Manitowoc I0320A Technician'S Handbook Download

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Technician’s Handbook

This manual is updated as new information and models are released.

Visit our website for the latest manual. www.manitowocice.com

America’s #1 Selling Ice Machine

Indigo™ Series

Ice Machines With R290

Refrigerant

Part Number STH038 5/12

Manitowoc

Summary of Contents for I0320A

Page 1: ...al is updated as new information and models are released Visit our website for the latest manual www manitowocice com America s 1 Selling Ice Machine Indigo Series Ice Machines With R290 Refrigerant Part Number STH038 5 12 Manitowoc ...

Page 2: ... Throughout this handbook you will see the following types of safety notices Warning Text in a Warning box alerts you to a potential personal injury situation Be sure to read the Warning statement before proceeding and work carefully Caution Text in a Caution box alerts you to a situation in which you could damage the equipment Be sure to read the Caution statement before proceeding and work caref...

Page 3: ...andbook you will see the following types of procedural notices NOTE Text set off as a Note provides you with simple but useful extra information about the procedure you are performing Important Text in an Important box provides you with information that may help you perform a procedure more efficiently Disregarding this information will not cause damage or injury but it may slow you down as you wo...

Page 4: ...n care and maintenance are essential for maximum performance and trouble free operation of your equipment Visit our website www manitowocfsg com for manual updates translations or contact information for service agents in your area Important Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty Warning Read this manual thoroughly before operating ...

Page 5: ...nd 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 and tag out procedures must be followed when working on this equipment Warning Do not damage the refri...

Page 6: ...rience 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 this appliance Warning All covers and access panels must be in place and properly secured before operating this equipment Warning Do not obstruct machine vents or openings Warning Do not store gasoline or other flammable vapors or ...

Page 7: ...0 hz models may contain up to 150 grams of R290 propane refrigerant R290 propane is flammable in concentrations of 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 q...

Page 8: ...tdoors f 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 cleaning Do not operate any appliance with a damaged cord or plug or after the appliance malfunctions or is dropped or damaged in any manner Contact the nearest authorized service facility for examin...

Page 9: ...ion of Ice Machine 20 Clearance Requirements 21 Ice Machine Heat of Rejection 21 Ice Deflector 22 Installation on a Bin 22 Installation on a Dispenser 22 Electrical Requirements 23 Maintenance Cleaning and Sanitizing 25 General 25 Cleaning Sanitizing Procedure 27 Preventative Maintenance Cleaning Proce dure 27 Exterior Cleaning 27 Cleaning Sanitizing Procedure 28 Cleaning Procedure 28 Sanitizing P...

Page 10: ...nd Messages 42 Main Menu 43 Machine Info Menu 44 Password Entry 45 Reset Password To Factory Defaults 47 Set Up Menu 48 Language 48 Time Date 48 Time Configuration 50 Units 50 Ice Clarity 51 LCD Brightness 51 Password On 52 Edit password 52 Clean Minder 52 IAuCS Runtime 53 Air Filter 53 Water Filter 54 LuminIce reminder 54 USB Setup 55 Factory Defaults 55 ...

Page 11: ...ace Control Board 65 USB Setup 65 Event Log Menu 66 Event Log 67 USB Flash Drive Specifications and Format ting 71 Upgrading Firmware with a Flash Drive or Transferring Setup Data To Multiple Ma chines 73 Exporting Data to a Flash Drive 75 Safe Operation Mode 76 Operational Checks 77 General 77 Ice Thickness Check 78 Sequence of Operation 79 Self Contained Air or Water Cooled 79 ...

Page 12: ...bleshooting By Symptom 88 Symptom 1 Ice Machine will not run 90 Symptom 2 Low Production Long Freeze 94 Symptom 2 Freeze Cycle Refrigeration System Operational Analysis Tables 96 Symptom 3 Harvest Problems 118 Symptom 3 Will Not Harvest Cubes Not Melted 119 Symptom 4 Will Not Harvest Cubes Melt ed 121 ...

Page 13: ...ines 131 Exporting Data to a Flash Drive 133 Programming A Replacement Control Board 135 Main Fuse 137 Bin Switch 138 Water Level Control Circuitry 141 Ice Thickness Probe Harvest Initiation 146 High Pressure Cutout HPCO Control 151 Fan Cycle Control 154 Thermistors 155 Harvest Assist Air Pump 159 Compressor Electrical Diagnostics 160 Diagnosing Start Components 162 Refrigerant Recovery Evacuation...

Page 14: ...ycle Times 24 Hour Ice Production Charts I0320A Air Cooled Model 168 I0500A Air Cooled Model 170 Diagrams Wiring Diagrams 173 Wiring Diagram Legend 173 I0320 174 I0500 175 Electronic Control Board 176 Refrigeration Tubing Schematics 177 ...

Page 15: ... Remote Air Cooled Condenser OR 9 Ice Beverage Remote Condensing Unit ICE CUBE SIZE R Regular D Dice Y Half Dice Not Used On IB Models Ice Machine Series CONDENSER TYPE A Self Contained Air Cooled W Self Contained Water Cooled N Remote Air Cooled C CVD Air Cooled DC IB Dice Model YC IB Half Dice 3 Three Phase E WRAS 50 Cycle Only NO INDICATOR 1 Phase VOLTAGE 161 115 60 1 261 208 230 60 1 251 230 5...

Page 16: ...ixed to the front and rear of the ice machine Ice Machine Warranty Information OWNER WARRANTY REGISTRATION CARD Warranty coverage begins the day the ice machine is installed If the OWNER WARRANTY REGISTRATION CARD is not returned Manitowoc will use the born on date recorded in the control board or the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice ...

Page 17: ...e ice machine The COMPANY S warranty hereunder with respect to the compressor shall apply for an additional twenty four months excluding all labor charges and with respect to the evaporator for an additional twenty four months including labor charges The obligation of the COMPANY under this warranty is limited to the repair or replacement of parts components or assemblies that in the opinion of th...

Page 18: ... actual purchase price paid by customer for the ice machine The foregoing warranty shall not apply to 1 any part or assembly that has been altered modified or changed 2 any part or assembly that has been subjected to misuse abuse neglect or accidents 3 any ice machine that has been installed and or maintained inconsistent with the technical instructions provided by the COMPANY or 4 any ice machine...

Page 19: ...OMPANY S liability under this warranty shall terminate The foregoing warranty shall constitute the sole liability of the COMPANY and the exclusive remedy of the customer or user To secure prompt and continuing warranty service the warranty registration card must be completed and sent to the COMPANY within five 5 days from the installation date To obtain warranty service or information regarding yo...

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Page 21: ...and refrigerant under pressure The technician must also be certified in proper refrigerant handling and servicing procedures All lockout and tag out procedures must be followed when working on this equipment Warning Some 50 hz models may contain up to 15 grams of R290 propane refrigerant R290 propane is flammable in concentrations of air between approximately 2 1 and 9 5 by volume LEL lower explos...

Page 22: ...must be at least 1 38 bar but must not exceed 5 52 bar The location must not be near heat generating equipment or in direct sunlight and protected from weather The location must not obstruct air flow through or around the ice machine Refer to chart for clearance requirements The ice machine must be protected if it will be subjected to temperatures below 0 C Failure caused by exposure to freezing t...

Page 23: ...ed Air Cooled Top Sides 305 mm Back 127 mm I0500 Self Contained Air Cooled Top Sides 203 mm Back 127 mm Series Ice Machine Heat of Rejection Air Conditioning Peak I0320 3800 6000 I0500 6100 6900 BTU Hour Because the heat of rejection varies during the ice making cycle the figure shown is an average ...

