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Manitowoc NEO UD0140A, Technician'S Handbook

The Manitowoc NEO UD0140A is a highly efficient ice machine designed for commercial use. Ensure proper setup and long-term performance with the free Installation, Operation, and Maintenance Manual available for download at manualshive.com. This comprehensive manual covers all aspects of the product, guiding users through setup, operation, and maintenance procedures.

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Part Number 000014797 Rev02 05/18 

209

6.  Let the system “settle” for 2 to 3 minutes.
7.  Place the toggle switch in the ICE position.

NOTE: Manifold gauge set must be removed properly to 

ensure that no refrigerant contamination or loss occurs.

8.  Verify 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 the freeze cycle.
B.  Verify the refrigerant cylinder valve is closed.
C.  Open the high and low side valves on the 

manifold gauge set. Any refrigerant in the lines 

will be pulled into the low side of the system.

D.  Allow the pressures to equalize while the ice 

machine is in the freeze cycle.

E.  Close the high and low side manifold gauge set 

and remove from the ice machine.

F.  Remove the temporary access fittings 

Summary of Contents for NEO UD0140A

Page 1: ...t Number 000014797 Rev02 05 18 Undercounter Ice Machines Technician s Handbook This manual is updated as new information and models are released Visit our website for the latest manual www manitowocice com ...

Page 2: ......

Page 3: ...ntact information for service agents in your area This equipment contains high voltage electricity and refrigerant charge Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure The technician must also be certified in proper refrigerant handling and servicing procedures All lockout an...

Page 4: ...m the power supply e g circuit breaker or disconnect switch is provided Check all wiring connections including factory terminals before operation Connections can become loose during shipment and installation For a cord connected appliance the following must be included Do not unplug by pulling on cord To unplug grasp the plug not the cord Unplug from outlet when not in use and before servicing or ...

Page 5: ...ned weight of the equipment and product Additionally the equipment must be level side to side and front to back Remove front panel before lifting and installing and use appropriate safety equipment during installation and servicing Two or more people are required to lift or move this appliance to prevent tipping and or injury Do not damage the refrigeration circuit when installing maintaining or s...

Page 6: ...air between approximately 2 1 and 9 5 by volume LEL lower explosion limit and UEL upper explosion limit An ignition source at a temperature higher than 470 C is needed for a combustion to occur Refer to nameplate to identify the type of refrigerant in your equipment Only trained and qualified personnel aware of the dangers are allowed to work on the equipment Read this manual thoroughly before ope...

Page 7: ... chemicals rubber gloves and eye protection and or face shield must be worn DANGER Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications This appliance is not intended for use by persons including children with reduced physical sensory or mental capabilities or lack of experience and knowledge unless they have ...

Page 8: ...ment Risk of fire shock All minimum clearances must be maintained Do not obstruct vents or openings Failure to disconnect power at the main power supply disconnect could result in serious injury or death The power switch DOES NOT disconnect all incoming power All utility connections and fixtures must be maintained in accordance with the authority having jurisdiction Turn off and lockout all utilit...

Page 9: ...uirements 24 Electrical Specifications 24 Water Service Drains 26 Water Supply 26 Cooling Tower Applications 27 Maintenance Cleaning and Sanitizing Procedure U140 U190 U240 U310 29 Preventative Maintenance Cleaning 39 Cleaning the Condenser 41 Removal from Service Winterization 42 Bin Removal 43 Cleaning and Sanitizing Procedure UDE065 44 Cleaning The Condenser 50 Removal from Service Winterizatio...

Page 10: ...d Timers 71 Safety Limits 72 U0140 UF0140 U0190 UF0190 U240 UF240 U310 UF310 Energized Parts Chart 74 Operational Checks 76 Ice Thickness Check 76 Ice Thickness Adjustment 76 Minimum Maximum Slab weight 77 Sequence of Operation UDE065 78 UDE065 Energized Parts Chart 80 Ice Thickness Adjustment 81 Sequence of Operation UDE080 82 UDE080 Energized Parts Chart 84 Operational Checks UDE080 86 Siphon Sy...

Page 11: ...s Contact with the Harvest Float Switch 94 Ice Machine Cycles Into Harvest Before Water Loses Contact with the Harvest Float Switch 96 Ice Production Check 98 Installation Visual Inspection Checklist 100 Water System Checklist 101 Ice Formation Pattern 102 Safety Limit Feature 104 Analyzing Discharge Pressure 111 Analyzing Suction Pressure 113 Harvest Valve 117 Comparing Evaporator Inlet Outlet Te...

Page 12: ... Temperature 144 Comparing Evaporator Inlet Outlet Temperatures 147 Discharge Line Temperature Analysis 148 Harvest Valve 150 Troubleshooting UDE080 154 Diagnosing An Ice Machine That Will Not Run 154 Safety Limit Feature 155 Diagnosing Ice Thickness Control Circuitry160 Ice Production Check 162 Installation Visual Inspection Checklist 164 Water System Checklist 165 Flooding Expansion Valve Sympto...

Page 13: ...F0140 U0190 UF0190 U240 UF240 U310 UF310 188 Water Trough Thermistor U0140 UF0140 U0190 UF0190 U240 UF240 U310 UF310 190 Bin Thermostat UDE065 192 Liquid Line Thermistor UDE065 193 ON OFF WASH Toggle Switch UDE065 UDE080 195 Compressor Electrical Diagnostics 196 Fan Cycle Control UDE080 U0140 UF0140 U0190 UF0190 U240 UF240 U310 UF310 198 High Pressure Cutout HPCO Control UDE080 U0140 UF0140 U0190 ...

Page 14: ...0 UF0140 U0190 UF0190 U240 UF240 U310 UF310 204 Recovery and Recharging Procedures UDE065 UDE080 207 System Contamination Cleanup 210 Determining Severity of Contamination 210 Mild System Contamination Cleanup Procedure 212 Severe System Contamination Cleanup Procedure 213 Replacing Pressure Controls without Removing Refrigerant Charge 214 Total System Refrigerant Charge 216 ...

Page 15: ... contained Air cooled 220 UDE080 Operating Temperatures 221 U0140 UF0140 Self contained Air cooled 222 U0140 Self contained Water cooled 223 U0190 UF0190 Self contained Air cooled 224 U0240 UF0240 Self contained Air cooled 225 U0240 UF0240 Self contained Water cooled 226 U0310 UF0310 Self contained Air cooled 227 U0310 UF0310 Self contained Water cooled 228 ...

Page 16: ...40 U0310 Wiring Diagram With J4 Thermistor Terminal 1Ph Air Water 242 U0310 Wiring Diagram Prior To Thermistor Terminal 1PH Air Water 244 Electronic Control Boards 246 Electronic Control Board UF Models 246 Electronic Control Board U Models with J4 Thermistor Terminal 248 Electronic Control Board U Models Prior to Thermistor Terminal 250 Electronic Control Board UDE065 252 Electronic Control Board...

Page 17: ...ers the following models Self contained Air cooled Self contained Water cooled UDE065A UDE080A UDF0140A UYF0140A URF0140A UDP0140A UYP0140A UDF0240A UDF0240W UYF0240A UYF0240W UDF0310A UDF0310W UYF0310A UYF0310W URF0310A URF0310W UDP0310A UYP0310A General Information ...

Page 18: ...A UD0140W UD0140AE UD0140WE UY0140A UY0140W UY0140AE UY0140WE UR0140A UR0140AE UD0190A UD0190AE UY0190A UY0190AE UR0190A UR0190AE UD0240A UD0240W UD0240AE UD0240WE UY0240A UY0240W UY0240AE UY0240WE UR0240A UR0240AE UD0310A UD0310W UD0310AE UD0310WE UY0310A UY0310W UY0310AE UY0310WE UR0310A UR0310AE ...

Page 19: ...performed by properly trained refrigeration technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure Ice Machine Warranty Information For warranty information visit http www manitowocice com Service Warranty Warranty Verification Warranty Registration View and download a copy of the warranty Owner Warranty Registration Card Warranty coverage begins t...

Page 20: ...20 Part Number 000014797 Rev02 05 18 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 21: ...e location must not be near heat generating equipment or in direct sunlight The location must be capable of supporting the weight of the ice machine and a full bin of ice The location must allow enough clearance for water drain and electrical connections in the rear of the ice machine The location must not obstruct airflow through or around the ice machine condenser airflow is in and out the front...

Page 22: ...ditioning Peak UDE065 1600 2350 UDE080 1750 2600 U0140 UF0140 2400 2900 U0190 UF0190 2200 2600 U0240 UF0240 2800 3300 U0310 UF0310 3800 6000 B T U Hour Because the heat of rejection varies during the ice making cycle the figure shown is an average 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 w...

Page 23: ...in as far as possible Caution The legs must be screwed in tightly to prevent them from bending 3 Move the ice machine into its final position 4 Level the ice machine to ensure that the drain system functions correctly Use a level on top of the ice machine Turn each foot as necessary to level the ice machine from front to back and side to side ...

Page 24: ...auge is also dependent upon location materials used length of run etc so it must be determined by a qualified electrician Electrical Specifications Air cooled Ice Machine NOTE Model serial plate information overrides all data listed in this chart Ice Machine Voltage Phase Cycle Max Fuse Circuit Breaker Total Amps U0140 UF0140 115 1 60 15 5 0 208 230 1 60 15 2 5 230 1 50 15 2 5 U0190 UF0190 115 1 6...

Page 25: ...60 15 7 0 208 230 1 60 15 4 0 230 1 50 15 4 0 U0310 UF0310 115 1 60 15 10 0 208 230 1 60 15 4 5 230 1 50 15 4 5 NOTE Model serial plate information overrides all data listed in this chart nWarning All wiring must conform to local state and national codes nWarning The ice machine must be grounded in accordance with national and local electrical code ...

Page 26: ...onnections nWarning For ice making connect to a potable water supply only Water Inlet Lines Follow these guidelines to install water inlet lines Do not connect the ice machine to a hot water supply Be sure all hot water restrictors installed for other equipment are working Check valves on sink faucets dishwashers etc If water pressure exceeds the maximum recommended pressure 80 psig 5 5 bar obtain...

Page 27: ... A water cooling tower installation does not require modification of the ice machine The water regulator valve for the condenser continues to control the refrigeration discharge pressure It is necessary to know the amount of heat rejected and the pressure drop through the condenser and water valves inlet to outlet when using a cooling tower on an ice machine Water entering the condenser must not e...

