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Table of Contents

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Section 6 - Electrical System

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Component Specifications and Diagnostics

Fuses.............................................................................................................................................................6-36
Bin Switch ....................................................................................................................................................6-36
Compressor Electrical Diagnostics .............................................................................................................. 6-38
PTCR Diagnostics ........................................................................................................................................6-39
Discharge Line Thermistor...........................................................................................................................6-43
Ice/Off/Clean Toggle Switch........................................................................................................................6-44
Control Board Relays ...................................................................................................................................6-45
Electronic Control Board (Old Style)........................................................................................................... 6-46
Electronic Control Board (New Style) ......................................................................................................... 6-47

Ice Thickness Probe

(Harvest Initiation)

General .........................................................................................................................................................6-50
How the Probe Works ..................................................................................................................................6-50
Freeze Time Lock-In Feature .......................................................................................................................6-50
Maximum Freeze Time ................................................................................................................................6-50
Installation of New Probe on Old Style Control Board................................................................................ 6-50
Diagnosing Probe Control Circuitry

Ice Machine Cycles Into Harvest Before Water Contact with Probe .....................................................6-51
Ice Machine Does Not Cycle Into Harvest When Water Contacts Probe ..............................................6-52

Diagnosing Ice Machine That Will Not Run.................................................................................................. 6-53

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Summary of Contents for J-1300

Page 1: ...J Model Service Manual 1997 Manitowoc Ice Inc Part No 83 5631 9 Rev A 8 97 Ice Machines ...

Page 2: ...ment before proceeding and work carefully Procedural Notices As you work on a J Series Ice Machine be sure to read the procedural notices in this manual These notices supply helpful information which may assist you as you work Throughout this manual you will see the following types of procedural notices Important Text in an Important box provides you with information that may help you perform a pr...

Page 3: ...ned Electrical Connections 2 8 Remote Electrical Connections 2 9 Water Connections and Drains 2 10 Cooling Tower Applications Water Cooled Models 2 11 Remote Condenser Line Set Installation Remote Ice Machines Refrigerant Charge 2 12 Routing Line Sets 2 13 Calculating Remote Condenser Installation Distances 2 14 Usage with Non Manitowoc Multi Circuit Condensers Warranty 2 16 Line Set Routing and S...

Page 4: ... Self Cleaning or Sanitizing Cycle After It Has Started 3 6 AuCSä Accessory 3 7 Removal of Parts for Cleaning Sanitizing 3 8 Water Treatment Filtration 3 14 Removal from Service Winterization General 3 15 Self Contained Air Cooled Ice Machines 3 15 Water Cooled Ice Machines 3 15 Remote Ice Machines 3 15 AuCSä Accessory 3 15 Section 4 Ice Machine Sequence of Operation Self Contained Air and Water C...

Page 5: ...ase 6 21 Old Style Self Contained J1300 J1800 3 Phase 6 22 Old Style Remote J450 J600 J800 J1000 1 Phase 6 23 Old Style Remote J800 J1000 3 Phase 6 24 Old Style Remote J1300 J1800 1 Phase 6 25 Old Style Remote J1300 J1800 3 Phase 6 26 New Style Self Contained J200 J250 J320 1 Phase 6 27 New Style Self Contained J420 J450 J600 J800 J1000 1 Phase 6 28 New Style Self Contained J800 J1000 3 Phase 6 29...

Page 6: ...nic Control Board Old Style 6 46 Electronic Control Board New Style 6 47 Ice Thickness Probe Harvest Initiation General 6 50 How the Probe Works 6 50 Freeze Time Lock In Feature 6 50 Maximum Freeze Time 6 50 Installation of New Probe on Old Style Control Board 6 50 Diagnosing Probe Control Circuitry Ice Machine Cycles Into Harvest Before Water Contact with Probe 6 51 Ice Machine Does Not Cycle Int...

Page 7: ...ansion Valve Ice Machines Comparing Evaporator Inlet and Outlet Temperatures 7 18 Analyzing Discharge Pressure During Freeze or Harvest Cycle Procedure 7 19 Freeze Cycle Discharge Pressure High Checklist 7 19 Freeze Cycle Discharge Pressure Low Checklist 7 19 Analyzing Suction Pressure During Freeze Cycle Procedure 7 20 Freeze Cycle Suction Pressure High Checklist 7 21 Freeze Cycle Suction Pressur...

Page 8: ... 33 J420 J450 7 34 J600 7 35 J800 7 37 J1000 7 38 J1300 7 40 J1800 7 41 Refrigerant Recovery Evacuating and Recharging Normal Self Contained Model Procedures 7 44 Normal Remote Model Procedures 7 46 System Contamination Cleanup 7 50 Replacing Pressure Controls Without Removing Refrigerant Charge 7 52 Filter Driers 7 54 Total System Refrigerant Charges 7 54 Refrigerant Definitions 7 55 Refrigerant ...

Page 9: ...e 1 Normal maintenance adjustments and cleaning as outlined in the Owner Operator Use and Care Guide 2 Repairs due to unauthorized modifications to the ice machine or the use of non standard parts without prior written approval Manitowoc Ice Inc 3 Damage caused by improper installation of the ice machine electrical supply water supply or drainage or damage caused by floods storms or other acts of ...

Page 10: ...Warranty Section 1 1 2 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 11: ...mensions ICE MACHINES J250 Ice Machine NOTE All measurements are in inches J320 J420 Ice Machine NOTE All measurements are in inches Ice Machine Dimension H J320 20 00 J420 25 00 H SV1319 SV1270 SV1271 14 25 0 63 6 50 7 00 H 1 25 10 00 22 00 1 56 0 63 1 56 23 50 4 63 0 75 1 75 10 00 32 50 6 50 3 50 30 00 15 00 28 00 4 00 2 25 1 50 3 00 4 50 ...

Page 12: ...0 20 00 10 50 J600 20 00 10 50 J800 25 00 10 50 J1000 28 00 10 50 J1300 J1800 Ice Machines NOTE All measurements are in inches Ice Machine Dimension H J1300 28 00 J1800 28 00 17 50 SV1181 SV1181 SV1180 SV1180 SV1500 SV1501 10 00 6 25 4 00 H 2 75 3 25 5 00 H 30 00 23 50 1 75 C 1 25 1 56 0 75 1 56 H 48 25 29 75 10 13 3 00 23 50 48 25 23 50 19 25 2 88 9 88 ...

Page 13: ...0 Ice Storage Bin C970 Ice Storage Bin WARNING All Manitowoc ice machines require an ice storage system with an ice deflector The J1300 and J1800 require a Manitowoc Ice Deflector Kit K00092 when installing with a non Manitowoc ice storage system For other Manitowoc Ice Machines do not use a non Manitowoc ice storage system before confirming with the manufacturer that their ice 30 00 SV1187 SV1272...

Page 14: ...Section 2 Installation References 2 4 deflector is compatible with Manitowoc ice machines ...

Page 15: ...862 29 50 27 94 SV1297 SV1301 SV1578 OPTIONAL 38 00 34 00 30 00 29 16 4 00 6 50 14 62 6 00 3 50 1 50 OPTIONAL 20 00 16 00 12 00 27 94 29 50 OPTIONAL 47 25 43 25 39 25 35 25 31 25 29 16 6 34 8 50 14 69 8 56 3 91 1 60 OPTIONAL 19 69 15 69 11 69 7 69 3 69 OPTIONAL 47 25 43 25 39 25 35 25 31 25 3 38 24 00 22 40 OPTIONAL 19 69 15 69 11 69 8 56 3 91 29 16 6 34 8 50 29 30 14 69 6 34 8 50 ...

