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Manitowoc S model, Service Manual

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Section 6

Electrical System

 Part Number 80-1480-3

6-23

S500/S600/S850/S1000 - REMOTE - 1 PHASE 

SV3158

(89)

(55)

(88)

(42)

High Pressure 

Cutout

Water Valve

Harvest Valve

Dump Valve

Water Pump

(20)

(21)

(79)

(74)

Ice Thickness 

Probe

Water Level Probe

Control 

Board

(61)

(60)

(57)

(98)

(99)

(76)

(81)

(77)

(80)

(26)

(25)

(58)

(59)

Contactor

Coil

(56)

Trans.

Fuse (7a) 

Low DC 

Voltage 

Plug

L1

(51)

(F1)

Fan Motor

Run Capacitor

PTCR

Compressor

Run 

Capacitor

(50)

(45)

L2 or N

L1

Ground

(2)

(6)

(5)

(1)

(7)

(4)

L2

Air Compressor

(When Used)

Bin Switch

Clean

OFF

ICE

(2)

(1)

(6)

(8)

(9)

Overload

(Red)

(Yellow)

(Black)

Contactor 

Contacts

(46)

R

R

(83)

(22)

(22)

(75)

Remote Condenser

(F2)

Clean

Left Bin

Right Bin

Wtr Probe

Rmt Bin

Ice Probe

Harvest

SL-2

SL-1

Liquid Line 
Solenoid

HPR Valve

(78)

(82)

Summary of Contents for S model

Page 1: ... installation care and maintenance your new Manitowoc Ice Machine will provide you with many years of reliable and economical performance S Model Ice Machines Service Manual Part Number 80 1480 3 01 2005 This manual is updated as new information and models are released Visit our website for the latest manual www manitowocice com ...

Page 2: ...lected damaged or altered modified from that of original manufactured specifications Warning Text in a Warning box alerts you to a potential personal injury situation Be sure to read the Warning statement before proceeding and work carefully Caution Text in a Caution box alerts you to a situation in which you could damage the ice machine Be sure to read the Caution statement before proceeding and ...

Page 3: ......

Page 4: ...aining on a Variety of Equipment Breakfast Lunch and Hotel Room Included with Tuition Contact Your Distributor or Manitowoc Ice Inc for Details OR Visit Our Website at www manitowocice com for School Dates MANITOWOC ICE INC 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 Phone 920 682 0161 Service Fax 920 683 7585 Web Site www manitowocice com 2004 Manitowoc Ice Inc ...

Page 5: ... S600 Remote Ice Machines 2 2 S300 S450 S500 S850 S1000 Air and Water Cooled Ice Machines 2 3 S500 S850 S1000 Remote Ice Machines 2 4 S1400 S1800 Air and Water Cooled Ice Machines 2 5 S1400 S1800 Remote Ice Machines 2 5 Ice Storage Bin Dimensions 2 6 30 inch 76 cm Ice Storage Bins 2 6 22 Inch 56 cm Ice Storage Bins 2 6 48 Inch 130 cm Ice Storage Bins 2 6 Remote Condenser Dimensions 2 6 JC0495 JC08...

Page 6: ...n Distances 2 16 Lengthening or Reducing Line Set Lengths 2 17 Connecting A Line Set 2 17 Remote Receiver Service Valve 2 17 Remote Ice Machine Usage with Non Manitowoc Multi Circuit Condensers 2 18 Warranty 2 18 Head Pressure Control Valve 2 18 Fan Motor 2 18 Internal Condenser Volume 2 18 Condenser DT 2 18 Refrigerant Charge 2 18 Quick Connect Fittings 2 18 Non Manitowoc Multi Circuit Condenser ...

Page 7: ...ction 5 Before Calling For Service Checklist 5 1 Safety Limit Feature 5 2 Section 6 Electrical System Energized Parts Charts 6 1 Self Contained Air And Water Cooled Models 6 1 Remote Models 6 2 Wiring Diagram Sequence of Operation 6 3 Self Contained Models 6 3 Remote Models 6 11 Wiring Diagrams 6 18 Wiring Diagram Legend 6 18 S300 S320 S420 S450 Self Contained 1 Phase 6 19 S500 S600 S850 S1000 Sel...

Page 8: ...Check 7 9 Installation Visual Inspection Checklist 7 10 Water System Checklist 7 10 Ice Formation Pattern 7 11 Safety Limits 7 13 Analyzing Discharge Pressure During Freeze or Harvest Cycle 7 16 Analyzing Suction Pressure During Freeze Cycle 7 17 Single Expansion Valve Ice Machines Comparing Evaporator Inlet and Outlet Temperatures 7 19 Harvest Valve Temperature Check 7 20 Discharge Line Temperatu...

Page 9: ... Model Procedures 7 44 Normal Remote Model Procedures 7 46 System Contamination Clean Up 7 50 Replacing Pressure Controls Without Removing Refrigerant Charge 7 52 Filter Driers 7 54 Total System Refrigerant Charges 7 55 Refrigerant Definitions 7 56 Refrigerant Re Use Policy 7 57 HFC Refrigerant Questions and Answers 7 58 ...

Page 10: ...Table of Contents continued 6 Part No 80 1480 3 ...

Page 11: ...1402A SY1404A SD1403W SY1405W SD1492N SY1494N SR1800A SD1802A SY1804A SR1801W SD1803W SY1805W SR1890N SD1892N SY1894N Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured specifications Warning PERSONAL INJURY POTENTIAL Remove all ice machine panels before lifting and installing Regular 1 1 ...

Page 12: ... affordable method of inhibiting scale formation filtering sediment and removing chlorine taste and odor MANITOWOC CLEANER AND SANITIZER Manitowoc Ice Machine Cleaner and Sanitizer are available in convenient 16 oz 473 ml bottles These are the only cleaner and sanitizer approved for use with Manitowoc products AUCS AUTOMATIC CLEANING SYSTEM This accessory reduces equipment cleaning expense The AuC...

Page 13: ...s are required when requesting information from your local Manitowoc distributor or Manitowoc Ice Inc The model and serial number are listed on the MODEL SERIAL NUMBER DECAL affixed to the ice machine remote condenser and storage bin Model Serial Number Location SV13147 MODEL SERIAL DECAL LOCATION ...

Page 14: ...m Manitowoc Ice Inc 3 Damage caused by improper installation of the ice machine electrical supply water supply or drainage or damage caused by floods storms or other acts of God 4 Premium labor rates due to holidays overtime etc travel time flat rate service call charges mileage and miscellaneous tools and material charges not listed on the payment schedule Additional labor charges resulting from ...

Page 15: ...e to follow these installation guidelines may affect warranty coverage 2 20 5 58cm H D W 6 68 16 96cm 5 06 12 85cm 1 1 2 6cm 1 8 4 6cm 2 6 6 6cm 19 3 49 0 cm 5 0 12 7cm 17 0 43 2cm 8 49 21 56cm 2 85 7 30cm 4 21 10 69cm 4 10cm 3 25 8 3cm ELECTRICAL AUCS TUBING MODULAR WIRE DRAIN 1 2 NPTF WATER INLET 3 8 FPT CONDENSER WATER OUTLET 1 2 FPT Water Cooled Only CONDENSER WATER INLET 3 8 FPT Water Cooled ...

Page 16: ...54 6 cm 1 50 3 81cm H D W 4 25 10 81 cm 17 25 43 81 cm 6 68 16 96cm 5 06 12 85cm 2 85 7 30cm 1 81 4 59cm 2 61 6 62cm A B 6 50 16 5cm 8 50 21 60cm 7 75 19 7 cm ELECTRICAL AUCS CONNECTIONS DRAIN 1 2 NPTF WATER INLET 3 8 FPT CONDENSER WATER OUTLET 1 2 FPT Water Cooled Only CONDENSER WATER INLET 3 8 FPT Water Cooled Only AUXILLARY BASE DRAIN 1 2 CPVC SOCKET 1 50 3 81cm H D W 16 0 40 64cm 11 50 29 21cm...