Page 24: ...ith sides and back of bin when placing ice machine on bin INSTALLATION ON A DISPENSER No deflector is needed for machines that match the size of the dispenser unless required by the dispenser manufacturer Adapters are required when a smaller ice machine is going on a larger dispenser Align sides and back of ice machine with sides and back of dispenser adapter when placing ice machine on dispenser ...

Page 25: ...reaker 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 Warning All wiring must conform to local state and national codes and t...

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Page 27: ...fficient operation If the ice machine requires more frequent cleaning and sanitizing consult a qualified service company to test the water quality and recommend appropriate water treatment An extremely dirty ice machine must be taken apart for cleaning and sanitizing Manitowoc Ice Machine Cleaner and Sanitizer are the only products approved for use in Manitowoc ice machines Warning Wear rubber glo...

Page 28: ...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 Caution Do not mix Cleaner and Sanitizer solutions together Do not use these solutions in a manner inconsistent with their labeling Warning Wear rubber gloves and safety goggles and or face shield when handling Ice Machine Cleaner or Sani...

Page 29: ...he bi yearly cleaning sanitizing procedure EXTERIOR CLEANING Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation Wipe surfaces with a damp cloth rinsed in water to remove dust and dirt from the outside of the ice machine If a greasy residue persists use a damp cloth rinsed in a mild dish soap and water solution Wipe dry with a clean soft clot...

Page 30: ...achine Cleaner and Sanitizer for this application Manitowoc Cleaner part number 94 0546 3 and Manitowoc Sanitizer part number 94 0565 3 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 Caution Do not mix Cleaner and Sanitizer solutions together It is a violation of Federal law to use th...

Page 31: ...or s Press the power switch and allow the ice to melt Step 2 Remove all ice from the bin dispenser Step 3 Press the clean switch Water will flow through the water dump valve and down the drain Wait until the water trough refills and the display indicates add solution approximately 1 minute then add the proper amount of ice machine cleaner Caution Never use anything to force ice from the evaporator...

Page 32: ...emove the water curtain Gently flex the curtain in the center and remove it from the right side Slide the left pin out B Remove the water trough Depress tabs on right and left side of the water trough Allow front of water trough to drop as you pull forward to disengage the rear pins Warning Disconnect the electric power to the ice machine at the electric service switch box B C D E A Off On Off Mod...

Page 33: ...ivot the ice thickness probe to disengage one pin then the other The ice thickness probe can be cleaned at this point without complete removal If complete removal is desired disconnect the ice thickness control wiring from the control board E Remove the water distribution tube NOTE Distribution tube thumbscrews are retained to prevent loss Loosen thumbscrews but do not pull thumbscrews out of dist...

Page 34: ... to mix enough solution to thoroughly clean all parts Step 7 Use 1 2 of the cleaner water mixture 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 nylon brush sponge or cloth NOT a wire brush to carefully clean the parts Soak parts for 5 minutes 15 20 minutes for heavily scaled parts Rinse all componen...

Page 35: ... parts including top bottom and sides Bin or dispenser Rinse all areas thoroughly with clean water SANITIZING PROCEDURE Step 9 Mix a solution of sanitizer and lukewarm water Step 10 Use 1 2 of the sanitizer water solution to sanitize all removed components Use a spray bottle to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer water soluti...

Page 36: ...12 Replace all removed components Step 13 Wait 20 minutes Step 14 Reapply power to the ice machine and press the Clean button Step 15 Wait until the water trough refills and the display indicates add solution approximately 1 minute Add the proper amount of Manitowoc Ice Machine Sanitizer to the water trough by pouring between the water curtain and evaporator Step 16 Select auto ice on press the ch...

Page 37: ...6 oz of water in a container 2 Soak probes in container of cleaner water solution while disassembling and cleaning water circuit components soak probes for 10 minutes or longer 3 Clean all probe surfaces including all plastic parts do not use abrasives Verify all surfaces are clean Thoroughly rinse probes with clean water 4 Reinstall probe then sanitize the ice machine and bin dispenser interior s...

Page 38: ...gh 5 Disconnect and drain the incoming ice making water line at the rear of the ice machine 6 Energize the ice machine and wait one minute for the water inlet valve to open 7 Blow compressed air in both the incoming water and the drain openings in the rear of the ice machine until no more water comes out of the water inlet lines or the drain 8 Make sure water is not trapped in any of the water lin...

Page 39: ...play panel BUTTONS Power Button Powers the ice machine when in the On Off Mode The ice machine can also be programmed to automatically power on and off in two Energy Saver modes Cleaning Button Initiates a cleaning cycle Refer to the Maintenance section for details Manitowoc Menu Button Power Button LCD Display Checkmark Cleaning Button Navigation Arrows ...

Page 40: ...underline within a line of settings NOTE The Right arrow can also be used on many screens interchangeably with the checkmark to make a selection Up and Down Arrows Move the highlight brackets up one line or down one line Checkmark Makes a selection and or moves to the next screen or line DISPLAY PANEL The LCD display panel is 16 characters wide and four lines deep During ice machine operation and ...

Page 41: ...e Info Set Up Fact Deflts Energy Saver Service Time Date Time Config Edit Password Units Ice Clarity LCD Bright Password On Off Clean Minder AuCS Run Time Air Filter Water Filter LuminIce Ice Program Water Miser Statistics Optional Password Entry 90 70 cap Model IMH Serial Cond Serial Warranty Machine Evaporator Compressor Install Date Manuf Date Main SW Ver Disply SW Ver Language USB Setup Ice Bi...

Page 42: ...kets down from the fourth line to view more of the menu displayed Arrows Two kinds of arrows give cues to additional information symbols show that another screen is available by pressing Checkmark while a line is highlighted and symbols indicate the limits of the screen viewed NOTE Another cue to the length of a menu screen is that Exit is the last item Time Date Time Config Units Language 07 24 1...

Page 43: ...Left arrows Use the Checkmark to move the cursor down one line Exit and re enter the screen to start again at the top Selections When parentheses appear they indicate a selection is available by pressing Checkmark while the line is highlighted If the choice is exclusive selecting it with the Checkmark will uncheck another selection That is in the above Time Config example selecting Day Mo Yr will ...

Page 44: ...list of alerts will appear in the display 2 Choose the alert you wish to address by moving the highlight brackets with the Down arrow 3 Press Checkmark again A screen appears with the date time and total number of times an alert has occurred Pressing the Down arrow will list some possible causes for the alert At the bottom of the screen you will be able to clear the alert by pressing the Checkmark...

Page 45: ... From the Home screen press the Menu button to enter the Main menu where you can choose to see machine information make setup changes set the Energy Saver mode or enter the Service Menu Machine Info Set Up Energy Saver Factory Defaults Service Exit ...

Page 46: ... serial number warranty installation date date of manufacture and software version Use the Down arrow to highlight an item and use the Checkmark to view the information Press the Left arrow to return to previous screens Set Up Menu Set Up Language Time Date Time Configuration Units Ice Clarity LCD Bright Password On Edit Password Clean Minder AuCS RunTime Air Filter Water Filter LUMINICE Ice Bin S...

Page 47: ...e Down arrow to highlight setup and press the Right arrow 3 Use the Down arrow to highlight Password ON and press the Right arrow 4 Press the Right arrow again with Enter Passwrd highlighted and an icon will flash 5 Use the Up Down arrows to enter the factory password 1 2 3 4 Enter the number 1 in the flashing icon first digit of the factory password 6 Press the right arrow to move to the next cel...

