Manitowoc NEO Technician'S Handbook Download

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Part Number STH042 3/14

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Summary of Contents for NEO

Page 1: ...ok This manual is updated as new information and models are released Visit our website for the latest manual www manitowocice com America s 1 Selling Ice Machine Manitowoc Undercounter Ice Machines Part Number STH042 3 14 ...

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Page 3: ... Throughout this handbook you will see the following types of safety notices Warning Text in a Warning box alerts you to a potential personal injury situation Be sure to read the Warning statement before proceeding and work carefully Caution Text in a Caution box alerts you to a situation in which you could damage the equipment Be sure to read the Caution statement before proceeding and work caref...

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

Page 5: ...tine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty Warning Read this manual thoroughly before operating installing or performing maintenance on the equipment Failure to follow instructions in this manual can cause property damage injury or death Warning Do not use electrical appliances or accessories other than those supplied by Manitowoc for your...

Page 6: ...he refrigeration circuit when installing maintaining or servicing the unit Warning 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 7: ...nity of this or any other appliance Warning Do not clean with water jet Warning It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures Warning Two or more people are required to move this equipment to prevent tipping ...

Page 8: ...included Do not unplug by pulling on cord To unplug grasp the plug not the cord Unplug from outlet when not in use and before servicing or cleaning Do not operate any appliance with a damaged cord or plug or after the appliance malfunctions or is dropped or damaged in any manner Contact the nearest authorized service facility for examination repair or electrical or mechanical adjustment g Follow a...

Page 9: ... 22 Leveling the Ice Machine 23 Electrical Requirements 24 Electrical Specifications 25 Water Service Drains 27 Water Supply 27 Water Inlet Lines 27 Drain Connections 28 Cooling Tower Applications 28 MAINTENANCE Interior Cleaning and Sanitizing 31 General 31 Cleaning and Sanitizing Procedure 31 Touch Pad Operation 32 Remove Parts for Cleaning 36 Preventative Maintenance Cleaning 41 Ice Machine Ins...

Page 10: ...Will Not Run 58 Ice Machine Does Not Cycle Into Harvest when Water Loses Contact with the Harvest Float Switch 59 Ice Machine Cycles Into Harvest Before Water loses Contact with the Harvest Float Switch 61 Ice Production Check 63 Installation Visual Inspection Checklist 64 Water System Checklist 65 Ice Formation Pattern 66 Safety Limit Feature 68 Analyzing Discharge Pressure 75 Analyzing Suction P...

Page 11: ...lter Driers 106 Refrigerant Recovery Evacuation 108 Definitions 108 Refrigerant Re use Policy 109 Recovery and Recharging Procedures 111 System Contamination Cleanup 114 Determining Severity of Contamination 114 Mild System Contamination Cleanup Procedure 116 Severe System Contamination Cleanup Procedure 117 Replacing Pressure Controls without Removing Refrigerant Charge 118 Total System Refrigera...

Page 12: ...ned Water cooled 123 U0190 Self contained Air cooled 124 U0240 Self contained Air cooled 125 U0240 Self contained Water cooled 126 U0310 Self contained Air cooled 127 U0310 Self contained Water cooled 128 DIAGRAMS Wiring Diagrams 129 Wiring Diagram All Models 130 Electronic Control Board 131 Tubing Schematic U0140 132 Tubing Schematic U0190 U0240 U0310 133 ...

Page 13: ...lf contained Water cooled UD0140A 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 14: ...and refrigerant charge Repairs are to be performed by properly trained refrigeration technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure A Air cooled W Water cooled Series Condenser Type Capacity U D 0140 A E R Regular D Dice Y Half dice Cube Size E WRAS 50Hz ...

Page 15: ...r Manitowoc Ice if you need further warranty information Parts 1 Manitowoc warrants the ice machine against defects in materials and workmanship under normal use and service for three 3 years from the date of original installation 2 The evaporator and compressor are covered by an additional two 2 year five years total warranty beginning on the date of the original installation Labor 1 Labor requir...

Page 16: ...arges not listed on the payment schedule Additional labor charges resulting from the inaccessibility of equipment are also excluded 5 Parts or assemblies subjected to misuse abuse neglect or accidents 6 Damage or problems caused by installation cleaning and or maintenance procedures inconsistent with the technical instructions provided in this manual 7 This warranty is intended exclusively for com...

