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Welbilt Manitowoc NEO UDP0080A, Technician'S Handbook

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Welbilt Manitowoc NEO UDP0080A Technician'S Handbook Download Page 13

Part Number STH098 06/19 13

Component Check Procedures

Main Fuse   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .131

Bin Switch  

UDP0080/UDP0140/UDP0240/UDP0310   .  .  .132

Touch Pad  

UDP0140/UDP0240/UDP0310 .  .  .  .  .  .  .  .  .  .  .  .134

Float Switch  

UDP0140/UDP0240/UDP0310 .  .  .  .  .  .  .  .  .  .  .  .136

Water Trough Thermistor  

UDP0140/UDP0240/UDP0310 .  .  .  .  .  .  .  .  .  .  .  .138

ON/OFF/WASH Toggle Switch  

UDP0080   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .140

Fan Cycle Control  

UDP0080/UDP0140/UDP0240/UDP0310   .  .  .141

High Pressure Cutout (HPCO) Control  

UDP0080 /UDP0140/UDP0240/UDP0310 .  .  .142

Compressor Electrical Diagnostics  .  .  .  .  .  .  .  .  .143

Filter-Driers

   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .145

Flammable Refrigerant Procedures

Servicing Requirements

   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .146

Refrigerant Purging Requirements    .  .  .  .  .  .  .  .147

Refrigerant Purging Procedure .  .  .  .  .  .  .  .  .  .  .  .148

Brazing Procedure  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .148

Pressure Testing .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .149

Evacuation   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .149

Refrigerant Charging

 .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .150

System Contamination Cleanup

   .  .  .  .  .  .  .  .  .  .  .  .  .  .152

Determining Severity of Contamination   .  .  .  .152

Mild System Contamination Cleanup Procedure  

   .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .154

Severe System Contamination Cleanup 

Procedure .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .  .155

Total System Refrigerant Charge

 .  .  .  .  .  .  .  .  .  .  .  .  .  .156

Summary of Contents for Manitowoc NEO UDP0080A

Page 1: ...r STH098 06 19 UDP R290 Refrigerant 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 manito...

Page 2: ......

Page 3: ...tact 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 aw...

Page 4: ...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 instal...

Page 5: ...ed weight of the equipment and product Additionally the equipment must be level side to side and front to back Remove front panel before lifting and installing and use appropriate safety equipment dur...

Page 6: ...ir 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 t...

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 manu...

Page 8: ...ent 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 dea...

Page 9: ...Ice Machine Heat of Rejection 20 Leveling the Ice Machine 21 Electrical Requirements 22 Electrical Specifications 23 Water Service Drains 24 Water Supply 24 Maintenance Detailed Descaling and Sanitizi...

Page 10: ...8 Control Board Timers 60 Safety Limits 61 UDP0140 UDP0240 UDP0310 Energized Parts Chart 63 Operational Checks 65 Ice Thickness Check 65 Ice Thickness Adjustment 65 Minimum Maximum Slab weight 66 Sequ...

Page 11: ...vest Float is down closed 89 Ice Production Check 91 Installation Visual Inspection Checklist 93 Water System Checklist 94 Refrigeration Diagnostics 96 Eliminate all non refrigeration problems before...

Page 12: ...Refrigeration Diagnostics 119 Eliminate all non refrigeration problems before diagnosing the refrigeration system 119 Analyzing Ice Formation Pattern 120 Discharge Line Temperature Analysis 122 Compar...

Page 13: ...Pressure Cutout HPCO Control UDP0080 UDP0140 UDP0240 UDP0310 142 Compressor Electrical Diagnostics 143 Filter Driers 145 Flammable Refrigerant Procedures Servicing Requirements 146 Refrigerant Purging...

Page 14: ...contained Air cooled 162 UDP0240 Operating Temperatures 163 UDP0310 Self contained Air cooled 164 UDP0310 Operating Temperatures 165 Diagrams Wiring Diagrams 167 UDP0080 Wiring Diagram 168 UDP0140 UDP...

Page 15: ...Capacity Condenser Type E WRAS 50Hz A Air 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...

Page 16: ...cation These numbers are required when requesting information from your local Manitowoc Distributor Service Representative or Manitowoc Ice The model serial number data plate is located in the evapora...

