRCUITRY DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE 13 L2 Li HIGH PRES CUTOUT N 50HZ ONLY ICE THICKNESS PROBE ig cLEAN LiGHT PEASE LEVEL LIGHT 62 BIN switcH BIN SWITCH 63 68 HARVEST LIGHT 5 V ISAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING LAB workin al 711 VIEW CLEAN 52 51 TERMINATES 53 834 PIN CONNECTIO REMOTE CONDENSE
29. 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 Complete the Operation 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 Step 2 Enter check marks oh 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 3 Add the check marks listed under each of the four columns Note the column number with the highest tota
30. cabinet ground Refer to the chart on the next page 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 58 Step 2 Jumper Wire Connected from Probe to Ground Water 9 Water Inlet Valve into the Level Sol id Cause Water Trough ight Is oil Is This is normal operation No On De energized Do not change any parts The water Yes On De energized inlet valve causing the problem Yes Off Energized Proceed to step 3 59 Step 3 Allow ice machine to run Disconnect water level probe from control board terminal 1F and connect a jumper wire from terminal 1F to any cabinet ground Remember if you are past 6 minutes from starting the ice machine will go into a Freeze cycle water inlet valve safety shut off mode and you will be unable to complete this test If past 6 minutes you must restart this test by disconnecting the jumper wire restarting the ice machine step 1 and then reinstalling the jumper wire to terminal 1F after the compressor starts Step 3 Jumper Wire Connected from Control Board Terminal 1F to Ground kii The The Water 9 water Inlet Valve into the Cause
31. eouenbeg 2291 syed lt mun 2 5 18195 1010 4 ujBue piousjos piousjos 4030 10 5944 as vs 5 2 40 9e8 U0D skejay 79 76 oouenbeg jsoAJeH Jo gt Syed THIS PAGE INTENTIONALLY LEFT BLANK 24 Electrical System WIRING 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 Warning Always disconnect power before working on electrical circuitry Wiring Diagram Legend The following symbols are used on all of the wiring diagrams 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 Electr
32. 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 3172 kPa 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 1 Will not reset below 300 psig 2068 kPa 2 Does not open at the specified cut out point 116 REFRIGERATION TUBING SCHEMATICS Self Contained Air or Water Cooled Models Q200 Q280 Q320 Q370 Q420 Q450 Q600 Q800 Q1000 2 1 EVAPORATOR HEAT EXCHANGER COMPRESSOR EXPANSION VALVE 9 HARVEST VALVE STRAINER AIR OR WATER CONDENSER WATER COOLED ONLY Q1300 Q1600 Q1800 l EVAPORATOR HEAT EXCHANGE EXPANSION VALVE SOLENOID VALVE COMPRESSOR Sasso Sole rA VALVE HARVEST SOLENOID VALVE STRAINER AIR OR WATER COOLED CONDENSER RECEIVER 117 Remote Models Q200 Q280 Q320 Q370 Q420 Q450 Q600 Q800 Q1000 Y EVAPORATOR 1 1 EXCHANGER J EXPANSION VALVE 4 STRAINER COMPRESSOR x A HARVEST SOLENOID VALVE CHECK VALVE REMOTE CONDENSER 3
33. has been surpassed 14 Harvest Sequence 5 Water Purge 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 The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge If set at less than 45 seconds the water fill valve does not energize during the 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 The harvest valve also opens at the beginning of the water purge to divert hot refrigerant gas into the evaporator 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 15 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 t
34. have a black micro processor Current production and replacement control boards have an orange label on the control board microprocessor Safety Limit 1 If the freeze time reaches 60 minutes the control board automatically initiates a harvest cycle Control Board with Black Microprocessor elf 3 consecutive 60 minute freeze cycles occur the ice machine stops Control Board with Orange Label on Microprocessor elf 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 Control Board with Black Microprocessor elf three consecutive 3 5 minute harvest cycles occur the ice machine stops Control Board with Orange Label on Microprocessor elf 500 consecutive 3 5 minute harvest cycles occur the ice machine stops 71 SAFETY LIMIT INDICATION Control Board with Black Microprocessor When a safety limit condition is exceeded for 3 consecutive cycles the ice machine stops and the harvest light on the control board continually flashes on and off Use the following procedures to determine which safety limit has stopped the ice machine 1 Move the toggle switch to OFF 2 Move the toggle switch back to ICE 3 Watch the harvest light It will flash one or two times corresponding to safety limits 1 and 2 to indicate which safety limit stopped the ice machine After safety limi
35. limit your diagnosis to only the items listed in the checklists 91 Single Expansion Valve Ice Machines Comparing Evaporator Inlet and Outlet Temperatures NOTE This procedure will not work on the dual expansion valve Q1300 Q1600 and Q1800 ice machines The temperatures of the suction lines entering and leaving the evaporator alone cannot diagnose an ice machine However comparing these temperatures during the freeze cycle along with using Manitowoc s Refrigeration System Operational Analysis Table can help diagnose an ice machine malfunction The actual temperatures entering and leaving the evaporator vary by model and change throughout the freeze cycle This makes documenting the normal inlet and outlet temperature readings difficult The key to the diagnosis lies in the difference between the two temperatures five minutes into the freeze cycle These temperatures must be within 7 of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Use a quality temperature meter capable of taking temperature readings on curved copper lines 2 Attach the temperature meter sensing device to the copper lines entering and leaving the evaporator Important Do not simply insert the sensing device under the insulation It must be attached to and reading the actual temperature of the copper line 92 3 five minutes into the freeze cycle 4 Record the tempe
36. or Manitowoc Ice Inc The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD They are also listed on the MODEL SERIAL NUMBER DECAL affixed to the ice machine ICE MACHINE WARRANTY INFORMATION Owner Warranty Registration Card Warranty coverage begins the day the ice machine is installed Important Complete and mail the OWNER WARRANTY REGISTRATION CARD as soon as possible to validate the installation date If the OWNER WARRANTY REGISTRATION CARD is not returned Manitowoc will use the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice machine 2 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 representative or Manitowoc Ice Inc 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 require
37. side refrigerant lines or component Safety Limit 2 Refer to page 75 for control board identification and safety limit operation Control Board with Black Microprocessor Harvest time exceeds 3 5 minutes for 3 consecutive harvest cycles or Control Board with Orange Label on Microprocessor Harvest time exceeds 3 5 minutes for 500 consecutive harvest cycles Possible Cause Checklist Improper Installation e Refer to 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 psig min Loss of water from sump area Clogged water distribution tube Dirty defective water fill valve Defective water pump 83 Electrical System e Ice thickness probe out of adjustment Ice thickness probe dirty e Bin switch defective e Premature harvest Refrigeration System e Non Manitowoc components Water regulating valve dirty defective Improper refrigerant charge Defective head pressure control valve remotes Defective harvest valve TXV flooding check bulb mounting Defective fan cycling control 84 Analyzing Discharge Pressure 1 Determine the ice machine operating conditions Air temp entering condenser Air temp around ice machine Water temp entering sump trough
38. the bridge connecting the cubes It should be about 1 8 in 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 NOTE Turning the adjustment 1 3 of a turn will change the ice thickness about 1 16 in 15 cm The starting point before final adjustment is approximately a 3 16 in gap Make sure the ice thickness probe wire and the bracket do not restrict movement of the probe ADJUSTING SCREW em 1 8 ICE BRIDGE THICKNESS 3114 ICE THICKNESS ADJUSTMENT 52 Thickness Probe Diagnostics Before diagnosing ice thickness control circuitry clean the ice thickness probe using the following procedure 1 Mix a solution of Manitowoc ice machine cleaner and water 2 ounces of cleaner to 16 ounces of water in a container 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 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 Reinstall ice thickness probe then sanitize all ic
39. throughout the freeze cycle 126 0370 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 10 3 11 7 11 0 12 5 12 2 13 9 80 26 7 10 6 12 1 11 3 12 9 12 6 14 4 xs 90 32 2 11 0 12 5 11 7 13 4 13 1 14 4 100 37 8 11 3 12 9 12 2 13 9 13 6 15 5 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 1 360 340 310 80 26 7 350 330 300 90 32 2 340 320 290 100 37 8 330 310 280 Based on average ice slab weight of 2 94 3 31 Ib CONDENSER WATER CONSUMPTION Air Temp Around Ice Machine 90 F 32 2 C Water Temperature F C 50 10 0 70 21 1 90 32 2 Gal 24 hours 220 490 3700 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Aroundlce Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 50 10 0 225 235 60 32 150 170 85 100 70 21 1 225 235 60 33 150 170 85 105 80 26 7 225 240 65 36 155 175 90 110 90 32 2 225 240 68 38 155 1
40. vacuum to 250 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 preliminary leak check You should use electronic leak detector after system charging to be sure there are no leaks 5 Charge the system with the proper refrigerant to the nameplate charge 6 Operate the ice machine 159 SEVERE SYSTEM CONTAMINATION 1 2 3 Remove the refrigerant charge Remove the compressor Disassemble the harvest solenoid valve If burnout deposits are found inside the valve install a rebuild kit and replace the manifold strainer TXV and harvest pressure regulating valve Wipe away any burnout deposits from suction and discharge lines at compressor Sweep through the open system with dry nitrogen Important Refrigerant sweeps are not recommended as they release CFCs 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 160 Important Dry nitrogen is recommended for this procedure This will prevent CFC release 10 Follow the normal evacuation procedure except replace the evacuation step w
41. water splashes on the probes The light s secondary function is to continuously flash when the ice machine is shut off on a safety limit and to indicate which safety limit shut off the ice machine 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 51 The control system includes a built in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 in 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
