Manitowoc MARINE MODEL S1800 Page 67 Service Manual Download

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Section 7

Refrigeration System

Part Number 80-1634-3

7-1

Section 7

Refrigeration System

Sequence of Operation

SELF-CONTAINED WATER -COOLED MODELS

Figure 7-1. Self-Contained Prechill and Freeze Cycle

Prechill Refrigeration Sequence

No water flows over the evaporator during the prechill.
The refrigerant 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.

HEAT
EXCHANGER

EVAPORATOR

CONDENSER

COMPRESSOR

EXPANSION VALVE

HOT GAS SOLENOID VALVE

AIR OR WATER

DRIER

STRAINER

RECEIVER

(WATER COOLED ONLY)

LOW PRESSURE VAPOR

LOW PRESSURE LIQUID

HIGH PRESSURE LIQUID

HIGH PRESSURE VAPOR

SV1569

Summary of Contents for MARINE MODEL S1800

Page 1: ...allation care and maintenance your new Manitowoc Ice Machine will provide you with many years of reliable and economical performance S1800 Marine Model Ice Machines Service Manual Part Number 80 1634 3 9 2004 This manual is updated as new information and models are released Visit our website for the latest manual www manitowocice com ...

Page 2: ...lected damaged or altered modified from that of original manufactured specifications 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 ice machine Be sure to read the Caution statement before proceeding and ...

Page 3: ...tions General 2 1 Ice Machine Dimensions 2 1 S1800 Water Cooled Ice Machines 2 1 Location of Ice Machine 2 2 Ice Machine Heat of Rejection 2 2 Electrical Service 2 3 General 2 3 Voltage 2 3 Minimum Circuit Ampacity 2 3 Electrical Requirements 2 3 Self Contained Electrical Wiring Connections 2 4 Self Contained Ice Machine 115 1 60 or 208 230 1 60 2 4 Self Contained Ice Machine 208 230 3 60 2 4 Self...

Page 4: ...n 4 Maintenance General 4 1 Ice Machine Inspection 4 1 Exterior Cleaning 4 1 Water Cooled Condenser and Water Regulating Valve 4 1 AlphaSan 4 1 Guardian 4 2 Installation 4 2 Sachet Replacement Frequency 4 2 Sachet Replacement Procedure 4 2 Clean Up Procedure for Damaged Packet 4 2 Interior Cleaning and Sanitizing 4 3 General 4 3 Cleaning Procedure 4 3 Sanitizing Procedure 4 4 Removal of Parts For ...

Page 5: ...er Level Probe Light 6 24 Water Inlet Valve Safety Shut Off 6 24 Freeze Cycle Circuitry 6 24 Harvest Cycle Circuitry 6 24 Diagnosing Water Level Control Circuitry 6 25 Diagnosing An Ice Machine That Will Not Run 6 27 Section 7 Refrigeration System Sequence of Operation 7 1 Self Contained Water Cooled Models 7 1 S1800 Self Contained Tubing Schematic 7 3 Operational Analysis Diagnostics 7 4 General ...

Page 6: ...mal Self Contained Model Procedures 7 21 System Contamination Clean Up 7 23 Replacing Pressure Controls Without Removing Refrigerant Charge 7 25 Filter Driers 7 27 Total System Refrigerant Charges 7 28 Refrigerant Definitions 7 29 Refrigerant Re Use Policy 7 30 HFC Refrigerant Questions and Answers 7 31 ...

Page 7: ... misused abused neglected damaged or altered modified from that of original manufactured specifications Warning PERSONAL INJURY POTENTIAL Remove all ice machine panels before lifting and installing Regular 1 1 8 x 1 1 8 x 7 8 2 86 x 2 86 x 2 22 cm Dice 7 8 x 7 8 x 7 8 2 22 x 2 22 x 2 22 cm Half Dice 3 8 x 1 1 8 x 7 8 0 95 x 2 86 x 2 22 cm S R 1801 W M ICE MACHINE MODEL ICE CUBE SIZE R REGULAR D DI...

