ICE MACHINES Q-Model Service Manual C 2004 Manitowoc Ice, Inc.
Safety Notices Procedural Notices As you work on a Q-Series 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. As you work on a Q-Series Ice Machine, be sure to read the procedural notices in this manual. These notices supply helpful information which may assist you as you work.
Attend A Manitowoc Factory Service School • Improve Your Service Techniques • Network with Your Peers • 4 1/2 Days of Intensive Training on Manitowoc Ice Machines • Extensive “Hands On” Training on a Variety of Equipment • Breakfast, Lunch and Hotel Room Included with Tuition • Contact Your Distributor or Manitowoc Ice, Inc. for Details OR • Visit Our Website at www.manitowocice.com for School Dates MANITOWOC ICE, INC. 2110 South 26th Street P.O.
Table of Contents Section 1 General Information Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Coverage . . .
Table of Contents (continued) Remote Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Ice Machine With Single Circuit Model Condenser 115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Ice Machine With Single Circuit Model Condenser 208-230/3/60 or 380-415/3/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Ice Machine With Single Circuit Model Condenser 230/1/50 . . .
Table of Contents (continued) AlphaSan“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure To Cancel A Cleaning Or Sanitizing Cycle After It Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents (continued) Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Wiring Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q200/Q280/Q320 - Self Contained - 1 Phase With Terminal Board . . . . . . . Q280/Q370 - Self Contained - 1 Phase Without Terminal Board . . . . . . . . . Q320 - Self Contained - 1 Phase Without Terminal Board . . . . . . . . . . . . . .
Table of Contents (continued) Section 7 Refrigeration System Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Contained Air or Water -Cooled Models . . . . . . . . . . . . . . . . . . . . . . . . Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1300/Q1600/Q1800 Refrigeration Tubing Schematics . . . . . . . . . . . . . . . Operational Analysis (Diagnostics) . . . . . . . . . . . . . .
Table of Contents (continued) Refrigerant Recovery/Evacuation and Recharging . . . . . . . . . . . . . . . . . . . . . Normal Self-Contained Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . Normal Remote Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Contamination Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Replacing Pressure Controls Without Removing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . .
Section 1 General Information Model Numbers How to Read a Model Number This manual covers the following models: Self-Contained Air-Cooled QR0320A QD0322A QY0324A QR0420A QD0422A QY0424A QR0200A QD0202A QY0204A QR0280A QD0282A QY0284A QD0372A QY0374A QR0450A QD0452A QY0454A QR0600A QD0602A QY0604A QR0800A QD0802A QY0804A QR1000A QD1002A QY1004A QR1300A QD1302A QY1304A --QR1800A QD1802A QY1804A Self-Contained Water-Cooled QR0321W QD0323W QY0325W QR0421W QD0423W QY0425W QR0201W QD0203W QY0205W QR0281W QD028
General Information Section 1 Model/Serial Number Location These numbers are required when requesting information from your local Manitowoc distributor, or Manitowoc Ice, Inc. The model and serial number are listed on the MODEL/ SERIAL NUMBER DECAL affixed to the ice machine, remote condenser and storage bin. SV1600 Figure 1-1. Model/Serial Number Location 1-2 Part No.
Section 1 General Information Warranty Coverage EXCLUSIONS GENERAL The following items are not included in the ice machine’s warranty coverage: The following Warranty outline is provided for your convenience. For a detailed explanation, read the warranty bond shipped with each product. Contact your local Manitowoc Distributor or Manitowoc Ice, Inc. if you need further warranty information. Important This product is intended exclusively for commercial application.
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Section 2 Installation Instructions General Refer to Installation Manual for complete installation guidelines. Important Failure to follow these installation guidelines may affect warranty coverage. Ice Machine Dimensions Q320/Q370/Q420 ICE MACHINES WATER COOLED AIR COOLED SV1602 Ice Machine Q320 Q370 Q420 Part No. 80-1100-3 SV1611 Dimension H 21.5 in (54.6 cm) 21.5 in (54.6 cm) 26.5 in (67.
