Marine Q 1300 Ice Machine Service Manual Thank you for selecting a Manitowoc Ice Machine, the dependability leader in ice making equipment and related products. With proper installation, care and maintenance, your new Manitowoc Ice Machine will provide you with many years of reliable and economical performance.
Safety Notices Procedural Notices When using or servicing a Q Model Ice Machine, be sure to pay close attention to the safety notices in this manual. Disregarding the notices may lead to serious injury and/or damage to the ice machine. When using or servicing a Q Model Ice Machine, be sure to read the procedural notices in this manual. These notices supply helpful and important information.
Table of Contents Electrical System Energized Parts Charts Self-Contained Water-Cooled Models ...........................................................................................................1 Wiring Diagram Sequence of Operation Self-Contained Models.....................................................................................................................................2 Wiring Diagrams Wiring Diagram Legend...............................................................................
Table of Contents Refrigeration System Sequence of Operation Self-Contained Water-Cooled Models .........................................................................................................28 Operational Analysis (Diagnostics) General............................................................................................................................................................29 Before Beginning Service ..................................................................................
Electrical System Electrical System Energized Parts Charts SELF-CONTAINED WATER-COOLED MODELS Ice Making Sequence Of Operation Start-Up1 Control Board Relays 1 2 3 4 Water Water Fill Hot Gas Valve Valve(s) Pump Water Dump Valve 5 5A Contactor Compressor Coil Length Of Time On Off On On Off Off 45 Seconds Off On On Off On On 5 Seconds 3. Pre-Chill Off Off Off On On 30 Seconds Freeze On May cycle On/Off during first 45 sec.
Electrical System Wiring Diagram Sequence of Operation SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (22) (21) SELF-CONTAINED MODELS (55) TB32 (61) TB35 WATER VALVE (60) HIGH PRES CUTOUT Initial Start-Up or Start-Up After Automatic Shut-Off 1. WATER PURGE Before the compressor starts, the water pump and water dump solenoid are energized for 45 seconds to purge old water from the ice machine. This ensures that the ice-making cycle starts with fresh water.
Electrical System Initial Start-Up Or Start-Up After Automatic Shut-Off (cont.) 2. REFRIGERATION SYSTEM START-UP The compressor starts after the 45second water purge, and it remains on throughout the Freeze and Harvest cycles.
Electrical System Freeze Sequence 3. PRE-CHILL To pre-chill the evaporator, the compressor runs for 30 seconds prior to water flow. SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (22) (21) (55) TB32 (61) TB35 WATER VALVE (60) The water fill valve remains on until the water level sensor closes for three continuous seconds.
Electrical System Freeze Sequence (cont.) 4. FREEZE The water pump starts after the 30second pre-chill. An even flow of water is directed across the evaporator and into each cube cell, where it freezes. SEE SERIAL PLATE FOR VOLTAGE L1 L2 (N) (22) (21) (55) TB32 (61) TB35 WATER VALVE (60) HIGH PRES CUTOUT When sufficient ice has formed, the water flow (not the ice) contacts the ice thickness probes. After approximately 7 seconds of continual contact, a harvest cycle is initiated.
Electrical System Harvest Sequence 5. WATER PURGE The water pump continues to run, and the water dump valve energizes for 45 seconds to purge the water in the sump trough. The water fill valve energizes (turns on) and de-energizes (turns off) strictly by time. The water fill valve energizes for the last 15 seconds of the 45-second water purge. The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge.
Electrical System Harvest Sequence (cont.) 6. HARVEST The hot gas valve(s) remains open, allowing refrigerant gas to warm the evaporator. This causes the cubes to slide, as a sheet, off the evaporator and into the storage bin. SEE SERIAL PLATE FOR VOLTAGE L1 L2 (N) (22) (21) (55) TB32 (61) TB35 WATER VALVE (60) HIGH PRES CUTOUT The sliding sheet of cubes swings the water curtain out, opening the bin switch.
Electrical System 7. Automatic Shut-Off If the storage bin is full at the end of a harvest cycle, the sheet of cubes fails to clear the water curtain and holds it open. After the water curtain is held open for 7 seconds, the ice machine shuts off. SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (22) (21) (55) TB32 (61) TB35 WATER VALVE (60) HIGH PRES CUTOUT 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.
Electrical System Wiring Diagrams The following pages contain electrical wiring diagrams. Be sure you are referring to the correct diagram for the ice machine which you are servicing. WARNING Always disconnect power before working on electrical circuitry.
