Manitowoc UG Series Technician'S Handbook Download

Page: 117 / 128

Part Number: 040006847 12/19

117

UGP0030A/UGP0040A/UGP0050A Air-Cooled

Number

Component

Bin Thermistor

Compressor

Compressor Overload

Compressor Relay

Compressor Start Capacitor

Compressor Start Relay

Condenser Fan Motor

Control Board

Fuse

Toggle Switch

Solenoid Valve - Harvest

Thermistor Liquid Line

Transformer Control Board

Water Inlet Valve

Water Pump

Water Trough Thermistor

Wiring Harness Connector

Wire Colors

BLK

Black

BLU

Blue

BRN

Brown

GRY

Grey

ORG

Orange

PRPL

Purple

RED

Red

WHT

White

YEL

Yellow

Summary of Contents for UG Series

Page 1: ...Part Number 040006847 12 19 UnderCounter Ice Machines UG Series Technician s Handbook ...

Page 2: ......

Page 3: ...ease visit the following website www manitowocice com 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 refrigerants under pressure The technicians must also be certified in proper refrigerant handling and servicing procedures All lock...

Page 4: ...hazardous situation that if not avoided may result in death or serious injury Caution Indicates a hazardous situation which if not avoided may result in minor or moderate injury Caution Indicates information considered important but not hazard related e g messages relating to property damage NOTE Indicates useful and extra information about the procedure you are performing ...

Page 5: ...ther means for disconnection from the power supply e g circuit breaker or disconnect switch is provided Check all wiring connections including factory terminals before installation 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 ...

Page 6: ...pliance 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 been given supervision concerning use of the appliance by a person responsible for their safety Do not allow children to play with clean or maintain this appliance without proper supervision ...

Page 7: ... tipping and or injury Do not damage the refrigeration circuit when installing maintaining or servicing the unit This equipment contains high voltage electricity and refrigerant charge Only refrigeration technicians who have received appropriate training and certification and are aware of the dangers of handling refrigerants and energized equipment are allowed to complete the installation and main...

Page 8: ...t be in place and properly secured when operating this equipment 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 a...

Page 9: ...ved When casters are installed the mass of this unit will allow it to move uncontrolled on an inclined surface These units must be tethered secured to comply with all applicable codes It is the responsibility of the site supervisor to ensure that operators fully understand the dangers inherent in operating this equipment Do not operate any equipment with damaged cords or plugs All repairs must be ...

Page 10: ...pressure are allowed to work on this equipment Only use parts recommended or provided by the manufacturer This equipment must be installed in accordance with ASHRAE 15 refrigeration system s safety standards This equipment cannot be installed in a corridor or hallway of a public building Equipment installation must comply with local sanitation and fire regulations When servicing this equipment be ...

Page 11: ...uctions in this manual can cause property damage injury or death Crush Pinch Hazard Keep hands clear of moving components Components can move without warning unless power is disconnected and all potential energy is removed Moisture collecting on the floor will create a slippery surface Clean up any water on the floor immediately to prevent a slip hazard Never use sharp objects or tools to remove i...

Page 12: ...PAGE INTENTIONALLY LEFT BLANK ...

Page 13: ...neral 21 Ice Machine Dimensions 21 Location of Ice Machine 22 Leveling the Ice Machine 23 Cooling of the Ice Machine 23 Water Service Drains 24 Electrical Service 26 Voltage 26 Fuse Circuit Breaker 26 Total Circuit Ampacity 26 Installation Checklist 28 Before Starting the Ice Machine 29 Operation Component Identification 31 Ice Making Sequence of Operation 32 Initial Start up 32 Operational Checks...

Page 14: ...denser 49 Removal from Service Winterization 50 Air Cooled Ice Machines 50 Troubleshooting Questions to Ask The Customer 51 Ice Machine Will Not Run 52 Compressor Won t Run 52 Water Pump Won t Run 56 Ice Machine Prematurely Harvests 57 Ice Machine Will Not Harvest 57 Water System Checklist 58 Ice Production Check 59 Analyzing Discharge Pressure 61 Discharge Pressure High Checklist 62 Freeze Cycle ...

Page 15: ...t Gas Valve 77 Flammable Refrigerant Procedures Servicing Requirements 81 Refrigerant Purging Requirements 82 Refrigerant Purging Procedure 83 Brazing Procedure 83 Pressure Testing 84 Evacuation 84 Refrigerant Charging 85 System Contamination Cleanup 87 Determining Severity of Contamination 87 Mild System Contamination Cleanup Procedure 89 Severe System Contamination Cleanup Procedure 90 ...

Page 16: ... Operating Temperatures 101 UGE0030A Self Contained Air Cooled 103 UGF0040A Self Contained Air Cooled 104 UGF0050A Self Contained Air Cooled 105 UGF0065A Self Contained Air Cooled 106 UGF0080A Self Contained Air Cooled 107 Wiring Diagrams Wiring Diagrams 109 Wiring Diagram Legend 109 UGE0020A Air Cooled 110 UGP0020A Air Cooled 112 UGE0030A UGF0040A UGF0050A UGF0065A Air Cooled 114 UGP0030A UGP0040...

Page 17: ...tained Air Cooled UGE0020A UGP0020A UGE0030A UGP0030A UGF0040A UGP0040A UGF0050A UGP0050A UGF0065A UGF0080A UGP0080A NOTE The model suffix is used to identify the voltage special model or country specific model See How to Read A Model Number on Page How to Read A Model Number on page 18 General Information ...

Page 18: ...oduction Condenser Type A Self Contained Air Cooled Blank Non market specific S Saudi Arabia C China D Germany E WARAS N Brazil F Schuko G Blade Z No Plug Bare Lead I Oblique Flat Blades with Ground B 115 V Grounded Power Cord Voltage 161 115 60 1 261 208 230 60 1 251 230 50 1 P R290 F R404A E R1B4a ...