Page 28: ...min 86 F 30 C max 34 8 psi 240 kPa min 89 9 psi 620 kPa max 3 4 Male Connection 3 8 95 cm min inside diameter Condenser Water Inlet 40 F 4 C min 90 F 32 C max 20 psi 1 38 bar min 150 psi 10 3 bar max 3 8 Female Pipe Thread U0310 only 1 2 Female Pipe Thread 3 8 9 5 mm min inside diameter U0310 only 1 2 Female Pipe Thread Condenser Water Drain 3 8 Female Pipe Thread 1 2 12 7 mm min inside diameter B...

Page 29: ... sanitizing Caution Use only Manitowoc approved Ice Machine Cleaner and Sanitizer It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Read and understand all labels printed on bottles before use Cleaning and Sanitizing Procedure U140 U190 U240 U310 Ice machine cleaner is used to remove lime scale and mineral deposits Ice machine sanitizer disinfects...

Page 30: ...machine will stop after the clean cycle Pausing the cleaning cycle Press the Clean button The clean light will flash indicating the clean cycle has paused Pressing the Clean button again will restart the clean cycle Step 1 Press the On Off button after ice falls from the evaporator at the end of a Harvest cycle Or press the On Off button and allow the ice to melt off the evaporator Caution Never u...

Page 31: ...until the water trough refills then add the proper amount of ice machine cleaner to the water trough Model Amount of Cleaner U0140 UF0140 2 ounces 60 ml U0190 UF0190 5 ounces 150 ml U240 UF0240 5 ounces 150 ml U310 UF0310 5 ounces 150 ml Wait until the clean cycle is complete approximately 22 minutes then press the On Off button and disconnect power and water supplies to the ice machine Step 4 Rem...

Page 32: ...ater solution to clean all components The cleaner solution will foam when it contacts lime scale and mineral deposits once the foaming stops use a soft bristle brush sponge or cloth not a wire brush to carefully clean the parts Soak the parts for 5 minutes 15 20 minutes for heavily scaled parts Rinse all components with clean water Step 6 While components are soaking use half of the cleaner water ...

Page 33: ...liberally apply the solution When sanitizing pay particular attention to the following areas Evaporator plastic parts including top bottom and sides Bin bottom sides and top Do not rinse the sanitized areas Step 9 Replace all removed components wait 10 minutes then reapply power and water to the ice machine Step 10 Select Clean Water will flow through the water dump valve and down the drain Wait u...

Page 34: ...ough the bulkhead grommet then disconnect the wire leads from the connector NOTE The wire from the top grommet goes to the ice thickness float switch front switch The wire from the bottom grommet goes to the Harvest float switch side switch Important Reversing the mounting location of the ice thickness and the harvest floats will result in a safety limit 2 failure The ice thickness float must be m...

Page 35: ...ber 000014797 Rev02 05 18 35 WIRE CONNECTORS ARE LOCATED BEHIND BULKHEAD PULL THROUGH GROMMET TO DISCONNECT HARVEST FLOAT SWITCH BRACKET ICE THICKNESS FLOAT SWITCH BRACKET DISCONNECT WIRES FOR COMPLETE REMOVAL ...

Page 36: ...Water Trough Remove the upper thumbscrew While supporting the water trough remove the thumbscrew and thermistor While supporting the water trough remove the lower thumbscrew from beneath the water trough Remove the water trough from the bin area UPPER THUMBSCREW LOWER THUMBSCREW ...

Page 37: ...18 37 3 Remove the Ice Damper Remove thumbscrew from bin switch cover Support ice damper and then pull bin switch cover and ice damper forward to remove 1 REMOVE THUMBSCREW 2 SUPPORT ICE DAMPER THEN SLIDE RIGHT SIDE FORWARD TO REMOVE ...

Page 38: ...vent loss Loosen thumbscrews but do not pull thumbscrews out of distribution tube Loosen the two outer screws and pull forward on the distribution tube to release NOTE For ease of assembly when reinstalling the water distribution tube install the top edge first 1 LOOSEN THUMBSCREWS 2 PULL DISTRIBUTION TUBE FORWARD TO REMOVE ...

Page 39: ...ng to force ice from the evaporator Damage may result nWarning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner or Sanitizer Step 2 To start a cleaning cycle press the Clean button Water will flow through the water dump valve and down the drain Wait until the water trough refills then add the proper amount of ice machine cleaner to the water trough Model A...

Page 40: ...nt of the ice machine There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life Exterior Cleaning Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation Sponge any dust and dirt off the outside of the ice machine with mild soap and water Wipe dry with a clean soft cloth Cleanup an...

Page 41: ... resulting in excessively high operating temperatures This reduces ice production and shortens component life Clean the condenser at least every six months nWarning The condenser fins are sharp Use care when cleaning them Shine a flashlight through the condenser to check for dirt between the fins Blow compressed air or rinse with water from the inside out opposite direction of airflow NOTE Cleanin...

Page 42: ... openings in the rear of the ice machine to remove all water 5 Press the On Off button and disconnect the electric power at the circuit breaker or the electric service switch 6 Fill spray bottle with sanitizer and spray all interior food zone surfaces Do not rinse and allow to air dry 7 Replace all panels Water cooled ice machines 1 Perform steps 1 6 under Self contained Aircooled Ice Machines 2 D...

Page 43: ...emove bin drain 6 Remove control box panel 7 Remove communication cable from control board 8 Remove rear cover 9 Slide bin forward to remove NOTE When reinstalling the bin ensure the bin seal is in place and is not pinched folded as it mates to the cabinet A watertight seal is required to prevent future condensation or water leakage from entering the ice machine base DISCONNECT COMMUNICATION CABLE...

Page 44: ... ice from the evaporator Damage may result Step 2 Remove all ice from the bin nWarning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner or Sanitizer Caution Do not mix Ice Machine Cleaner and Sanitizer solutions together It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Step 3 To start a cleaning cycle mov...

Page 45: ...he ice machine at the electric switch box before proceeding Step 6 Remove parts for cleaning A Remove the Overflow Tube To remove the tube lift it up while using a slight back and forth motion to loosen it from the drain hole When installing the tube be sure it is completely inserted into the drain hole to prevent water leakage during normal operation B Remove vinyl hose Disconnect the water pump ...

Page 46: ...er Depending on the amount of mineral buildup a larger quantity of solution may be required Use the ratio in the table below to mix enough solution to thoroughly clean all parts Solution Type Water Mixed with Cleaner 1 gal 4 l 16 oz 500 ml cleaner Step 8 Use of the cleaner water solution to clean all components The cleaner solution will foam when it contacts lime scale and mineral deposits once th...

Page 47: ...l 4 oz 120 ml sanitizer Step 11 Use 1 2 of the sanitizer water solution to sanitize all removed components Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer water solution Do not rinse parts after sanitizing Step 12 Use 1 2 of the sanitizer water solution to sanitize all foodzone surfaces of the ice machine and bin...

Page 48: ...6 to remove parts for hand sanitizing Step 18 Mix a solution of sanitizer and warm water Solution Type Water Mixed With Sanitizer 6 gal 23 l 4 oz 120 ml sanitizer Step 19 Use 1 2 of the sanitizer water solution to sanitize all removed components Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer water solution Do no...

Page 49: ... outside of the ice machine with mild soap and water Wipe dry with a clean soft cloth Treat all exterior stainless steel surfaces with a commercial grade stainless steel cleaner polish Ice Machine Inspection Check all water fittings and lines for leaks Also make sure the refrigeration tubing is not rubbing or vibrating against other tubing panels etc Do not put anything boxes etc in front of the i...

Page 50: ...side of the 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 Blow compressed air through the condenser fins from the inside Be careful not to bend the fan blades 4 Use a commercial condenser coil cleaner Fol...

Page 51: ... time or exposed to ambient temperatures of 320F 00C or below 1 Disconnect the electric power at the circuit breaker or the electric service switch 2 Turn off the water supply 3 Remove the water from the water trough 4 Disconnect the drain and the incoming ice making water line at the rear of the ice machine 5 Make sure no water is trapped inside the ice machine incoming water lines drain lines di...

Page 52: ... ice from the evaporator Damage may result Step 2 Remove all ice from the bin nWarning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner or Sanitizer Caution Do not mix Ice Machine Cleaner and Sanitizer solutions together It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Step 3 To start a cleaning cycle mov...

Page 53: ...sconnect electric power to the ice machine at the electric switch box before proceeding Step 6 Remove parts for cleaning A Remove Two Thumbscrews and Water Pump Cover B Remove the Vinyl Hose Connecting the Water Pump and Water Distribution Tube C Remove Water Pump Disconnect the water pump power cord Loosen the screws securing the pump mounting bracket to the bulkhead Lift the pump and bracket ass...

Page 54: ...or a flat object between the back wall and the grommet and prying forward Pull the bulkhead grommet and wire forward until the connector is accessible then disconnect the wire lead from the connector Ice Thickness Probe Cleaning Mix a solution of Manitowoc ice machine cleaner and water 2 ounces of cleaner to 16 ounces of water in a container Soak the ice thickness probe a minimum of 10 minutes Cle...

Page 55: ...e the Water Distribution Tube Loosen the two thumbscrews which secure the distribution tube Lift the distribution tube up off the thumbscrews Disassembly Twist the barbed end until the tab lines up with the key way Pull the inner tube end outward ...

Page 56: ...Float Valve Turn the splash shield counterclockwise one or two turns Pull the float valve forward and off the mounting bracket Disconnect the water inlet tube from the float valve at the compression fitting Remove the cap and filter screen for cleaning ...

Page 57: ...Trough Apply downward pressure on the siphon tube and remove from the bottom of the water trough Remove the upper thumbscrew While supporting the water trough remove the two thumbscrews from beneath the water trough Remove the water trough from the bin area ...

Page 58: ...ht hand ice damper mounting bracket Pull forward on the ice damper until the left hand mounting pin disengages Installation Grasp the right side of ice damper and place left hand pin in the mounting bracket While applying pressure against the left hand mounting bracket push the damper until the right hand mounting pin engages ...

Page 59: ...b While applying pressure against the bin door pull down on the rear of each bin door track until the door pins clear the stop tabs Slide the rear door pins off the end and then below the door track Slide bin door forward allowing the back of the door to lower into the bin Continue forward with the bin door until the front pins bottom out in the track Lift right side of door until the front pins c...

Page 60: ...s once the foaming stops use a soft bristle brush sponge or cloth not a wire brush to carefully clean the parts Soak the parts for 5 minutes 15 20 minutes for heavily scaled parts Rinse all components with clean water Step 9 While components are soaking use of the cleaner water solution to clean all foodzone surfaces of the ice machine and bin Use a nylon brush or cloth to thoroughly clean the fol...