Page 17: ...es and Manitowoc receives a valid warranty claim prior to the expiration of the warranty period Manitowoc shall at its option 1 repair the Product at Manitowoc s cost including standard straight time labor charges 2 replace the Product with one that is new or at least as functionally equivalent as the original or 3 refund the purchase price for the Product Replacement parts are warranted for 90 da...

Page 18: ...ED WARRANTY IS THE SOLE AND EXCLUSIVE WARRANTY OF MANITOWOC WITH REGARD TO THE PRODUCT ALL IMPLIED WARRANTIES ARE STRICTLY LIMITED TO THE DURATION OF THE LIMITED WARRANTY APPLICABLE TO THE PRODUCTS AS STATED ABOVE INCLUDING BUT NOT LIMITED TO ANY WARRANTY OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE Some states do not allow limitations on how long an implied warranty lasts so the abov...

Page 19: ...rranty registration card must be completed and sent to Manitowoc within thirty 30 days from the sale date Complete the following registration card and send it to Manitowoc at the address shown above Retain a copy for your records HOW TO OBTAIN WARRANTY SERVICE To obtain warranty service or information regarding your Product please contact us at MANITOWOC ICE 2110 S 26th St P O Box 1720 Manitowoc W...

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Page 21: ...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 Refer to the chart below fo...

Page 22: ...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 when sizing air conditioning equipment where self contained air cooled ice machines are installed Self contained Air cooled Self contained Water cooled Top Sides 5 127 mm 5 ...

Page 23: ...its final position 4 Level the ice machine to ensure that the siphon 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 Leg Installation Caution The legs must be screwed in tightly to prevent them from bending THREAD LEVELING LEG INTO BASE OF CABINET THREAD FOOT IN AS FAR AS POSSIBLE SV1606 ...

Page 24: ...up when the electrical load is highest Fuse Circuit Breaker A separate fuse circuit breaker must be provided for each ice machine Total Circuit Ampacity The total circuit ampacity is used to help select the wire size of the electrical supply The wire size or gauge is also dependent upon location materials used length of run etc so it must be determined by a qualified electrician ...

Page 25: ...y data Ice Machine Voltage Phase Cycle Max Fuse Circuit Breaker Total Amps U140 115 1 60 15 5 0 208 230 1 60 15 2 5 230 1 50 15 2 5 U190 115 1 60 15 6 0 208 230 1 60 15 2 5 230 1 50 15 2 5 U240 115 1 60 15 7 0 208 230 1 60 15 4 0 230 1 50 15 4 0 U310 115 1 60 15 10 0 208 230 1 60 15 4 5 230 1 50 15 4 5 ...

Page 26: ...Total Amps U140 115 1 60 15 5 0 208 230 1 60 15 2 5 230 1 50 15 2 5 U240 115 1 60 15 7 0 208 230 1 60 15 4 0 230 1 50 15 4 0 U310 115 1 60 15 10 0 208 230 1 60 15 4 5 230 1 50 15 4 5 Warning All wiring must conform to local state and national codes Warning The ice machine must be grounded in accordance with national and local electrical code ...

Page 27: ... 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 a water pressure regulator from your Manitowoc distributor Install a water shut off valve for ice making potable water Insulate water inlet lines to prevent condensation Important If you are installing a Manitowoc water filter system refer ...

Page 28: ...ter 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 exceed...

Page 29: ...er 3 8 9 5 mm min inside diameter Ice Machine Fitting 3 8 Female Pipe Thread 3 8 Female Pipe Thread 3 8 Female Pipe Thread Water Pressure 20 psi 1 38 bar min 80 psi 5 5 bar max 20 psi 1 38 bar min 150 psi 10 3 bar max Water Temperature 33 F 0 6 C min 90 F 32 2 C max 33 F 0 6 C min 90 F 32 2 C max Location Ice Making Water Inlet Condenser Water Inlet Condenser Water Drain ...