Page 48: ... Password and press the Right arrow 4 Using the Up Down arrows enter the first digit of the factory password in the flashing icon 5 Press the right arrow to move to the next cell and use the Up Down arrows to add the number 2 Repeat this process to add 3 4 6 When the last number is entered press the Checkmark button 7 Follow steps 4 5 and enter your 4 digit password 8 When the last number is enter...

Page 49: ... button two times to reset the ice machine The display will return to the Set Up menu and the defaults listed below will be in effect Refer to Setup to adjust settings Setting Default Language English Time Date Month Day Year Time Time Configuration Mo Day Yr 24 Hour Units Fahrenheit Lbs Gallons Ice Clarity Off LCD Brightness Level 2 Password On Off Enter Password Default Password 1234 Edit Passwo...

Page 50: ...highlighting your choice and pressing the Checkmark Selecting one language will deselect the others 3 When the check reflects your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu TIME DATE When the ice machine is installed the correct time and date needs to be set for its location Set the Time and Date 1 Press the Menu button 2 P...

Page 51: ...r Down arrow adjust the day if necessary 8 When the correct day appears use the Right arrow to move the blinking cursor to year 9 Using the Up or Down arrow adjust the year if necessary 10 When the correct year appears press the Checkmark Use the Right arrow to move the blinking cursor to hour 11 Using the Up or Down arrow adjust the hour if necessary 12 When the correct hour appears use the Right...

Page 52: ...cks reflect your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu UNITS 1 From the Set Up menu use the Down arrow to highlight Units 2 Press the Checkmark On this screen you can choose whether the ice machine will display measurements in Celsius or Fahrenheit kilograms or pounds and gallons or liters by highlighting your choice of...

Page 53: ...ose to turn the ice clarity feature ON or OFF by highlighting your choice and pressing the Checkmark Selecting one will deselect the other 3 When the check reflects your preference use the Down arrow to navigate to Exit and press the Checkmark The display will return to the Set Up menu LCD BRIGHTNESS Here the brightness of the LCD display can be adjusted 1 From the Set Up menu use the Down arrow t...

Page 54: ... current password 3 Enter new password and press the Checkmark 4 Press the Left arrow to return to previous screens and to the Set Up menu CLEAN MINDER Clean Minder is a feature that displays a cleaning reminder at a set time interval 1 From the Set Up menu use the Down arrow to highlight Clean Minder 2 Press the Checkmark On this screen you can choose to turn the reminder ON or OFF by highlightin...

Page 55: ...ting Set Interval and pressing the Checkmark 4 Press the Left arrow to return to previous screens and to the Set Up menu AIR FILTER The ice machine has a feature that displays a clean air filter reminder at a set time interval 1 From the Set Up menu use the Down arrow to highlight Air Filter 2 Press the Checkmark On this screen you can choose to turn the reminder to AUTO or OFF by highlighting you...

Page 56: ...screen by highlighting Set Interval and pressing the Checkmark 6 Press the Left arrow to return to previous screens and to the Set Up menu LUMINICE REMINDER The LuminIce growth inhibitor recirculates the air in the ice machine foodzone over a UV bulb This process will inhibit the growth of common micro organisms on all exposed foodzone surfaces The Bulb Minder is a feature that displays a reminder...

Page 57: ...et Up menu use the Down arrow to highlight Fact Deflts 2 Press the Checkmark two times to reset the ice machine The display will return to the Set Up menu NOTE For more details and instructions for changing ice machine settings see Set Up Menu Setting Default Language English Time Date Month Day Year Time Time Configuration Mo Day Yr 24 Hour Units Fahrenheit Lbs Gallons Ice Clarity Off LCD Brightn...

Page 58: ...arrow to navigate to Energy Saver and press the Checkmark Set up an energy saving ice program enable the Water Miser and view usage statistics from this menu Press the Left arrow to return to previous screens Energy Saver Menu Energy Saver Ice Program Water Miser Statistics Exit ...

Page 59: ...he other If one of them is selected and you wish to turn both off highlight the choice and press Checkmark again 3 If neither of the programs is selected highlighting Settings and pressing the Checkmark will simply return to the top of this screen If one of the programs is selected highlight Settings and press the Checkmark to choose the times or bin levels NOTE For details on how to use the curso...

Page 60: ...highlighting your choice and pressing the Checkmark Selecting one will deselect the other NOTE Settings will not be saved if the Checkmark is not pressed after choosing On or Off 3 Press the Left arrow to return to previous screens and to the Energy Saver menu STATISTICS 1 From the Energy Saver menu use the Down arrow to highlight Statistics 2 Press the Checkmark Choose to view ice production pota...

Page 61: ...u The following pages list the navigation options available by drilling into the menus with the down arrow Service Data History 00000000 00000000 00000000 00000000 00000000 00000000 Lifetime Exit RealTime Data Time Temp Inputs Outputs Exit Diagnostics Control Board Temp Sensors Inputs Exit Man Harvest Hrvst Started Exit Repl Cntl Bd Manual Setup USB Setup Exit USB Setup USB Stick Exit Event Log Vi...

Page 62: ...Repl Cnt Bd USB Setup Current Day Current Day 1 Current Day 2 Current Day 3 Current Day 4 Current Day 5 Lifetime Control Board Temp Sensors Input Time Temp Inputs Outputs Harvest Started Manual Setup USB Setup Event Log Download Firm Download Conf Export ALL Export Setup Clear View USB Stick ...

Page 63: ...the available information For each of the dates use the Checkmark to view Minimum Freeze Maximum Freeze Minimum Harvest Maximum Harvest Maximum Temperature Delta T3 T4 Delta T3 T4 RunTime Ice Production Cycle Count Potable Water Clean Cycles Exit For Lifetime use the Checkmark to view Install Date Control Board Replacement Date Control Board DOM Date Of Manufacture RunTime Cycle Count Potable Wate...

Page 64: ... stage of cycle Time T1 Thermistor Temperature T2 Thermistor Temperature T3 Thermistor Temperature T4 Thermistor Temperature T3 T4 Delta Temperature 100 hz 120 hz Exit Inputs Status Off On Displays stage of cycle Curtain Switch 1 Curtain Switch 2 LPCO Switch HPCO Switch Bin Level Low Optional Bin Level Probe Status Bin Level Medium Optional Bin Level Probe Status Bin Level High Optional Bin Level ...

Page 65: ... Outputs Status Off On Displays stage of cycle Water Pump Off On Hot Gas Valve 1 Off On Hot Gas Valve 2 Off On Air Pump Off On Water Valve Off On Dump Valve Off On Compressor Control Off On AuCS Relay Off On LuminIce Off On Exit ...

Page 66: ...Thermistor Temperature T2 Thermistor Temperature T3 Thermistor Temperature T4 Thermistor Temperature Exit Inputs Curtain Switch 1 Closed Open Curtain Switch 2 Closed Open LPCO Switch Closed Open HPCO Switch Closed Open Bin Level Low Optional Bin Level Probe Closed Open Bin Level Medium Optional Bin Level Probe Closed Open Bin Level High Optional Bin Level Probe Closed Open Sensing Ice No Yes Water...

Page 67: ...l board refer to exporting data to a flash drive page xx or entered manually through the Indigo interface Manual Setup Board Install Date Input Model Number Ice Machine serial Number Condenser condensing unit serial number USB Setup Insert Drive Press Checkmark and wait for completion Exit USB SETUP USB Stick Download Firmware Insert drive and wait for completion Download Configuration Insert driv...