Page 17: ... D Dimension H S300 30 in 76 2 cm 24 50 in 62 2 cm 16 5 in 41 9 cm S450 30 in 76 2 cm 24 50 in 62 2 cm 21 5 in 54 6 cm S500 30 in 76 2 cm 24 50 in 62 2 cm 21 5 in 54 6 cm S850 30 in 76 2 cm 24 50 in 62 2 cm 26 5 in 67 3 cm S1000 30 in 76 2 cm 24 50 in 62 2 cm 26 5 in 67 3 cm Ice Machine Electrical AuCS Dimension A Dimension B Dimension C Dimension E Dimension F S300 14 00 in 35 6 cm NA 10 0 in 25 ...

Page 18: ...ECTRICAL REMOTE CONDENSER ELECTRICAL Ice Machine Dimension A Dimension B Dimension W Dimension D Dimension H S300 14 00 in 35 6 cm NA 30 in 76 2 cm 24 50 in 62 2 cm 16 5 in 41 9 cm S450 19 25 in 48 9 cm 17 5 in 44 45 cm 30 in 76 2 cm 24 50 in 62 2 cm 21 5 in 54 6 cm S500 19 25 in 48 9 cm 17 5 in 44 45 cm 30 in 76 2 cm 24 50 in 62 2 cm 21 5 in 54 6 cm S850 23 82 in 60 5 cm 22 32 in 56 69 cm 30 in 7...

Page 19: ...trical AuCS Dimension A Dimension B Dimension C Dimension E Dimension F S1400 22 75 in 57 8 cm 22 25 in 56 5 cm 14 0 in 35 6 cm 9 5 in 24 1 cm 7 5 in 19 1 cm S1800 22 75 in 57 8 cm 22 25 in 56 5 cm 14 0 in 35 6 cm 9 5 in 24 1 cm 7 5 in 19 1 cm 2 50 6 35cm H D W 11 0 27 9cm 10 25 26 0cm 2 0 5 1cm 5 75 14 6cm 4 0 10 2cm A B 3 0 7 6cm 3 75 9 5cm 11 0 27 9cm 7 8 19 8cm 1 1 2 8cm C E F 8 0 20 3cm 23 75...

Page 20: ...130 CM ICE STORAGE BINS Remote Condenser Dimensions JC0495 JC0895 JC1395 Bin Model Dimension A Dimension B B170 29 5 in 74 9 cm 19 1 in 48 5 cm B420 34 0 in 86 3 cm 32 0 in 81 3 cm B570 34 0 in 86 3 cm 44 0 in 111 7 cm Bin Model Dimension A Dimension B B320 34 0 in 86 3 cm 32 0 in 81 3 cm B420 34 0 in 86 3 cm 44 0 in 111 7 cm SV1609 SV1614 SV1297 B970 SV1297 ...

Page 21: ... to reduce air conditioning loads The amount of heat added to an air conditioned environment by an ice machine using a water cooled or remote condenser is negligible Knowing the amount of heat rejected is also important when sizing a cooling tower for a water cooled condenser Use the peak figure for sizing the cooling tower S300 S320 S420 S450 S500 S600 S850 S1000 Self Contained Air Cooled Water C...

Page 22: ...e installation Manitowoc bins come with a closed cell foam gasket installed along the top surface of the bin 7 Remove all panels from ice machine before lifting Remove both front panels top cover left and right side panels 8 Install ice machine on bin Leveling Leg and Foot Air Cooled Baffle SELF CONTAINED AIR COOLED ONLY The air cooled baffle prevents condenser air from recirculating To install 1 ...

Page 23: ...ocal electrical codes Important Observe correct polarity of incoming line voltage Ice Machine Voltage Phase Cycle Air Cooled Water Cooled Remote Maximum Fuse Circuit Breaker Minimum Circuit Amps Maximum Fuse Circuit Breaker Minimum Circuit Amps Maximum Fuse Circuit Breaker Minimum Circuit Amps S300 115 1 60 20 12 9 20 12 1 N A N A 230 1 50 15 6 4 15 5 9 N A N A S320 115 1 60 15 11 3 15 10 5 N A N ...

Page 24: ... GROUND ICE MACHINE CONNECTIONS SV1258 TO SEPARATE FUSE BREAKER L1 L1 GROUND GROUND ICE MACHINE CONNECTIONS TO SEPARATE FUSE BREAKER L2 L3 L2 L3 SV1190 L1 L1 N N GROUND GROUND ICE MACHINE CONNECTIONS TO SEPARATE FUSE BREAKER DISCONNECT ALL POLES SV1191 For United Kingdom Only As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings identifying the ...

Page 25: ...onform to local state and national electrical codes Though wire nuts are shown in the drawings the ice machine field wiring connections may use either wire nuts or screw terminals L1 NOTE CONDENSER FAN MOTOR VOLTAGE MATCHES ICE MACHINE VOLTAGE 115V OR 208 230V GROUND SINGLE CIRCUIT REMOTE CONDENSER ICE MACHINE SV1255 L2 L1 L2 GROUND TO SEPARATE FUSE BREAKER GROUND L1 L2 F2 F1 N 115V OR L2 208 230V...

Page 26: ...enough to accommodate drainage from all drains Run separate bin and ice machine drain lines Insulate them to prevent condensation Vent the bin and ice machine drain to the atmosphere Do not vent the condenser drain on water cooled models Cooling Tower Applications Water Cooled Models A water cooling tower installation does not require modification of the ice machine The water regulator valve for t...

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

Page 28: ...uid Line RT 1 2 1 27 cm 5 16 79 cm RL 1 2 1 27 cm 3 8 95 cm Air Temperature Around the Condenser Minimum Maximum 20 F 29 C 120 F 49 C IMPORTANT EPA CERTIFIED TECHNICIANS If remote line set length is between 50 and 100 15 25 30 5 m add 1 5 lb 24 oz 0 68 kg of refrigerant to the nameplate charge Tubing length ______________________________ Refrigerant added to nameplate ________________ New total re...

Page 29: ...y 1 Optional Make the service loop in the line sets as shown below This permits easy access to the ice machine for cleaning and service Do not use hard rigid copper at this location 2 Required Do not form traps in the refrigeration lines except the service loop Refrigerant oil must be free to drain toward the ice machine or the condenser Route excess tubing in a supported downward horizontal spira...

Page 30: ...calculated rise of 17 feet 2 Insert the measured drop into the formula below Multiply by 6 6 to get the calculated drop Example A condenser located 10 feet below the ice machine has a calculated drop of 66 feet 3 Insert the measured horizontal distance into the formula below No calculation is necessary 4 Add together the calculated rise calculated drop and horizontal distance to get the total calc...

Page 31: ...achine 2 Apply refrigeration oil to the threads on the quick disconnect couplers before connecting them to the condenser 3 Carefully thread the female fitting to the condenser or ice machine by hand 4 Tighten the couplings with a wrench until they bottom out 5 Turn an additional 1 4 turn to ensure proper brass to brass seating Torque to the following specifications 6 Check all fittings and valve c...

Page 32: ...s circuit be used to control the condenser fan s on the multi circuit condenser to assure it is on at the proper time Do not exceed the rated amps for the fan motor circuit listed on the ice machine s serial tag INTERNAL CONDENSER VOLUME The multi circuit condenser internal volume must not be less than or exceed that used by Manitowoc see chart on next page Do not exceed internal volume and try to...

Page 33: ...ressure coupling P N 83 6035 3 coupling P N 83 6034 3 Manitowoc P N 83 6809 3 S600 R404A 6 5 lbs 9 000 13 900 0 045 0 060 S850 R 404A 8 5 lbs 12 000 18 000 0 045 0 060 2 500 psig 17237 kpa S1000 R 404A 8 5 lbs 16 000 22 000 0 045 0 060 172 37 bar burst pressure no substitutes S1400 R 404A 11 lbs 19 000 28 000 0 085 0 105 mounting flange P N 83 6006 3 mounting flange P N 83 6005 3 S1800 R 404A 12 5...