Installation Instructions Section 2 Q200 – Q1000 ICE MACHINES Q1300/Q1600/Q1800 ICE MACHINES WATER-COOLED SELF CONTAINED AIR-COOLED SV1612 AIR-COOLED SV1628 SELF CONTAINED WATER-COOLED SV1613 Ice Machine Q200 – Q280 Q450 Q600 Q800 Q1000 2-2 Dimension H 16.5 in (41.9 cm) 21.5 in (54.6 cm) 21.5 in (54.6 cm) 26.5 in (67.3 cm) 29.5 in (74.9 cm) SV1627 Ice Machine Q1300/Q1600 Q1800 Dimension H 29.5 in (74.9 cm) 29.5 in (74.9 cm) Part No.
Section 2 Installation Instructions Q1300/Q1600/Q1800 ICE MACHINES (CONT.) Ice Storage Bin Dimensions S170/S400/S570 ICE STORAGE BINS REMOTE AIR-COOLED SV1629 SV1609 Bin Model S170 S400 S570 Dimension A 29.5 in (74.9 cm) 34.0 in (86.3 cm) 34.0 in (86.3 cm) Dimension B 19.1 in (48.5 cm) 32.0 in (81.3 cm) 44.0 in (111.7 cm) S320/S420 ICE STORAGE BINS SV1614 Bin Model S320 S420 Part No. 80-1100-3 Dimension A 34.0 in (86.3 cm) 34.0 in (86.3 cm) Dimension B 32.0 in (81.3 cm) 44.0 in (111.
Installation Instructions Section 2 Remote Condenser Dimensions S970 ICE STORAGE BINS JC0495/JC0895/JC1095/JC1395 SV1610 ! Warning SV1297 JC1895 All Manitowoc ice machines require the ice storage system (bin, dispenser, etc.) to incorporate an ice deflector. The Q1300, Q1600 and Q1800 series ice machines require adding Manitowoc Ice Deflector Kit K00139 when installing with non-Manitowoc ice storage systems.
Section 2 Installation Instructions Location of Ice Machine The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location. • The location must be free of airborne and other contaminants. • The air temperature must be at least 35°F (1.6°C), but must not exceed 110°F (43.4°C). • The location must not be near heat-generating equipment or in direct sunlight.
Installation Instructions Section 2 Leveling the Ice Storage Bin Air-Cooled Baffle 1. Screw the leveling legs onto the bottom of the bin. 2. Screw the foot of each leg in as far as possible. The air-cooled baffle prevents condenser air from recirculating. To install: 1. Remove the back panel screws next to the condenser. ! Caution The legs must be screwed in tightly to prevent them from bending. 2. Align the mounting holes in the air baffle with the screw holes and reinstall the screws. 3.
Section 2 Installation Instructions Electrical Service FUSE/CIRCUIT BREAKER GENERAL A separate fuse/circuit breaker must be provided for each ice machine. Circuit breakers must be H.A.C.R. rated (does not apply in Canada). ! Warning All wiring must conform to local, state and national codes. MINIMUM CIRCUIT AMPACITY VOLTAGE The minimum circuit ampacity is used to help select the wire size of the electrical supply. (Minimum circuit ampacity is not the ice machine’s running amp load.
Installation Instructions Section 2 Table 2-1. Q320/370/420 Ice Machines Voltage Phase Cycle Ice Machine Q320 Q370 Q420 115/1/60 208-230/1/60 230/1/50 115/1/60 208-230/1/60 230/1/50 115/1/60 208-230/1/60 230/1/50 Air-Cooled Maximum Fuse/ Minimum Circuit Breaker Circuit Amps 15 11.2 15 4.8 15 5.2 20 12.9 15 6.2 15 6.2 20 12.3 15 7.8 15 6.3 Water Cooled Maximum Fuse/ Minimum Circuit Breaker Circuit Amps 15 10.5 15 4.2 15 4.7 20 12.2 15 5.8 15 5.8 20 11.4 15 7.4 15 5.9 Table 2-2.