42. 0 220 250 40 22 135 170 75 95 70 21 1 240 260 40 22 140 180 80 95 80 26 7 240 270 41 22 140 190 80 95 90 32 2 250 290 42 22 140 200 80 95 100 37 8 280 320 46 22 140 210 80 95 110 43 3 310 360 48 24 140 220 85 100 Suction pressure drops gradually throughout the freeze cycle 142 91600 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Entering Freeze Time Condenser Water Temperature F C FC 50 10 0 70 21 1 90 32 2 70 21 1 7 2 8 1 8 0 9 0 8 9 9 9 80 26 7 7 3 8 2 8 1 9 1 9 2 10 2 90 32 2 7 4 8 2 8 2 9 1 9 6 10 7 100 37 8 7 4 8 3 8 4 9 4 9 7 10 8 Harvest Time Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature Condenser F C 50 10 0 70 21 1 90 32 2 70 21 1 1650 1510 1390 80 26 7 1635 1500 1350 90 32 2 1625 1490 1300 100 37 8 1620 1450 1290 70 21 1 1650 1510 1390 Based on average ice slab weight of 10 0 11 0 Ib Ratings with JC1395 condenser dice or half dice cubes CONDENSER WATER CONSUMPTION Air Temp Around Ice Machine 90 F 32 2 C Water Temperature F C 50 10 0 70 21 1 90 32 2 Gal 24 hours 1400 2235 6500 Water regulating valve set to maintain 240 PSIG discharge pressure OPERATING PRESSURES
43. 0 70 21 1 225 250 40 22 190 200 70 90 80 26 7 240 260 42 22 190 205 70 90 90 32 2 255 265 44 22 195 205 70 90 100 37 8 275 295 44 24 200 210 70 90 110 43 3 280 320 46 26 200 225 75 100 Suction pressure drops gradually throughout the freeze cycle 139 91300 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time F C 50 10 0 70 21 1 90 32 2 70 21 1 9 4 10 5 9 9 11 1 10 9 12 2 80 26 7 9 9 11 1 10 6 11 8 11 6 12 9 45 90 32 2 11 0 12 3 11 5 12 8 12 8 14 2 100 37 8 12 3 13 7 13 2 14 7 14 7 16 3 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 70 21 1 1320 1260 1160 80 26 7 1260 1190 1100 90 32 2 1150 1110 1010 100 37 8 1040 980 890 Based average ice slab weight of 10 0 11 0 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F PC PSIG PSIG PSIG PSIG 50 10 0 220 280 40 20 140 170 65 80 70 21 1 220 280 40 20 145 170 70 80 80 26 7 220 280 42 22 150 185 70 80 90 32 2 245 300 48 26 160 190 70 85 100 37
44. 0 36 170 210 90 120 100 37 8 225 260 52 36 170 210 90 120 110 43 3 225 265 54 36 175 215 95 125 Suction pressure drops gradually throughout the freeze cycle 125 0370 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 10 3 11 7 11 7 13 4 12 6 14 4 80 26 7 11 3 12 9 12 6 14 4 13 9 15 8 due 90 32 2 12 9 14 7 13 9 15 8 15 4 17 6 100 37 8 14 5 16 5 16 1 18 4 17 3 19 7 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 70 21 1 360 320 300 80 26 7 330 300 275 90 32 2 295 275 250 100 37 8 265 240 225 Based on average ice slab weight of 2 94 3 31 Ib OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 50 10 0 200 250 60 34 145 165 75 95 70 21 1 215 250 60 36 150 170 85 100 80 26 7 250 290 65 38 165 185 90 110 90 32 2 260 330 70 40 175 195 100 120 100 37 8 300 380 80 41 195 220 130 150 110 43 3 310 390 80 42 200 225 135 155 Suction pressure drops gradually
45. 135 Suction pressure drops gradually throughout the freeze cycle 131 9600 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Time Machine 50 10 0 70 21 1 90 32 2 70 21 1 7 4 8 7 8 2 9 7 9 5 11 2 80 26 7 7 5 8 9 8 4 9 9 9 7 11 4 Dus 90 32 2 7 8 9 2 8 7 10 3 9 9 11 7 100 37 8 7 9 9 4 8 9 10 5 10 1 11 9 Times minutes 24 HOUR ICE PRODUCTION Air Temp Around Water Temperature F C Ice Machine 50 10 0 70 21 1 90 32 2 70 21 1 670 610 540 80 26 7 660 600 530 90 32 2 640 580 520 100 37 8 630 570 510 Based on average ice slab weight of 4 12 4 75 Ib Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Ice Machine 90 F 32 2 C Water Temperature F C 50 10 0 70 21 1 90 32 2 Gal 24 hours 600 1250 6800 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Around Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure F PC PSIG PSIG PSIG PSIG 50 10 0 225 235 46 25 140 184 80 102 70 21 1 225 235 46 2
46. 2 166 Factory School e Improve Your Service Techniques e 4 1 2 Days of Intensive Training on Manitowoc Ice Machines e Contact Your Distributor for Dates and Further Information MANITOWOC ICE INC 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 USA Phone 920 682 0161 Fax 920 683 7585 Website www manitowocice com 2003 Manitowoc Ice Inc
47. 2 225 245 62 28 190 200 80 90 100 37 8 225 250 62 30 190 200 80 90 110 43 3 225 260 64 32 195 205 80 95 Suction pressure drops gradually throughout the freeze cycle 123 0320 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 12 2 13 9 13 1 14 9 14 2 16 2 80 26 7 13 6 15 5 14 8 16 8 16 1 18 4 Ex 90 32 2 16 1 18 4 17 7 20 2 19 7 22 3 100 37 8 19 7 22 3 22 0 25 0 25 0 28 3 Times minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 70 21 1 310 290 270 80 26 7 280 260 240 90 32 2 240 220 200 100 37 8 200 180 160 Based on average ice slab weight of 2 94 3 31 10 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 200 250 50 36 150 180 75 90 70 21 1 200 250 50 36 160 190 80 100 80 26 7 220 280 50 36 170 200 90 110 90 32 2 230 320 54 38 180 220 90 120 100 37 8 270 360 56 40 200 250 95 140 110 43 3 280 380 58 42 210 260 95 150 Suction pres
48. 245 265 46 26 156 174 82 100 90 32 2 250 265 48 26 157 174 84 100 100 37 8 265 295 52 26 158 176 84 100 110 43 3 300 335 52 28 158 176 84 105 Suction pressure drops gradually throughout the freeze cycle 133 9800 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 8 9 10 2 9 7 11 1 10 3 11 9 80 26 7 9 3 10 7 10 2 11 7 10 9 12 5 pd 90 32 2 10 3 11 9 11 4 13 1 12 3 14 1 100 37 8 12 1 13 8 13 3 15 2 14 4 16 5 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C cra 5010 0 70211 90 322 70 21 1 800 740 700 80 26 7 770 710 670 90 32 2 700 640 600 100 37 8 610 560 520 Based on average ice slab weight of 5 75 6 50 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 220 280 31 18 135 180 65 90 70 21 1 220 280 32 18 140 180 70 90 80 26 7 225 280 36 20 140 180 70 95 90 32 2 260 295 38 22 150 200 80 100 100 37 8 300 330 40 24 210 225 80 100 110 43 3 320 360 44 26
49. 299JJ y YEM ubiH 10 pu3 s eJnsseJd uonong SI eJnsseJd uonong SI uonong SI eJnsseJd uonong Lx Mr Buipeeooud 2984 1 uo jou sjueuoduuoo 0415 29 0 eJnsseJg uonongs ulejqoud eunssaJd uonons JO uiu 9z99JJ 19491 JO eunsseJd uonons 9 o 2 9209914 9J2 9 9jnutui eBueuosiq 9 2 9 929914 sisAjeuy 5 STAGOW 8 YO f O 102 JosseJduio AXL Bues AXL 40 ui pexoeuo Jaquunu 180 sisAjeuy 2 JO pue 99112 10 Dob L2 3 091 eJnjejeduua eui ezooJl y jo pue 99112 3 091 uey ssa 2 y JO pue 991 10 2 12 4091 7 JO pue JeuBiu 10 2 112 40091 eJnjeJeduJa eui eBJeuosiq 2 do JO pue 1e Sip 2 eur
50. 42 24 210 225 80 100 110 43 3 320 360 44 24 210 240 85 120 Suction pressure drops gradually throughout the freeze cycle 137 91000 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 10 0 10 7 10 6 11 4 12 1 13 0 80 26 7 10 1 10 9 10 8 11 6 12 3 13 2 T5 90 32 2 10 2 11 0 10 9 11 7 12 5 14 3 100 37 8 10 4 11 1 11 0 11 8 12 6 14 4 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Around Ice Water Temperature F C Machine F C 50 10 0 70 21 1 90 32 2 70 21 1 970 920 820 80 26 7 960 910 810 90 32 2 950 900 800 100 37 8 940 890 790 Based on average ice slab weight of 7 75 8 25 Ib Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Water Temperature F C Machine 90 F 32 2 C 5400 70 21 1 90 32 2 Gal 24 hours 750 1500 6200 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Aroundlce Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG 50 10 0 225 235 36 18 160 185 65 8
51. 43 3 310 390 85 40 250 270 120 150 120 9200 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 11 5 13 5 12 8 15 0 14 5 16 9 80 26 7 12 0 14 1 13 5 15 7 15 2 17 8 90 32 2 12 6 14 7 14 1 16 5 16 1 18 7 100 37 8 13 1 15 4 14 8 17 3 17 0 19 8 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Around Ice Water Temperature F C Machine F C 50 10 0 70 21 1 90 32 2 70 21 1 270 245 220 80 26 7 260 235 210 90 32 2 250 225 200 100 37 8 240 215 190 Based on average ice slab weight of 2 44 2 81 10 Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Ice Machine 90 F 32 2 C Water Temperature F C 50 10 0 70 21 1 90 32 2 Gal 24 hours 240 480 2100 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Harvest Cycle Air Temp Freeze Cycle Around Ice Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 225 235 60 28 170 200 90 110 70 21 1 225 235 60 28 170 200 90 110 80 26 7 225 240
52. 5 70 21 1 225 235 38 18 165 185 70 85 80 26 7 225 235 40 18 165 185 70 85 90 32 2 225 235 40 20 165 185 70 85 100 37 8 225 235 40 20 165 185 70 85 110 43 3 225 240 42 20 170 190 75 90 Suction pressure drops gradually throughout the freeze cycle 138 01000 Series Remote Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 A 701 405 443 413 122 12 1 13 0 80 26 7 10 7 11 5 11 5 12 3 12 3 13 2 90 32 2 10 8 11 6 116125 125 3134 125 100 37 8 11 5 12 3 12 5 13 4 13 4 14 3 110 43 3 12 3 13 2 13 4 14 3 14 4 15 5 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 20 28 9 70 21 1 930 870 820 80 26 7 915 860 810 90 32 2 906 850 800 100 37 8 860 800 750 110 43 3 810 750 700 Based on average ice slab weight of 7 75 8 25 Ib Regular cube derate is 7 Ratings with JC1095 condenser dice or half dice cubes OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 220 250 40 22 180 200 65 9
53. 5 235 34 20 165 185 70 85 80 26 7 225 235 34 20 165 185 70 85 90 32 2 225 235 36 22 165 185 70 85 100 37 8 225 235 36 22 165 185 70 85 110 43 3 225 240 38 24 170 190 75 90 Suction pressure drops gradually throughout the freeze cycle 135 0800 Series Remote Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 707 5 10 106 122 11 6 13 4 80 26 7 9 7 11 1 10 8 12 4 11 9 13 6 90 32 2 98 113 110 126 124 138 125 100 37 8 10 6 12 2 11 9 13 6 13 2 15 1 110 43 3 11 9 13 6 13 4 15 4 14 7 16 9 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 20 28 9 10 70 21 1 750 685 630 80 26 7 740 675 620 90 32 2 730 665 610 100 37 8 685 620 565 110 43 3 620 555 510 Based on average ice slab weight of 5 75 6 50 Ib Regular cube derate is 7 Ratings with JC0895 condenser dice or half dice cubes OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG pos dud 220 250 30 22 180 200 65 90 70 21 1 225 2
54. 50 32 22 190 200 70 90 80 26 7 240 260 33 22 190 205 70 90 90 32 2 255 265 34 22 195 205 70 90 100 37 8 275 295 38 24 200 210 70 90 110 43 3 280 320 40 26 200 225 75 100 Suction pressure drops gradually throughout the freeze cycle 136 91000 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 9 9 10 6 10 6 11 4 11 3 12 2 80 26 7 10 2 11 0 11 2 12 0 11 9 12 8 90 32 2 10 9 11 7 11 9 12 8 12 8 13 7 100 37 8 12 1 13 0 13 2 14 1 14 2 15 2 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 70 21 1 980 920 870 80 26 7 950 880 830 90 32 2 900 830 780 100 37 8 820 760 710 Based on average ice slab weight of 7 75 8 25 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG 50 10 0 220 280 38 18 135 180 65 90 70 21 1 220 280 40 18 140 180 70 90 80 26 7 225 280 42 20 140 180 70 95 90 32 2 260 295 42 22 150 200 80 100 100 37 8 300 330
