Manitowoc Indigo Series Technician'S Handbook Download Page 233

Page: 233 / 270

Part Number STH025 02/12

233

I0500W

Self-Contained Water-Cooled Model

Characteristics vary depending on operating conditions.
CYCLE TIMES

Freeze Time + Harvest Time = Total Cycle Time

24 HOUR ICE PRODUCTION

OPERATING PRESSURES

Air Temp.

Entering

Condenser

°F/°C

Freeze Time

Harvest

Time

1 Times in minutes

Water Temperature °F/°C

50/10

70/21

90/32

70/21

10.5-12.1

13.2-15.1

15.3-17.5

1-2.5

80/27

11.9-13.6

13.7-15.7

15.5-17.7

90/32

12.3-14.1

13.9-15.9

15.7-17.9

100/38

12.6-14.4

14.3-16.3

16.2-18.5

110/43

12.9-14.8

14.5-16.5

16.6-19.0

Air Temp. Around Ice

Machine °F/°C

Water Temperature °F/°C

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 Suction pressure drops gradually throughout the freeze cycle

2 Water regulating valve set to maintain 230 psig

3 Condenser Water Usage = 165 gal/100 lb ice @ 90

/70

70/21

230-240

60-33

130-150

95-120

80/27

230-240

65-33

130-160

95-120

90/32

230-250

70-33

170-190

95-120

100/38

235-250

75-33

170-190

95-120

110/43

235-250

75-33

170-190

95-120

Summary of Contents for Indigo 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 02 12 Manitowoc ...

Page 2: ......

Page 3: ...st you as you work Throughout this handbook you will see the following types of procedural 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 pro...

Page 4: ...covered by this handbook do not proceed contact Manitowoc Foodservice We will be happy to provide assistance Important Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications ...

Page 5: ...rcial Warranty Coverage 16 Residential Ice Machine Limited Warranty 18 Installation Ice Deflector 23 Location of Ice Machine 24 Clearance Requirements 25 Air Water Remote Condenser Models 25 Ice Machine Heat of Rejection 26 Installation on a Bin 27 Ice Machine on a Dispenser Installation 27 Lineset Applications 28 Remote Condenser 29 Additional Refrigerant Charge For 51 to 100 Line Sets 30 Calcula...

Page 6: ...Cleaning Procedure 40 Sanitizing Procedure 43 Parts Removal for Cleaning Sanitizing 46 Removal from Service Winterization 52 Air Cooled Ice Machines 52 Water Cooled Ice Machines 53 Operation Control Panel Features 57 Buttons 57 Display Panel 58 Menu Navigation Overview 59 Display Panel Navigation 60 Alerts and Messages 62 Main Menu 63 Machine Info Menu 64 Password Entry 65 Reset Password To Factor...

Page 7: ... USB Setup 75 Factory Defaults 75 Energy Saver Menu 76 Ice Program 77 Water Miser 78 Statistics 78 Service Menu 79 Data History 81 Real Time Data 82 Diagnostics 84 Manual Harvest 85 Replace Control Board 85 USB Setup 85 Event Log Menu 86 Event Log 87 USB Flash Drive Specifications and Format ting 91 Upgrading Firmware with a Flash Drive or Transferring Setup Data To Multiple Ma chines 93 Exporting...

Page 8: ...fety Limit 1 111 Safety Limit 2 112 Troubleshooting By Symptom 115 Symptom 1 Ice Machine will not run 117 Symptom 2 Self contained Air Water Remote Condenser Models 123 Symptom 2 Freeze Cycle Refrigeration System Operational Analysis Tables 125 Symptom 3 Harvest Problems Self contained Air Water Remote Con denser Models 148 Symptom 3 Self Contained Air or Water cooled 149 Symptom 3 Remote Condense...

Page 9: ... Control Board 168 Main Fuse 170 Bin Switch 171 Water Level Control Circuitry 174 Ice Thickness Probe Harvest Initiation 178 High Pressure Cutout HPCO Control 182 Fan Cycle Control 185 Thermistors 186 Harvest Assist Air Pump 190 Compressor Electrical Diagnostics 191 Diagnosing Start Components 193 Refrigeration Components 198 Head Pressure Control Valve 198 Harvest Pressure Regulating HPR System R...

Page 10: ...ssure Charts 225 I0300 Series 226 I0320 Series 228 I0450 Series 230 I0500 Series 232 I0520 Series 235 I0600 Series 237 I0850 Series 240 I1000 Series 243 I1200 Series 246 I1400 Series 248 I1800 Series 251 Diagrams Wiring Diagrams 255 Wiring Diagram Legend 255 I0300 I0450 I0500 I0520 256 I0320 257 I0500 258 I0600 I0850 I1000 I1200 259 I0600 I0850 I1000 260 I1400 I1800 261 I1400 I1800 262 Electronic ...