Page 16: ...ed for efficient operation and servicing Important Two stacked ice machines may share a single ice storage bin A stacking kit is required for stacking two ice machines Follow the instructions supplied with the stacking kit Heat of Rejection Ice machines like other refrigeration equipment reject heat through the condenser It is helpful to know the amount of heat rejected by the ice machine when you...

Page 17: ...sed to help select the wire size of the electrical supply It is NOT the ice machine s running amp load The wire size or gauge is also dependent upon the location materials used length of run etc and therefore must be determined by a qualified electrician J250 Ice Machines with Power Cord Cord is 6 long with NEMA 5 15P plug configuration Air Cooled Water Cooled Ice Machine Voltage Phase Cycle Maxim...

Page 18: ...rcuit Amps 115 1 60 15 10 5 15 10 0 N A N A J200 208 230 1 60 15 5 4 15 4 8 N A N A 230 1 50 15 4 8 15 4 2 N A N A 115 1 60 20 12 7 20 11 8 20 13 7 J450 208 230 1 60 15 7 8 15 7 4 N A N A 230 1 50 15 5 7 15 5 4 N A N A J600 208 230 1 60 15 7 4 15 6 9 15 8 2 230 1 50 15 6 4 15 6 1 15 6 5 208 230 1 60 20 11 8 20 11 1 20 12 1 J800 208 230 3 60 15 7 7 15 6 7 15 7 6 230 1 50 15 10 7 15 9 9 15 9 7 208 2...

Page 19: ...rounding must conform to local state and national electrical codes Self Contained Ice Machine 115 1 60 or 208 230 1 60 Self Contained Ice Machine 208 230 3 60 Self Contained Ice Machine 208 240 1 50 GROUND SV1258 GROUND L1 L1 N 115V OR L2 208 230V TO SEPARATE FUSE BREAKER ICE MACHINE CONNECTIONS SV1190 L1 L1 L2 L2 L3 L3 GROUND GROUND TO SEPARATE FUSE BREAKER ICE MACHINE CONNECTIONS SV1191 L1 L1 N ...

Page 20: ...Condenser 115 1 60 or 208 230 1 60 Remote Ice Machine With Single Circuit Model Condenser 208 230 3 60 or 380 415 3 50 Remote Ice Machine With Single Circuit Model Condenser 230 1 50 SV1255 SV1256 SINGLE CIRCUIT REMOTE CONDENSER GROUND L1 N 115V OR L2 208 230V TO SEPARATE FUSE BREAKER ICE MACHINE L2 L1 L2 F2 F1 GROUND GROUND L1 L2 NOTE CONDENSER FAN MOTOR VOLTAGE MATCHES ICE MACHINE VOLTAGE SV1199...

Page 21: ... 20 psi min 150 psi max J1300 J1800 1 2 F P T All Others 3 8 F P T Condenser Water Drain 1 2 F P T 1 2 Bin Drain 3 4 F P T 3 4 1 F P T Female Pipe Thread CONDENSER WATER DRAIN FITTING 1 2 F P T SV1304 CONDENSER WATER INLET FITTING 1 2 F P T CONDENSER WATER DRAIN TUBING 1 2 MIN I D CONDENSER WATER INLET TUBING 1 2 MIN I D WATER SHUT OFF VALVE ICE MAKING WATER DRAIN FITTING 1 2 F P T ICE MAKING WATE...

Page 22: ...ssure It is necessary to know the amount of heat rejection and the pressure drop through the condenser and water valves inlet and outlet when using a cooling tower on an ice machine Water entering the condenser must not exceed 90 F 32 2 C Water flow through the condenser must not exceed 5 gallons per minute Allow for a pressure drop of 7 psi between the condenser water inlet and the outlet of the ...

Page 23: ... 25 30 5 m long If additional refrigerant is required an additional label located next to the serial tag states the amount of refrigerant to be added Typical Additional Refrigerant Label If there is no additional label the nameplate charge is sufficient for line sets up to 100 30 5 m See the chart below Ice Machine Nameplate Charge Total Charge Shipped in Ice Machine Refrigerant to be Added for 50...

Page 24: ...ured by Manitowoc Ice Inc unless specifically approved in writing by Manitowoc Ice Inc Guidelines for Routing Line Sets First cut a 2 5 63 5 mm circular hole in the wall or roof for tubing routing Connect the line set end with the 90 bend to the ice machine Connect the straight end to the remote condenser Then follow these guidelines when routing the refrigerant lines This will help insure proper ...

Page 25: ...e measured rise into the formula below Multiply by 1 7 to get the calculated rise Example A condenser located 10 feet above the ice machine has a calculated rise of 17 feet 2 Insert the measured drop into the formula below Multiply by 6 6 to get the calculated drop Example A condenser located 10 feet below the ice machine has a calculated drop of 66 feet 3 Insert the measured horizontal distance i...

Page 26: ...CUIT REMOTE CONDENSER DISCHARGE LINE LIQUID LINE ELECTRICAL DISCONNECT NOTE BORE A 2 5 DIAMETER HOLE IN THE ROOF OR WALL FOR TUBING SEAL WITH TAR OR PITCH SLOPE TO PREVENT ENTRANCE OF MOISTURE ELECTRICAL DISCONNECT ELECTRICAL SUPPLY ICE MACHINE BIN LIQUID REFRIGERANT LINE DISCHARGE REFRIGERANT LINE 36 00 DROP ...

Page 27: ...T ROUTING AND SIZING Remote condenser installations consist of vertical and horizontal line set distances to the condenser that when combined must fit within approved guidelines The line set sizing guidelines drawings and length calculation methods must be followed to verify a proper remote condenser installation Refer to the Installation Instructions for specifications for remote line sets and ma...

Page 28: ...ets come with quick connect fittings It is recommended that matching quick connects available from Manitowoc distributors be installed in the multi circuit condenser and a vapor holding charge 5 oz of refrigerant be added Model Refrigerant Heat of Rejection Internal Condenser Volume cu ft Design Pressure Quick Connect Stubs Male Ends Head Pressure Control Type Charge Avg BTU Hr Peak BTU Hr Min Max...

Page 29: ...Section 2 Installation References 2 18 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 30: ...V1205 WATER DUMP VALVE DRAIN HOSE COMPRESSOR REMOTE COUPLINGS CONDENSER FAN AIR COOLED MODELS AIR CONDENSER WATER COOLED MODEL CONDENSER WATER REGULATING VALVE WATER CONDENSER DISTRIBUTION TUBE ICE THICKNESS PROBE EVAPORATOR HIGH PRESSURE CUTOUT MANUAL RESET WATER CURTAIN WATER TROUGH ICE OFF CLEAN SWITCH WATER PUMP FLOAT VALVE BIN SWITCH ...

Page 31: ...ket B Raise or lower the float valve assembly as necessary then tighten the screws C If further adjustment is required carefully bend the float arm to achieve the correct water level ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 3 2 mm NOTE Make sure the water curtain is in place when performing this check It prevents water from splashing ou...

Page 32: ... Clean the outside of the condenser bottom of a remote condenser with a soft brush or a vacuum with a brush attachment Clean from top to bottom not side to side Be careful not to bend the condenser fins 3 Shine a flashlight through the condenser to check for dirt between the fins If dirt remains A Blow compressed air through the condenser fins from the inside Be careful not to bend the fan blades ...