Page 34: ... drains vented F Are all electrical leads free from contact with refrigeration lines and moving equipment F Has the owner operator been instructed regarding maintenance and the use of Manitowoc Cleaner and Sanitizer F Has the owner operator completed the warranty registration card F Has the ice machine and bin been sanitized F Is the toggle switch set to ice The toggle switch is located directly b...

Page 35: ...es of the owner operator Adjustments and maintenance procedures outlined in this manual are not covered by the warranty AuCS Automatic Cleaning System This optional accessory monitors ice making cycles and initiates cleaning procedures automatically The AuCS accessory can be set to automatically clean or sanitize the ice machine every 2 4 or 12 weeks Refer to the AuCS Installation Use and Care Man...

Page 36: ...Installation Instructions Section 2 2 22 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 37: ...ce Machine Operation Component Identification sv3150 sv3149 Check Valve Ice Thickness Probe Dump Valve Toggle Switch Water Curtain Water Distribution Tube Water Level Probe Water Pump Water Inlet Location Water Inlet Valve Located in Refrigeration Compartment Bin Switch ...

Page 38: ...en shuts off At the same time the compressor starts the condenser fan motor air cooled models is supplied with power throughout the entire Freeze and Harvest Sequences The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off The compressor and condenser fan motor are wired through the contactor As a result anytime the contactor coil is energized the compressor ...

Page 39: ...achine remains off for 3 minutes before it can automatically restart The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain As the water curtain swings back to the operating position the bin switch re closes and the ice machine restarts steps 1 2 provided the 3 minute delay period is complete SAFETY TIMERS The control ...

Page 40: ...lean the water level probe with ice machine cleaner rinse thoroughly and re check operation Repair or replace the probe as necessary ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 32 cm NOTE Make sure the water curtain is in place when performing this check It prevents water from splashing out of the water trough 1 Inspect the bridge connecti...

Page 41: ...must be at the factory setting of 45 seconds for the water fill valve to energize during the last 15 seconds of the water purge If it is set to less than 45 seconds the water fill valve will not energize during the water purge Water Purge Adjustment For your safety and to eliminate errors we recommend that a qualified service technician make the harvest water purge adjustment Warning Disconnect el...

Page 42: ...Ice Machine Operation Section 3 3 6 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 43: ...ing the Condenser GENERAL A dirty condenser restricts airflow resulting in excessively high operating temperatures This reduces ice production and shortens component life Clean the condenser at least every six months Follow the steps below 1 The washable aluminum filter on self contained ice machines is designed to catch dust dirt lint and grease Clean the filter with a mild soap and water 2 Clean...

Page 44: ...phaSan is to keep the plastic surfaces of an ice machine cleaner by reducing or delaying the formation of bio film The active ingredient in AlphaSan is the element silver in the form of silver ions Ag AlphaSan slowly releases silver ions via an ion exchange mechanism When AlphaSan is compounded directly into a plastic part a controlled release of silver ions from the surface is regulated to mainta...

Page 45: ...age allows moisture in the air to activate the sachet contents 5 Close the left front door and tighten the screw Guardianf Location SACHET REPLACEMENT FREQUENCY Sachet packet s require replacement every thirty 30 days or whenever they come in direct contact with water Refer to chart below for requirements Guardianf sachet packets are available through your local Manitowoc ice machine dealer SACHET...

Page 46: ...ndicate the Cleaning cycle is completed This entire cycle lasts approximately 30 minutes Step 6 When the cleaning process stops move the toggle switch to OFF position Refer to Sanitizing Procedure on the next page Step 7 A The ice machine may be set to start and finish a self cleaning procedure then automatically start ice making again B You must wait about one minute into the cleaning cycle until...

Page 47: ...ater and sanitizer Step 4 Use the sanitizing solution and a sponge or cloth to sanitize wipe all parts and interior surfaces of the ice machine Sanitize the following areas A Side walls B Base area above water trough C Evaporator plastic parts D Bin or dispenser Step 5 Rinse all sanitized areas with clear water Step 6 Install the removed parts restore power and place toggle switch in the ice posit...

Page 48: ...l the removed parts NOTE Incomplete rinsing of the ice thickness probe or water level probe may leave a residue This could cause the ice machine to malfunction For best results brush or wipe the probes off while rinsing it Thoroughly dry the probes before installing them 9 Turn on the water and electrical supply Warning Disconnect electric power to the ice machine and dispenser if applicable at th...

Page 49: ...he ice thickness probe Ice Thickness Probe Removal B Pivot the ice thickness probe to disengage one pin then the other The ice thickness probe can be cleaned at this point without complete removal Follow Step C for complete removal C Disconnect the ice thickness control wiring from the control board SV3153 STEP 1 STEP 2 Warning Disconnect the electric power to the ice machine at the electric servi...

Page 50: ...rews to distribution tube B Pull inner half of water distribution tube forward to release slip joint from water pump tubing connection 4 Water Trough A Depress tabs on right and left side of the water trough B Allow front of water trough to drop as you pull forward to disengage the rear pins Warning Removing the distribution tube while the water pump is running will allow water to spray from ice m...

Page 51: ...n Water Pump Removal 2 Remove the water trough 3 The water pump normally does not require removal for cleaning The water pump base can be wiped and cleaned in place or proceed to step 4 4 Grasp pump and pull straight down on pump assembly until water pump disengages and electrical connector is visible 5 Disconnect the electrical connector 6 Remove the water pump assembly from ice machine 7 Do not ...

Page 52: ... off the valve body and the enclosing tube 4 Press down on the plastic nut on the enclosing tube and rotate it 1 4 turn Remove the enclosing tube plunger and plastic gasket from the valve body NOTE At this point the water dump valve can easily be cleaned If complete removal is desired continue with step 5 NOTE During cleaning do not stretch damage or remove the spring from the plunger If it is rem...

Page 53: ...Drain Line Check Valve The drain line check valve normally does not require removal for cleaning Water loss from the sump trough will indicate removal and cleaning are required 1 Remove check valve and tube assembly A Tip assembly to right until tubing disengages B Lift up on assembly to remove 2 Remove insulation from check valve assembly 3 Remove vinyl tubing from top of check valve 4 Soak in cl...

Page 54: ...re below to remove the water inlet valve 1 Remove the 1 4 hex head screws 2 Remove clean and install the filter screen Removing the Front Panels NOTE The front panels do not normally have to be removed If needed perform the following procedure 1 Loosen screws Do not remove they are retained by o rings to prevent loss 2 30 Inch and 48 Inch Models Only To remove right front door lift up and remove 2...

Page 55: ...f the water lines drain lines distribution tubes etc WATER COOLED ICE MACHINES 1 Perform steps 1 6 under Self Contained Air Cooled Ice Machines 2 Disconnect the incoming water and drain lines from the water cooled condenser 3 Insert a large screwdriver between the bottom spring coils of the water regulating valve Pry upward to open the valve Pry Open the Water Regulating Valve 4 Hold the valve ope...

Page 56: ...Maintenance Section 4 4 14 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 57: ... sanitize the ice machine See Section 4 Ice machine is not level Level the ice machine See Section 2 Low air temperature around ice machine head section Air temperature must be at least 35 F 1 6 C Fan cycling control does not de energize condenser fan motor Verify pressure is below cut out setpoint replace fan cycling control Ice machine does not cycle into harvest mode The six minute freeze time ...

Page 58: ...uces shallow or incomplete cubes or the ice fill pattern on the evaporator is incomplete Ice thickness probe is out of adjustment Adjust the ice thickness probe See Section 4 Water trough level is too low Check the water level probe for damage See Section 3 Water inlet valve filter screen is dirty Remove the water inlet valve and clean the filter screen See Section 4 Water filtration is poor Repla...

Page 59: ...Section 5 Before Calling For Service Part Number 80 1480 3 5 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 60: ...Before Calling For Service Section 5 5 4 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 61: ...ce steps 5 6 The maximum harvest time is 3 1 2 minutes at which time the control board automatically terminates the harvest sequence If the bin switch is open the ice machine will go to automatic shut off step 7 If the bin switch is closed the ice machine will go to the freeze sequence steps 3 4 Ice Making Sequence Of Operation Control Board Relays Contactor Length Of Time 1 2 3 4 5 6 7 7A 7B Wate...