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Page 31: ...r treatment The ice machine must be taken apart for cleaning and sanitizing CLEANING AND SANITIZING PROCEDURE Ice machine cleaner is used to remove lime scale and mineral deposits Ice machine sanitizer disinfects and removes algae and slime Caution Use only Manitowoc approved Ice Machine Cleaner part number 94 0546 3 and Sanitizer part number 94 0565 3 It is a violation of Federal law to use these...

Page 32: ...ne 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 Step 2 Remove all ic...

Page 33: ...utes then press the On Off button and disconnect power and water supplies to the ice machine Step 4 Remove parts for cleaning Refer to the proper parts removal for your machine Continue with step 6 when the parts have been removed 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 label...

Page 34: ...ng 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 solution to clean all foodzone surfaces of the ice machine and bin Use a nylon brush or cloth to thoroughly clean the following ice ...

Page 35: ...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 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 ...

Page 36: ...s can easily be cleaned If complete removal is desired follow the wires to the bulkhead grommet exit point in the back wall Pull the wire connector through 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 Warning ...

Page 37: ...t Number STH042 3 14 37 WIRE CONNECTORS ARE LOCATED BEHIND BULKHEAD PULL THROUGH GROMMET TO DISCONNECT ICE THICKNESS FLOAT SWITCH BRACKET HARVEST FLOAT SWITCH BRACKET DISCONNECT WIRES FOR COMPLETE REMOVAL ...

Page 38: ...2 3 14 B Remove the Water Trough Remove the upper thumbscrew While supporting the water trough remove the thumbscrew from beneath the water trough Remove the water trough from the bin area UPPER THUMBSCREW LOWER THUMBSCREW ...

Page 39: ... C 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 2 SUPPORT ICE DAMPER THEN SLIDE RIGHT SIDE FORWARD TO REMOVE 1 REMOVE THUMBSCREW ...

Page 40: ...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 2 PULL DISTRIBUTION TUBE FORWARD TO REMOVE 1 LOOSEN THUMBSCREWS ...

Page 41: ... 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 Wait until the clean cycle is complete approximately 22 minutes then press the On Off button Caution Never use anything to force ice from the evaporator Damage may result Warning Wear rubbe...

Page 42: ...te 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 A commercial grade stainless steel cleaner polish ca...

Page 43: ...ne 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 If dirt still remains call a service agent to clean the condenser Warning Disconnect electric power to the ice machine head section and the remote condensing unit at the electric service switches before cleaning the condenser Warning The...

Page 44: ...d drain the water trough 4 Energize the ice machine wait one minute for the water inlet valve to open and blow compressed air in both the incoming water and the drain 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 f...

Page 45: ...ch pad communication cable 5 Slide bin forward to remove NOTE When reinstalling the bin insure the bin seal is in place and is not pinched folded as it mates to the cabinet A water tight seal is required to prevent future condensation or water leakage from entering the ice machine base LOOSEN SCREWS AND SLIDE CLIPS DISCONNECT CLAMP AND REMOVE BIN DRAIN DISCONNECT COMMUNICATION CABLE ...

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Page 47: ...n Off Button is used to start and stop ice making The blue light indicates whether the ice machine is in Ice Making light on or Off light off 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 Bin Full Blue Bin Is Full Off Bin Is Not Full Service Red Solid or Flashing Needs Service Off Doesn t Need Service ...

Page 48: ...hen power is restored the ice machine will start an ice making cycle CLEAN Pressing the Clean button for 3 seconds will start a clean cycle After the clean cycle is complete the ice machine will automatically start an ice making cycle Pressing the Clean button again within 45seconds of the clean cycle starting will abort the clean cycle Pressing the Clean button after 45 seconds into the Clean cyc...

Page 49: ... 14 49 BIN FULL The Bin Full light energizes when the bin is full or is de energized if the bin is not full SERVICE The service light indicates the machine needs attention Refer to safety limits if this light is energized ...

Page 50: ...ness float switch is satisfied Freeze Water flowing across the evaporator freezes and builds ice on the evaporator After a sheet of ice has formed the Harvest float switch signals the control board to start a harvest cycle Harvest Cycle Any remaining water is purged down the drain as refrigerant gas warms the evaporator When the evaporator warms the sheet of cubes slides off the evaporator and int...