Page 33: ...ater consumption High operating temperatures High operating pressures If the ice machine is experiencing any of these symptoms the water cooled condenser and water regulating valve may require cleaning due to scale build up The cleaning procedures require special pumps and cleaning solutions Follow the manufacturer s instructions for the specific cleaner being used ...

Page 34: ...he ice to melt off the evaporator CAUTION Never use anything to force ice from the evaporator Damage may result Step 2 To start self cleaning place the toggle switch in the CLEAN position The water will flow through the water dump valve and down the drain The Clean light will turn on to indicate the ice machine is in the Self Cleaning mode Step 3 Wait about one minute or until water starts to flow...

Page 35: ...ing mode is completed This entire cycle lasts approximately 25 minutes If the bin requires sanitizing remove all the ice and sanitize it with a solution of one ounce 30ml of sanitizer with up to 4 gallons 15 L of water Step 6 When the self sanitizing process stops move the toggle switch to ICE position to start ice making again Step 7 A The ice machine may be set to start and finish a self sanitiz...

Page 36: ...hen the curtain recloses Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle Or set the switch to the OFF position and allow the ice to melt off the evaporator CAUTION Never use anything to force ice from the evaporator Damage may result Step 2 To start the automatic cleaning system move the toggle switch to the CLEAN position The wate...

Page 37: ...ion 3 Soak the removed parts in a properly mixed solution Solution Type Water Mixed With Cleaner 1 gal 4 l 16 oz 500 ml cleaner Sanitizer 4 gal 15 l 1 oz 30 ml sanitizer 4 Use a soft bristle brush or sponge NOT a wire brush to carefully clean the parts CAUTION Do not immerse the water pump motor in the cleaning or sanitizing solution 5 Use the solution and a brush to clean the top sides and bottom...

Page 38: ...vice switch box 1 If so equipped remove the water dump valve shield from its mounting bracket 2 Lift and slide the coil retainer cap from the top of the coil 3 Note the position of the coil assembly on the valve for assembly later Leaving the wires attached lift the coil assembly off the valve body and the enclosing tube 4 Press down on the plastic nut on the enclosing tube and rotate it 1 4 turn ...

Page 39: ...p valve and the mounting bracket Dump Valve Removal WATER PUMP WARNING Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply 1 Disconnect the water pump power cord Water Pump Removal 2 Disconnect the hose from the pump outlet 3 Loosen the two screws securing the pump mounting bracket to the bulkhead 4 Lift the pump and bracket assembly of...

Page 40: ... service switch box 2 Disconnect the wire leads from the control board inside the electrical control box WATER TROUGH Water trough removal varies slightly by model The following procedure is typical 1 Remove the push in screws holding the trough in place Water Trough Removal 2 Lower the right side of the trough into the bin 3 Disengage the left side of the trough from its holding pegs and remove t...

Page 41: ... valve forward and off the mounting bracket 4 Disconnect the water inlet tube from the float valve at the compression fitting 5 Remove the filter screen and cap for cleaning WATER CURTAIN 1 Gently flex the curtain in the center and remove it from the right side Water Curtain Removal 2 Slide the left pin out SV1217 WATER INLET TUBE SV1213 COMPRESSION FITTING FILTER SCREEN AND CAP SPLASH SHIELD STEP...

Page 42: ...e locating pin then slide it back and to the right CAUTION Do not force this removal Be sure the locating pin is clear of the hole before sliding the distribution tube out 4 Disassemble for cleaning Water Distribution Tube Disassembly A Twist both of the inner tube ends until the tabs line up with the keyways B Pull the inner tube ends outward SV1210 SV1211 THUMBSCREW DISTRIBUTION TUBE THUMBSCREW ...

Page 43: ...the pressure release button to relieve the pressure 3 Unscrew the housing from the cap 4 Remove the used filter cartridge from the housing and discard it 5 Remove the O ring from the housing groove Wipe the housing groove and the O ring clean 6 Lubricate the O ring with petroleum jelly 7 Press the O ring into the housing groove 8 Insert a new filter cartridge into the housing Make sure it slips do...

Page 44: ...ming water and the drain openings in the rear of the ice machine until no more water comes out of the float valve or the drain 6 Make sure water is not trapped in any of the water lines drain lines distribution tubes etc WATER COOLED ICE MACHINES 1 Perform steps 1 6 under Self Contained Air Cooled Ice Machines 2 Disconnect the incoming water and drain lines from the water cooled condenser 3 Insert...

Page 45: ...Section 3 Maintenance 3 16 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 46: ...ompressor start up and then shuts off At the same time the compressor starts the fan condenser motor air cooled models is supplied with power throughout the entire Freeze and Harvest Sequences The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off The compressor and condenser fan motor are wired through the contactor As a result anytime the contactor coil is ...

Page 47: ...ubes swings the water curtain out opening the bin switch The momentary opening and re closing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence Step 3 4 Harvest Sequence Typical J450 Shown AUTOMATIC SHUT OFF 7 Automatic Shut Off When the storage bin is full at the end of a harvest sequence the sheet of cubes fails to clear the water curtain and wi...

Page 48: ...PR solenoid valves remain on for 5 seconds during initial compressor start up and then shut off The remote condenser fan motor starts at the same time the compressor starts and remain on throughout the entire Freeze and Harvest Sequences The compressor and condenser fan motor are wired through the contactor therefore anytime the contactor coil is energized the compressor and fan motor are on FREEZ...

Page 49: ...wings the water curtain out opening the bin switch The momentary opening and re closing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence Step 3 4 Harvest Sequence Typical J450 Shown AUTOMATIC SHUT OFF 7 Automatic Shut Off When the storage bin is full at the end of a harvest sequence the sheet of cubes fails to clear the water curtain and will hol...

Page 50: ... dump solenoid are energized for 45 seconds to purge old water from the water trough This ensures that the ice making cycle starts with fresh water FREEZE CYCLE 2 To pre chill the evaporator there is no water flow over the evaporator for the first 30 seconds of the freeze cycle 3 The water pump starts after the 30 second pre chill An even flow of water is directed across the evaporator and into ea...

Page 51: ... trough 5 After the 45 second purge the water pump and water dump valve de energize NOTE New style control boards have an adjustable water purge in the harvest cycle This permits a 0 off 15 30 or 45 second purge cycle AUTOMATIC SHUT OFF There is no water flow during an automatic shut off Water Flow Down the Drain SV1456 TO DISTRIBUTION TUBE WATER DUMP VALVE WATER PUMP TO DRAIN ...

Page 52: ...r The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off Harvest Water Purge New style circuit boards have an adjustable water purge in the havest cycle This permits a 0 off 15 30 or 45 second purge cycle Auto Shut Off The ice machine remains off for 3 minutes before it can automatically restart The ice machine restarts steps 1 2 immediately after the delay p...

Page 53: ...he ice machine remains off for 3 minutes before it can automatically restart The ice machine restarts steps 1 2 immediately after the delay period if the bin switch re closes prior to 3 minutes Harvest Water Purge New style circuit boards have an adjustable water purge in the havest cycle This permits a 0 off 15 30 or 45 second purge cycle Safety Timers The control board has the following non adju...

Page 54: ...ve ON 4 Open Contactor Coil OFF Compressor OFF Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1559 L1 TB35 TB30 TB30 TB30 TB30 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 61 60 77 80 76 75 98 99 TB3 TB37 59 73 74 56 58 57 HOT GAS SOLENOID D...

Page 55: ...itch ICE Bin Switch Closed Control Board Relays 1 Open Water Pump OFF 2 Closed Hot Gas Solenoid ON 3 Open Water Dump Valve OFF 4 Closed Contactor Coil ON Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1560 L1 TB35 TB30 TB30 T...