Section 2 Installation Instructions Self-Contained Electrical Wiring Connections ! Warning These diagrams are not intended to show proper wire routing, wire sizing, disconnects, etc., only the correct wire connections. SELF CONTAINED ICE MACHINE 208-230/3/60 All electrical work, including wire routing and grounding, must conform to local, state and national electrical codes. Though wire nuts are shown in the drawings, the ice machine field wiring connections may use either wire nuts or screw terminals.
Installation Instructions Section 2 Remote Electrical Wiring Connections REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 208-230/3/60 OR 380-415/3/50 ! Warning These diagrams are not intended to show proper wire routing, wire sizing, disconnects, etc., only the correct wire connections. All electrical work, including wire routing and grounding, must conform to local, state and national electrical codes.
Section 2 Installation Instructions Water Supply and Drain Requirements DRAIN CONNECTIONS WATER SUPPLY Follow these guidelines when installing drain lines to prevent drain water from flowing back into the ice machine and storage bin: Local water conditions may require treatment of the water to inhibit scale formation, filter sediment, and remove chlorine odor and taste.
Installation Instructions Section 2 WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS ! Caution Plumbing must conform to state and local codes. Location Water Temperature Water Pressure Ice Machine Fitting Ice Making Water Inlet 33°F (0.6°C) Min. 90°F (32.2°C) Max. 20 psi (137.9 kPA) Min. 80 psi (551.5 kPA) Max. 3/8" Female Pipe Thread Ice Making Water Drain --- --- Condenser Water Inlet 33°F (0.6°C) Min. 90°F (32.2°C) Max. 20 psi (137.9 kPA) Min. 150 psi (1034.2 kPA) Max.
Section 2 Installation Instructions Remote Condenser/Line Set Installation Ice Machine Q490 Q690 Q890 Q1090 Q1390 Q1690 Q1890 Remote Single Circuit Condenser JC0495 JC0895 JC1095 JC1395 JC1695 JC1895 Line Set* RT-20-R404A RT-35-R404A RT-50-R404A RL-20-R404A RL-35-R404A RL-50-R404A Additional refrigerant may be required for installations using line sets between 50' and 100' (15.25-30.5 m) long.
Installation Instructions Section 2 GENERAL GUIDELINES FOR ROUTING LINE SETS Condensers must be mounted horizontally with the fan motor on top. First, cut a 2.5" (6.35 cm) circular hole in the wall or roof for tubing routing. The line set end with the 90° bend will connect to the ice machine. The straight end will connect to the remote condenser. Remote condenser installations consist of vertical and horizontal line sets between the ice machine and the condenser.
Section 2 Installation Instructions Make the following calculations to make sure the line set layout is within specifications. CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES Line Set Length 1. Insert the measured rise into the formula below. Multiply by 1.7 to get the calculated rise. (Example: A condenser located 10 feet above the ice machine has a calculated rise of 17 feet.) The maximum length is 100' (30.5 m). The ice machine compressor must have the proper oil return.
Installation Instructions Section 2 LENGTHENING OR REDUCING LINE SET LENGTHS REMOTE RECEIVER SERVICE VALVE In most cases, by routing the line set properly, shortening will not be necessary. When shortening or lengthening is required, do so before connecting the line set to the ice machine or the remote condenser. This prevents the loss of refrigerant in the ice machine or condenser. The receiver service valve is closed during shipment. Open the valve prior to starting the ice machine.
Section 2 Installation Instructions Remote Ice Machine Usage with Non-Manitowoc Multi-Circuit Condensers WARRANTY FAN MOTOR The sixty (60) month compressor warranty, including thirty six (36) month labor replacement warranty, shall not apply when the remote ice machine is not installed within the remote specifications. The foregoing warranty shall not apply to any ice machine installed and/or maintained inconsistent with the technical instructions provided by Manitowoc Ice, Inc.
Installation Instructions Section 2 NON-MANITOWOC MULTI-CIRCUIT CONDENSER SIZING CHART Ice Machine Model Refrigerant Heat of Rejection Internal Condenser Volume (cu ft) Peak Btu/hr 9,600 13,900 Min Max 6 lbs. 8 lbs. Average Btu/hr 7,000 9,000 0.020 0.045 0.035 0.060 8 lbs. 9.5 lbs. 14 lbs.1 17 lbs.1 17 lbs. 12,400 16,000 24,000 36,000 36,000 19,500 24,700 35,500 50,000 50,000 0.045 0.065 0.085 0.130 0.130 0.060 0.085 0.105 0.170 0.