Page 68: ...when it occurred and how many times Use the Down arrow to view information on subsequent event codes For more information on event codes see Service Menu Use the Left arrow to return to the Event Log menu To clear the event log In the Event Log Menu use the Down arrow to highlight Clear ELog and press the Checkmark Press the Left arrow to return to previous screens Event Log Menu Event Log View EL...

Page 69: ...tch Fault Open more than 12 hours E13 Spare E14 Spare E15 Fan Cycle Control Fault Lo Liquid Line Temperature E16 Remote Condenser Fault E17 Spare E18 Spare E19 Ice Thickness Probe Fault E20 Water System Fault E21 T1 Temperature Sensor Issue E22 T2 Temperature Sensor Issue E23 T3 Temperature Sensor Issue E24 T4 Temperature Sensor Issue E25 Bin Level Probe Low Sensor Fault E26 Bin Level Probe Medium...

Page 70: ...m When power is interrupted to the ice machine the control board will log the event in the ELOG and stamp the loss of power on power up E04 Hi Cnd Temp or Wtr Cnd Fault Air Condenser High temp or water Condenser High temperature 1 Liquid Line Temperature too High for Self contained Air Cooled Ice machine Air Cooled Condenser Fault 2 Liquid Line Temperature too High for Self contained Water Cooled ...

Page 71: ... at least 10 F Measured from Refrigeration Start up to Two Minutes into the Freeze cycle E12 Curtain Fault Curtain Switch open for more than 12 hours Curtain Fault The ice machine is set to ice making and remains in bin full condition for more than 12 hours The curtain switch is open or curtain is off E13 Spare E Log Display Text Error Description Definition Detail Event Log Service Definition ...

Page 72: ...ature range E22 T2 Fault T2 Sensor E23 T3 Fault T3 Sensor E24 T4 Fault T4 Sensor E25 Bin Prb Fault Bin Low Sens Each thermistor reading is monitored continuously using six second average values A thermistor had a six second average value outside of the valid range for more than 10 continous minutes E26 Bin Prb Fault Bin Med Sens E Log Display Text Error Description Definition Detail Event Log Serv...

Page 73: ...s Vista Computers 1 Insert USB flash drive your computer may indicate Found New Hardware follow the prompts to install the USB flash drive USB flash drive may auto play Close auto play window 2 Press Windows Key and E key simultaneously to access windows explorer 3 Right click on your USB Flash Drive 4 Left click on Format 5 Verify or select the settings below USB flash drive capacity 2 GB or less...

Page 74: ...n OK Left click on Disk Management 3 Verify USB flash drive capacity is 2 GB or less 4 Right click on the USB flash drive then left click on Format from the drop down list 5 Verify or select the settings below Volume Label is Optional Rename if desired File System Fat32 Allocation Unit Size must be 512 MB Deselect Perform A Quick Format no checkmark 6 Left click on OK you will receive a warning Fo...

Page 75: ...ess the Checkmark The Service menu will be displayed 6 Press the Down arrow until USB Setup is highlighted 7 Press the Checkmark USB Stick will appear highlighted 8 Press the Checkmark again A submenu with Download Frm Download Firmware appears 9 Ensure that Download Frm is highlighted and press the Checkmark A display of instructions will appear Important The flash drive must be formatted before ...

Page 76: ...r the On Off screen will appear 12 Verify the new firmware version loaded by navigating to Menu Machine information Main Software Version and verify the firmware version number RT Harvest Compressor LT Harvest Pump Display Light Micro Light Clean Light Harvest Light SL 1 Light SL 2 Light Fuse Thermistors T1 T2 T3 T4 Display RS485 Bin LED Water Level Probe LuminIce Transformer Battery Bin Switches ...

Page 77: ...power is on 2 Press the Menu button 3 Press the Down arrow until Service is highlighted 4 Press the Checkmark The Service menu will be displayed 5 Press the Down arrow until USB Setup is highlighted 6 Press the Checkmark USB Stick will appear highlighted 7 Press the Checkmark again A submenu with Export ALL and Export Setup appears NOTE There are four files stored in ice machine memory Asset Data ...

Page 78: ...FE OPERATION MODE Allows the ice machine to operate up to 72 hours if the ice thickness probe E19 fault and or water level probe sensors fail E20 fault When the control board starts the safe mode an alert is flashed on the LCD display to notify the end user they have a production problem The control board automatically initiates and monitors the safe mode The control will automatically exit the sa...

Page 79: ...nt Normally new installations do not require any adjustment To ensure proper operation always follow the Operational Checks when starting the ice machine for the first time after a prolonged out of service period after cleaning and sanitizing NOTE Routine adjustments and maintenance procedures are not covered by the warranty ...

Page 80: ... mm 1 8 thick 2 If adjustment is necessary turn the ice thickness probe adjustment screw clockwise to increase bridge thickness counterclockwise to decrease bridge thickness As a starting point place a 7 mm 9 32 drill bit between the ice thickness probe and the evaporator Make final adjustments to achieve a 3 mm 1 8 thick bridge NOTE Turning the adjustment 1 3 of a turn will change the ice thickne...

Page 81: ...enoid energize to purge the ice machine of old water This feature ensures that the ice making cycle starts with fresh water 2 Refrigeration System Equalization and Start Up The harvest valve s and air pump s energize to equalize high and low side refrigeration pressure After 5 seconds the contactor energizes the compressor and supplies power to the condenser fan motor After 5 seconds the harvest v...

Page 82: ...e freeze lock expires and enough ice has formed to send a signal from the ice thickness probe to the control board Harvest Sequence 5 Water Purge The air pump s when used and the harvest valve s open at the beginning of the water purge to divert hot refrigerant gas into the evaporator The water pump s continues to run and the water dump valve energizes to purge the water in the water trough 6 Harv...

Page 83: ... dampers As the water curtain ice dampers swing back to the closed position the bin switch re closes and the ice machine restarts steps 1 2 provided the 3 minute delay period is complete Control Board Timers The control board has the following non adjustable timers The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated This can be overridden by initia...

Page 84: ...ce of Operation Water Pump Harvest Valve s Air Pump s Water Inlet Valve Water Dump Valve Contactor Coil Compressor Condenser Fan Motor Length of Time Start Up 1 Water Purge On Off Off Off On Off Off Off 45 Seconds 2 Refrigeration Off On On Off Off Off Off Off 5 Seconds ...

Page 85: ...On On May Cycle On Off Factory Set at 45 Seconds Single Evaporator Models Energized Parts Chart Continued Ice Making Sequence of Operation Water Pump Harvest Valve s Air Pump s Water Inlet Valve Water Dump Valve Contactor Coil Compressor Condenser Fan Motor Length of Time ...

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Page 87: ...hree cycles The number of cycles required to stop the ice machine varies for each safety limit Safety Limit 1 If the freeze time reaches 60 minutes the control board automatically initiates a harvest cycle If 6 consecutive 60 minute freeze cycles occur the ice machine stops Safety Limit 2 If the harvest time reaches 3 5 minutes the control board automatically returns the ice machine to the freeze ...

Page 88: ...ve water level probe Electrical System Low incoming voltage Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non operational Defective fan cycling control Defective fan motor Miscellaneous High inlet air temperature Condenser discharge air recirculation Restricted air flow dirty condenser fins Defective harvest valve No...

Page 89: ...37 bar min 20 psig Vent tube not installed on water outlet drain Clogged water distribution tube Dirty defective water fill valve Defective water pump Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Electrical System Ice thickness probe out of adjustment Ice thickness probe dirty Bin switch closed defective Premature harvest Refrigeration Syst...

