Manitowoc STH042 4/16 Technician'S Handbook Download | Manualshive

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Part Number STH042 4/16

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Refrigeration Component Diagnostics

All electrical and water related problems must be
corrected before these charts will work properly. These
tables must be used with charts, 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.

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Summary of Contents for STH042 4/16

Page 1: ...Part Number STH042 4 16 Undercounter Ice Machines Technician s Handbook This manual is updated as new information and models are released Visit our website for the latest manual www manitowocice com ...

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

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

Page 5: ...non OEM ice storage system with this ice machine contact the bin manufacturer to assure their ice deflector is compatible Remove all removable panels before lifting and installing and use appropriate safety equipment during installation and servicing Two or more people are required to lift or move this appliance to prevent tipping and or injury Do not damage the refrigeration circuit when installi...

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

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

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

Page 9: ...allation Location of Ice Machine 18 Ice Machine Clearance Requirements 19 Ice Machine Heat of Rejection 19 Leveling the Ice Machine 20 Electrical Requirements 21 Electrical Specifications 22 Water Service Drains 24 Water Supply 24 Water Inlet Lines 24 Drain Connections 25 Cooling Tower Applications 25 Water Supply and Drain Line Sizing Connections 26 ...

Page 10: ...eaning 37 Ice Machine Inspection 38 Cleaning the Condenser 39 Removal from Service Winterization 40 Bin Removal 41 Operation Touch Pad Features 43 On Off 43 Delay 44 Clean 44 Bin Full 45 Service 45 Ice Making Sequence of Operation 46 Control Board Timers 49 Safety Limits 50 Energized Parts Chart 52 Operational Checks 54 Ice Thickness Check 54 Ice Thickness Adjustment 54 Minimum Maximum Slab weight...

Page 11: ... 61 Ice Machine Cycles Into Harvest Before Water Loses Contact with the Harvest Float Switch 63 Ice Production Check 65 Installation Visual Inspection Checklist 67 Water System Checklist 68 Ice Formation Pattern 69 Safety Limit Feature 71 Analyzing Discharge Pressure 78 Analyzing Suction Pressure 80 Harvest Valve 84 Comparing Evaporator Inlet Outlet Temperatures 88 Discharge Line Temperature Analy...

Page 12: ... Control 111 Filter Driers 112 Refrigerant Recovery Evacuation 113 Definitions 113 Refrigerant Re use Policy 114 Recovery and Recharging Procedures 116 System Contamination Cleanup 119 Determining Severity of Contamination 119 Mild System Contamination Cleanup Procedure 121 Severe System Contamination Cleanup Procedure 122 Replacing Pressure Controls without Removing Refrigerant Charge 123 Total S...

Page 13: ...ontained Water cooled 133 Diagrams Wiring Diagrams 135 U140 U190 U240 wiring diagram Without J4 thermistor terminal 136 U310 wiring diagram Without J4 thermistor terminal 137 U140 U190 U240 wiring diagram With J4 thermistor terminal 138 U310 wiring diagram With J4 thermistor terminal 139 Electronic Control Board with J4 thermistor terminal 140 Electronic Control Board with J1 and without J4 Thermi...

Page 14: ...14 Part Number STH042 4 16 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 15: ...ooled 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 General Information ...

Page 16: ...RAS 50Hz A Air cooled W Water cooled R Regular D Dice Y Half dice nWarning An ice machine contains high voltage electricity 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 ...

Page 17: ...ation For warranty information visit http www kool aire com Service Warranty Warranty Verification Warranty Registration View and download a copy of the warranty Owner Warranty Registration Card Warranty coverage begins the day the ice machine is installed ...

Page 18: ...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 for clearance requirements T...

Page 19: ...r efficient operation and servicing only Ice Machine Heat of Rejection Series Ice Machine Heat of Rejection Air Conditioning Peak U140 2400 2900 U190 2200 2600 U240 2400 3400 U310 3800 6000 B T U Hour Because the heat of rejection varies during the ice making cycle the figure shown is an average Ice machines like other refrigeration equipment reject heat through the condenser It is helpful to know...

Page 20: ...ewed in tightly to prevent them from bending 3 Move the ice machine into its final position 4 Level the ice machine to ensure that the 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 THREAD LEVELING LEG INTO BASE OF CABINET THREAD FOOT IN AS FAR AS POSSIBLE SV1606 Leg Installation ...

