Manitowoc b970 series Technician'S Handbook Download Page 257

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Part Number STH025 8/12

257

I1400/I1800

Self Contained Air & Water-cooled - 1 & 3 Ph

Summary of Contents for b970 series

Page 1: ... is updated as new information and models are released Visit our website for the latest manual www manitowocice com America s 1 Selling Ice Machine Indigo Series Air Water Remote Condenser Ice Machines Part Number STH025 8 12 Manitowoc ...

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Page 3: ... 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 situation in which you could damage the equipment Be sure to read the Caution statement before proceeding and work caref...

Page 4: ...andbook you will see the following types of procedural notices NOTE Text set off as a Note provides you with simple but useful extra information about the procedure you are performing Important Text in an Important box provides you with information that may help you perform a procedure more efficiently Disregarding this information will not cause damage or injury but it may slow you down as you wo...

Page 5: ...are and maintenance are essential for maximum performance and trouble free operation of your equipment Visit our website www manitowocfsg com for manual updates translations or contact information for service agents in your area Important Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty Warning Read this manual thoroughly before operating ins...

Page 6: ...nd refrigerant charge Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure The technician must also be certified in proper refrigerant handling and servicing procedures All lockout and tag out procedures must be followed when working on this equipment Warning Do not damage the refri...

Page 7: ...rience and knowledge unless they have been given supervision concerning use of the appliance by a person responsible for their safety Do not allow children to play with this appliance Warning All covers and access panels must be in place and properly secured before operating this equipment Warning Do not obstruct machine vents or openings Warning Do not store gasoline or other flammable vapors or ...

Page 8: ...lity of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures Warning Two or more people are required to move this equipment to prevent tipping ...

Page 9: ...tdoors f For a cord connected appliance the following must be included Do not unplug by pulling on cord To unplug grasp the plug not the cord Unplug from outlet when not in use and before servicing or cleaning Do not operate any appliance with a damaged cord or plug or after the appliance malfunctions or is dropped or damaged in any manner Contact the nearest authorized service facility for examin...

Page 10: ...We reserve the right to make product improvements at any time Specifications and design are subject to change without notice ...

Page 11: ...nty Registration Card 21 Commercial Warranty Coverage 22 Residential Ice Machine Limited Warranty 24 Installation Ice Deflector 29 Location of Ice Machine 30 Clearance Requirements 31 Air Water Remote Condenser Models 31 Ice Machine Heat of Rejection 32 Installation on a Bin 33 Ice Machine on a Dispenser Installation 33 Lineset Applications 34 Remote Condenser 35 Additional Refrigerant Charge For ...

Page 12: ...aning Sanitizing 48 Preventative Maintenance Cleaning Proce dure 54 Removal from Service Winterization 56 Air Cooled Ice Machines 56 Water Cooled Ice Machines 57 Operation Control Panel Features 59 Buttons 59 Display Panel 60 Menu Navigation Overview 61 Display Panel Navigation 62 Alerts and Messages 64 Main Menu 65 Machine Info Menu 66 Reset Password To Factory Defaults 66 Set Up Menu 67 Language...

Page 13: ...84 Real Time Data 85 Diagnostics 87 Manual Harvest 88 Replace Control Board 88 USB Setup 88 Event Log Menu 89 Event Log 90 USB Flash Drive Specifications and Format ting 94 Upgrading Firmware with a Flash Drive 96 Exporting Data to a Flash Drive 98 Operational Checks 100 General 100 Ice Thickness Check 101 Sequence of Operation 102 Self Contained Air or Water Cooled 102 Energized Parts Chart Self ...

Page 14: ... Reset To Factory Defaults 118 Symptom 1 Ice Machine Will Not Run 119 Symptom 2 Low Production Long Freeze Cycle 122 Symptom 2 Freeze Cycle Refrigeration System Operational Analysis Tables 125 Symptom 3 4 Harvest Problems Self contained Air Water Remote Con denser Models 154 Symptom 3 Self Contained Air or Water cooled 155 Symptom 3 Remote Condenser 157 Symptom 4 Self Contained Air Water cooled or...

Page 15: ...est Assist Air Pump 189 Compressor Electrical Diagnostics 190 Diagnosing Start Components 192 Refrigeration Components 195 Head Pressure Control Valve 195 Harvest Pressure Regulating HPR System Remote Condenser Only 199 Water Regulating Valve 202 Refrigerant Recovery Evacuation 203 Self Contained Model Procedure 203 Remote Condenser Model Procedure 207 System Contamination Clean Up 213 Determining...

Page 16: ...3 I0850 Series 236 I1000 Series 239 I1200 Series 242 I1400 Series 244 I1800 Series 247 Diagrams Wiring Diagrams 251 Wiring Diagram Legend 251 I0300 I0450 I0500 I0520 252 I0320 253 I0500 254 I0600 I0850 I1000 I1200 255 I0600 I0850 I1000 256 I1400 I1800 257 I1400 I1800 258 Electronic Control Board 259 Refrigeration Tubing Schematics 260 Self Contained Air or Water Cooled 260 Remote Condenser Models ...

Page 17: ... Unit 9 Remote Air Cooled Condenser OR 9 Ice Beverage Remote Condensing Unit ICE CUBE SIZE R Regular D Dice Y Half Dice Not Used On IB Models Ice Machine Series CONDENSER TYPE A Self Contained Air Cooled W Self Contained Water Cooled N Remote Air Cooled C CVD Air Cooled DC IB Dice Model YC IB Half Dice 3 Three Phase E WRAS 50 Cycle Only NO INDICATOR 1 Phase VOLTAGE 161 115 60 1 261 208 230 60 1 25...

Page 18: ...MODEL SERIAL NUMBER DECAL affixed to the front and rear of the ice machine Regular 1 1 8 x 1 1 8 x 7 8 2 86 x 2 86 x 2 22 cm Dice 7 8 x 7 8 x 7 8 2 22 x 2 22 x2 22 cm Half Dice 3 8 x 1 1 8 x 7 8 0 95 x 2 86 x 2 22 cm Warning All Manitowoc ice machines require the ice storage system bin dispenser etc to incorporate an ice deflector Prior to using a non Manitowoc ice storage system with other Manito...

Page 19: ...456A ID0453W IY0455W ID0456W IY0456W IR0500A ID0502A IY0504A IR0501W ID0503W IY0505W IR0590N ID0592N IY0594N ID0602A IY0604A ID0606A IY0606A ID0603W IY0605W ID0606W IY0606W ID0692N IY0694N ID0696N IY0696N IR0850A ID0852A IY0854A IR0856A ID0856A IY0856A IR0851W ID0853W IY0855W IR0856W ID0856W IY0856W IR0890N ID0892N IY0894N IR0896N ID0896N IY0896N ID1002A IY1004A ID1006A IY1006A ID1003W IY1005W ID1...

Page 20: ...x at the end of the model number indicates a 3 phase unit Example IY1004A3 ID1402A IY1404A ID1406A IY1406A ID1403W IY1405W ID1406W IY1406W ID1492N IY1494N ID1496N IY1496N IR1800A ID1802A IY1804A IR1801W ID1803W IY1805W IR1890N ID1892N IY1894N Self Contained Air Cooled Self Contained Water Cooled Remote ...

Page 21: ...d If the OWNER WARRANTY REGISTRATION CARD is not returned Manitowoc will use the born on date recorded in the control board or the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice machine Important Complete and mail the OWNER WARRANTY REGISTRATION CARD as soon as possible to validate the installation date ...

Page 22: ... warranty is limited to the repair or replacement of parts components or assemblies that in the opinion of the COMPANY are defective This warranty is further limited to the cost of parts components or assemblies and standard straight time labor charges at the servicing location Time and hourly rate schedules as published from time to time by the COMPANY apply to all service procedures Additional e...

Page 23: ...ions in writing THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OR GUARANTEES OF ANY KIND EXPRESSED OR IMPLIED INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE In no event shall the COMPANY be liable for any special indirect incidental or consequential damages Upon the expiration of the warranty period the COMPANY S liability under this warranty shall terminat...

Page 24: ...e free of defects in material or workmanship for the warranty period outlined below under normal use and maintenance and upon proper installation and start up in accordance with the instruction manual supplied with the Product HOW LONG DOES THIS LIMITED WARRANTY LAST WHO IS COVERED BY THIS LIMITED WARRANTY This limited warranty only applies to the original consumer of the Product and is not transf...

Page 25: ...e balance of the original warranty period whichever is longer The foregoing constitutes Manitowoc s sole obligation and the consumer s exclusive remedy for any breach of this limited warranty Manitowoc s liability under this limited warranty is limited to the purchase price of Product Additional expenses including without limitation service travel time overtime or premium labor charges accessing o...

Page 26: ...talled and or maintained in accordance with the instruction manual or technical instructions provided by Manitowoc To the extent that warranty exclusions are not permitted under some state laws these exclusions may not apply to you EXCEPT AS STATED IN THE FOLLOWING SENTENCE THIS LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY OF MANITOWOC WITH REGARD TO THE PRODUCT ALL IMPLIED WARRANTIES ARE S...

Page 27: ...TRACT TORT OR ANY OTHER THEORY OF LIABILITY Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation or exclusion may not apply to you HOW STATE LAW APPLIES This limited warranty gives you specific legal rights and you may also have rights that vary from state to state or from one jurisdiction to another REGISTRATION CARD To secure prompt ...

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Page 29: ...in Warning PERSONAL INJURY POTENTIAL Remove all ice machine panels before lifting Caution The ice machine head section must be protected if it will be subjected to temperatures below 32 F 0 C Failure caused by exposure to freezing temperatures is not covered by the warranty See Removal from Service Winterization page 56 ...

Page 30: ...49 C Ice Making Water Inlet Water Pressure must be at least 20 psi 1 38 bar but must not exceed 80 psi 5 52 bar Condenser Water Inlet Water Pressure must be at least 20 psi 1 38 bar but must not exceed 150 psi 10 34 bar The location must not be near heat generating equipment or in direct sunlight and protected from weather The location must not obstruct air flow through or around the ice machine R...

Page 31: ... 20 3 cm 8 20 3 cm Back 5 12 7 cm 5 12 7 cm I0320 I0520 Self Contained Air Cooled Water Cooled and Remote Top Sides 12 30 5 cm 8 20 3 cm Back 5 12 7 cm 5 12 7 cm I0520 Tropical Rating Top 24 61 cm N A Sides back 12 30 5 cm N A I1400 I1800 Self Contained Air Cooled Water Cooled and Remote Top Sides 24 61 0 cm 8 20 3 cm Back 12 30 5 cm 5 12 7 cm There is no minimum clearance required for water coole...