55. 6 148 184 82 104 80 26 7 225 235 48 26 154 186 86 108 90 32 2 225 240 48 26 154 190 86 108 100 37 8 225 245 50 28 162 194 86 112 110 43 3 225 250 52 28 165 200 86 115 Suction pressure drops gradually throughout the freeze cycle 132 0600 Series Remote Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Entering Freeze Time Harvest Condenser Water Temperature F C Time FC 5050 0 70 21 1 90 322 20 28 9 to 70 21 1 7 9 9 4 8 9 10 5 9 5 11 2 80 26 7 8 0 9 4 9 0 10 6 9 6 11 3 90 32 2 8 1 9 5 9 1 10 7 9 7 11 4 100 37 8 8 4 9 9 9 5 11 2 10 1 11 9 110 43 3 8 9 10 5 10 1 11 9 10 9 12 8 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser 50 10 0 70 21 1 90 32 2 20 28 9 10 70 21 1 630 570 540 80 26 7 625 565 535 90 32 2 620 560 530 100 37 8 600 540 510 110 43 3 570 510 480 Based on average ice slab weight of 4 12 4 75 Ib Regular cube derate is 7 Ratings with JC0895 condenser dice or half dice cubes OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG 220 250 42 26 152 170 75 100 70 21 1 225 260 44 26 155 172 82 100 80 26 7
56. 60 28 175 205 90 110 90 32 2 225 245 65 30 175 205 90 115 100 37 8 225 250 70 32 180 210 90 115 110 43 3 225 260 75 34 185 215 90 120 Suction pressure drops gradually throughout the freeze cycle 121 0280 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time F C 50 10 0 70 21 1 90 32 2 70 21 1 10 6 12 5 11 8 13 8 12 6 14 7 80 26 7 11 5 13 5 12 8 15 0 13 8 16 1 1655 90 32 2 12 6 14 7 14 1 16 5 15 2 17 8 100 37 8 14 5 16 9 16 5 19 3 18 0 21 0 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 70 21 1 290 265 250 80 26 7 270 245 230 90 32 2 250 225 210 100 37 8 220 195 180 Based on average ice slab weight of 2 44 2 81 10 Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 195 250 60 20 150 190 70 90 70 21 1 195 250 60 20 150 190 70 90 80 26 7 220 280 60 26 180 220 70 90 90 32 2 250 310 66 30 190 220 80 100 100 37 8 280 350 70 32 220 250 80 110 110 43 3 310 390 85 40 250 270 80 120
57. 75 90 110 100 37 8 235 260 75 40 175 200 100 120 110 43 3 240 265 85 40 185 205 105 125 Suction pressure drops gradually throughout the freeze cycle 127 Q420 450 Series Self Contained Air Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Entering Water Temperature F C Harvest Condenser Time 50 10 0 70 21 1 90 32 2 70 21 1 9 7 11 4 10 9 12 8 12 0 14 0 80 26 7 10 9 12 8 12 3 14 4 13 3 15 6 5 90 32 2 12 3 14 4 14 1 16 5 15 5 18 0 100 37 8 14 5 17 0 16 5 19 2 18 3 21 3 Times minutes 24 HOUR ICE PRODUCTION Air Temp Entering Water Temperature F C Condenser F C 50 10 0 70 21 1 90 32 2 70 21 1 530 480 440 80 26 7 480 430 400 90 32 2 430 380 350 100 37 8 370 330 300 Based on average ice slab weight of 4 12 4 75 Ib Regular cube derate is 7 OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure F IPC PSIG PSIG PSIG PSIG 50 10 0 195 260 45 30 150 170 75 90 70 21 1 200 260 47 33 165 180 80 100 80 26 7 230 265 50 35 165 185 80 100 90 32 2 260 290 55 36 190 210 90 110 100 37 8 290 340 60 38 215 235 105 125 110 43 3 195 260 45 30 235 255 125 140 Suctio
58. 8 275 330 50 26 160 210 70 90 110 43 3 280 360 52 28 165 225 75 100 Suction pressure drops gradually throughout the freeze cycle 140 91300 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 9 0 10 1 9 8 10 9 11 4 12 6 80 26 7 9 1 10 1 9 8 11 0 11 6 12 9 ois 90 32 2 9 2 10 3 10 0 11 2 12 0 13 3 100 37 8 9 4 10 5 10 1 11 3 12 2 13 6 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Around Water Temperature F C Ice Machine F C 50 10 0 70 21 1 90 32 2 70 21 1 1370 1280 1120 80 26 7 1360 1270 1100 90 32 2 1340 1250 1070 100 37 8 1320 1240 1050 Based on average ice slab weight of 10 0 11 0 Ib Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Ice Water Temperature F C Machine 90 F 32 2 C 400 70 211 90 32 2 Gal 24 hours 1150 2220 7400 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Around Ice Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure F PC PSIG PSIG PSIG PSIG 50 10 0 235 245 40 18 150
59. AGRAM SHOWN DURING FREEZE CYCLE VALVE SEE SERIAL PLATE FOR VOLTAGE 20 L2 N HIGH PRES CUTOUT TERMINATES AT PIN CONNECTION ICE THICKNESS PROBE gg gm WATER LEVEL PROBE 1 1 NOT USED Lown 8 CLEAN LIGHT MC 9 LeveL Be switch Xx HARVEST LIGHT WF SAFETY LIMIT CODE LIGHT TOGGLE SWITCH CONTACTOR 74 VIEW FOR WIRING 68 CONTACTOR CONTACTS FAN MOTOR AIR COOLED ONLY RUN CAPACITOR OVERLOAI 48 2070 28 Q420 Q450 Q600 Q800 Q1000 Self Contained 1 Phase With Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY SEE SERIAL PLATE FOR VOLTAGE DIAGRAM SHOWN DURING FREEZE CYCLE L2 N 335 HIGH PRES CUTOUT 98 TB31 FUSE 7A Bu TERMINATES AT PIN CONNECTION 74 ICE THICKNESS PROBE 7830 9 1 ONTACTOR 1 56 CoL r TB30 WATER LEVEL PROBE CLEAN LIGHT WATER LEVEL LIGHT BIN SWITCH LIGHT I tHARVEST LIGHT JSAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING 68 c9 OFF 62 CLEAN LOW D C 16 VOLTAGE PLUG NOT USED NTERNAL WORKING VIEW 66 COMPRESSOR 5 RUN CAPACITOR CONTACTOR TB30 CONTACTS 835 PTCR 52 85 86 53 52 86 53 TB34 MOTOR AIR COOLED ONLY FA
60. CUATION 1 Place the toggle switch in the OFF position 2 Install manifold gauges charging cylinder scale and recovery unit or two stage vacuum pump 3 Open backseat the high and low side ice machine service valves 4 Open the receiver service valve halfway 5 Open high and low side on the manifold gauge set 6 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 250 microns Then allow the pump to run for an additional hour Turn off the pump and perform a standing vacuum leak check NOTE Check for leaks using a halide or electronic leak detector after charging the ice machine 7 Follow the Charging Procedures 153 EVAPORATOR HEAT EXCHANGER EXPANSION HARVEST SOLENOID 1 4777 VALVES SERVICE VALVE 4 7 COMPRESSOR STRAINER HARVEST HARVEST PRESSURE PRESSURE CHECK REGULATIN VALVE K gt LIQUID HIGH SIDE LINE SERVICE VALVE BACKSEATED SOLENOID DISCHARGE LINE QUICK CONNECT SCHRAEDER FITTING DRIER REMOTE CONDENSEF 1 2 OPEN CHECK VALVE lt HEAD PRESSURE CONTROL VALVE MANIFOLD SET OPEN VACUUM PUMP RECOVERY UNIT CLOSED SCALE
61. E SV1616 FREEZE CYCLE WATER LEVEL SETTING 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 for damage probe bent etc Repair 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 six 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 This is important to remember when performing diagnostic procedures on the water level control circuitry 56 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 e The water inlet valve turns OFF after water contacts the water level probe for 3 continuous seconds e 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 inl
62. G ICE THICKNESS PROBE WATER LEVEL PROBE eF NOT USEI PLUG OFF WORKING 66 CLEAN 5 TB34 ANWOTOR AIR COOLED ONLY FAN CYCLE CONTROL COMPRESSOR RUN CAPACITOR SV1647a 31 Q800 Q1000 Self Contained 3 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY SEE SERIAL PLATE FOR VOLTAGE DIAGRAM SHOWN DURING FREEZE CYCLE 13 L2 L1 HARVEST SOLENOID HIGH PRES CUTOUT TERMINATES AT PIN CONNECTION ICE THICKNESS PROBE WATER LEVEL prose na oW DC CLEAN LIGHT VOLTAGE NOT USED PLUG bare LEVEL BIN SWITCH LIGHT HARVEST LIGHT SAFETY LIMIT CODE LIGHT TOGGLE SWITCH contactor FAN MOTOR CONTACTS AIR COOLED ONLY 51 FAN CYCLE CONTROL RUN CAPACITOR 2072 32 Q1300 Q1800 Self Contained 1 Phase With Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY DIAGRAM SHOWN DURING FREEZE CYCLE PATER 1832 55 TB35 HIGH PRES CUTOUT PIN CONNECTION 74 ICE THICKNESS PROBE TERMINATES AT LIGHT WATER LEVEL LIGHT SWITCH LIGHT HARVEST LIGHT I SAFETY LIMIT CODE LIGHT VIEW FOR WIRING 68 INTERNAL WORKING OFF VIEW 66 CLEAN 82 75 TB35 CONTACTOR OVERLOAD CONTACTOR CONTACTS CONTACTS 7835 us FAN MOTOR AIR COOLED ONLY 1652 33
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64. Level Solenoid Water Light Is Coil Is Trough i The water level probe is causing the No On De energized E ean or replace the water level probe The control board is Yes Off Energized causing the problem The water fill Yes Off De energized valy problem 60 Problem Water Will Not 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 starting Step 2 Wait until the Freeze cycle starts approximately 45 seconds the Freeze cycle starts when the compressor energizes and then refer to the chart Step 2 Checking for Normal Operation 15 Water The The Water Flowing Water Inlet Valve into the 3 Cause Level Solenoid Water Lightis Coil Is Trough g i This is normal Yes Off Energized Do not change any parts No On or Proceed to Off step 3 De energized 61 Step 3 Leave ice machine run then disconnect the water level probe from control board termin
65. Manitowoc SERVICE TECHNICIAN S HANDBOOK Q Model Ice Machines Manitowoc Ice Inc P N 80 1099 9 8 03 Safety Notices As you work on a Q Model Ice Machine be sure to pay close attention to the safety notices in this handbook Disregarding the notices may lead to serious injury and or damage to the ice machine Throughout this handbook you will see the following types of safety notices 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 alerts you to a potential personal injury situation Be sure to read the Caution statement before proceeding and work carefully Procedural Notices As you work on a Q Model Ice Machine be sure to read the procedural notices in this handbook These notices supply helpful information that may assist you as you work Throughout this handbook you will see the following types of procedural notices Important Text 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 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 installati
66. N CYCLE CONTROL TB30 RUN CAPACITOR SV1646 29 Q420 Q450 Q600 Q800 Q1000 Self Contained 1 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING H ON ELECTRICAL CIRCUITRY DIAGRAM SHOWN DURING FREEZE CYCLE cd SEE SERIAL PLATE FOR VOLTAGE gt o 22 HARVEST HIGH PRES SOLENOID CUTOUT 1 m A ba 1 e 9 2 DUMP 80 Lc SOLENOID a Tre 63 76 81 WATER L TERMINATES AT PIN CONNECTION ICE THICKNESS 46 WATER LEVEL LOWD C she 1 VOLTAGE um LIGHT NOT 0 WATER LEVEL 59 BIN LIGHT 59 HARVEST LIGHT T SAFETY LIMIT CODE LIGHT TOGGLE SWITCH P ICE VIEW FOR WIRING INTERNAL WORKING 8 69 OFF te CLEAN 62 49 49 CONTACTOR RUN CONTACTS 67 42 46 50 OVERLOAD T 48 Ti L 9 TIR 51 85 86 FAN CYCLE CONTROL D FAN MOTOR AIR COOLED ONLY RUN CAPACITOR 30 Q800 Q1000 Self Contained 3 Phase With Terminal Board SEE SERIAL PLATE FOR VOLTAGE CAUTION DISCONNECT POWER BEFORE WORKING 2 ON ELECTRICAL CIRCUITRY 5 DIAGRAM SHOWN DURING FREEZE CYCLE HIGH PRES CUTOUT TERMINATES AT PIN CONNECTION 74 CONTACTOR 56 COIL CLEAN LIGHT WATER LEVEL LIGHT BN SWITCH LIGHT T HARVEST LIGHT LIMIT CODE LIGHT VIEW FOR WIRIN
67. Phase Without Terminal 40 Q1300 Q1800 Remote 1 Phase With Terminal Board 41 01300 01600 01800 Remote 1 Phase Without Terminal Board 42 Q1300 Q1800 Remote 3 Phase With Terminal 43 Q1300 Q1600 Q1800 Remote 3 Phase Without Terminal 44 Component Specifications and 45 2 rerom orte rcr 45 Safety Limits 2 nee 45 i then Nand tetas 45 46 Bin SWICK 47 Water Curtain Removal 5 49 ICE OFF CLEAN Toggle Switch 50 Ice Thickness Probe Harvest Initiation 51 Ice Thickness Probe Diagnostics 53 Diagnosing Ice Thickness Control Circuitry 54 Water Level Control 56 Diagnosing an Ice Machine Head Section that Will Not Run een 63 Compressor Electrical Diagnostics 64 Diagnosing Capacitors 66 Refrigeration System Refrigeration System Diagnostics 71 Before Beginning Service 71 Ice Production 72 Installation Visual Inspection Checklist 73 Water System Che