Page 21: ...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 22: ...ne 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 23: ...15 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 nWarning All wiring must conform to local state and national codes nWarning The ice machine must be grounded in accordance with national and local electrical code ...

Page 24: ...tions nWarning For ice making connect to a potable water supply only WATER INLET LINES Follow these guidelines to install water inlet lines Do not connect the ice machine to a hot water supply Be sure all hot water restrictors installed for other equipment are working Check valves on sink faucets dishwashers etc If water pressure exceeds the maximum recommended pressure 80 psig 5 5 bar obtain a wa...

Page 25: ...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 26: ...8 kPa min 80 psi 550 kPa max 3 8 Female Pipe Thread 3 8 9 5 mm min inside diameter Condenser Water Inlet 40 F 4 C min 90 F 32 C max 20 psi 1 38 bar min 150 psi 10 3 bar max 3 8 Female Pipe Thread U310 only 1 2 Female Pipe Thread 3 8 9 5 mm min inside diameter U310 only 1 2 Female Pipe Thread Condenser Water Drain 3 8 Female Pipe Thread 1 2 12 7 mm min inside diameter Bin Drain 1 2 Female Pipe thre...

Page 27: ...riate water treatment The ice machine must be taken apart for cleaning and sanitizing Caution Use only Manitowoc approved Ice Machine Cleaner and Sanitizer It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling Read and understand all labels printed on bottles before use CLEANING AND SANITIZING PROCEDURE Ice machine cleaner is used to remove lime scale...

Page 28: ...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 Caution Never use an...

Page 29: ...e drain Wait until the water trough refills then add the proper amount of ice machine cleaner to the water trough Model Amount of Cleaner U0140 2 ounces 60 ml U0190 5 ounces 150 ml U0240 5 ounces 150 ml U0310 5 ounces 150 ml Wait until the clean cycle is complete approximately 22 minutes then press the On Off button and disconnect power and water supplies to the ice machine Step 4 Remove parts for...

Page 30: ...solution to clean all components The cleaner solution will foam when it contacts lime scale and mineral deposits once the foaming stops use a soft bristle brush sponge or cloth not a wire brush to carefully clean the parts Soak the parts for 5 minutes 15 20 minutes for heavily scaled parts Rinse all components with clean water Step 6 While components are soaking use half of the cleaner water solut...

Page 31: ...to liberally apply the solution When sanitizing pay particular attention to the following areas Evaporator plastic parts including top bottom and sides Bin bottom sides and top Do not rinse 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...

Page 32: ...the bulkhead grommet then disconnect the wire leads from the connector NOTE The wire from the top grommet goes to the ice thickness float switch front switch The wire from the bottom grommet goes to the Harvest float switch side switch Important Reversing the mounting location of the ice thickness and the harvest floats will result in a safety limit 2 failure The ice thickness float must be mounte...

Page 33: ...t Number STH042 4 16 33 WIRE CONNECTORS ARE LOCATED BEHIND BULKHEAD PULL THROUGH GROMMET TO DISCONNECT HARVEST FLOAT SWITCH BRACKET ICE THICKNESS FLOAT SWITCH BRACKET DISCONNECT WIRES FOR COMPLETE REMOVAL ...

Page 34: ... Trough Remove the upper thumbscrew While supporting the water trough remove the thumbscrew and thermistor While supporting the water trough remove the lower thumbscrew from beneath the water trough Remove the water trough from the bin area UPPER THUMBSCREW LOWER THUMBSCREW ...

Page 35: ... 3 Remove the Ice Damper Remove thumbscrew from bin switch cover Support ice damper and then pull bin switch cover and ice damper forward to remove 1 REMOVE THUMBSCREW 2 SUPPORT ICE DAMPER THEN SLIDE RIGHT SIDE FORWARD TO REMOVE ...

Page 36: ...loss Loosen thumbscrews but do not pull thumbscrews out of distribution tube Loosen the two outer screws and pull forward on the distribution tube to release NOTE For ease of assembly when reinstalling the water distribution tube install the top edge first 1 LOOSEN THUMBSCREWS 2 PULL DISTRIBUTION TUBE FORWARD TO REMOVE ...