Page 90: ...or Has a History of Shutting Down Refer to Ice Machine Stops Running Flow Chart SYMPTOM 2 Ice Machine has a Long Freeze Cycle Ice Formation is Thick or Thin Ice Fill on Top or Bottom of Evaporator or Low Production Safety Limit 1 possible Refer to Freeze Cycle Refrigeration System Operational Analysis Table SYMPTOM 3 Ice Machine Will Not Harvest Freeze Cycle is Normal and Ice Cubes are Not Melted ...

Page 91: ...e ice machine to factory defaults use the following procedure 1 Ensure that the ice machine s power is on 2 Press the Menu button 3 From the Main menu use the Down button to highlight Fact Deflts 4 Press either the Checkmark or right arrow two times to reset the ice machine The display will return to the Set Up menu and the defaults listed below will be in affect Refer to Setup to adjust settings ...

Page 92: ...L NOT RUN Yes START Is the display interface energized and functioning Is there an Alert or Error Logged Refer to Alert Error Log Yes No Does the ice machine start when the Power button is pushed Yes Are there any lights on Yes No ...

Page 93: ...H038 5 1 Yes Display light flashing heartbeat No Install the water curtain damper No Line voltage at wires 55 56 on 9 pin control board connector Supply power to the Refer to display control board diagnostics Yes Yes ...

Page 94: ...ess power button to start ice making does safety limit light flash Is magnet on the water curtain damper Yes Replace the water curtain damper No Yes Ice machine starts No Yes Refer to bin switch diagnostics ...

Page 95: ...ed the fuse is okay 4 Verify all bin switches function properly A defective bin switch can falsely indicate a full bin of ice 5 Perform control board display board and touch screen diagnostics Be sure steps 1 6 were followed thoroughly Intermittent problems are not usually related to the control board Warning High line voltage is applied to the control board terminals 55 and 56 at all times Removi...

Page 96: ...ables and external items and problems which can cause good refrigeration components to appear defective The tables list different defects that may affect the ice machine s operation The items listed below must be followed to provide accurate data 1 Before starting see Before Beginning Service for a few questions to ask when talking to the ice machine owner 2 All doors and panels must be in place 3...

Page 97: ...ound it is not necessary to complete the remaining procedures Step 2 Enter Checkmarks Each time the actual findings of an item in the Operational Analysis column matches the published findings on the table enter a Checkmark Example Freeze cycle suction temperature is determined to be low Enter a Checkmark in the low column Step 3 Add the Checkmarks listed under each of the four columns Note the co...

Page 98: ...ndenser_____________ Water Temperature Entering Ice Machine_________ Published 24 hour ice production________________ Calculated actual ice production_______________ NOTE The ice machine is operating properly if the ice fill patterns 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 proce...

Page 99: ...ature is High or Low refer to freeze cycle high or low suction temperature problem checklist page 109 to eliminate problems and or components not listed on this table before proceeding Suction temperature is High Suction temperature is Low or Normal Suction temperature is High Suction temperature is High SINGLE EXPANSION VALVE SELF CONTAINED AIR and WATERCOOLED CONDENSER Operational Analysis 1 2 3...

Page 100: ... on and the compressor discharge line is Hot The harvest valve inlet is Cool enough to hold hand on and the compressor discharge line is Cool enough to hold hand on The harvest valve inlet is Cool enough to hold hand on and the compressor discharge line is Hot Discharge Line Temperature Record freeze cycle Discharge line Discharge line Discharge line Discharge line SINGLE EXPANSION VALVE SELF CONT...

Page 101: ...etermining factor in the final diagnosis Ask these questions before beginning service When does the ice machine malfunction night day all the time only during the Freeze cycle etc When do you notice low ice production one day a week every day on weekends etc Can you describe exactly what the ice machine seems to be doing Has anyone been working on the ice machine During store shutdown is the circu...

Page 102: ...ater temp entering sump trough ____ 2 Refer to the appropriate 24 Hour Ice Production Chart starting on page 167 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 kilograms Perform an ice production check using the formula below 1 _________ F...

Page 103: ...ction Charts may be used 3 Compare the results of step 3 with step 2 Ice production checks that are within 10 of the chart are considered normal If they match closely determine if Another ice machine is required More storage capacity is required Relocating the existing equipment to lower the load conditions is required Contact the local Manitowoc Distributor for information on available options an...

Page 104: ...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 Line set is improperly installed Reinstall according to the Installation Manual ...

Page 105: ...C 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 Water dump valve leaking during the Freeze cycle Clean replace dump valve as needed Vent tube is not installed on water outlet drain See Installation Instructions Hoses fittings etc are leaking water Repair replace as needed Water fill valve is stuck open ...

Page 106: ...r than on the outlet At the end of the Freeze cycle ice formation at the outlet will be close to or just a bit thinner than ice formation at the inlet The dimples in the cubes at the outlet of the evaporator may be more pronounced than those on the inlet This is normal It is normal for ice thickness to vary up to 1 5 mm across the surface of the evaporator The ice bridge thickness at the ice thick...

Page 107: ...outlet of the evaporator reaches 3 mm to initiate a harvest but there is no ice formation at all on the inlet of the evaporator 4 No Ice Formation The ice machine operates for an extended period but there is no ice formation at all on the evaporator Evaporator Tubing Routing Routing of the tubing on the back of the evaporator determines the ice fill pattern failure mode The evaporator outlet tubin...

Page 108: ...ons determined in step 1 to find the published normal discharge temperatures Freeze Cycle______ Harvest Cycle______ 3 Perform an actual discharge temperature check 4 Compare the actual discharge temperature step 3 with the published discharge temperature step 2 The discharge temperature is normal when the actual temperature falls within the published temperature range for the ice machine s operati...

Page 109: ...t page 102 Air Condenser Dirty condenser filter Dirty condenser fins High inlet air temperature Condenser discharge air recirculation Defective fan cycling control page 154 Defective fan motor Other Overcharged Non condensable air in system Wrong type of refrigerant Non Manitowoc components in system High side refrigerant lines component restricted ...

Page 110: ... CYCLE DISCHARGE TEMPERATURE LOW CHECKLIST Improper Installation Refer to Installation Visual Inspection Checklist page 102 Other Undercharged Wrong type of refrigerant Non Manitowoc components in system Liquid line component restricted ...

Page 111: ...le time NOTE Analyze discharge temperature before analyzing suction temperature High or low discharge temperature may be causing high or low suction temperature Procedure Step 1 Determine the ice machine operating conditions Temperature of air entering the condenser Look up and determine the published suction temperature range 2 Perform an actual suction temperature check at the 3 minutes into the...

Page 112: ...ng suction temperature refer to Freeze Cycle Discharge Temperature High Checklist page 107 Improper Refrigerant Charge Overcharged also see Freeze Cycle Discharge Temperature High Checklist page 107 Wrong type of refrigerant Non condensable in system Components Harvest valve leaking continue the table TXV flooding continue the table Defective compressor continue the table Other Non Manitowoc compo...

Page 113: ...affecting low side refer to Freeze Cycle Discharge Temperature Low Checklist page 108 Improper Refrigerant Charge Undercharged Wrong type of refrigerant Other Non Manitowoc components in system Improper water supply over evaporator refer to Water System Checklist page 103 Restricted plugged liquid line drier Restricted plugged tubing in suction side of refrigeration system TXV starving continue th...

Page 114: ...hange throughout the freeze cycle This makes documenting the normal inlet and outlet temperature readings difficult The key to the diagnosis lies in the difference between the two temperatures five minutes into the freeze cycle These temperatures must be within 4 C of each other Use this procedure to document freeze cycle inlet and outlet temperatures 1 Navigate to Service Real Time Data Time Temp...