Page 61: ...reas Evaporator plastic parts including top bottom and sides Bin bottom sides and top Do not rinse the sanitized areas Step 13 Replace all removed components Step 14 Reapply power and water to the ice machine and place the toggle switch in the WASH position Step 15 Add the proper amount of Manitowoc Ice Machine Sanitizer to the water trough Model Amount of Sanitizer UDE080 1 5 ounces 45 ml Step 16...

Page 62: ...ed parts in the sanitizer water solution Do not rinse parts after sanitizing Step 20 Use 1 2 of the sanitizer water solution to sanitize all foodzone surfaces of the ice machine and bin Use a cloth or sponge to liberally apply the solution When sanitizing pay particular attention to the following areas Evaporator plastic parts including top bottom and sides Bin bottom sides and top Do not rinse th...

Page 63: ...side of the 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 Blow compressed air through the condenser fins from the inside Be careful not to bend the fan blades 4 Use a commercial condenser coil cleaner Fol...

Page 64: ... time or exposed to ambient temperatures of 320F 00C or below 1 Disconnect the electric power at the circuit breaker or the electric service switch 2 Turn off the water supply 3 Remove the water from the water trough 4 Disconnect the drain and the incoming ice making water line at the rear of the ice machine 5 Make sure no water is trapped inside the ice machine incoming water lines drain lines di...

Page 65: ...ressure sensitive buttons to control ice machine operation and provide operational status On Off Blue Machine On Off Machine Is Off Delay Blue Delay Mode On Off Delay Mode Is Off Clean Yellow Clean Cycle On Off Cleaning is Off Flashing Cleaning Is Paused Bin Full Blue Bin Is Full Off Bin Is Not Full Service Red Needs Service Off Doesn t Need Service Operation ...

Page 66: ...se from the evaporator Delay Pressing the Delay button will start a delay period The ice machine will finish the freeze and harvest cycle and then start the delay period Pressing the button once will start a 4 hour delay period Pressing the button twice will start a 12 hour delay period Pressing the button three times will start a 24 hour delay period Pressing the button four times will cancel the...

Page 67: ...n cycle The On Off light will flash on off to indicate pause mode Pressing the On Off button again will continue the Clean cycle from the point of interruption Pressing the control board test button anytime during the clean cycle will cancel the clean cycle Opening the damper for 30 seconds during the clean cycle will start and automatic shutdown sequence Bin Full The Bin Full light energizes when...

Page 68: ... can be used without thermistors or EC fan motors SOFTWARE REVISIONS In addition to the primary sequence of operation the following software changes have been added Control boards with water trough thermistor and firmware version before 2 70 The water trough thermistor performs the following function in the freeze cycle When the temperature of the water reaches 34 F the water pump de energizes for...

Page 69: ... the ice thickness float switch is satisfied Freeze Water flowing across the evaporator cools as the freeze cycle progresses Software version 2 58 or higher The water pump turns off for 25 seconds and the water inlet valve energizes for 7 seconds when the pump restarts Water flowing across the evaporator will start to freeze and build ice on the evaporator After a sheet of ice has formed the harve...

Page 70: ...st cycle initiates using the following sequence 1 The compressor de energizes 2 The water inlet valve energizes and fills the water trough 3 The water pump energizes for 2 minutes and circulates water over the evaporator If the bin switch did not open close 4 The water dump valve energizes and drains water from the water trough 5 Step 1 through 4 repeat 6 A freeze cycle starts NOTE If the bin swit...

Page 71: ...rvest sequence The maximum harvest time is a total of 7 minutes If the bin switch does not activate within 3 5 minutes the harvest cycle extends another 3 5 minutes If 7 minutes is exceeded a Harvest Assist Cycle starts The water fill valve is de energized 1 minute after the freeze cycle starts The control board will energize the water inlet valve one more times 3 minutes into the freeze cycle Con...

Page 72: ...l flash on off at 1 second intervals If 6 consecutive 45 minute freeze cycles occur the ice machine stops and the SL 1 light on the control board and the Service wrench light on the touch pad will be on continuously Safety Limit 2 If the harvest time reaches 3 5 minutes the control board automatically energizes the water pump and extends the harvest cycle another 3 5 minutes 7 minutes total If the...

Page 73: ...cycles if the freeze time reaches 4 minutes and water is not sensed the ice machine stops and initiates a 30 minute delay period Control board lights SL 1 and SL 2 along with the touch pad Service wrench light will flash on off at 1 second intervals The ice machine automatically restarts at the end of the 30 minute delay period and stops flashing the control board and Service wrench lights If 100 ...

Page 74: ...at Switch Ice Thickness Float Switch Length of Time Initial Start up 1 Water purge Off On Off On Off Closed Closed 20 seconds 2 Refrigeration System Start up Off On Off Off On Closed Closed 5 seconds Freeze Sequence 3 Pre chill Off Off On Off On Open Closed 60 Seconds 120 Seconds Initial Cycle After Automatic Shutoff 4 Freeze On Off On Off On Open Then Closed Closed Then Open Until Harvest Float S...

Page 75: ...t may cycle on and off F irmware 2 58 with thermistor When the water temperature reaches 34 F the water pump de energizes for 25 seconds When the pump restarts the water inlet valve energizes for 7 seconds Firmware 2 58 without thermistor At 3 75 minutes the water pump de energizes for 25 seconds When the pump restarts the water inlet valve energizes for 7 seconds Firmware prior to 2 58 The water ...

Page 76: ...t the thickness of the bridge refer to ice thickness adjustment ICE THICKNESS ADJUSTMENT The ice thickness can be adjusted to three levels 1 Pull forward on the bottom of the bracket until clear of the tab 2 Slide the bracket over the desired tab and release The center position is the normal factory setting To increase bridge thickness raise the water level To decrease bridge thickness lower the w...

Page 77: ... Ice Weight Per Cycle lbs Grams Maximum Ice Weight Per Cycle lbs Grams U0140 UF0140 1 13 lbs 513 grams 1 36 lbs 617 grams U0190 UF0190 2 26 lbs 1025 grams 2 93 lbs 1329 grams U0240 UF0240 2 26 lbs 1025 grams 2 93 lbs 1329 grams U0310 UF0310 2 26 lbs 1025 grams 2 93 lbs 1329 grams ...

Page 78: ... minutes 175 seconds after the water fill valve and hot gas valve are energized The water fill valve and hot gas valve remain energized for 5 seconds during compressor start up and then shut off The compressor remains on throughout the entire freeze and harvest cycles 3 Freeze Cycle The condenser fan motor and water pump are energized and remain on throughout the entire freeze cycle An even flow o...

Page 79: ...nes the length of the harvest cycle based on the temperature of the refrigeration system liquid line at the end of the freeze cycle At the end of the harvest cycle the ice machine returns to another freeze cycle step 3 5 Automatic Shut off The level of ice in the ice storage bin controls the ice machine shut off When the bin is full ice cubes contact the bin thermostat bulb holder which cools down...

Page 80: ...Compressor 2 Hot Gas Valve Water Fill Valve 3 Water Pump Fan Motor Initial Start up 1 Water Purge 2 Refrigeration Start up off on off 175 Seconds 2 9 minutes on on off 5 Seconds 3 Freeze Cycle on off on Automatically Determined 4 Harvest cycle on on off Automatically Determined 5 Automatic Shut off off off off Until Bin Thermostat Closes ...

Page 81: ...igh the ice slab The combined weight of all cubes from one harvest should weigh between 200 270g 7 9 oz If the slab weight is within this range the ice machine is working properly and no further action is needed If the slab weight is not within this range or you desire a slightly thicker or thinner cube continue to step four 4 Remove the air filter the two screws holding the front panel in place a...

Page 82: ...ower 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 relay As a result any time the relay coil is energized the compressor and fan motor are supplied with power 3 Prechill The compressor is on for 30 seconds prior to water flow to prechill th...

Page 83: ...ntary opening and re closing of the bin switch terminates the harvest cycle and returns the ice machine to freeze steps 3 4 6 Automatic Shut off When the storage bin is full at the end of a harvest sequence the sheet of cubes fails to clear the ice damper and will hold it down After the ice damper is held open for 7 seconds the ice machine shuts off The ice machine remains off for 3 minutes before...

Page 84: ...alve 3 Relay Coil 3A Compressor 3B Compressor Fan Motor Initial Start up 1 Water purge off on off off off 15 seconds 2 Refrigeration System Start up off on on on on 5 seconds Freeze Sequence 3 Prechill off off on on on 30 seconds 4 Freeze on off on on on Until 7 sec Water contact w ice thickness probe Harvest Sequence 5 Harvest off on on on on Bin switch activation ...

Page 85: ... ICE MAKING SEQUENCE OF OPERATION Control Board Relays Relay Length of Time 1 Water Pump 2 Hot Gas Valve 3 Relay Coil 3A Compressor 3B Compressor Fan Motor Automatic Shut off 6 Auto Shut off off off off off off Until bin switch re closes ...

Page 86: ...ction The siphon action stops when the water level in the sump trough drops When the siphon action stops the float valve refills the water trough to the correct level Follow steps 1 through 6 under water level check to verify the siphon system functions correctly WATER LEVEL Check the water level while the ice machine is in the ice mode and the water pump is running The correct water level is 1 4 ...

Page 87: ...e stops adding water 4 Adjust the water level to 1 4 to 3 8 6 3 to 9 5 mm below the standpipe the line in the water trough A Loosen the two screws on the float valve bracket B Raise or lower the float valve assembly as necessary then tighten the screws C Move the main ON OFF WASH toggle switch to the OFF position The water level in the trough will rise above the standpipe and run down the drain 5 ...

Page 88: ...t to maintain an ice bridge of 1 8 3 2 mm If an adjustment is needed follow the steps below 1 Turn the ice thickness probe adjustment screw clockwise for a thicker ice bridge or counterclockwise for a thinner ice bridge 2 Make sure the ice thickness probe wire and bracket does not restrict movement of the probe 1 8 Ice Bridge Thickness Adjustment Screw ...

Page 89: ...fer to Safety Limit Feature Ice sheet is thick Water trough level is too high Adjust ice thickness float Power button was turned off on during freeze cycle and ice remained on evaporator Allow ice to thaw and release from evaporator then restart Ice damper was opened then closed in the harvest cycle before the ice released Allow ice to thaw and release from evaporator then restart Ice machine does...

Page 90: ... Ice machine produces shallow or incomplete cubes or the ice fill pattern on the evaporator is incomplete Ice thickness switch is out of adjustment Adjust the ice thickness switch Water trough level is too high or too low Check the water level Water filtration is poor Replace the filter Hot incoming water Connect the ice machine to a cold water supply Incorrect incoming water pressure Water pressu...