Page 19: ...Part Number 040006847 12 19 19 Model Serial Number Location Model Serial Number Location ...

Page 20: ... machine is installed WARRANTY REGISTRATION Completing the warranty registration process is a quick and easy way to protect your investment Scan the QR code with your smart device or enter the link in a web browser to complete your warranty registration WWW MANITOWOCICE COM SERVICE WARRANTY WARRANTY REGISTRATION Registering your product insures warranty coverage and streamlines the process if any ...

Page 21: ... instructions are provided to assist the qualified installer Ice Machine Dimensions Model L W H UG0020 mm 450 475 650 UG0030 mm 450 475 650 UG0040 mm 550 550 800 UG0050 mm 550 550 800 UG0065 mm 700 600 902 UG0080 mm 700 600 902 Installation L H W ...

Page 22: ... sunlight 5 The location must be capable of supporting the weight of the ice machine and a full bin of ice 6 The location must not obstruct airflow through or around the ice machine Refer to the chart below for clearance recommendations Self Contained Air Cooled Top Sides 8 203mm Back 5 127mm There is no minimum clearance requirement for the top or left and right sides of the ice machine The liste...

Page 23: ...position 3 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 Cooling of the Ice Machine Ice Machine Model Cooling Air conditioning Peak UG0020 1400 2600 UG0030 1900 3300 UG0040 2100 4100 UG0050 2600 5000 UG0065 2900 5000 UG0080 4300 7400 BTU Hour The amount of heat dissipated varies during the ice making cycle The listed ...

Page 24: ...10 C and 90 F 32 C Be sure all hot water restrictors installed for other equipment are working Check valves on sink faucets dishwashers etc 2 Water pressure to the machine should be between 20 to 80 psi 140 to 550 kPa 3 The minimum inner diameter of the pipe is 1 2 15 mm Drain Connections Drain lines must have a 1 5 inch 3 8 cm drop of run for each meter 3 feet and must not create traps The floor ...

Page 25: ...Outlet Inlet water temperature 50 F 10 C Min 90 F 32 C Max Inlet Water Pressure 20 psi 140 kPa Min 80 psi 550 kPa Max Ice Machine Fitting 3 4 male pipe thread 7 8 fitting barbed Tubing Size Up to Ice Machine Fitting 1 2 15mm minimum inner diameter 3 4 18mm minimum inner diameter Electrical Ice Making Water Inlet Drain ...

Page 26: ...is supplied 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 determine the wire size of the power supply line The wire size or gauge is also dependent upon location materials used length of run etc This must be determined by a qualified electrician Ice Machine Voltage Phase Cycle Maximum Fuse Air...

Page 27: ...ical disconnect and lock out to prevent accidentally energizing Connect all electrical wiring before use do not energize ice machine until installation is complete 1 Wiring Connect the three supply lead wires Blue Brown and Yellow Green to the field wiring terminal L N and G and the Yellow Green wire must connect to the G ground 2 After connecting the wiring to the terminal strip the supply lead m...

Page 28: ...emain in the range of 50 F 110 F 10 C 43 C o Has the ice machine been installed where the incoming water temperature will remain in the range of 50 F 90 F 10 C 32 C o Are all electrical leads free from contact with refrigeration lines and moving equipment o Has the owner operator been instructed regarding maintenance and the use of Manitowoc Cleaner and Sanitizer o Has the owner operator completed...

Page 29: ...per operation follow the Operational Checks as specified in Section 3 Completing the Operational Checks is the responsibilities of the owner Adjustments and maintenance procedures outlined in this manual are not covered by the warranty nWarning Personal Injury Potential Do not operate equipment that has been misused abused neglected damaged or altered modified from that of original manufactured sp...

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Page 31: ...art Number 040006847 12 19 31 Component Identification Operation Water Curtain Water Sump Trough Control Board Air Cooled Condenser On off wash Toggle Switch Evaporator Ice Chute Spray Nozzles Spray Bar ...

Page 32: ...the water pump and the fan motor are energized and the machine goes into freeze cycle 2 Freeze Cycle As the ice making process begins the pump sprays water into the inverted cups The water freezes layer by layer until an ice cube forms in each cup When the water temperature in the sump is equal to or less than 2 C for more than 5 seconds the control board will read the settings of liquid line temp...

Page 33: ...s directed into the bin by the ice chute The harvest cycle continues until the harvest time has elapsed and then the machine goes into a new freeze cycle 4 Automatic Shut Off When the storage bin is full the ice will come in contact with the bin thermostat which is located inside the bin The machine will stop after approximately 45 seconds of continuous ice contact with the bin thermostat probe Th...

Page 34: ... for the first time after a prolonged out of service period after cleaning and sanitizing Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty Important It is recommended that adjustments made to this ice machine be made by a qualified technician Improper adjustment may seriously affect the life of this ice machine CUBE SHAPE The standard cube has ...

Page 35: ...ise the DIP switch level to increase the cube size For example if the original setting is 0 then pull up the 0 switch and press down the 1 switch Allow the ice machine to complete three cycles and then check the cube shape 4 If cubes are too full no dimple lower the DIP switch level to decrease the cube size For example if the original setting is 0 then pull up the 0 switch and press down the 1 sw...

Page 36: ...them to test the water quality and recommend an appropriate water treatment method A dirty ice machine must be disassembled descaled and sanitized Manitowoc ice machine cleaner descaler and sanitizer are the only products approved for use on Manitowoc ice machines Caution Use only Manitowoc approved cleaner descaler Part Number 9405463 and sanitizer Part Number 9405653 Failure to follow the instru...