Page 11: ... Condensing 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 ...

Page 12: ...is appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have been given supervision concerning use of the appliance by a person responsible for their safety Warning All Manitowoc ice machines require the ice storage system bin dispenser etc to incorporate an ice deflector Prior to using ...

Page 13: ...hen requesting information from your local Manitowoc Distributor service representative or Manitowoc Ice The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD They are also listed on the MODEL SERIAL NUMBER DECAL affixed to the front and rear of the ice machine ...

Page 14: ... IY0305W ID0322A IY0324A ID0323W IY0325W IR0520A ID0522A IY0524A IR0421W ID0423W IY0425W ID0452A IY0454A ID0453W IY0455W IR0500A ID0502A IY0504A IR0501W ID0503W IY0505W IR0590N ID0592N IY0594N ID0602A IY0604A ID0603W IY0605W ID0692N IY0694N IR0850A ID0852A IY0854A IR0851W ID0853W IY0855W IR0890N ID0892N IY0894N ID1002A IY1004A ID1003W IY1005W ID1092N IY1094N ID1202A IY1204A ID1203W IY1205W ID1402A...

Page 15: ...ed 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 16: ... 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 17: ...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 18: ...be 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 trans...

Page 19: ...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 20: ...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 21: ...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 23: ...bin 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 52 ...

Page 24: ... 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 ...

Page 25: ... 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 26: ...itioning 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 27: ...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 28: ...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 29: ... 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 30: ...r 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 1 lb 454g ...

Page 31: ...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 32: ...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 ...

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Page 35: ...ent Identification I Model Single Evaporator Models O f f O n O f f M o d e WATER DISTRIBUTION TUBE WATER TROUGH ICE THICKNESS CONTROL REFRIGERATION ACCESS VALVES EVAPORATOR DISPLAY WATER PUMP WATER LEVEL PROBE CONTROL BOX WATER CURTAIN ...

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Page 37: ...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 38: ...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 39: ...he bi yearly cleaning sanitizing procedure 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 rinsed in a mild dish soap and water solution Wipe dry with a clean soft clot...

Page 40: ...Machine 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 t...

Page 41: ...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 42: ...th step 6 when the parts have been removed Single Evaporator Ice Machines page 46 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 b...

Page 43: ...rfaces 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 sol...

Page 44: ...to 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 45: ...water 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 46: ...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 47: ...ss 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 distributio...

Page 48: ...es 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 sur...

Page 49: ... 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 Dis...

Page 50: ...do 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 p...

Page 51: ...g 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 52: ...ve 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 53: ...ned 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 57: ...splay 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 58: ...underline 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 DISPLAY PANEL The LCD display panel is 16 characters wide and four lines deep During ice machine operation and ...

Page 59: ...e Info Set Up Fact Deflts Energy Saver Service Time Date Time Config Edit Password Units Ice Clarity LCD Bright Password On Off Clean Minder AuCS Run Time Air Filter Water Filter LuminIce Ice Program Water Miser Statistics Optional Password Entry 90 70 cap Model IMH Serial Cond Serial Warranty Machine Evaporator Compressor Install Date Manuf Date Main SW Ver Disply SW Ver Language USB Setup Ice Bi...

Page 60: ...kets 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 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 1...

Page 61: ...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 will ...

Page 62: ... 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 Checkmar...

Page 63: ... From the 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 Machine Info Set Up Energy Saver Factory Defaults Service Exit ...

Page 64: ...r serial number warranty installation date date of manufacture and software version Use the Down arrow to highlight an item and use the Checkmark to view the information 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 ...

Page 65: ...e 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 an icon will flash 5 Use the Up Down arrows to enter the factory password 1 2 3 4 Enter the number 1 in the flashing icon first digit of the factory password 6 Press the right arrow to move to the next cel...

Page 66: ...t Password and press the Right arrow 4 Using the Up Down arrows enter the first digit of the factory password in the flashing icon 5 Press the right arrow to move to the next cell and use the Up Down arrows to add the number 2 Repeat this process to add 3 4 6 When 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 ente...

Page 67: ... button two times to reset the ice machine The display will return to the Set Up menu and the defaults listed below will be in effect Refer to Setup to adjust settings Setting Default Language English Time Date Month Day Year Time Time Configuration Mo Day Yr 24 Hour Units Fahrenheit Lbs Gallons Ice Clarity Off LCD Brightness Level 2 Password On Off Enter Password Default Password 1234 Edit Passwo...