68. R 1651 43 Q1300 Q1600 Q1800 Remote 3 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE L3 L2 L1 HIGH PRES CUTOUT WATER LEVEL LIGHT 9 jBIN SWITCH LIGHT 1 68 20 HARVEST LIGHT LIMIT CODE LIGHT GLE SWITCH ICE INTERNAL WORKING OFF VIEW VIEW FOR WIRING NOTE WIRE 96 15 NOT USED ON 50HZ 1 COMPRESSOR REMOTE CONDENSER 2077 44 COMPONENT SPECIFICATIONS AND DIAGNOSTICS General Q Model control boards use a 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 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 for information relating to ho
69. REMOTE RECOVERY EVACUATION CONNECTIONS 154 REMOTE CHARGING PROCEDURES 1 Be sure the toggle switch is in the OFF position 2 Close the vacuum pump valve the low and high side service valves frontseat and the low side manifold gauge valve 3 Open the charging cylinder and add the proper refrigerant charge shown on nameplate into the system high side receiver outlet valve and discharge lines quick connect fitting 4 If the high side does not take the entire charge close the high side on the manifold gauge set and backseat open the low side service valve and receiver outlet service valve Start the ice machine and add the remaining charge through the low side in vapor form until the machine is fully charged 5 Ensure all vapor in charging hoses is drawn into the machine then disconnect the manifold gauges NOTE Backseat the receiver outlet service valve after charging is complete and before operating the ice machine If the access valve core removal and installation tool is used on the discharge quick connect fitting reinstall the Schraeder valve core before disconnecting the access tool and hose 6 Run the ice machine in freeze cycle 7 Close the high side service valve at the ice machine 8 Open the low side service valve at the ice machine 9 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 10 Allow the p
70. SSS SSS Y LINE SOLENOID vE HARVEST PRESSURE HEAD REGULATING VALVE PRESSURE 41 CONTROL VALVE DRIER SOLENOID VALVE RECEIVER SERVICE VALVE Q1300 Q1600 Q1800 L RECEIVER S HEAT EXCHANGE EXPANSION VALVE HARVEST SOLENOID VALVE HARVEST SOLENOID VALVE REMOTE HARVEST PRESSURE REGULATING VALVE COMPRESSOR STRAINER SOLENOID VALVE DRIER RECEIVER SERVICE VALVE SOLENOID VALVE 118 CYCLE TIMES 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
71. ZE CYCLE TB32 HIGH PRES CUTOUT ICE THICKNESS PROBE 56 WATER LEVEL PROB CLEAN LIGHT 16 LOWD C AUCS DISPENSE VOLTAGE LEVEL LIGHT ACTOR COIL 62 HARVEST LIGHT SAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING 68 69 opr INTERNAL WORKING 62 TERMINATES AT 52 TB34 CONNECTIOI 1649 39 Q800 Q1000 Remote 3 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY VALVE BRU 9 DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE HIGH PRES 77 ee ee ee ICE THICKNESS PROBE WATER LEVEL PROBE CLEAN LIGHT NOT USED VOLTAGE WATER LEVEL 49 BIN SWITCH LIGHT 595 HARVEST LIGHT 1 SAFETY LIMIT CODE LIGHT INTERNAL WORKING VIEW ICE OFF contactor CONTACTS COMPRESSOR CONDENSER 2074 91300 01800 1 Phase With Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING SEE SERIAL PLATE FOR VOLTAGE ELECTRICAL CIRCUITRY WATER 120 DIAGRAM SHOWN DURING FREEZE CYCLE VALVE TB32 TB35 65 PRES CUTOUT H SOLENOID CLEAN LIGHT WATER LEVEL LIGHT 62 SWITCH LIGHT HARVEST LIGHT M SAFETY LIMIT CODE LIGHT 084 BIN SWITCH 6 VIEW FOR WIRING
72. al 1F 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 Step 3 Disconnect Probe from 1F Water into Water Inlet Valve Cause Level Solenoid Water Lights Coil Is Trough The water level probe is causing the Yes Off Energized replace the water level probe The water No Off Energized inlet valve 3 causing the problem The control On or Y board is No Of De energized causing the problem 62 Diagnosing an Ice Machine Head Section that Will Not Run 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 power supplied to the control board 1 Verify primary voltage is supplied to ice machine head section and the fuse circuit breaker is closed 2 Verify the High Pressure cutout is closed The HPCO is closed if primary power voltage is present at terminals 55 and 56 on the control board 3 Verify control board fuse is okay If the bin switch or water level probe light functions the fuse is okay 4 Verify all bin switches function properly A defective bin s
73. 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 80 SAFETY LIMIT NOTES Because there are many possible external problems do not limit your diagnosis to only the items listed in these charts A continuous 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 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 If the Harvest light did not flash prior to the ice machine restarting then the ice machine did not stop because it exceeded a safety limit SAFETY LIMIT CHECKLIST 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 agt Safety Limit 1 Refer to page 75 for control board identification and safety limit operation Control Board with
74. and perform the calculations again MAXIMUM LINE SET DISTANCE FORMULA Step 1 Measured Rise X1 7 Calculated Rise 35 ft Max Step 2 Measured Drop ___ 6 6 Calculated Drop 15 ft Max Step 3 Measured Horizontal Distance Horizontal 100 ft Max Distance Step 4 Total Calculated Distance Total Calculated 150 ft Max Distance 8 THIS PAGE INTENTIONALLY LEFT BLANK 9 THIS PAGE INTENTIONALLY LEFT BLANK 10 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 AIR 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 water lines drain l
75. ant flow when the pressure at the outlet rises above the valve setting Cie INLET OUTLET SV3053 HPR VALVE FREEZE CYCLE The system is not used during the freeze cycle The solenoid is closed de energized preventing refrigerant flow into the H P R valve HARVEST CYCLE During the harvest cycle the check valve in the discharge line prevents refrigerant in the remote condenser and receiver from backfeeding into the evaporator and condensing to liquid The solenoid is opened energized during the harvest cycle allowing refrigerant gas from the top of the receiver to flow into the H P R valve The H P R valve modulates open and closed raising the suction pressure high enough to sustain heat for the harvest cycle without allowing refrigerant to condense to liquid in the evaporator In general harvest cycle suction pressure rises then stabilizes in the range of 75 100 psig 517 758 kPA Exact pressures vary from model to model Refer to the Operational Refrigerant Pressures charts 109 HPR DIAGNOSTICS Steps 1 through 4 can be quickly verified without attaching a manifold gauge set or thermometer All questions must have a yes answer to continue the diagnostic procedure 1 Liquid line warm Body temperature is normal If liquid line is warmer or cooler than body temperature refer to headmaster diagnostics
76. ater 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 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 7 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 drop 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 21 aqold Sseuxolu 99 2 spuooes 02 spuooes euo HO uo 99 ysuy Buunp plousjog plousjog 40ssaJduio 403283UO as vs 5 2 40 9e U0D skejay 979914 aouenbas 2 14 dn uejs uiejs S uoneJeBujes nd JejeM Jo
77. ce machine in ambient temperatures between 20 F 28 9 C and 120 F 49 C with line set lengths of up to 100 30 5 m LINE SET RISE DROP The maximum rise is 35 10 7 m The maximum drop is 15 4 5 Caution If a line set has a rise followed by a drop another rise cannot be made Likewise if a line set has a drop followed by a rise another drop cannot be made T CALCULATED LINE SET DISTANCE The maximum calculated distance is 150 45 7 m Line set rises drops horizontal runs or combinations of these in excess of the stated maximums will exceed compressor start up and design limits This will cause poor oil return to the compressor Make the following calculations to make sure the line set layout is within specifications 1 Insert the measured rise into the formula below Multiply by 1 7 to get the calculated rise Example A condenser located 10 feet above the ice machine has a calculated rise of 17 feet Insert the measured drop into the formula below Multiply by 6 6 to get the calculated drop Example A condenser located 10 feet below the ice machine has a calculated drop of 66 feet Insert the measured horizontal distance into the formula below No calculation is necessary Add together the calculated rise calculated drop and horizontal distance to get the total calculated distance If this total exceeds 150 45 7 m move the condenser to a new location
78. ces in water and air temperature Actual temperatures will seldom match the chart exactly If they match closely determine if e Another ice machine is required e More storage capacity is required e Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc Distributor for information on available options and accessories Installation Visual Inspection Checklist Possible Problem List e Corrective Action List Ice machine is not level e Level the ice machine Condenser is dirty e Clean the condenser Water filtration is plugged if used e Install a new water filter Water drains are not run separately and or are not vented e Run and vent drains according to the Installation Manual Line set is improperly installed e Reinstall according to the Installation Manual 73 Water System Checklist A water related problem often causes the same symptoms as a refrigeration system component malfunction Example A water dump valve leaking during the Freeze cycle a system low on charge and a starving TXV have similar symptoms Water system problems must be identified and eliminated prior to replacing refrigeration components Possible Problem List e Corrective Action List Water area evaporator is dirty e Clean as needed Water inlet pressure not between 20 and 80 psig e Install a water regulator valve or increase the water pressure Incoming water temperature is n
79. cklist 74 Ice Formation 75 Safety 2 77 Analyzing Discharge Pressure 85 Analyzing Suction 88 Single Expansion Valve Ice Machines Comparing Evaporator Inlet and Outlet 92 Discharge Line Temperature Analysis 96 How to Use the Refrigeration System Operational Analysis Tables 98 Refrigeration System Operational Analysis RADIOS eden 101 Pressure Control Specifications and 108 Harvest Pressure Regulating HPR System Remotes 108 Headmaster Control Valve 112 Fan Cycle Control Self Contained Air Cooled Models Only 115 High Pressure Cutout HPCO Control 116 Refrigeration Tubing Schematics 117 Self Contained Air or Water Cooled 117 Remote Models 118 Cycle Times 24 Hour Ice Production Refrigerant Pressure 119 Q200 Series Self Contained 120 Self Contained Water Cooled 121 Q280 Series Self Contained