Page 37: ...nce that the end user and service technician should perform and the frequency These figures are the minimum required If the ice machine is supplied with hard water more frequent evaporator cleaning should be performed If the condenser air filter is totally blocked after one week more frequent cleaning is recommended Maintenance Weekly Monthly Semi Annual Annual After prolonged shutdown At start up...

Page 38: ...liness and efficient operation Wipe any dust and dirt off the surface of the ice machine with a damp cloth and wipe any oil off with a cloth dampened with a soap solution Wipe dry with a clean soft cloth Do not use a wire brush or coarse cloth for cleaning Do not wipe the surface with products containing chlorine or abrasives ...

Page 39: ... will violate relevant laws nWarning When handling cleaners and sanitizers wear rubber gloves and safety goggles and or face shield Cleaner descaler is used to remove lime scale or other mineral deposits Sanitizer is used to remove algae or slime Step 1 Set the toggle switch to the OFF position at the end of a harvest cycle after ice releases from the evaporator Or set the switch to the OFF positi...

Page 40: ...ts are soaking use a nylon brush to scrub the inside of the ice bin Scrub inside of the door door track bin sump trough and evaporator moldings With clean water rinse all of these areas thoroughly Step 7 Replace the sump overflow tube and pour remaining 2 liters of mixture into the water sump Replace all other parts Step 8 To start a cleaning cycle press the toggle switch to the WASH position and ...

Page 41: ...rub the inside of the door door track bin water sump water distribution assembly and evaporator moldings Do not rinse Step 14 Replace the sump drain overflow tube and transfer remaining 2 liters of solution into the sump trough Replace all other components Step 15 To start a sanitizing cycle press the toggle switch to the WASH position and hold for 5 seconds Step 16 Wait until the cycle is complet...

Page 42: ... new ice making cycle NOTE To terminate a clean cycle press the toggle switch in the WASH position and hold for more than 30 seconds Caution If the cleaner sanitizer solution has been poured into the water trough then the entire clean cycle must be completed Don t terminate the cleaning cycle or the ice machine will not purge the remaining cleaner sanitizer solution from the water trough ...

Page 43: ... easiest access to the evaporator compartment the top cover can be removed 1 Remove two screws on the rear of the ice machine 2 Slide top cover back to disengage the three pins from the front panel Remove the two screws and slide the top cover backwards to remove ...

Page 44: ...g water from escaping the evaporator compartment Removal of the bin door is not required but enhances access Grasp one end of the water curtain and lift up To re install the water curtain into ice machine pivot the water curtain and pull it down into position Make sure tabs are secure in grooves ...

Page 45: ...g water from escaping the evaporator compartment Removal of the bin door is not required but enhances access Grasp one end of the water curtain and lift up To re install the water curtain into ice machine pivot the water curtain and pull it down into position Make sure tabs are secure in grooves Water Curtain ...

Page 46: ...nt edge inside the water trough or the spray nozzles will not be aligned with the spray holes and spray water will fall into bin 1 Grab protruding spray holes on one end and lift up 2 Pivot ice chute and remove 3 To re install the ice chute grasp protruding spray holes and position over the spray bar Make sure the rear supports are over Spray Bar Assembly and front edge is inside the water trough ...

Page 47: ...ic clips on water inlet tubing by grasping both ears on clip and separating 3 Apply a food grade lubricant to ease re assembly of spray bar components when necessary 4 To re install spray bar position the water inlet tubing on the inlet ports of the spray bar and squeeze the clips until tight 5 Reposition the assembly on the water trough seat Nozzles and inserts can be removed for cleaning by unsc...

Page 48: ...ow tube is located in the evaporator water sump 1 Remove the water curtain and ice chute 2 Lift spray bar or disconnect and remove for easiest access 3 Pull up on the overflow tube to remove 4 To replace plug insert in hole and push with force to make a tight seal Overflow Tube ...

Page 49: ... grill by removing two Phillips head screws Clean grill openings before replacing 2 Clean the outside of the condenser with a soft brush or a vacuum with a brush attachment Clean from top to bottom not side to side Be careful not to bend the condenser fins 3 Shine a flashlight through the condenser to check for dirt between the fins If dirt remains A Blow compressed air through the condenser fins ...

Page 50: ...ure is not covered by the warranty Follow the applicable procedure below AIR COOLED ICE MACHINES 1 Press the on off switch to turn off the ice machine 2 Disconnect the water supply 3 Drain the water from the water sump and water pump by disconnecting the water pump tubing 4 Disconnect and drain the incoming ice making water line 5 Blow compressed air in the water inlet and drain pipes of the ice m...

Page 51: ...s Ask these questions before service When does the malfunction occur Evening day all day or just during the freeze cycle When is ice production low A certain day in a week every day or weekend Describe the ice machine s status in detail Has anyone ever operated the ice machine Did the air switch water supply or ambient temperature change when the ice machine was in downtime What has caused the wat...

Page 52: ...nostics If the water pump does not run place the toggle switch in the ice position 2 Verify correct voltage is present and matches the nameplate voltage 3 The bin thermostat must be closed before any components can be energized COMPRESSOR WON T RUN If the water pump is running and the compressor is not it may be tripping on overload or tripping the breaker fuse Check for grounded winding if the br...

Page 53: ...ch 49 C 120 F or below to ensure that the overload is closed and the resistance readings will be accurate SINGLE PHASE COMPRESSORS 1 Disconnect power from the ice machine and remove the wires from the compressor terminals 2 The measured 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...

Page 54: ...se size indicated on the serial tag The wiring must be correctly sized to minimize voltage drop at compressor start up The voltage when the compressor is trying to start must be within 6 of the nameplate voltage COMPRESSOR DRAWING LOCKED ROTOR The three likely causes of this are Low voltage supply check voltage while compressor is trying to start Defective starting component Mechanically seized co...