Page 115: ...n during the freeze cycle 1 Wait five minutes into the freeze cycle 2 Feel the inlet of the harvest valve s 3 Feel the compressor discharge line 4 Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison The harvest valve outlet is on...

Page 116: ...t valve is hot and approaches the temperature of a hot compressor discharge line Hot Hot This is an indication something is wrong as the harvest valve inlet did not cool down during the freeze cycle If the compressor dome is also entirely hot the problem is not a harvest valve leaking but rather something causing the compressor and the entire ice machine to get hot Both the inlet of the harvest va...

Page 117: ...at the compressor Lower ambient air temperatures at the condenser and or lower supply water temperature lower discharge line temperatures at the compressor Regardless of ambient and water temperatures the freeze cycle discharge line temperature will be higher than 71 C at the end of the freeze cycle PROCEDURE 1 Navigate to Service Real Time Data Time Temp T2 Thermistor See page 59 Service Menu Nav...

Page 118: ...s Verify the ice machine is not low on charge before replacing an expansion valve 1 Add refrigerant charge to verify a low charge Do not add more than 20 of nameplate refrigerant charge If the problem is corrected the ice machine is low on charge 2 Find the refrigerant leak The ice machine must operate with the nameplate charge If the leak cannot be found proper refrigerant procedures must still b...

Page 119: ... valve bulb causes the expansion valve to flood Check bulb mounting insulation etc before changing the valve Verify refrigerant amount is correct by weighing recovered refrigerant before replacing a TXV COLUMN 4 COMPRESSOR Replace the compressor To receive warranty credit the compressor ports must be properly sealed ...

Page 120: ... is on the evaporator preventing the ice slab from releasing Follow the appropriate flow chart in Troubleshooting to determine the cause of the problem A manual cleaning procedure must always be performed when this problem is encountered Normal sheet of cubes at the end of the harvest cycle Ice is difficult to remove from the evaporator by hand Once removed the back of the cubes are square and sho...

Page 121: ...arvest Freeze Cycle is Normal and Ice Cubes are Not Melted After Harvest Low production Normal fill pattern long harvest cycle Possible SL 2 Back of cubes are not melted Discharge line temperature is normal at the end of the freeze cycle Refer to Symptom 2 Freeze Cycle Operational Analysis Table START ...

Page 122: ...S NO NO Self Contained Air cooled Condenser Fan cycling control operates correctly in freeze cycle Fan cycling control opens below setpoint in harvest cycle Replace Fan Cycling Control Are you sure Discharge line YES ...

Page 123: ...OM 4 WILL NOT HARVEST CUBES MELTED Level Ice Machine Is Ice Machine level Are back of the cubes melted at end of harvest cycle YES NO Ice Machine Will Not Harvest Freeze Cycle is Normal and Ice Cubes are Melted After Harvest START ...

Page 124: ...122 Is the evaporator dirty Dry evaporator first then check YES NO NO ...

Page 125: ...ike a heartbeat The two green lights are located on the top right corner of the control board Display Diagnostics 1 Micro light flashes and display light is off 2 Disconnect and reconnect both ends of the communication cable running between the control board and the back of the display module 3 Press the power button on the display and watch the green Display light on the control board A Display l...

Page 126: ...llowing keystrokes on the display Press Menu scroll down to Service and press right arrow Scroll down to Diagnostics and press right arrow Display reads Control Board press right arrow Display reads Self Check press right arrow to start control board test The control board performs a self test As the test progresses the display will show Checkmarks at the top left of the display screen When the fi...

Page 127: ...st press the right arrow 4 Test the functionality of all buttons on the touch pad NOTE Pushing the power button will start and stop the ice machine Testing it last will allow the ice machine to continue running a freeze cycle As you press the buttons the first letter of the corresponding word will flash indicating the push button is operating correctly Press the right arrow 5 times rapidly to exit...

Page 128: ... The fan cycle control must close to energize the fan motor 1 Press power button to turn off ice machine 2 Perform the following keystrokes on the display Press Menu scroll down to Service and press the right arrow Scroll down to Diagnostics press the right arrow and select Diagnostics Display reads Control Board press right arrow Scroll down to enbl relays and press right arrow to start control b...

Page 129: ...nt B Voltage is not present at the component Proceed to step 5 5 Refer to wiring diagram and determine wire location on the 9 pin molex connector for the component you are testing 6 Check for line voltage at the control board 9 pin molex connector A Line voltage at 9 pin connector Repair wiring to component B No power at 9 pin connector Replace control board ...

Page 130: ...smaller USB flash drive All USB flash drives must be formatted before use to remove any software programs or files currently on the flash drive USB Flash Drive Specifications USB 2 Version 2 GB or less capacity Fat32 File System 512 Byte File Allocation Unit USB Flash Drive Formatting Procedure to format a USB flash drive varies with operating system software ...

Page 131: ... windows explorer 3 Right click on your USB Flash Drive 4 Left click on Format 5 Verify or select the settings below USB flash drive capacity 2 GB or less File System Fat32 Allocation Unit Size Must be 512 Byte Volume Label is Optional Rename if desired Deselect Perform A Quick Format no checkmark 6 Left click on Start You will receive a warning Formatting will remove all data left click OK A Form...

Page 132: ... OK Left click on Disk Management 3 Verify USB flash drive capacity is 2 GB or less 4 Right click on the USB flash drive then left click on Format from the drop down list 5 Verify or select the settings below Volume Label is Optional Rename if desired File System Fat32 Allocation Unit Size must be 512 Byte Deselect Perform A Quick Format no checkmark 6 Left click on OK you will receive a warning F...

Page 133: ...ltiple machines 3 Ensure that the ice machine s power is on 4 Press the Menu button 5 Press the Down arrow until Service is highlighted 6 Press the Checkmark The Service menu will be displayed 7 Press the Down arrow until USB Setup is highlighted 8 Press the Checkmark USB Stick will appear highlighted 9 Press the Checkmark 10 Select Download Cnf and press the Checkmark A display of instructions wi...

Page 134: ...chine information Main Software Version and verify the firmware version number RT Harvest Compressor LT Harvest Pump Water Dump Display Light Micro Light Clean Light Harvest Light SL 1 Light SL 2 Light Fuse Thermistors T1 T2 T3 T4 Display RS485 Bin LED Water Level Probe AuCS Remote CVD LuminIce Transformer Battery Bin Switches Bin Thermostat USB Ice Thickness Probe Light Water Level Probe Light Ri...

Page 135: ...onnel for analysis or as an aid to troubleshooting The data files are small and can be attached to an email 1 Ensure that the ice machine s power is on 2 Press the Menu button 3 Press the Down arrow until Service is highlighted 4 Press the Checkmark The Service menu will be displayed 5 Press the Down arrow until USB Setup is highlighted 6 Press the Checkmark USB Stick will appear highlighted Impor...

Page 136: ...e same user specified settings Select Export All if you are installing a replacement board 8 Highlight Export ALL or Export Setup depending on your requirements and press the Checkmark A display of instructions will appear 9 Follow these on screen instructions to A Insert Drive Insert the flash drive into the USB port on the ice machine s control board B Press Check Press the Checkmark C Wait For ...

Page 137: ...rent ways USB Setup or Manual Setup USB Setup Applicable when the control board is operational and has a mechanical issue such as a sticking relay The asset data is transferred to the replacement control board from the faulty control board Refer to page 133 Exporting Data To A Flash Drive before installing the replacement board Follow the instructions on page 131 Upgrading Firmware with a Flash Dr...