Page 56: ...ormer Fuse On Control Board Closed Thermistor Operation OK SV1561 L1 TB35 TB30 TB30 TB30 TB30 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 61 60 77 80 76 75 98 99 TB3 TB37 59 73 74 56 58 57 HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL TRANS FUSE FUSE 7A ICE THICKNESS PROBE DISCHARGE LINE THERMISTOR 3 1 2 4 1D 1C 1B 1A BIN SWITCH 62 63 65 64 66 66 67 62 69 68 H...

Page 57: ...F 4 Closed Contactor Coil ON Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1562 L1 TB35 TB30 TB30 TB30 TB30 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 61 60 77 80 76 75 98 99 TB3 TB37 59 73 74 56 58 57 HOT GAS SOLENOID DUMP S...

Page 58: ...N 4 Closed Contactor Coil ON Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1563 L1 TB35 TB30 TB30 TB30 TB30 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 61 60 77 80 76 75 98 99 TB3 TB37 59 73 74 56 58 57 HOT GAS SOLENOID DUMP S...

Page 59: ... Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1564 L1 TB35 TB30 TB30 TB30 TB30 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 61 60 77 80 76 75 98 99 TB3 TB37 59 73 74 56 58 57 HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATE...

Page 60: ...pen Hot Gas Solenoid OFF 3 Open Water Dump Valve OFF 4 Open Contactor Coil OFF Compressor OFF Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1565 L1 TB35 TB30 TB30 TB30 TB30 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 61 60 77 80 76 75 98 9...

Page 61: ...OFF Liquid Line Solenoid De Energized Compressor OFF Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1552 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78 61 60 71 76 80 HOT GAS SOLENOID DUMP SO...

Page 62: ...Dump Valve OFF 4 Closed Contactor Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1553 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78 61 60 ...

Page 63: ...sformer Fuse On Control Board Closed Thermistor Operation OK SV1554 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78 61 60 71 76 80 HOT GAS SOLENOID DUMP SOLENOID TB30 TB30 TB30 TB30 75 98 99 WATER PUMP TB31 TB37 57 58 59 82 83 LIQUID LINE SOLENOID CONTACTOR COIL 56 73 81 TRANS FUSE FUSE 7A 3 1 2 4 ICE THICKNESS PROBE DISCHARGE LINE THERMISTOR 1D 1A 1C ...

Page 64: ...Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1555 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78 61 60 71 76 80 HOT GAS SOLENOID DUMP SOLENOID TB...

Page 65: ...or Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1556 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78 61 60 71 76 80 HOT GAS SOLENOID DUMP ...

Page 66: ...id Energized Compressor ON Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1557 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78 61 60 71 76 80 HOT GAS SOLENOID DUMP SOLENOID TB30 TB30 TB30 TB30 ...

Page 67: ...er Dump Valve OFF 4 Open Contactor Coil OFF Liquid Line Solenoid De Energized Compressor OFF Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed Transformer Fuse On Control Board Closed Thermistor Operation OK SV1558 74 L1 TB35 SEE SERIAL PLATE FOR VOLTAGE L2 N TB32 55 HIGH PRESSURE CUT OUT HPR SOLENOID 79 78...

Page 68: ... WIRING DIAGRAM LEGEND The following symbols are used on all of the wiring diagrams Internal Compressor Overload Some models have external compressor overloads Fan Motor Run Capacitor Some models do not incorporate fan motor run capacitor TB Terminal Board Connection Terminal board numbers are printed on the actual terminal board Wire Number Designation The number is marked at each end of the wire...

Page 69: ... TB37 3 1 2 4 TRANS FUSE FUSE 7A 1D 1C 1B 1A HIGH PRESSUR E CUT ICE THICKNESS PROBE LOW D C VOLTAGE PLUG DISCHARGE LINE THERMISTOR BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 47 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW OVERLOAD CONTACTOR CONTACTS 42 51 52 85 86 53 TB33 TB34 S R C 50 PTCR FAN MOTOR AIR COOLE...

Page 70: ... 7A 1D 1C 1B 1A HIGH PRESSUR E CUT ICE THICKNESS PROBE LOW D C VOLTAGE PLUG DISCHARGE LINE THERMISTOR BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 49 47 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL TB35 TB30 TB30 OVE...

Page 71: ...SSUR E CUT ICE THICKNESS PROBE LOW D C VOLTAGE PLUG DISCHARGE LINE THERMISTOR HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 62 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR TB30 TB30 CON...

Page 72: ...SS PROBE LOW D C VOLTAGE PLUG DISCHARGE LINE THERMISTOR BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 49 47 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL TB35 TB30 TB30 OVERLOAD CONTACTOR CONTACTS 48 42 51 52 85 86 ...

Page 73: ... DISCHARGE LINE THERMISTOR HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 62 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR TB30 TB30 CONTACTOR CONTACTS 42 51 52 85 86 53 TB33 TB34 FAN ...

Page 74: ... E CUT OUT ICE THICKNESS PROBE LOW D C VOLTAGE PLUG DISCHARGE LINE THERMISTOR BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL HPR SOLENOID 79 78 83 82 LIQUID LINE SOLENOID 49 47 COMPRESSOR TB35 TB30 TB30 OVERLOAD C...

Page 75: ...GHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 62 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR CONTACTOR CONTACTS 42 L1 TB35 L2 L3 T2 T1 T3 TB30 77 76 80 75 98 57 81 58 59 73 56 74 TB31 TB37 HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL HPR SOLENOID 79 78 83 82 LIQUID LI...

Page 76: ...VIEW TB30 77 76 80 75 98 57 99 81 58 59 73 56 74 TB31 TB37 LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL HPR SOLENOID 79 78 83 82 LIQUID LINE SOLENOID TB30 TB30 TB30 RH HOT GAS 87 88 SEE SERIAL PLATE FOR VOLTAGE L2 N 49 47 COMPRESSOR TB35 TB30 TB30 OVERLOAD CONTACTOR CONTACTS 48 42 51 52 53 TB33 TB34 S R C 50 PTCR RUN CAPACITOR L1 46 RUN CAPACITOR CRANKCASE HEATER TB35 R R 44 95 94 C...

Page 77: ...E THERMISTOR HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR TB30 TB30 CONTACTOR CONTACTS 42 51 52 53 TB33 TB34 96 L1 TB35 L2 L3 T2 T1 T3 RH HOT GAS 88 87 TB30 TB35 NOT...

Page 78: ...B37 3 1 2 4 TRANS FUSE 7A 1C 1F HIGH PRESSUR E CUT ICE THICKNESS PROBE LOW D C VOLTAGE PLUG CONNECTION NOT USED BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 47 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW OVERLOAD CONTACTOR CONTACTS 42 51 85 86 53 TB33 TB34 S R C 50 PTCR FAN MOTOR AIR COOLED ONLY FAN CYCLE CONTR...

Page 79: ...TRANS FUSE 7A 1C 1F HIGH PRESSUR E CUT ICE THICKNESS PROBE LOW D C VOLTAGE PLUG CONNECTION NOT USED BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 47 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW OVERLOAD CONTACTOR CONTACTS 42 51 85 86 53 TB33 TB34 S R C 50 PTCR FAN MOTOR AIR COOLED ONLY FAN CYCLE CONTROL RUN CAPAC...

Page 80: ...HICKNESS PROBE LOW D C VOLTAGE PLUG CONNECTION NOT USED HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 62 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR TB30 TB30 CONTACTOR CONTACTS 42 51 ...