80. d 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 the original installation EXCLUSIONS The following items are not included in the ice machine s warranty coverage 1 Normal maintenance adjustments and cleaning as outlined in this manual 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 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 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
81. dations 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 liquid line filter drier to prevent voiding the warranty CONNECTIONS Important Recovery evacuation of remote system requires connections at four points for complete system evacuation Make these connections e Suction side of the compressor through the suction service valve e Discharge side of the compressor through the discharge service valve e Receiver outlet service valve which evacuates the area between the check valve in the liquid line and the pump down solenoid e Access Schraeder valve on the discharge line quick connect fitting located on the outside of the compressor evaporator compartment This connection evacuates the condenser Without it the magnetic check valves would close when the 152 pressure drops during evacuation preventing complete evacuation of the condenser NOTE Manitowoc recommends using an access valve core removal and installation tool on the discharge line quick connect fitting This permits access valve core removal This allows for faster evacuation and charging without removing the manifold gauge hose REMOTE RECOVERY EVA
82. e Specifications Model Cut In Close Cut Out Open Q200 Q280 Q320 Q370 250 psig 5 200 psig 5 Q420 Q450 1724 35 1379 kPa 35 Q600 Q800 Q1000 275 psig 5 225 psig 5 Q1300 Q1800 1896 kPa 35 1551 kPa 35 CHECK PROCEDURE 1 Verify fan motor windings are not open or grounded and fan spins freely 2 Connect manifold gauges to ice machine 3 Hook voltmeter in parallel across the fan cycle control leaving wires attached 4 Refer to chart below s Reading Fan FCC Setpoint should Should Be Above Cut In 0 Volts Running Below Cut Out Line Voltage Off 115 High Pressure Cutout 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 Cut In 450 psig 10 Manual Automatic 3103 kPa 69 Reset Must be below 300 psig 2068 kPa to reset CHECK PROCEDURE 1 Set ICE OFF CLEAN switch to OFF Manual reset HPCO reset if tripped 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 6 No water or air
83. e machine and bin dispenser interior surfaces 53 Diagnosing Ice Thickness Control Circuitry 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 Wait until the water starts to flow over the evaporator Step 2 Clip the jumper wire leads to the ice thickness probe and any cabinet ground Monitor the Harvest light Harvest Light On e The Harvest light comes on and 6 10 seconds later the ice machine cycles from Freeze to Harvest The ice thickness control circuitry is functioning properly Do not change any parts e The Harvest light comes on but the ice machine stays in the Freeze sequence The ice thickness 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 Harvest Light Off e The Harvest light does not come on Proceed to step 3 54 Step 3 Disconnect the ice thickness probe from the control board at terminal 1C Clip the jumper wire leads to terminal 1C on the control board and any cabinet ground Monitor the Harvest light Harvest Light On e The harvest light comes on and 6 10 seconds later the ice machine cycles from Freeze to Harvest The ice thickness probe is causing the malfunction e The Harvest light comes on but the ice machine stays in
84. e temperature Higher ambient air temperatures at the condenser higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser lower discharge line temperatures at the compressor Regardless of ambient temperature the freeze cycle discharge line temperature will be higher than 160 F 71 1 C on a normally operating ice machine PROCEDURE Connect a temperature probe on the compressor discharge line with in 6 15 24 cm 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 temperature 96 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 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 10096 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 97 How to Use the Refrigeration System Operational Analysis Tables GENERAL These tables must be used with charts checklists
85. erate is 7 Ratings with JC1895 condenser dice or half dice cubes OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG DV 220 250 38 24 160 180 60 80 70 21 1 220 260 40 24 170 180 60 80 80 26 7 250 270 48 24 175 190 70 90 90 32 2 250 280 50 24 180 200 80 90 100 37 8 270 300 52 28 205 215 80 95 110 43 3 300 350 54 28 205 230 80 100 Suction pressure drops gradually throughout the freeze cycle 147 REFRIGERANT RECOVERY EVACUATION Normal Self Contained Model Procedures 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 OEM 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 e Suction side of the compressor through the suction service valve e Discharge side of the compressor through the dischar
86. ering condenser machine operating 90 F 32 2 C conditions 2 Air temp around ice machine 80 F 26 7 C Water temp entering water fill valve 70 F 21 1 C 2A Refer to Cycle Time and Operating Pressure charts for ice machine 13 7 14 1 minutes model being checked TENE Published Freeze cycle time Using operating conditions from step 1 5 determine published 55 36 psi Published Freeze cycle suction pressure Freeze cycle time and published Freeze cycle suction pressure 2B Compare the published Published Freeze Cycle Time Freeze cycle time and minutes published Freeze cycle 13 5 7 9 12 14 suction pressure Develop 55 52 48 44 41 38 36 Published Freeze Cycle Suction Pressure psig In the example the proper suction pressure should be approximately 44 psig at 7 minutes 41 psig at 9 minutes etc 3 Perform an actual suction Manifold gauges were connected to the pressure check at the example ice machine and suction pressure beginning middle andend readings taken as follows of the Freeze cycle Note si the times at which the peg readings are taken Beginning of Freeze cycle 59 at 1 min Middle of Freeze cycle 48 at 7 min End of Freeze cycle 40 at 14 min 4 Compare the actual In this example the suction pressure is Freeze cycle suction pressure step 3 to the published Freeze cycle time and pressure comparison step 2B Determine if the suction pressu
87. et 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 turns on and de energizes turns off strictly by time The harvest water purge adjustment dial may be set at 15 30 or 45 seconds NOTE The water purge must be at the factory setting of 45 seconds for the water inlet valve to energize during the last 15 seconds of the water purge If set at 15 or 30 seconds the water inlet valve will not energize during the harvest water purge CONTROL BOARD TELE HARVEST WATER PURGE ADJUSTMENT 57 DIAGNOSING WATER LEVEL CONTROL CIRCUITRY Problem Water Trough During the Freeze Cycle Step 1 Start a new Freeze sequence by moving the ICE OFF CLEAN toggle switch to OFF and 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 starting Step 2 Wait until the Freeze cycle starts approximately 45 seconds the Freeze cycle starts when the compressor energizes then connect a jumper from the water level probe to any
88. 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 7 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 20 Harvest Sequence 5 Water Purge 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 The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge If set at less than 45 seconds the water fill valve does not energize during the water purge After the 45 second water purge the water fill valve water pump and dump valve de energize Refer to Water Purge Adjustment The harvest valve s and HPR solenoid valve also open at the beginning of the water purge 6 Harvest The HPR valve and the harvest valve s remain 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 w
89. f 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 95 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 lin
90. ge service valve 148 SELF CONTAINED RECOVERY EVACUATION 1 Place the toggle switch in the OFF position 2 Install manifold gauges charging cylinder scale and recovery unit or two stage vacuum pump MANIFOLD SET OPEN BACKSEATED BACKSEATED LOW SIDE m HIGH SIDE SERVICE D SERVICE VALVE VALVE VACUUM PUMP RECOVERY UNIT CLOSED LL RECOVERY EVACUATION CONNECTIONS 3 Open backseat the high and low side ice machine service valves if required 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 250 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 149 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 CLOSED OPEN FRONTSEATED BACKSEATED LOW SIDE m HIGH SIDE SERVICE O SERVICE VALVE VALVE VACUUM PUMP RECOVERY UNIT CLOSED CHARGING CONNECTIONS 150 2 Close the vacuum pump valve the l
91. he water curtain is held open for 7 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 16 24044 sseuxolu 29 PUN Spuooas 02 3235 4030 1109 Jossaidwog 40 0e U0D jo oouenbes uy6ue1 as vs 5 2 BUEN 221 9 syed 9JouJ euo HO ueu uo 7295 ysuy Buunp oouenbes 929914 979914 dn uejs uiejs S uoneJeBujes eBung JejeM YOUMS 2 79 spuooes je jeg K40j984 eouenbes jsoAJeH uoneJod Sul Jo 20 203923009 4938 as vs S 2 221 pJeog 04 syed
92. ical Box Side gt gt Compressor Compartment Side 25 Q200 Q280 Q320 Contained 1 Phase With Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE 7839 HIGH PRES CUTOUT TERMINATES AT PIN CONNECTION ICE THICKNESS PROBE 4C WATER LEVEL PROBE NOT USED cuEAN LIGHT waren LeveL BIN SWITCH LIGHT HARVEST LIGHT EJ SAFETY LIMIT CODE LIGHT TOGGLE SWITCH VIEW FOR WIRING CONTACTOR CONTACTS 1 2 FAN CYCLE CONTROL RUN CAPACITOR SV1654 26 0280 0370 Self Contained 1 Phase Without Terminal Board SEE SERIAL PLATE FOR VOLTAGE u CAUTION DISCONNECT POWER BEFORE WORKING L2 N ELECTRICAL CIRCUITRY 20 7 DIAGRAM SHOWN DURING FREEZE CYCLE TERMINATES AT PIN CONNECTION ICE THICKNESS PROBE cp CONTACTOR WATER LEVEL PROBE 4 Gon NoT usep Low p c VOLTAGE 4 74 PLUG HARVEST LIGHT SAFETY LIMIT CODE LIGHT VIEW FOR WIRING ICE TOGGLE SWITCH INTERNAL WORKING OFF VIEW CLEAN CONTACTOR CONTACTS SHUNT ON CONTACTOR COMPRESSOR TERMINAL LAYOUT VIEWED FROM END OF COMPRESSOR AN MOTOR AIR COOLED ONLY FAN CYCLE CONTROL 3 RUN CAPACITOR 5 3018 27 0320 Self Contained 1 Phase Without Terminal Board CAUTION DISCONNECT POWER BEFORE WORKING ELECTRICAL CIRCUITRY DI
93. ines distribution tubes etc WATER COOLED ICE MACHINES 1 Perform steps 1 6 under Self Contained Air Cooled Ice Machines 2 Disconnect the incoming water and drain lines from the water cooled condenser 11 3 Insert large screwdriver between the bottom spring coils of the water regulating valve Pry upward to open the valve 1624 4 Hold valve open and blow compressed air through the condenser until no water remains REMOTE ICE MACHINES 1 Move the ICE OFF CLEAN switch to OFF 2 Frontseat shut off the receiver service valves Hang a tag on the switch as a reminder to open the valves before restarting 3 Perform steps 1 6 under Self Contained Cooled Ice Machines AUCS ACCESSORY Refer to the AuCS Accessory manual for winterization of the AuCS Accessory 12 Making Sequence of Operation SELF CONTAINED AIR AND WATER COOLED 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 the ice machine of old water This ensures that the ice making cycle starts with fresh water The harvest valve s is also energized during the water purge although it stays on for an additional 5 seconds 50 second total on time during the initial refrigeration system start up 2 Refrigeration System Start Up The compressor starts after the 45 sec