Page 17: ...chine 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...

Page 18: ...18 Part Number STH098 06 19 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 19: ...on must not be near heat generating equipment or in direct sunlight The location must be capable of supporting the weight of the ice machine and a full bin of ice The location must allow enough cleara...

Page 20: ...itioning Peak UDP0080 1750 2600 UDP0140 2400 2900 UDP0240 2800 3300 UDP0310 3800 6000 B T U Hour Because the heat of rejection varies during the ice making cycle the figure shown is an average Ice mac...

Page 21: ...far as possible Caution The legs must be screwed in tightly to prevent them from bending 3 Move the ice machine into its final position 4 Level the ice machine to ensure that the drain system functio...

Page 22: ...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 sele...

Page 23: ...Amps UDP0080 230 1 50 15 2 81 UDP0140 230 1 50 15 2 63 UDP0240 230 1 50 15 3 45 UDP0310 230 1 50 15 5 65 NOTE Model serial plate information overrides all data listed in this chart nWarning All wirin...

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...

Page 25: ...ne and storage bin Drain lines must have a 1 5 inch drop per 5 feet of run 2 5 cm per meter and must not create traps The floor drain must be large enough to accommodate drainage from all drains Insta...

Page 26: ...emperature Water Pressure Ice Machine Fitting Tubing Size Up to Ice Machine Fitting Ice Making Water Inlet 40 F 4 C min 90 F 32 C max 20 psi 138 kPa min 80 psi 550 kPa max 3 8 Female Pipe Thread 3 8 9...

Page 27: ...sanitizing Caution Use only Manitowoc approved Ice Machine Cleaner Descaler 9405463 and Sanitizer 9405463 It is a violation of Federal law to use these solutions in a manner inconsistent with their l...

Page 28: ...ill stop after the cycle Pausing the cycle Press the Clean button The clean light will flash indicating the cycle has paused Pressing the Clean button again will restart the cycle Step 1 Press the On...

Page 29: ...ait until the water trough refills then add the proper amount of ice machine cleaner descaler to the water trough Model Amount of Cleaner Descaler Part Number 9405463 UDP0140 2 ounces 60 ml UDP0240 5...

Page 30: ...e cleaner descaler and water solution to descale all components The solution will foam when it contacts lime scale and mineral deposits once the foaming stops use a soft bristle brush sponge or cloth...

Page 31: ...pray bottle 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 rins...

Page 32: ...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...

Page 33: ...ULKHEAD PULL THROUGH GROMMET TO DISCONNECT HARVEST FLOAT SWITCH BRACKET ICE THICKNESS FLOAT SWITCH BRACKET DISCONNECT WIRES FOR COMPLETE REMOVAL Caution Do not disassemble float for descaling Incorrec...

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 R...

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 R...

Page 36: ...oss 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...

Page 37: ...rce ice from the evaporator Damage may result nWarning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner Descaler or Sanitizer Step 2 To start a cycle press th...

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...

Page 39: ...ting 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 whe...

Page 40: ...f the ice machine and 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 t...

Page 41: ...ve bin drain 6 Remove control box panel 7 Remove communication cable from control board 8 Remove rear cover 9 Slide bin forward to remove NOTE When reinstalling the bin ensure the bin seal is in place...

Page 42: ...mage may result Step 2 Remove all ice from the bin nWarning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner Descaler or Sanitizer Caution Do not mix Ice Mach...

Page 43: ...electric power to the ice machine at the electric switch box before proceeding Step 6 Remove parts for descaling A Remove Two Thumbscrews and Water Pump Cover B Remove the Vinyl Hose Connecting the Wa...

Page 44: ...between the back wall and the grommet and prying forward Pull the bulkhead grommet and wire forward until the connector is accessible then disconnect the wire lead from the connector Ice Thickness Pro...

Page 45: ...Water Distribution Tube Loosen the two thumbscrews which secure the distribution tube Lift the distribution tube up off the thumbscrews Disassembly Twist the barbed end until the tab lines up with the...

Page 46: ...Valve Turn the splash shield counterclockwise one or two turns Pull the float valve forward and off the mounting bracket Disconnect the water inlet tube from the float valve at the compression fitting...