Page 68: ...highlighting your choice and pressing the Checkmark Selecting one language will deselect the others 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 P...

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: ...oose 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 arrow ...

Page 72: ...m current password 3 Enter new password and press the Checkmark 4 Press the Left arrow to return to previous screens and to the Set Up menu 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 to turn the reminder ON or OFF by highlighti...

Page 73: ...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 74: ...screen by highlighting Set Interval and pressing the Checkmark 6 Press the Left arrow to return to previous screens and to the Set Up menu LUMINICE REMINDER The LuminIce growth inhibitor recirculates the air in the ice machine foodzone over a UV bulb This process will inhibit the growth of common micro organisms on all exposed foodzone surfaces The Bulb Minder is a feature that displays a reminder...

Page 75: ...e Set Up menu use the Down arrow to highlight Fact Deflts 2 Press the Checkmark two times to reset the ice machine The display will return to the Set Up menu For more details and instructions for changing ice machine settings see Set Up Menu Setting Default Language English Time Date Month Day Year Time Time Configuration Mo Day Yr 24 Hour Units Fahrenheit Lbs Gallons Ice Clarity Off LCD Brightnes...

Page 76: ...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 77: ...he other If one of them is selected and you wish to turn both off highlight the choice and press Checkmark again 3 If neither of the programs is selected highlighting Settings and pressing the Checkmark will simply return to the top of this screen If one of the programs is selected highlight Settings and press the Checkmark to choose the times or bin levels NOTE For details on how to use the curso...

Page 78: ... highlighting your choice and pressing the Checkmark Selecting one will deselect the other NOTE Settings will not be saved if the Checkmark is not pressed after choosing On or Off 3 Press the Left arrow to return to previous screens and 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 production pot...

Page 79: ...nu The following pages list the navigation options available by drilling into the menus with the down 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 80: ...Repl 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 Firm Download Conf Export ALL Export Setup Clear View USB Stick ...

Page 81: ... 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 Wat...

Page 82: ... 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 83: ... 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 LuminIce Off On Exit ...

Page 84: ...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 85: ...l board refer to exporting data to a flash drive page xx or entered manually through the Indigo interface Manual Setup Board Install Date Input Model Number Ice Machine 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 driv...

Page 86: ...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 87: ...tch Fault Open more than 12 hours E13 Spare E14 Spare E15 Fan Cycle Control Fault Lo Liquid Line Temperature E16 Remote Condenser Fault 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 E24 T4 Temperature Sensor Issue E25 Bin Level Probe Low Sensor Fault E26 Bin Level Probe Medium...

Page 88: ...nt Log only No Alarm When power is interrupted to the ice machine the control board will log the event in the ELOG and stamp the loss of power on power up E04 Hi Cnd Temp or Wtr Cnd Fault Air Condenser High temp or water Condenser High temperature 1 Liquid Line Temperature too High for Self contained Air Cooled Ice machine Air Cooled Condenser Fault 2 Liquid Line Temperature too High for Self cont...

Page 89: ... at least 10 F Measured from Refrigeration Start up to Two Minutes into the Freeze cycle E12 Curtain Fault Curtain Switch open for more than 12 hours Curtain Fault The ice machine is set to ice making and remains in bin full condition for more than 12 hours The curtain switch is open or curtain is off E13 Spare E Log Display Text Error Description Definition Detail Event Log Service Definition ...

Page 90: ...ature range E22 T2 Fault T2 Sensor E23 T3 Fault T3 Sensor E24 T4 Fault T4 Sensor E25 Bin Prb Fault Bin Low Sens Each thermistor reading is monitored continuously using six second average values A thermistor had a six second average value outside of the valid range for more than 10 continous minutes E26 Bin Prb Fault Bin Med Sens E Log Display Text Error Description Definition Detail Event Log Serv...

Page 91: ...ws 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 les...

Page 92: ...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 93: ...ress the Checkmark The Service menu will be displayed 6 Press the 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...

Page 94: ...he display 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 Bin LED Water Level Probe LuminIce Transformer Battery Bin Switches Bin Thermostat USB Ic...

Page 95: ... will be displayed 5 Press the Down arrow until USB Setup is highlighted 6 Press the Checkmark USB Stick will appear highlighted 7 Press the Checkmark again A submenu with Export ALL and Export Setup appears 8 Highlight Export ALL or Export Setup depending on your requirements and press the Checkmark A display of instructions will appear 9 Follow these on screen instructions to A Insert Drive Inse...

Page 96: ...iates and monitors the safe mode The control will automatically exit the safe mode if a normal signal is received from the input After 72 hours the control board will enter a standby mode and turn off NOTE The control board needs a five cycle history to operate safe mode If five cycles have never been successfully completed the ice machine will shut off Example The ice machine is a new installatio...