94. ing the information gathered refer to the chart below NOTE A headmaster that will not bypass will function properly with condenser air temperatures of approximately 70 F 21 1 C or above When the temperature drops below 70 F 21 1 C the headmaster fails to bypass and the ice machine malfunctions Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle feels warm to hot Symptom Probable Corrective Cause Measure Valve not Non Install a Manitowoc maintaining approved Headmaster control pressures valve valve with proper setting Discharge pressure Ice machine See Low low Liquid line low on Charge Verification entering receiver charge Discharge pressure Valve stuck in Replace valve entering receiver feels extremely cold extremely high bypass Liquid line entering receiver feels hot Discharge pressure Valve not Replace valve low Liquid line bypassing 113 LOW CHARGE VERIFICATION The remote ice machine requires more refrigerant charge at lower ambient temperatures than at higher temperatures A low on charge ice machine may function properly during the day and then malfunction at night Check this possibility If you cannot verify that the ice machine is low on charge 1 Add refrigerant in 2 Ib increments but do not exceed 6 lbs 2 If the ice machine was low on charge the headmaster f
95. ith the following A Pull vacuum to 1000 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig 35 kPa Change the vacuum pump oil UJ C Pull vacuum to 500 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig 35 kPa D Change the vacuum pump oil E Pull vacuum to 250 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 are no leaks 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 If the pressure drop is less than 1 psig the filter drier should be adequate for complete cleanup B If the pressure drop exceeds 1 psig 7 kPa 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 evacuation procedures 161 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 refrigera
96. l and proceed to Final Analysis 98 NOTE If two columns have matching high numbers procedure was not performed properly and or supporting material was not analyzed correctly FINAL ANALYSIS The column with the highest number of check marks identifies the refrigeration problem COLUMN 1 HARVEST VALVE LEAKING Replace the valve as required COLUMN 2 LOW STARVING 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 Do not add more than 30 of nameplate refrigerant charge If the problem is corrected the ice machine is low on charge Find the refrigerant leak 2 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 3 If the problem is not corrected by adding charge the expansion valve is faulty On dual expansion valve ice machines change only the that is starving If both TXV s are starving they are probably good and are being affected by some other malfunction such as low charge 90 COLUMN 3 TXV FLOODING A loo
97. les The ice at the top of the evaporator reaches 1 8 in to initiate a harvest but there is no ice formation at all on the bottom of the evaporator Possible cause Insufficient water flow flooding etc 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 backside of the evaporator 5 No Ice Formation The ice machine operates for an extended period but there is no ice formation at all on the evaporator Possible cause Water inlet valve water pump starving expansion valve low refrigerant charge compressor etc Important Q1300 Q1600 and Q1800 model machines have left and right expansion valves 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 right side of the evaporator 76 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 There are two control boards with different safety limit sequences Original production control boards
98. 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 e 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 Warning Disconnect electrical power to the entire ice machine at the building electrical disconnect box before proceeding CHECKING THE PTCR 1 Visually inspect the PTCR Check for signs of 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 on the next page If the resistance falls outside of the acceptable range replace it 67 Model Manitowoc Part Number Cera Mite Part Number Room Temperature Resistance 0200 0280 0320 0420 0450 8505003 305 20 22 50 Ohms
99. n pressure drops gradually throughout the freeze cycle 128 Q420 450 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 9 9 11 7 11 4 13 4 12 6 14 8 80 26 7 10 1 11 9 11 7 13 7 13 0 15 2 iis 90 32 2 10 4 12 2 12 0 14 0 13 3 15 6 100 37 8 10 6 12 5 12 3 14 4 13 7 16 0 Times minutes 24 HOUR ICE PRODUCTION Air Temp Around Ice Water Temperature F C Machine F C 50 10 0 70 21 1 90 32 2 70 21 1 520 460 420 80 26 7 510 450 410 90 32 2 500 440 400 100 37 8 490 430 390 Based on average ice slab weight of 4 12 4 75 Ib Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Ice Machine 90 F 32 2 C Water Temperature F C 50 10 0 70 21 1 90 32 2 Gal 24 hours 400 740 2400 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Aroundlce Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG 50 10 0 235 245 50 35 165 180 85 100 70 21 1 235 245 50 35 165 180 85 100 80 26 7 235 245 50 35
100. n switch wires to isolate the bin switch from the control board Connect an ohmmeter to the disconnected bin switch wires Cycle the bin switch by opening and closing the water curtain NOTE To prevent misdiagnosis Always use the water curtain magnet to cycle the switch Larger or smaller magnets will affect switch operation Watch for consistent readings when the bin switch is open and closed Bin switch failure could be erratic 48 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 e 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 49 ICE OFF CLEAN Toggle Switch FUNCTION The switch is used to place the ice machine in ICE OFF or CLEAN mode of operation SPECIFICATIONS Double pole double throw switch The switch is connected into a varying low D C voltage circuit CHECK PROCEDURE NOTE Because of a
101. o the operating water and air temperatures This means a condensing unit with a 70 F 21 2 C outdoor ambient temperature and 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 2 C water 1 Determine the ice machine operating conditions Air temp entering condenser Air temp around ice machine o Water temp entering sump trough 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 e Times are in minutes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights in pounds Example 2 Ib 6 oz converts to 2 375 Ib 6 02 16 oz 375 Ib 3 Perform an ice production check using the formula below 1 Freeze Time Harvest Time Total Cycle Time 2 1440 24 Time 3 x Weight of One Cycles per Day Actual 24 Hour Harvest Production Weighing the ice is the only 100 accurate check However if the ice pattern is normal and the 1 8 in thickness is maintained the ice slab weights listed with the 24 Hour Ice Production Charts may be used 72 4 Compare results of step 3 with step 2 Ice production checks that are within 10 of the chart are considered normal This is due to varian
102. on care and maintenance are essential for maximum ice production and trouble free operation of your Manitowoc Ice Machine 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 Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications Warning PERSONAL INJURY POTENTIAL The ice machine head section contains refrigerant charge Installation and brazing of the line sets must be performed by a properly trained refrigeration technician aware of the dangers of dealing with refrigerant charged equipment technician must also be U S Government Environmental Protection Agency EPA certified in proper refrigerant handling and servicing procedures Table of Contents General Information How to Read a Model 1 Ice Cube 1 Model Serial Number Location 2 Ice Machine Warranty Information 2 Owner Warranty Registration Card
103. ond 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 It remains on until the water level sensor closes for 3 continuous seconds or until a six minute time period has expired 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 13 Freeze Sequence 3 Prechill The compressor is on for 30 seconds prior to water flow to prechill the evaporator 4 Freeze The water pump restarts after the 30 second 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 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 7 seconds of continual water contact the Harvest sequence is initiated The ice machine cannot initiate a Harvest sequence until a 6 minute freeze lock
104. ot between 35 F 1 7 C and 90 F 32 2 C e too hot check the hot water line check valves other store equipment Water filtration is plugged if used e Install a new water filter Water dump valve leaking during the Freeze cycle e Clean replace dump valve as needed Vent tube is not installed on water outlet drain e See Installation Instructions Hoses fittings etc are leaking water e Repair replace as needed Water fill valve is stuck open or closed e Clean replace as needed Water is spraying out of the sump trough area e Stop the water spray Uneven water flow across the evaporator e Clean the ice machine Water is freezing behind the evaporator e Correct the water flow Plastic extrusions and gaskets are not secured to the evaporator e Remount replace as needed 74 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 Any number of problems can cause improper ice formation Example An ice formation that is extremely thin on top could be caused by a hot water supply a dump valve leaking water a faulty water fill valve a low refrigerant charge etc Important Keep the water curtain in
105. ow side service valve and the low side manifold gauge valve 3 Open the high side manifold gauge valve and backseat the high side service valve 4 Open the charging cylinder and add the proper refrigerant charge shown on nameplate through the discharge service valve 5 Let the system settle for 2 to 3 minutes 6 Place the toggle switch in the ICE position 7 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 151 Normal Remote Model Procedures REFRIGERANT RECOVERY EVACUATION Do not purge refrigerant to the atmosphere Capture refrigerant using recovery equipment Follow the manufacturer s recommen