Page 91: ...ring the freeze cycle and ice remained on the evaporator Allow ice to thaw and release from the evaporator then restart Ice damper was opened and closed in the harvest cycle before the ice released Allow ice to thaw and release from the evaporator then restart Long harvest cycles with repeated safety limit indication Clean the ice machine perform diagnostic procedures as required ...

Page 92: ...nitiate and complete one ice making cycle then stop Canceling a test cycle To cancel a test cycle press the test button a second time Restarting a test cycle The test cycle will restart each time the test button is pressed for a 3 second time period OPERATING ICE MACHINE WITH BIN AND TOUCH PAD REMOVED The ice machine is designed to allow diagnostic procedures to be performed with the bin removed T...

Page 93: ...er is closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 4 Verify power button functions properly A defective power button may keep the ice machine in the OFF mode Refer to touch pad diagnostics page 186 when Steps 1 3 test good 5 Be sure Steps 1...

Page 94: ...osed in the harvest cycle before the ice releases Remove all ice from the evaporator before starting diagnostic procedures Freeze Time Lock In Feature The ice machine control system incorporates a freeze time lock in feature This prevents the ice machine from short cycling in and out of harvest The control board locks the ice machine in the freeze cycle for six minutes After six minutes a harvest ...

Page 95: ...itch Diagnostics The harvest light stays off and the ice machine remains in freeze Proceed to Step 3 Step 3 Disconnect the harvest float switch wire from the control board and place a jumper on the control board harvest float switch terminals Bypass the freeze time lock in feature by pressing the power button to cycle the ice machine off on Wait until water flows over the evaporator then refer to ...

Page 96: ...nnect power to the ice machine remove the electrical panel to allow viewing of the control board lights and pull the wire connector for the harvest float switch through the bulkhead and disconnect WIRE CONNECTORS ARE LOCATED BEHIND BULKHEAD PULL THROUGH GROMMET TO DISCONNECT HARVEST FLOAT SWITCH BRACKET ICE THICKNESS FLOAT SWITCH BRACKET ...

Page 97: ...cycles from freeze to harvest and the control board harvest light energizes Proceed to Step 3 Step 3 Disconnect the harvest float switch wire from the control board and bypass the freeze time lock in feature by pressing the power button to cycle the ice machine off on Wait until water flows over the evaporator then refer to chart Result Correction The harvest light does not come on The harvest flo...

Page 98: ..._ Water temp entering sump trough ____ 2 Refer to the appropriate Cycle Times 24 Hr Ice Production and Refrigerant Pressure Charts on page 217 Use the operating conditions determined in Step 1 to find published 24 Hour Ice Production _____ Times are in minutes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights are in pounds Example 2 lb 6 oz converts to 2 375 lb 6 o...

Page 99: ...p 3 with step 2 Ice production is normal when these numbers match closely If they match closely determine if Another larger ice machine is required Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc distributor for information on available options and accessories ...

Page 100: ...HECKLIST Ice machine is not level Level the ice machine Condenser is dirty Clean the condenser Water filtration is plugged if used Install a new water filter Water drains are not run separately and or are not vented Run and vent drains according to the Installation Manual ...

Page 101: ...alve or increase the water pressure Incoming water temperature is not between 40 F 3 C and 90 F 32 C If too hot check the hot water line check valves in other store equipment Water filtration is plugged if used Install a new water filter Vent tube is not installed on water outlet drain See Installation Instructions Hoses fittings etc are leaking water Repair replace as needed Water valve is stuck ...

Page 102: ...amples of Evaporator Tubing Routing Normal Ice Formation Ice forms across the entire evaporator surface At the beginning of the Freeze cycle it may appear that more ice is forming on the inlet of the evaporator than at the outlet At the end of the Freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet o...

Page 103: ...nsiderable lack of ice formation at the inlet of the evaporator Examples The ice at the outlet of the evaporator reaches the correct thickness but there is no ice formation at all at the inlet of the evaporator Possible cause Insufficient water flow flooding TXV etc Spotty Ice Formation There are small sections on the evaporator where there is no ice formation This could be a single corner or a si...

Page 104: ...ze cycles occur the ice machine stops and the SL 1 light on the control board and the Service wrench light on the touch pad will be on continuously Safety Limit 2 If the harvest time reaches 3 5 minutes the control board automatically energizes the water pump and extends the harvest cycle another 3 5 minutes 7 minutes total If the ice damper does not open and close within the 7 minute harvest cycl...

Page 105: ...cycles if the freeze time reaches 4 minutes and water is not sensed the ice machine stops and initiates a 30 minute delay period Control board lights SL 1 and SL 2 along with the touch pad Service wrench light will flash on off at 1 second intervals The ice machine automatically restarts at the end of the 30 minute delay period and stops flashing the control board and Service wrench lights If 100 ...

Page 106: ...sh SL 3 neither float opened within 4 minutes of the freeze cycle CONTROL BOARD SAFETY LIMIT LIGHT OPERATION USING THE POWER BUTTON 1 Press the power button once 2 Press the power button again to start ice making 3 Watch the safety limit lights One will flash corresponding to safety limits 1 or 2 4 Safety limit 3 is indicated by both SL 1 SL 2 flashing After safety limit indication the ice machine...

Page 107: ...Water Level too high or defective float switch water escaping water trough Low water pressure 20 psig min High water pressure 80 psig max High water temperature 90 F 32 2 C max Clogged water distribution tube Dirty defective water inlet valve Defective water pump Electrical System Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operational Restricted c...

Page 108: ... System Non Manitowoc components Improper refrigerant charge Defective compressor TXV starving or flooding check bulb mounting Non condensible in refrigeration system Plugged or restricted high side refrigerant lines or component Defective harvest valve ...

Page 109: ...lled on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Low water pressure 20 psig min Loss of water from sump area Clogged water distribution tube Dirty defective water inlet valve Defective water pump Electrical system Water inlet valve defective Bin switch defective Premature harvest Refrigeration system Non Manitowoc com...

Page 110: ...l Inspection Checklist on page 100 Water System Dirty defective water dump valve Low water float valve dirty or defective Vent tube not installed on water outlet drain Low water pressure 20 psig min Dirty defective water filter when used Loss of water from sump area Dirty defective water inlet valve Electrical system Water inlet valve coil defective Low water float valve defective ...

Page 111: ...ressures Freeze Cycle ______ Harvest Cycle ______ 3 Perform an actual discharge pressure check Freeze Cycle PSIG Harvest Cycle PSIG Beginning of Cycle __________ __________ Middle of Cycle __________ __________ End of Cycle __________ __________ 4 Compare the actual discharge pressure Step 3 with the published discharge pressure Step 2 The discharge pressure is normal when the actual pressure fall...

Page 112: ...ondensible in system Wrong type of refrigerant Other Non Manitowoc components in system High side refrigerant lines component restricted before mid condenser Freeze Cycle Discharge Pressure Low Checklist Improper Installation Refer to Installation Visual Inspection Checklist on page 100 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system High...

Page 113: ...r temperature entering the ice machine changes These variables also determine the freeze cycle times To analyze and identify the proper suction pressure drop throughout the freeze cycle compare the published suction pressure to the published freeze cycle time NOTE Analyze discharge pressure before analyzing suction pressure High or low discharge pressure may be causing high or low suction pressure...

Page 114: ...6 Published Freeze Cycle Suction Pressure psig In the example the proper suction pressure should be approximately 39 psig at 7 minutes 30 psig at 12 minutes etc 3 Perform an actual suction pressure check at the beginning middle and end of the freeze cycle Note the times at which the readings are taken Example Manifold gauge set was connected to the example ice machine and suction pressure readings...

Page 115: ...100 Discharge Pressure Discharge pressure is too high and is affecting suction pressure refer to Discharge Pressure High Checklist on page 112 Improper Refrigerant Charge Overcharged Wrong type of refrigerant Non condensible in system Other Non Manitowoc components in system Harvest valve leaking TXV flooding check bulb mounting Defective compressor ...

Page 116: ...sure Low Checklist on page 112 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Improper water supply over evaporator refer to Water System Checklist on page 101 Loss of heat transfer from tubing on back side of evaporator Restricted plugged liquid line drier Restricted plugged tubing in suction side of refrigeration system TXV starving NO...

Page 117: ...The harvest valve is not used during the freeze cycle The harvest valve is de energized closed preventing refrigerant flow from the receiver into the evaporator 2 Allows refrigerant vapor to enter the evaporator in the harvest cycle During the harvest cycle the harvest valve is energized open allowing refrigerant gas from the discharge line of the compressor to flow into the evaporator The heat is...

Page 118: ...emaining partially open during the freeze cycle can be similar to symptoms of an expansion valve float valve or compressor problem Symptoms are dependent on the amount of leakage in the freeze cycle A small amount of leakage will cause increased freeze times and an ice fill pattern that is Thin at the Outlet but fills in at the end of the cycle As the amount of leakage increases the length of the ...

Page 119: ...let or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking 3 Feel the compressor discharge line nWarning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand Just touch them momentarily 4 Compare the temperature...

Page 120: ...he temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest valve and the compressor discharg...

Page 121: ...e cycle These temperatures must be within 7 F 4 C 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 Importan Do not simply insert the sensing device under the insul...

Page 122: ...t air temperatures affect the maximum discharge line temperature Higher ambient air temperatures at the condenser higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser lower discharge line temperatures at the compressor Regardless of ambient temperature the freeze cycle discharge line temperature will be higher than 150 F 66 C on a normally operating ...

Page 123: ...nsion valve sensing bulb is positioned and secured correctly Discharge Line Temperature Below 150 F 66 C at End of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that decreases each cycle Verify the expansion valve sensing bulb is 100 insulated and sealed airtight Condenser air contacting an incorrectly insulated sensing bulb will caus...

Page 124: ...eck marks in the boxes Each time the actual findings of an item in the Operational Analysis column matches the published findings on the table enter a check mark Example Freeze cycle suction pressure is determined to be low Enter a check mark in the low box Perform the procedures and check all information listed Each item in this column has supporting reference material While analyzing each item s...

Page 125: ... charge of refrigerant If the problem 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 evacuate the system and weigh in the proper charge If the problem is not corrected by adding charge the expansion valve is fa...

Page 126: ...ed capacity Installation and Water System All installation and water related problems must be corrected before proceeding with chart Ice Formation Pattern Ice formation is extremely thin on outlet of evaporator or No ice formation on entire evaporator Ice formation is extremely thin on outlet of evaporator or No ice formation on entire evaporator Ice formation is normal or Ice formation is extreme...