Page 8: ...affordable method of inhibiting scale formation filtering sediment and removing chlorine taste and odor MANITOWOC CLEANER AND SANITIZER Manitowoc Ice Machine Cleaner and Sanitizer are available in convenient 16 oz 473 ml bottles These are the only cleaner and sanitizer approved for use with Manitowoc products AUCS AUTOMATIC CLEANING SYSTEM This accessory reduces equipment cleaning expense The AuCS...

Page 9: ...s are required when requesting information from your local Manitowoc distributor or Manitowoc Ice Inc The model and serial number are listed on the MODEL SERIAL NUMBER DECAL affixed to the ice machine remote condenser and storage bin Model Serial Number Location SV13147 MODEL SERIAL DECAL LOCATION ...

Page 10: ...m Manitowoc Ice Inc 3 Damage caused by improper installation of the ice machine electrical supply water supply or drainage or damage caused by floods storms or other acts of God 4 Premium labor rates due to holidays overtime etc travel time flat rate service call charges mileage and miscellaneous tools and material charges not listed on the payment schedule Additional labor charges resulting from ...

Page 11: ...these installation guidelines may affect warranty coverage 2 50 6 35cm H D W 11 0 27 9cm 10 25 26 0cm 2 0 5 1cm 5 75 14 6cm 4 0 10 2cm A B 3 0 7 6cm 3 75 9 5cm 11 0 27 9cm 7 8 19 8cm 1 1 2 8cm C E F ELECTRICAL CONDENSER WATER OUTLET 1 2 FPT Water Cooled Only DRAIN 1 2 NPTF CONDENSER WATER INLET 3 8 FPT Water Cooled Only AUXILLARY BASE DRAIN 1 2 CPVC SOCKET WATER INLET 3 8 FPT AuCS Connections Ice ...

Page 12: ...machines are installed This information is also necessary when evaluating the benefits of using water cooled or remote condensers to reduce air conditioning loads The amount of heat added to an air conditioned environment by an ice machine using a water cooled or remote condenser is negligible Knowing the amount of heat rejected is also important when sizing a cooling tower for a water cooled cond...

Page 13: ...city is not the ice machine s running amp load The wire size or gauge is also dependent upon location materials used length of run etc so it must be determined by a qualified electrician ELECTRICAL REQUIREMENTS Refer to Ice Machine Model Serial Plate for voltage amperage specifications S Series Ice Machines indicates preliminary data Warning All wiring must conform to local state and national code...

Page 14: ... GROUND ICE MACHINE CONNECTIONS SV1258 TO SEPARATE FUSE BREAKER L1 L1 GROUND GROUND ICE MACHINE CONNECTIONS TO SEPARATE FUSE BREAKER L2 L3 L2 L3 SV1190 L1 L1 N N GROUND GROUND ICE MACHINE CONNECTIONS TO SEPARATE FUSE BREAKER DISCONNECT ALL POLES SV1191 For United Kingdom Only As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings identifying the ...

Page 15: ... be large enough to accommodate drainage from all drains Run separate bin and ice machine drain lines Insulate them to prevent condensation Vent the bin and ice machine drain to the atmosphere Do not vent the condenser drain on water cooled models Cooling Tower Applications A water cooling tower installation does not require modification of the ice machine The water regulator valve for the condens...

Page 16: ...nser Water Inlet 40 F 4 4 C Min 90 F 32 2 C Max 20 psi 137 9 kPA Min 150 psi 1034 2 kPA Max 3 8 Female Pipe Thread Condenser Water Drain 1 2 Female Pipe Thread 1 2 1 27 cm minimum inside diameter Bin Drain 3 4 Female Pipe Thread 3 4 1 91 cm minimum inside diameter SV3142 ELECTRICAL ENTRANCE 18 46 CM VENT TUBE AIR GAP 1 2 1 3 CM MIN DRAIN ID 1 2 DRAIN CONNECTION PLASTIC FITTING ON OPPOSITE SIDE DO ...

Page 17: ...coming water temperature will remain in the range of 35 90 F 1 6 32 2 C F Is there a separate drain for the water cooled condenser F Is there a separate drain for the bin F Are the ice machine and bin drains vented F Are all electrical leads free from contact with refrigeration lines and moving equipment F Has the owner operator been instructed regarding maintenance and the use of Manitowoc Cleane...