Page 138: ...ghted then press the Checkmark 3 Scroll down to Replacement Control Board and press the Checkmark 4 Select Manual Setup and press the Checkmark Verify the date correctly auto populates Yes Go to step 5 No Highlight date with the right arrow then use up down arrows to enter the correct date Use the right arrow to exit the date columns 5 Scroll down to Input Model then use up down arrows to enter th...

Page 139: ...curtain ice dampers closed the fuse is good 2 Remove the fuse Check for continuity across the fuse with an ohmmeter Warning High line voltage is applied to the control board terminals 55 and 56 at all times Removing the control board fuse or pressing the On Off button will not remove the power supplied to the control board Warning Disconnect electrical power to the entire ice machine before procee...

Page 140: ...at the end of a Harvest cycle the sheet of cubes fails to clear the water curtain ice dampers and holds it open After the water curtain ice dampers are held open for 30 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 water curtain ice dampers As the water curtain ice dampers swing back t...

Page 141: ...tion in D C voltage it is not recommended that a voltmeter be used to check bin switch operation Diagnostics SYMPTOMS Bin Switch Fails Open The ice machine will not start an ice making cycle and the display indicates Curtain Open The ice machine will run in the clean cycle Bin Switch Fails Closed When running a Long Harvest alert is displayed and safety limit 2 indicated May be off on a safety lim...

Page 142: ... closed and control board light energizes de energizes Bin switch is operating normally B Curtain switch remains closed and control board light remains on Replace bin switch C Curtain switch remains open and control board light remains off Go to next step 3 Disconnect bin switch wire from control board 4 Jumper control board bin switch wire to ground press the power button and observe the display ...

Page 143: ...s to the short probe SPECIFICATIONS Freeze Cycle Water Level Setting During the Freeze cycle the water level probe is set to maintain the proper water level above the water pump housing The water level is not adjustable If the water level is incorrect check the water level probe position Reposition or replace the probe as necessary Water Inlet Valve Safety Shut Off In the event of a water level pr...

Page 144: ... the water level probes for 3 continuous seconds The water inlet valve will cycle ON and OFF once in the prechill and up to two times in the freeze cycle Maximum fill time is 6 minutes for single evaporator After 45 seconds into the Freeze cycle The water inlet valve will cycle ON and then OFF one more time to refill the water trough The water inlet valve is now OFF for the duration of the freeze ...

Page 145: ...o Service Diagnostics Inputs and press down arrow until Wtr Low and Wtr High are displayed No is displayed Control board is not receiving a sensing water signal Continue with step 5 Yes is displayed Control board is receiving a sensing water signal Clean the water level probe and test run Step 5 Start a new freeze cycle by pressing the power button Step 6 Wait until the pre chill cycle begins then...

Page 146: ...ugh The Water Level Light Is The Water Inlet Valve Solenoid Coil Is Cause No On De energized The interconnecting wire or water level probe is causing the problem Ohm then clean or replace the water level probe or wire Yes Off Energized The control board is causing the problem Yes On De energized The water fill valve is causing the problem ...

Page 147: ...tr High are displayed A Yes is displayed Control board is receiving a sensing water signal Proceed to step 3 B No is displayed Control board is not receiving a sensing water signal Proceed to Control Board Diagnostics page 124 Step 3 Disconnect water level probe observe LCD display text A No is displayed Clean the water level probe and test interconnecting wiring B Yes is displayed Refer to Contro...

Page 148: ...rol system incorporates a freeze time lock in feature This prevents the ice machine from short cycling in and out of harvest The control board locks the ice machine in the freeze cycle and a harvest cycle can not start for six minutes Maximum Freeze Time The control system includes a built in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle Ma...

Page 149: ...t should be about 3 mm thick 2 If adjustment is necessary turn the ice thickness probe adjustment screw clockwise to increase bridge thickness or counterclockwise to decrease bridge thickness Set a 7 mm gap between the ice thickness probe and evaporator as a starting point Then adjust to achieve 3 mm ice thickness 3 Make sure the ice thickness probe wire and the bracket do not restrict movement of...

Page 150: ...Failure Low ice production Thin ice in bin Freeze cycles are faster than published cycle times Will not harvest Display indicates ITP Failure Low ice production Thick ice in bin Large sheet of ice on evaporator Harvest cycle doesn t start Freeze cycles are slower than published cycle times ...

Page 151: ... ice thickness probe gap is approximately 7 mm 3 Wait six minutes Ice Machine remains in freeze cycle Allow ice machine to run Ice machine cycles into harvest Replace ice thickness probe to determine if problem is resolved If problem persists replace the control board NOTE Do not disconnect the ITP leads from the control board as this will cause the ice machine to go into harvest after the 6 min l...

Page 152: ... freeze cycle will start after the manual harvest cycle is complete 1 Reboot the control board by disconnecting and reconnecting line voltage to the ice machine 2 Verify ice thickness probe gap is approximately 7 mm 3 Wait for ice to contact the ice thickness probe Ice Machine cycles into harvest normally Allow ice machine to run Ice machine will not cycle into harvest Replace ice thickness probe ...

Page 153: ...point the ice machine attempts a restart If the HPCO is closed the ice machine will continue to run If the HPCO remains open after the 60 minute delay or reopens when the compressor starts the ice machine will start another 60 minute delay period The ice machine will lockout after 10 failed attempts 1 Machine is off and the display indicates Delay XX min HPCO Active 2 Machine is running and the di...

Page 154: ...switch has reset and closed B No line voltage present HPCO switch is open 3 Depending on timing either wait for the delay period to end or start a new freeze cycle The ice machine will go to an initial start sequence When the compressor relay closes the control board checks the HPCO A HPCO is open Another 60 minute delay period starts B HPCO closed A 3 5 minute harvest cycle starts followed by an ...

Page 155: ... to HPC Fault 5 Open the event and view when and how often HPCO Fault has occurred 2 If this is a one time event it may be intermittent and caused by conditions around the unit changing For example High ambient temperature blocked vents etc 3 Run the system to see if the control trips If HPCO opens find the root cause Fan motor dirty condenser refrigeration system issue etc ...

Page 156: ...n motor windings are not open or grounded and fan spins freely 2 Connect manifold gauges to ice machine 3 Hook voltmeter in parallel across the fan cycle control leaving wires attached 4 Refer to chart below Specifications Model Cut In Close Cut Out Open I0320 I0520 1723 kPa 34 17 23 bar 34 1517 kPa 34 15 17 bar 34 FCC Setpoint Reading Should Be Fan Should Be Above Cut In 0 Volts Running Below Cut...

Page 157: ...60 70 98 930 10 20 50 68 98 930 62 015 20 30 68 86 62 015 39 695 30 40 86 104 39 695 25 070 40 50 104 122 25 070 17 481 50 60 122 140 17 481 11 860 60 70 140 158 11 860 8 1900 70 80 158 176 8 1900 5 7530 80 90 176 194 5 7530 4 1015 90 100 194 212 4 1015 2 9735 100 110 212 230 2 9735 2 1885 110 120 230 248 2 1885 1 6290 120 130 248 266 1 6290 1 2245 130 140 266 284 1 2245 0 9319 140 150 284 302 0 9...

Page 158: ...rature sensor located at the outlet of the condenser T2 Air or Water cooled Models Discharge line temperature sensor located near the compressor T3 Single Expansion Valve Models Suction line temperature sensor located at the inlet of the evaporator T4 Single Expansion Valve Models Suction line temperature sensor located at the outlet of the evaporator ...