Page 127: ... evaporator or No ice formation on entire evaporator Ice formation is extremely thin on outlet of evaporator or No ice formation on entire evaporator Ice formation is normal or Ice formation is extremely thin on the bottom of evaporator or No ice formation on evaporator Ice formation is normal or No ice formation on entire evaporator Safety Limits Refer to Analyzing Safety Limits to eliminate all ...

Page 128: ...list 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 to freeze cycle high or low suction pressure problem checklist to eliminate problems and or components not listed on this table before proceeding Suction pressure is High Suction pressure is Low Suc...

Page 129: ...The compressor discharge line is HOT Discharge Line Temp Record freeze cycle discharge line temp at the end of freeze cycle Discharge line temp 150 F 66 C or higher at the end of freeze cycle Discharge line temp 150 F 66 C or higher at the end of freeze cycle Discharge line temp less than 150 F 66 C at the end of freeze cycle Discharge line temp 150 F 66 C or higher at the end of freeze cycle Fina...

Page 130: ...cuit breaker is closed 2 Verify control board fuse is okay If the bin switch light functions the fuse is okay 3 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 4 Verify ON OFF WASH toggle switch functions properly A defective toggle switch may keep the ice machine in the OFF mode 5 Verify low DC voltage is properly grounded Loose DC wire conne...

Page 131: ...fill pattern Clean with Manitowoc Ice Machine cleaner to remove any mineral buildup before diagnosing the refrigeration system The following can be used for diagnostics 1 Install a temperature lead on the compressor suction line within 6 of the compressor 2 Install a temperature lead on the compressor discharge line within 6 of the compressor 3 Refer to the Cycle Times 24 Hr Ice Production and Ref...

Page 132: ...YCLE Suction line temperature at the compressor will range from 64 F 18 C to 111 F 44 C through the harvest cycle An obstructed capillary tube will not effect suction line temperature range during the harvest cycle Low refrigerant charge will have a lower temperature than normal Discharge line temperature at the compressor will range from 180 F 82 C to 150 F 60 C through the harvest cycle Ice fill...

Page 133: ...ult in a starving evaporator An obstructed capillary tube or low refrigerant charge will have a suction line temperature higher than normal An obstructed capillary tube or low refrigerant charge will have a discharge line temperature lower than normal An obstructed capillary tube will not effect the discharge line temperature during the harvest cycle A low freeze and discharge line temperature in ...

Page 134: ...__ Water temp entering sump trough ____ 2 Refer to the appropriate Cycle Times 24 Hr Ice Production and Refrigerant Pressure Charts on page 217 Use the operating conditions determined in Step 1 to find published 24 Hour Ice Production _____ Times are in minutes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights are in pounds Example 2 lb 6 oz converts to 2 375 lb 6 ...

Page 135: ...p 3 with step 2 Ice production is normal when these numbers match closely If they match closely determine if Another larger ice machine is required Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc distributor for information on available options and accessories ...

Page 136: ...HECKLIST Ice machine is not level Level the ice machine Condenser is dirty Clean the condenser Water filtration is plugged if used Install a new water filter Water drains are not run separately and or are not vented Run and vent drains according to the Installation Manual ...

Page 137: ...ot check the hot water line check valves in other store equipment Water filtration is plugged if used Install a new water filter Vent tube is not installed on water outlet drain See Installation Instructions Hoses fittings etc are leaking water Repair replace as needed Water valve is stuck open closed or is leaking Clean replace as needed Water is spraying out of the sump trough area Stop the wate...

Page 138: ...ycle is not used for diagnostics Start monitoring temperatures 3 minutes into the second freeze cycle Compare Suction and Discharge temperatures to your model in the charts starting on page 217 The charts list normal suction and discharge temperatures Analysis Discharge Line Temp Suction Line Temp Ice Fill Pattern Refer to Diagnostics for Normal Normal Less fill on the left side of the evaporator ...

Page 139: ...ERANT CHARGE SYMPTOMS A Ice Fill Pattern Thin on top two rows of the evaporator Thin on entire left side of the evaporator Thick on the bottom of the evaporator B Freeze time longer than normal Diagnosis can be confirmed by adding installing a temporary access valve and adding 2 oz 56 7 g of refrigerant If the suction line temperature drops or the ice fill pattern on the top two rows fills in the ...

Page 140: ...NLET Normal Ice Formation Ice forms across the entire evaporator surface At the beginning of the Freeze cycle it may appear that more ice is forming on the inlet of the evaporator than at the outlet At the end of the Freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet of the evaporator may be more pr...

Page 141: ...nsiderable lack of ice formation at the inlet of the evaporator Examples The ice at the outlet of the evaporator reaches the correct thickness but there is no ice formation at all at the inlet of the evaporator Possible cause Insufficient water flow flooding TXV etc Spotty Ice Formation There are small sections on the evaporator where there is no ice formation This could be a single corner or a si...

Page 142: ...ratures Freeze Cycle ______ Harvest Cycle ______ 3 Perform an actual discharge temperature check Freeze Cycle Temperature Harvest Cycle Temperature Beginning of Cycle __________ __________ Middle of Cycle __________ __________ End of Cycle __________ __________ 4 Compare the actual discharge temperature Step 3 with the published discharge temperature Step 2 The discharge temperature is normal when...

Page 143: ...n condensible in system Wrong type of refrigerant Other Non Manitowoc components in system High side refrigerant lines component restricted before mid condenser Freeze Cycle Discharge Temperature Low Checklist Improper Installation Refer to Installation Visual Inspection Checklist on page 136 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in syste...

Page 144: ...ting conditions Air temperature entering condenser ______ Air temperature around ice machine ______ Water temperature entering sump trough ______ Use the operating conditions determined in step 1 to find the published normal suction temperatures Freeze Cycle ______ Harvest Cycle ______ 2 Perform an actual suction temperature check Freeze Cycle Temperature Harvest Cycle Temperature Beginning of Cyc...

Page 145: ...ischarge Pressure Discharge temperature is too high and is affecting suction temperature refer to Discharge Line Temperature High Checklist on page 143 Improper Refrigerant Charge Overcharged Wrong type of refrigerant Non condensible in system Other Non Manitowoc components in system Harvest valve leaking TXV flooding check bulb mounting Defective compressor ...

Page 146: ...emperature Low Checklist on page 143 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Improper water supply over evaporator refer to Water System Checklist on page 137 Loss of heat transfer from tubing on back side of evaporator Restricted plugged liquid line drier Restricted plugged tubing in suction side of refrigeration system TXV starv...

Page 147: ...in 7 F 4 C 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 Importan Do not simply insert the sensing device under the insulation It must be attached to and readin...

Page 148: ...t air temperatures affect the maximum discharge line temperature Higher ambient air temperatures at the condenser higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser lower discharge line temperatures at the compressor Regardless of ambient temperature the freeze cycle discharge line temperature will be higher than 150 F 66 C on a normally operating ...

Page 149: ...nsion valve sensing bulb is positioned and secured correctly Discharge Line Temperature Below 150 F 66 C at End of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that decreases each cycle Verify the expansion valve sensing bulb is 100 insulated and sealed airtight Condenser air contacting an incorrectly insulated sensing bulb will caus...

Page 150: ...rom entering the evaporator during the freeze cycle The harvest valve is not used during the freeze cycle The harvest valve is de energized closed preventing refrigerant flow from the receiver into the evaporator 2 Allows refrigerant vapor to enter the evaporator in the harvest cycle During the harvest cycle the harvest valve is energized open allowing refrigerant gas from the discharge line of th...

Page 151: ...emaining partially open during the freeze cycle can be similar to symptoms of an expansion valve float valve or compressor problem Symptoms are dependent on the amount of leakage in the freeze cycle A small amount of leakage will cause increased freeze times and an ice fill pattern that is Thin at the Outlet but fills in at the end of the cycle As the amount of leakage increases the length of the ...

Page 152: ...let or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking 3 Feel the compressor discharge line nWarning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand Just touch them momentarily 4 Compare the temperature...

Page 153: ...t and approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest valve and the c...

Page 154: ...it breaker is closed 2 Verify control board fuse is okay 3 If the bin switch light functions the fuse is okay 4 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 5 Verify ON OFF WASH toggle switch functions properly A defective toggle switch may keep the ice machine in the OFF mode 6 Verify low DC voltage is properly grounded Loose DC wire conne...

Page 155: ...tically returns the ice machine to the freeze cycle 3 cycles outside the time limit Safety Limit must be MANUALLY reset Safety Limit Stand by Mode The first time a safety limit shut down occurs the ice machine turns off for 60 minutes Stand by Mode The ice machine will then automatically restart to see if the problem reoccurs During the Stand by Mode the harvest light will be flashing continuously...

Page 156: ...o ON 3 Watch the harvest light It will flash one or two times corresponding to safety limits 1 and 2 to indicate which safety limit stopped the ice machine After safety limit indication the ice machine will restart and run until a safety limit is exceeded again Safety Limit Notes A continuous run of 100 harvests automatically erases the safety limit code The control board will store and indicate o...

Page 157: ...ge 164 Water System Water Level too high or defective float water escaping water trough Low water pressure 20 psig min High water pressure 80 psig max High water temperature 90 F 32 2 C max Clogged water distribution tube Defective water pump Electrical System Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operational Restricted condenser air flow Hig...

Page 158: ... System Non Manitowoc components Improper refrigerant charge Defective compressor TXV starving or flooding check bulb mounting Non condensible in refrigeration system Plugged or restricted high side refrigerant lines or component Defective harvest valve ...

Page 159: ...tube not installed on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Low water pressure 20 psig min Loss of water from sump area Clogged water distribution tube Dirty defective water inlet float Defective water pump Electrical system Bin switch defective Premature harvest Refrigeration system Non Manitowoc components Improp...

Page 160: ...e ice control circuitry is functioning properly The ice machine is in a six minute freeze time lock in Verify Step 1 of this procedure was followed correctly The harvest light does not come on Proceed to Step 3 Step 3 Disconnect the ice thickness probe from the control board terminal Clip the jumper wire to the terminal on the control board and any cabinet ground Monitor the harvest light Step 3 J...

Page 161: ...est light Step 2 Disconnect the ice thickness probe from the control board terminal Step 2 Disconnect probe from control board terminal Monitoring 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 Verify that the Ice Thickness probe is adjusted correctly The harvest light comes on and 6 10 seco...

Page 162: ...ice machine operating conditions Air temperature entering condenser ____ Air temperature around ice machine ____ Water temperature entering sump trough ____ 2 Refer to the appropriate model in the Cycle Times 24 Hr Ice Production and Refrigerant Pressure Charts on page 217 Use the operating conditions determined in Step 1 to find published 24 Hour Ice Production _____ Times are in minutes Example ...