Page 18: ...s of the owner operator Adjustments and maintenance procedures outlined in this manual are not covered by the warranty AuCS Automatic Cleaning System This optional accessory monitors ice making cycles and initiates cleaning procedures automatically The AuCS accessory can be set to automatically clean or sanitize the ice machine every 2 4 or 12 weeks Refer to the AuCS Installation Use and Care Manu...

Page 19: ...ce Machine Operation Component Identification sv3150 sv3149 Check Valve Ice Thickness Probe Dump Valve Toggle Switch Water Curtain Water Distribution Tube Water Level Probe Water Pump Water Inlet Location Water Inlet Valve Located in Refrigeration Compartment Bin Switch ...

Page 20: ...en shuts off At the same time the compressor starts the condenser fan motor air cooled models is supplied with power throughout the entire Freeze and Harvest Sequences The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off The compressor and condenser fan motor are wired through the contactor As a result anytime the contactor coil is energized the compressor ...

Page 21: ...achine remains off for 3 minutes before it can automatically restart The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain As the water curtain swings back to the operating position the bin switch re closes and the ice machine restarts steps 1 2 provided the 3 minute delay period is complete SAFETY TIMERS The control ...

Page 22: ...lean the water level probe with ice machine cleaner rinse thoroughly and re check operation Repair or replace the probe as necessary ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 32 cm NOTE Make sure the water curtain is in place when performing this check It prevents water from splashing out of the water trough 1 Inspect the bridge connecti...

Page 23: ...must be at the factory setting of 45 seconds for the water fill valve to energize during the last 15 seconds of the water purge If it is set to less than 45 seconds the water fill valve will not energize during the water purge Water Purge Adjustment For your safety and to eliminate errors we recommend that a qualified service technician make the harvest water purge adjustment Warning Disconnect el...

Page 24: ...Ice Machine Operation Section 3 3 6 Part Number 80 1634 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 25: ... High operating temperatures High operating pressures If the ice machine is experiencing any of these symptoms the water cooled condenser and water regulating valve may require cleaning due to scale build up Because the cleaning procedures require special pumps and cleaning solutions qualified maintenance or service personnel must perform them AlphaSan The goal of AlphaSan is to keep the plastic s...

Page 26: ...r Removing the foil package allows moisture in the air to activate the sachet contents 5 Close the left front door and tighten the screw Guardian Location SACHET REPLACEMENT FREQUENCY Sachet packet s require replacement every thirty 30 days or whenever they come in direct contact with water Refer to chart below for requirements Guardian sachet packets are available through your local Manitowoc ice...

Page 27: ...stop The Clean light will turn off to indicate the Cleaning cycle is completed This entire cycle lasts approximately 30 minutes Step 6 When the cleaning process stops move the toggle switch to OFF position Refer to Sanitizing Procedure on the next page Step 7 A The ice machine may be set to start and finish a self cleaning procedure then automatically start ice making again B You must wait about o...

Page 28: ...ater and sanitizer Step 4 Use the sanitizing solution and a sponge or cloth to sanitize wipe all parts and interior surfaces of the ice machine Sanitize the following areas A Side walls B Base area above water trough C Evaporator plastic parts D Bin or dispenser Step 5 Rinse all sanitized areas with clear water Step 6 Install the removed parts restore power and place toggle switch in the ice posit...

Page 29: ...l the removed parts NOTE Incomplete rinsing of the ice thickness probe or water level probe may leave a residue This could cause the ice machine to malfunction For best results brush or wipe the probes off while rinsing it Thoroughly dry the probes before installing them 9 Turn on the water and electrical supply Warning Disconnect electric power to the ice machine and dispenser if applicable at th...

Page 30: ...he ice thickness probe Ice Thickness Probe Removal B Pivot the ice thickness probe to disengage one pin then the other The ice thickness probe can be cleaned at this point without complete removal Follow Step C for complete removal C Disconnect the ice thickness control wiring from the control board SV3153 STEP 1 STEP 2 Warning Disconnect the electric power to the ice machine at the electric servi...

Page 31: ...rews to distribution tube B Pull inner half of water distribution tube forward to release slip joint from water pump tubing connection 4 Water Trough A Depress tabs on right and left side of the water trough B Allow front of water trough to drop as you pull forward to disengage the rear pins Warning Removing the distribution tube while the water pump is running will allow water to spray from ice m...