Page 32: ...tioning Peak I0300 4600 5450 I0320 3800 6000 I0450 5400 6300 I0500 6100 6900 I0520 5300 6100 I0600 9000 13900 I0850 13000 16000 I1000 16250 18600 I1200 20700 24500 I1400 23500 27000 I1800 30000 35000 BTU Hour Because the heat of rejection varies during the ice making cycle the figure shown is an average ...

Page 33: ...ut a deflector Ice Machine on a Dispenser Installation No deflector is needed for machines that match the size of the dispenser 30 head section on a 30 dispenser unless required by the dispenser manufacturer Adapters are required when a smaller ice machine is going on a larger dispenser 22 machine on a 30 dispenser Warning PERSONAL INJURY POTENTIAL Do not operate any ice machine with the deflector...

Page 34: ...odified with a condenser heat reclaim device or other parts or assemblies not manufactured by Manitowoc Ice Warning Recovery locations vary by model Verify you are making the correct connections for your model to prevent accidental release of high pressure refrigerant Important Manitowoc remote systems are only approved and warranted as a complete new package Warranty on the refrigeration system w...

Page 35: ...RT 50 R404A I0690N I0890N JC0895 RT 20 R404A RT 35 R404A RT 50 R404A I1090N JC0995 RT 20 R404A RT 35 R404A RT 50 R404A I1490N I1890N JC1395 RL 20 R404A RL 35 R404A RL 50 R404A Line Set Discharge Line Liquid Line RT 1 2 1 27 cm 5 16 79 cm RL 1 2 1 27 cm 3 8 95 cm Air Temperature Around the Condenser Minimum Maximum 20 F 29 C 120 F 49 C ...

Page 36: ... 51 to 100 Line Sets Ice Machine Condenser Additional Amount of Refrigerant To Be Added To Nameplate Charge I0590N JC0495 1 5 lbs 680g I0690N JC0895 1 5 lbs 680g I0890N JC0895 2 lbs 907g I1090N JC0995 2 lbs 907g I1490N JC1395 2 lbs 907g I1890N JC1395 2 lbs 907g ...

Page 37: ...p The maximum rise is 35 10 7 m The maximum drop is 15 4 5 m 35 ft 10 7 m Rise The maximum distance the Condenser or Condensing Unit can be above the ice machine 15 ft 4 5 m Drop The maximum distance the Condenser or Condensing Unit can be below the ice machine SV1751 35 FT 10 7 M MAXIMUM DISTANCE SV1750 15 FT 4 5 M MAXIMUM DISTANCE ...

Page 38: ...red 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 3 Insert the measured horizontal distance into the formula below No calculation is necessary 4 Add together the calculated rise calculated drop and horizontal distance to get the total calculated distance If this total exceeds 150 45 ...

Page 39: ...lean and sanitize the ice machine every six months for efficient operation If the ice machine requires more frequent cleaning and sanitizing consult a qualified service company to test the water quality and recommend appropriate water treatment An extremely dirty ice machine must be taken apart for cleaning and sanitizing Manitowoc Ice Machine Cleaner and Sanitizer are the only products approved f...

Page 40: ...ion of Federal law to use these solutions in a manner inconsistent with their labeling Read and understand all labels printed on bottles before use Caution Do not mix Cleaner and Sanitizer solutions together It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Warning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine ...

Page 41: ...itiation and completion of a clean or sanitize cycle after which the ice machine automatically starts ice making again EXTERIOR CLEANING Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation Wipe surfaces with a damp cloth rinsed in water to remove dust and dirt from the outside of the ice machine If a greasy residue persists use a damp cloth r...

Page 42: ...achine Cleaner and Sanitizer for this application Manitowoc Cleaner part number 94 0546 3 and Manitowoc Sanitizer part number 94 0565 3 It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Read and understand all labels printed on bottles before use Caution Do not mix Cleaner and Sanitizer solutions together It is a violation of Federal law to use th...

Page 43: ...he ice to melt Step 2 Remove all ice from the bin dispenser Step 3 Press the clean switch Water will flow through the water dump valve and down the drain Wait until the water trough refills and the display indicates add solution approximately 1 minute then add the proper amount of ice machine cleaner Caution Never use anything to force ice from the evaporator Damage may result Model Amount of Clea...

Page 44: ...h step 6 when the parts have been removed Single Evaporator Ice Machines page 48 Step 6 Mix a solution of cleaner and lukewarm water Depending upon the amount of mineral buildup a larger quantity of solution may be required Use the ratio in the table below to mix enough solution to thoroughly clean all parts Warning Disconnect the electric power to the ice machine at the electric service switch bo...

Page 45: ...faces of the ice machine and bin or dispenser Use a nylon brush or cloth to thoroughly clean the following ice machine areas Side walls Base area above water trough Evaporator plastic parts including top bottom and sides Bin or dispenser Rinse all areas thoroughly with clean water SANITIZING PROCEDURE Step 9 Mix a solution of sanitizer and lukewarm water Step 10 Use 1 2 of the sanitizer water solu...

Page 46: ...o liberally apply the solution When sanitizing pay particular attention to the following areas Side walls Base area above water trough Evaporator plastic parts including top bottom and sides Bin or dispenser Do not rinse the sanitized areas Step 12 Replace all removed components Step 13 Wait 20 minutes Step 14 Reapply power to the ice machine and press the Clean button ...

Page 47: ...ater trough by pouring between the water curtain and evaporator Step 16 Select auto ice on press the checkmark and close and secure the front door The ice machine will automatically start ice making after the sanitize cycle is complete approximately 24 minutes Model Amount of Sanitizer I0300 I0320 I0520 3 ounces 90 ml I0450 I0500 I0600 I0850 I1000 I1200 3 ounces 90 ml I1400 I1800 12 ounces 355 ml ...

Page 48: ...epress tabs on right and left side of the water trough Allow front of water trough to drop as you pull forward to disengage the rear pins C Remove the water level probe Pull the water level probe straight down to disengage Lower the water level probe until the wiring connector is visible Disconnect the wire lead from the water level probe Remove the water level probe from the ice machine B C D E A...

Page 49: ...s control wiring from the control board E Remove the water distribution tube NOTE Distribution tube thumbscrews are retained to prevent loss Loosen thumbscrews but do not pull thumbscrews out of distribution tube Loosen the two outer screws do not remove screws completely they are retained to prevent loss and pull forward on the distribution tube to release from slip joint Disassemble distribution...

Page 50: ...s of water in a container 2 Soak probes in container of cleaner water solution while disassembling and cleaning water circuit components soak probes for 10 minutes or longer 3 Clean all probe surfaces including all plastic parts do not use abrasives Verify all surfaces are clean Thoroughly rinse probes with clean water 4 Reinstall probe then sanitize the ice machine and bin dispenser interior surf...

Page 51: ...water inlet valve must allow the proper water flow through it Press the Power button to energize the ice machine Watch for water flow into the ice machine If the water flow is slow or only trickles into the ice machine refer to water system checklist Follow the procedure below to remove the water inlet valve 1 Remove the 1 4 hex head screws 2 Remove clean and install the filter screen Warning Disc...

Page 52: ...o not remove it Instead follow the Ice Machine Cleaning Procedure Follow the procedure below to remove the dump valve 4 If so equipped remove the water dump valve shield from its mounting bracket 5 Leaving the wires attached twist coil and rotate it counter clockwise1 4 turn 6 Lift the coil assembly off the valve body 7 Remove the spring plunger and nylon gasket from the valve body NOTE At this po...

Page 53: ... cleaning do not stretch or damage the spring 1 Remove the tubing from the dump valve by twisting the clamps off 2 Remove the valve body twist off Dump Valve Disassembly SPRING PLUNGER DIAPHRAM VALVE BODY COIL MOUNTING BRACKET NYLON GASKET ...

Page 54: ...fects and removes algae and slime NOTE Although not required and dependant on your installation removing the ice machine top cover may allow easier access 1 Ice must not be on the evaporator during the clean sanitize cycle Follow one of the methods below Press the power switch at the end of a harvest cycle after ice falls from the evaporator s Press the power switch and allow the ice to melt 2 Ope...

Page 55: ...proximately 1 minute then add the proper amount of ice machine cleaner 4 Select Auto Ice On press the Checkmark and close and secure the front door The ice machine will automatically start ice making after the clean cycle is complete approximately 24 minutes Model Amount of Cleaner I0300 I0320 I0520 3 ounces 90 ml I0450 I0500 I0600 I0850 I1000 I1200 5 ounces 150 ml I1400 I1800 9 ounces 265 ml ...

Page 56: ...e the water from the water trough 5 Disconnect and drain the incoming ice making water line at the rear of the ice machine 6 Energize the ice machine and wait one minute for the water inlet valve to open 7 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 water inlet lines or the drain 8 Make sure water is not ...

Page 57: ...ed Air Cooled Ice Machines 2 Disconnect the incoming water and drain line from the water cooled condenser 3 Energize the ice machine in the freeze cycle The increasing refrigerant pressure will open the water regulating valve 4 Blow compressed air through the condenser until no water remains ...

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Page 59: ...play panel BUTTONS Power Button Powers the ice machine when in the On Off Mode The ice machine can also be programmed to automatically power on and off in two Energy Saver modes Cleaning Button Initiates a cleaning cycle Refer to the Maintenance section for details Manitowoc Menu Button Power Button LCD Display Checkmark Cleaning Button Navigation Arrows ...

Page 60: ...derline within a line of settings NOTE The Right arrow can also be used on many screens interchangeably with the checkmark to make a selection Up and Down Arrows Move the highlight brackets up one line or down one line Checkmark Makes a selection and or moves to the next screen or line and is used like an enter button DISPLAY PANEL The LCD display panel is 16 characters wide and four lines deep Du...

Page 61: ...Serial Number Condenser Serial Number Warranty Install Date Manufacture Date Main Software Version Display Software Version Exit Language Time Date Time Config Units Ice Clarity LCD Brightness Password On Edit Password Clean Minder AuCS Run Time Air Filter Water Filter LUMINICE Ice Bin Sensor USB Setup Exit Ice Program Water Miser Statistics Exit Data History Real Time Data Diagnostics Manual Harv...

Page 62: ...ts down from the fourth line to view more of the menu displayed Arrows Two kinds of arrows give cues to additional information symbols show that another screen is available by pressing Checkmark or while a line is highlighted and symbols indicate the limits of the screen viewed NOTE Another cue to the length of a menu screen is that Exit is the last item Time Date Time Config Units Language 07 24 ...

Page 63: ...and Left arrows Use the Checkmark to move the cursor down one line Exit and re enter the screen to start again at the top Selections When parentheses appear they indicate a selection is available by pressing Checkmark while the line is highlighted If the choice is exclusive selecting it with the Checkmark will uncheck another selection That is in the above Time Config example selecting Day Mo Yr w...