Page 163: ...es per Day Actual 24 Hour Production Weighing the ice is the only 100 accurate check 4 Compare the results of step 3 with step 2 Ice production is normal when these numbers match closely If they match closely determine if Another larger ice machine is required Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc distributor for information on avail...

Page 164: ...HECKLIST Ice machine is not level Level the ice machine Condenser is dirty Clean the condenser Water filtration is plugged if used Install a new water filter Water drains are not run separately and or are not vented Run and vent drains according to the Installation Manual ...

Page 165: ...hot check the hot water line check valves in other store equipment Water filtration is plugged if used Install a new water filter Vent tube is not installed on water outlet drain See Installation Instructions Hoses fittings etc are leaking water Repair replace as needed Water valve is stuck open closed or is leaking Clean replace as needed Water is spraying out of the sump trough area Stop the wat...

Page 166: ...ycle is not used for diagnostics Start monitoring temperatures 3 minutes into the second freeze cycle Compare Suction and Discharge temperatures to your model in the charts starting on page 217 The charts list normal suction and discharge temperatures Analysis Discharge Line Temp Suction Line Temp Ice Fill Pattern Refer to Diagnostics for Normal Normal Less fill on the left side of the evaporator ...

Page 167: ...ERANT CHARGE SYMPTOMS A Ice Fill Pattern Thin on top two rows of the evaporator Thin on entire left side of the evaporator Thick on the bottom of the evaporator B Freeze time longer than normal Diagnosis can be confirmed by adding installing a temporary access valve and adding 2 oz 56 7 g of refrigerant If the suction line temperature drops or the ice fill pattern on the top two rows fills in the ...

Page 168: ...NLET Normal Ice Formation Ice forms across the entire evaporator surface At the beginning of the Freeze cycle it may appear that more ice is forming on the inlet of the evaporator than at the outlet At the end of the Freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet of the evaporator may be more pr...

Page 169: ...nsiderable lack of ice formation at the inlet of the evaporator Examples The ice at the outlet of the evaporator reaches the correct thickness but there is no ice formation at all at the inlet of the evaporator Possible cause Insufficient water flow flooding TXV etc Spotty Ice Formation There are small sections on the evaporator where there is no ice formation This could be a single corner or a si...

Page 170: ...ratures Freeze Cycle ______ Harvest Cycle ______ 3 Perform an actual discharge temperature check Freeze Cycle Temperature Harvest Cycle Temperature Beginning of Cycle __________ __________ Middle of Cycle __________ __________ End of Cycle __________ __________ 4 Compare the actual discharge temperature Step 3 with the published discharge temperature Step 2 The discharge temperature is normal when...

Page 171: ...n condensible in system Wrong type of refrigerant Other Non Manitowoc components in system High side refrigerant lines component restricted before mid condenser Freeze Cycle Discharge Temperature Low Checklist Improper Installation Refer to Installation Visual Inspection Checklist on page 164 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in syste...

Page 172: ...ting conditions Air temperature entering condenser ______ Air temperature around ice machine ______ Water temperature entering sump trough ______ Use the operating conditions determined in step 1 to find the published normal suction temperatures Freeze Cycle ______ Harvest Cycle ______ 2 Perform an actual suction temperature check Freeze Cycle Temperature Harvest Cycle Temperature Beginning of Cyc...

Page 173: ...ischarge Pressure Discharge temperature is too high and is affecting suction temperature refer to Discharge Line Temperature High Checklist on page 171 Improper Refrigerant Charge Overcharged Wrong type of refrigerant Non condensible in system Other Non Manitowoc components in system Harvest valve leaking TXV flooding check bulb mounting Defective compressor ...

Page 174: ...emperature Low Checklist on page 171 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Improper water supply over evaporator refer to Water System Checklist on page 165 Loss of heat transfer from tubing on back side of evaporator Restricted plugged liquid line drier Restricted plugged tubing in suction side of refrigeration system TXV starv...

Page 175: ...in 7 F 4 C 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 Importan Do not simply insert the sensing device under the insulation It must be attached to and readin...

Page 176: ...mperatures affect the maximum discharge line temperature Higher ambient air temperatures at the condenser equal higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser equal lower discharge line temperatures at the compressor NOTE Regardless of ambient temperature the freeze cycle discharge line temperature will be higher than 150 F 66 C on a normally o...

Page 177: ...nsion valve sensing bulb is positioned and secured correctly Discharge Line Temperature Below 150 F 66 C at End of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that decreases each cycle Verify the expansion valve sensing bulb is 100 insulated and sealed airtight Condenser air contacting an incorrectly insulated sensing bulb will caus...

Page 178: ...rom entering the evaporator during the freeze cycle The harvest valve is not used during the freeze cycle The harvest valve is de energized closed preventing refrigerant flow from the receiver into the evaporator 2 Allows refrigerant vapor to enter the evaporator in the harvest cycle During the harvest cycle the harvest valve is energized open allowing refrigerant gas from the discharge line of th...

Page 179: ...emaining partially open during the freeze cycle can be similar to symptoms of an expansion valve float valve or compressor problem Symptoms are dependent on the amount of leakage in the freeze cycle A small amount of leakage will cause increased freeze times and an ice fill pattern that is Thin at the Outlet but fills in at the end of the cycle As the amount of leakage increases the length of the ...

Page 180: ...let or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking 3 Feel the compressor discharge line nWarning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand Just touch them momentarily 4 Compare the temperature...

Page 181: ...t and approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest valve and the c...

Page 182: ...182 Part Number 000014797 Rev02 05 18 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 183: ...age is applied to the control board at all times Removing the control board fuse or pressing the power button will not remove the power supplied to the control board Check Procedure 1 If the curtain light is on with the ice damper closed the fuse is good nWarning Disconnect electrical power to the entire ice machine before proceeding 2 Remove the fuse Check the resistance across the fuse with an o...

Page 184: ... opening 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 ice damper and holds it down After the ice damper is held down for 7 seconds the ice machine shuts off The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the ice dampe...

Page 185: ...ain light off indicates the bin switch has opened properly Ohm 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 numerous times by opening and closing the water curtain NOTE To prevent mis diagnosis Always use the water curtain magnet to cycle the switch a larger ...

Page 186: ... button Power light turns on With power light energized press the delay button 4 times Cycles through 4 hour delay 12 hour delay 24 hour delay and off Press and hold the power button for 3 seconds Power light turns off Press and hold the clean button for 3 seconds Clean light turns on Press and hold the clean button for 3 seconds Clean light turns off If any switches do not operate correctly disco...

Page 187: ... that functions correctly will close as the button is pressed and open as the button is released Do not insert electrical probe into end of connector This will stretch the connector and cause intermittent connection issues All readings must be taken on the flat exterior of the connector Selection Wires On Off 2 7 Delay 3 7 Clean 4 7 1 2 3 4 5 6 7 8 9 10 11 12 TOUCH ELECTRICAL PROBE TO THESE LOCATI...

Page 188: ... the up position the magnet in the float opens the contacts Check Procedure The ice machine uses two float switches Ice Thickness Float Indicates the water level has been reached Harvest Float Indicates a harvest cycle needs to be initiated Initial testing can be performed by viewing the control board light s while raising and lowering the float The corresponding control board light must turn on a...

Page 189: ...switch through the bulkhead and disconnect 2 Attach an ohm meter lead to each float switch wire 3 Place the float in the down position The float switch must be closed 4 Place the float in the up position The float switch must be open FLOAT CLOSED FLOAT OPEN NOTE Make adjustments with the ice machine in the off position Making adjustments during the freeze cycle may produce an initial sheet of ice ...

Page 190: ... machine is experiencing long freeze cycle shut down we recommend removing the thermistor and bracket permanently Check procedure THERMISTOR 1 Disconnect thermistor from control board and measure resistance 2 Measure temperature at the thermistor 3 Compare measured resistance temperature readings to resistance temperature relationship chart A Within 10 of the published resistance value Thermistor ...

Page 191: ... 03 1 1 34 30 85 1 5 34 7 30 25 2 0 35 6 29 49 2 5 36 5 28 76 3 0 37 28 05 3 5 38 27 36 4 0 10 5 39 51 26 68 19 43 11 0 15 0 52 59 18 97 15 71 15 5 20 0 60 68 15 35 12 49 20 5 25 0 69 77 12 21 10 00 25 5 30 0 78 86 9 78 8 05 30 5 35 0 87 95 7 88 6 39 36 5 40 0 98 104 6 14 5 32 40 5 46 0 105 115 5 22 4 20 NOTE The control board will default to a 3 75 minute pump delay in the freeze cycle whenever t...

Page 192: ...e thermostat bulb holder to warm and closes the bin thermostat restarting the ice machine Specifications Control Setting Bin Thermostat Cut in 40 F 4 5 C Cut out 34 F 1 0 C nWarning Disconnect electrical power to the entire ice machine before proceeding 1 Remove the back panel to access the bin thermostat 2 Disconnect both wires from the bin thermostat and check the resistance across the bin therm...

Page 193: ...lated thermistor wire leads 2 Using a temperature meter capable of taking readings on curved copper lines attach the temperature meter sensing device to the liquid line next to the thermistor Importan Do not simply insert the sensing device under the insulation It must be attached to and reading the actual temperature of the copper liquid line 3 With the ice machine running verify that the tempera...

Page 194: ... 31 11 88 21 1 26 7 70 80 11 88 9 29 26 7 32 2 80 90 9 29 7 33 32 2 37 8 90 100 7 33 5 82 37 8 43 3 100 110 5 82 4 66 43 3 48 9 110 120 4 66 3 75 48 9 54 5 120 130 3 75 3 05 54 5 60 0 130 140 3 05 2 49 60 0 65 6 140 150 2 49 2 04 65 6 17 1 150 160 2 04 1 68 76 7 82 2 170 180 1 40 1 17 82 2 87 3 180 190 1 17 0 98 87 8 93 3 190 200 0 98 0 82 93 3 98 9 200 210 0 82 0 70 100 212 0 73 0 62 Boiling wate...

Page 195: ...E Because of a wide variation in D C voltage it is not recommended that a voltmeter be used to check toggle switch operation 1 Inspect the toggle switch for correct wiring 2 Isolate the toggle switch by disconnecting all wires from the switch or by disconnecting the Molex connector from the control board 3 Check across the toggle switch terminals using a calibrated ohmmeter Note where the wire num...