Page 62: ...s at which time the control board automatically terminates the harvest sequence If the bin switch is open the ice machine will go to automatic shut off step 7 If the bin switch is closed the ice machine will go to the freeze sequence steps 3 4 Ice Making Sequence Of Operation Control Board Relays Contactor Length Of Time 1 2 3 4 5 6 7 7A 7B Water Pump Harvest Valve Left HPR Valve Harvest Valve Rig...

Page 63: ... 45 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor 35 sec OFF 10 sec ON 5 Water Inlet Valve OFF 6 Water Dump Valve ON 7 Contactor Coil Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Cont...

Page 64: ...d Refrigeration System Start Up Table 6 2 Self Contained Models 2 Refrigeration System Start Up 5 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve ON 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF Safety Control...

Page 65: ... 5 Water Inlet Valve On 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed SV3137 3 89 55 88 High Pressure Cutout Control Board L1 Ground 2 6 5 1 7 4 L2 or N Water Valve Harvest Valve 20 21 22 61 Dump Valve Water Pump 60 76 81...

Page 66: ...osed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve Cycles OFF then ON one more time 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control B...

Page 67: ...nds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON after 35 seconds 5 Water Inlet Valve 30 seconds OFF 15 seconds ON 6 Water Dump Valve ON 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF May Cycle ON Safety Controls Which could stop ice machine operation High Pressure Cut...

Page 68: ...h Activation Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Closed ON 7A Compressor ON 7B Condenser Fan Motor OFF May Cycle ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse...

Page 69: ...ed Models 7 Automatic Shut Off Until Bin Switch Closes Toggle Switch ICE Bin Switch Open Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pre...

Page 70: ...Electrical System Section 6 6 10 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 71: ...1 60 57 98 22 76 81 77 80 26 25 58 59 Contactor Coil 56 L2 Air Compressor 8 83 88 22 75 Liquid Line Solenoid HPR Valve 55 89 9 78 82 42 50 45 46 F2 F1 51 Black Red Yellow L1 L1 L2 6 1 2 Remote Fan Motor Remote Condenser Run Capacitor Contactor Contacts Compressor Ice Thickness Probe Water Level Probe High Pressure Cut out Ground Run Cap OFF Clean ON Bin Switch Trans Fuse 7A Control Board 2 6 5 1 7...

Page 72: ...frigeration System Start Up 5 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left HPR Valve ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve ON 6 Water Dump Valve OFF 7 Contactor Coil Liquid Line Solenoid Closed ON 7A Compressor ON 7B Condenser Fan Motor ON Safety Controls Which could stop ice machine operati...

Page 73: ...et Valve ON 6 Water Dump Valve OFF 7 Contactor Coil Liquid Line Solenoid Closed ON 7A Compressor ON 7B Condenser Fan Motor May Cycle ON OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control Board Closed SV3158 3 Water Valve Harvest Valve Dump Valve Water Pump 20 21 79 74 61 60 57 98 22 76 81 77 80 26 25 58 59 Contactor Coil 56 L2 Air Compresso...

Page 74: ...d Relays 1 Water Pump ON 2 Harvest Valve Left HPR Valve OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve Cycles OFF then ON one more time 6 Water Dump Valve OFF 7 Contactor Coil Liquid Line Solenoid Closed ON 7A Compressor ON 7B Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed Main Fuse On Control B...

Page 75: ...ustment for details Remote Water Purge Table 6 12 Remote Models 5 Water Purge 45 Seconds Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump ON 2 Harvest Valve Left HPR Valve ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON after 35 seconds 5 Water Inlet Valve 30 seconds OFF 15 seconds ON 6 Water Dump Valve ON 7 Contactor Coil Liquid Line Solenoid Closed ON 7A Compressor...

Page 76: ... Bin Switch Activation Toggle Switch ICE Bin Switch Closed Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left HPR Valve ON 3 Harvest Valve Right ON When Used 4 Air Compressor ON When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Liquid Line Solenoid Closed ON 7A Compressor ON 7B Condenser Fan Motor ON Safety Controls Which could stop ice machine operation High Pressu...

Page 77: ...s Toggle Switch ICE Bin Switch Open Control Board Relays 1 Water Pump OFF 2 Harvest Valve Left HPR Valve OFF 3 Harvest Valve Right OFF When Used 4 Air Compressor OFF When Used 5 Water Inlet Valve OFF 6 Water Dump Valve OFF 7 Contactor Coil Liquid Line Solenoid Open OFF 7A Compressor OFF 7B Condenser Fan Motor OFF Safety Controls Which could stop ice machine operation High Pressure Cut Out Closed M...

Page 78: ... of the wiring diagrams Internal Compressor Overload Some models have external compressor overloads Fan Motor Run Capacitor Some models do not incorporate fan motor run capacitor TB Terminal Board Connection Terminal board numbers are printed on the actual terminal board Wire Number Designation The number is marked at each end of the wire Multi Pin Connection Electrical Box Side Compressor Compart...

Page 79: ...HICKNESS PROBE WATER LEVEL PROBE SOLENOID 57 DUMP 81 75 76 HARVEST SOLENOID 80 77 VALVE WATER 60 61 22 21 7 2 1 6 5 HIGH PRESSURE CUTOUT 55 L2 OR N SEE SERIAL PLATE FOR VOLTAGE L1 89 88 20 59 CLEAN LEFT BIN RIGHT BIN RMT BIN WTR PROBE ICE PROBE HARV SL 1 SL 2 6 2 1 9 8 42 CONTROL BOARD 4 85 51 CONTACTOR CONTACTS L1 FAN CYCLE CONTROL RUN CAPACITOR FAN MOTOR AIR COOLED ONLY 49 START CAPACITOR CURREN...

Page 80: ...1 60 57 98 99 76 81 75 77 80 26 25 58 59 Contactor Coil 56 Trans Fuse 7a Low DC Voltage Plug L1 51 85 86 Fan Cycle Control Fan Motor Run Capacitor Compressor Run Capacitor 50 45 L2 or N L1 Ground 2 6 5 1 7 4 L2 Air Compressor When Used Bin Switch Clean OFF ICE 2 1 6 8 9 Overload Contactor Contacts 46 99 49 47 44 52 53 48 5 2 1 4 S C R S R C Compressor Terminal Layout Viewed from End of Compressor ...

Page 81: ...ckness Probe Water Level Probe Control Board 61 60 57 98 99 76 81 75 77 80 26 25 58 59 Contactor Coil 56 Trans Fuse 7a Low DC Voltage Plug L1 51 85 86 Fan Cycle Control Fan Motor Run Capacitor PTCR Compressor Run Capacitor 50 45 L2 or N L1 Ground 2 6 5 1 7 4 L2 Air Compressor When Used Bin Switch Clean OFF ICE 2 1 6 8 9 Overload Red Yellow Black Contactor Contacts 46 99 Clean Left Bin Right Bin Wt...

Page 82: ... 22 74 Ice Thickness Probe Water Level Probe Control Board 61 60 57 98 99 76 81 75 77 80 26 25 58 59 Contactor Coil 56 Trans Fuse 7a Low DC Voltage Plug L1 51 85 86 Fan Cycle Control Fan Motor Run Capacitor Compressor L1 Ground 2 6 5 1 7 4 L2 Air Compressor When Used Bin Switch Clean OFF ICE 2 1 6 8 9 Contactor Contacts 75 L2 L3 L2 L3 T2 T1 T3 99 Clean Left Bin Right Bin Wtr Probe Rmt Bin Ice Prob...

Page 83: ...61 60 57 98 99 76 81 77 80 26 25 58 59 Contactor Coil 56 Trans Fuse 7a Low DC Voltage Plug L1 51 F1 Fan Motor Run Capacitor PTCR Compressor Run Capacitor 50 45 L2 or N L1 Ground 2 6 5 1 7 4 L2 Air Compressor When Used Bin Switch Clean OFF ICE 2 1 6 8 9 Overload Red Yellow Black Contactor Contacts 46 R R 83 22 22 75 Remote Condenser F2 Clean Left Bin Right Bin Wtr Probe Rmt Bin Ice Probe Harvest SL...