Page 64: ...list of alerts will appear in the display 2 Choose the alert you wish to address by moving the highlight brackets with the Down arrow 3 Press Checkmark again A screen appears with the date time and total number of times an alert has occurred Pressing the Down arrow will list some possible causes for the alert At the bottom of the screen you will be able to clear the alert by pressing the Checkmark...

Page 65: ...Home screen press the Menu button to enter the Main menu where you can choose to see machine information make setup changes set the Energy Saver mode or enter the Service Menu Main Menu Machine Info Set Up Energy Saver Factory Defaults Service Exit ...

Page 66: ...o highlight an item and use the Checkmark to view the information Press the Left arrow to return to previous screens Machine Info Menu 90 70 capacity Model Ice Machine Head Serial Condenser Serial Warranty Machine Evaporator Compressor Install Date Manufacture Date Main Control Board Software Version Display Software Version RESET PASSWORD TO FACTORY DEFAULTS The password can be reset to the facto...

Page 67: ... Checkmark Select and customize machine settings on this menu Press the Left arrow to return to previous screens Set Up Menu Set Up Language Time Date Time Configuration Units Ice Clarity LCD Bright Password On Edit Password Clean Minder AuCS RunTime Air Filter Water Filter LUMINICE Ice Bin Sensor USB Setup Exit ...

Page 68: ... 3 When the check reflects your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu TIME DATE When the ice machine is installed the correct time and date needs to be set for its location Set the Time and Date 1 Press the Menu button 2 Press the Down arrow until Set Up is highlighted bracketed 3 Press the Checkmark The Set Up menu wil...

Page 69: ...r Down arrow adjust the day if necessary 8 When the correct day appears use the Right arrow to move the blinking cursor to year 9 Using the Up or Down arrow adjust the year if necessary 10 When the correct year appears press the Checkmark Use the Right arrow to move the blinking cursor to hour 11 Using the Up or Down arrow adjust the hour if necessary 12 When the correct hour appears use the Right...

Page 70: ...cks reflect your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu UNITS 1 From the Set Up menu use the Down arrow to highlight Units 2 Press the Checkmark On this screen you can choose whether the ice machine will display measurements in Celsius or Fahrenheit kilograms or pounds and gallons or liters by highlighting your choice of...

Page 71: ... choose to turn the ice clarity feature ON or OFF by highlighting your choice and pressing the Checkmark Selecting one will deselect the other 3 When the check reflects your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu LCD BRIGHTNESS Here the brightness of the LCD display can be adjusted 1 From the Set Up menu use the Down arr...

Page 72: ...Down arrow to highlight setup and press the Right arrow 3 Use the Down arrow to highlight Password ON and press the Right arrow 4 Press the Right arrow again with Enter Passwrd highlighted and a cursor will flash 5 Use the Up Down arrows to enter the factory password 1 2 3 4 Enter the number 1 in the flashing cursor first digit of the factory password 6 Press the right arrow to move to the next ce...

Page 73: ...the last number is entered press the Checkmark button 7 Follow steps 4 5 and enter your 4 digit password 8 When the last number is entered press the Checkmark button to save your entry CLEAN MINDER Clean Minder is a feature that displays a cleaning reminder at a set time interval 1 From the Set Up menu use the Down arrow to highlight Clean Minder 2 Press the Checkmark On this screen you can choose...

Page 74: ...ting Set Interval and pressing the Checkmark 4 Press the Left arrow to return to previous screens and to the Set Up menu AIR FILTER The ice machine has a feature that displays a clean air filter reminder at a set time interval 1 From the Set Up menu use the Down arrow to highlight Air Filter 2 Press the Checkmark On this screen you can choose to turn the reminder to AUTO or OFF by highlighting you...

Page 75: ...roll down to exit and press the Checkmark 3 You can also choose to turn the reminder to AUTO NONE or OFF by highlighting your choice and pressing the Checkmark Selecting one will deselect the other Selecting Auto sets the reminder based on water usage for the selected filter Selecting None will turn off the reminder Selecting Off sets the timer to the selected reminder time 2 weeks to 6 months 4 Y...

Page 76: ...re that displays a reminder to change its bulb every 12 months 1 From the Set Up menu use the Down arrow to highlight LuminIce Minder 2 Press the Checkmark On this screen you can choose to turn the reminder to AUTO or OFF by highlighting your choice and pressing the Checkmark Selecting one will deselect the other 3 When the check reflects your preference use the Down arrow to navigate to Exit and ...

Page 77: ...se to set the ice level to Low Medium or High by highlighting your choice and pressing the Checkmark Selecting one will deselect the other When the check reflects your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu USB SETUP Refer to Upgrading Firmware with a Flash Drive and Exporting Data to a Flash Drive for more information o...

Page 78: ...arrow to navigate to Energy Saver and press the Checkmark Set up an energy saving ice program enable the Water Miser and view usage statistics from this menu Press the Left arrow to return to previous screens Energy Saver Menu Energy Saver Ice Program Water Miser Statistics Exit ...

Page 79: ...hlighting your choice and pressing the Checkmark Selecting one will deselect the other If one of them is selected and you wish to turn both off highlight the choice and press Checkmark again 3 If none of the programs are selected highlighting Settings and pressing the Checkmark will select the times bin level or pounds of ice per day If one of the programs is selected highlight Settings and press ...

Page 80: ... OFF by highlighting your choice and pressing the Checkmark Selecting one will deselect the other 3 Use the Down arrow to navigate to Exit and press the Checkmark to return to the Energy Saver menu STATISTICS 1 From the Energy Saver menu use the Down arrow to highlight Statistics 2 Press the Checkmark Choose to view ice usage or potable water and energy statistics by highlighting your choice and p...

Page 81: ...t the ice machine The display will return to the Set Up menu Setting Default Language English Time Configuration Mo Day Yr 24 Hour Units Fahrenheit Lbs Gallons Ice Clarity Off LCD Brightness Level 2 Password Off Enter Password Default Password 1234 Edit Password Off Edit Password Clean Minder Off AuCS RunTime Off Air Filter Minder Off Water Filter Minder Auto LuminIce Bulb Minder No Ice Bin Sensor...

Page 82: ...u The following pages list the navigation options available by drilling into the menus with the Right arrow Service Data History 00000000 00000000 00000000 00000000 00000000 00000000 Lifetime Exit RealTime Data Time Temp Inputs Outputs Exit Diagnostics Control Board Temp Sensors Inputs Exit Man Harvest Hrvst Started Exit Repl Cntl Bd Manual Setup USB Setup Exit USB Setup USB Stick Exit Event Log V...

Page 83: ...Cnt Bd USB Setup Current Day Current Day 1 Current Day 2 Current Day 3 Current Day 4 Current Day 5 Lifetime Control Board Temp Sensors Input Time Temp Inputs Outputs Harvest Started Manual Setup USB Setup Event Log Download Frm Download Cnf Export ALL Export Setup View E Log Clear E Log USB Stick ...

Page 84: ...the available information For each of the dates use the Checkmark to view Minimum Freeze Maximum Freeze Minimum Harvest Maximum Harvest Maximum Temperature Delta T3 T4 Delta T3 T4 RunTime Ice Production Cycle Count Potable Water Clean Cycles Exit For Lifetime use the Checkmark to view Install Date Control Board Replacement Date Control Board DOM Date Of Manufacture RunTime Cycle Count Potable Wate...

Page 85: ... stage of cycle Time T1 Thermistor Temperature T2 Thermistor Temperature T3 Thermistor Temperature T4 Thermistor Temperature T3 T4 Delta Temperature 100 hz 120 hz Exit Inputs Status Off On Displays stage of cycle Curtain Switch 1 Curtain Switch 2 LPCO Switch HPCO Switch Bin Level Low Optional Bin Level Probe Status Bin Level Medium Optional Bin Level Probe Status Bin Level High Optional Bin Level ...

Page 86: ...Outputs Status Off On Displays stage of cycle Water Pump Off On Hot Gas Valve 1 Off On Hot Gas Valve 2 Off On Air Pump Off On Water Valve Off On Dump Valve Off On Compressor Control Off On AuCS Relay Off On Ionic Cln Off On Exit ...

Page 87: ...Thermistor Temperature T2 Thermistor Temperature T3 Thermistor Temperature T4 Thermistor Temperature Exit Inputs Curtain Switch 1 Closed Open Curtain Switch 2 Closed Open LPCO Switch Closed Open HPCO Switch Closed Open Bin Level Low Optional Bin Level Probe Closed Open Bin Level Medium Optional Bin Level Probe Closed Open Bin Level High Optional Bin Level Probe Closed Open Sensing Ice No Yes Water...

Page 88: ...ol board refer to Exporting Data to a Flash Drive on page 98 or entered manually through the Indigo interface Manual Setup Board Install Date Input Model Number Input Serial Number Condenser condensing unit serial number USB Setup Insert Drive Press Checkmark and wait for completion Exit USB SETUP USB Stick Download Firmware Insert drive and wait for completion Download Configuration Insert drive ...

Page 89: ...when it occurred and how many times Use the Down arrow to view information on subsequent event codes For more information on event codes see Service Menu Use the Left arrow to return to the Event Log menu To clear the event log In the Event Log Menu use the Down arrow to highlight Clear ELog and press the Checkmark Press the Left arrow to return to previous screens Event Log Menu Event Log View EL...

Page 90: ...ult E12 Curtain Switch Fault E Board Open more than 12 hours G Board after Revision 4 017 Open more than 24 hours E13 Spare E14 Spare E15 Fan Cycle Control Fault Lo Liquid Line Temperature E16 Remote Condensing Unit Fault ICVD Only E17 Spare E18 Spare E19 Ice Thickness Probe Fault E20 Water System Fault E21 T1 Temperature Sensor Issue E22 T2 Temperature Sensor Issue E23 T3 Temperature Sensor Issue...

Page 91: ... for Self contained Water Cooled ice machine Water Cooled Condenser Fault E05 HPC Fault High Pressure Cutout HPC The high pressure cutout switch HPCO opened 3 times in 4 hour period E06 Spare E07 Starving TXV Starving Evaporator for single TXV or low on charge 10 consecutive occurrences where the Difference of the Average evaporator inlet T3 and outlet T4 is greater than 12 F in the last 1 minute ...

Page 92: ...ensing Unit only If the liquid line temperature drops below 40 F or exceeds 140 F for more than 1 continuous minute during the freeze cycle E17 Spare E18 Spare E19 ITP Fault Ice Probe ITP The monitored Frequencies is out of the appropriate range Probe unplugged or problem with microphone E20 WTR Fault Water System Fault Any of the following 1 Sensing high water probe and not low water probe Water ...

Page 93: ... When the AUCS clean option is selected from the menu the control checks for the presence of the AUCS board and if the AUCS is not connected it will signal an Event AUCS This will be cleared as soon as the hardware is detected E29 USB COMM USB Comm Event Log only No Alarm USB Communication error no USB drive in port or defective USB drive E30 USB DNLD USB download error dlnd Event Log only No alar...