Page 47: ...h Apply downward pressure on the siphon tube and remove from the bottom of the water trough Remove the upper thumbscrew While supporting the water trough remove the two thumbscrews from beneath the wa...

Page 48: ...d ice damper mounting bracket Pull forward on the ice damper until the left hand mounting pin disengages Installation Grasp the right side of ice damper and place left hand pin in the mounting bracket...

Page 49: ...le applying pressure against the bin door pull down on the rear of each bin door track until the door pins clear the stop tabs Slide the rear door pins off the end and then below the door track Slide...

Page 50: ...sits once the foaming stops use a soft bristle brush sponge or cloth not a wire brush to carefully descale the parts Soak the parts for 5 minutes 15 20 minutes for heavily scaled parts Rinse all compo...

Page 51: ...plastic parts including top bottom and sides Bin bottom sides and top Do not rinse the sanitized areas Step 13 Replace all removed components Step 14 Reapply power and water to the ice machine and pla...

Page 52: ...emoved parts in the sanitizer water solution Do not rinse parts after sanitizing Step 20 Use 1 2 of the sanitizer water solution to sanitize all foodzone surfaces of the ice machine and bin Use a clot...

Page 53: ...f 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...

Page 54: ...or exposed to ambient temperatures of 320F 00C or below 1 Disconnect the electric power at the circuit breaker or the electric service switch 2 Turn off the water supply 3 Remove the water from the w...

Page 55: ...buttons to control ice machine operation and provide operational status On Off Blue Machine On Off Machine Is Off Delay Blue Delay Mode On Off Delay Mode Is Off Clean Yellow Clean Cycle On Off Cleani...

Page 56: ...om the evaporator Delay Pressing the Delay button will start a delay period The ice machine will finish the freeze and harvest cycle and then start the delay period Pressing the button once will start...

Page 57: ...le The On Off light will flash on off to indicate pause mode Pressing the On Off button again will continue the Clean cycle from the point of interruption Pressing the control board test button anytim...

Page 58: ...the prechill and remains on until the ice thickness float switch is satisfied Freeze Water flowing across the evaporator cools as the freeze cycle progresses The water pump turns off for 25 seconds a...

Page 59: ...ter 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 troug...

Page 60: ...ence is initiated The maximum freeze 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 do...

Page 61: ...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 co...

Page 62: ...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 li...

Page 63: ...ckness 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...

Page 64: ...reafter 6 Harvest Off On Off Off On Closed Closed Bin switch activation 7 Automatic Shutoff Off Off Off Off Off Closed Closed 3 Minute delay and bin switch re closure Condenser Fan Motor The fan motor...

Page 65: ...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...

Page 66: ...ber STH098 06 19 MINIMUM MAXIMUM SLAB WEIGHT Model Minimum Ice Weight Per Cycle Grams Maximum Ice Weight Per Cycle lbs Grams UDP0140 480 grams 540 grams UDP0240 1107 grams 1247grams UDP0310 1107 grams...

Page 67: ...throughout the entire Freeze and Harvest Sequences The fan motor is wired through a fan cycle pressure control therefore it may cycle on and off The compressor and condenser fan motor are wired throug...

Page 68: ...opening and re closing of the bin switch terminates the harvest cycle and returns the ice machine to freeze steps 3 4 6 Automatic Shut off When the storage bin is full at the end of a harvest sequence...

Page 69: ...3 Relay Coil 3A Compressor 3B Compressor Fan Motor Initial Start up 1 Water purge off on off off off 15 seconds 2 Refrigeration System Start up off on on on on 5 seconds Freeze Sequence 3 Prechill off...

Page 70: ...MAKING SEQUENCE OF OPERATION Control Board Relays Relay Length of Time 1 Water Pump 2 Hot Gas Valve 3 Relay Coil 3A Compressor 3B Compressor Fan Motor Automatic Shut off 6 Auto Shut off off off off of...

Page 71: ...The siphon action stops when the water level in the sump trough drops When the siphon action stops the float valve refills the water trough to the correct level Follow steps 1 through 6 under water l...