Page 37: ...e anything to force ice from the evaporator Damage may result nWarning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner or Sanitizer Step 2 To start a cleaning cycle press the Clean button Water will flow through the water dump valve and down the drain Wait until the water trough refills then add the proper amount of ice machine cleaner to the water trough...

Page 38: ... the ice machine There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life Exterior Cleaning Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation Sponge any dust and dirt off the outside of the ice machine with mild soap and water Wipe dry with a clean soft cloth Cleanup any fal...

Page 39: ...ty 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 nWarning The condenser fins are sharp Use care when cleaning them Shine a flashlight through the condenser to check for dirt between the fins Blow compressed air or rinse with water from the inside out opposite dir...

Page 40: ...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 41: ... 6 Remove control box panel 7 Remove communication cable from control board 8 Remove rear cover 9 Slide bin forward to remove NOTE When reinstalling the bin ensure the bin seal is in place and is not pinched folded as it mates to the cabinet A watertight seal is required to prevent future condensation or water leakage from entering the ice machine base DISCONNECT COMMUNICATION CABLE DISCONNECT CLA...

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Page 43: ...ning is Off Flashing Cleaning Is Paused Bin Full Blue Bin Is Full Off Bin Is Not Full Service Red Needs Service Off Doesn t Need Service ON OFF The On 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 NOTE Stopping and restarting a freeze cycle with ice on the evaporator will result in a thick bridge and larg...

Page 44: ...e 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 On Off button after 45 seconds will pause the Clean cycle The On Off light w...

Page 45: ... 16 45 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 46: ...rs in the freeze cycle WITH WATER TROUGH THERMISTOR The following sequence occurs in the freeze cycle When the temperature of the water reaches 34 F the water pump de energizes for 25 seconds then re energizes When the water pump restarts the water inlet solenoid energizes for 7 seconds WITHOUT WATER TROUGH THERMISTOR The following sequence occurs in the freeze cycle At 3 75 minutes the water pump...

Page 47: ...energizes for 7 seconds when the pump restarts Water flowing across the evaporator will start to freeze and build ice on the evaporator After a sheet of ice has formed the 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 t...

Page 48: ...r inlet valve energizes and fills the water trough 3 The water pump energizes for 2 minutes and circulates water over the evaporator If the bin switch did not open close 4 The water dump valve energizes and drains water from the water trough 5 Step 1 through 4 repeat 6 A freeze cycle starts NOTE If the bin switch opens closes anytime during the cycle the ice machine starts a new freeze cycle The m...

Page 49: ...ze time is 45 minutes at which time the control board automatically initiates a harvest sequence The maximum harvest time is a total of 7 minutes If the bin switch does not activate within 3 5 minutes the harvest cycle extends another 3 5 minutes If 7 minutes is exceeded a Harvest Assist Cycle starts The water fill valve is de energized 1 minute after the freeze cycle starts The control board will...

Page 50: ...sh on off at 1 second intervals If 6 consecutive 45 minute freeze cycles occur the ice machine stops and the SL 1 light on the control board and the Service wrench light on the touch pad will be on continuously Safety Limit 2 If the harvest time reaches 3 5 minutes the control board automatically energizes the water pump and extends the harvest cycle another 3 5 minutes 7 minutes total If the ice ...

Page 51: ...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 52: ...arvest 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 60 Seconds 4 Freeze ON OFF ON OFF ON OPEN THEN CLOSED CLOSED THEN OPEN Until Harvest Float Switch closes for 10 continual seconds ...

Page 53: ... cycle on and off F irmware 2 58 with thermistor when the water temperature reaches 34 F the water pump de energizes for 25 seconds When the pump restarts the water inlet valve energizes for 7 seconds Firmware 2 58 without thermistor At 3 75 minutes the water pump de energizes for 25 seconds When the pump restarts the water inlet valve energizes for 7 seconds Firmware prior to 2 58 The water fill ...

Page 54: ... thickness of the bridge refer to ice thickness adjustment ICE THICKNESS ADJUSTMENT The ice thickness can be adjusted to three levels 1 Pull forward on the bottom of the bracket until clear of the tab 2 Slide the bracket over the desired tab and release The center position is the normal factory setting To increase bridge thickness raise the water level To decrease bridge thickness lower the water ...