Page 32: ...n Water Pump Removal 2 Remove the water trough 3 The water pump normally does not require removal for cleaning The water pump base can be wiped and cleaned in place or proceed to step 4 4 Grasp pump and pull straight down on pump assembly until water pump disengages and electrical connector is visible 5 Disconnect the electrical connector 6 Remove the water pump assembly from ice machine 7 Do not ...

Page 33: ... off the valve body and the enclosing tube 4 Press down on the plastic nut on the enclosing tube and rotate it 1 4 turn Remove the enclosing tube plunger and plastic gasket from the valve body NOTE At this point the water dump valve can easily be cleaned If complete removal is desired continue with step 5 NOTE During cleaning do not stretch damage or remove the spring from the plunger If it is rem...

Page 34: ...Drain Line Check Valve The drain line check valve normally does not require removal for cleaning Water loss from the sump trough will indicate removal and cleaning are required 1 Remove check valve and tube assembly A Tip assembly to right until tubing disengages B Lift up on assembly to remove 2 Remove insulation from check valve assembly 3 Remove vinyl tubing from top of check valve 4 Soak in cl...

Page 35: ...ine is on the water inlet valve must allow the proper water flow through it Set the toggle switch to ON Watch for water flow into the ice machine If the water flow is slow or only trickles into the ice machine refer to Section 5 Follow the procedure below to remove the water inlet valve 1 Remove the 1 4 hex head screws 2 Remove clean and install the filter screen Warning Disconnect the electric po...

Page 36: ...g water and the drain openings in the rear of the ice machine until no more water comes out of the inlet water lines or the drain 6 Make sure water is not trapped in any of the water lines drain lines distribution tubes etc 7 Disconnect the incoming water and drain lines from the water cooled condenser 8 Insert a large screwdriver between the bottom spring coils of the water regulating valve Pry u...

Page 37: ...lean and sanitize the ice machine See Section 4 Ice machine is not level Level the ice machine See Section 2 Low air temperature around ice machine head section Air temperature must be at least 35 F 1 6 C Ice machine does not cycle into harvest mode The six minute freeze time lock in has not expired yet Wait for the freeze lock in to expire Ice thickness probe is dirty Clean and sanitize the ice m...

Page 38: ...e Cause To Correct Ice machine produces shallow or incomplete cubes or the ice fill pattern on the evaporator is incomplete Ice thickness probe is out of adjustment Adjust the ice thickness probe See Section 4 Water trough level is too low Check the water level probe for damage See Section 3 Water inlet valve filter screen is dirty Remove the water inlet valve and clean the filter screen See Secti...

Page 39: ...teps 5 6 The maximum harvest time is 3 1 2 minutes at which time the control board automatically terminates the harvest sequence If the bin switch is open the ice machine will go to automatic shut off step 7 If the bin switch is closed the ice machine will go to the freeze sequence steps 3 4 Ice Making Sequence Of Operation Control Board Relays Contactor Length Of Time 1 2 3 4 5 6 7 7A 7B Water Pu...

Page 40: ...econds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor 35 sec OFF 10 sec ON 5 Water Inlet Valve OFF 6 Water Dump Valve ON 7 Contactor Coil Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control B...

Page 41: ...d Refrigeration System Start Up Table 6 2 Self Contained Models 2 Refrigeration System Start Up 5 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve ON 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF Safety Control...

Page 42: ... 5 Water Inlet Valve On 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed SV3137 3 89 55 88 High Pressure Cutout Control Board L1 Ground 2 6 5 1 7 4 L2 or N Water Valve Harvest Valve 20 21 22 61 Dump Valve Water Pump 60 76 81...

Page 43: ...osed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve Cycles OFF then ON one more time 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control B...

Page 44: ...nds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON after 35 seconds 5 Water Inlet Valve 30 seconds OFF 15 seconds ON 6 Water Dump Valve ON 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF May Cycle ON Safety Controls Which could stop ice machine operation High Pressure Cut...

Page 45: ...h Activation Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF May Cycle ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse...

Page 46: ...ed Models 7 Automatic Shut Off Until Bin Switch Closes Toggle Switch ICE Bin Switch Open Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pre...