Electrical System Q1300 - 1 PHASE CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. NOTE: DIAGRAM SHOWN DURING FREEZE CYCLE. SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (21) (22) WATER VALVE TB32 TB35 (55) (61) HIGH PRESSURE CUT-OUT RH HOT GAS SOLENOID (61) (88) (60) (87) (77) LH HOT GAS SOLENOID 2 4 (80) 1 5 (57) TB31 TRANS.
Electrical System Component Specifications and Diagnostics MAIN FUSE BIN SWITCH Function The control board fuse stops ice machine operation if electrical components fail causing high amp draw. Function Bin switch operation is controlled by movement of the water curtain. The bin switch has two main functions: 1. Terminating the harvest cycle and returning the ice machine to the freeze cycle. Specifications The main fuse is 250 Volt, 7 amp.
Electrical System Check Procedure 1. Set the toggle switch to OFF. 2. Watch the bin switch light on the control board. 3. Move the water curtain toward the evaporator. The bin switch must close. The bin switch light “on” indicates the bin switch has closed properly. 4. Move the water curtain away from the evaporator. The bin switch must open. The bin switch light “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.
Electrical System COMPRESSOR ELECTRICAL DIAGNOSTICS The compressor will not start or will trip repeatedly on overload. Check Resistance (Ohm) Values NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter. Perform the resistance test after the compressor cools. The compressor dome should be cool 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.
Electrical System PTCR DIAGNOSTICS What is a PTCR? A PTCR (or Positive Temperature Coefficient Resistor) is made from high-purity, semiconducting ceramics. A PTCR is useful because of its resistance versus temperature characteristic. The PTCR has a low resistance over a wide (low) temperature range, but upon reaching a certain higher temperature, its resistance greatly increases, virtually stopping current flow. When the source of heat is removed, the PTCR returns to its initial base resistance.
Electrical System Q-Model Automatic Shut-Off and Restart When the storage bin is full at the end of a harvest cycle, the sheet of cubes fails to clear the water curtain and will hold it open. After the water curtain is held open for 7 seconds, the ice machine shuts off. To assure the PTCR has cooled, the ice machine remains off for 3 minutes before it can automatically restart.
Electrical System There are other problems that may cause compressor start-up failure with a good PTCR in a new, properly wired ice machine. • The voltage at the compressor during start-up is too low. Manitowoc ice machines are rated at ±10% of nameplate voltage at compressor start-up. (Ex: An ice machine rated at 208-230 should have a compressor start-up voltage between 187 and 253 volts.
Electrical System ICE/OFF/CLEAN TOGGLE SWITCH Function The switch is used to place the ice machine in ICE, OFF or CLEAN mode of operation. CONTROL BOARD RELAYS Function The control board relays energize and de-energize system components. Specifications Double-pole, double-throw switch. The switch is connected into a varying low D.C. voltage circuit. Specifications Relays are not field replaceable. There are five relays on the control board: Check Procedure NOTE: Because of a wide variation in D.C.
Electrical System ELECTRONIC CONTROL BOARD AC LINE VOLTAGE ELECTRICAL PLUG (NUMBERS MARKED ON WIRES) 20 57 60 CLEAN LIGHT YELLOW 58 61 55 L1 PRIMARY POWER SUPPLY N 115V L2 208-230V 56 WATER LEVEL PROBE LIGHT GREEN MAIN FUSE (7A) BIN SWITCH LIGHT GREEN AUTOMATIC CLEANING SYSTEM (AuCS) ACCESSORY PLUG HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT RED ICE THICKNESS PROBE (3/16” CONNECTION) 1C WATER LEVEL PROBE 1F Q1800 ONLY 1G 67 68 62 63 65 DC LOW VOLTAGE ELECTRICAL PLUG (NUMBERS MARKED ON WI
Electrical System General Q-Model control boards use a dual voltage transformer. This means only one control board is needed for both 115V and 208-230V use. Safety Limits In addition to standard safety controls, such as the high pressure cut-out, the control board has builtin safety limits. These safety limits protect the ice machine from major component failures. For more information, see “Safety Limits”.
Electrical System Ice Thickness Probe (Harvest Initiation) HOW THE PROBE WORKS Manitowoc’s electronic sensing circuit does not rely on refrigerant pressure, evaporator temperature, water levels or timers to produce consistent ice formation. As ice forms on the evaporator, water (not ice) contacts the ice thickness probe. After the water completes this circuit across the probe continuously for 6-10 seconds, a harvest cycle is initiated.