Page 81: ... VOLTAGE PLUG CONNECTION NOT USED BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 49 47 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL TB35 TB30 TB30 OVERLOAD CONTACTOR CONTACTS 48 42 51 52 85 86 53 TB33 TB34 S R C 50 ...

Page 82: ...ED HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP TERMINATES AT PIN CONNECTION CONTACTOR COIL L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 62 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR TB30 TB30 CONTACTOR CONTACTS 42 51 52 85 86 53 TB33 TB34 FAN MOTOR AIR COOLED ONLY FA...

Page 83: ...HICKNESS PROBE LOW D C VOLTAGE PLUG CONNECTION NOT USED BIN SWITCH 62 63 64 65 66 66 67 HARVEST LIGHT SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL HPR SOLENOID 79 78 83 82 LIQUID LINE SOLENOID 49 47 COMPRESSOR TB35 TB30 TB30 OVERLOAD CONTACTOR CONTACTS 48 4...

Page 84: ...GHT BIN SWITCH LIGHT L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 62 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 68 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR CONTACTOR CONTACTS 42 L1 TB35 L2 L3 T2 T1 T3 TB30 77 76 80 75 98 57 81 58 59 73 56 74 TB31 TB37 HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL HPR SOLENOID 79 78 83 82 LIQUID LINE SOLENOID 51 52 53 TB3...

Page 85: ...98 57 99 81 58 59 73 56 74 TB31 TB37 LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL HPR SOLENOID 79 78 83 82 LIQUID LINE SOLENOID TB30 TB30 TB30 RH HOT GAS 87 88 SEE SERIAL PLATE FOR VOLTAGE L2 N 49 47 COMPRESSOR TB35 TB30 TB30 OVERLOAD CONTACTOR CONTACTS 48 42 51 52 53 TB33 TB34 S R C 50 PTCR RUN CAPACITOR L1 46 RUN CAPACITOR CRANKCASE HEATER TB35 R R 44 95 94 CONTACTOR CONTACTS 96 L...

Page 86: ... SAFETY LIMIT CODE LIGHT BIN SWITCH LIGHT LH HOT GAS SOLENOID DUMP SOLENOID WATER PUMP CONTACTOR COIL L2 L3 SEE SERIAL PLATE FOR VOLTAGE BIN SWITCH 63 64 65 66 66 67 68 69 62 VIEW FOR WIRING 66 67 69 62 TOGGLE SWITCH CLEAN OFF ICE INTERNAL WORKING VIEW COMPRESSOR TB30 TB30 CONTACTOR CONTACTS 42 51 52 53 TB33 TB34 96 L1 TB35 L2 L3 T2 T1 T3 RH HOT GAS 88 87 TB30 TB35 NOTE WIRE 96 IS NOT USED ON 50HZ...

Page 87: ...n The bin switch has two main functions 1 Terminating the harvest cycle and returning the ice machine to the freeze cycle This occurs when the bin switch is opened and closed again within 7 seconds during the harvest cycle 2 Automatic ice machine shut off If the storage bin is full at the end of a harvest cycle the sheet of cubes fails to clear the water curtain and holds it open After the water c...

Page 88: ...losed Resistance readings of less than 70 ohms indicates a correctly operating bin switch Important Any reading between 70 and 30 000 ohms regardless of curtain position indicates a defective bin switch Bin Switch Resistance Readings Water Curtain Removal Notes The water curtain must be on bin switch closed to start ice making While a freeze cycle is in progress the water curtain can be removed an...

Page 89: ...gain Check Motor Windings to Ground Check continuity between all three terminals and the compressor shell or copper refrigeration line NOTE Scrape the metal surface to get good contact If continuity is present the compressor windings are grounded and the compressor should be replaced Determine if the Compressor is Seized Check the amp draw while the compressor is trying to start COMPRESSOR DRAWING...

Page 90: ... discharge and suction pressures to be somewhat equalized prior to the compressor starting To assure equalization of pressures the hot gas valve and HPR valve on remotes will energize for 45 seconds prior to compressor starting The hot gas valve and HPR valve on remotes remains on for an additional 5 seconds while the compressor is starting 2 When starting the compressor the contactor closes and t...

Page 91: ...fore it can automatically restart The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain As the water curtain swings back to operating position the bin switch closes and the ice machine restarts provided the three minute delay period is complete During Start Up First 25 1 0 Seconds After Start Up Current Flows Through ...

Page 92: ... temperature is too high Though rare very high air temperatures intense sunlight etc can greatly increase the temperature of the control box and its contents This may require a longer off time to allow the PTCR to cool The compressor has short cycled or the compressor overload has opened Move the toggle switch to OFF and allow the compressor and PTCR to cool There are other problems that may cause...

Page 93: ...east 10 minutes for the PTCR to cool to room temperature 3 Remove the PTCR from the ice machine 4 Measure the resistance of the PTCR as shown below If the resistance falls outside of the acceptable range replace it Model Manitowoc Part Number Cera Mite Part Number Room Temperature Resistance J200 J250 J320 J420 J450 8505003 305C20 22 50 Ohms J600 J800 J1000 8504993 305C19 18 40 Ohms J1300 J1800 85...

Page 94: ...ge and moisture concerns Verify that the thermistor resistance is accurate and corresponding to the high and low temperature ranges 1 Disconnect the thermistor from terminals 1A and 1B on the control board 2 Connect the ohm meter to the isolated thermistor wire leads 3 Acquire a temperature meter capable of taking readings on curved copper lines Attach the sensing device to the compressor discharg...

Page 95: ...40 250 115 6 121 1 4 3 3 7 250 260 121 1 126 7 3 7 3 3 ICE OFF CLEAN TOGGLE SWITCH Function The switch is used to place the ice machine in ICE OFF or CLEAN mode of operation Specifications Double pole double throw switch The switch is connected into a varying low D C voltage circuit Check Procedure NOTE Because of a wide variation in D C voltage it is not recommended that a volt meter be used to c...

Page 96: ...citor and resistor is milliamps Always measure voltage with the component connected to the relay contacts which result in a 0 reading when the contacts are open For example a service technician turns the toggle switch OFF relay contact open and unplugs the water pump component disconnected The service technician places the voltmeter leads into the water pump plug taking voltage through open contac...

Page 97: ...t Up or Start Up After Automatic Shut Off Freeze Sequence Harvest Sequence Automatic Shut Off Self Cleaning Refer to pages 6 48 and 6 49 for additional control board information 57 55 58 68 65 60 61 56 1D 1C 1B 1A 67 63 62 MAIN FUSE 7A AUTOMATIC CLEANING SYSTEM AuCS ACCESSORY PLUG ICE THICKNESS PROBE 3 16 CONNECTION DISCHARGE LINE THERMISTOR 1 4 CONNECTION DC LOW VOLTAGE ELECTRICAL PLUG NUMBERS MA...

Page 98: ...purge can be set to 15 30 or 45 seconds This will not affect clean cycle purge time CAUTION This control is factory set to 45 seconds A reduced setting will increase cleaning frequency Safety limits 3 and 4 have been eliminated no thermistor is required Exact control board replacement when replacing an old style control board with a new style control board Electrical sequence of operation is ident...

Page 99: ...ke a voltage reading HARVEST SAFETY LIMIT LIGHT This light s primary function is to be on as water contacts the ice thickness probe during the freeze cycle and remain on throughout the entire harvest cycle The light will flicker as water splashes on the probes The light s secondary function is to continuously flash when the ice machine is shut off on a safety limit and to indicate which safety lim...