Page 47: ...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 Multi Pin Connection Electrical Box Side Compressor Compartm...

Page 48: ...ONTROL 59 CLEAN LEFT BIN RIGHT BIN RMT BIN WTR PROBE ICE PROBE HARVEST SL 1 SL 2 6 25 26 L2 AIR COMP 9 8 42 CONTROL BOARD BIN SWITCH LOW D C VOLTAGE PLUG CONTACTOR COIL 56 TERMINATES AT PIN CONNECTION PUMP WATER 99 98 58 FUSE 7A TRANS ICE THICKNESS WATER LEVEL SOLENOID 57 DUMP 81 76 LH HARVEST SOLENOID 87 77 WATER VALVE 60 61 22 21 7 2 1 5 HIGH PRESSURE CUTOUT 55 L2 OR N 88 20 AIR COMPRESSOR WHEN ...

Page 49: ...E WATER LEVEL PROBE SOLENOID DUMP 81 75 76 LH HARVEST SOLENOID 87 77 VALVE WATER 60 61 22 21 7 2 1 6 5 HIGH PRESSURE CUTOUT 55 89 88 20 59 CLEAN LEFT BIN RIGHT BIN RMT BIN WTR PROBE ICE PROBE HARV SL 1 SL 2 AIR COMPRESSOR WHEN USED 6 2 1 9 25 26 L2 AIR COMP FAN CYCLE CONTROL T3 L2 L3 COMPRESSOR T1 T2 51 85 86 CONTACTS CONTACTOR L1 L2 L3 L1 AIR COOLED ONLY FAN MOTOR RUN CAPACITOR FUSE 7A TRANS 4 99...

Page 50: ...ice machine shuts off The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain As the water curtain swings back to the operating position the bin switch closes and the ice machine restarts provide the three minute delay has expired Specifications The bin switch is a magnetically operated reed switch The magnet is at...

Page 51: ...le With the curtain open the reading must be infinity OL Continuity Test 1 Disconnect the bin switch wires to isolate the bin switch from the control board 2 Connect an ohmmeter to the disconnected bin switch wires 3 Cycle the bin switch open and closed 25 times by opening and closing the water curtain Watch for consistent readings each time the bin switch is cycled open and closed bin switch fail...

Page 52: ...he readings again Check Motor Windings to Ground Check continuity between all three terminals and the compressor shell or copper refrigeration line Scrape metal surface to get good contact If continuity is present the compressor windings are grounded and the compressor should be replaced Determine if the Compressor is Seized Check the amp draw while the compressor is trying to start COMPRESSOR DRA...

Page 53: ...igerant discharge and suction pressures to be somewhat equalized prior to the compressor starting To assure equalization of pressures the harvest valve and HPR valve on remotes will energize for 45 seconds prior to compressor starting The harvest valve and HPR valve on remotes remains on for an additional 5 seconds while the compressor is starting 2 When starting the compressor the contactor close...

Page 54: ... if the PTCR is properly cooled say 60 F 15 6 C when the compressor starts it will take 25 to 1 0 seconds before its temperature reaches 260 F 126 6 C and current flow is stopped If the PTCR is still warm say 160 F 71 1 C when the compressor starts it will take only 125 to 50 seconds before its temperature reaches 260 F 126 6 C and current flow is stopped This decreased time may be insufficient to...

Page 55: ...arts and remains on 5 seconds after the compressor starts Make sure this is occurring and the harvest valve and HPR solenoid coil is functional before assuming that the PTCR is bad CHECKING THE PTCR 1 Visually inspect the PTCR Check for signs of physical damage NOTE The PTCR case temperature may reach 210 F 100 C while the compressor is running This is normal Do not change a PTCR just because it i...

Page 56: ...ergized Relay Operation Check 1 Disconnect wires from relay terminals 2 Verify the contacts are closed Measure the resistance between terminals 1 and 2 No continuity indicates open contacts Replace the relay 3 Check the relay coil Measure the resistance between terminals 2 and 5 No resistance indicates an open coil Replace the relay HARVEST ASSIST AIR COMPRESSOR Function The air compressor breaks ...