Page 94: ...s Vista Computers 1 Insert USB flash drive your computer may indicate Found New Hardware follow the prompts to install the USB flash drive USB flash drive may auto play Close auto play window 2 Press Windows Key and E key simultaneously to access windows explorer 3 Right click on your USB Flash Drive 4 Left click on Format 5 Verify or select the settings below USB flash drive capacity 2 GB or less...

Page 95: ...n OK Left click on Disk Management 3 Verify USB flash drive capacity is 2 GB or less 4 Right click on the USB flash drive then left click on Format from the drop down list 5 Verify or select the settings below Volume Label is Optional Rename if desired File System Fat32 Allocation Unit Size must be 512 MB Deselect Perform A Quick Format no checkmark 6 Left click on OK you will receive a warning Fo...

Page 96: ... Down arrow until USB Setup is highlighted 7 Press the Checkmark USB Stick will appear highlighted 8 Press the Checkmark again A submenu with Download Frm Download Firmware appears 9 Ensure that Download Frm is highlighted and press the Checkmark A display of instructions will appear Important The flash drive must be formatted before using All files and software on the flash drive are removed duri...

Page 97: ...screen in the off mode 11 Reboot control board by removing power for 15 seconds and reapplying power 12 Verify the new firmware version loaded by navigating to Menu Machine information Main Software Version and verify the firmware version number RT Harvest Compressor LT Harvest Pump Display Light Micro Light Clean Light Harvest Light SL 1 Light SL 2 Light Fuse Thermistors T1 T2 T3 T4 Display RS485...

Page 98: ... or as an aid to troubleshooting The data files are small and can be attached to an email 1 Ensure that the ice machine s power is on 2 Press the Menu button 3 Press the Down arrow until Service is highlighted 4 Press the Checkmark The Service menu will be displayed 5 Press the Down arrow until USB Setup is highlighted Important The flash drive must be formatted before using Refer to page 94 USB F...

Page 99: ...ur requirements and press the Checkmark A display of instructions will appear 9 Follow these on screen instructions to A Insert Drive Insert the flash drive into the USB port on the ice machine s control board B Press Check Press the Checkmark C Wait For Comp Wait approximately 5 to 10 minutes for the download to complete D Depending on software version either Export Complete Success or the Home s...

Page 100: ... proper operation always follow the Operational Checks when starting the ice machine for the first time after a prolonged out of service period after cleaning and sanitizing NOTE Routine adjustments and maintenance procedures are not covered by the warranty Important Refrigeration compressors must be operated for a minimum break in period of 24 hours before full ice production will be reached ...

Page 101: ... be about 1 8 3 mm thick 2 If adjustment is necessary turn the ice thickness probe adjustment screw clockwise to increase bridge thickness counterclockwise to decrease bridge thickness As a starting point place a 9 32 7 mm drill bit between the ice thickness probe and the evaporator Make final adjustments to achieve a 1 8 3 mm thick bridge NOTE Turning the adjustment 1 3 of a turn will change the ...

Page 102: ... energize to purge the ice machine of old water This feature ensures that the ice making cycle starts with fresh water 2 Refrigeration System Equalization and Start Up The harvest valve s and air pump s energize to equalize high and low side refrigeration pressure After 5 seconds the contactor energizes the compressor and supplies power to the condenser fan motor After 5 seconds the harvest valve ...

Page 103: ...from energizing after two 6 minute water fill time limits After water contacts the low and high water probes the water fill valve de energizes Ice builds on the evaporator and the water level drops When water loses contact with the high water probe the water fill valve energizes until water contacts the high water probe again Ice Thickness Probe The freeze cycle continues until the six minute free...

Page 104: ... 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 ice damper and will hold it open After the water curtain ice damper is held open for 30 seconds the ice machine shuts of...

Page 105: ...cle can be initiated This can be overridden by initiating a manual harvest Refer to Manual Harvest on page 88 The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence The maximum harvest time is 3 5 minutes The control board automatically initiates a freeze sequence when these times are exceeded The maximum water fill is 12 minutes ...

Page 106: ...nser Fan Motor Length of Time Start Up 1 Water Purge On Off Off Off On Off Off Off 45 Seconds 2 Refrigeration System Start up Off On On Off Off On On May Cycle On Off 5 Seconds Freeze Sequence 3 Prechill Off Off Off May Cycle On Off during pre chill Off On On May Cycle On Off Initial Start Up is 60 Seconds 30 Seconds thereafter 4 Freeze On Off Off Cycles Off then On two more times Off On On May Cy...

Page 107: ... Off Bin Switch Activation 7 Automatic Shut Off Off Off Off Off Off Off Off Off Until 3 Minute Delay Expires and Bin Switch Re closes NOT USED ON ALL MODELS Self Contained Air Water Cooled Models Continued Ice Making Sequence of Operation Water Pump Harvest Valve s Air Pump s Water Inlet Valve Water Dump Valve Contactor Coil Compressor Condenser Fan Motor Length of Time ...

Page 108: ...r 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 2 Refrigeration System Equalization and Start Up The harvest valve air pump s and harvest pressure regulating HPR solenoid valves energize to equalize high and low side refrigeration pressure After 5 seconds the liquid l...

Page 109: ...from energizing after two 6 minute water fill time limits After water contacts the low and high water probes the water fill valve de energizes Ice builds on the evaporator and the water level drops When water loses contact with the high water probe the water fill valve energizes until water contacts the high water probe again Ice Thickness Probe The freeze cycle continues until the six minute free...

Page 110: ...per and 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 ice damper and will hold it open After the water curtain ice damper is held open...

Page 111: ...Liquid Line Solenoid Compressor Condenser Fan Motor Length of Time Initial Start Up 1 Water Purge On Off Off Off On Off Off Off 45 Seconds 2 Refrigeration System Start up Off On On Off Off On On On 5 Seconds Freeze Sequence 3 Prechill Off Off Off May Cycle On Off during pre chill Off On On On Initial Start Up is 60 Seconds 30 Seconds thereafter 4 Freeze On Off Off Cycles Off Then On Two more times...

Page 112: ...hut Off Off Off Off Off Off Off Off Off Until 3 Minute Delay Expires and Bin Switch Re closes Not Used On All Models Remote Air Cooled Condenser Models Energized Parts Chart Continued Ice Making Sequence of Operation Water Pump Harvest Valve Right When Used Air Pumps Water Inlet Valve Water Dump Valve Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Length of Time ...

Page 113: ...tomatically returns the ice machine to the freeze cycle If 500 consecutive 3 5 minute harvest cycles occur the ice machine stops SAFE OPERATION MODE Allows the ice machine to operate up to 72 hours if the ice thickness probe E19 fault and or water level probe sensors fail E20 fault When the control board starts the safe mode an alert is flashed on the LCD display to notify the end user they have a...

Page 114: ...ure at night a water pressure drop the water is turned off one night a week etc Refrigeration and electrical component failures will cause a safety limit trip Eliminate all electrical components and external causes first If it appears that the refrigeration system is causing the problem use Manitowoc s Freeze Cycle Refrigeration System Operational Analysis Table along with detailed charts checklis...

Page 115: ...e water pump Loss of water from sump area Electrical System Low incoming voltage Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operational Defective fan cycling control Defective fan motor Miscellaneous Non Manitowoc components Improper refrigerant charge Defective head pressure control Defective harvest valve De...

Page 116: ...Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Clogged water distribution tube Electrical System Ice thickness probe out of adjustment Bin switch closed defective Premature harvest Refrigeration System Non Manitowoc components Improper refrigerant charge Defective head pressure control valve Defective harvest valve TXV flooding check bulb mou...

Page 117: ...machine is in Ice Making cycle or Has a History of Shutting Down Refer to Ice Machine Stops Running Flow Chart SYMPTOM 2 Ice Machine has a Long Freeze Cycle Ice Formation is Thick or Thin Ice Fill on Inlet or Outlet of Evaporator or Low Production Safety Limit 1 possible Refer to Freeze Cycle Refrigeration System Operational Analysis Table SYMPTOM 3 Ice Machine Will Not Harvest Freeze Cycle is Nor...

Page 118: ...one of the following A Copy settings to a usb device and flash settings into the control board when diagnostics are complete B Write down any customer settings so they can be re entered when diagnostics are complete This procedure also resets the password to the factory default The default factory password is 1234 To reset the ice machine to factory defaults Reset Password To Factory Defaults on p...

Page 119: ...rd diagnostics Is there an Alert or Error Logged Refer to Alert Error Log Yes No No No Does the ice machine start when the Power button is pushed Yes Are there any lights on or flashing on the control board No Refer to display control board diagnostics Cycle Power to Board are lights flashing Display light Flashing No Unit has adequate ground Install Ground No No Yes Yes Yes Yes ...

Page 120: ...Yes Yes No Yes No Install the water curtain damper All water curtains or dampers in place Line voltage at wires 55 56 on 9 pin control board connector Supply power to the ice machine Yes No Yes Replace fuse determine which component caused fuse to blow Refer to display control board diagnostics No Yes ...

Page 121: ...net on the water curtain damper Yes Replace the water curtain damper No Yes Ice machine starts No No Test run ice machine Yes Which light flashes Yes Yes Refer to Safety Limit 2 long harvest cycle Refer to Safety Limit 1 long freeze cycle Refer to bin switch diagnostics Refer to display control board diagnostics ...

Page 122: ...ists 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 co...

Page 123: ... found it is not necessary to complete the remaining procedures Step 2 Enter Checkmarks Each time the actual findings of an item in the Operational Analysis column matches the published findings on the table enter a Checkmark Example Freeze cycle suction pressure is determined to be low Enter a Checkmark in the low column Step 3 Add the Checkmarks listed under each of the four columns Note the col...

Page 124: ...etermining factor in the final diagnosis Ask these questions before beginning service When does the ice machine malfunction night day all the time only during the Freeze cycle etc When do you notice low ice production one day a week every day on weekends etc Can you describe exactly what the ice machine seems to be doing Has anyone been working on the ice machine During store shutdown is the circu...

Page 125: ...erly if the ice fill patterns is normal and ice production is within 10 of charted capacity Installation and Water System Reference Water System Checklist on page 136 All installation and water related problems must be corrected before proceeding with chart Ice Formation Pattern Reference Ice Formation Pattern on page 137 Ice formation is extremely thin on outlet of evaporator or No ice formation ...

Page 126: ...re proceeding Freeze Cycle Suction Pressure _______ ______ _____ 1 minute Middle End If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist page 144 to eliminate problems and or components not listed on this table before proceeding Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High SINGLE EVA...