Page 84: ...trol Board 61 60 57 98 99 76 81 75 77 80 26 25 58 59 Contactor Coil 56 Trans Fuse 7a Low DC Voltage Plug L1 51 F1 Fan Motor Run Capacitor Compressor L1 Ground 2 6 5 1 7 4 L2 Air Compressor When Used Bin Switch Clean OFF ICE 2 1 6 8 9 Contactor Contacts 75 L2 L3 L2 L3 T2 T1 T3 Liquid Solenoid F2 83 22 82 78 79 82 74 75 HPR Valve Water Valve Clean Left Bin Right Bin Wtr Probe Rmt Bin Ice Probe Harve...

Page 85: ...YCLE CONTROL 59 CLEAN LEFT BIN RIGHT BIN RMT BIN WTR PROBE ICE PROBE HARVEST SL 1 SL 2 6 25 26 L2 AIR COMP 9 8 42 CONTROL BOARD BIN SWITCH LOW D C VOLTAGE PLUG CONTACTOR COIL 56 TERMINATES AT PIN CONNECTION PUMP WATER 99 98 58 FUSE 7A TRANS ICE THICKNESS WATER LEVEL SOLENOID 57 DUMP 81 76 LH HARVEST SOLENOID 87 77 WATER VALVE 60 61 22 21 7 2 1 5 HIGH PRESSURE CUTOUT 55 L2 OR N 88 20 AIR COMPRESSOR...

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

Page 87: ...REMOTE FAN MOTOR RUN CAPACITOR F2 F1 BLACK OVERLOAD C R COMPRESSOR YELLOW RED CONTACTOR L1 BIN SWITCH LOW D C VOLTAGE PLUG CONTACTOR COIL 56 74 WATER PUMP 98 58 FUSE 7A TRANS ICE THICKNESS PROBE WATER LEVEL PROBE 57 DUMP SOLENOID 81 75 76 RH HARVEST SOLENOID 87 88 HPR SOLENOID 60 61 22 82 7 2 1 6 5 HIGH PRESSURE CUTOUT 55 L2 OR N CONTACTS 89 88 78 AIR COMPRESSOR WHEN USED 4 LIQUID SOLENOID 83 REMO...

Page 88: ...TCH LOW D C VOLTAGE PLUG CONTACTOR COIL 56 74 58 FUSE 7A TRANS SOLENOID 57 DUMP 76 RH HARVEST SOLENOID 88 60 61 7 2 1 6 5 55 59 CLEAN LEFT BIN RIGHT BIN RMT BIN WTR PROBE ICE PROBE HARV SL 1 SL 2 AIR COMPRESSOR WHEN USED 6 2 1 25 26 L2 AIR COMP 9 8 CONTROL BOARD 4 83 51 F1 FAN MOTOR REMOTE F2 REMOTE CONDENSER RUN CAPACITOR PUMP WATER 98 81 75 87 HPR SOLENOID 22 82 78 LIQUID SOLENOID 79 WATER VALVE...

Page 89: ...ice machine shuts off The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain As the water curtain swings back to the operating position the bin switch closes and the ice machine restarts provide the three minute delay has expired Specifications The bin switch is a magnetically operated reed switch The magnet is at...

Page 90: ...le With the curtain open the reading must be infinity OL Continuity Test 1 Disconnect the bin switch wires to isolate the bin switch from the control board 2 Connect an ohmmeter to the disconnected bin switch wires 3 Cycle the bin switch open and closed 25 times by opening and closing the water curtain Watch for consistent readings each time the bin switch is cycled open and closed bin switch fail...

Page 91: ...he readings again Check Motor Windings to Ground Check continuity between all three terminals and the compressor shell or copper refrigeration line Scrape metal surface to get good contact If continuity is present the compressor windings are grounded and the compressor should be replaced Determine if the Compressor is Seized Check the amp draw while the compressor is trying to start COMPRESSOR DRA...

Page 92: ...refrigerant discharge and suction pressures to be somewhat equalized prior to the compressor starting To assure equalization of pressures the harvest valve and HPR valve on remotes will energize for 45 seconds prior to compressor starting The harvest valve and HPR valve on remotes remains on for an additional 5 seconds while the compressor is starting 2 When starting the compressor the contactor c...

Page 93: ... if the PTCR is properly cooled say 60 F 15 6 C when the compressor starts it will take 25 to 1 0 seconds before its temperature reaches 260 F 126 6 C and current flow is stopped If the PTCR is still warm say 160 F 71 1 C when the compressor starts it will take only 125 to 50 seconds before its temperature reaches 260 F 126 6 C and current flow is stopped This decreased time may be insufficient to...

Page 94: ...re this is occurring and the harvest valve and HPR solenoid coil is functional before assuming that the PTCR is bad CHECKING THE PTCR 1 Visually inspect the PTCR Check for signs of physical damage NOTE The PTCR case temperature may reach 210 F 100 C while the compressor is running This is normal Do not change a PTCR just because it is hot 2 Wait at least 10 minutes for the PTCR to cool to room tem...

Page 95: ...ergized Relay Operation Check 1 Disconnect wires from relay terminals 2 Verify the contacts are closed Measure the resistance between terminals 1 and 2 No continuity indicates open contacts Replace the relay 3 Check the relay coil Measure the resistance between terminals 2 and 5 No resistance indicates an open coil Replace the relay HARVEST ASSIST AIR COMPRESSOR Function The air compressor breaks ...

Page 96: ...ded that a volt meter be used to check toggle switch operation 1 Inspect the toggle switch for correct wiring 2 Isolate the toggle switch by disconnecting the Molex connector 3 Check continuity across the toggle switch terminals Note where the wire numbers are connected to the switch terminals or refer to the wiring diagram to take proper readings 4 Replace the toggle switch if ohm readings do not...

Page 97: ...ICKNESS PROBE 3 16 CONNECTION WATER LEVEL PROBE DC LOW VOLTAGE ELECTRICAL PLUG NUMBERS MARKED ON WIRES WATER PROBE LIGHT GREEN LEFT BIN LIGHT GREEN HARVEST LIGHT RED REMOTE BIN CLEAN LIGHT YELLOW WATER PURGE ADJUSTMENT AIR COMPRESSOR NOT USED ON ALL MODELS RIGHT BIN LIGHT GREEN PRIMARY POWER SUPPLY N 115V L2 208 230V REMOTE BIN LIGHT GREEN ICE PROBE LIGHT GREEN SAFETY LIMIT 1 LIGHT RED SAFETY LIMI...

Page 98: ... board along with inputs controls all electrical components including the ice machine sequence of operation Prior to diagnosing you must understand how the inputs affect the control board operation Refer to specific component specifications inputs wiring diagrams and ice machine sequence of operation sections for details As an example refer to Ice Thickness Probe on the next page for information r...

Page 99: ...control system includes a built in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle ICE THICKNESS CHECK The ice thickness probe is factory set to maintain the ice bridge thickness at 1 8 32 cm NOTE Make sure the water curtain is in place when performing this check It prevents water from splashing out of the water trough 1 Inspect the bridge co...

Page 100: ...orator then monitor the harvest light Monitoring of Harvest Light Correction The harvest light comes on and 10 seconds later ice machine cycles from freeze to harvest The ice thickness probe is causing the malfunction The harvest light comes on but the ice machine stays in the freeze sequence The control circuitry is functioning properly The ice machine is in a six minute freeze time lock in verif...

Page 101: ...ter level control During the freeze cycle the water inlet valve energizes turns on and de energizes turns off in conjunction with the water level probe located in the water trough During the first 45 seconds of the Freeze Cycle The water inlet valve is on when there is no water in contact with the water level probe The water inlet valve turns off after water contacts the water level probe for 3 co...

Page 102: ...ne is not in a freeze cycle water inlet valve safety shut off mode You must complete the entire diagnostic procedure within 6 minutes of starting Important For the test to work properly you must wait until the freeze cycle starts prior to connecting the jumper wire If you restart the test you must disconnect the jumper wire restart the ice machine step 1 and then reinstall the jumper wire after th...