Page 100: ...ll Water curtain is put back on If the bin switch closes prior to reaching the 3 5 minute point the ice machine immediately returns to another freeze sequence prechill Fuses The main fuse stops ice machine operation if electrical components fail cauing high amp draw The old style circuit board has an additional fuse The transformer fuse protects the primary of the transformer only SAFETY LIMITS In...

Page 101: ... lock in feature This prevents the ice machine from short cycling in and out of harvest The control board locks the ice machine in the freeze cycle for six minutes If water contacts the ice thickness probe during these six minutes the harvest light will come on to indicate that water is in contact with the probe but the ice machine will stay in the freeze cycle After the six minutes are up a harve...

Page 102: ...n flowing over the evaporator 4 Monitor the harvest light Dual Probe Single Probe Monitoring of Harvest Light Correction The harvest light stays off and the ice machine remains in the freeze sequence The ice thickness probe is causing the malfunction The harvest light comes on and 6 10 seconds later ice machine cycles from freeze to harvest The control board is causing the malfunction SV1572 SV159...

Page 103: ...to Step 4 below 4 Disconnect the ice thickness probe from the control board 5 Clip the jumper wire leads to terminal 1C on the control board and ground to try to initiate a harvest cycle 6 Monitor the harvest light Dual Probe Single Probe Monitoring of Harvest Light Correction The harvest light comes on and 6 10 seconds later ice machine cycles from freeze to harvest The ice thickness probe is cau...

Page 104: ...imary power voltage is present at terminals 55 and 56 on the control board 3 Verify main and transformer if applicable control board fuses are OK If the bin switch light functions the fuses are OK 4 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 5 Verify ICE OFF CLEAN toggle switch functions properly A defective toggle switch may keep the ice...

Page 105: ...Section 6 Electrical System 6 54 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 106: ...rant absorbs heat picked up during the harvest cycle from the evaporator The suction pressure decreases during the prechill Freeze Cycle Refrigeration Sequence The refrigerant absorbs heat from water running over the evaporator surface The suction pressure gradually drops as ice forms SV1569 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE STRAINER AIR OR WATER CONDENSER RECEIVER W...

Page 107: ... allow the proper amount of refrigerant into the evaporator This specific sizing along with the proper system refrigerant charge assures proper heat transfer without the refrigerant condensing and slugging the compressor SV1570 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE STRAINER AIR OR WATER CONDENSER RECEIVER WATER COOLED ONLY COMPRESSOR DRIER HIGH PRESSURE VAPOR HIGH PRESSU...

Page 108: ...water running over the evaporator surface The suction pressure gradually drops as ice forms The headmaster control valve maintains discharge pressure in cold ambient temperatures See Headmaster Control Valve on page 7 28 SV1566 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE STRAINER REMOTE CONDENSER RECEIVER SERVICE VALVE COMPRESSOR DRIER HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID ...

Page 109: ...fer without the hot gas condensing to liquid and slugging the compressor The harvest pressure regulating H P R valve helps maintain the suction pressure during the harvest cycle See H P R System on page 7 26 SV1567 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE STRAINER REMOTE CONDENSER RECEIVER SERVICE VALVE COMPRESSOR DRIER HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE ...

Page 110: ...enoid prevents refrigerant from migrating back into the low side This protects the compressor from refrigerant migration during the off cycle preventing refrigerant slugging upon start up SV1568 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HOT GAS SOLENOID VALVE STRAINER REMOTE CONDENSER RECEIVER SERVICE VALVE COMPRESSOR DRIER LIQUID LINE SOLENOID VALVE RECEIVER CHECK VALVE CHECK VALVE HARVEST PRESSU...

Page 111: ...uence for self contained dual expansion valve ice machines is identical to self contained single expansion valve ice machines See pages 7 1 and 7 2 for sequence of operation DRIER RECEIVER CHECK VALVE J1800 AIR COOLED ONLY COMPRESSOR AIR OR WATER COOLED CONDENSER STRAINER EXPANSION VALVE EXPANSION VALVE EVAPORATOR HEAT EXCHANGE HOT GAS SOLENOID VALVES SV1512 ...

Page 112: ...on valve ice machines See pages 7 3 7 4 and 7 5 for sequence of operation SV1513 HARVEST PRESSURE REGULATING VALVE H P R SOLENOID VALVE RECEIVER SERVICE VALVE REMOTE CONDENSER HEAD PRESSURE CONTROL VALVE B R C CHECK VALVE DRIER RECEIVER LIQUID LINE SOLENOID VALVE COMPRESSOR EXPANSION VALVE EXPANSION VALVE HEAT EXCHANGE EVAPORATOR STRAINER HOT GAS SOLENOID VALVES CHECK VALVE ...

Page 113: ...tually the problem loose bulb was corrected when the technician properly mounted the bulb of the replacement expansion valve The service technician s failure to check the expansion valve bulb for proper mounting an external check resulted in a misdiagnosis and the needless replacement of a good expansion valve 2 An ice machine that is low on charge may cause a good expansion valve to starve If a s...

Page 114: ... with 70 F 21 2 C water 1 Determine the ice machine operating conditions Air temp entering condenser ____ Air temp around ice machine ____ Water temp entering float valve ____ 2 Refer to the appropriate 24 Hour Ice Production Chart These charts begin on page 7 31 Use the operating conditions determined in Step 1 to find the published 24 ice production ______ 3 Perform an actual ice production chec...

Page 115: ...tem problems must be identified and eliminated prior to replacing refrigeration components Possible Problem Corrective Action Water area evaporator is dirty Clean as needed Water inlet pressure not between 20 and 80 psi Install a water regulator valve or increase the water pressure Incoming water temperature is not between 35 F 1 7 C and 90 F 32 2 C If too hot check the hot water line check valves...

Page 116: ...e it may appear that more ice is forming on the bottom of the evaporator than on the top At the end of the freeze cycle ice formation on the top will be close to or just a bit thinner than ice formation on the bottom The dimples in the cubes at the top of the evaporator may be more pronounced than those on the bottom This is normal The ice thickness probe must be set to maintain the ice bridge thi...

Page 117: ... evaporator This is generally caused by loss of heat transfer from the tubing on the back side of the evaporator Spotty Ice Formation 5 No Ice Formation The ice machine operates for an extended period but there is no ice formation at all on the evaporator Important The J1300 and J1800 model machines have left and right expansion valves and separate evaporator circuits These circuits operate indepe...

Page 118: ...p the Ice Machine According to the refrigeration industry a high percentage of compressors fail as a result of external causes These can include flooding or starving expansion valves dirty condensers water loss to the ice machine etc The safety limits protect the ice machine primarily the compressor from external failures by stopping ice machine operation before major component damage occurs The s...

Page 119: ...er temperature 90 F 32 2 C max Dirty condenser Dirty defective water regulating valve Water regulating valve out of adjustment Refrigeration system Non Manitowoc components Improper refrigerant charge Defective head pressure control remotes Defective hot gas valve Defective compressor TXV starving or flooding check bulb mounting Non condensibles in refrigeration system Plugged or restricted high s...

Page 120: ...ogged water distribution tube Dirty defective float valve Defective water pump Electrical system Ice thickness probe out of adjustment Ice thickness probe dirty Bin switch defective Premature harvest Refrigeration system Non Manitowoc components Water regulating valve dirty defective Improper refrigerant charge Defective head pressure control valve remotes Defective harvest pressure control HPR va...