Page 127: ...ed Remote Condenser Single Expansion Valve Machines on page 147 Inlet and outlet within 7 F 4 C of each other Inlet and outlet not within 7 F 4 C of each other and Inlet is colder than outlet Inlet and outlet within 7 F 4 C of each other or Inlet and outlet not within 7 F 4 C of each other and Inlet is warmer than outlet Inlet and outlet within 7 F 4 C of each other SINGLE EVAPORATOR SINGLE EXPANS...

Page 128: ...old hand on The harvest valve inlet is Cool enough to hold hand on and the compressor discharge line is Hot Discharge Line Temperature Record freeze cycle discharge line temperature at the end of the freeze cycle T2 _________ F C Reference Discharge Line Temperature Analysis on page 150 Discharge line temp 150 F 65 C or higher at the end of the freeze cycle Discharge line temp 150 F 65 C or higher...

Page 129: ...rmed exactly for the table to work correctly Final Analysis Enter total number of boxes checked in each column Reference Final Analysis Self contained Air Water Remote Condenser Models on page 152 Harvest Valve Leaking Low On Charge Or TXV Starving TXV Flooding Compressor SINGLE EVAPORATOR SINGLE EXPANSION VALVE SELF CONTAINED AIR WATER REMOTE CONDENSER Operational Analysis 1 2 3 4 ...

Page 130: ...arted capacity Installation and Water System All installation and water related problems must be corrected before proceeding with table Ice Formation Pattern Top or 1 Side_________ Bottom or 1 Side_________ Ice formation is extremely thin on outlet of evaporator or No ice formation on one side or Top or Bottom of evaporator Ice formation is extremely thin on outlet of one side or Top or Bottom of ...

Page 131: ... before proceeding Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into the freeze cycle Compare temperatures of compressor discharge line and both harvest valve inlets The harvest valve inlet is Hot and approaches the temperature of a Hot compressor discharge line The harvest valve inlet is Cool enough to hold hand on and...

Page 132: ... F 65 C or higher at the end of the freeze cycle Discharge line temp less than 150 F 65 C at the end of the freeze cycle Discharge line temp 150 F 65 C or higher at the end of the freeze cycle Final Analysis Enter total number of boxes checked in each column Harvest Valve Leaking Low On Charge Or TXV Starving TXV Flooding Compressor SINGLE EVAPORATOR DUAL EXPANSION VALVE SELF CONTAINED AIR WATER R...

Page 133: ...entering sump trough ____ 2 Refer to the appropriate 24 Hour Ice Production Chart starting on page 221 Use the operating conditions determined in step 1 to find published 24 Hour Ice Production _____ Times are in minutes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights are in pounds Example 2 lb 6 oz converts to 2 375 lb 6 oz 16 oz 375 lb 3 Perform an ice producti...

Page 134: ...on Charts may be used 4 Compare the results of step 3 with step 2 Ice production checks that are within 10 of the chart are considered normal If they match closely determine if Another ice machine is required More storage capacity is required Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc Distributor for information on available options and a...

Page 135: ... machine is not level Level the ice machine Condenser is dirty Clean the condenser Water filtration is plugged if used Install a new water filter Water drains are not run separately and or are not vented Run and vent drains according to the Installation Manual Line set is improperly installed Reinstall according to the Installation Manual Reference Lineset Applications on page 34 ...

Page 136: ... F 2 C and 90 F 32 C If too hot check the hot water line check valves in other store equipment Water filtration is plugged if used Install a new water filter Water dump valve leaking during the Freeze cycle Clean replace dump valve as needed Vent tube is not installed on water outlet drain See Installation Instructions Hoses fittings etc are leaking water Repair replace as needed Water fill valve ...

Page 137: ... than on the outlet At the end of the Freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet of the evaporator may be more pronounced than those on the inlet This is normal It is normal for ice thickness to vary up to 1 16 across the surface of the evaporator The ice bridge thickness at the ice thicknes...

Page 138: ...the evaporator reaches 1 8 in to initiate a harvest but there is no ice formation at all on the inlet of the evaporator 4 No Ice Formation The ice machine operates for an extended period but there is no ice formation at all on the evaporator Evaporator Tubing Routing Routing of the tubing on the back of the evaporator determines the ice fill pattern failure mode One Evaporator One TXV models The e...

Page 139: ...tern varies depending on which circuit is affected Extremely Thin at the Evaporator Outlet will first be visible either 1 4 or 3 4 of the way down the evaporator Extremely Thin at the Evaporator Inlet will show at the bottom of the evaporator or 1 2 of the way down depending on the circuit affected ICE Thin at Inlet Inlet Outlet ICE ICE ICE ICE Inlet Outlet Thin at Outlet ...

Page 140: ...tor Only one side of the evaporator may be affected depending on failure A TXV failure will usually show on only one side while low on refrigerant can affect one or both sides depending on the amount of refrigerant loss and ambient temperature Extremely Thin at the Evaporator Inlet will show at the bottom of the evaporator Depending on the failure either the entire bottom of the evaporator or one ...

Page 141: ... pressures Freeze Cycle______ Harvest Cycle______ 3 Perform an actual discharge pressure check 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 ...

Page 142: ...ecirculation Defective fan cycling control page 185 Defective fan motor Defective head pressure control valve Remote Water Condenser Low water pressure 20 psig 138 kPa min High inlet water temperature 90 F 32 C max Dirty condenser Dirty Defective water regulating valve Water regulating valve out of adjustment Other Overcharged Non condensable air in system Wrong type of refrigerant Non Manitowoc c...

Page 143: ...ge 135 Air Cooled Condensers Defective head pressure control valve won t bypass page 195 Defective fan cycle control stuck closed page 185 Water Cooled Condensers Water Regulating Valve out of adjustment Water Regulating Valve Defective Other Undercharged Wrong type of refrigerant Non Manitowoc components in system Liquid line component restricted ...

Page 144: ...enser______ Air temp around ice machine______ Water temp entering sump trough______ 2 Refer to Operating Pressure table starting on page 221 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 suction pressure check 4 Compare the actual suction pressure step 3 wit...

Page 145: ...s affecting suction pressure refer to Freeze Cycle Discharge Pressure High Checklist page 142 Improper Refrigerant Charge Overcharged also see Freeze Cycle Discharge Pressure High Checklist page 142 Wrong type of refrigerant Non condensable in system Components Harvest valve leaking Harvest pressure solenoid valve leaking TXV flooding Defective compressor Other Non Manitowoc components in system ...

Page 146: ...ffecting low side refer to Freeze Cycle Discharge Pressure Low Checklist page 143 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Improper water supply over evaporator refer to Water System Checklist page 136 Restricted plugged liquid line drier Restricted plugged tubing in suction side or liquid line of refrigeration system TXV starving ...

Page 147: ...e 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 should be within 7 of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Navigate to ...

Page 148: ...NTAINED OR REMOTE CONDENSER MODELS HARVEST VALVE ANALYSIS 1 Wait five minutes into the freeze cycle 2 Feel the inlet of the harvest valve s 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 Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this compariso...

Page 149: ...minutes into the freeze cycle The inlet of the harvest valve is hot and approaches the temperature of a hot compressor discharge line Hot Hot Leaking Harvest Valve The harvest valve inlet did not cool down during the freeze cycle due to continual leakage of compressor discharge gas through the valve Both the inlet of the harvest valve and the compressor discharge line are cool enough to touch Cool...

Page 150: ...ondenser and or higher inlet water temperature higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser and or lower supply water temperature lower discharge line temperatures at the compressor Regardless of ambient and water temperatures the freeze cycle discharge line temperature will be higher than 150 F 66 C at the end of the freeze cycle PROCEDURE 1...

Page 151: ...lean or replace valve Discharge pressure extremely high Liquid line entering receiver feels hot Water regulating valve incorrectly set or not opening Insufficient water volume undersized kinked lines mineral or scale buildup in lines Verify Head Pressure Control Valve operation before changing water regulating valve Discharge pressure low Liquid line entering receiver feels warm to hot Ice machine...

Page 152: ...water self contained only Do not add more than 30 of nameplate refrigerant charge If the problem is corrected the ice machine is low on charge Do not add charge to remote models The symptoms of a remote low on charge will result in a safety limit 1 in cool ambient temperatures Check the liquid line temperature at the ice machine The liquid line will be hot with a normal or below normal head pressu...

Page 153: ...the expansion valve to flood Check bulb mounting insulation etc before changing the valve Verify refrigerant amount is correct by weighing recovered refrigerant before replacing a TXV COLUMN 4 COMPRESSOR Replace the compressor To receive warranty credit the compressor ports must be properly sealed by crimping and soldering them closed ...

Page 154: ... the cubes are square and show no signs of melting This indicates a refrigeration problem The source of the problem could be in the freeze or harvest cycle Use the appropriate flow chart in Troubleshooting to determine the cause of the problem Symptom 4 Melted sheet of cubes at the end of the harvest cycle Ice can be removed rather easily by hand The back of the cubes are misshapen and melted This...

Page 155: ...roduction Normal fill pattern long harvest cycle Possible SL 2 Back of cubes are not melted Discharge line temperature is normal at the end of the freeze cycle Refer to Symptom 2 Freeze Cycle Operational Analysis Table Is harvest valve energized Refer to Sequence of Operation Wiring Diagrams Is head pressure high suction pressure low in harvest Refer to Pressure Charts Replace harvest valve START ...

Page 156: ...eze cycle Fan cycling control opens below setpoint in harvest cycle Replace Fan Cycling Control Maintains correct pressure in freeze cycle Stops water flow 100 in harvest cycle Adjust or Replace Water Regulating Valve Traditional Remote Air cooled Condenser Are you sure Discharge line temperature is normal Repeat this flowchart verify all data Refer to Symptom 3 Traditional Remotes Only Chart ...

Page 157: ...ormally above 70F 21C YES YES YES NO Liquid Line Temperature Cool NO Liquid Line Temperature Hot Liquid Line Temperature Warm body temperature Wet condenser with water during freeze cycle Replace Headmaster System low on refrigerant Normal ice fill long harvest cycle possible SL 2 back of cubes are not melted at the end of harvest cycle Discharge line temperature is normal at the end of the freeze...

Page 158: ...rvest Is head pressure normal suction pressure normal in harvest Refer to Harvest Pressure Regulating Valve Diagnostics Repeat this flowchart verify all data Refer to Symptom 4 Will Not Harvest Freeze Cycle Normal Ice Cubes are Melted Flowchart Single Evaporator Systems with Dual Harvest Valves If one Harvest Vavle is open and the other is restricted stuck closed you may have normal harvest pressu...

Page 159: ...r in the first 45 seconds of harvest Is Ice Machine level Are back of the cubes melted at end of harvest cycle Does ice remain frozen to the evaporator at the end of the harvest cycle YES YES YES YES NO NO NO NO Ice Machine Will Not Harvest Freeze Cycle is Normal and Ice Cubes are Melted After Harvest Refer to Symptom 2 Freeze Cycle Operational Analysis Table START ...