Page 103: ...f mode You must complete the entire diagnostic procedure within 6 minutes of starting Important For the test to work properly you must wait until the freeze cycle starts prior to disconnecting the water level probe If you restart the test you must reconnect the water level probe restart the ice machine step 1 and then disconnect the water level probe after the compressor starts Step 3 Disconnect w...

Page 104: ...sed The H P C O is closed if primary power voltage is present at terminals 55 and 56 on the control board 3 Verify control board fuse is OK If the bin switch light functions the fuse is OK 4 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 5 Verify ICE OFF CLEAN toggle switch functions properly A defective toggle switch may keep the ice machine...

Page 105: ...Section 6 Electrical System Part Number 80 1480 3 6 45 S1000 SELF CONTAINED 1 PHASE WITH TERMINAL BOARD SV2071 2 1 3 4 5 6 ...

Page 106: ...Electrical System Section 6 6 46 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 107: ...bsorbs heat picked up during the harvest cycle from the evaporator The suction pressure decreases during the prechill Freeze Cycle Refrigeration Sequence The refrigerant absorbs heat from water running over the evaporator surface The suction pressure gradually drops as ice forms HEAT EXCHANGER EVAPORATOR CONDENSER COMPRESSOR EXPANSION VALVE HOT GAS SOLENOID VALVE AIR OR WATER DRIER STRAINER RECEIV...

Page 108: ...w the proper amount of refrigerant into the evaporator This specific sizing along with the proper system refrigerant charge assures proper heat transfer without the refrigerant condensing and slugging the compressor HEAT EXCHANGER EVAPORATOR CONDENSER COMPRESSOR EXPANSION VALVE HOT GAS SOLENOID VALVE AIR OR WATER DRIER STRAINER RECEIVER WATER COOLED ONLY LOW PRESSURE VAPOR LOW PRESSURE LIQUID HIGH...

Page 109: ...at from the water running over the evaporator surface The suction pressure gradually drops as ice forms The headmaster control valve maintains discharge pressure in ambient temperatures below 70 F 21 1 C See Headmaster Control Valve X X HEAT EXCHANGER EVAPORATOR SOLENOID LINE LIQUID CHECK VALVE SERVICE RECEIVER CONDENSER REMOTE COMPRESSOR RECEIVER EXPANSION VALVE HOT GAS SOLENOID VALVE VALVE HARVE...

Page 110: ...es proper heat transfer without the hot gas condensing to liquid and slugging the compressor The harvest pressure regulating H P R valve helps maintain the suction pressure during the harvest cycle See H P R System HEAT EXCHANGER EVAPORATOR SOLENOID LINE LIQUID CHECK VALVE SERVICE RECEIVER CONDENSER REMOTE COMPRESSOR RECEIVER EXPANSION VALVE HOT GAS SOLENOID VALVE VALVE HARVEST PRESSURE REGULATING...

Page 111: ...d line solenoid prevents refrigerant from migrating back into the low side This protects the compressor from refrigerant migration during the off cycle preventing refrigerant slugging upon start up X X X HEAT EXCHANGER EVAPORATOR SOLENOID LINE LIQUID CHECK VALVE SERVICE RECEIVER CONDENSER REMOTE COMPRESSOR RECEIVER EXPANSION VALVE HOT GAS SOLENOID VALVE VALVE HARVEST PRESSURE REGULATING VALVE H P ...

Page 112: ...for self contained dual expansion valve ice machines is identical to self contained single expansion valve ice machines See Pages 7 1 and 7 2 for sequence of operation x x HARVEST SOLENOID VALVE AIR OR WATER COOLED CONDENSER COMPRESSOR HEAT EXCHANGER RECEIVER DRIER STRAINER EXPANSION VALVE EXPANSION VALVE EVAPORATOR HARVEST SOLENOID VALVE ...

Page 113: ...valve ice machines is identical to remote single expansion valve ice machines See Pages 7 3 7 4 and 7 5 for sequence of operation REMOTE CONDENSER COMPRESSOR HEAT EXCHANGER RECEIVER DRIER EXPANSION VALVE EXPANSION VALVE EVAPORATOR x HPR VALVE LLSV CHECK VALVE CHECK VALVE x x HARVEST SOLENOID VALVE STRAINER HARVEST SOLENOID VALVE HEAD PRESSURE CONTROL VALVE ...

Page 114: ...n valve Actually the problem loose bulb was corrected when the technician properly mounted the bulb of the replacement expansion valve The service technician s failure to check the expansion valve bulb for proper mounting an external check resulted in a misdiagnosis and the needless replacement of a good expansion valve 2 An ice machine that is low on charge may cause a good expansion valve to sta...

Page 115: ...1 Determine the ice machine operating conditions Air temp entering condenser _______ Air temp around ice machine _______ Water temp entering sump trough _______ 2 Refer to the appropriate 24 Hour Ice Production Chart Use the operating conditions determined in Step 1 to find published 24 hour ice production 3 Perform an actual ice production check Use the formula below 4 Compare the results of step...

Page 116: ...ter area evaporator is dirty Clean as needed Water inlet pressure not between 20 and 80 psi 1 5 Bar 138 552 kPa Install a water regulator valve or increase the water pressure Incoming water temperature is not between 35 F 1 6 C and 90 F 32 2 C If too hot check the hot water line check valves in other store equipment Water filtration is plugged if used Install a new water filter Water dump valve le...

Page 117: ... cubes at the outlet of the evaporator may be more pronounced than those at the inlet This is normal The ice thickness probe must be set to maintain the ice bridge thickness at approximately 1 8 If ice forms uniformly across the evaporator surface but does not reach 1 8 in the proper amount of time this is still considered normal 2 Extremely Thin at Evaporator Outlet There is no ice or a considera...

Page 118: ... by loss of heat transfer from the tubing on the back side of the evaporator Figure 7 8 Spotty Ice Formation 5 No Ice Formation The ice machine operates for an extended period but there is no ice formation at all on the evaporator Possible causes Water inlet valve water pump starving expansion valve low refrigerant charge compressor etc Figure 7 9 No Ice Formation Figure 7 10 S1400 S1600 S1800 Eva...

Page 119: ...frigeration industry a high percentage of compressors fail as a result of external causes These can include flooding or starving expansion valves dirty condensers water loss to the ice machine etc The safety limits protect the ice machine primarily the compressor from external failures by stopping ice machine operation before major component damage occurs The safety limit system is similar to a hi...

Page 120: ... water pressure 80 psi 552 kPa max High water temperature 90 F 32 2 C max Clogged water distribution tube Dirty defective water fill valve Dirty defective water dump valve Defective water pump Loss of water from sump area Electrical system Low incoming voltage Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operati...

Page 121: ...machine did not stop because it exceeded a safety limit Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Water system Water area evaporator dirty Dirty defective water dump valve Vent tube not installed on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Low water pressure 20 psi...

Page 122: ...______ __________ End of Cycle __________ __________ Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Restricted condenser air flow air cooled models High inlet air temperature Self Contained 110 F 43 3 C max Remote 120 F 49 C max Condenser discharge air recirculation Dirty condenser filter Dirty condenser Defective fan cycling control Defective fan m...

Page 123: ...C 2A Refer to Cycle Time and Operating Pressure charts for ice machine model being checked Using operating conditions from Step 1 determine published freeze cycle time and published freeze cycle suction pressure Published freeze cycle time Published freeze cycle suction pressure 8 5 9 8 minutes 58 28 PSIG 2B Compare the published freeze cycle time and published freeze cycle suction pressure Develo...

Page 124: ...Other Non Manitowoc components in system H P R solenoid leaking Harvest valve stuck open TXV flooding check bulb mounting Defective compressor Possible Cause Check Correct Improper installation See Installation Visual Inspection Checklist Discharge pressure Discharge pressure is too low and is affecting low side See Freeze Cycle Discharge Pressure Low Checklist Improper refrigerant charge Undercha...