Page 55: ...acitor tester when checking a suspect capacitor CURRENT RELAY The relay has a set of contacts that energize and de energize the compressor start winding The contacts on the relay are normally open start winding de energized When power is applied the run winding will be at LRA Locked rotor Amperage The relay coil becomes an electromagnet and closes the contacts start winding energized As the compre...

Page 56: ...oltage at the hot gas valve 1 Yes Repair or replace the hot gas valve coil 2 No Is the hot gas valve relay LED on the control board lit Yes Repair or replace the hot gas valve coil No Repair or replace the control board Water Inlet Valve Won t Energize Is there line voltage at the water inlet valve 1 Yes Repair or replace the water inlet valve coil 2 No Is the water inlet valve LED on the control ...

Page 57: ... the cube size increase the ice freeze time 3 Refer to Thermistor Diagnostics and test the Water Thermistor and the Liquid Line Thermistor Ice Machine Will Not Harvest 1 Is the Liquid Line Thermistor temperature set too low 2 Is the Liquid Line Thermistor sensor installed correctly 3 Refer to the Thermistor Diagnostics to test the Liquid Line Thermistor 4 Is there line voltage at the hot gas valve...

Page 58: ...WEEN 1 4 AND 5 5 BAR 20 80PSI Install a water regulator valve INCOMING WATER TEMPERATURE IS NOT BETWEEN 1 7 C AND 32 2 C 35 90 F Hot water does not enter the ice machine WATER FILTRATION IS PLUGGED IF USED Replace the filter element or install a new water filtration system HOSES FITTINGS ETC ARE LEAKING WATER Repair or replace leaking parts WATER INLET VALVE IS STUCK OPEN OR CLOSED Clean replace a...

Page 59: ...chine with a 32 C 90 F ambient temperature 21 C 70 F supply water 1 Determine the ice machine operating conditions Air temperature entering condenser Ambient temperature Water temperature entering sump trough 2 Refer to the appropriate 24 Hour Ice Production Chart 3 Use the operating conditions determined in Step 1 to find the published nominal 24 hr ice production Times are in minutes Example 1 m...

Page 60: ...es per Day 3 Weight of One Harvest Cycles per Day Actual 24 Hour Production Weighing the ice is the only 100 accurate check 5 Compare the results of Step 3 with Step 2 Ice production is normal when these numbers are within 10 of each other If they match closely determine if Another ice machine is required Relocating the existing equipment to lower the load conditions is required ...

Page 61: ... published normal discharge pressures Freeze Cycle Harvest Cycle 4 Perform an actual discharge pressure check Freeze Cycle PSIG Harvesting Cycle PSIG Beginning of Cycle End of Cycle Compare the actual discharge pressure Step 3 with the published nominal discharge pressure Step 2 The discharge pressure is normal when the actual pressure falls within the published nominal pressure range for the ice ...

Page 62: ...gerant Charge Overcharged Non condensable in system Wrong type of refrigerant Other High side refrigerant lines component restricted before mid condenser Freeze Cycle Discharge Pressure Low Checklist Improper Installation Refer to Installation section Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other High side refrigerant lines component restricted before mid condenser NOTE ...

Page 63: ...on section Discharge Pressure A high discharge pressure will affect the suction pressure Refer to Discharge Pressure High Checklist Improper Refrigerant Charge Overcharged Non condensable in system Wrong type of refrigerant Other Hot gas valve leaking TXV flooding check bulb mounting Defective compressor ...

Page 64: ...per Refrigerant Charge Undercharged Wrong type of refrigerant Other Improper water supply over evaporator Refer to Water System Checklist Loss of heat transfer from tubing on back side of evaporator Restricted plugged liquid line drier Restricted plugged tubing or capillary tube in suction side of refrigeration system TXV starving Moisture in refrigeration system NOTE Do not limit your diagnosis t...

Page 65: ...in a consistent maximum discharge line temperature Ambient air temperatures affect the maximum discharge line temperature Higher ambient air temperatures at the condenser higher discharge line temperatures at the compressor Lower ambient air temperatures at the condenser lower discharge line temperatures at the compressor Regardless of ambient temperature the freeze cycle discharge line temperatur...

Page 66: ...mum discharge line temperatures above 71 C 155 F DISCHARGE LINE TEMPERATURE BELOW 71 C 155 F 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 overfeedin...

Page 67: ...by disconnecting all wires from the switch 3 Check across the toggle switch terminals using a calibrated ohmmeter Note where the wire numbers are connected to the switch terminals or refer to the wiring diagram to take proper readings Switch Setting Terminals Ohm Reading ON 5 6 Open 5 4 Closed 2 1 Closed 2 3 Open WASH 5 4 Open 5 6 Closed 2 3 Closed 2 1 Open OFF 2 3 Open 2 1 Open 5 6 Open 5 4 Open ...

Page 68: ...arts The bin thermistor temperature setting is determined by the point of T2 liquid line thermistor at the time when T1 sump water thermistor comes below 2 C Refer to the Specifications Charts below for clearance Specifications UG18 UG20 UG30 T1 C T2 C Shut down T3 Power on T3 2 0 T2 32 1 7 2 2 2 0 32 T2 51 2 2 3 7 2 0 51 T2 3 0 4 5 UG40 UG50 UG65 T1 C T2 C Shut down T3 Power on T3 2 0 T2 28 1 5 2...

Page 69: ...orrectly 35 5 cm 14 in the bulb well Disconnect the wires from the bin thermostat and check the resistance across the terminals No Ice on Bulb Ice on Bulb Result Closed O Open OL Thermostat is good Open OL Closed O Replace thermostat NOTE After covering uncovering the bulb holder with ice wait at least 3 minutes to allow the thermostat to react Open Close ...