Page 160: ...e Cycle Operational Analysis Table Refer to Heavily Scaled Cleaning Procedure Discharge line temperature is normal at the end of the freeze cycle Refer to Manual Cleaning Procedure Is the evaporator dirty Dry evaporator first then check YES YES NO NO NO ...

Page 161: ...Display Diagnostics Symptom Micro light flashes and display light is off 1 Disconnect both ends of the communication cable running between the control board and the back of the display module and inspect for bent or damaged pins Reconnect after inspection 2 Reboot ice machine by disconnecting power for a minimum of 15 seconds reapplying power and checking micro light for normal flashing 3 Press th...

Page 162: ...own to Service and press right arrow Scroll down to Diagnostics and press right arrow Display reads Control Board press right arrow Display reads Self Check press right arrow to start control board test The control board performs a self test As the test progresses the display will show Checkmarks at the top left of the display screen When the fifth Checkmark appears the display will show Status Fa...

Page 163: ...ds Key Pad Test press the right arrow 4 Test the functionality of all buttons on the touch pad NOTE Pushing the power button will start and stop the ice machine Testing it last will allow the ice machine to continue running a freeze cycle As you press the buttons the first letter of the corresponding word will flash indicating the push button is operating correctly or the corresponding arrow or ze...

Page 164: ...ess the right arrow and select Diagnostics Display reads Control Board press right arrow Scroll down to enbl relays and press right arrow to start control board test 3 The control board will energize all relays and the red light next to the relay The red light indicates the relay coil is energized 4 Test for line voltage at the individual components A Line voltage is present and the component is n...

Page 165: ...al Setup Applicable when the control board is non operational or data from the faulty board is suspect Install replacement control board and reapply power G series blue control boards will go directly to the Replacement Control Board screen and pause for input Select either Manual or USB setup option E series beige control boards require navigation to the Replacement Control Board Repl Cntl Bd scr...

Page 166: ...ndicate the electrical requirements example 261 Press the right arrow until the cursor disappears 6 Scroll down until brackets are in the space below Input Serial Press the right arrow to activate the blinking cursor then use the up down arrows to select the first character in the serial number Use the right arrow to move to the next space Add characters in this manner until the serial number is c...

Page 167: ...ith the water curtain ice dampers closed the fuse is good 2 Remove the fuse Check for continuity across the fuse with an ohmmeter Warning High line voltage is applied to the control board terminals 55 and 56 at all times Removing the control board fuse or pressing the On Off button will not remove the power supplied to the control board Warning Disconnect electrical power to the entire ice machine...

Page 168: ...huts 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 ice dampers As the water curtain ice dampers swing back to the operating position the bin switch closes and the ice machine restarts provide the 3 minute delay has expired SPECIFICATIONS The bin switch is a magnetically operated reed switch The magnet...

Page 169: ...splays Full Bin Remove Ice in the clean cycle E Control Boards with firmware versions prior to Rev 2 047 The ice machine will not start an ice making cycle and the display indicates Curtain Open The ice machine will run in the clean cycle Bin Switch Fails Closed When running a Long Harvest alert is displayed and safety limit 2 indicated May be off on a safety limit 2 The harvest cycle continues af...

Page 170: ... cycles open closed and control board light energizes de energizes Bin switch is operating normally B Curtain switch remains closed and control board light remains on Go to step 3 C Curtain switch remains open and control board light remains off Go to step 3 3 Disconnect bin switch wire from control board 4 Jumper control board bin switch wire to ground press the power button and observe the displ...

Page 171: ...S 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 position Reposition or clean the probe as necessary Water Inlet Valve Safety Shut Off In the event of a water level probe failure this feature limits the ...

Page 172: ... in the prechill and up to two times in the freeze cycle Maximum fill time is 12 5 minutes for single evaporator machines The water inlet valve energizes in the Prechill cycle and will de energize if water touches the high level probe in most instances the water trough can t fill in the prechill cycle and the water inlet valve will remain energized into the freeze cycle The water inlet valve will ...

Page 173: ...is below 80 psig before replacing the water inlet valve If the water stops continue with next step Step 3 Check water level probe mounting and verify secure wiring connections at the probe and control board Step 4 Scroll to Service Diagnostics Inputs and press down arrow until Wtr Low and Wtr High are displayed No is displayed on both Wtr low and Wtr high The control board is not receiving a sensi...

Page 174: ...12 Step 5 Disconnect the water level probe wiring harness from the control board and ohm harness and water level probe Normal readings will show no resistance Ohm water Level Probe and Wiring Harness Short Probe Black White Red ...

Page 175: ...When any measurement fails disconnect the wiring harness from the water level probe and ohm the water level probe with the wiring harness removed from the circuit Results will determine whether the wiring harness or probe will need replacement Ohm Water Level Probe Short Probe Empty Terminal ...

Page 176: ...ltage at the water inlet valve coil Step 3 Disconnect water level probe observe LCD display text A No is displayed Clean the water level probe and test interconnecting wiring B Yes is displayed Replace the Control Board Step 4 Ohm probe Refer to previous page for procedure WATER LEVEL PROBE CIRCUIT CHECK AT CONTROL BOARD Wait until prechill cycle starts then jumper water level probe connections 2 ...

Page 177: ...corporates a 6 minute freeze time lock in feature This prevents the ice machine from short cycling in and out of harvest Maximum Freeze Time The control system includes a built in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle Maximum Temperature Maximum temperature for the ice thickness probe is 120 degrees F 49 degree s C Do not clean prob...

Page 178: ...t is made 1 Inspect the bridge connecting the cubes It should be about 1 8 in 32 mm thick 2 If adjustment is necessary turn the ice thickness probe adjustment screw clockwise to increase bridge thickness or counterclockwise to decrease bridge thickness Set a 9 32 gap between the ice thickness probe and evaporator as a starting point Then adjust to achieve 1 8 ice thickness 3 Make sure the ice thic...

Page 179: ...s Probe tap test Press the menu button scroll down to Service press the right arrow scroll down to Real Time Data press right arrow With the brackets around Time Temp press the right arrow Scroll down until 100Hz 120Hz are displayed Slowly increasing and decreasing numbers typically in the 200Hz to 300Hz range will display to the right of 100Hz 120Hz Lift the Ice Thickness Probe and continuously t...

Page 180: ... lead to the black wire Normal readings 1 4 to 2 5 KΩ s Reverse leads Connect black meter lead to the red wire red meter lead to the black wire Normal readings 1 2 to 1 5 KΩ s 6 Check control board voltage Set VOM to DC voltage scale Check voltage across the top and bottom pin Normal readings 3 25 to 3 35 VDC Pass Ohm values are within range Check control board voltage at the ice thickness probe c...

Page 181: ...l down to Manual Harvest and press right arrow A new freeze cycle will start after the manual harvest cycle is complete NOTE Ice must be off the evaporator before starting the procedure 1 Disconnect the ice thickness probe from the control board then reboot the control board by disconnecting and reconnecting line voltage to the ice machine 2 Wait six minutes into the freeze cycle timing starts whe...

Page 182: ...inutes to 0 minutes at which point the ice machine attempts a restart If the HPCO is closed the ice machine will continue to run If the HPCO remains open after the 60 minute delay or reopens when the compressor starts the ice machine will start another 60 minute delay period 1 Machine is off and the display indicates Delay XX min HPCO Active 2 Machine is running and the display has an alert triang...

Page 183: ...ther wait for the delay period to end or start a new freeze cycle by cycling the power button A HPCO is open Another 60 minute delay period starts B HPCO closed A 3 5 minute harvest cycle starts followed by an ice making cycle 4 Run the system to see if the control trips at the rated pressure If HPCO opens at a pressure significantly lower or higher than the control setting of 450 psig replace the...

Page 184: ...curred 2 If this is a one time event it may be intermittent and caused by conditions around the unit changing For example High ambient temperature water turned off to condenser water cooled unit etc 3 Run the system to see if the control trips at the rated pressure If HPCO opens at a pressure significantly lower than the control setting of 450 psig replace the HPCO 4 If the control opens at the co...

Page 185: ... 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 Specifications Model Cut In Close Cut Out Open I0300 I0320 I0520 I0450 I0500 I0600 I0660 I0850 JC0995 250 5 1723 kPa 34 17 23 bar 34 200 5 1517 kPa 34 15 17 bar 34 I1000 I1400 I1800 275 psig 5 1896 kPa 34 18 96 bar 34 225 psig 5 1551 kPa 34 ...

Page 186: ...60 70 98 930 10 20 50 68 98 930 62 015 20 30 68 86 62 015 39 695 30 40 86 104 39 695 25 070 40 50 104 122 25 070 17 481 50 60 122 140 17 481 11 860 60 70 140 158 11 860 8 1900 70 80 158 176 8 1900 5 7530 80 90 176 194 5 7530 4 1015 90 100 194 212 4 1015 2 9735 100 110 212 230 2 9735 2 1885 110 120 230 248 2 1885 1 6290 120 130 248 266 1 6290 1 2245 130 140 266 284 1 2245 0 9319 140 150 284 302 0 9...

Page 187: ...iver Outlet T3 T4 T2 T1 T4 T3 T2 T1 T4 T3 T2 T1 T3 T1 T2 T4 T3 T1 T2 TEMPERATURE SENSOR LOCATION Ice Machine Description 22 30 1 Evaporator with 1 Circuit IMH Air Cooled Water Cooled T3 T4 T2 T1 T4 30 48 1 Evaporator with 2 Circuits IMH Air Cooled Water Cooled 30 1 Evaporator with 1 Circuit RCU Air Cooled 30 48 1 Evaporator with 2 Circuits RCU Air Cooled QuietQube 1 Evaporator with 1 Circuit RCU A...

Page 188: ...F 246 C Thermistor Test 1 Disconnect thermistor from control board and measure resistance 2 Measure temperature at the thermistor 3 Compare measured resistance temperature readings to resistance temperature relationship chart A Within 10 of the published resistance value Thermistor is good B Not within 10 of the published resistance value Thermistor is defective Control Board Test 1 Disconnect the...

Page 189: ...cles SPECIFICATIONS 115 Volt or 230 Volt matches the ice machine voltage CHECK PROCEDURE 1 The air pump is wired in parallel with the harvest valve Verify the ice machine is in the harvest cycle and the harvest valve is energized 2 If there is voltage at the air pump connector use a volt ohm meter to verify there is no continuity through the motor windings then replace motor ...

Page 190: ...from the compressor terminals 2 The resistance values between C and S and between C and R when added together should equal the resistance value between S and 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 power and rem...

Page 191: ...aw while the compressor is trying to start The two likely causes of this are a defective starting component or a mechanically seized compressor To determine which you have 1 Install high and low side gauges 2 Try to start the compressor 3 Watch the pressures closely A If the pressures do not move the compressor is seized Replace the compressor B If the pressures move the compressor is turning slow...