Page 159: ... Defrost W 1 T3 T4 T2 T1 Self Contained d Water Cooled d Hot Gas Defrost A W 48 48 T4 T3 T2 T1 Self Contained d Air Coo ooled Water Cooled d Hot Gas Defrost N 1 T3 T4 T2 Spl plit System Remote Condenser Hot Gas Defrost N 48 48 T4 T3 T2 T1 Spl plit System Remote Condenser Hot Gas Defrost C 1 T3 T4 T1 T2 Spl plit System Remote Condensing Un Unit Coo ool Vapor Defrost C 2 5 T4 T3 T1 T2 Spl plit Syste...

Page 160: ...s 246 C Thermistor Test 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 Board Test 1 Disconnect the...

Page 161: ...t cycles SPECIFICATIONS 230 Volt matches the ice machine voltage CHECK PROCEDURE 1 The air pump is wired in parallel with the harvest valve Verify the ice machine is in the harvest cycle and the harvest valve is energized 2 If there is voltage at the air pump connector use a volt ohm meter to verify there is no continuity through the motor windings then replace motor ...

Page 162: ... enough to touch below 120 F 49 C to assure that the overload is closed and the resistance readings will be accurate SINGLE PHASE COMPRESSORS 1 Disconnect power then remove 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 read...

Page 163: ...sor windings are grounded and the compressor should be replaced COMPRESSOR DRAWING LOCKED ROTOR To determine if the compressor is seized check the amp draw while the compressor is trying to start The two likely causes of this are a defective starting component and a mechanically seized compressor COMPRESSOR DRAWING HIGH AMPS The continuous amperage draw on start up should not be near the maximum f...

Page 164: ...apacitor Use a capacitor tester when checking a suspect capacitor Clip the bleed resistor off the capacitor terminals before testing If the compressor attempts to start or hums and trips the overload protector check the starting components before replacing the compressor Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane Do not assume a capacitor is good ...

Page 165: ...generated by the start winding and opens the contacts as the compressor motor starts The contacts remain open until the compressor is de energized RELAY OPERATION CHECK 1 Disconnect wires from relay terminals 2 Verify the contacts are closed Measure the resistance between terminals 1 and 2 No continuity indicates open contacts Replace the relay 3 Check the relay coil Measure the resistance between...

Page 166: ... be cooled before attempting to start the compressor otherwise the PTCR will heat up too quickly and stop current flow through the start winding before the compressor motor reaches full speed NOTE If a PTCR is dropped internal damage can occur to the ceramic PTCR discs The ceramic disc can chip and cause arcing which leads to PTCR failure Since there is no way to open the PTCR in order to determin...

Page 167: ...may reach 100 C while the compressor is running This is normal Do not change a PTCR just because it is hot 2 Wait at least 10 minutes for the PTCR to cool to room temperature 3 Remove the PTCR from the ice machine 4 Measure the resistance of the PTCR as shown The resistance reading must be between 18 and 40 ohms Measure Resistance At Ends PTCR ...

Page 168: ...chines have a back flushing action that takes place during every Harvest cycle A Manitowoc filter drier has high moisture and acid removal capability The size of the filter drier is important The refrigerant charge is critical Using an improperly sized filter drier will cause the ice machine to be improperly charged with refrigerant TOTAL SYSTEM REFRIGERANT CHARGE NOTE All machines listed use R 29...

Page 169: ...ion of data is essential to obtain the correct diagnosis 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 Symptom 2 Operational Analysis Table page 94 for the list of data that must be collected for refrigeration diagnostics ...

Page 170: ... 27 C 80 F NO DATA 32 C 90 F 38 C 100 F Air Temp Entering Condenser C F Water Temperature C F1 1 Based on average ice slab weight of 2087 2359 g 4 60 5 20 lb 10 C 50 F 21 C 70 F 32 C 90 F 21 C kgs 70 F lbs 27 C kgs 80 F lbs NO DATA 32 C kgs 90 F lbs 38 C kgs 100 F lbs Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Temp T2 Suction Temp1 T4 1 Suction temperature drops gradually...

Page 171: ... drops gradually throughout the freeze cycle Discharge Temp T2 Suction Temp T4 10 C 50 F 21 C 70 F NO DATA 27 C 80 F 32 C 90 F 38 C 100 F Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Temp T2 Suction Temp1 T4 1 Suction temperature drops gradually throughout the freeze cycle Discharge Temp T2 Suction Temp T4 10 C 50 F 21 C 70 F 27 C 80 F NO DATA 32 C 90 F 38 C 100 F ...

Page 172: ...rage ice slab weight of 1474 1655 g 3 25 3 65lb 10 C 50 F 21 C 70 F 32 C 90 F 21 C kgs 70 F lbs 202 445 188 415 175 385 27 C kgs 80 F lbs 188 415 177 390 165 365 32 C kgs 90 F lbs 175 385 163 360 147 325 38 C kgs 100 F lbs 161 355 147 325 134 295 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Temp T2 Suction Temp1 T4 1 Suction temperature drops gradually throughout the freeze...

Page 173: ...5 145 3 13 37 55 32 C 90 F 88 93 190 200 4 9 25 15 60 66 140 150 3 13 37 55 38 C 100 F 96 113 205 235 4 6 25 20 68 85 155 185 4 13 40 55 Air Temp Entering Condenser F C Freeze Cycle Harvest Cycle Discharge Temp T2 Suction Temp1 T4 1 Suction temperature drops gradually throughout the freeze cycle Discharge Temp T2 Suction Temp T4 10 C 50 F 78 88 173 190 5 11 22 12 47 54 117 130 3 14 38 58 21 C 70 F...

Page 174: ...172 Part Number STH038 5 12 This Page Intentionally Left Blank ...

Page 175: ... following symbols are used on all of the wiring diagrams Internal Compressor Overload Some models have external compressor overloads Fan Motor Run Capacitor Some models do not incorporate fan motor run capacitor Wire Number Designation The number is marked at each end of the wire Multi Pin Connection Electrical Box Side Compressor Compartment Side Warning Always disconnect power before working on...

Page 176: ...174 Part Number STH038 5 12 I0320 Self Contained 1 Ph ...

Page 177: ...Part Number STH038 5 12 175 I0500 Self Contained 1 Ph ...

Page 178: ...3 T4 Display RS485 Bin LED Water Level Probe AuCS Remote CVD LuminIce Transformer Battery Bin Switches Bin Thermostat USB Ice Thickness Probe Light Water Level Probe Light Right Bin Switch Light Left Bin Switch Light Dump Valve HPC Ice Thickness Probe Water Pump Compressor L1 Not Used L2 Water Inlet Valve Right Harvest Valve Left Harvest Valve Dump Valve Relay Lights V C LPC HPC1 HPC2 CVD Contacto...

Page 179: ...Refrigeration Tubing Schematics X RECEIVER WATER COOLED ONLY DRIER COMPRESSOR STRAINER CONDENSER AIR OR WATER HOT GAS SOLENOID VALVE EXPANSION VALVE EVAPORATOR HEAT EXCHANGER T1 Thermistor T4 Thermistor T3 Thermistor T2 Thermistor ...

Page 180: ...178 Part Number STH038 5 12 ...

Page 181: ......

Page 182: ...Manitowoc Ice 2110 South 26th Street P O Box 1720 Manitowoc WI 54221 1720 USA Ph 001 920 682 0161 Fax 001 920 683 7589 Visit us online at www manitowocfsg com 2012 Manitowoc Part Number STH038 5 12 ...

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Manitowoc I0320A, Technician'S Handbook

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