Page 72: ...ps adding water 4 Adjust the water level to 1 4 to 3 8 6 3 to 9 5 mm below the standpipe the line in the water trough A Loosen the two screws on the float valve bracket B Raise or lower the float valv...

Page 73: ...maintain an ice bridge of 1 8 3 2 mm If an adjustment is needed follow the steps below 1 Turn the ice thickness probe adjustment screw clockwise for a thicker ice bridge or counterclockwise for a thin...

Page 74: ...74 Part Number STH098 06 19 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 75: ...estarted by turning the ice machine OFF ON Safety limit feature stopping the ice machine Refer to Safety Limit Feature Ice sheet is thick Water trough level is too high Adjust ice thickness float Powe...

Page 76: ...e machine produces shallow or incomplete cubes or the ice fill pattern on the evaporator is incomplete Ice thickness switch is out of adjustment Adjust the ice thickness switch Water trough level is t...

Page 77: ...he freeze cycle and ice remained on the evaporator Allow ice to thaw and release from the evaporator then restart Ice damper was opened and closed in the harvest cycle before the ice released Allow ic...

Page 78: ...es 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 t...

Page 79: ...les 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...

Page 80: ...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 li...

Page 81: ...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...

Page 82: ...evel 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 tub...

Page 83: ...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 refrige...

Page 84: ...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 di...

Page 85: ...ection Checklist on page 93 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 de...

Page 86: ...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...

Page 87: ...rvest cycle before the ice releases Remove all ice from the evaporator before starting diagnostic procedures Freeze Time Lock In Feature The ice machine control system incorporates a freeze time lock...

Page 88: ...g the power button to cycle the ice machine on Wait until water flows over the evaporator then refer to chart Result Correction 10 seconds into the freeze cycle the ice machine cycles from freeze to h...

Page 89: ...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 FL...

Page 90: ...r flows over the evaporator then refer to chart Result Correction The harvest light does not come on and the ice machine stays in freeze The ice thickness float switch connectors or wiring is causing...

Page 91: ...temp entering sump trough ____ 2 Refer to the appropriate Cycle Times 24 Hr Ice Production and Refrigerant Temperature Charts on page 157 Use the operating conditions determined in Step 1 to find pub...

Page 92: ...th 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 condit...

Page 93: ...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 n...

Page 94: ...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 u...

Page 95: ...able 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 evapor...

Page 96: ...ON PROBLEMS BEFORE DIAGNOSING THE REFRIGERATION SYSTEM Perform a visual inspection for clearances drains dirty condenser filter and water filter replacement Verify water flow is even across the entire...

Page 97: ...s 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 evapo...

Page 98: ...atures at the compressor Discharge Line Temperature Procedure 1 Connect a temperature probe on the compressor discharge line within 6 15 2 cm of the compressor 2 Observe the discharge line temperature...

Page 99: ...e These temperatures must be within 7 F 4 C of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Use a quality temperature meter capable of taking temperature read...

Page 100: ...within 10 of the data in the charts 5 Record the temperatures throughout the freeze and harvest cycles NOTE First cycle is not used for refrigeration system diagnostics Run a minimum of two cycles to...

Page 101: ...orator B Freeze time longer than normal A failed TXV or low refrigerant charge will have a suction line temperature higher than normal and a discharge line temperature lower than normal An failed TXV...

Page 102: ...y filter or condenser will result in higher than normal temperatures Always clean the filter and condenser before diagnosing the refrigeration system Hot water entering the ice machine will result in...

Page 103: ...vest 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 evapor...

Page 104: ...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 smal...

Page 105: ...outlet or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking...

Page 106: ...approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor do...

Page 107: ...automatically returns the ice machine to the freeze cycle 3 cycles outside the time limit Safety Limit must be MANUALLY reset Safety Limit Stand by Mode The first time a safety limit shut down occurs...

Page 108: ...Watch the harvest light It will flash one or two times corresponding to safety limits 1 and 2 to indicate which safety limit stopped the ice machine After safety limit indication the ice machine will...

Page 109: ...7 Water System Water Level too high or defective float water escaping water trough Low water pressure 20 psig min High water pressure 80 psig max High water temperature 90 F 32 2 C max Clogged water d...

Page 110: ...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 refrige...