106. 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 on the bottom of the evaporator than on the top At the end of the Freeze cycle ice formation the top will be close to or just a bit thinner than ice formation on the bottom The dimples in the cubes at the top of the evaporator may be more pronounced than those on the bottom This is normal The ice thickness probe must be set to maintain the ice bridge thickness at approximately 1 8 in If ice forms uniformly across the evaporator surface but does not reach 1 8 in in the proper amount of time this is still considered normal 75 2 Extremely Thin at Evaporator Outlet There is no ice or a considerable lack of ice formation on the top of the evaporator tubing outlet Examples No ice at all on the top of the evaporator but ice forms on the bottom half of the evaporator Or the ice at the top of the evaporator reaches 1 8 in to initiate a harvest but the bottom of the evaporator already has 1 2 in to 1 in of ice formation Possible cause Water loss low on refrigerant starving TXV hot water supply faulty water fill valve etc 3 Extremely Thin at Evaporator Inlet There is no ice or a considerable lack of ice formation on the bottom of the evaporator tubing inlet Examp
107. provisions of the warranty a refrigeration service company qualified and authorized by your Manitowoc Distributor or a Contracted Service Representative must perform the warranty repair NOTE If the dealer you purchased the ice machine from is not authorized to perform warranty service contact your Manitowoc Distributor or Manitowoc lce 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 in this manual and the ice machine still does not perform properly call your Local Distributor or the Service Department at Manitowoc Ice Inc 4 Installation LOCATION OF ICE MACHINE The location selected for the ice machine head section must meet the following criteria If any of these criteria are not met select another location e The location must be free of airborne and other contaminants e The air temperature must be at least 35 F 1 6 C but must not exceed 110 F 43 4 e The location must not be near heat generating equipment or in direct sunlight e The location must not obstruct air flow through or around the ice machine Refer to chart below for clearance requirements e The ice machine must be protected if it will be subjected to temperatures below 32 F 0 C Failure caused by exposure to freezing temperatures is not cove
108. r 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 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 acid oil test Check the chart on the next page to determine the type of cleanup required 157 Contamination Cleanup Chart Symptoms Findings Required Cleanup Procedure No symptoms or suspicion of contamination Normal evacuation recharging procedure Moisture Air Contamination symptoms e Refrigeration system open to atmosphere for longer than 15 minutes e Refrigeration test kit and or acid oil test shows contamination e Leak in water cooled condenser No burnout deposits in open compre
109. ratures below and determine the difference between them 5 Use this with other information gathered on the Refrigeration System Operational Analysis Table to determine the ice machine malfunction Inlet Temperature Outlet Temperature Difference Must be within 7 at 5 minutes into freeze cycle 93 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 2 Feel the inlet of the harvest valve s Important Feeling the harvest valve outlet or across the harvest 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 3 Feel the compressor discharge line 4 Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line Warning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand Just touch them momentarily 94 Findings Comments The inlet o
110. re is high low or acceptable considered high throughout the Freeze cycle It should have been Approximately 55 psig at 1 minute not 59 Approximately 44 psig at 7 minutes not 48 Approximately 36 psig at 14 minutes not 40 89 SUCTION PRESSURE HIGH CHECKLIST Problem e Cause Improper Installation e Refer to Installation Visual Inspection Checklist Discharge Pressure e Discharge pressure is too high and is affecting low side refer to Freeze Cycle Discharge Pressure High Checklist Improper Refrigerant Charge e Overcharged e Wrong type of refrigerant Other e Non Manitowoc components in system e HPR solenoid leaking e Harvest valve leaking e TXV flooding check bulb mounting e Defective compressor 90 SUCTION PRESSURE LOW CHECKLIST Problem Cause Improper Installation Refer to Installation Visual Inspection Checklist Discharge Pressure Discharge pressure is too low and is affecting low side refer to 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 refer to 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 refrigeration system TXV starving NOTE Do not
111. red by the warranty See Removal from Service Winterization ICE MACHINE HEAD SECTION CLEARANCE REQUIREMENTS Self Contained Q370 Air Cooled Water Cooled Top Sides 12 30 5 cm 5 12 7 cm Back 5 12 7 cm 5 12 7 cm Q1300 Q1600 Self Contained Water Cooled Q1800 Air Cooled and Remote Top Sides 24 61 cm 8 20 3 cm Back 12 30 5 cm 5 12 7 cm other Self Contained Water Cooled Q models Air Cooled and Remote Top Sides 8 20 3 cm 5 12 7 cm Back 5 12 7 cm 5 12 7 cm Q1600 is not available as an air cooled model 5 STACKING TWO ICE MACHINES SINGLE STORAGE BIN A stacking kit is required for stacking two ice machines Installation instructions are supplied with the stacking kit Q450 Q600 Stacked Stacked 0800 01000 Self Contained Water Cooled and Air Cooled Remote Top Sides 16 40 64 cm 5 12 70 cm Back 5 12 70 cm 5 12 70 cm Q1300 Stacked Stacked Q1600 Self Contained Water Cooled and Q1800 Air Cooled Remote Top Sides 48 121 92 cm 24 60 96 cm Back 12 30 48 cm 12 30 48 cm Q1600 is not available as an air cooled model 6 Calculating Remote Condenser Installation Distances LINE SET LENGTH The maximum length is 100 30 5 The ice machine compressor must have the proper oil return The receiver is designed to hold a charge sufficient to operate the i
112. ressures to equalize while the ice machine is in the freeze cycle 11 Close the low side service valve at the ice machine 12 Remove the hoses from the ice machine and install the caps 155 EVAPORATOR EXCHANGER LOW SIDE SERVICE VALVE BACKSEATED COMPRESSOR EXPANSION VALVE HARVEST SOLENOID VALVES STRAINER HARVEST PRESSURE M SOLENOID CHECK PRESSURE VALVE REGULATING gt VALVE LIQUID HIGH SIDE LINE SERVICE VALVE SOLENOID BACKSEATED DISCHARGE LINE UICK CONNECT DRIER 9 REMOTE CONDENSEF recever o UOUS SERVICE VALVE 12 a CHECK VALVE lt lt HEAD PRESSURE CONTROL VALVE MANIFOLD SET CLOSED OPEN CLOSED VACUUM PUMPI SCALE RECOVERY UNIT OPEN REMOTE CHARGING CONNECTIONS 156 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 the sole responsibility of the servicing company Determining Severity Of Contamination System contamination is generally caused by eithe
113. rrectly sized to minimize voltage drop at compressor start up The voltage when the compressor is trying to start must be within 10 of the nameplate voltage 65 Diagnosing Capacitors If the compressor attempts to start or hums and trips the overload protector check the starting components before replacing the compressor 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 TROUBLESHOOTING 5 WHY A GOOD PTCR MAY FAIL TO START THE COMPRESSOR A good PTCR might not 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 longer 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 66 The voltage compressor during start up is too
114. se 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 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 crimping and soldering them closed Old start components must be returned with the faulty compressor 100 Ayayes uo sdojs Ajejes uo sdojs L Ajejes uo Ajojes uo sdojys sulej qoud UOU Kjejes Syur Joyesodens eJnue UO 89 ON 10 JEWJOU uoneuuo 821 UO 89 ON 10 JojeJode e uo UOIjeuuo e JO Jeuuou 921 JoyeJode e UO ON JO JojeJode e jo uo S 821 JojeJode e UO 89 ON 10 Jo uo uly S uoneuuo 51 eyo eJojeq eq sue qoJd pue
115. ssor lines Mild contamination cleanup procedure Mild Compressor Burnout symptoms Oil appears clean but smells acrid e Refrigeration test kit or acid oil test shows harmful acid content e No burnout deposits in open compressor lines Mild contamination cleanup procedure Severe Compressor Burnout symptoms e Oil is discolored acidic and smells acrid e Burnout deposits found in the compressor lines and other components Severe contamination cleanup procedure 158 SYSTEM CONTAMINATION 1 Replace any failed components 2 If the compressor is good change the 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 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 psig 35 kPa B Pull vacuum to 500 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig 35 kPa Change the vacuum pump D Pull
116. sure drops gradually throughout the freeze cycle 124 0320 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 12 6 14 4 13 6 15 5 15 4 17 6 80 26 7 13 1 14 9 14 2 16 2 16 1 18 4 90 32 2 13 6 15 5 14 8 16 8 16 9 19 2 100 37 8 14 2 16 2 15 4 17 6 17 7 20 2 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Water Temperature F C Around Ice Machine F C 50 10 0 70 21 1 90 32 2 70 21 1 300 280 250 80 26 7 290 270 240 90 32 2 280 260 230 100 37 8 270 250 220 Based on average ice slab weight of 2 94 3 31 Ib CONDENSER WATER CONSUMPTION Air Temp Around Water Temperature F C Machine 90 F 32 2 C 5040 0 70 21 1 90 32 2 Gal 24 hours 270 560 3200 Water regulating valve set to maintain 230 PSIG discharge pressure OPERATING PRESSURES Air Temp Freeze Cycle Harvest Cycle Around gt 2 Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure 5 PSIG PSIG PSIG 50 10 0 225 235 50 36 160 180 80 110 70 21 1 225 235 50 36 170 190 85 115 80 26 7 225 240 50 36 170 200 85 115 90 32 2 225 250 5
117. t indication the ice machine will restart and run until a safety limit is exceeded again Control Board with Orange Label on Microprocessor When a safety limit condition is exceeded for 3 consecutive cycles 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 harvest light If a safety limit has been recorded the harvest light will flash one or two times corresponding to safety limit 1 or 2 78 When a safety limit condition is exceeded 6 consecutive cycles for Safety Limit 1 or 500 cycles for Safety Limit 2 the ice machine stops and the harvest light on the control board continually flashes on and off Use the following procedures to determine which safety limit has stopped the machine 1 Move the toggle switch to OFF 2 Move the toggle switch back to ICE 3 Watch the harvest light It will flash one or two times corresponding to safety limit 1 or 2 to indicate which safety limit stopped the ice machine After safety limit indication the ice machine will restart and run until a safety limit is exceeded again WOY CAO D x k DO 3 LOG gt 29 LABEL ON MICROPROCESSOR 79
118. t 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 7 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 provide the 3 minute delay has expired Caution 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 evaporator mounting bracket 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 47 CHECK PROCEDURE 1 2 3 Set the toggle switch to OFF Watch the bin switch light on the control board Move the water curtain toward the evaporator The bin switch must close The bin switch light on indicates the bin switch has closed properly Move the water curtain away from the evaporator The bin switch must open The bin switch light off indicates the bin switch has opened properly OHM TEST 1 Disconnect bi