Page 70: ...nction with the control board to determine the length of the freeze and harvest cycles Specifications The sump water thermistor R2 0 C 0 5 C 14 75 K ohm 1 The liquid line thermistor R25 C 0 5 C 10 K ohm 1 Check Procedure 1 Make sure the thermistor sensors are installed correctly 2 Disconnect the thermistor from the control board and measure its resistance values 3 Measure the temperature at the th...

Page 71: ...Ohms 1000 50 344 6 26 4 771 49 320 5 27 4 567 48 298 2 28 4 375 47 277 6 29 4 190 46 258 7 30 4 016 45 241 1 31 3 849 44 224 8 32 3 690 43 209 8 33 3 538 42 195 9 34 3 394 41 183 0 35 3 256 40 171 0 36 3 124 39 159 9 37 2 999 38 149 5 38 2 879 37 140 0 39 2 764 36 131 1 40 2 656 35 122 8 41 2 551 34 115 1 42 2 452 33 108 0 43 2 356 32 101 2 44 2 266 31 95 03 45 2 179 30 89 24 46 2 095 29 83 83 47 ...

Page 72: ... 55 1 491 20 48 72 56 1 437 19 45 97 57 1 385 18 43 39 58 1 336 17 40 96 59 1 289 16 38 69 60 1 243 15 36 56 61 1 200 14 34 56 62 1 158 13 32 68 63 1 117 12 30 92 64 1 079 11 29 25 65 1 041 10 27 70 66 1 006 9 26 24 67 0 9715 8 24 85 68 0 9386 7 23 55 69 0 9069 6 22 33 70 0 8766 5 21 18 71 0 8173 4 20 09 72 0 8192 3 19 07 73 0 7922 2 18 10 74 0 7662 1 17 19 75 0 7411 0 16 33 76 0 7170 1 15 52 77 0...

Page 73: ... 6094 6 12 07 82 0 5902 7 11 49 83 0 5717 8 10 94 84 0 5538 9 10 43 85 0 5367 10 9 932 86 0 5201 11 9 466 87 0 5041 12 9 025 88 0 4887 13 8 608 89 0 4739 14 8 211 90 0 4595 15 7 836 91 0 4457 16 7 480 92 0 4323 17 7 142 93 0 4194 18 6 821 94 0 4069 19 6 516 95 0 3950 20 6 228 96 0 3833 21 5 953 97 0 3722 22 5 692 98 0 3613 23 5 444 99 0 3508 24 5 208 100 0 3407 25 4 984 ...

Page 74: ...000 C K Ohms 1000 40 225 1 36 6 623 39 212 8 37 6 387 38 200 6 38 6 162 37 189 3 39 5 945 36 178 7 40 5 738 35 168 8 41 5 538 34 159 4 42 5 347 33 150 6 43 5 163 32 142 4 44 4 987 31 134 7 45 4 817 30 127 5 46 4 655 29 120 6 47 4 498 28 114 2 48 4 348 27 108 2 49 4 203 26 102 5 50 4 064 25 97 20 51 3 931 24 92 17 52 3 803 23 87 44 53 3 680 22 82 97 54 3 561 21 78 77 55 3 446 20 74 80 56 3 336 19 7...

Page 75: ... 12 50 07 64 2 585 11 47 68 65 2 505 10 45 43 66 2 428 9 43 30 67 2 354 8 41 27 68 2 283 7 39 36 69 2 214 6 37 55 70 2 147 5 35 83 71 2 082 4 34 19 72 2 020 3 32 65 73 1 960 2 31 18 74 1 902 1 29 78 75 1 846 0 28 49 76 1 791 1 27 20 77 1 739 2 26 01 78 1 688 3 24 88 79 1 639 4 23 80 80 1 592 5 22 78 81 1 546 6 21 81 82 1 502 7 20 88 83 1 459 8 20 00 84 1 417 9 19 16 85 1 377 10 18 36 86 1 338 ...

Page 76: ...0 91 1 162 16 14 30 92 1 129 17 13 73 93 1 098 18 13 19 94 1 068 19 12 67 95 1 039 20 12 17 96 1 011 21 11 70 97 0 9838 22 11 24 98 0 9572 23 10 81 99 0 9316 24 10 40 100 0 9066 25 10 00 101 0 8832 26 9 622 102 0 8604 27 9 260 103 0 8384 28 8 913 104 0 8170 29 8 582 105 0 7964 30 8 265 106 0 7762 31 7 961 107 0 7564 32 7 670 108 0 7374 33 7 391 109 0 7190 34 7 124 110 0 7010 35 6 868 ...

Page 77: ...s refrigerant vapor to enter the evaporator in the harvest cycle During the harvest cycle the hot gas valve is energized open allowing refrigerant gas from the discharge line of the compressor to flow into the evaporator The heat is absorbed by the evaporator and allows release of the ice slab Exact pressures vary according to ambient temperature and ice machine model Harvest pressures can be foun...

Page 78: ... complete ice cube will eventually form Refer to the Parts Manual for proper valve application If replacement is necessary use only original Welbilt replacement solenoid valves Use the following procedure to help determine if a harvest valve is remaining partially open during the freeze cycle 1 Wait 5 minutes into the freeze cycle 2 Feel the inlet of the hot gas valve Important Feeling the hot gas...

Page 79: ... the freeze cycle The inlet of the hot gas valve is hot and approaches the temperature of a hot compressor discharge line 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...

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Page 81: ... the detector to beep at approximately heart beat rate Equipment using hydrocarbon refrigerants have fittings unique to flammable refrigerants Work in well ventilated open spaces A ventilation fan can be used to disperse any residual refrigerant Place the fan a minimum of 10 3m away from the work area Eliminate all ignition sources The filter drier must be replaced whenever the system is opened to...