Page 196: ...move the wires from the compressor terminals 2 The resistance values between C and S and between C and R when added together should equal the resistance value between S and R 3 If the overload is open there will be a resistance reading between S and R and open readings between C and S and between C and R Allow the compressor to cool then check the readings again Check Motor Windings to Ground Chec...

Page 197: ...he pressures do not move the compressor is seized Replace the compressor If the pressures move the compressor is turning slowly and is not seized Check the capacitors and relay Compressor Drawing High Amps The continuous amperage draw on start up should not be near the maximum fuse size indicated on the serial tag The wiring must be correctly sized to minimize voltage drop at compressor start up T...

Page 198: ...g 5 200 psig 5 U0240 U0310 275 psig 5 225 psig 5 Check Procedure Disconnect electrical power to the ice machine at the electrical service disconnect Verify fan motor windings are not open or grounded and fan spins freely Connect manifold gauge to ice machine Hook voltmeter in parallel across the fan cycle control leaving wires attached Reconnect electrical power to the ice machine and press the po...

Page 199: ...ook voltmeter in parallel across the HPCO leaving wires attached 4 On water cooled models close the water service valve to the water condenser inlet On self contained air cooled models disconnect the fan motor 5 Set to ON No water or air 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 nWarning ...

Page 200: ...nitowoc drier has dirt retaining filtration with fiberglass filters on both the inlet and outlet ends This is very important because ice machines have a back flushing action that takes place during every harvest cycle A Manitowoc filter drier has a very high moisture removal capability and a good acid removal capacity Importan The liquid line drier is covered as a warranty part The liquid line dri...

Page 201: ...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 202: ...bility for use of contaminated refrigerant Damage resulting from the use of contaminated recovered or recycled refrigerant is the sole responsibility of the servicing company Manitowoc approves the use of 1 New Refrigerant Must be of original nameplate type 2 Reclaimed Refrigerant Must be of original nameplate type Must meet ARI Standard 700 latest edition specifications 3 Recovered or Recycled Re...

Page 203: ...ed and recharged properly following failure s Whether the system has been contaminated by this failure Compressor motor burnouts and improper past service prevent refrigerant re use Refer to Recovery and Recharging Procedures UDE065 UDE080 on page 207 to test for contamination 5 Substitute or Alternative Refrigerant Must use only Manitowoc approved alternative refrigerants Must follow Manitowoc pu...

Page 204: ...umes no responsibility for the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company Importan Replace the liquid line drier before evacuating and recharging Use only a Manitowoc O E M liquid line filter drier to prevent voiding the warranty CONNECTIONS 1 Suction side of the compressor through the suction servic...

Page 205: ...n off the pump and perform a standing vacuum leak check NOTE Check for leaks using an electronic leak detector after charging the ice machine Follow the Charging Procedures below CHARGING PROCEDURES Importan The charge is critical on all Manitowoc ice machines Use a scale or a charging cylinder to ensure the proper charge is installed 1 Be sure the power button is in the OFF position 2 Close the v...

Page 206: ... 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 when supplied or disconnect the low loss fitting from the access valve D Open the high and low side valves on the manifold gauge set Any refrigerant in the lines will be pulled into the low side of the system E Allow the pressures to equalize while the ice machine is...

Page 207: ...ing Use only a Manitowoc OEM liquid line filter drier to prevent voiding the warranty CONNECTIONS These ice machines are critically charged There are no refrigerant access ports on these ice machines 1 Locate the high and low side process tubes 2 Install a piercing valve saddle valve on both the high and low side process tubes Importan Remove piercing valves after charging Unit is critically charg...

Page 208: ...anding vacuum leak check NOTE Check for leaks using a halide or electronic leak detector after charging the ice machine CHARGING PROCEDURES Importan The charge is critical on all Manitowoc ice machines Use a scale to ensure the proper charge is installed A quick disconnect is required for the high side connection 1 Verify the toggle switch is in the OFF position 2 Close the vacuum pump valve and t...

Page 209: ...rawn into the ice machine before disconnecting the charging hoses A Run the ice machine in the freeze cycle B Verify the refrigerant cylinder valve is closed C Open the high and low side valves on the manifold gauge set Any refrigerant in the lines will be pulled into the low side of the system D Allow the pressures to equalize while the ice machine is in the freeze cycle E Close the high and low ...

Page 210: ...igeration system Inspection of the refrigerant usually provides the first indication of system contamination Obvious moisture or an acrid odor in the refrigerant indicates contamination If either condition is found or if contamination is suspected use a test kit If a refrigerant test kit indicates harmful levels of contamination or if a test kit is not available inspect the compressor oil 1 Remove...

Page 211: ...d or acid oil test shows contamination No burnout deposits in open compressor lines Mild contamination cleanup procedure Mild Compressor Burnout symptoms Oil appears clean but smells acrid Refrigeration test kit or acid oil test shows harmful acid content No burnout deposits in open compressor lines Mild contamination cleanup procedure Severe Compressor Burnout symptoms Oil is discolored acidic an...

Page 212: ...eplace the evacuation step with the following A Pull vacuum to 1000 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig B Pull vacuum to 500 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig C Change the vacuum pump oil D Pull vacuum to 500 microns Run the vacuum pump for 1 2 hour on self contained models...

Page 213: ...ressurize to a minimum of 5 psig B Change the vacuum pump oil C Pull vacuum to 500 microns Break the vacuum with dry nitrogen and sweep the system Pressurize to a minimum of 5 psig D Change the vacuum pump oil E Pull vacuum to 500 microns Run the vacuum pump for 1 additional hour 10 Charge the system with the proper refrigerant to the nameplate charge 11 Operate the ice machine for one hour Then c...

Page 214: ...far from the pressure control as feasible See the figure on next page Clamp down on the tubing until the pinch off is complete nWarning Do not unsolder a defective component Cut it out of the system Do not remove the pinch off tool until the new component is securely in place 3 Cut the tubing of the defective component with a small tubing cutter 4 Solder the replacement component in place Allow th...

Page 215: ...Part Number 000014797 Rev02 05 18 215 FIG A PINCHING OFF TUBING FIG B RE ROUNDING TUBING Using Pinch Off Tool ...

Page 216: ... Model Air Cooled Water Cooled Refrigerant Type UDE065 5 8 oz 165 g NA R134A UDE080 8 oz 227 g NA R134A U0140 10 oz 283 g 11 oz 312 g R404A UF0140 6 7 oz 12g 11 oz 312 g R404A U0190 UF0190 12 oz 340 g NA R404A U0240 13 oz 369 g 12 oz 340 g R404A UF240 13 oz 369 g 13 oz 369 g R404A U0310 Serial Number 310304977 and Earlier 15 oz 425 g 14 oz 397 g R404A U0310 Serial Number 310304978 and After 15 oz ...

Page 217: ...ariances in water and air temperature Actual temperatures will seldom match the chart exactly Regular cube production derate is 7 Refer to Operational Analysis Chart for the list of data that must be collected for refrigeration diagnostics Zero out manifold gauge set before obtaining pressure readings to avoid mis diagnosis Discharge and suction pressure are highest at the beginning of the cycle S...

Page 218: ... 6 12 7 11 2 14 8 12 3 16 3 80 27 10 7 14 1 12 6 16 7 14 0 18 6 90 32 12 0 15 9 14 0 18 6 15 6 20 9 100 38 15 2 20 2 16 6 22 2 18 3 24 5 110 43 20 3 27 3 21 1 28 4 22 0 29 5 Times in minutes 24 Hour Ice Production Air Temp Entering Condenser F C Water Temperature F C 50 10 Lbs Kg 70 21 Lbs Kg 90 32 Lbs Kg 50 10 58 26 3 52 23 5 48 21 7 70 21 57 25 8 50 22 7 46 20 8 80 27 52 23 5 45 20 4 41 18 6 90 ...

Page 219: ...Temp F C Suction Line Temp F C 50 10 105 120 40 50 52 12 11 11 130 140 54 60 100 115 38 46 70 21 125 155 51 68 60 4 16 20 145 155 63 68 115 135 46 57 80 27 130 160 54 71 70 0 21 18 155 170 68 77 110 145 43 63 90 32 150 165 66 74 75 5 24 15 165 175 74 79 125 150 51 66 100 38 175 185 79 85 85 10 29 12 185 195 85 91 145 165 63 74 110 43 180 190 82 88 90 12 32 11 190 200 88 93 145 170 63 77 ...

Page 220: ...uction Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 95 80 70 80 27 90 75 65 90 32 80 65 55 100 38 70 60 50 Based on average ice slab weight of 1 0 1 3 lb 400 600 g Operating Temperatures 50 F 10 C Water Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Line Temp F C Suction Line Temp F C Discharge Line Temp F C Suction Line Temp F C 50 10 150 165...

Page 221: ... 94 55 70 13 21 90 32 180 205 82 96 85 65 29 18 185 210 85 99 55 75 13 24 100 38 190 220 88 104 88 70 31 21 200 220 93 104 60 75 16 24 90 F 32 C Water Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Line Temp F C Suction Line Temp F C Discharge Line Temp F C Suction Line Temp F C 50 10 155 180 68 82 75 50 24 10 160 185 71 85 52 65 11 18 70 21 160 185 71 85 75 53 24 12 165 190 ...

Page 222: ... 24 Hour Ice Production Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 130 110 105 80 27 120 105 95 90 32 115 95 85 100 38 95 85 80 110 43 85 80 70 Based on average ice slab weight of 1 06 1 19 lb 481 540 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pr...

Page 223: ...F C 50 10 70 21 90 32 70 21 135 120 105 80 27 130 115 100 90 32 115 105 90 100 38 105 90 80 110 43 95 80 70 Based on average ice slab weight of 1 06 1 19 lb 481 540 g Regular cube derate is 7 Water regulating valve set to maintain 230 PSIG discharge pressure Condenser water usage 185 gallons per 100 lbs of ice at 90 F 70 F Operating Pressures Air Temp Around Ice Machine F C Freeze Cycle Harvest Cy...

Page 224: ... Ice Production Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 200 165 155 80 27 165 150 135 90 32 150 140 115 100 38 130 115 105 110 43 115 105 100 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge...

Page 225: ...ur Ice Production Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 225 190 175 80 27 210 180 160 90 32 195 160 145 100 38 170 150 140 110 43 150 140 135 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Dischar...

Page 226: ...re F C 50 10 70 21 90 32 70 21 200 190 180 80 27 195 185 175 90 32 180 170 160 100 38 175 165 155 110 43 170 160 150 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Water regulating valve set to maintain 235 PSIG discharge pressure Condenser water usage 149 gallons per 100 lbs of ice at 90 F 70 F Operating Pressures Air Temp Around Ice Machine F C Freeze Cycle...