Page 192: ... before testing Relay The relay has a set of contacts that connect and disconnect the start capacitor from the compressor start winding The contacts on the relay are normally closed start capacitor in series with the start winding The relay senses the voltage generated by the start winding and opens the contacts as the compressor motor starts The contacts remain open until the compressor is de ene...

Page 193: ...ust be cooled before attempting to start the compressor otherwise the PTCR will heat up too quickly and stop current flow through the start winding before the compressor motor reaches full speed NOTE If a PTCR is dropped internal damage can occur to the ceramic PTCR discs The ceramic disc can chip and cause arcing which leads to PTCR failure Since there is no way to open the PTCR in order to deter...

Page 194: ...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 The resistance reading must be between Two Terminal PTCR Black 24 5 to 45 5 ohms Two Terminal PTCR Blue 21 to 39 ohms Three Terminal PTCR Tan 10 5 to 19 5 ohms Three Terminal PTCR Measure Resistance At Ends Two Terminal PTCR Leave Jumper...

Page 195: ...ons at night and or fails whenever the outdoor temperature drops A Safety limit is stored in control board memory Refrigerant loss and ambient temperature are directly related to each other As the ambient temperature drops more refrigerant is stored in the condenser When the refrigerant charge and ambient temperature create an undercharge of refrigerant in the freeze cycle the receiver dip tube wi...

Page 196: ...rectly to the receiver Harvest Cycle Operation Remote Condenser Models The head pressure control cycles into full bypass due to the pressure drop when the harvest valve opens Refrigerant flows from the compressor to the evaporator through the harvest valve and the head pressure valve is out of the circuit Diagnostics FREEZE CYCLE REMOTE CONDENSER 1 Determine if the coil is clean 2 Determine the ai...

Page 197: ... and the ice machine malfunctions Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle Condition Probable Cause Corrective Measure Discharge Pressure High Liquid Line Temperature Hot Valve stuck in bypass Replace valve Discharge Pressure Low Liquid Line Temperature Cold Valve not bypassing Replace valve Discharge Pressure Low Liquid Line Temper...

Page 198: ...arvest is displayed Harvest cycle suction pressure is low Harvest cycle discharge pressure is low Liquid line entering receiver feels warm to hot in the freeze cycle Overcharge Symptoms Safety limit 2 in control board memory a flashing triangle alert and after pressing left arrow Long Harvest is displayed Harvest cycle discharge pressure is normal Freeze cycle time suction and discharge pressure a...

Page 199: ...ally operated valve which opens when energized and closes when de energized Harvest pressure regulating valve HPR 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 refrigerant flow when the pressure at the outlet rises above the valve setting INLET OUTLET FLOW HPR SOLENOID SV3...

Page 200: ...on 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 70 100 psig 517 758 kPa Exact pressures vary from model to model Refer to cycle time 24 hour ice production and operational pressure charts HPR DIAGNOSTICS Steps 1 through 5 can be quickly ...

Page 201: ... Analysis on page 150 6 Connect refrigeration manifold gauge set to the access valves on the front of the ice machine Establish baseline by recording suction and discharge pressure and freeze harvest cycle times Refer to Freeze Cycle Refrigeration System Operational Analysis Tables for data collection detail page 125 7 Freeze cycle Head Pressure is in the range indicated in the cycle time 24 hour ...

Page 202: ... discharge pressure 4 Determine the temperature of the liquid line entering the receiver by feeling it This line is normally warm body temperature 5 Using the information gathered refer to the list for diagnosis Problem Freeze Cycle Valve not maintaining discharge pressure Valve incorrectly set dirty or defective Adjust clean or replace valve Discharge pressure extremely high Liquid line entering ...

Page 203: ...e these connections Suction side of the compressor through the suction service valve Discharge side of the compressor through the discharge service valve Important Manitowoc 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 after reco...

Page 204: ...ery or evacuation A Recovery Operate the recovery unit as directed by the manufacturer s instructions B Evacuation prior to recharging Pull the system down to 500 microns Then allow the pump to run for an additional half hour Turn off the pump and perform a standing vacuum leak check 4 Follow the Charging Procedures MANIFOLD SET OPEN VACUUM PUMP RECOVERY UNIT CLOSED OPEN LOW SIDE ACCESS VALVE HIGH...

Page 205: ...chine is off Important The charge is critical on all Manitowoc ice machines Use a scale to ensure the proper charge is installed MANIFOLD SET CLOSED SCALE VACUUM PUMP RECOVERY UNIT OPEN CLOSED LOW SIDE ACCESS VALVE HIGH SIDE ACCESS VALVE OPEN REFRIGERANT CYLINDER CHARGING CONNECTIONS ...

Page 206: ...he suction service valve if necessary NOTE Manifold gauges must be removed properly to ensure that no refrigerant contamination or loss occurs 9 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 Remove the high side low loss fitting from the access valve C Open the high and low side va...

Page 207: ...recommendations Important Manitowoc Ice 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 after recovering the refrigerant and before evacuating and recharging Use only a Manitowoc O E M liquid line filter drier to prevent voiding the...

Page 208: ... the outside of the compressor evaporator compartment This connection evacuates the condenser Without it the magnetic check valves would close when the 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 T...

Page 209: ...fold gauge set 4 Perform recovery or evacuation A Recovery Operate the recovery unit as directed by the manufacturer s instructions B Evacuation prior to recharging Pull the system down to 500 microns Then allow the pump to run for an additional hour Turn off the pump and perform a standing vacuum leak check NOTE Check for leaks with an electronic leak detector after charging the ice machine 5 Fol...

Page 210: ...210 Part Number STH025 8 12 ACCESS REMOTE RECOVERY EVACUATION CONNECTIONS ...

Page 211: ...achine Add the remaining refrigerant through the low side in vapor form until the machine is fully charged NOTE If an access valve core removal and installation tool is used on any of the Schraeder valves reinstall the cores before disconnecting the access tool and hose 4 Remove the high side low loss fitting from the access valve 5 Open the high and low side valves on the manifold gauge set Any r...

Page 212: ...RECOVERY UNIT VACUUM PUMP ACCESS VALVE RECEIVER MANIFOLD SET OPEN DRIER SOLENOID LINE VALVE REGULATING PRESSURE HARVEST LIQUID ACCESS VALVE CHECK VALVE TEE OPEN C B R HIGH SIDE ACCESS VALVE LOW SIDE COMPRESSOR HARVEST PRESSURE SOLENOID VALVE VALVE EXPANSION VALVE CHECK STRAINER VALVE SOLENOID HEAT EXCHANGER EVAPORATOR REMOTE CHARGING CONNECTIONS ...

Page 213: ...agnostic 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 Inspec...

Page 214: ...hows contamination Leak in water cooled condenser No burnout deposits in open compressor lines Mild contamination cleanup procedure Mild Compressor Burnout symptoms Oil appears clean but smells acrid Refrigeration test kit or acid oil test shows harmful acid content No burnout deposits in open compressor lines Mild contamination cleanup procedure Severe Compressor Burnout symptoms Oil is discolore...

Page 215: ...microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig 35 kPa 35 bar 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 35 bar C Change the vacuum pump oil D Pull vacuum to 500 microns Run the vacuum pump for 1 2 hour on self contained models 1 hour on remotes NOTE You may perform ...

Page 216: ...burnout deposits from suction and discharge lines at compressor 4 Sweep through the open system with dry nitrogen 5 Install a new compressor and new start components 6 Install a suction line filter drier with acid and moisture removal capability Place the filter drier as close to the compressor as possible 7 Install an access valve at the inlet of the suction line drier 8 Install a new liquid line...

Page 217: ... a preliminary leak check You should use an electronic leak detector after system charging to be sure there are no leaks 10 Charge the system with the proper refrigerant to the nameplate charge 11 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 7 kPa 7 bar the filter drier should be adequate for compl...

Page 218: ... 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 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 ...

Page 219: ...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 high moisture and acid removal capability The size of the filter drier is important The refrigerant charge is critical Using an improperly sized filter drier will cause the ice machine to be improperly charged with refrigerant Important Dr...

Page 220: ...on these pages Model Air Cooled Water Cooled Remote Additional Refrigerant for Line Sets 51 100 Maximum System Charge I0300 15 oz 12 oz NA NA NA I0320 20 oz 18 oz NA NA NA I0450 20 oz 14 oz NA NA NA I0500 24 oz 23 oz 6 lb 1 5 lb 7 5 lb I0520 22 oz 14 oz NA NA NA I0600 32 oz 28 oz 6 5 lb 1 5 lb 7 5 lb I0850 34 oz 26 oz 8 5 lb 2 lb 10 5 lb I1000 36 oz 28 oz 7 lb 2 lb 9 lb I1200 42 oz 34 oz NA NA NA ...

Page 221: ...hat 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 Refer to Symptom 2 Operational Analysis Table page 125 for the list of data that must be collected for refrigeration diagnostics Zero out manifold gauge set before obtaining pressure readings to avoid misdiagnosis Discharge and suction p...

Page 222: ...6 2 19 2 110 43 15 0 17 7 15 8 18 7 17 7 20 9 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 2 40 2 80 lb 50 10 70 21 90 32 70 21 310 280 250 80 27 285 250 230 90 32 260 225 210 100 38 235 215 195 110 43 210 200 180 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction P...

Page 223: ...6 15 7 110 43 10 8 12 9 11 8 14 0 12 9 15 3 Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 300 275 250 80 27 295 270 250 90 32 290 260 245 100 38 285 260 245 110 43 280 260 240 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG1 1 Suction pressure drops gradually throu...

Page 224: ...100 38 21 3 24 6 23 0 26 6 24 3 28 1 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 3 40 3 90 lb 50 10 70 21 90 32 70 21 335 285 270 80 27 285 260 240 90 32 250 225 215 100 38 215 200 190 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG1 1 Suction pres...

Page 225: ...ound Ice Machine F C Water Temperature F C1 1 Based on average ice slab weight of 3 40 3 90 lb 50 10 70 21 90 32 70 21 330 290 270 80 27 320 280 260 90 32 310 270 250 100 38 300 260 240 110 43 290 250 230 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually through...

Page 226: ... 16 6 19 3 110 43 16 3 18 9 17 7 20 5 19 3 22 4 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 3 40 3 90 lb 50 10 70 21 90 32 70 21 420 390 360 80 27 380 355 330 90 32 350 320 300 100 38 320 290 270 110 43 275 255 235 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction...

Page 227: ... Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 3 40 3 90 lb 50 10 70 21 90 32 70 21 430 390 360 80 27 420 375 350 90 32 415 360 340 100 38 410 350 330 110 43 400 340 310 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG1 1 Suction pressure drops gradually throu...