Page 111: ...not installed on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Low water pressure 20 psig min Loss of water from sump area C...

Page 112: ...sed 2 Verify control board fuse is okay 3 If the bin switch light functions the fuse is okay 4 Verify the bin switch functions properly A defective bin switch can falsely indicate a full bin of ice 5...

Page 113: ...control circuitry is functioning properly The ice machine is in a six minute freeze time lock in Verify Step 1 of this procedure was followed correctly The harvest light does not come on Proceed to St...

Page 114: ...ght Step 2 Disconnect the ice thickness probe from the control board terminal Step 2 Disconnect probe from control board terminal Monitoring Harvest Light Correction The harvest light stays off and th...

Page 115: ...hine operating conditions Air temperature entering condenser ____ Air temperature around ice machine ____ Water temperature entering sump trough ____ 2 Refer to the appropriate model in the Cycle Time...

Page 116: ...r Day Actual 24 Hour Production Weighing the ice is the only 100 accurate check 4 Compare the results of step 3 with step 2 Ice production is normal when these numbers match closely If they match clos...

Page 117: ...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 n...

Page 118: ...k 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...

Page 119: ...gnostics checklists Perform a visual inspection for clearances drains dirty condenser filter and water filter replacement Verify water flow is even across the entire evaporator Verify ice fill pattern...

Page 120: ...ormal 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...

Page 121: ...able 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 evapor...

Page 122: ...ratures at the compressor Discharge Line Temperature Procedure 1 Connect a temperature probe on the compressor discharge line within 6 15 2 cm of the compressor 2 Observe the discharge line temperatur...

Page 123: ...ve minutes into the freeze cycle These temperatures must be within 7 F 4 C of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Use a quality temperature meter cap...

Page 124: ...and harvest cycles and compare suction and discharge temperatures to your model in the charts starting on page 157 NOTE First cycle is not used for refrigeration system diagnostics Run a minimum of tw...

Page 125: ...porator B Freeze time longer than normal A failed TXV or low refrigerant charge will have a suction line temperature higher than normal and a discharge line temperature lower than normal An failed TXV...

Page 126: ...y filter or condenser will result in higher than normal temperatures Always clean the filter and condenser before diagnosing the refrigeration system Hot water entering the ice machine will result in...

Page 127: ...vest 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 evapor...

Page 128: ...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 smal...

Page 129: ...outlet or across the harvest valve itself will not work for this comparison The harvest valve outlet is on the suction side cool refrigerant It may be cool enough to touch even if the valve is leaking...

Page 130: ...approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor do...

Page 131: ...l board at all times Removing the control board fuse or pressing the power button will not remove the power supplied to the control board Check Procedure 1 If the curtain light is on with the ice damp...

Page 132: ...he harvest cycle 2 Automatic ice machine shut off If the storage bin is full at the end of a harvest cycle the sheet of cubes fails to clear the ice damper and holds it down After the ice damper is he...

Page 133: ...ght off indicates the bin switch has opened properly Ohm Test 1 Disconnect the bin switch wires to isolate the bin switch from the control board 2 Connect an ohmmeter to the disconnected bin switch wi...

Page 134: ...ht turns on With power light energized press the delay button 4 times Cycles through 4 hour delay 12 hour delay 24 hour delay and off Press and hold the power button for 3 seconds Power light turns of...

Page 135: ...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...

Page 136: ...machine uses two float switches Ice Thickness Float Indicates the water level has been reached Harvest Float Indicates a harvest cycle needs to be initiated Initial testing can be performed by viewing...

Page 137: ...h through the bulkhead and disconnect 2 Attach an ohm meter lead to each float switch wire 3 Place the float in the down position The float switch must be closed 4 Place the float in the up position T...

Page 138: ...encing long freeze cycle shut down we recommend removing the thermistor and bracket permanently Check procedure THERMISTOR 1 Disconnect thermistor from control board and measure resistance 2 Measure t...

Page 139: ...1 34 30 85 1 5 34 7 30 25 2 0 35 6 29 49 2 5 36 5 28 76 3 0 37 28 05 3 5 38 27 36 4 0 10 5 39 51 26 68 19 43 11 0 15 0 52 59 18 97 15 71 15 5 20 0 60 68 15 35 12 49 20 5 25 0 69 77 12 21 10 00 25 5 30...