Page 55: ...del Minimum Ice Weight Per Cycle lbs Grams Maximum Ice Weight Per Cycle lbs Grams U140 1 13 lbs 513 grams 1 36 lbs 617 grams U190 2 26 lbs 1025 grams 2 93 lbs 1329 grams U240 2 26 lbs 1025 grams 2 93 lbs 1329 grams U310 2 26 lbs 1025 grams 2 93 lbs 1329 grams ...

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Page 57: ...art Ice damper was opened then closed in the harvest cycle before the ice released Allow ice to thaw and release from evaporator then restart Ice machine does not release ice or is slow to harvest Ice machine is dirty Clean and sanitize the ice machine Ice machine is not level Level the ice machine Low air temperature around ice machine air cooled models Air temperature must be at least 40 F 4 C I...

Page 58: ...evel Level the ice machine Low ice capacity The condenser is dirty Clean the condenser High air temperature around ice machine air cooled models Air temperature must not exceed 110 F 43 C Inadequate clearance around the ice machine Provide adequate clearance Objects stacked around ice machine blocking condenser airflow Remove items blocking airflow Hot incoming water Connect to cold water Incorrec...

Page 59: ...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 to allow...

Page 60: ... closed 2 Verify control board fuse is okay NOTE If any control board lights are on the fuse is okay 3 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 4 Verify power button functions properly A defective power button may keep the ice machine in the OFF mode Refer to page 98 touch pad diagnostics when Steps 1 3 test good 5 Be sure Steps 1 4 wer...

Page 61: ...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 62: ...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 63: ... power to the ice machine remove the electrical panel to allow viewing of the control board lights and pull the wire connector for the harvest float switch through the bulkhead and disconnect WIRE CONNECTORS ARE LOCATED BEHIND BULKHEAD PULL THROUGH GROMMET TO DISCONNECT HARVEST FLOAT SWITCH BRACKET ICE THICKNESS FLOAT SWITCH BRACKET ...

Page 64: ...s from freeze to harvest and the control board harvest light energizes Proceed to Step 3 Step 3 Disconnect the harvest float switch wire from the control board and bypass the freeze time lock in feature by pressing the power button to cycle the ice machine off on Wait until water flows over the evaporator then refer to chart Result Correction The harvest light does not come on The harvest float sw...

Page 65: ...chine ____ Water temp entering sump trough ____ 2 Refer to the appropriate 24 Hour Ice Production Chart starting on page 121 Use the operating conditions determined in Step 1 to find published 24 Hour Ice Production _____ Times are in minutes Example 1 min 15 sec converts to 1 25 min 15 seconds 60 seconds 25 minutes Weights are in pounds Example 2 lb 6 oz converts to 2 375 lb 6 oz 16 oz 375 lb 3 P...

Page 66: ...ith step 2 Ice production is normal when these numbers match closely If they match closely determine if Another larger ice machine is required Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc distributor for information on available options and accessories ...

Page 67: ...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 68: ...r increase the water pressure Incoming water temperature is not between 40 F 3 C and 90 F 32 C If too hot check the hot water line check valves in other store equipment Water filtration is plugged if used Install a new water filter Vent tube is not installed on water outlet drain See Installation Instructions Hoses fittings etc are leaking water Repair replace as needed Water valve is stuck open c...

Page 69: ...es of Evaporator Tubing Routing Normal Ice Formation Ice forms across the entire evaporator surface At the beginning of the Freeze cycle it may appear that more ice is forming on the inlet of the evaporator than at the outlet At the end of the Freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet of th...

Page 70: ...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 71: ...cles occur the ice machine stops and the SL 1 light on the control board and the Service wrench light on the touch pad will be on continuously Safety Limit 2 If the harvest time reaches 3 5 minutes the control board automatically energizes the water pump and extends the harvest cycle another 3 5 minutes 7 minutes total If the ice damper does not open and close within the 7 minute harvest cycle the...

Page 72: ...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 73: ... 3 neither float opened within 4 minutes of the freeze cycle CONTROL BOARD SAFETY LIMIT LIGHT OPERATION USING THE POWER BUTTON 1 Press the power button once 2 Press the power button again to start ice making 3 Watch the safety limit lights One will flash corresponding to safety limits 1 or 2 4 Safety limit 3 is indicated by both SL 1 SL 2 flashing After safety limit indication the ice machine will...