Page 82: ...erify wind direction will not introduce refrigerant into building Verify refrigerant does not enter buildings through intake air vents Although not required hydrocarbon refrigerants can be recovered instead of venting to the atmosphere Purge system with dry nitrogen to displace any trapped propane DANGER Disconnect all electric power to the system Shorting electrical wires to refrigeration tubing ...

Page 83: ...refrigerant charge 5 Purge refrigerant from both low and high side 6 Purge the system with dry nitrogen for 3 minutes 7 Evacuate the system with a vacuum pump 8 Purge the system again with dry nitrogen 9 Open the system by cutting the tubes with a tube cutter Do not use a torch to open the system BRAZING PROCEDURE 10 Always purge nitrogen whenever using a torch The nitrogen pressure regulator must...

Page 84: ...the maximum test pressure DANGER Failure to properly purge or pressure test a system for leaks can result in serious injury or death from explosion fire or contact with refrigerant or lubricant mists EVACUATION 13 Slowly release the nitrogen and evacuate to a minimum of 500 microns NOTE Do not start the compressor while it is in a vacuum or energize the compressor with the terminal cover off Alway...

Page 85: ...e reading to settle NOTE It is important that the scales and hoses are positioned so that they will not be disturbed when adding refrigerant Important The charge is critical on all Manitowoc ice machines Use a scale to ensure the proper charge is installed A quick disconnect is required for the high side connection 16 Add refrigerant through the high side and close the valve just before the namepl...

Page 86: ... freeze cycle B Remove the high side low loss fitting C Open the high and low side valves on the manifold gauge set Any refrigerant in the lines will be pulled into the low side of the system D Allow the suction pressures in the refrigeration system and the manifold gauge set to equalize while the ice machine is in the freeze cycle E Isolate and remove the low side hose 19 Use a pinch off tool on ...

Page 87: ...ation Obvious moisture or an acrid odor in the refrigerant indicates contamination If either condition is found or if contamination is suspected use a test kit If a refrigerant test kit indicates harmful levels of contamination or if a test kit is not available inspect the compressor oil 1 Remove the refrigerant charge from the ice machine 2 Remove the compressor from the system 3 Check the odor a...

Page 88: ...r 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 s...

Page 89: ...ace 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 ...

Page 90: ...ents 7 Install suction line filter drier in front of compressor 8 Install a new liquid line drier 9 Follow the normal evacuation procedure except replace 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 Change the vacuum pump oil C Pull vacuum to 500 microns Break the vacuum with dry nit...

Page 91: ...ilter drier A If the pressure drop is less than 2 psig the filter drier should be adequate for complete cleanup B If the pressure drop exceeds 2 psig change the suction line filter drier and the liquid line drier Repeat until the pressure drop is acceptable 12 Operate the ice machine for 48 72 hours Replace the suction line and liquid line drier if necessary 13 Follow normal evacuation procedures ...

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Page 93: ...rify that the water flow is uniform throughout the evaporator 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 Refer to Operational Analysis Chart for the list of data that must be collected for refrigeration diagnostics Zero out manifold gauge set before obtaini...

Page 94: ... C Freeze Time Harvest Time Water Temperature F C 50 10 70 21 90 32 70 21 15 0 16 9 1 6 3 5 80 27 90 32 21 0 23 6 100 38 110 43 31 2 34 9 Times are in minutes 24 Hour Ice Production Ambient Temperature F C Inlet Water Temperature F C 50 10 70 21 90 32 70 21 24 80 27 90 32 18 100 38 110 43 12 50 Based on the average ice weight of 288 230 grams Individual cube weight 19 grams Number of individual cu...

Page 95: ... Cycle Discharge Temperature C Suction Temperature C Harvest Valve Inlet Temperature C Discharge Temperature C Suction Temperature C 50 10 37 57 9 33 17 13 54 29 4 10 70 21 49 60 7 32 24 21 54 38 7 18 80 27 60 66 32 26 35 31 66 43 7 21 90 32 68 74 32 23 41 35 66 49 7 10 110 43 85 92 11 21 52 49 77 60 7 29 ...

Page 96: ... C Freeze Time Harvest Time Water Temperature F C 50 10 70 21 90 32 70 21 16 3 18 3 1 6 3 5 80 27 90 32 21 0 23 6 100 38 110 43 31 6 35 4 Times are in minutes 24 Hour Ice Production Ambient Temperature F C Inlet Water Temperature F C 50 10 70 21 90 32 70 21 34 80 27 90 32 27 100 38 110 43 18 5 Based on the average ice weight of 432 480 grams Individual cube weight 19 grams Number of individual cub...

Page 97: ...ycle Discharge Temperature C Suction Temperature C Harvest Valve Inlet Temperature C Discharge Temperature C Suction Temperature C 50 10 41 54 1 21 24 23 54 41 10 27 70 21 52 68 1 21 33 31 67 52 12 32 80 27 64 82 0 18 42 39 81 63 14 38 90 32 77 96 1 17 51 48 94 74 17 43 110 43 88 107 2 15 60 57 107 85 18 49 ...

Page 98: ... C Freeze Time Harvest Time Water Temperature F C 50 10 70 21 90 32 70 21 18 6 20 8 1 6 3 5 80 27 90 32 24 1 26 8 100 38 110 43 34 5 38 3 Times are in minutes 24 Hour Ice Production Ambient Temperature F C Inlet Water Temperature F C 50 10 70 21 90 32 70 21 53 80 27 90 32 42 100 38 110 43 30 Based on the average ice weight of 760 840 grams Individual cube weight 20 1 grams Number of individual cub...