Page 97: ... 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 72 hours before full ice production will be reached ...

Page 98: ...t 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 ice thic...

Page 99: ...lenoid 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 ...

Page 100: ...te freeze lock expires and enough ice has formed to send a signal from the ice thickness probe to the control board Harvest Sequence 5 Water Purge The air pump s when used and the harvest valve s open at the beginning of the water purge to divert hot refrigerant gas into the evaporator The water pump s continues to run and the water dump valve energizes to purge the water in the water trough 6 Har...

Page 101: ...e dampers As the water curtain ice dampers swing back to the closed position the bin switch re closes and the ice machine restarts steps 1 2 provided the 3 minute delay period is complete Control Board Timers The control board has the following non adjustable timers The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated This can be overridden by initi...

Page 102: ...ce 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 Start Up 1 Water Purge On Off Off Off On Off Off Off 45 Seconds 2 Refrigeration Off On On Off Off Off Off Off 5 Seconds ...

Page 103: ...n Off Factory Set at 45 Seconds Single Evaporator Self Contained Air Water Cooled Models Energized Parts Chart 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 104: ...ssure After 5 seconds the liquid line solenoid valve energizes and the contactor energizes the compressor and condenser fan motor Freeze Sequence 3 Prechill The compressor is on for 30 seconds 60 seconds initial cycle prior to water flow to prechill the evaporator The water fill valve is also energized and will remain on until water completes the water level probe circuit 4 Freeze The water pump s...

Page 105: ...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 for...

Page 106: ...rvest Valve Left HPR Valve Harvest Valve Right When Used Air Pump When Used Water Inlet Valve Water Dump Valve Contactor Coil LiquidLine Solenoid Compressor Condenser Fan Motor Length of Time Initial Start Up 1 Water Purge On Off Off Off Off On Off Off Off 45 Seconds 2 Refrigeration Off On On On Off Off Off Off Off 5 Seconds ...

Page 107: ...Evaporator Remote Air Cooled Condenser Models Energized Parts Chart Continued Ice Making Sequence of Operation Water Pump Harvest Valve Left HPR Valve Harvest Valve Right When Used Air Pump When Used Water Inlet Valve Water Dump Valve Contactor Coil LiquidLine Solenoid Compressor Condenser Fan Motor Length of Time ...

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Page 109: ...umber of cycles required to stop the ice machine varies for each safety limit Safety Limit 1 all models If the freeze time reaches 60 minutes the control board automatically initiates a harvest cycle If 6 consecutive 60 minute freeze cycles occur the ice machine stops Safety Limit 2 single evaporator models If the harvest time reaches 3 5 minutes the control board automatically returns the ice mac...

Page 110: ...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 111: ...ectrical 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 Defective compressor TXV starving or flooding ...

Page 112: ... securely mounted to the evaporator Low water pressure 20 psig min Loss of water from sump area Clogged water distribution tube Dirty defective water fill valve Defective water pump Electrical System Ice thickness probe out of adjustment Ice thickness probe dirty Bin switch closed defective Premature harvest Refrigeration System Non Manitowoc components Improper refrigerant charge Defective head p...

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Page 114: ...114 Part Number STH025 02 12 This Page Intentionally Left Blank ...

Page 115: ...e 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 Top or Bottom 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 116: ...he ice machine to factory defaults use the following procedure 1 Ensure that the ice machine s power is on 2 Press the Menu button 3 From the Main menu use the Down button to highlight Fact Deflts 4 Press either the Checkmark or right arrow two times to reset the ice machine The display will return to the Set Up menu and the defaults listed below will be in affect Refer to Setup to adjust settings...

Page 117: ...r STH025 02 SYMPTOM 1 ICE MACHINE WILL NOT RUN Start Are there any lights on or flashing on the control board Line voltage at wires 55 56 on 9 pin control board connector Supply power to the ice machine No No Yes ...

Page 118: ...118 Yes Display light flashing heartbeat Install the water curtain damper All water curtains or dampers in place Yes No Refer to display control board diagnostics No No ...

Page 119: ...Part Number STH025 02 Press power button to start ice making does safety limit light flash Ice machine starts No No Yes Refer to display control board diagnostics ...

Page 120: ...zed the fuse is okay 4 Verify all bin switches function properly A defective bin switch can falsely indicate a full bin of ice 5 Perform control board display board and touch screen diagnostics Be sure steps 1 6 were followed thoroughly Intermittent problems are not usually related to the control board Warning High line voltage is applied to the control board terminals 55 and 56 at all times Remov...