119. ted in the cycle times refrigerant pressures 24 hour ice production chart Replace Harvest Pressure Regulating system HPR Valve and HPR solenoid valve 111 Headmaster Control Valve Manitowoc remote systems require headmaster control valves with special settings Replace defective headmaster control valves only with original Manitowoc replacement parts OPERATION The R404A headmaster control valve is non adjustable At ambient temperatures of approximately 70 F 21 1 C or above refrigerant flows through the valve from the condenser to the receiver inlet At temperatures below this or at higher temperatures if it is raining the head pressure control dome s nitrogen charge closes the condenser port and opens the bypass port from the compressor discharge line In this modulating mode the valve maintains minimum head pressure by building up liquid in the condenser and bypassing discharge gas directly to the receiver DIAGNOSING 1 Determine the air temperature entering the remote condenser 2 Determine if the head pressure is high or low in relationship to the outside temperature Refer to the proper Operational Pressure Chart If the air temperature is below 70 F 21 1 C the head pressure should be modulating about 225 PSIG 1551 kPa 3 Determine the temperature of the liquid line entering the receiver by feeling it This line is normally warm body temperature 112 4 Us
120. the Freeze sequence 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 Harvest Light Off e The Harvest light does not come on The control board is causing the malfunction ICE MACHINE CYCLES INTO HARVEST BEFORE WATER CONTACT WITH THE ICE THICKNESS PROBE Step 1 Bypass the freeze time lock in feature by moving the ICE OFF CLEAN switch to OFF and back to ICE Wait until the water starts to flow over the evaporator then monitor the Harvest light Step 2 Disconnect the ice thickness probe from the control board at terminal 1C e The Harvest light stays off and the ice machine remains in the Freeze sequence The ice thickness probe is causing the malfunction Verify that the ice thickness probe is adjusted correctly and clean e The Harvest light comes on and 6 10 seconds later the ice machine cycles from Freeze to Harvest The control board is causing the malfunction 55 Water Level Control Circuitry 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 WATER PUMP WATER LEVEL ABOVE HOUSING PUMP IMPELLER HOUSING WATER LEVEL SENSOR PROB
121. tion Condenser Pressure Pressure Pressure Pressure FC PSIG PSIG PSIG PSIG 50 10 0 220 280 40 20 155 190 60 80 70 21 1 220 280 40 20 160 190 65 80 80 26 7 230 290 42 20 160 190 65 80 90 32 2 260 320 44 22 185 205 70 90 100 37 8 300 360 46 24 210 225 75 100 110 43 3 320 400 48 26 215 240 80 100 Suction pressure drops gradually throughout the freeze cycle 145 91800 Series Self Contained Water Cooled Characteristics may vary depending on operating conditions CYCLE TIMES Freeze Time Harvest Time Total Cycle Time Air Temp Freeze Time Around Ice Water Temperature F C Harvest Machine Time 50 10 0 70 21 1 90 32 2 70 21 1 8 7 9 6 9 6 10 5 10 8 11 9 80 26 7 9 0 9 9 9 6 10 6 10 8 11 9 90 32 2 9 1 10 1 9 7 10 7 10 9 12 0 100 37 8 9 2 10 1 9 8 10 7 11 1 12 1 Times in minutes 24 HOUR ICE PRODUCTION Air Temp Around Ice Water Temperature F C Machine 50 10 0 70 21 1 90 32 2 70 21 1 1840 1690 1520 80 26 7 1780 1680 1520 90 32 2 1760 1670 1510 100 37 8 1750 1660 1490 Based on average ice slab weight of 13 0 14 12 Ib Regular cube derate is 7 CONDENSER WATER CONSUMPTION Air Temp Around Machine 90 F 32 2 C Water Temperature 50 10 0 70 21 1 90 32 2 Gal 24 hours 2000 2670 7750 Water regulating valve
122. tion system is operational and leak free Fan cycle control air cooled only Water regulating valve water cooled only High pressure cut out control e 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 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 wing nuts until the block is tight and the tubing is rounded NOTE The pressure controls will operate normally once the tubing is re rounded Tubing may not re round 100 162 FIG PINCHING OFF TUBING FIG RE ROUNDING TUBING USING PINCH OFF TOOL SV1406 163 Filter Driers The filter driers used on Manitowoc ice machines are manufactured to Manitowoc specifications
123. unction and discharge pressure will return to normal after the charge is added Do not let the ice machine continue to run To assure operation in all ambient conditions the refrigerant leak must be found and repaired the liquid line drier must be changed and the ice machine must be evacuated and properly recharged 3 If the ice machine does not start to operate properly after adding charge replace the headmaster FAN CYCLE CONTROL VS HEADMASTER A fan cycle control cannot be used in place of a headmaster The fan cycle control is not capable of bypassing the condenser coil and keeping the liquid line temperature and pressure up This is very apparent when it rains or the outside temperature drops When it rains or the outside temperature drops the fan begins to cycle on and off At first everything appears normal But as it continues raining or getting colder the fan cycle control can only turn the fan off All the refrigerant must continue to flow through the condenser coil being cooled by the rain or low outside temperature This causes excessive sub cooling of the refrigerant As a result the liquid line temperature and pressure are not maintained for proper operation 114 Fan Cycle Control Self Contained Air Cooled Models Only FUNCTION Cycles the fan motor on and off to maintain proper operating discharge pressure The fan cycle control closes on an increase and opens on a decrease in discharge pressur
124. w the probe and control board function together This section will include items such as How a harvest cycle is initiated e How the harvest light functions with the probe e Freeze time lock in feature e Maximum freeze time e Diagnosing ice thickness control circuitry 45 FUNCTION The control board fuse stops ice machine operation if electrical components fail causing high amp draw SPECIFICATIONS The main fuse is 250 Volt 7 amp 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 CHECK PROCEDURE 1 If the bin switch light is on with the water curtain closed the fuse is good Warning Disconnect electrical power to the entire ice machine before proceeding 2 Remove the fuse Check for continuity across the fuse with an ohmmeter Reading Result Open OL Replace fuse Closed O Fuse is good 46 Switch 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 7 seconds during the Harvest cycle 2 Automatic ice machine shut off If the storage bin is full a
125. wer from the condensing unit and remove the wires from the compressor terminals 2 The resistance values must be within published guidelines for the compressor The resistance values between L1 and L2 between L2 and L3 and between L3 and 11 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 64 CHECK MOTOR WINDINGS 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 To determine if the compressor is seized check the amp draw while the compressor is trying to start COMPRESSOR DRAWING LOCKED ROTOR The two likely causes of this are a defective starting component and a mechanically seized compressor To determine which you have e Install high and low side gauges e Try to start the compressor e Watch the pressures closely If the pressures do not move the compressor is seized Replace the compressor If the pressures move the compressor is turning slowly and is not seized Check the capacitors and 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 The wiring must be co
126. wide variation in D C voltage it is not recommended that a voltmeter be used to check toggle switch operation 1 Inspect the toggle switch for correct wiring 2 Isolate the toggle switch by disconnecting all wires from the switch or by disconnecting the Molex connector and removing wire 69 from the toggle switch 3 Check across the toggle switch terminals using a calibrated ohmmeter Note where the wire numbers are connected to the switch terminals or refer to the wiring diagram to take proper readings end Terminals Ohm Reading 66 62 Open ICE 67 68 Closed 67 69 Open 66 62 Closed CLEAN 67 68 Open 67 69 Closed 66 62 Open OFF 67 68 Open 67 69 Open 4 Replace the toggle switch if ohm readings do not match all three switch settings 50 Thickness Probe Harvest Initiation HOW THE 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 HARVEST SAFETY LIMIT LIGHT This light s primary 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
127. witch can falsely indicate a full bin of ice 5 Verify ICE OFF CLEAN toggle switch functions properly A defective toggle switch may keep the ice machine in the OFF mode 6 Verify low DC voltage is properly grounded Loose DC wire connections may intermittently stop the ice machine 7 Replace the control board Be sure steps 1 6 were followed thoroughly Intermittent problems are not usually related to the control board 63 Compressor Electrical Diagnostics The compressor does not start or will trip repeatedly on overload Check Resistance Ohm Values NOTE Compressor windings can have very low ohm values Use a properly 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 condensing unit and remove the wires from the compressor terminals 2 The resistance values must be within published guidelines for the compressor The resistance values between C and S and between C and R when added together should equal the resistance value between S and R 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 po
128. woc components in system e High side refrigerant lines component restricted before mid condenser e Defective head pressure control valve 86 FREEZE CYCLE DISCHARGE PRESSURE LOW CHECKLIST Problem e Cause Improper Installation e Refer to Installation Visual Inspection Checklist Improper Refrigerant Charge e Undercharged e Wrong type of refrigerant Water regulating valve water cooled condensers Out of adjustment e Defective Other Non Manitowoc components in system e High side refrigerant lines component restricted after mid condenser e Defective head pressure control valve e Defective fan cycle control NOTE Do not limit your diagnosis to only the items listed in the checklists 87 Analyzing Suction Pressure The suction pressure gradually drops throughout the Freeze cycle The actual suction pressure and drop rate changes as the air and water temperature entering the ice machine changes These variables also determine the 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 NOTE Analyze discharge pressure before analyzing suction pressure High or low discharge pressure may be causing high or low suction pressure 88 Example Using Step QY0454A Model Ice Machine 1 Determine the Air temp ent

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