Page 57: ...ded that a volt meter be used to check toggle switch operation 1 Inspect the toggle switch for correct wiring 2 Isolate the toggle switch by disconnecting the Molex connector 3 Check continuity across the toggle switch terminals Note where the wire numbers are connected to the switch terminals or refer to the wiring diagram to take proper readings 4 Replace the toggle switch if ohm readings do not...

Page 58: ...ICKNESS PROBE 3 16 CONNECTION WATER LEVEL PROBE DC LOW VOLTAGE ELECTRICAL PLUG NUMBERS MARKED ON WIRES WATER PROBE LIGHT GREEN LEFT BIN LIGHT GREEN HARVEST LIGHT RED REMOTE BIN CLEAN LIGHT YELLOW WATER PURGE ADJUSTMENT AIR COMPRESSOR NOT USED ON ALL MODELS RIGHT BIN LIGHT GREEN PRIMARY POWER SUPPLY N 115V L2 208 230V REMOTE BIN LIGHT GREEN ICE PROBE LIGHT GREEN SAFETY LIMIT 1 LIGHT RED SAFETY LIMI...

Page 59: ... board along with inputs controls all electrical components including the ice machine sequence of operation Prior to diagnosing you must understand how the inputs affect the control board operation Refer to specific component specifications inputs wiring diagrams and ice machine sequence of operation sections for details As an example refer to Ice Thickness Probe on the next page for information r...

Page 60: ...ol system includes a built in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 32 cm NOTE Make sure the water curtain is in place when performing this check It prevents water from splashing out of the water trough 1 Inspect the bridge connect...

Page 61: ...orator then monitor the harvest light Monitoring of Harvest Light Correction The harvest light comes on and 10 seconds later ice machine cycles from freeze to harvest The ice thickness probe is causing the malfunction The harvest light comes on but the ice machine stays in the freeze sequence The control circuitry is functioning properly The ice machine is in a six minute freeze time lock in verif...

Page 62: ...ter level control During the freeze cycle the water inlet valve energizes turns on and de energizes turns off in conjunction with the water level probe located in the water trough During the first 45 seconds of the Freeze Cycle The water inlet valve is on when there is no water in contact with the water level probe The water inlet valve turns off after water contacts the water level probe for 3 co...

Page 63: ...ne is not in a freeze cycle water inlet valve safety shut off mode You must complete the entire diagnostic procedure within 6 minutes of starting Important For the test to work properly you must wait until the freeze cycle starts prior to connecting the jumper wire If you restart the test you must disconnect the jumper wire restart the ice machine step 1 and then reinstall the jumper wire after th...

Page 64: ...f mode You must complete the entire diagnostic procedure within 6 minutes of starting Important For the test to work properly you must wait until the freeze cycle starts prior to disconnecting the water level probe If you restart the test you must reconnect the water level probe restart the ice machine step 1 and then disconnect the water level probe after the compressor starts Step 3 Disconnect w...

Page 65: ...sed The H P C O is closed if primary power voltage is present at terminals 55 and 56 on the control board 3 Verify control board fuse is OK If the bin switch light functions the fuse is OK 4 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 5 Verify ICE OFF CLEAN toggle switch functions properly A defective toggle switch may keep the ice machine...

Page 66: ...Electrical System Section 6 6 28 Part Number 80 1634 3 SELF CONTAINED 1 PHASE WITH TERMINAL BOARD SV2071 2 1 3 4 5 6 ...

Page 67: ...rbs 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 HEAT EXCHANGER EVAPORATOR CONDENSER COMPRESSOR EXPANSION VALVE HOT GAS SOLENOID VALVE AIR OR WATER DRIER STRAINER RECEIVER ...

Page 68: ...w 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 HEAT EXCHANGER EVAPORATOR CONDENSER COMPRESSOR EXPANSION VALVE HOT GAS SOLENOID VALVE AIR OR WATER DRIER STRAINER RECEIVER WATER COOLED ONLY LOW PRESSURE VAPOR LOW PRESSURE LIQUID HIGH...

Page 69: ...lf 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 x x HARVEST SOLENOID VALVE AIR OR WATER COOLED CONDENSER COMPRESSOR HEAT EXCHANGER RECEIVER DRIER STRAINER EXPANSION VALVE EXPANSION VALVE EVAPORATOR HARVEST SOLENOID VALVE ...