Page 51: ...sition for 10 continuous seconds during the start of a freeze cycle a harvest sequence is initiated The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence The maximum harvest time is 3 5 minutes The control board automatically initiates a freeze sequence when these times are exceeded The water fill valve is de energized 1 minute after the f...

Page 52: ...ash on off at 1 second intervals If 6 consecutive 60 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 returns the ice machine to the freeze cycle If three consecutive 3 5 minute harvest cycles occur the ...

Page 53: ...s 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 conse...

Page 54: ...mp Valve Compressor Condenser Fan Motor Harvest Float 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 120 Seconds initial cycle Thereafter 60 seconds ...

Page 55: ...the water inlet valve for 7 seconds one last time 3 minutes into the freeze cycle regardless of float position 4 Freeze ON OFF ON OFF ON OPEN THEN CLOSED CLOSED THEN OPEN Until Harvest Float Switch closes for 10 continual seconds Harvest Sequence 5 Water Purge OFF ON OFF ON FOR 20 SECONDS THEN OFF ON CLOSED CLOSED 20 seconds 6 Harvest OFF ON OFF OFF ON CLOSED CLOSED Bin switch activation 7 Automat...

Page 56: ...ckness 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 water leve...

Page 57: ...control lights After 2 minutes the control board will automatically initiate 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 ...

Page 58: ...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 page 98 touch pad diagnostics when steps 1 3 test good 5 Be sure Steps 1 4 were followed thoroughly Intermittent problems are not usually related to the control board Replace control board if touch pad operation is correct Warning High line voltage is applied to the...

Page 59: ...six minutes After six minutes a harvest cycle can be initiated To allow the service technician to initiate a harvest cycle without delay this feature is not used on the first cycle after pressing the power button OFF and back to ON Step 1 Disconnect 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 sw...

Page 60: ...flows over the evaporator then refer to chart Result Correction 10 seconds into the freeze cycle the ice machine cycles from freeze to harvest and the control board harvest light energizes The ice thickness float switch wire is causing the malfunction The harvest light comes on but the ice machine remains in the freeze cycle The ice machine is in a 6 minute freeze lock Cycle on off and retest The ...

Page 61: ... 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 ICE THICKNESS FLOAT SWITCH BRACKET HARVEST FLOAT SWITCH BRACKET ...

Page 62: ...in freeze Refer to Float Switch Diagnostics The harvest light comes on but the ice machine stays in a freeze cycle The ice machine is in a 6 minute freeze lock Cycle on off and retest 10 seconds into the freeze cycle the ice machine cycles from freeze to harvest and the control board harvest light energizes Proceed to Step 3 Result Correction The harvest light does not come on The harvest float sw...

Page 63: ...utes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights are in pounds Example 2 lb 6 oz converts to 2 375 lb 6 oz 16 oz 375 lb 3 Perform an ice production check using the formula below 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 i...

Page 64: ...st 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 65: ...increase the water pressure Incoming water temperature is not between 35 F 1 7 C and 90 F 32 2 C If too hot check the hot water line check valves 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...

Page 66: ...on 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 pronounced than those at ...

Page 67: ...rable 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 single ...

Page 68: ... at 1 second intervals If 6 consecutive 60 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 returns the ice machine to the freeze cycle If three consecutive 3 5 minute harvest cycles occur the SL 2 light...

Page 69: ...s 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 conse...

Page 70: ... 2 flash 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 m...

Page 71: ...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 condens...

Page 72: ...m Non Manitowoc components Improper refrigerant charge Defective compressor TXV starving or flooding check bulb mounting Non condensable in refrigeration system Plugged or restricted high side refrigerant lines or component Defective harvest valve ...

Page 73: ...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 componen...

Page 74: ...pection Checklist on page 64 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 75: ...ures Freeze Cycle ______ Harvest Cycle ______ 3 Perform an actual discharge pressure check 4 Compare the actual discharge pressure step 3 with the published discharge pressure step 2 The discharge pressure is normal when the actual pressure falls within the published pressure range for the ice machine s operating conditions It is normal for the discharge pressure to be higher at the beginning of t...

Page 76: ...sable 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 64 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system High side ...