Electrical System DIAGNOSING ICE THICKNESS CONTROL CIRCUITRY Ice Machine Does Not Cycle Into Harvest when Water Contacts the Ice Thickness Control Probe Step 1 Bypass the freeze time lock-in feature by moving the ICE/OFF/CLEAN switch to OFF and back to ICE. Wait until the water starts to flow over the evaporator. Step 2 Clip the jumper wire leads to the ice thickness probe and any cabinet ground.
Electrical System Ice Machine Cycles Into Harvest Before Water Contact With The Ice Thickness Probe Step 1 Disconnect the ice thickness probe from the control board at terminal 1C. Step 2 Bypass the freeze time lock-in feature by moving the ICE/OFF/CLEAN switch to OFF and back to ICE. Wait until the water starts to flow over the evaporator, then monitor the harvest light.
Electrical System Water Level Control Circuitry WATER LEVEL PROBE LIGHT The water level probe circuit can be monitored by watching the water level light. The water level light is on when water contacts the probe, and off when no water is in contact with the probe. The water level light functions any time power is applied to the ice machine, regardless of toggle switch position.
Electrical System DIAGNOSING FREEZE CYCLE POTABLE WATER LEVEL CONTROL CIRCUITRY Problem: Water Trough Overfilling During The Freeze Cycle Step 1 Start a new freeze sequence by moving the ICE/OFF/CLEAN toggle switch to OFF, then back to ICE. Important This restart must be done prior to performing diagnostic procedures. This assures the ice machine is not in a freeze cycle water inlet valve safety shut-off mode. You must complete the entire diagnostic procedure with-in 6 minutes of starting.
Electrical System Problem: Water Trough Overfilling During The Freeze Cycle (continued) Step 3 Allow ice machine to run. Disconnect the water level probe from control board terminal 1F, and connect a jumper wire from terminal 1F to any cabinet ground. Remember if you are past 6 minutes from starting, the ice machine will go into a freeze cycle water inlet valve safety shut-off mode, and you will be unable to complete this test.
Electrical System Problem: Water Will Not Run Into The Sump Trough During The Freeze Cycle Step 1 Verify water is supplied to the ice machine, and then start a new freeze sequence by moving the ICE/OFF/CLEAN toggle switch to OFF then back to ICE. Important This restart must be done prior to performing diagnostic procedures. This assures the ice machine is not in a freeze cycle water inlet valve safety shut-off mode. You must complete the entire diagnostic procedure with-in 6 minutes of starting.
Electrical System Diagnosing Ice Machine That Will Not Run WARNING High (line) voltage is applied to the control board (terminals #55 and #56) at all times. Removing control board fuse or moving the toggle switch to OFF will not remove the power supplied to the control board. Step Check 1 Verify primary voltage supply to ice machine. 2 Verify the high-pressure cutout is closed. 3 Verify control board fuse is OK. 4 Verify the bin switch functions properly.
Refrigeration System Refrigeration System Sequence of Operation Q1300 REFRIGERATION TUBING SCHEMATICS EVAPORATOR HEAT EXCHANGE EXPANSION VALVE EXPANSION VALVE HOT GAS SOLENOID VALVES COMPRESSOR STRAINER WATER COOLED CONDENSER DRIER RECEIVER Q1300 Self-Contained Water-Cooled Models 28 SV1512
Refrigeration System Operational Analysis (Diagnostics) GENERAL When analyzing the refrigeration system, it is important to understand that different refrigeration component malfunctions may cause very similar symptoms. Also, many external factors can make good refrigeration components appear bad. These factors can include improper installation, or water system malfunctions such as hot incoming water supply or water loss.
Refrigeration System BEFORE BEGINNING SERVICE Ice machines may experience operational problems only during certain times of the day or night. A machine may function properly while it is being serviced, but malfunctions later. Information provided by the user can help the technician start in the right direction, and may be a determining factor in the final diagnosis.
Refrigeration System INSTALLATION/VISUAL INSPECTION CHECKLIST Possible Problem Ice machine is not level Improper clearance around top, sides and/or back of ice machine Ice machine is not on an independent electrical circuit Water filtration is plugged (if used) Water drains are not run separately and/or are not vented Corrective Action Level the ice machine Reinstall according to the Installation Manual Reinstall according to the Installation Manual Install a new water filter Run and vent drains according
Refrigeration System ICE FORMATION PATTERN Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction. However, when this analysis is used along with Manitowoc’s Refrigeration System Operational Analysis Table, it can help diagnose an ice machine malfunction. Improper ice formation can be caused by any number of problems. 2.