Page 70: ...n valve Actually the problem loose bulb was corrected when the technician properly mounted the bulb of the replacement expansion valve The service technician s failure to check the expansion valve bulb for proper mounting an external check resulted in a misdiagnosis and the needless replacement of a good expansion valve 2 An ice machine that is low on charge may cause a good expansion valve to sta...

Page 71: ...1 Determine the ice machine operating conditions Air temp entering condenser _______ Air temp around ice machine _______ Water temp entering sump trough _______ 2 Refer to the appropriate 24 Hour Ice Production Chart Use the operating conditions determined in Step 1 to find published 24 hour ice production 3 Perform an actual ice production check Use the formula below 4 Compare the results of step...

Page 72: ...er area evaporator is dirty Clean as needed Water inlet pressure not between 20 and 80 psi 1 5 Bar 138 552 kPa Install a water regulator valve or increase the water pressure Incoming water temperature is not between 35 F 1 6 C and 90 F 32 2 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 lea...

Page 73: ... cubes at the outlet of the evaporator may be more pronounced than those at the inlet This is normal The ice thickness probe must be set to maintain the ice bridge thickness at approximately 1 8 If ice forms uniformly across the evaporator surface but does not reach 1 8 in the proper amount of time this is still considered normal 2 Extremely Thin at Evaporator Outlet There is no ice or a considera...

Page 74: ...nerally caused by loss of heat transfer from the tubing on the back side of the evaporator Figure 7 5 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 Possible causes Water inlet valve water pump starving expansion valve low refrigerant charge compressor etc Figure 7 6 No Ice Formation Figure 7 7 S1800 Ev...

Page 75: ...rigeration industry a high percentage of compressors fail as a result of external causes These can include flooding or starving expansion valves dirty condensers water loss to the ice machine etc The safety limits protect the ice machine primarily the compressor from external failures by stopping ice machine operation before major component damage occurs The safety limit system is similar to a hig...

Page 76: ...em Low water pressure 20 psi 138 kPa min High water pressure 80 psi 552 kPa max High water temperature 90 F 32 2 C max Clogged water distribution tube Dirty defective water fill valve Dirty defective water dump valve Defective water pump Loss of water from sump area Electrical system Low incoming voltage Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not e...

Page 77: ... did not flash prior to the ice machine restarting then the ice machine did not stop because it exceeded a safety limit Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Water system Water area evaporator dirty Dirty defective water dump valve Vent tube not installed on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets ...

Page 78: ... Discharge Pressure Low Checklist NOTE Do not limit your diagnosis to only the items listed in the checklists Freeze Cycle PSIG kPa Harvest Cycle PSIG kPa Beginning of Cycle __________ __________ Middle of Cycle __________ __________ End of Cycle __________ __________ Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Restricted condenser water flow Low...

Page 79: ...C 2A Refer to Cycle Time and Operating Pressure charts for ice machine model being checked Using operating conditions from Step 1 determine published freeze cycle time and published freeze cycle suction pressure Published freeze cycle time Published freeze cycle suction pressure 8 5 9 8 minutes 58 28 PSIG 2B Compare the published freeze cycle time and published freeze cycle suction pressure Develo...

Page 80: ...refrigerant Other Non Manitowoc components in system Harvest valve stuck open TXV flooding check bulb mounting Defective compressor Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Discharge pressure Discharge pressure is too low and is affecting low side See Freeze Cycle Discharge Pressure Low Checklist Improper refrigerant charge Undercharged Wrong ...

Page 81: ...e 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 comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is lea...

Page 82: ...ambient and water temperatures the freeze cycle discharge line temperature will be higher than 160 F 71 1 C on a normally operating ice machine Procedure Connect a temperature probe on the compressor discharge line with in 6 of the compressor and insulate Observe the discharge line temperature for the last three minutes of the freeze cycle and record the maximum discharge line temperature Discharg...

Page 83: ... number with the highest total and proceed to Final Analysis NOTE If two columns have matching high numbers a procedure was not performed properly and or supporting material was not analyzed correctly Final Analysis The column with the highest number of check marks identifies the refrigeration problem COLUMN 1 HARVEST VALVE LEAKING A leaking harvest valve must be replaced COLUMN 2 LOW CHARGE TXV S...