Page 77: ...perature 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 78: ...eze 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 gauges were connected to the example ice machine and suction pressure readings taken as follows...

Page 79: ...ischarge Pressure Discharge pressure is too high and is affecting suction pressure refer to Discharge Pressure High Checklist on page 76 Improper Refrigerant Charge Overcharged Wrong type of refrigerant Non condensable in system Other Non Manitowoc components in system Harvest valve leaking TXV flooding check bulb mounting Defective compressor ...

Page 80: ...ssure Low Checklist 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 65 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 NOTE Do not li...

Page 81: ...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 abs...

Page 82: ...ing 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 freez...

Page 83: ...re the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking Warning The inlet of the harvest valve and the compressor...

Page 84: ... valve is hot and approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest val...

Page 85: ...e 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 3 Wait five minutes into the freeze cycle 4 Record the temperatures be...

Page 86: ... 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 ice m...

Page 87: ... 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 cause ove...

Page 88: ...ts checklists and other references to eliminate refrigeration components not listed and external items and problems that will cause good refrigeration components to appear defective The tables list four different defects that may affect the ice machine s operation NOTE A low on charge ice machine and a starving expansion valve have very similar characteristics and are listed under the same column ...

Page 89: ...all information listed Each item in this column has supporting reference material While analyzing each item separately you may find an external problem causing a good refrigerant component to appear bad Correct problems as they are found If the operational problem is found it is not necessary to complete the remaining procedures Step 2 Add the check marks listed under each of the four columns Note...

Page 90: ...e 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 faulty C...

Page 91: ...d problems must be corrected before proceeding with chart Ice formation is normal or No ice formation on entire evaporator 3 Ice formation is normal or ice formation is extremely thin on the bottom of the evaporator or No ice formation on evaporator 2 Ice formation is extremely thin on outlet of evaporator or No ice formation on entire evaporator 1 Ice formation is extremely thin on outlet of evap...

Page 92: ...hecklist to eliminate problems and or components not listed on this table before proceeding Suction pressure is High 3 Stops on safety limit 1 or 2 Suction pressure is High 2 Stops on safety limit 1 Suction pressure is Low 1 Stops on safety limit 1 or 2 Suction pressure is High Operational Analysis Safety limits Refer to Analyzing Safety Limits to eliminate all non refrigeration problems Freeze cy...

Page 93: ...looding 2 The harvest valve inlet is COOL and The compressor discharge line is HOT Discharge line temp 150 F 66 C or higher at the end of freeze cycle Low On Charge or TXV Starving 1 The harvest valve inlet is HOT and The compressor discharge line is HOT Discharge line temp 150 F 66 C or higher at the end of freeze cycle Harvest Valve Leaking Operational Analysis harvest Valve Discharge Line Temp ...

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Page 95: ...in light is on with the ice damper closed the fuse is good 2 Remove the fuse Check the resistance across the fuse with an ohmmeter Warning High line voltage 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 Warning Disconnect electrical power to the entire ice machine before proceeding R...

Page 96: ...wn 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 damper As the ice damper swings back to the operating position the bin switch closes and the ice machine restarts Check Procedure 1 Press the power button to OFF 2 Watch the curtain light on the control board 3 Move the ice dam...

Page 97: ...in switch wires 3 Cycle the bin switch open and closed numerous times by opening and closing the water curtain NOTE To prevent misdiagnosis Always use the water curtain magnet to cycle the switch a larger or smaller magnet will affect switch operation Watch for consistent readings when the bin switch is cycled open and closed bin switch failure could be erratic ...

Page 98: ...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 disconnect main power to the ice m...

Page 99: ...tly 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 Control Board Connector TOUCH ELECTRICAL PROBE TO THESE LOCA...

Page 100: ...ng the control board light s while raising and lowering the float The corresponding control board light must turn on and off when the float is raised and lowered Harvest Float switch A The light must be on in the down position B The light must be off in the up position Ice Thickness Float Switch A The light must be off in the down position B The light must be on in the up position If the control b...

Page 101: ...TH042 3 14 101 NOTE Make adjustments with the ice machine in the off position Making adjustments during the freeze cycle may produce an initial sheet of ice that is thicker than future cycles FLOAT CLOSED FLOAT OPEN ...