Page 99: ...t Cycle Discharge Temperature C Suction Temperature C Harvest Valve Inlet Temperature C Discharge Temperature C Suction Temperature C 50 10 38 49 7 19 29 21 49 32 1 21 70 21 43 54 9 19 32 27 57 41 1 23 80 27 49 63 10 18 38 32 63 47 2 26 90 32 54 68 12 15 43 38 71 54 3 27 110 43 27 88 22 9 53 49 88 68 4 27 ...

Page 100: ...C Freeze Time Harvest Time Water Temperature F C 50 10 70 21 90 32 70 21 18 0 20 1 1 6 3 5 80 27 90 32 20 9 23 3 100 38 110 43 32 0 35 6 Times are in minutes 24 Hour Ice Production Ambient Temperature F C Inlet Water Temperature F C 50 10 70 21 90 32 70 21 76 5 80 27 90 32 67 100 38 110 43 45 Based on the average ice weight of 1064 1176 grams Individual cube weight 20 1 grams Number of individual ...

Page 101: ...Cycle Discharge Temperature C Suction Temperature C Harvest Valve Inlet Temperature C Discharge Temperature C Suction Temperature C 50 10 49 64 3 15 24 21 61 46 2 21 70 21 57 77 7 14 39 36 77 56 4 32 80 27 60 83 10 13 40 36 182 60 4 35 90 32 68 91 10 11 44 41 88 64 8 38 110 43 77 107 10 12 54 52 99 72 10 38 ...

Page 102: ...ient Temperature F C Water temperature F C 50 10 70 21 90 32 50 10 21 37 70 21 21 57 90 32 16 89 100 38 14 06 110 43 11 32 Based on the average ice weight of 430 480 grams Individual cube weight 19 1 grams Number of individual cubes per cycle 24 OPERATING PRESSURES Ambient Temperature F C Freeze Cycle Harvest Cycle Discharge Pressure bar Suction Pressure bar Discharge Pressure bar Suction Pressure...

Page 103: ...bient Temperature F C Water temperature F C 50 10 70 21 90 32 50 10 28 37 70 21 30 96 90 32 25 48 100 38 20 66 110 43 16 11 Based on the average ice weight of 430 480 grams Individual cube weight 19 1 grams Number of individual cubes per cycle 24 OPERATING PRESSURES Ambient Temperature F C Freeze Cycle Harvest Cycle Discharge Pressure bar Suction Pressure bar Discharge Pressure bar Suction Pressur...

Page 104: ... Temperature F C Water temperature F C 50 10 70 21 90 32 50 10 43 52 70 21 46 5 90 32 39 28 100 38 31 08 110 43 24 90 Based on the average ice weight of 720 800 grams Individual cube weight 19 1 grams Number of individual cubes per cycle 40 OPERATING PRESSURES Ambient Temperature F C Freeze Cycle Harvest Cycle Discharge Pressure bar Suction Pressure bar Discharge Pressure bar Suction Pressure bar ...

Page 105: ... Temperature F C Water temperature F C 50 10 70 21 90 32 50 10 61 9 70 21 56 1 90 32 43 22 100 38 34 6 110 43 23 4 Based on the average ice weight of 720 800 grams Individual cube weight 19 1 grams Number of individual cubes per cycle 40 OPERATING PRESSURES Ambient Temperature F C Freeze Cycle Harvest Cycle Discharge Pressure bar Suction Pressure bar Discharge Pressure bar Suction Pressure bar 50 ...

Page 106: ...nt Temperature F C Water temperature F C 50 10 70 21 90 32 50 10 62 1 70 21 66 9 90 32 59 1 100 38 48 7 110 43 39 2 Based on the average ice weight of 1010 1120 grams Individual cube weight 19 1 grams Number of individual cubes per cycle 56 OPERATING PRESSURES Ambient Temperature F C Freeze Cycle Harvest Cycle Discharge Pressure bar Suction Pressure bar Discharge Pressure bar Suction Pressure bar ...

Page 107: ...perature F C Water temperature F C 50 10 70 21 90 32 50 10 88 7 70 21 85 8 90 32 66 8 100 38 55 6 110 43 44 9 Based on the average ice weight of 1010 1120 grams Individual cube weight 19 1 grams Number of individual cubes per cycle 56 OPERATING PRESSURES Ambient Temperature F C Freeze Cycle Harvest Cycle Discharge Pressure bar Suction Pressure bar Discharge Pressure bar Suction Pressure bar 50 10 ...

Page 108: ...108 Part Number 040006847 12 19 PAGE INTENTIONALLY LEFT BLANK ...

Page 109: ...ore 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 Compa...

Page 110: ...020A AIR COOLED Self Contained Air Cooled Diagram shown in freeze cycle 18 BRN 12 BRN 17 RED 14 PRPL 16 ORG 15 YLW 23 BLU 24 BLU 22 BLU 21 BLU 19 BRN 13 BLU 20 BLU L1 L2 N 6 BLU 4 BRN 5 GRY 19 56 12 42 7 13 28 40 14 60 58 54 61 5 4 49 10 ...

Page 111: ...itor 13 Compressor Start Relay 14 Condenser Fan Motor 19 Control Board 28 Fuse 40 Toggle Switch 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 54 Transformer Control Board 56 Water Inlet Valve 58 Water Pump 60 Water Trough Thermistor 61 Wiring Harness Connector Wire Colors BLK Black BLU Blue BRN Brown GRY Grey ORG Orange PRPL Purple RED Red WHT White YEL Yellow ...

Page 112: ... COOLED Self Contained Air Cooled Diagram shown in freeze cycle 18 BRN 12 BRN 17 RED 14 PRPL 16 ORG 15 YLW 23 BLU 24 BLU 22 BLU 21 BLU 19 BRN 13 BLU 20 BLU L1 L2 N 6 BLU 4 BRN 5 GRY 19 56 11 42 7 9 28 40 14 60 58 54 61 5 4 49 040006979_01 10 S R ...