Page 84: ...ty limit 1 or 2 Freeze Cycle Discharge Pressure _____ ______ ______ 1 minute Middle End into cycle If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist to eliminate problems and or components not listed on this table before proceeding Freeze Cycle Suction Pressure _____ ______ ______ 1 minute Middle End If suction pressure is High or Low refer...

Page 85: ...OFF CLEAN switch to OFF 2 Connect manifold gauges 3 Hook voltmeter in parallel across the HPCO leaving wires attached 4 Close the water service valve to the water condenser inlet 5 Set ICE OFF CLEAN switch to ICE 6 No water flowing through the condenser will cause the HPCO control to open because of excessive pressure Watch the pressure gauge and record the cut out pressure Replace the HPCO contro...

Page 86: ...50Hz production derate is 7 50Hz regular cube total production derate is 14 S1800 SERIES Self Contained Water Cooled NOTE These characteristics may vary depending on operating conditions Cycle Times Freeze Time Harvest Time Total Cycle Time 24 Hour Ice Production Operating Pressures Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 8 5 9...

Page 87: ...cuation Connections 3 Open backseat the high and low side ice machine service valves and open high and low side on manifold gauges 4 Perform recovery or evacuation A Recovery Operate the recovery unit as directed by the manufacturer s instructions B Evacuation prior to recharging Pull the system down to 500 microns Then allow the pump to run for an additional half hour Turn off the pump and perfor...

Page 88: ...hat no refrigerant contamination or loss occurs 8 Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses A Run the ice machine in freeze cycle B Close the high side service valve at the ice machine C Open the low side service valve at the ice machine D Open the high and low side valves on the manifold gauge set Any refrigerant in...

Page 89: ...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 Important Manitowoc Ice Inc assumes no responsibility for the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing ...

Page 90: ...cuum 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 the compressor 3 Disassemble the harvest solenoid valve If burnout deposits are...

Page 91: ...ine drier and change the liquid line drier 14 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 Water regulating valve High pressure cut out control High side service valve Low side se...

Page 92: ...Refrigeration System Section 7 7 26 Part Number 80 1634 3 Figure 7 10 Using Pinch Off Tool SV1406 ...

Page 93: ...arvest cycle These filter driers have a very high moisture removal capability and a good acid removal capability The size of the filter drier is important The refrigerant charge is critical Using an improperly sized filter drier will cause the ice machine to be improperly charged with refrigerant Listed below are the recommended O E M field replacement driers Important Driers are covered as a warr...

Page 94: ...NOTE All ice machines are charged using R 404A refrigerant Important This information is for reference only Refer to the ice machine serial number tag to verify the system charge Serial plate information overrides information listed on this page Series Version Charge S1800M Water Cooled 48 oz ...

Page 95: ...op Reclaim To reprocess refrigerant to new product specifications see below by means which may include distillation A chemical analysis of the refrigerant is required after processing to be sure that product specifications are met This term usually implies the use of processes and procedures available only at a reprocessing or manufacturing facility Chemical analysis is the key requirement in this...

Page 96: ...t 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 meet this standard Recovered refrigerant must come from a contaminant free system To decide whether the system is contaminant free consider Type s of previous failure s Whether the system was cleaned evacuated a...

Page 97: ...igerant pressure assume that moisture has entered the POE oil After the leak is found and repaired the compressor oil must be changed The compressor must be removed and at least 95 of the oil drained from the suction port of the compressor Use a measuring cup to replace the old oil with exactly the same amount of new POE oil such as Mobil EAL22A Remember care must be taken to prevent moisture from...

Page 98: ...Refrigeration System Section 7 7 32 Part Number 80 1634 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

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Page 100: ...aining on a Variety of Equipment Breakfast Lunch and Hotel Room Included with Tuition Contact Your Distributor or Manitowoc Ice Inc for Details OR Visit Our Website at www manitowocice com for School Dates MANITOWOC ICE INC 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 Phone 920 682 0161 Service Fax 920 683 7585 Web Site www manitowocice com 2004 Manitowoc Ice Inc ...

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Manitowoc MARINE MODEL S1800, Service Manual

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Summary of Contents for MARINE MODEL S1800

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