Page 140: ...e of a wide variation in D C voltage it is not recommended that a voltmeter be used to check toggle switch operation 1 Inspect the toggle switch for correct wiring 2 Isolate the toggle switch by disco...

Page 141: ...psig 5 Check Procedure Disconnect electrical power to the ice machine at the electrical service disconnect Verify fan motor windings are not open or grounded and fan spins freely Connect manifold gaug...

Page 142: ...ure 1 Switch to OFF 2 Connect manifold gauge 3 Hook voltmeter in parallel across the HPCO leaving wires attached 4 Disconnect the fan motor 5 Set to ON No air flow through the condenser will cause the...

Page 143: ...he 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...

Page 144: ...ssures 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...

Page 145: ...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 h...

Page 146: ...he detector on the floor and set the detector to beep at approximately heart beat rate Equipment using hydrocarbon refrigerants have fittings unique to flammable refrigerants Work in well ventilated o...

Page 147: ...ify 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 ins...

Page 148: ...ll 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 nitr...

Page 149: ...e 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 EV...

Page 150: ...reading to settle NOTE It is important that the scales and hoses are positioned so that they will not be disturbed when adding refrigerant Importan The charge is critical on all Manitowoc ice machines...

Page 151: ...reeze 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 th...

Page 152: ...ion 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 harmfu...

Page 153: ...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 te...

Page 154: ...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...

Page 155: ...ize 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...

Page 156: ...r reference only Refer to the ice machine serial number tag to verify the system charge Serial plate information overrides information listed on this page Model Air Cooled Refrigerant Type UDP0080 110...

Page 157: ...lacement Verify water flow is even across the entire evaporator Verify ice fill pattern Mineral build up on the evaporator assembly will cause water tracking and an erratic ice fill pattern Descale wi...

Page 158: ...rvest Time Water Temperature F C 50 10 70 21 90 32 70 21 14 6 16 5 17 6 19 9 20 3 23 0 1 0 2 5 80 27 15 5 17 5 18 9 21 3 22 0 24 9 90 32 17 6 19 9 22 0 24 9 26 3 29 7 100 38 20 3 23 0 23 9 27 1 29 0 3...

Page 159: ...Line Temp F C Suction Line Temp F C 50 F 10 C 130 150 54 65 30 0 1 18 80 70 26 21 150 130 65 54 30 60 1 15 70 F 21 C 135 155 57 68 45 0 7 18 80 70 26 21 155 135 68 57 35 60 1 6 15 80 F 27 C 148 170 64...

Page 160: ...C 50 10 70 21 90 32 70 21 10 2 11 7 12 4 14 1 13 0 14 8 1 0 2 5 80 27 11 2 12 8 13 0 14 8 14 6 16 5 90 32 11 8 13 4 14 6 16 5 17 6 19 9 100 38 14 6 16 5 17 6 19 9 19 9 17 6 110 43 16 5 18 7 19 9 17 6...

Page 161: ...ge Line Temp F C Suction Line Temp F C 50 F 10 C 105 135 41 57 20 0 7 17 85 60 29 16 135 105 57 41 20 50 7 10 70 F 21 C 105 135 41 57 12 5 11 21 95 70 35 21 133 105 56 41 22 50 6 10 80 F 27 C 115 144...

Page 162: ...10 70 21 90 32 70 21 14 1 16 1 17 0 19 3 18 6 21 1 1 0 2 5 80 27 15 2 17 4 18 0 20 5 20 5 23 3 90 32 16 5 18 8 20 5 23 3 22 7 25 8 100 38 19 2 21 8 21 9 24 9 23 6 26 8 110 43 21 9 24 9 23 6 26 8 24 5...

Page 163: ...ne Temp F C Suction Line Temp F C Harvest Valve Inlet Temp F C Discharge Line Temp F C Suction Line Temp F C 50 F 10 C 120 142 30 7 80 70 142 122 7 50 70 F 21 C 132 155 30 10 83 70 135 105 10 45 80 F...