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Page 122: ...122 Part Number STH025 02 12 This Page Intentionally Left Blank ...

Page 123: ...be used with charts checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear defective The tables list five different defects that may affect the ice machine s operation NOTE A low on charge ice machine and a starving expansion valve have very similar characteristics and ar...

Page 124: ...s 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 co...

Page 125: ...rational Analysis 1 2 3 4 Ice Production Air Temperature Entering Condenser_____________ Water Temperature Entering Ice Machine_________ Published 24 hour ice production________________ Calculated actual ice production_______________ NOTE The ice machine is operating properly if the ice fill patterns is normal and ice production is within 10 of charted capacity ...

Page 126: ...mponents 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 Wait 5 minutes into the freeze cycle Compare temperatures of evaporator inlet and Inlet and outlet not within 7 F 4 C Inlet and outlet within 7 F 4 C of each other or SINGLE EXPANSION VALVE SELF CONTAINED AIR WATER REMOTE CONDENSER Operati...

Page 127: ... line The harvest valve inlet is Cool enough to hold hand on and the compressor discharge line is Hot The harvest valve inlet is Cool enough to hold hand on and the compressor discharge line is Cool enough to hold hand on The harvest valve inlet is Cool enough to hold hand on and the compressor discharge line is Hot Discharge Line SINGLE EXPANSION VALVE SELF CONTAINED AIR WATER REMOTE CONDENSER Op...

Page 128: ...determining factor in the final diagnosis Ask these questions before beginning service When does the ice machine malfunction night day all the time only during the Freeze cycle etc When do you notice low ice production one day a week every day on weekends etc Can you describe exactly what the ice machine seems to be doing Has anyone been working on the ice machine During store shutdown is the circ...

Page 129: ...entering sump trough ____ 2 Refer to the appropriate 24 Hour Ice Production Chart starting on page 225 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 130: ...ion 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 ...

Page 131: ... 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 ...

Page 132: ...5 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 133: ...r 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 thickne...

Page 134: ... the outlet of 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 The evaporator outle...

Page 135: ...e 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 136: ...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 137: ...age 131 Air Cooled Condensers Defective head pressure control valve won t bypass page 198 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 138: ... published freeze cycle time NOTE Analyze discharge pressure before analyzing suction pressure High or low discharge pressure may be causing high or low suction pressure Procedure Step 1 Determine the ice machine operating conditions Temperature of air entering the condenser Look up and determine the published suction pressure 2 Perform an actual suction pressure check at the beginning middle and ...

Page 139: ...Freeze Cycle Discharge Pressure High Checklist page 136 Improper Refrigerant Charge Overcharged also see Freeze Cycle Discharge Pressure High Checklist page 136 Wrong type of refrigerant Non condensable in system Components Harvest valve leaking continue the table Harvest pressure solenoid valve leaking continue the table TXV flooding continue the table Defective compressor continue the table Othe...

Page 140: ...ecting low side refer to Freeze Cycle Discharge Pressure Low Checklist page 137 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 132 Restricted plugged liquid line drier Restricted plugged tubing in suction side of refrigeration system TXV starving continue the tabl...

Page 141: ...he 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 142: ...ONTAINED 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 comparis...

Page 143: ...t valve is hot and approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest va...

Page 144: ...ompressor 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 Navigate to Service Real Time Data Time Temp T2 Thermistor See page 79 Service Menu Navig...

Page 145: ...to cycle times 24 hour productions charts clean or replace valve Discharge pressure extremely high Liquid line entering receiver feels hot Water regulating valve incorrectly set or not opening Verify Head Pressure Control Valve operation before changing water regulating valve Discharge pressure low Liquid line entering receiver feels warm to hot Ice machine low on charge Verify Total System Refrig...

Page 146: ... 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 press...

Page 147: ...g 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 COLUMN 5 HARVEST PRESSURE VALVE LEAKING 4 EVAPORATOR MODELS ONLY Replace the valve as required ...

Page 148: ... This indicates something is on the evaporator preventing the ice slab from releasing Follow the appropriate flow chart in Troubleshooting to determine the cause of the problem A manual cleaning procedure must always be performed when this problem is encountered Normal sheet of cubes at the end of the harvest cycle Ice is difficult to remove from the evaporator by hand Once removed the back of the...

Page 149: ...arvest Freeze Cycle is Normal and Ice Cubes are Not Melted After Harvest Low production 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 START ...

Page 150: ...cooled Condenser Fan cycling control operates correctly in freeze cycle Fan cycling control opens below setpoint in harvest cycle Replace Fan Cycling Control Are you sure Discharge line temperature is normal Repeat this flowchart verify all data ...