Section 2 Installation Check List Installation Instructions Are the ice machine and bin drains vented? Is the Ice Machine level? Has all of the internal packing been removed? Are all electrical leads free from contact with refrigeration lines and moving equipment? Have all of the electrical and water connections been made? Has the owner/operator been instructed regarding maintenance and the use of Manitowoc Cleaner and Sanitizer? Has the supply voltage been tested and checked against the rating on the
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Section 3 Maintenance Component Identification AIR CONDENSER HARVEST VALVE CONDENSER WATER REGULATING VALVE REMOTE COUPLINGS WATER DUMP VALVE COMPRESSOR WATER CONDENSER DRAIN HOSE DISTRIBUTION TUBE ICE THICKNESS PROBE EVAPORATOR WATER COOLED MODEL SV1604G HIGH PRESSURE CUTOUT/ MANUAL RESET (When applicable) ICE/OFF/CLEAN SWITCH WATER PUMP WATER CURTAIN WATER TROUGH SV1605 BIN SWITCH Figure 3-1. Component Identification (Typical Q450 Shown) Part No.
Maintenance Section 3 Operational Checks ICE THICKNESS CHECK GENERAL The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8" (3.2 mm). Manitowoc ice machines are factory-operated and adjusted before shipment. Normally, new installations do not require any adjustment.
Section 3 Maintenance Cleaning the Condenser HARVEST SEQUENCE WATER PURGE The harvest sequence water purge adjustment may be used when the ice machine is hooked up to special water systems, such as a de-ionized water treatment system. ! Warning Disconnect electric power to the ice machine and the remote condenser at the electric service switch before cleaning the condenser. Important The harvest sequence water purge is factory-set at 45 seconds.
Maintenance Section 3 3. Shine a flashlight through the condenser to check for dirt between the fins. If dirt remains: WATER-COOLED CONDENSER AND WATER REGULATING VALVE A. Blow compressed air through the condenser fins from the inside. Be careful not to bend the fan blades. Symptoms of restrictions in the condenser water circuit include: • Low ice production B. Use a commercial condenser coil cleaner. Follow the directions and cautions supplied with the cleaner.
Section 3 Maintenance Interior Cleaning and Sanitizing GENERAL Clean and sanitize the ice machine every six months for efficient 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 or installation of AuCS accessory (Automatic Cleaning System). If required, an extremely dirty ice machine may be taken apart for cleaning and sanitizing.
Maintenance Section 3 CLEANING PROCEDURE Ice machine cleaner is used to remove lime scale or other mineral deposits. It is not used to remove algae or slime. Refer to the section on Sanitizing for removal of algae and slime. Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle. Or, set the switch to the OFF position and allow the ice to melt off the evaporator. ! Caution Never use anything to force ice from the evaporator. Damage may result.
Section 3 Maintenance SANITIZING PROCEDURE Use sanitizer to remove algae or slime. Do not use it to remove lime scale or other mineral deposits. Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle. Or, set the switch to the OFF position and allow the ice to melt off the evaporator. Step 4 Use the sanitizing solution and a sponge or cloth to sanitize (wipe) all parts and interior surfaces of the ice machine. Sanitize the following areas: A.
Maintenance Section 3 AUTOMATIC CLEANING SYSTEM (AuCS) This accessory monitors ice making cycles and initiates cleaning (or sanitizing) procedures automatically. The AuCS Accessory can be set to automatically clean or sanitize the ice machine every 2, 4, or 12 weeks. Manual Start Operation Step 1 Set the toggle switch to the OFF position after ice falls from the evaporator at the end of a Harvest cycle. Or, set the switch to the OFF position and allow the ice to melt off the evaporator.