Page 125: ...he difference between the two temperatures five minutes into the freeze cycle These temperatures must be within 7 of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Use a quality temperature meter capable of taking temperature readings on curved copper lines 2 Attach the temperature meter sensing device to the copper lines entering and leaving the evaporator ...

Page 126: ...ycle 2 Feel the inlet of the harvest valve s 3 Feel the compressor discharge line 4 Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to tou...

Page 127: ...nutes of the freeze cycle and record the maximum discharge line temperature Discharge Line Temperature Above 160 F 71 1 C At End Of Freeze Cycle Ice machines that are operating normally will have consistent maximum discharge line temperatures above 160 F 71 1 C Discharge Line Temperature Below 160 F 71 1 C At End Of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum...

Page 128: ... number with the highest total and proceed to Final Analysis NOTE If two columns have matching high numbers a procedure was not performed properly and or supporting material was not analyzed correctly Final Analysis The column with the highest number of check marks identifies the refrigeration problem COLUMN 1 HARVEST VALVE LEAKING A leaking harvest valve must be replaced COLUMN 2 LOW CHARGE TXV S...

Page 129: ... to eliminate problems and or components not listed on this table before proceeding Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Wait 5 minutes into the freeze cycle Compare temperatures of evaporator inlet evaporator outlet Inlet ____ F C Outlet ____ F C Difference ____ F C Inlet and outlet within 7 of each other Inlet and outlet not...

Page 130: ...ty limit 1 or 2 Freeze Cycle Discharge Pressure _____ ______ ______ 1 minute Middle End into cycle If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist to eliminate problems and or components not listed on this table before proceeding Freeze Cycle Suction Pressure _____ ______ ______ 1 minute Middle End If suction pressure is High or Low refer...

Page 131: ...is not used during the freeze cycle The H P R solenoid is closed de energized preventing refrigerant flow into the H P R valve HARVEST CYCLE During the harvest cycle the check valve in the discharge line prevents refrigerant in the remote condenser and receiver from backfeeding into the evaporator and condensing to liquid The H P R solenoid is opened energized during the harvest cycle allowing ref...

Page 132: ...ol board indicates safety limit 2 Refer to Cycle Times Refrigerant Pressures 24 Hour Ice Production Charts Connect refrigeration manifold gauge set to the access valves on the front of the ice machine and a thermometer thermocouple on the discharge line within 6 of the compressor insulate thermocouple Establish baseline by recording suction and discharge pressure discharge line temperature and fre...

Page 133: ...de temperature Refer to the proper Operational Pressure Chart later in this section 3 Determine the temperature of the liquid line entering the receiver by feeling it This line is normally warm body temperature 4 Using the information gathered refer to the chart below NOTE A headmaster that will not bypass will function properly with condenser air temperatures of approximately 70 F 21 1 C or above...

Page 134: ... or the outside temperature drops When it rains or the outside temperature drops the fan begins to cycle on and off At first everything appears normal But as it continues raining or getting colder the fan cycle control can only turn the fan off All the refrigerant must continue to flow through the condenser coil being cooled by the rain or low outside temperature This causes excessive sub cooling ...

Page 135: ...eck Procedure 1 Set ICE OFF CLEAN switch to OFF 2 Connect manifold gauges 3 Hook 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 and remote models disconnect the fan motor 5 Set ICE OFF CLEAN switch to ICE 6 No water or air flowing through the condenser will cause the HPCO ...

Page 136: ...ts comparing evaporator inlet outlet temperatures discharge and suction pressure analysis Ice production checks that are within 10 of the chart are considered normal This is due to variances in water and air temperature Actual temperatures will seldom match the chart exactly Zero out manifold gauge set before obtaining pressure readings to avoid misdiagnosis Discharge and suction pressure are high...

Page 137: ...4 135 165 80 110 80 26 7 220 290 60 25 150 170 90 120 90 32 2 250 330 70 27 170 195 115 135 100 37 8 285 370 74 28 200 220 130 155 110 43 3 330 415 78 30 230 250 150 175 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 9 8 11 6 10 8 12 7 12 0 14 1 1 2 5 80 26 7 10 0 11 8 11 0 ...

Page 138: ... 165 90 120 80 26 7 215 295 75 36 140 165 110 125 90 32 2 240 320 80 38 155 180 120 135 100 37 8 290 365 90 40 175 215 14 165 110 43 3 325 415 95 42 200 230 160 185 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 12 7 14 4 13 6 15 5 15 2 17 3 1 2 5 80 26 7 13 1 14 9 14 1 16 0...

Page 139: ... 21 1 195 270 60 30 135 190 80 115 80 26 7 220 285 62 32 135 195 80 115 90 32 2 250 320 70 34 175 195 85 115 100 37 8 290 390 75 35 190 215 115 140 110 43 3 320 400 80 37 225 250 130 170 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 8 9 9 5 9 6 10 3 10 7 11 5 1 2 5 80 26 7 ...

Page 140: ... 21 1 195 270 60 30 135 190 80 115 80 26 7 220 285 62 32 135 195 80 115 90 32 2 250 320 70 34 175 195 85 115 100 37 8 290 390 75 35 190 215 115 140 110 43 3 320 400 80 37 225 250 130 170 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 8 9 9 5 9 6 10 3 10 7 11 5 1 2 5 80 26 7 ...

Page 141: ...135 160 80 95 80 26 7 220 295 50 29 160 175 90 105 90 32 2 250 325 55 31 175 205 105 120 100 37 8 270 370 60 32 200 225 120 145 110 43 3 290 425 75 36 220 260 150 165 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 9 3 10 9 10 6 12 5 12 0 14 0 1 2 5 80 26 7 9 7 11 4 10 9 12 8...

Page 142: ...le Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 20 28 9to 50 10 0 210 240 42 29 105 160 75 100 70 21 1 235 250 48 31 105 165 85 100 80 26 7 245 260 50 32 110 165 85 100 90 32 2 250 270 52 33 110 170 90 105 100 37 8 265 315 60 34 125 175 90 110 110 43 3 295 365 62 35 130 185 95 115 Suction pressure drops gradually throughout the freeze cy...

Page 143: ...sure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 50 10 0 225 235 36 26 140 190 65 95 70 21 1 225 235 36 26 140 190 65 95 80 26 7 225 245 40 28 150 195 70 100 90 32 2 230 255 40 29 160 200 70 100 100 37 8 230 260 40 30 170 205 75 105 110 43 3 230 260 40 30 180 210 80 110 Suction pressure drops gradually throughout the freeze cycle Air Temp Entering Condenser F C Freeze ...

Page 144: ...0 40 28 130 145 70 85 80 26 7 230 275 50 28 150 165 70 90 90 32 2 260 310 54 32 165 185 85 105 100 37 8 300 355 65 32 180 210 105 125 110 43 3 325 405 70 38 215 235 120 150 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 7 9 9 1 8 7 10 1 9 8 11 3 1 2 5 80 26 7 8 0 9 3 8 9 10 ...

Page 145: ...ze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG Suction pressure drops gradually throughout the freeze cycle 20 28 9 to 50 10 0 220 250 50 30 100 160 70 90 70 21 1 220 260 50 30 100 160 70 90 80 26 7 240 265 50 30 100 160 75 90 90 32 2 250 280 52 30 100 160 75 95 100 37 8 280 320 52 30 110 165 75 95 110 43 3 310 365 62 31 125 170 8...

Page 146: ...scharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 50 10 0 235 245 40 24 160 175 75 90 70 21 1 235 245 40 25 160 175 75 90 80 26 7 235 250 42 26 170 185 80 95 90 32 2 240 270 48 28 175 205 85 105 100 37 8 250 280 52 28 180 210 90 110 110 43 3 250 285 54 28 185 215 95 115 Suction pressure drops gradually throughout the freeze cycle Air Temp Entering Condenser ...

Page 147: ...8 24 140 180 70 90 80 26 7 240 300 38 25 155 180 75 95 90 32 2 265 340 38 26 175 195 85 100 100 37 8 310 390 40 27 200 215 95 110 110 43 3 340 430 42 29 225 240 115 130 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 7 1 7 9 7 8 8 7 9 1 10 1 1 2 5 80 26 7 7 4 8 2 7 9 8 8 9 1 ...