Page 121: ... installation See Installation Visual Inspection Checklist on page 7 10 Restricted condenser air flow air cooled models High inlet air temperature 110 F 43 3 C max Condenser air recirculation discharge Dirty condenser filter Dirty condenser fins Defective fan cycling control Defective fan motor Restricted condenser water flow water cooled models Low water pressure 20 psi min High water temperature...

Page 122: ...gas valves Important Feeling the hot gas valve outlet or across the hot gas valve itself will not work for this comparison The hot gas valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking 3 Feel the compressor discharge line WARNING The inlet of the hot gas valve and the compressor discharge line could be hot enough to burn your hand Just...

Page 123: ...the difference between the two temperatures five minutes into the freeze cycle These temperatures must be within 7 of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Use a quality temperature meter capable of taking temperature readings on curved copper lines 2 Attach the temperature meter sensing device to the copper lines entering and leaving the evaporator...

Page 124: ...ation Visual Inspection Checklist on page 7 10 Restricted condenser air flow air cooled models High inlet air temperature 110 F 43 3 C max Condenser discharge air recirculation Dirty condenser filter Dirty condenser fins Defective fan cycling control Defective fan motor Restricted condenser water flow water cooled models Low water pressure 20 psi min High inlet water temperature 90 F 32 2 C max Di...

Page 125: ...ime and Operating Pressure charts for ice machine model being checked Using operating conditions from Step 1 determine published freeze cycle time and published freeze cycle suction pressure Published freeze cycle time 10 6 12 5 minutes Published freeze cycle suction pressure 52 23 PSIG Published Freeze Cycle Time minutes 2B Compare the published freeze cycle time and published freeze cycle suctio...

Page 126: ...ze Cycle Suction Pressure Low Checklist Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist on page 7 10 Discharge pressure Discharge pressure is too low and is affecting low side See Freeze Cycle Discharge Pressure Low Checklist on page 7 19 Improper refrigerant charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Impro...

Page 127: ...edures and check all information listed Each item in this column has supporting reference material to help analyze each step While analyzing each item separately you may find an external problem causing a good refrigerant component to appear bad Correct problems as they are found If the operational problem is found it is not necessary to complete the remaining procedures Step 2 Enter check marks 3...

Page 128: ...em is corrected the ice machine is low on charge Find the refrigerant leak The ice machine must operate with the nameplate charge If the leak cannot be found proper refrigerant procedures must still be followed Change the liquid line drier Then evacuate and weigh in the proper charge 2 If the problem is not corrected by adding charge the expansion valve is faulty On dual expansion valve ice machin...

Page 129: ...re compressor discharge line temp to hot gas valve inlet temp Compressor ______ Hot Gas Inlet ______ Inlet of hot gas valve is HOT and approaches the temperature of a HOT compressor discharge line Inlet of hot gas valve is COOL enough to hold hand on and compressor discharge line is HOT Inlet of hot gas valve is COOL enough to hold hand on and compressor discharge line is COOL enough to hold hand ...

Page 130: ...nd or components not listed on this table Stops on safety limit 1 Stops on safety limit 1 or 4 Stops on safety limit 1 or 2 or 3 Stops on safety limit 1 or 4 Wait five minutes into the freeze cycle Compare compressor discharge line temp to hot gas valve inlet temps Compressor ______ Left Hot Gas Inlet ______ Right Hot Gas Inlet ______ Inlet of one hot gas valve is HOT and approaches the temperatur...

Page 131: ...e The H P R solenoid is closed de energized preventing refrigerant flow into the H P R valve HARVEST CYCLE During the harvest cycle the check valve in the discharge line prevents refrigerant in the remote condenser and receiver from backfeeding into the evaporator and condensing to liquid The H P R solenoid is opened energized during the harvest cycle allowing refrigerant gas from the top of the r...

Page 132: ... during the freeze cycle causes the H P R valve to appear as though it is not feeding properly during the harvest cycle Verify correct discharge pressure during the freeze cycle PRIOR TO assuming the H P R valve is faulty H P R solenoid remains closed or H P R valve remains closed Freeze Cycle The discharge pressure is normal and the suction pressure is slightly high or normal Harvest Cycle The di...

Page 133: ...roper Operational Pressure Chart later in this section If the air temperature is below 70 F 21 1 C the head pressure should be modulating about 225 PSIG 3 Determine the temperature of the liquid line entering the receiver by feeling it This line is normally warm body temperature 4 Using the information gathered refer to the chart below NOTE A headmaster that will not bypass will function properly ...

Page 134: ... and the ice machine must be evacuated and properly recharged 3 If the ice machine does not start to operate properly after adding charge replace the headmaster FAN CYCLE CONTROL VS HEADMASTER A fan cycle control cannot be used in place of a headmaster The fan cycle control is not capable of bypassing the condenser coil and keeping the liquid line temperature and pressure up This is very apparent ...

Page 135: ... CONTROL Function Stops the ice machine if subjected to excessive high side pressure The HPCO control is normally closed and opens on a rise in discharge pressure Specifications Cut out 450 psig 10 Cut in Manual below 300 psig to reset Check Procedure 1 Set ICE OFF CLEAN switch to OFF and reset HPCO if tripped 2 Connect manifold gauges 3 Hook voltmeter in parallel across the HPCO leaving wires att...

Page 136: ...ressure drops gradually throughout the freeze cycle J200 SERIES WATER COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Around Ice Machine Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 70 21 1 11 8 13 8 14 5 16 9 17 0 19 8 80 26 7 12 0 14 1 14 5 16 9 17 0 19 8 1 2 5 90 32 2 12 6 14 7 15...

Page 137: ...out the freeze cycle J250 SERIES WATER COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Around Ice Machine Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 70 21 1 11 0 13 0 13 8 16 1 16 1 18 7 80 26 7 11 0 13 0 13 8 16 1 16 1 18 7 1 2 5 90 32 2 11 5 13 5 14 5 16 9 17 0 19 8 100 37 8 11 5...

Page 138: ...t the freeze cycle J320 SERIES WATER COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Around Ice Machine Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 70 21 1 11 9 13 6 13 8 15 8 16 1 18 4 80 26 7 12 1 13 9 14 4 16 5 16 5 18 8 1 2 5 90 32 2 12 6 14 4 15 0 17 1 17 3 19 7 100 37 8 13 1 1...

Page 139: ...ut the freeze cycle J420 450 SERIES WATER COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Around Ice Machine Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 70 21 1 9 9 11 7 11 4 13 4 13 3 15 6 80 26 7 10 1 11 9 11 7 13 7 13 7 16 0 1 2 5 90 32 2 10 4 12 2 12 0 14 1 14 1 16 5 100 37 8 10...

Page 140: ... 195 85 100 90 32 2 245 270 54 32 185 200 85 100 100 37 8 280 310 57 32 190 205 90 105 110 43 3 290 325 64 39 190 205 95 110 1 Suction pressure drops gradually throughout the freeze cycle J600 SERIES SELF CONTAINED AIR COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Entering Condenser Water Te...

Page 141: ...6 154 190 86 108 100 37 8 225 245 50 28 162 194 86 112 110 43 3 225 250 52 28 165 200 86 115 1 Suction pressure drops gradually throughout the freeze cycle J600 SERIES REMOTE NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Entering Condenser Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 20 2...

Page 142: ...hout the freeze cycle J800 SERIES WATER COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Around Ice Machine Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 70 21 1 8 8 10 2 9 7 11 1 11 9 13 6 80 26 7 9 1 10 5 10 5 11 5 12 3 14 1 1 2 5 90 32 2 9 4 10 8 10 3 11 9 12 8 14 6 100 37 8 9 7 11 ...