Refrigeration System 3. Extremely Thin at Evaporator Inlet There is no ice, or a considerable lack of ice formation on the bottom of the evaporator (tubing inlet). Examples: The ice at the top of the evaporator reaches 1/8” to initiate a harvest, but there is no ice formation at all on the bottom of the evaporator. 5. No Ice Formation The ice machine operates for an extended period, but there is no ice formation at all on the evaporator.
Refrigeration System SAFETY LIMITS General In addition to standard safety controls, such as high pressure cut-out, the control board has two built in safety limit controls which protect the ice machine from major component failures. Safety Limit #1: If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle. If three consecutive 60-minute freeze cycles occur, the ice machine stops. Safety Limit #2: If the harvest time reaches 3.
Refrigeration System Safety Limit #1 Freeze time exceeds 60 minutes for 3 consecutive freeze cycles. Possible Cause Improper installation Water system Electrical system Restricted condenser water flow (water-cooled models) Refrigeration system • • • • • • • • • • • • • • • • • • • • • • • • Check/Correct See “Installation/Visual Inspection Checklist” on page 7-10 Low water pressure (20 psi min.) High water pressure (80 psi max.) High water temperature (90°F/32.2°C max.
Refrigeration System Safety Limit #2 Harvest time exceeds 3.5 minutes for 3 consecutive harvest cycles.
Refrigeration System HOT GAS VALVE TEMPERATURE CHECK General A hot gas valve requires a critical orifice size. This meters the amount of hot gas flowing into the evaporator during the harvest cycle. If the orifice is even slightly too large or too small, long harvest cycles will result. A too-large orifice causes refrigerant to condense to liquid in the evaporator during the harvest cycle. This liquid will cause compressor damage. A toosmall orifice does not allow enough hot gas into the evaporator.
Refrigeration System ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE 1. Determine the ice machine operating conditions: 3. Perform an actual discharge pressure check. Air temp. entering condenser Air temp. around ice machine Water temp. entering sump trough ______ ______ ______ 2. Refer to Operating Pressure Chart for ice machine being checked. Use the operating conditions determined in Step 1 to find the published normal discharge pressures.
Refrigeration System ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE The suction pressure gradually drops throughout the To analyze and identify the proper suction pressure freeze cycle. The actual suction pressure (and drop drop throughout the freeze cycle, compare the rate) changes as the air and water temperatures published suction pressure to the published freeze entering the ice machine change. This affects freeze cycle time. “Operating Pressure” and “Freeze Cycle cycle times.
Refrigeration System Freeze Cycle Suction Pressure High Checklist Possible Cause Improper installation Discharge pressure Improper refrigerant charge Other • • • • • • • • Check/Correct See “Installation/Visual Inspection Checklist” Discharge pressure is too high, and is affecting low side (See “Freeze Cycle Discharge Pressure High Checklist”) Overcharged Wrong type of refrigerant Non-Manitowoc components in system Hot gas valve stuck open TXV flooding (check bulb mounting) Defective compressor Freeze Cy
Refrigeration System HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES General Final Analysis These tables must be used with charts, checklists The column with the highest number of check and other references to eliminate refrigeration marks identifies the refrigeration problem. components not listed on the tables and external COLUMN 1 - HOT GAS VALVE LEAKING items and problems which can cause good Normally, a leaking hot gas valve can be repaired refrigeration components to appear defective.
Refrigeration System Q Model Dual Expansion Valve Refrigeration System Operational Analysis Table This table must be used with charts, checklists and other references to eliminate refrigeration components not listed on the table and external items and problems which can cause good refrigeration components to appear defective.
Refrigeration System Pressure Control Specifications and Diagnostics HIGH PRESSURE CUTOUT (HPCO) CONTROL Function Stops the ice machine if subjected to excessive high-side pressure. The HPCO control is normally closed, and opens on a rise in discharge pressure. Specifications Cut-out: 450 psig ±10 Cut-in: Manual or automatic reset (Must be below 300 psig to reset). Check Procedure 1. Set ICE/OFF/CLEAN switch to OFF, (Manual reset HPCO reset if tripped). 2. Connect manifold gauges. 3.