Page 113: ... Compressor Run Capacitor 14 Condenser Fan Motor 19 Control Board 28 Fuse 40 Toggle Switch 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 54 Transformer Control Board 56 Water Inlet Valve 58 Water Pump 60 Water Trough Thermistor 61 Wiring Harness Connector Wire Colors BLK Black BLU Blue BRN Brown GRY Grey ORG Orange PRPL Purple RED Red WHT White YEL Yellow ...

Page 114: ... UGF0050A UGF0065A AIR COOLED Self Contained Air Cooled Diagram shown in freeze cycle 18 BRN 12 BRN 17 RED 14 PRPL 16 ORG 15 YLW 23 BLU 24 BLU 22 BLU 21 BLU 19 BRN 13 BLU 20 BLU L1 L2 N 6 BLU 4 BRN 5 GRY 19 56 12 42 7 13 28 40 14 60 58 54 61 5 4 49 10 ...

Page 115: ...r Start Capacitor 13 Compressor Start Relay 14 Condenser Fan Motor 19 Control Board 28 Fuse 40 Toggle Switch 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 54 Transformer Control Board 56 Water Inlet Valve 58 Water Pump 60 Water Trough Thermistor 61 Wiring Harness Connector Wire Colors BLK Black BLU Blue BRN Brown GRY Grey ORG Orange PRPL Purple RED Red WHT White YEL Yellow ...

Page 116: ...Self Contained Air Cooled Diagram shown in freeze cycle 040006978_01 L1 18 BRN 12 BRN 17 RED 14 PRPL 16 ORG 15 YLW L2 N 23 BLU 24 BLU 22 BLU 21 BLU 20 BLU 13 BLU 19 BRN 6 BLU 5 GRY 4 BRN R S 13 11 10 19 56 12 42 7 13 28 40 14 60 58 54 61 5 4 49 10 L2 UGP30 40 L1 UGP30 40 ...

Page 117: ...art Capacitor 13 Compressor Start Relay 14 Condenser Fan Motor 19 Control Board 28 Fuse 40 Toggle Switch 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 54 Transformer Control Board 56 Water Inlet Valve 58 Water Pump 60 Water Trough Thermistor 61 Wiring Harness Connector Wire Colors BLK Black BLU Blue BRN Brown GRY Grey ORG Orange PRPL Purple RED Red WHT White YEL Yellow ...

Page 118: ...ED Self Contained Air Cooled Diagram shown in freeze cycle L1 18 BRN 12 BRN 17 RED 14 PRPL 16 ORG 15 YLW L2 N 23 BLU 24 BLU 22 BLU 20 BLU 13 BLU 19 BRN 21 BLU 5 BLU 50 RED 6 BLU 4 BRN 5 GRY 1 2 5 4 R C S 19 56 12 42 7 8 28 40 14 60 58 54 61 5 4 49 10 ...

Page 119: ...Compressor Relay 12 Compressor Start Capacitor 14 Condenser Fan Motor 19 Control Board 28 Fuse 40 Toggle Switch 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 54 Transformer Control Board 56 Water Inlet Valve 58 Water Pump 60 Water Trough Thermistor 61 Wiring Harness Connector Wire Colors BLK Black BLU Blue BRN Brown GRY Grey ORG Orange PRPL Purple RED Red WHT White YEL Yellow ...

Page 120: ...OOLED Self Contained Air Cooled Diagram shown in freeze cycle 040007029_00 R S 1 2 L1 18 BRN 12 BRN 17 RED 14 PRPL 16 ORG 15 YLW L2 N 23 BLU 24 BLU 22 BLU 21 BLU 20 BLU 13 BLU 19 BRN 6 BLU 5 GRY 4 BRN 19 56 12 42 7 13 28 40 14 60 58 54 61 5 4 49 10 ...

Page 121: ...itor 13 Compressor Start Relay 14 Condenser Fan Motor 19 Control Board 28 Fuse 40 Toggle Switch 42 Solenoid Valve Harvest 49 Thermistor Liquid Line 54 Transformer Control Board 56 Water Inlet Valve 58 Water Pump 60 Water Trough Thermistor 61 Wiring Harness Connector Wire Colors BLK Black BLU Blue BRN Brown GRY Grey ORG Orange PRPL Purple RED Red WHT White YEL Yellow ...

Page 122: ...7 12 19 Tubing Schematics UG0020A 1 5 6 7 2 4 3 9 8 Number Component 1 Compressor 2 Harvest Solenoid 3 Condenser 4 Receiver Water Cooled Only 5 Liquid Line Drier 6 Heat Exchanger 7 Heat Exchanger 8 Capillary Tube 9 Evaporator ...

Page 123: ...30A UG0040A UG0065A 1 5 6 7 2 4 3 9 8 Number Component 1 Compressor 2 Harvest Solenoid 3 Condenser Air Cooled or Water Cooled 4 Receiver Water Cooled Only 5 Liquid Line Drier 6 Heat Exchanger 7 Heat Exchanger 8 Capillary Tube 9 Evaporator ...

Page 124: ... 12 19 UG0050A UG0080A Number Component 1 Compressor 2 Harvest Solenoid 3 Condenser Air Cooled or Water Cooled 4 Receiver Water Cooled Only 5 Liquid Line Drier 6 Heat Exchanger 7 TXV Expansion Valve 8 Evaporator 1 2 4 5 7 6 8 1 ...

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Page 128: ...MANITOWOC ICE 2110 SOUTH 26TH STREET MANITOWOC WI 54220 844 724 2273 WWW MANITOWOCICE COM Part Number 040006847 12 19 2018 Welbilt Inc except where explicitly stated otherwise All rights reserved ...

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Manitowoc UG Series, Technician'S Handbook

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