Section 3 Maintenance REMOVAL OF PARTS FOR CLEANING/SANITIZING 1. Turn off the water supply to the ice machine at the water service valve. 4. Use a soft-bristle brush or sponge (NOT a wire brush) to carefully clean the parts. ! Caution ! Warning Disconnect electric power to the ice machine at the electric switch box before proceeding. 2. Remove the water curtain and the components you want to clean or sanitize. See the following pages for removal procedures for these parts.
Maintenance Section 3 Water Dump Valve The water dump valve normally does not require removal for cleaning. To determine if removal is necessary: 1. Locate the water dump valve. 2. Set the toggle switch to ICE. 3. While the ice machine is in the freeze mode, check the dump valve’s clear plastic outlet drain hose for leakage. A. If the dump valve is leaking, remove, disassemble and clean it. B. If the dump valve is not leaking, do not remove it. Instead, follow the “Cleaning Procedure” on Page 3-5.
Section 3 Maintenance Ice Thickness Probe Water Pump 1. Compress the side of the ice thickness probe near the top hinge pin and remove it from the bracket. ! Warning Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply. 1. Disconnect the water pump power cord. DISCONNECT WIRE LEAD COMPRESS HINGE PIN TO REMOVE POWER CORD LOOSEN SCREWS WATER PUMP ICE THICKNESS PROBE SV1619 Figure 3-10.
Maintenance Section 3 Water Level Probe 1. Loosen the screw that holds the water level probe in place. The probe can easily be cleaned at this point without proceeding to step 2. ! Warning Disconnect the electrical power to the ice machine at the electrical disconnect before proceeding. 2. If complete removal is required, disconnect the wire lead from the control board inside the electrical control box. Follow the procedure below to remove the water inlet valve.
Section 3 Maintenance Water Curtain Water Distribution Tube 1. Disconnect the water hose from the distribution tube. 3 1. LIFT UP 2. SLIDE BACK 3. SLIDE TO RIGHT 1. Gently flex the curtain in the center and remove it from the right side. 2 1 DISTRIBUTION TUBE THUMBSCREW STEP 1 LOCATING PIN STEP 2 THUMBSCREW SV1213 SV1620 Figure 3-14. Water Distribution Tube Removal 1. Loosen the two thumbscrews which secure the distribution tube. Figure 3-16. Water Curtain Removal 2. Slide the left pin out. 2.
Maintenance Section 3 Water Treatment/Filtration 3. Unscrew the housing from the cap. GENERAL 4. Remove the used filter cartridge from the housing and discard it. Local water conditions may require the installation of a water treatment system to inhibit scale formation, filter out sediment, and remove chlorine taste and odor. Consult your local distributor for information on Manitowoc’s full line of NSF-certified Tri-Liminator filtration systems.
Section 3 Maintenance Removal from Service/Winterization GENERAL Special precautions must be taken if the ice machine is to be removed from service for an extended period of time or exposed to ambient temperatures of 32°F (0°C) or below. ! Caution WATER-COOLED ICE MACHINES 1. Perform steps 1-6 under “Self-Contained Air-Cooled Ice Machines.” 2. Disconnect the incoming water and drain lines from the water-cooled condenser. 3.
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Section 4 Ice Machine Sequence of Operation Self-Contained Air- and Water-Cooled Q200/Q280/Q320/Q370/Q420/Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 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 completely purge the ice machine of old water. This feature ensures that the ice making cycle starts with fresh water.
Ice Machine Sequence of Operation Section 4 HARVEST SEQUENCE AUTOMATIC SHUT-OFF 5. Water Purge 7. Automatic Shut-Off 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.
Section 4 Ice Machine Sequence of Operation Remote Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 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 completely purge the ice machine of old water. This feature ensures that the ice making cycle starts with fresh water.
Ice Machine Sequence of Operation Section 4 HARVEST SEQUENCE AUTOMATIC SHUT-OFF 5. Water Purge 7. Automatic Shut-Off 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.
Section 5 Water System Ice Making Sequence of Operation NOTE: The sequence of operation is the same for selfcontained and remote models. INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF 1. Before the ice machine starts, the water pump and water dump solenoid are energized for 45 seconds to purge old water from the water trough. This ensures that the ice-making cycle starts with fresh water.