Page 143: ...5 70 90 90 32 2 255 265 34 22 195 205 70 90 100 37 8 275 295 38 24 200 210 70 90 110 43 3 280 320 40 26 200 225 75 100 1 Suction pressure drops gradually throughout the freeze cycle J1000 SERIES SELF CONTAINED AIR COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Entering Condenser Water Tempera...

Page 144: ... 165 185 70 85 100 37 8 225 235 40 20 165 185 70 85 110 43 3 225 240 40 20 170 190 75 90 1 Suction pressure drops gradually throughout the freeze cycle J1000 SERIES REMOTE NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Entering Condenser Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 20 28 9...

Page 145: ...out the freeze cycle J1300 SERIES WATER COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Around Ice Machine Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 70 21 1 8 5 9 5 9 5 10 6 11 1 12 4 80 26 7 8 6 9 7 9 7 10 8 11 4 12 6 1 2 5 90 32 2 8 8 9 8 9 8 11 0 11 6 12 9 100 37 8 8 9 10 0 10 ...

Page 146: ...90 80 95 90 32 2 250 290 42 22 140 200 80 95 100 37 8 280 320 46 22 140 210 80 95 110 43 3 310 360 48 24 140 220 85 100 1 Suction pressure drops gradually throughout the freeze cycle J1800 SERIES SELF CONTAINED AIR COOLED NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Entering Condenser Water Temper...

Page 147: ...175 190 65 80 100 37 8 235 255 44 22 175 190 65 80 110 43 3 235 260 46 22 175 190 65 80 1 Suction pressure drops gradually throughout the freeze cycle J1800 SERIES REMOTE NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Cycle Time Air Temp Freeze Time Harvest Entering Condenser Water Temperature F C Time F C 50 10 0 70 21 1 90 32 2 20 28 9 ...

Page 148: ...Section 7 Refrigeration System 7 43 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 149: ...sor through the discharge service valve SELF CONTAINED RECOVERY EVACUATION 1 Place the toggle switch in the OFF position 2 Install manifold gauges charging cylinder scale and recovery unit or two stage vacuum pump Recovery Evacuation Connections 3 Open backseat the high and low side ice machine service valves and open high and low side on manifold gauges 4 Perform recovery or evacuation A Recovery...

Page 150: ...ining vapor charge through the suction service valve if necessary NOTE Manifold gauges must be removed properly to ensure that no refrigerant contamination or loss occurs 8 Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses A Run the ice machine in freeze cycle B Close the high side service valve at the ice machine C Open the...

Page 151: ...ne quick connect fitting located on the outside of the compressor evaporator compartment This connection evacuates the condenser Without it the magnetic check valves would close when the 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 ...

Page 152: ... R C B REMOTE CONDENSER CHECK VALVE RECEIVER SERVICE VALVE HALF OPEN DRIER LIQUID LINE SOLENOID HARVEST PRESSURE REGULATING VALVE HIGH SIDE SERVICE VALVE BACKSEATED DISCHARGE LINE QUICK CONNECT SCHRAEDER FITTING CHECK VALVE LOW SIDE SERVICE VALVE BACKSEATED COMPRESSOR STRAINER HOT GAS SOLENOID VALVES EXPANSION VALVE EVAPORATOR HEAT EXCHANGER HARVEST PRESSURE SOLENOID VALVE ...

Page 153: ... fully charged 5 Ensure all vapor in charging hoses is drawn into the machine then disconnect the manifold gauges NOTE Backseat the receiver outlet service valve after charging is complete and before operating the ice machine If the access valve core removal and installation tool is used on the discharge quick connect fitting reinstall the Schraeder valve core before disconnecting the access tool ...

Page 154: ...R C B REMOTE CONDENSER CHECK VALVE RECEIVER SERVICE VALVE HALF OPEN DRIER LIQUID LINE SOLENOID HARVEST PRESSURE REGULATING VALVE HIGH SIDE SERVICE VALVE BACKSEATED DISCHARGE LINE QUICK CONNECT SCHRAEDER FITTING CHECK VALVE LOW SIDE SERVICE VALVE BACKSEATED COMPRESSOR STRAINER HOT GAS SOLENOID VALVES EXPANSION VALVE EVAPORATOR HEAT EXCHANGER HARVEST PRESSURE SOLENOID VALVE ...

Page 155: ...t is not available inspect the compressor oil 1 Remove the refrigerant charge from the ice machine 2 Remove the compressor from the system 3 Check the odor and appearance of the oil 4 Inspect open suction and discharge lines at the compressor for burnout deposits 5 If no signs of contamination are present perform an acid oil test Check the chart below to determine the type of cleanup required Cont...

Page 156: ...r on self contained models 1 hour on remotes NOTE You may perform a standing vacuum test to make a preliminary leak check You should use an electronic leak detector after system charging to be sure there is no leak 5 Charge the system with the proper refrigerant to the nameplate charge 6 Operate the ice machine Severe System Contamination Cleanup Procedure 1 Remove the refrigerant charge 2 Remove ...

Page 157: ...hen remove the suction line drier and change the liquid line drier 15 Follow normal evacuation procedures REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE This procedure reduces repair time and cost Use it when any of the following components require replacement and the refrigeration system is operational and leak free Fan cycle control air cooled only Water regulating valve water c...

Page 158: ...Section 7 Refrigeration System 7 53 Using Pinch Off Tool TYPICAL PRESSURE CONTROL SHOWN SV1406 PINCH OFF TOOL USED HERE SEE FIG A AND FIG B FIG A PINCHING OFF TUBING FIG B RE ROUNDING TUBING ...

Page 159: ...r Size End Connection Size Part Number J200 J250 J320 J420 J450 J600 UK 032S 1 4 89 3022 9 J800 J1000 J1300 J1800 UK 083S 3 8 89 3026 9 Suction Filter1 UK 165S 5 8 89 3028 9 1 Used when cleaning up severely contaminated systems Important Driers are covered as a warranty part The drier must be replaced any time the system is opened for repairs TOTAL SYSTEM REFRIGERANT CHARGES Important Refer to the...

Page 160: ...To reprocess refrigerant to new product specifications see below by means which may include distillation A chemical analysis of the refrigerant is required after processing to be sure that product specifications are met This term usually implies the use of processes and procedures available only at a reprocessing or manufacturing facility Chemical analysis is the key requirement in this definition...

Page 161: ...st edition specifications Recovered or Recycled Refrigerant Must be recovered or recycled in accordance with current local state and federal laws Must be recovered from and re used in the same Manitowoc product Re use of recovered or recycled refrigerant from other products is not approved Recycling equipment must be certified to ARI Standard 740 latest edition and be maintained to consistently me...

Page 162: ...needed components at the site Remove new system component plugs and caps just prior to brazing Be prepared to connect a vacuum pump immediately after brazing 4 Are there any special procedures required if a POE system is diagnosed with a refrigerant leak For systems found with positive refrigerant system pressure no special procedures are required For systems found without any positive refrigerant...

Page 163: ... HFC usage Once designated and calibrated if needed for HFC use this equipment should be used specifically with HFC refrigerants only 8 Do I have to recover HFC refrigerants Yes Like other refrigerants government regulations require recovering HFC refrigerants 9 Will R 404A or R 134A separate if there is a leak in the system No Like R 502 the degree of separation is too small to detect 10 How do I...

Page 164: ......

Page 165: ...MANITOWOC ICE INC 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 Phone 920 682 0161 Service Fax 920 683 7585 Web Site http www manitowoc com ã1997 Manitowoc Ice Inc Litho in U S A ...

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