Page 151: ...Remote Ice Machine Long Harvest Low Production Intermittent Safety Limit 2 Fails at night or in low ambient Operates normally above 70F 21C YES YES NO Normal ice fill long harvest cycle possible SL 2 back of cubes are not melted at the end of harvest cycle START ...

Page 152: ...r to Sequence of Operation Wiring Diagrams YES YES NO NO YES YES Is harvest valve energized Is head pressure high suction pressure low in harvest Replace Harvest Valve Is head pressure low suction pressure low ...

Page 153: ...LF CONTAINED AIR WATER COOLED OR REMOTE Level Ice Machine Is Ice Machine level Are back of the cubes melted at end of harvest cycle YES NO Ice Machine Will Not Harvest Freeze Cycle is Normal and Ice Cubes are Melted After Harvest START ...

Page 154: ...154 Is the evaporator dirty Dry evaporator first then check YES NO NO ...

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Page 156: ...156 Part Number STH025 02 12 This Page Intentionally Left Blank ...

Page 157: ...like a heartbeat The two green lights are located on the top right corner of the control board Display Diagnostics 1 Micro light flashes and display light is off 2 Disconnect and reconnect both ends of the communication cable running between the control board and the back of the display module 3 Press the power button on the display and watch the green Display light on the control board A Display ...

Page 158: ...llowing keystrokes on the display Press Menu scroll down 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 fi...

Page 159: ...st 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 Press the right arrow 5 times rapidly to exit...

Page 160: ...ss 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 no...

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Page 162: ...ws 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 les...

Page 163: ...on 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 F...

Page 164: ...ltiple machines 3 Ensure that the ice machine s power is on 4 Press the Menu button 5 Press the Down arrow until Service is highlighted 6 Press the Checkmark The Service menu will be displayed 7 Press the Down arrow until USB Setup is highlighted 8 Press the Checkmark USB Stick will appear highlighted 9 Press the Checkmark 10 Select Download Cnf and press the Checkmark A display of instructions wi...

Page 165: ...or LT Harvest Pump Water Dump Display Light Micro Light Clean Light Harvest Light SL 1 Light SL 2 Light Fuse Thermistors T1 T2 T3 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 Compresso...

Page 166: ...is highlighted 4 Press the Checkmark The Service menu will be displayed 5 Press the Down arrow until USB Setup is highlighted 6 Press the Checkmark USB Stick will appear highlighted 7 Press the Checkmark again A submenu with Export ALL and Export Setup appears NOTE There are four files stored in ice machine memory Asset Data ASDATAoo CSV Operating Data OPDATAoo CSV Real Time Data RTDATAoo CSV Ice ...

Page 167: ... D Export Complete will appear on the display RT Harvest Compressor LT Harvest Pump Water Dump Display Light Micro Light Clean Light Harvest Light SL 1 Light SL 2 Light Fuse Thermistors T1 T2 T3 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 Swi...

Page 168: ...erent ways USB Setup or Manual Setup USB Setup Applicable when the control board is operational and has a mechanical issue such as a sticking relay The asset data is transferred to the replacement control board from the faulty control board Refer to page 166 Exporting Data To A Flash Drive before installing the replacement board Follow the instructions on page 164 Upgrading Firmware with a Flash D...

Page 169: ...ghted then press the Checkmark 3 Scroll down to Replacement Control Board and press the Checkmark 4 Select Manual Setup and press the Checkmark Verify the date correctly auto populates Yes Go to step 5 No Highlight date with the right arrow then use up down arrows to enter the correct date Use the right arrow to exit the date columns 5 Scroll down to Input Model then use up down arrows to enter th...

Page 170: ...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 before procee...

Page 171: ...machine shuts off The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain 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 T...

Page 172: ...erify bin switch damper and damper magnet are in place Press the Menu button Scroll down to Service and press right arrow Scroll down to Diagnostics and press right arrow Scroll down to Inputs and press right arrow to display curtain switch readings Curt SW1 Curt SW2 etc 2 Open and close the ice damper s repeatedly while observing the display and control board lights A Curtain switch cycles open c...

Page 173: ...tch wire to ground press the power button and observe the display and control board lights A Curtain switch closes control board light energizes and ice machine starts Replace bin switch B Curtain switch remains open and control board light is off Verify procedure was correctly followed Replace control board ...

Page 174: ...es to the short probe SPECIFICATIONS 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 replace the probe as necessary Water Inlet Valve Safety Shut Off In the event of a water level p...