Refrigeration System Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts Q1300 SERIES WATER-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Cycle Time Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Harvest Time Water Temperature °F/°C 50/10.0 9.0-10.1 9.1-10.1 9.2-10.3 9.4-10.5 70/21.1 9.8-10.9 9.8-11.0 10.0-11.2 10.1-11.3 90/32.2 11.4-12.6 11.6-12.9 12.0-13.3 12.2-13.6 1-2.
Refrigeration System Refrigerant Recovery/Evacuation and Recharging NORMAL SELF-CONTAINED MODEL PROCEDURES Refrigerant Recovery/Evacuation Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important Manitowoc Ice, Inc. assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
Refrigeration System Self-Contained Charging Procedures Important The charge is critical on all Manitowoc ice machines. Use a scale or a charging cylinder to ensure the proper charge is installed. 1. Be sure the toggle switch is in the OFF position. MANIFOLD SET CLOSED FRONTSEATED LOW SIDE SERVICE VALVE OPEN BACKSEATED HIGH SIDE SERVICE VALVE 2. Close the vacuum pump valve, the low side service valve, and the low side manifold gauge valve. 3.
Refrigeration System SYSTEM CONTAMINATION CLEANUP General This section describes the basic requirements for restoring contaminated systems to reliable service. Important Manitowoc Ice, Inc. assumes no responsibility for the use of contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
Refrigeration System Mild System Contamination Cleanup Procedure 1. Replace any failed components. 2. If the compressor is good, change the oil. 3. Replace the liquid line drier. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation. Do not position heat lamps too close to plastic components, or they may melt or warp. Important Dry nitrogen is recommended for this procedure. This will prevent CFC release.
Refrigeration System 11. Follow the normal evacuation procedure, except replace the evacuation step with the following: Important Dry nitrogen is recommended for this procedure. This will prevent CFC release. A. Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi. 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 psi. D.
Refrigeration System FIG. A - “PINCHING OFF” TUBING TYPICAL PRESSURE CONTROL SHOWN “PINCH-OFF” TOOL USED HERE SEE FIG. A AND FIG. B FIG.
Refrigeration System FILTER-DRIERS The filter-driers used on Manitowoc ice machines are manufactured to Manitowoc specifications. The difference between Manitowoc driers and offthe-shelf driers is in filtration. Manitowoc driers have dirt-retaining filtration, with fiberglass filters on both the inlet and outlet ends. This is very important because ice machines have a backflushing action which takes place during every harvest cycle.
Refrigeration System REFRIGERANT DEFINITIONS Recover To remove refrigerant, in any condition, from a system and store it in an external container, without necessarily testing or processing it in any way. Recycle To clean refrigerant for re-use by oil separation and single or multiple passes through devices, such as replaceable core filter-driers, which reduce moisture, acidity and particulate matter. This term usually applies to procedures implemented at the field job site or at a local service shop.
Section 7 REFRIGERANT RE-USE POLICY Manitowoc recognizes and supports the need for proper handling, re-use, and disposal of, CFC and HCFC refrigerants. Manitowoc service procedures require recapturing refrigerants, not venting them to the atmosphere. It is not necessary, in or out of warranty, to reduce or compromise the quality and reliability of your customers’ products to achieve this. Important Manitowoc Ice, Inc. assumes no responsibility for use of contaminated refrigerant.
Refrigeration System Section 7 HFC REFRIGERANT QUESTIONS AND ANSWERS 4. Manitowoc uses R-404A and R-134A HFC refrigerants with ozone depletion potential (ODP) factors of zero (0.0). R-404A is used in ice machines and reach-in freezers and R-134A is used in reach-in refrigerators. 1. What compressor oil does Manitowoc require for use with HFC refrigerants? Manitowoc products use Polyol Ester (POE) type compressor oil. It is the lubricant of choice among compressor manufacturers. 2.
Section 7 7. Is other special equipment required to service HFC refrigerants? No. Standard refrigeration equipment such as gauges, hoses, recovery systems, vacuum pumps, etc., are generally compatible with HFC refrigerants. Consult your equipment manufacturer for specific recommendations for converting existing equipment to HFC usage. Once designated (and calibrated, if needed) for HFC use, this equipment should be used specifically with HFC refrigerants only. Refrigeration System 8.
Refrigeration System 56 Section 7
MANITOWOC ICE, INC. 2110 South 26th Street P.O. Box 1720 Manitowoc, WI 54221-1720 Phone: (920) 682-0161 We reserve the right to make product improvements at any time. Specifications and design are subject to change without notice. Fax: (920) 683-7585 Web Site - www.manitowocice.com ©2001 Manitowoc Ice, Inc. Litho in U.S.A.