Page 74: ...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 75: ...m Non Manitowoc components Improper refrigerant charge Defective compressor TXV starving or flooding check bulb mounting Non condensible in refrigeration system Plugged or restricted high side refrigerant lines or component Defective harvest valve ...

Page 76: ...n 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 component...

Page 77: ...pection Checklist on page 67 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 78: ...ures Freeze Cycle ______ Harvest Cycle ______ 3 Perform an actual discharge pressure check Freeze Cycle PSIG Harvest Cycle PSIG Beginning of Cycle __________ __________ Middle of Cycle __________ __________ End of Cycle __________ __________ 4 Compare the actual discharge pressure Step 3 with the published discharge pressure Step 2 The discharge pressure is normal when the actual pressure falls wi...

Page 79: ...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 67 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system High side ...

Page 80: ...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 81: ...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 82: ...ischarge Pressure Discharge pressure is too high and is affecting suction pressure refer to Discharge Pressure High Checklist on page 79 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 83: ...Low Checklist on page 79 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 68 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 n...

Page 84: ...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 85: ...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 86: ... across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking 3 Feel the compressor discharge line nWarning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand Just touch them momentarily 4 Compare the temperature of th...

Page 87: ...perature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest valve and the compressor discharge line...

Page 88: ...le These temperatures must be within 7 F 4 C of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Use a quality temperature meter capable of taking temperature readings on curved copper lines 2 Attach the temperature meter sensing device to the copper lines entering and leaving the evaporator Importan Do not simply insert the sensing device under the insulation...

Page 89: ... 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 90: ... 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 91: ...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 92: ...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 93: ...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 94: ...e production________________ Calculated actual 24 hour ice production_______________ NOTE The ice machine is operating properly if the ice fill pattern is normal and ice production is within 10 of charted capacity Installation and Water System All installation and water related problems must be corrected before proceeding with chart ...

Page 95: ...ator or No ice formation on entire evaporator Ice formation is normal or Ice formation is extremely thin on the bottom of evaporator or No ice formation on evaporator Ice formation is normal or No ice formation on entire evaporator Safety Limits Refer to Analyzing Safety Limits to eliminate all non refrigeration problems Stops on safety limit 1 or 2 Stops on safety limit 1 Stops on safety limit 1 ...

Page 96: ...to eliminate problems and or components not listed on this table before proceeding Freeze Cycle Suction Pressure ________ ______ ______ 1 minute Middle End If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist to eliminate problems and or components not listed on this table before proceeding Suction pressure is High Suction pressure is Low Suction ...

Page 97: ...ompressor discharge line is HOT Discharge Line Temp Record freeze cycle discharge line temp at the end of freeze cycle Discharge line temp 150 F 66 C or higher at the end of freeze cycle Discharge line temp 150 F 66 C or higher at the end of freeze cycle Discharge line temp less than 150 F 66 C at the end of freeze cycle Discharge line temp 150 F 66 C or higher at the end of freeze cycle Final Ana...

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Page 99: ... at all times Removing the control board fuse or pressing the power button will not remove the power supplied to the control board Check Procedure 1 If the curtain light is on with the ice damper closed the fuse is good nWarning Disconnect electrical power to the entire ice machine before proceeding 2 Remove the fuse Check the resistance across the fuse with an ohmmeter Reading Result Open OL Repl...

Page 100: ...own 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 Importan The ice damper must be up bin switch closed to start ice making Check Procedure 1 Press the power butto...

Page 101: ...bin 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 102: ...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 103: ... functions correctly will close as the button is pressed and open as the button is released Do not insert electrical probe into end of connector This will stretch the connector and cause intermittent connection issues All readings must be taken on the flat exterior of the connector Selection Wires On Off 2 7 Delay 3 7 Clean 4 7 1 2 3 4 5 6 7 8 9 10 11 12 TOUCH ELECTRICAL PROBE TO THESE LOCATIONS O...

Page 104: ...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 105: ...TH042 4 16 105 FLOAT OPEN FLOAT CLOSED 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 ...

Page 106: ...conds then turn off Check procedure THERMISTOR 1 Disconnect thermistor from control board and measure resistance 2 Measure temperature at the thermistor 3 Compare measured resistance temperature readings to resistance temperature relationship chart A Within 10 of the published resistance value Thermistor is good B Not within 10 of the published resistance value Thermistor is defective CONTROL BOAR...