Page 102: ...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 Check con...

Page 103: ...essures 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 The vo...

Page 104: ... 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 power button to ON Wait until water flows over the evaporator then refer to chart below Model Cut In Close Cut Out Open U140 U190 250 psig 5 200 psig ...

Page 105: ...he 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 6 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 Replace the HPCO control if it Will not r...

Page 106: ...oc 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 Important The liquid line drier is covered as a warranty part The liquid line drier m...

Page 107: ...Part Number STH042 3 14 107 This Page Intentionally Left Blank ...

Page 108: ...claim 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 defi...

Page 109: ...t be of original nameplate type Must meet ARI Standard 700 latest edition specifications 3 Recovered or Recycled Refrigerant Must be recovered or recycled in accordance with current local state and federal laws Must be recovered from and re used in the same Manitowoc product Re use of recovered or recycled refrigerant from other products is not approved Recycling equipment must be certified to ARI...

Page 110: ...acuated 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 System Contamination Cleanup on page 114 to test for contamination 5 Substitute or Alternative Refrigerant Must use only Manitowoc approved alternative refrigerants Must follow Manitowoc published convers...

Page 111: ... suction service valve 2 Discharge side of the compressor through the discharge service valve Important Manitowoc Ice assumes no responsibility for the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company Important Replace the liquid line drier before evacuating and recharging Use only a Manitowoc O E M liquid...

Page 112: ... 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 1 Be sure the power button is in the OFF position 2 Close the vacuum pump valve the low side service valve and the low side manifold gauge valve 3 Open the high side manifold gauge valve and backseat the hi...

Page 113: ...g the charging hoses A Run the ice machine in freeze cycle B Close the high side service valve at the ice machine C Open the low side service valve at the ice machine 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...

Page 114: ...a similar diagnostic tool These devices sample refrigerant eliminating the need to take an oil sample Follow the manufacturer s directions If a refrigerant test kit indicates harmful levels of contamination or if a test kit is not available inspect the compressor oil 1 Remove the refrigerant charge from the ice machine 2 Remove the compressor from the system 3 Check the odor and appearance of the ...

Page 115: ...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 and sme...

Page 116: ...e 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 1 ho...

Page 117: ... the vacuum with dry nitrogen and sweep the system Pressurize 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 c...

Page 118: ...easible See the figure on next page Clamp down on the tubing until the pinch off is complete 3 Cut the tubing of the defective component with a small tubing cutter 4 Solder the replacement component in place Allow the solder joint to cool 5 Remove the pinch off tool 6 Re round the tubing Position the flattened tubing in the proper hole in the pinch off tool Tighten the wing nuts until the block is...

Page 119: ...Part Number STH042 3 14 119 Using Pinch Off Tool SV1406 FIG A PINCHING OFF TUBING FIG B RE ROUNDING TUBING ...

Page 120: ...er to the ice machine serial number tag to verify the system charge Serial plate information overrides information listed on this page Model Air Cooled Water Cooled Refrigerant Type U140 10 oz 296 g 11 oz 325 g R404A U190 12 oz 355 g N A R404A U240 13 oz 385 g 12 oz 355 g R404A U310 16 oz 473 g 14 oz 414 g R404A ...

Page 121: ... variances 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...

Page 122: ... 11 7 12 4 14 1 13 0 14 8 1 0 2 5 80 27 11 2 12 8 13 0 14 8 14 6 16 5 90 32 11 8 13 4 14 6 16 5 17 6 19 9 100 38 14 6 16 5 17 6 19 9 19 9 17 6 110 43 16 5 18 7 19 9 17 6 20 3 23 0 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 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discha...

Page 123: ... Harvest Time Water Temperature F C 50 10 70 21 90 32 70 21 9 8 11 2 11 2 12 8 13 0 14 8 1 0 2 5 80 27 10 2 11 7 11 8 13 4 13 8 15 6 90 32 11 8 13 4 13 0 14 8 15 5 17 5 100 38 13 0 14 8 15 5 17 5 17 6 19 9 110 43 14 6 16 5 17 6 19 9 20 3 23 0 Air Temp Around Ice Machine F C Water Temperature 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...