Page 227: ...r Ice Production Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 305 265 225 80 27 295 255 235 90 32 280 235 210 100 38 255 210 185 110 43 205 170 155 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharg...

Page 228: ...ture F C 50 10 70 21 90 32 70 21 270 275 260 80 27 305 270 255 90 32 300 250 240 100 38 295 250 235 110 43 290 245 230 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Water regulating valve set to maintain 235 PSIG discharge pressure Condenser water usage 149 gallons per 100 lbs of ice a 90 F 70 F Operating Pressures Air Temp Around Ice Machine F C Freeze Cycl...

Page 229: ...wer before working on electrical circuitry Wiring Diagram Legend The following symbols are used on all of the wiring diagrams Internal Compressor Overload Some models have external compressor overloads Fan Motor Run Capacitor Some models do not incorporate fan motor run capacitor Wire Number Designation The number is marked at each end of the wire Multi pin Connection Electrical Box Side Compresso...

Page 230: ...0014797 Rev02 05 18 UDE065 WIRING DIAGRAM 1PH Self Contained Air cooled 040006021 1 2 3 1 1 2 2 3 3 4 4 5 5 0 22 23 24 N 25 26 20 21 3 6 7 8 14 2 1 12 13 4 9 L1 GRND 27 4 5 7 19 13 56 18 32 49 58 42 17 41 40 34 28 23 14 ...

Page 231: ...enser Fan Motor 17 Contactor Coil 18 Contactor Contacts 19 Control Board 23 Jumper Air cooled or Drain Pump Safety Switch Water cooled 28 Fuse 32 Ice Thickness Control 34 Light Harvest 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 56 Water Inlet Valve 58 Water Pump Refer to control board schematic for control board detail ...

Page 232: ...00014797 Rev02 05 18 UDE080 WIRING DIAGRAM 1PH Self Contained Air cooled 11 10 13 R S C 3 000001517_00 22 23 24 L2 N 10 11 20 21 2 3 6 7 8 5 9 4 12 13 15 14 L1 GRND 3 5 7 12 13 14 31 17 25 58 42 17 33 40 34 1 34 2 19 41 ...

Page 233: ... 13 Compressor Start Relay 14 Condenser Fan Motor 17 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 28 Fuse 31 High Pressure Cutout 33 Ice Thickness Probe 34 1 Light Bin Switch 34 2 Light Harvest 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve Harvest 58 Water Pump Refer to control board schematic for control board detail ...

Page 234: ...tained Air Water cooled RED WHT 1 2 3 4 L1 BLU 14 BRN 12 PRPL 15 BRN 13 BRN 3 C S 10 13 R 11 040004017 REV04 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 5 12 25 3 42 17 56 55 41 19 28 18 7 13 40 14 27 26 58 31 49 ...

Page 235: ...7 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve 49 Thermistor 55 Water Dump Valve 56 Water Inlet Valve 58 Water Pump Wire Colors BLK Black BLU Blue BRN Brown PNK Pink PRPL Purple RED Red WHT White YEL Yel...

Page 236: ...R WATER Self Contained Air Water cooled RED WHT 1 2 3 4 L1 BLU 14 BRN 12 PRPL 15 BRN 13 BRN 3 C S 10 13 R 11 040004017 REV04 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 5 12 25 3 42 17 56 55 41 19 28 18 7 13 40 14 27 26 58 31 49 ...

Page 237: ... Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve 49 Thermistor 55 Water Dump Valve 56 Water Inlet Valve 58 Water Pump Wire Colors BLK Black BLU Blue BRN Brown PNK Pink PRPL Purple RED Red WHT White YEL Yell...

Page 238: ...AIR WATER Self Contained Air Water cooled RED WHT 1 2 3 4 L1 BLU 14 BRN 12 PRPL 15 BRN 13 BRN 3 C S 10 13 R 11 041114017 REV02 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 5 12 25 3 42 17 56 55 41 19 28 18 7 13 40 14 27 26 58 31 ...

Page 239: ...r 17 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve Harvest 55 Water Dump Valve 56 Water Inlet Valve 58 Water Pump Wire Colors BLK Black BLU Blue BRN Brown PNK Pink PRPL Purple RED Red WHT White YEL Yellow...

Page 240: ...Water cooled RED WHT 1 2 3 4 L1 14 BRN 12 PRPL 15 BRN 48 BLK C S R S 040005873_00 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 47 YEL 49 RED R 46 ORG 45 BLU 5 11 25 42 17 56 55 41 19 28 18 7 9 40 14 27 26 58 31 34 3 49 ...

Page 241: ...otor 17 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve 49 Thermistor 55 Water Dump Valve 56 Water Inlet Valve 58 Water Pump Wire Colors BLK Black BLU Blue BRN Brown PNK Pink PRPL Purple RED Red WHT White Y...

Page 242: ...ained Air Water cooled RED WHT 1 2 3 4 L1 14 BRN 12 PRPL 15 BRN 48 BLK C S R S 040003315 REV05 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 47 YEL 49 RED R 46 ORG 45 BLU 5 11 25 42 17 56 55 41 19 28 18 7 9 40 14 27 26 58 31 14 34 3 49 ...

Page 243: ...r 17 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve 49 Thermistor 55 Water Dump Valve 56 Water Inlet Valve 58 Water Pump Wire Colors BLK Black BLU Blue BRN Brown PNK Pink PRPL Purple RED Red WHT White YEL ...

Page 244: ...ntained Air Water cooled RED WHT 1 2 3 4 L1 14 BRN 12 PRPL 15 BRN 48 BLK C S R S 040003315 REV05 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 47 YEL 49 RED R 46 ORG 45 BLU 5 11 25 42 17 56 55 41 19 28 18 7 9 40 14 27 26 58 31 14 34 3 ...

Page 245: ...Fan Motor 17 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solenoid Valve 55 Water Dump Valve 56 Water Inlet Valve 58 Water Pump Wire Colors BLK Black BLU Blue BRN Brown PNK Pink PRPL Purple RED Red WHT White YEL Yellow...

Page 246: ...246 Part Number 000014797 Rev02 05 18 Electronic Control Boards ELECTRONIC CONTROL BOARD UF MODELS 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 18 20 21 23 24 25 22 ...

Page 247: ...ED Thermistor 7 LED Thermistor 8 LED Thermistor 9 LED Water Fill Valve 10 LED Harvest Float 11 LED Water Level Float 12 LED Bin Switch 13 LED Safety Limit 2 14 LED Safety Limit 1 15 LED Harvest 16 LED Test Mode 17 Fuse 18 Motor Connector 12V J8 19 EC Fan Motor Connector 12V J9 20 Bin Switch Connector J5 21 Float Switch Water Level 22 Float Switch Harvest 23 Thermistor 2 J10 24 Test Switch 25 Therm...

Page 248: ...248 Part Number 000014797 Rev02 05 18 ELECTRONIC CONTROL BOARD U MODELS WITH J4 THERMISTOR TERMINAL 1 2 3 4 5 6 9 10 11 12 13 14 15 16 17 19 18 20 7 8 ...

Page 249: ... Dump Valve Relay 4 LED Harvest Solenoid Valve 5 LED Clean 6 LED Thermistor 7 JP1 Jumper or Thermistor Connector 8 LED Water Fill Valve 9 LED Harvest Float 10 LED Water Level Float 11 LED Bin Switch 12 LED Safety Limit 2 13 LED Safety Limit 1 14 LED Harvest 15 LED Test Mode 16 Fuse 17 Bin Switch Connector J5 18 Float Switch Water Level 19 Float Switch Harvest 20 Test Switch ...

Page 250: ...250 Part Number 000014797 Rev02 05 18 ELECTRONIC CONTROL BOARD U MODELS PRIOR TO THERMISTOR TERMINAL 1 2 3 4 5 16 9 10 11 12 13 14 15 6 17 7 8 ...

Page 251: ...2 Compressor Relay 3 Water Dump Valve Relay 4 Harvest Solenoid Valve 5 Water Inlet Valve Relay 6 Fuse 7 LED Ice Level Float 8 LED Test Mode 9 LED Curtain Switch 10 LED Safety Limit 2 11 LED Safety Limit 1 12 LED Harvest 13 LED Water Level Float 14 Test Switch 15 Bin Switch Connector J5 16 Float Switch Water Level 17 Float Switch Harvest ...

Page 252: ...252 Part Number 000014797 Rev02 05 18 ELECTRONIC CONTROL BOARD UDE065 1 2 3 4 5 6 ...

Page 253: ...Number 000014797 Rev02 05 18 253 Electronic Control Board UDE065 Number Component 1 Liquid Line Thermistor 2 Ice Thickness Adjustment 3 Overflow Jumper Wire 4 Harvest Light 5 Fuse 6 Control Board Transformer ...

Page 254: ...254 Part Number 000014797 Rev02 05 18 ELECTRONIC CONTROL BOARD UDE080 1 2 3 4 5 6 7 8 9 10 ...

Page 255: ...Board UDE080 Number Component 1 Ice Thickness Probe Connection 2 Ice Off Clean Toggle Switch Connection 3 Bin Switch Light 4 Harvest Light 5 Control Board Transformer 6 Compressor Relay 7 Harvest Valve Relay 8 Water Pump Relay 9 Line Voltage Connector 10 Fuse ...

Page 256: ...256 Part Number 000014797 Rev02 05 18 Tubing Schematics TUBING SCHEMATIC UDE065 EVAPORATOR HEAT EXCHANGER AIR OR WATER CONDENSER HARVEST SOLENOID DRIER COMPRESSOR ...

Page 257: ... CONDENSER DRIER RECEIVER WATER COOLED ONLY EXPANSION VALVE HARVEST SOLENOID EVAPORATOR COMPRESSOR STRAINER TUBING SCHEMATIC U0190 UF0190 U0240 UF0240 U0310 UF0310 HEAT EXCHANGER AIR OR WATER CONDENSER DRIER RECEIVER WATER COOLED ONLY EXPANSION VALVE HARVEST SOLENOID VALVE EVAPORATOR COMPRESSOR STRAINER ...

Page 258: ...258 Part Number 000014797 Rev02 05 18 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 259: ......

Page 260: ...quipment and solutions Our cutting edge designs and lean manufacturing tactics are powered by deep knowledge operator insights and culinary expertise All of our products are backed by KitchenCare our aftermarket repair and parts service WWW WELBILT COM CLEVELAND CONVOTHERM DELFIELD FITKITCHEN FRYMASTER GARLAND KOLPAK LINCOLN MANITOWOC MERCO MERRYCHEF MULTIPLEX 2018 Welbilt Inc except where explici...

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