Page 107: ...0 37 280 53 3 5 38 273 60 4 0 10 5 39 51 266 86 194 30 11 0 15 0 52 59 189 72 157 12 15 5 20 0 60 68 153 51 124 93 20 5 25 0 69 77 122 14 100 00 25 5 30 0 78 86 97 83 80 57 30 5 35 0 87 95 78 87 63 98 36 5 40 0 98 104 61 40 53 27 40 5 46 0 105 115 52 21 42 02 NOTE The control board will default to a 3 75 minute pump delay in the freeze cycle whenever the thermistor is disconnected or reads outside...

Page 108: ...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 109: ...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 110: ...ck Procedure Disconnect electrical power to the ice machine at the electrical service disconnect Verify fan motor windings are not open or grounded and fan spins freely Connect manifold gauge to ice machine Hook voltmeter in parallel across the fan cycle control leaving wires attached Reconnect electrical power to the ice machine and press the power button to ON Wait until water flows over the eva...

Page 111: ...e 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 nWarning If discharge pressure exceeds 460...

Page 112: ...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 Importan The liquid line drier is covered as a warranty part The liquid line drier mu...

Page 113: ...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 114: ... the use of contaminated recovered or recycled refrigerant is the sole responsibility of the servicing company Manitowoc approves the use of 1 New Refrigerant Must be of original nameplate type 2 Reclaimed Refrigerant Must be of original nameplate type Must meet ARI Standard 700 latest edition specifications 3 Recovered or Recycled Refrigerant Must be recovered or recycled in accordance with curre...

Page 115: ...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 119 to test for contamination 5 Substitute or Alternative Refrigerant Must use only Manitowoc approved alternative refrigerants Must follow Manitowoc published convers...

Page 116: ...r the use of contaminated refrigerant Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company Importan Replace the liquid line drier before evacuating and recharging Use only a Manitowoc O E M liquid line filter drier to prevent voiding the warranty CONNECTIONS 1 Suction side of the compressor through the suction service valve 2 Discharge side ...

Page 117: ... the pump and perform a standing vacuum leak check NOTE Check for leaks using an electronic leak detector after charging the ice machine Follow the Charging Procedures below CHARGING PROCEDURES Importan The charge is critical on all Manitowoc ice machines Use a scale or a charging cylinder to ensure the proper charge is installed 1 Be sure the power button is in the OFF position 2 Close the vacuum...

Page 118: ...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 119: ...f system contamination Obvious moisture or an acrid odor in the refrigerant indicates contamination If either condition is found or if contamination is suspected use a Total Test Kit from Totaline or 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 contami...

Page 120: ...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 121: ...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 122: ... 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 123: ...l around the tubing as far from the pressure control as feasible See the figure on next page Clamp down on the tubing until the pinch off is complete nWarning Do not unsolder a defective component Cut it out of the system Do not remove the pinch off tool until the new component is securely in place 3 Cut the tubing of the defective component with a small tubing cutter 4 Solder the replacement comp...

Page 124: ...124 Part Number STH042 4 16 FIG A PINCHING OFF TUBING FIG B RE ROUNDING TUBING SV1406 Using Pinch Off Tool ...

Page 125: ...e system charge Serial plate information overrides information listed on this page Model Air Cooled Water Cooled Refrigerant Type U140 10 oz 283 g 11 oz 312 g R404A U190 12 oz 340 g N A R404A U240 13 oz 369 g 12 oz 340 g R404A U310 Serial Number 310304977 and Earlier 15 oz 425 g 14 oz 397 g R404A U310 Serial Number 310304978 and After 15 oz 425 g 18 oz 510g R404A ...

Page 126: ...126 Part Number STH042 4 16 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 127: ...ces 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 Suctio...

Page 128: ...Ice Production Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 130 110 105 80 27 120 105 95 90 32 115 95 85 100 38 95 85 80 110 43 85 80 70 Based on average ice slab weight of 1 06 1 19 lb 481 540 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressure PS...

Page 129: ...0 10 70 21 90 32 70 21 135 120 105 80 27 130 115 100 90 32 115 105 90 100 38 105 90 80 110 43 95 80 70 Based on average ice slab weight of 1 06 1 19 lb 481 540 g Regular cube derate is 7 Water regulating valve set to maintain 230 PSIG discharge pressure Condenser water usage 185 gallons per 100 lbs of ice at 90 F 70 F Operating Pressures Air Temp Around Ice Machine F C Freeze Cycle Harvest Cycle D...