Page 124: ... 19 8 22 5 21 2 24 0 1 0 2 5 80 27 19 8 22 5 21 9 24 9 24 5 27 8 90 32 21 9 24 9 23 6 26 8 29 0 32 9 100 38 25 5 29 0 29 1 32 9 32 0 36 2 110 43 29 1 32 9 32 0 36 2 33 6 38 1 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 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Di...

Page 125: ... 1 17 0 19 3 18 6 21 1 1 0 2 5 80 27 15 2 17 4 18 0 20 5 20 5 23 3 90 32 16 5 18 8 20 5 23 3 22 7 25 8 100 38 19 2 21 8 21 9 24 9 23 6 26 8 110 43 21 9 24 9 23 6 26 8 24 5 27 8 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 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle ...

Page 126: ...rvest Time Water Temperature F C 50 10 70 21 90 32 70 21 16 1 18 3 17 0 19 3 18 0 20 5 1 0 2 5 80 27 16 5 18 8 17 5 19 9 18 6 21 1 90 32 17 0 19 3 18 0 20 5 19 2 21 8 100 38 17 5 19 9 18 6 21 1 19 9 22 5 110 43 18 0 20 5 19 2 21 8 20 5 23 3 Air Temp Around Ice Machine F C Water Temperature F C 50 10 70 21 90 32 70 21 200 190 180 80 27 195 185 175 90 32 190 180 170 100 38 185 175 165 110 43 180 170...

Page 127: ... 70 21 90 32 70 21 9 8 11 3 11 8 13 4 14 1 16 1 1 0 2 5 80 27 10 4 11 9 12 3 14 0 13 5 15 4 90 32 11 0 12 6 13 5 15 4 15 2 17 4 100 38 12 3 14 0 15 2 17 4 17 5 19 9 110 43 15 6 17 8 19 2 21 8 21 2 24 0 Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 310 265 225 80 27 295 255 235 90 32 280 235 210 100 38 255 210 185 110 43 205 170 155 Air Temp Entering Condenser F C Fr...

Page 128: ...Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 70 21 90 32 70 21 9 8 11 3 11 3 12 9 12 0 13 7 1 0 2 5 80 27 10 0 11 5 11 5 13 2 12 3 14 0 90 32 10 2 11 7 12 3 14 0 12 6 14 3 100 38 10 4 11 9 12 6 14 3 12 8 14 7 110 43 10 6 12 2 12 8 14 7 13 1 15 0 Air Temp Around Ice Machine F C Water Temperature F C 50 10 70 21 90 32 70 21 310 275 260 80 27 305 270 255 90 32 300 255 250 100 ...

Page 129: ... 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 Compressor Compartment Side Warning Always disconnect power before working on...

Page 130: ...130 Part Number STH042 3 14 WIRING DIAGRAM ALL MODELS ...

Page 131: ...H042 3 14 131 ELECTRONIC CONTROL BOARD WATER PUMP MAIN COMP WATER DUMP HARVEST WATER FILL FUSE HIGH FLOAT LOW FLOAT BIN SWITCH TEST SWITCH WATER LEVEL FLOAT HARVEST SAFETY 1 SAFETY 2 CURTAIN TEST MODE ICE LEVEL FLOAT ...

Page 132: ...132 Part Number STH042 3 14 Tubing Schematic U0140 HEAT EXCHANGER STRAINER COMPRESSOR DRIER EVAPORATOR HARVEST SOLENOID AIR OR WATER CONDENSER EXPANSION VALVE RECEIVER WATER COOLED ONLY ...

Page 133: ...art Number STH042 3 14 133 Tubing Schematic U0190 U0240 U0310 HEAT EXCHANGER STRAINER DRIER EVAPORATOR HARVEST SOLENOID VALVE AIR OR WATER CONDENSER EXPANSION VALVE RECEIVER WATER COOLED ONLY COMPRESSOR ...

Page 134: ...134 Part Number STH042 3 14 This Page Intentionally Left Blank ...

Page 135: ......

Page 136: ...Manitowoc Ice 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 USA Ph 920 682 0161 Fax 920 683 7589 Visit us online at www manitowocfoodservice com 2013 Manitowoc Part Number STH042 3 14 ...

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