Page 164: ...2 70 21 10 0 11 5 11 8 13 4 14 1 16 1 1 0 2 5 80 27 10 4 11 9 12 3 14 0 13 5 15 4 90 32 11 0 12 6 13 5 15 4 15 2 17 4 100 38 12 3 14 0 15 2 17 4 17 5 19 9 110 43 15 6 17 8 19 2 21 8 21 2 24 0 Times in...

Page 165: ...Line Temp F C Suction Line Temp F C Harvest Valve Inlet Temp F C Discharge Line Temp F C Suction Line Temp F C 50 F 10 C 140 170 25 0 80 68 175 130 35 60 70 F 21 C 140 170 20 0 90 75 170 125 35 62 80...

Page 166: ...166 Part Number STH098 06 19 THIS PAGE INTENTIONALLY LEFT BLANK...

Page 167: ...fore 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...

Page 168: ...r STH098 06 19 UDP0080 WIRING DIAGRAM 1PH Self Contained Air cooled 11 10 13 R S C 3 000001517_00 22 23 24 L2 N 10 11 20 21 2 3 6 7 8 5 9 4 12 13 15 14 L1 GRND 3 5 7 12 13 14 31 17 25 58 42 17 33 40 3...

Page 169: ...ompressor Start Relay 14 Condenser Fan Motor 17 Contactor Coil 18 Contactor Contacts 19 Control Board 25 Fan Cycle Control 28 Fuse 31 High Pressure Cutout 33 Ice Thickness Probe 34 1 Light Bin Switch...

Page 170: ...lf Contained Air cooled L2 N 11 BLU 10 BLU 30 BLU 32 BLU 31 BLU 42 WHT 37 ORG 2 BLU 7 BLU 8 BLU 30 BLU 32 BLK 34 PRPL 5 PNK 4 YEL 6 RED 3 YEL 12 PRPL 13 BRN 15 BRN 14 BRN BLU YEL RED W H T 040004017_0...

Page 171: ...acts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detail 42 Solen...

Page 172: ...1 2 3 4 L1 14 BRN 12 PRPL 15 BRN 48 BLK C S R S 040003315_07 30 BLU 32 BLK 8 BLU 7 BLU 32 BLK 31 BLU 30 BLU 10 BLU 11 BLU L2 N 42 WHT 37 ORG 2 BLU 4 YEL 3 YEL 6 RED 5 PNK 34 PRPL GRD 47 YEL 49 RED R 4...

Page 173: ...actor Contacts 19 Control Board 25 Fan Cycle Control 26 Float Switch Harvest 27 Float Switch Water Level 28 Fuse 31 High Pressure Cutout 40 On Off Clean Switch 41 See Control Board Schematic For Detai...

Page 174: ...174 Part Number STH098 06 19 ELECTRONIC CONTROL BOARDS ELECTRONIC CONTROL BOARD UDP0140 UDP0240 UDP0310 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 19 18 20 21 23 24 25 22...

Page 175: ...LED Thermistor 7 LED Thermistor 8 LED Thermistor 9 LED Water Fill Valve 10 LED Harvest Float 11 LED Water Level Float 12 LED Bin Switch 13 LED Safety Limit 2 14 LED Safety Limit 1 15 LED Harvest 16 L...

Page 176: ...176 Part Number STH098 06 19 ELECTRONIC CONTROL BOARD UDP0080 1 2 3 4 5 6 7 8 9 10...

Page 177: ...UDP0080 Number Component 1 Ice Thickness Probe Connection 2 Ice Off Clean Toggle Switch Connection 3 Bin Switch Light 4 Harvest Light 5 Control Board Transformer 6 Compressor Relay 7 Harvest Valve Rel...

Page 178: ...MATIC UDP0080 UDP0140 HEAT EXCHANGER AIR CONDENSER DRIER EXPANSION VALVE HARVEST SOLENOID EVAPORATOR COMPRESSOR STRAINER TUBING SCHEMATIC UDP0240 UDP0310 HEAT EXCHANGER AIR CONDENSER DRIER EXPANSION V...

Page 179: ......

Page 180: ...nt and solutions Our cutting edge designs and lean manufacturing tactics are powered by deep knowledge operator insights and culinary expertise All of our products are backed by KitchenCare our afterm...

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