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

Page 131: ...roduction Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 225 190 175 80 27 210 180 160 90 32 195 160 145 100 38 170 150 140 110 43 150 140 135 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Press...

Page 132: ... 10 70 21 90 32 70 21 200 190 180 80 27 195 185 175 90 32 180 170 160 100 38 175 165 155 110 43 170 160 150 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Water regulating valve set to maintain 235 PSIG discharge pressure Condenser water usage 149 gallons per 100 lbs of ice at 90 F 70 F Operating Pressures Air Temp Around Ice Machine F C Freeze Cycle Harvest ...

Page 133: ...duction Air Temp Entering Condenser F C Water Temperature F C 50 10 70 21 90 32 70 21 305 265 225 80 27 295 255 235 90 32 280 235 210 100 38 255 210 185 110 43 205 170 155 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Operating Pressures Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG Discharge Pressur...

Page 134: ...50 10 70 21 90 32 70 21 270 275 260 80 27 305 270 255 90 32 300 250 240 100 38 295 250 235 110 43 290 245 230 Based on average ice slab weight of 2 44 2 75 lb 1107 1247 g Regular cube derate is 7 Water regulating valve set to maintain 235 PSIG discharge pressure Condenser water usage 149 gallons per 100 lbs of ice a 90 F 70 F Operating Pressures Air Temp Around Ice Machine F C Freeze Cycle Harvest...

Page 135: ...efore working on electrical circuitry Wiring Diagram Legend The following symbols are used on all of the wiring diagrams Internal Compressor Overload Some models have external compressor overloads Fan Motor Run Capacitor Some models do not incorporate fan motor run capacitor Wire Number Designation The number is marked at each end of the wire Multi pin Connection Electrical Box Side Compressor Com...

Page 136: ...136 Part Number STH042 4 16 U140 U190 U240 WIRING DIAGRAM WITHOUT J4 THERMISTOR TERMINAL ...

Page 137: ...Part Number STH042 4 16 137 U310 WIRING DIAGRAM WITHOUT J4 THERMISTOR TERMINAL ...

Page 138: ...138 Part Number STH042 4 16 U140 U190 U240 WIRING DIAGRAM WITH J4 THERMISTOR TERMINAL ...

Page 139: ...Part Number STH042 4 16 139 U310 WIRING DIAGRAM WITH J4 THERMISTOR TERMINAL ...

Page 140: ...4 16 ELECTRONIC CONTROL BOARD WITH J4 THERMISTOR TERMINAL WTR Pump Compressor WTR Dump Harvest Clean Thermistor Water Fill Low LVL FLT High LVL FLT Bin Switch Safety 2 Safety 1 Harvest Test Mode J3 J4 J5 J7 J6 J1 Test Switch ...

Page 141: ...ECTRONIC CONTROL BOARD WITH J1 AND WITHOUT J4 THERMISTOR TERMINAL WTR Pump Compressor WTR Dump Harvest Clean Thermistor Water Fill Low LVL FLT High LVL FLT Bin Switch Safety 2 Safety 1 Harvest Test Mode J3 J1 J5 J7 J6 J1 Test Switch ...

Page 142: ... ELECTRONIC CONTROL BOARD PRIOR TO J1 THE TERMINAL 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 143: ...ONDENSER DRIER RECEIVER WATER COOLED ONLY EXPANSION VALVE HARVEST SOLENOID EVAPORATOR COMPRESSOR STRAINER Tubing Schematic U0190 U0240 U0310 HEAT EXCHANGER AIR OR WATER CONDENSER DRIER RECEIVER WATER COOLED ONLY EXPANSION VALVE HARVEST SOLENOID VALVE EVAPORATOR COMPRESSOR STRAINER ...

Page 144: ...144 Part Number STH042 4 16 THIS PAGE INTENTIONALLY LEFT BLANK ...

Page 145: ......

Page 146: ...ntinuing product improvement may necessitate change of specifications without notice Part Number STH042 4 16 Every new piece of Manitowoc Foodservice equipment comes with KitchenCare and you choose the level of service that meets your operational needs from one restaurant to multiple locations StarCare Warranty lifetime service certified OEM parts global parts inventory performance audited ExtraCa...

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