Page 175: ...ater inlet valve will cycle ON and then OFF one more time to refill the water trough The water inlet valve is now OFF for the duration of the freeze cycle Diagnostics SYMPTOMS Water trough overfills Water trough will not fill Display indicates a Long Freeze alert and may or may not also indicate a safety limit 1 Ice production is low WATER TROUGH OVERFILLING DURING THE FREEZE CYCLE Step 1 Press th...

Page 176: ...light energizes and water flow stops Repair wire or replace water level probe B Water level light does not energize and water continues to flow Replace control board Step 6 Water level probe wires 2 3 jumpered at the control board connector Is Water Flowing into the Water Trough The Water Level Light Is The Water Inlet Valve Solenoid Coil Is Cause No On De energized The interconnecting wire or wat...

Page 177: ...Wtr High are displayed A Yes is displayed Control board is receiving a sensing water signal Proceed to step 3 B No is displayed Control board is not receiving a sensing water signal Proceed to Control Board Diagnostics page 158 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 Refer to Contr...

Page 178: ...tem incorporates a freeze time lock in feature This prevents the ice machine from short cycling in and out of harvest The control board locks the ice machine in the freeze cycle and a harvest cycle can not start for six minutes 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 T...

Page 179: ... 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 thickness probe wire and the bracket do not restrict movem...

Page 180: ... MACHINE CYCLES INTO HARVEST BEFORE ICE CONTACTS THE ICE THICKNESS PROBE 1 Reboot the control board by disconnecting and reconnecting line voltage to the ice machine 2 Verify ice thickness probe gap is approximately 9 32 7 mm 3 Wait six minutes Ice Machine remains in freeze cycle Allow ice machine to run Ice machine cycles into harvest Replace ice thickness probe to determine if problem is resolve...

Page 181: ...reeze cycle will start after the manual harvest cycle is complete 1 Reboot the control board by disconnecting and reconnecting line voltage to the ice machine 2 Verify ice thickness probe gap is approximately 9 32 7 mm 3 Wait for ice to contact the ice thickness probe Ice Machine cycles into harvest normally Allow ice machine to run Ice machine will not cycle into harvest Replace ice thickness pro...

Page 182: ... 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 The ice machine will lockout after 10 failed attempts 1 Machine is off and the display indicates Delay XX min HPCO Active 2 Machine is running and the d...

Page 183: ...cut in find root cause problem 3 Depending on timing either wait for the delay period to end or start a new freeze cycle The ice machine will go to an initial start sequence When the compressor relay closes the control board checks the HPCO 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...

Page 184: ...ne 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 440 psig replace the HPCO 4 If the control opens at the correct pressure 10 lbs f...

Page 185: ... fan spins freely 2 Connect manifold gauges to ice machine 3 Hook voltmeter in parallel across the fan cycle control leaving wires attached 4 Refer to chart below Specifications Model Cut In Close Cut Out Open I0300 I0320 I0520 I0450 I0500 I0600 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 15...

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: ...perature sensor located at the inlet of the receiver T2 Air or Water cooled Models Discharge line temperature sensor located near the compressor T2 Remote Condenser or Remote Condensing Unit Models Liquid line temperature sensor located at the outlet of the receiver T3 Single Expansion Valve Models Suction line temperature sensor located at the inlet of the evaporator T4 Single Expansion Valve Mod...

Page 188: ... Defrost W 1 T3 T4 T2 T1 Self Contained d Water Cooled d Hot Gas Defrost A W 48 48 T4 T3 T2 T1 Self Contained d Air Coo ooled Water Cooled d Hot Gas Defrost N 1 T3 T4 T2 Spl plit System Remote Condenser Hot Gas Defrost N 48 48 T4 T3 T2 T1 Spl plit System Remote Condenser Hot Gas Defrost C 1 T3 T4 T1 T2 Spl plit System Remote Condensing Un Unit Coo ool Vapor Defrost C 2 5 T4 T3 T1 T2 Spl plit Syste...

Page 189: ... 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 th...

Page 190: ...es 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 191: ...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 192: ...aw while the compressor is trying to start The two likely causes of this are a defective starting component and 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 slo...

Page 193: ...apacitor Use a capacitor tester when checking a suspect capacitor Clip the bleed resistor off the capacitor terminals before testing If the compressor attempts to start or hums and trips the overload protector check the starting components before replacing the compressor Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane Do not assume a capacitor is good ...

Page 194: ... generated by the start winding and opens the contacts as the compressor motor starts The contacts remain open until the compressor is de energized RELAY OPERATION CHECK 1 Disconnect wires from relay terminals 2 Verify the contacts are closed Measure the resistance between terminals 1 and 2 No continuity indicates open contacts Replace the relay 3 Check the relay coil Measure the resistance betwee...