Page 228: ... 20 2 22 1 22 2 25 2 Air Temp Entering Condenser F C Water Temperature F C12 1 Based on average ice slab weight of 4 60 5 20 lb 2 230 50 1 is approximately 12 lower than 230 60 1 50 10 70 21 90 32 70 21 530 460 420 80 27 475 405 400 90 32 415 390 350 100 38 375 345 310 110 43 330 305 280 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discha...

Page 229: ...6 6 19 0 Air Temp Around Ice Machine F C Water Temperature F C1 1 Based on average ice slab weight of 4 60 5 20 lb 50 10 70 21 90 32 70 21 550 450 395 80 27 495 435 390 90 32 480 430 385 100 38 470 420 375 110 43 460 415 365 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure dro...

Page 230: ...0 43 13 3 15 4 14 5 16 7 16 0 18 5 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 4 60 5 20 lb 50 10 70 21 90 32 20 29 to 70 21 480 445 415 90 32 455 430 390 100 38 440 405 375 110 43 425 395 360 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG1 1 Suct...

Page 231: ...16 6 19 3 110 43 15 4 17 9 16 6 19 3 18 1 21 0 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 3 40 3 90 lb 50 10 70 21 90 32 70 21 475 420 370 80 27 430 380 320 90 32 400 325 290 100 38 350 300 270 110 43 290 270 250 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction ...

Page 232: ... 3 15 5 Air Temp Around Ice Machine F C Water Temperature F C1 1 Based on average ice slab weight of 3 4 3 9 lb 50 10 70 21 90 32 70 21 460 395 370 80 27 450 385 360 90 32 440 375 350 100 38 430 365 340 110 43 420 355 330 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG1 1 Suction pressure drops g...

Page 233: ...100 38 11 1 13 1 12 3 14 4 12 8 15 0 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 4 12 4 75 lb 50 10 0 70 21 1 90 32 2 70 21 650 540 505 80 27 575 520 495 90 32 530 475 460 100 38 470 430 415 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG1 1 Suctio...

Page 234: ...chine F C Water Temperature F C1 1 Based on average ice slab weight of 4 12 4 75 lb 50 10 70 21 90 32 70 21 650 565 530 80 27 575 560 520 90 32 565 560 520 100 38 560 540 505 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually throughout the freeze cycle 2 Water r...

Page 235: ... 0 12 8 15 0 Air Temp Entering Condenser F C Water Temperature F C12 1 Based on average ice slab weight of 4 12 4 75 lb 2 Ratings with JC0895 condenser dice cubes 50 10 70 21 90 32 20 29 to 70 21 630 520 495 80 27 565 520 485 90 32 560 520 485 100 38 520 480 450 110 43 480 440 415 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pre...

Page 236: ...14 6 16 7 110 43 14 9 17 0 15 8 18 0 16 5 18 8 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 5 75 6 50 lb 50 10 70 21 90 32 70 21 785 735 690 80 27 715 675 630 90 32 645 575 575 100 38 575 545 515 110 43 505 480 460 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction ...

Page 237: ... F C Water Temperature F C1 1 Based on average ice slab weight of 5 75 6 50 lb 50 10 70 21 90 32 70 21 835 755 680 80 27 810 740 665 90 32 780 640 655 100 38 755 700 645 110 43 730 680 635 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually throughout the freeze c...

Page 238: ...4 1 16 2 110 43 12 8 14 6 13 8 15 8 14 9 17 0 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 5 75 6 5 lb 50 10 70 21 90 32 20 29 to 70 21 750 665 615 80 27 720 675 650 90 32 645 610 555 100 38 615 570 530 110 43 580 540 505 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG S...

Page 239: ... 13 4 15 8 14 7 17 4 Air Temp Entering Condenser F C Water Temperature F C12 1 Based on average ice slab weight of 6 2 7 2 lb 2 230 50 1 is approximately 12 lower than 230 60 1 50 10 70 21 90 32 70 21 990 920 870 80 27 900 830 780 90 32 810 735 690 100 38 730 665 620 110 43 650 600 550 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharg...

Page 240: ... Water Temperature F C1 1 Based on average ice slab weight of 6 2 7 2 lb 50 10 70 21 90 32 70 21 1000 895 820 80 27 980 875 810 90 32 960 855 800 100 38 950 845 790 110 43 940 835 780 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually throughout the freeze cycle ...

Page 241: ...4 14 7 110 43 12 2 14 5 12 7 15 0 13 6 16 1 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 6 2 7 2 lb 50 10 70 21 90 32 70 21 960 870 800 80 27 880 800 740 90 32 800 725 680 100 38 720 670 630 110 43 640 620 580 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Press...

Page 242: ...16 8 Air Temp Entering Condenser F C Water Temperature F C12 1 Based on average ice slab weight of 7 5 8 25 lb 2 230 50 1 is approximately 12 lower than 230 60 1 50 10 70 21 90 32 70 21 1100 1035 965 80 27 1010 950 890 90 32 925 870 810 100 38 840 785 730 110 43 750 700 650 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure P...

Page 243: ... Water Temperature F C1 1 Based on average ice slab weight of 7 25 8 25 lb 50 10 70 21 90 32 70 21 1165 1050 935 80 27 1040 935 830 90 32 1030 900 825 100 38 1020 870 820 110 43 1010 860 815 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually throughout the freeze...

Page 244: ...ir Temp Entering Condenser F C Water Temperature F C12 1 Based on average ice slab weight of 10 25 11 50lb 2 230 50 1 is approximately 12 lower than 230 60 1 50 10 70 21 90 32 70 21 1500 1395 1260 80 27 1395 1295 1160 90 32 1325 1155 1090 100 38 1205 1050 980 110 43 1095 935 920 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Press...

Page 245: ...r Temperature F C1 1 Based on average ice slab weight of 10 25 11 50lb 50 10 70 21 90 32 70 21 1515 1295 1225 80 27 1505 1285 1215 90 32 1495 1275 1210 100 38 1485 1265 1205 110 43 1475 1255 1200 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually throughout the f...

Page 246: ...10 43 11 1 12 6 11 8 13 4 13 7 15 6 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 10 25 11 50lb 50 10 70 21 90 32 70 21 1430 1290 1200 80 27 1410 1270 1180 90 32 1380 1220 1140 100 38 1290 1130 1050 110 43 1175 1110 970 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suct...

Page 247: ...ir Temp Entering Condenser F C Water Temperature F C12 1 Based on average ice slab weight of 13 20 14 80lb 2 230 50 1 is approximately 12 lower than 230 60 1 50 10 70 21 90 32 70 21 1840 1710 1590 80 27 1710 1560 1460 90 32 1600 1430 1350 100 38 1470 1300 1220 110 43 1330 1160 1080 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pr...

Page 248: ...Water Temperature F C1 1 Based on average ice slab weight of 13 20 14 80lb 50 10 70 21 90 32 70 21 1850 1680 1520 80 27 1820 1660 1510 90 32 1810 1640 1500 100 38 1780 1610 1490 110 43 1790 1590 1480 Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 1 1 Suction pressure drops gradually throughout t...

Page 249: ...110 43 11 9 13 6 13 2 15 0 14 7 16 6 Air Temp Entering Condenser F C Water Temperature F C1 1 Based on average ice slab weight of 13 20 14 80lb 50 10 70 21 90 32 70 21 1775 1635 1535 80 27 1705 1565 1465 90 32 1625 1495 1385 100 38 1525 1395 1285 110 43 1415 1295 1175 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Su...

Page 250: ...250 Part Number STH025 8 12 This Page Intentionally Left Blank ...

Page 251: ...ber page 21 to reference the correct diagrams 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 Wire Number Designation The number is marked at each end of the wire Multi Pin Connection Electrical Box Side Compre...

Page 252: ...252 Part Number STH025 8 12 I0300 I0450 I0500 I0520 Self Contained Air Water cooled 1 Ph ...

Page 253: ...Part Number STH025 8 12 253 I0320 Self Contained Air Water cooled 1 Ph ...

Page 254: ...254 Part Number STH025 8 12 I0500 Remote Air cooled 1Ph ...

Page 255: ...Part Number STH025 8 12 255 I0600 I0850 I1000 I1200 Self Contained Air Water cooled 1 3 Ph ...

Page 256: ...256 Part Number STH025 8 12 I0600 I0850 I1000 Remote Condenser Air cooled 1 3 Ph ...

Page 257: ...Part Number STH025 8 12 257 I1400 I1800 Self Contained Air Water cooled 1 3 Ph ...

Page 258: ...258 Part Number STH025 8 12 I1400 I1800 Remote Air cooled 1 3 Ph ...

Page 259: ...3 T4 Display RS485 Bin LED Water Level Probe AuCS Remote CVD LuminIce Transformer Battery Bin Switches Bin Thermostat USB Ice Thickness Probe Light Water Level Probe Light Right Bin Switch Light Left Bin Switch Light Dump Valve HPC Ice Thickness Probe Water Pump Compressor L1 Not Used L2 Water Inlet Valve Right Harvest Valve Left Harvest Valve Dump Valve Relay Lights V C LPC HPC1 HPC2 CVD Contacto...

Page 260: ...NLY DRIER COMPRESSOR STRAINER CONDENSER AIR OR WATER HOT GAS SOLENOID VALVE EXPANSION VALVE EVAPORATOR HEAT EXCHANGER T1 Thermistor T4 Thermistor T3 Thermistor T2 Thermistor x x CONDENSER COMPRESSOR HEAT EXCHANGER RECEIVER DRIER EVAPORATOR HARVEST SOLENOID VALVE STRAINER HARVEST SOLENOID VALVE EXPANSION VALVE EXPANSION VALVE T2 Thermistor T3 Thermistor T4 Thermistor T1 Thermistor ...

Page 261: ...SOLENOID VALVE CONDENSER REMOTE EXPANSION VALVE EVAPORATOR HEAT EXCHANGER SOLENOID LINE LIQUID VALVE X X T2 Thermistor T4 Thermistor T1 Thermistor T3 Thermistor x x x REMOTE CONDENSER COMPRESSOR HEAT EXCHANGER RECEIVER DRIER EXPANSION VALVE EVAPORATOR HPR VALVE LLSV CHECK VALVE CHECK VALVE HARVEST SOLENOID VALVE STRAINER HARVEST SOLENOID VALVE HEAD PRESSURE CONTROL VALVE EXPANSION VALVE RECEIVER A...

Page 262: ...262 Part Number STH025 8 12 This Page Intentionally Left Blank ...

Page 263: ......

Page 264: ...Manitowoc Ice 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 USA Ph 920 682 0161 Fax 920 683 7589 Visit us online at www manitowocice com 2012 Manitowoc Part Number STH025 8 12 ...

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Manitowoc b970 series, Technician'S Handbook

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