Page 148: ...28 160 180 70 90 80 26 7 225 290 44 30 160 180 70 90 90 32 2 260 310 46 30 180 200 80 100 100 37 8 290 360 48 31 200 220 90 115 110 43 3 320 400 50 32 220 250 100 140 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 8 9 10 0 9 8 10 9 11 2 12 5 1 2 5 80 26 7 8 9 10 0 9 8 10 9 1...

Page 149: ...n Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 20 28 9to 50 10 0 210 240 38 28 100 160 70 85 70 21 1 240 265 40 28 110 170 70 90 80 26 7 250 275 41 29 110 180 70 95 90 32 2 250 290 42 30 110 180 70 95 100 37 8 275 335 43 31 110 185 75 100 110 43 3 310 375 45 32 120 190 80 100 Suction pressure drops gradually throughout the freeze cycle Air Temp Entering Condenser F C Freeze Time Har...

Page 150: ...le Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PSIG Suction Pressure PSIG 50 10 0 235 245 46 27 160 175 70 90 70 21 1 235 275 50 27 160 180 70 95 80 26 7 240 280 52 28 160 190 70 100 90 32 2 240 285 52 28 160 190 75 100 100 37 8 250 290 52 29 165 195 75 100 110 43 3 255 295 52 30 170 200 80 100 Suction pressure drops gradually throughout the freeze cycle Air Temp...

Page 151: ...5 70 21 1 220 275 40 26 160 180 70 85 80 26 7 225 290 42 28 175 200 80 95 90 32 2 260 330 44 28 175 200 80 95 100 37 8 300 380 46 30 190 215 90 110 110 43 3 320 415 50 30 210 250 105 140 Suction pressure drops gradually throughout the freeze cycle Air Temp Around Ice Machine F C Freeze Time Harvest Time Water Temperature F C 50 10 0 70 21 1 90 32 2 70 21 1 8 5 9 4 9 2 10 1 10 7 11 8 1 2 5 80 26 7 ...

Page 152: ...13 7 Times in minutes Air Temp Entering Condenser F C Water Temperature F C 50 10 0 70 21 1 90 32 2 20 28 9 to 70 21 1 1800 1630 1540 80 26 7 1780 1620 1520 90 32 2 1750 1610 1520 100 37 8 1690 1630 1430 110 43 3 1570 1440 1340 Based on average ice slab weight of 13 14 125 lb Ratings with JC1395 condenser Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pr...

Page 153: ...acuation Connections 3 Open backseat the high and low side ice machine service valves and open high and low side on manifold gauges 4 Perform recovery or evacuation A Recovery Operate the recovery unit as directed by the manufacturer s instructions B Evacuation prior to recharging Pull the system down to 500 microns Then allow the pump to run for an additional half hour Turn off the pump and perfo...

Page 154: ...that no refrigerant contamination or loss occurs 8 Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses A Run the ice machine in freeze cycle B Close the high side service valve at the ice machine C Open the low side service valve at the ice machine D Open the high and low side valves on the manifold gauge set Any refrigerant i...

Page 155: ...oving the manifold gauge hose REMOTE RECOVERY EVACUATION 1 Place the toggle switch in the OFF position 2 Install manifold gauges charging cylinder scale and recovery unit or two stage vacuum pump 3 Open backseat the high and low side ice machine service valves 4 Open the receiver service valve halfway 5 Open high and low side on the manifold gauge set 6 Perform recovery or evacuation A Recovery Op...

Page 156: ... CONDENSER CLOSED SCALE OPEN RECOVERY UNIT VACUUM PUMP SERVICE VALVE 1 2 OPEN RECEIVER MANIFOLD SET OPEN DRIER SOLENOID LINE VALVE REGULATING PRESSURE HARVEST LIQUID BACKSEATED SERVICE VALVE CHECK VALVE TEE OPEN C B R HIGH SIDE BACKSEATED SERVICE VALVE LOW SIDE COMPRESSOR HARVEST PRESSURE SOLENOID VALVE VALVE EXPANSION VALVE CHECK STRAINER VALVES SOLENOID HEAT EXCHANGER EVAPORATOR SV1461 ...

Page 157: ... machine is fully charged 5 Ensure all vapor in charging hoses is drawn into the machine then disconnect the manifold gauges NOTE Backseat the receiver outlet service valve after charging is complete and before operating the ice machine If the access valve core removal and installation tool is used on the discharge quick connect fitting reinstall the Schraeder valve core before disconnecting the a...

Page 158: ...T VACUUM PUMP SERVICE VALVE 1 2 OPEN RECEIVER MANIFOLD SET OPEN DRIER SOLENOID LINE VALVE REGULATING PRESSURE HARVEST LIQUID BACKSEATED SERVICE VALVE CHECK VALVE TEE OPEN C B R HIGH SIDE BACKSEATED SERVICE VALVE LOW SIDE COMPRESSOR HARVEST PRESSURE SOLENOID VALVE VALVE EXPANSION VALVE CHECK STRAINER VALVES SOLENOID HEAT EXCHANGER EVAPORATOR SV1462 Figure 7 16 Remote Charging Connections ...

Page 159: ...open suction and discharge lines at the compressor for burnout deposits 5 If no signs of contamination are present perform an acid oil test Check the chart below to determine the type of cleanup required Important Manitowoc Ice Inc assumes no responsibility for the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing ...

Page 160: ...cuum test to make a preliminary leak check You should use an electronic leak detector after system charging to be sure there is no leak 5 Charge the system with the proper refrigerant to the nameplate charge 6 Operate the ice machine Severe System Contamination Cleanup Procedure 1 Remove the refrigerant charge 2 Remove the compressor 3 Disassemble the harvest solenoid valve If burnout deposits are...

Page 161: ...iquid line drier 14 Follow normal evacuation procedures REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE This procedure reduces repair time and cost Use it when any of the following components require replacement and the refrigeration system is operational and leak free Fan cycle control air cooled only Water regulating valve water cooled only High pressure cut out control High side...

Page 162: ...Refrigeration System Section 7 7 56 Part Number 80 1480 3 Figure 7 17 Using Pinch Off Tool SV1406 ...

Page 163: ...ze of the filter drier is important The refrigerant charge is critical Using an improperly sized filter drier will cause the ice machine to be improperly charged with refrigerant Listed below are the recommended O E M field replacement driers Important Driers are covered as a warranty part The drier must be replaced any time the system is opened for repairs Model Drier Size End Connection Size Par...

Page 164: ...ir Cooled 26 oz Water Cooled 22 oz Remote 6 lb S600 Air Cooled 32 oz Water Cooled 28 oz Remote 6 5 lb S850 Air Cooled 36 oz Water Cooled 32 oz Remote 8 5 lb S1000 Air Cooled 36 oz Water Cooled 38 oz Remote 8 5 lb S1200 Air Cooled 38 oz Water Cooled 42 oz S1400 Air Cooled 44 oz Water Cooled 40 oz Remote 11 lb S1600 Air Cooled 48 oz Water Cooled 48 oz Remote 11 5 lb S1800 Air Cooled 52 oz Water Cool...

Page 165: ...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 166: ...t Re use of recovered or recycled refrigerant from other products is not approved Recycling equipment must be certified to ARI Standard 740 latest edition and be maintained to consistently meet this standard Recovered refrigerant must come from a contaminant free system To decide whether the system is contaminant free consider Type s of previous failure s Whether the system was cleaned evacuated a...

Page 167: ... For systems found without any positive refrigerant pressure assume that moisture has entered the POE oil After the leak is found and repaired the compressor oil must be changed The compressor must be removed and at least 95 of the oil drained from the suction port of the compressor Use a measuring cup to replace the old oil with exactly the same amount of new POE oil such as Mobil EAL22A Remember...

Page 168: ...Refrigeration System Section 7 7 62 Part Number 80 1480 3 THIS PAGE INTENTIONALLY LEFT BLANK ...

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