Page 195: ...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 196: ... change a PTCR just because it is hot 2 Wait at least 10 minutes for the PTCR to cool to room temperature 3 Remove the PTCR from the ice machine 4 Measure the resistance of the PTCR as shown The resistance reading must be between Two Terminal PTCR 18 to 40 ohms Three Terminal PTCR 8 to 22 ohms Three Terminal PTCR Measure Resistance At Ends Two Terminal PTCR Leave Jumper Wire Attached Measure Resis...

Page 197: ...Part Number STH025 02 12 197 This Page Intentionally Left Blank ...

Page 198: ...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 199: ...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 200: ... 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 201: ...t 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 Harvest cycle suction pressure is low Harvest cycle discharge pressure is normal Freeze cycle time suction and discharge pressure are normal and the ice machine will not harvest The sheet of ice cubes ...

Page 202: ...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 203: ...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 4 can be quickly ...

Page 204: ...ure and freeze harvest cycle times Refer to Freeze Cycle Refrigeration System Operational Analysis Tables for data collection detail page 123 5 Discharge line temperature is greater than 150 F 66 C I0850 I1000 Air Water Only 140 F 60 C at the end of the freeze cycle See Discharge Line Temperature Analysis on page 144 6 Freeze cycle Head Pressure is in the range indicated in the cycle time 24 hour ...

Page 205: ...e 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 206: ...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 207: ...very 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 HIG...

Page 208: ...achine 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 209: ...the 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 v...

Page 210: ...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 211: ... 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 212: ...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 213: ...Part Number STH025 02 12 213 ACCESS REMOTE RECOVERY EVACUATION CONNECTIONS ...

Page 214: ...fold gauge set and start the ice machine Add the remaining charge 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 Open the high and low side valves on the manifold gauge set Any refrigerant in the lines will be p...

Page 215: ... 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 216: ...iagnostic 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 Inspe...

Page 217: ...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 218: ...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 219: ...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 220: ... 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 221: ... 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 222: ...222 ...

Page 223: ... the inlet and outlet ends This is very important because ice machines have a back flushing action that takes place during every Harvest cycle A Manitowoc filter drier has 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 I...

Page 224: ... Refer to the ice machine serial number tag to verify the system charge Serial plate information overrides information listed 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 ...

Page 225: ...Refer to Symptom 2 Operational Analysis Table page 123 for the list of data that must be collected for refrigeration diagnostics This list includes before beginning service ice production check installation visual inspection water system checklist ice formation pattern safety limits comparing evaporator inlet outlet temperatures discharge and suction pressure analysis Zero out manifold gauge set b...

Page 226: ...16 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 ...

Page 227: ...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 228: ... 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 pre...

Page 229: ...round 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 throug...

Page 230: ... 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 231: ...p 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 thro...

Page 232: ... 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 233: ...16 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 dr...

Page 234: ...10 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 Suc...

Page 235: ...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 236: ... 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 237: ... 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 Sucti...

Page 238: ...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 239: ...4 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 Pr...

Page 240: ... 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 241: ... 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 242: ...14 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 ...

Page 243: ...5 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 Dischar...

Page 244: ...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 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 245: ...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 246: ...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 247: ...C 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 freez...

Page 248: ...Air 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 Pres...

Page 249: ...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 250: ...110 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 Suc...

Page 251: ...Air 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 P...

Page 252: ... 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 ...

Page 253: ... 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 S...

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Page 255: ...ber page 15 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 256: ...256 Part Number STH025 02 12 I0300 I0450 I0500 I0520 Self Contained Air Water cooled 1 Ph ...

Page 257: ...Part Number STH025 02 12 257 I0320 Self Contained Air Water cooled 1 Ph ...

Page 258: ...258 Part Number STH025 02 12 I0500 Remote Air cooled 1Ph ...

Page 259: ...Part Number STH025 02 12 259 I0600 I0850 I1000 I1200 Self Contained Air Water cooled 1 3 Ph ...

Page 260: ...260 Part Number STH025 02 12 I0600 I0850 I1000 Remote Condenser Air cooled 1 3 Ph ...

Page 261: ...Part Number STH025 02 12 261 I1400 I1800 Self Contained Air Water cooled 1 3 Ph ...

Page 262: ...262 Part Number STH025 02 12 I1400 I1800 Remote Air cooled 1 3 Ph ...

Page 263: ...T3 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 Contact...

Page 264: ...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 265: ... 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 ...

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Page 267: ...Part Number STH025 02 12 267 This Page Intentionally Left Blank ...

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Page 269: ......

Page 270: ...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 2011 Manitowoc Part Number STH025 02 12 ...

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Manitowoc Indigo Series, Technician'S Handbook

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