Water System Ice Making Sequence of Operation Section 5 AUTOMATIC SHUT-OFF HARVEST CYCLE 4. The water pump and water dump solenoid are energized for 45 seconds to purge the water from the water trough. The water fill valve energizes for the last 15 seconds of the 45-second purge cycle, to flush sediment from the bottom of the water trough. There is no water flow during an automatic shut-off. 5. After the 45-second purge, the water pump and water dump valve de-energize.
Section 6 Electrical System Energized Parts Charts SELF-CONTAINED AIR- AND WATER-COOLED MODELS Ice Making Sequence Of Operation START-UP 1 1. Water Purge 2. Refrigeration System Start-Up FREEZE SEQUENCE 3. Pre-Chill 4.
Electrical System Section 6 REMOTE MODELS 1 Ice Making Sequence Of Operation START-UP 1 1. Water Purge 2. Refrigeration System Start-Up FREEZE SEQUENCE 3. Pre-Chill 2 Control Board Relays 3 4 a. Harvest Valve(s) Contactor Water Dump Valve 5 a. Contactor Coil b. Liquid Line Solenoid 5A 5B Compressor Condenser Fan Motor Length Of Time Water Pump Water Fill Valve On Off On On Off Off Off 45 Seconds Off On On Off On On On 5 Seconds Off Off On On On 30 Seconds Until 7 sec.
Section 6 Electrical System Wiring Diagram Sequence of Operation SELF-CONTAINED MODELS SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (61) WATER VALVE (60) Initial Start-Up or Start-Up After Automatic Shut-Off HIGH PRES CUTOUT (77) 2 1 (76) 3 (57) (58) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL (62) The harvest valve(s) is also energized during the water purge.
Electrical System Section 6 2. REFRIGERATION SYSTEM START-UP The compressor starts after the 45second water purge, and it remains on throughout the Freeze and Harvest cycles. SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (61) WATER VALVE (60) HIGH PRES CUTOUT (77) 2 1 (57) (58) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C.
Section 6 Electrical System Freeze Sequence SEE SERIAL PLATE FOR VOLTAGE 3. PRE-CHILL To pre-chill the evaporator, the compressor runs for 30 seconds prior to water flow. L2 (N) L1 (61) WATER VALVE (60) HIGH PRES CUTOUT (77) 2 (80) HARVEST SOLENOID 4 The water fill valve remains on until the water level sensor closes for three continuous seconds.
Electrical System Section 6 4. FREEZE SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 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. (20) (61) WATER VALVE (60) HIGH PRES CUTOUT (77) 2 1 (76) 3 After six minutes the water inlet valve is locked out and can not add additional water. (57) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C.
Section 6 Electrical System Harvest Sequence SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 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 deenergizes (turns off) strictly by time. The water fill valve energizes for the last 15 seconds of the 45-second water purge.
Electrical System Section 6 6. HARVEST SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 The harvest 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. (20) (55) TB32 WATER VALVE (60) HIGH PRES CUTOUT (77) 2 (80) HARVEST SOLENOID 4 1 (76) 3 The sliding sheet of cubes swings the water curtain out, opening the bin switch.
Section 6 Electrical System Automatic Shut-Off 7. AUTOMATIC SHUT-OFF SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 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. (61) WATER VALVE (60) HIGH PRES CUTOUT (77) 2 1 (76) 3 (57) (58) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C.
Electrical System Section 6 REMOTE MODELS SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (21) (20) Initial Start-Up Or Start-Up After Automatic Shut-Off TB32 TB35 (55) HPR SOLENOID (61) (60) 1. WATER PURGE HIGH PRES CUTOUT 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.
Section 6 Electrical System 2. REFRIGERATION SYSTEM START-UP The compressor, remote condenser fan motor and liquid line solenoid valve energize after the 45-second water purge, and remain on throughout the Freeze and Harvest cycles. SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (20) TB32 TB35 (55) (60) (78) (77) 4 HARVEST SOLENOID (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 TRANS.
Electrical System Section 6 Freeze Sequence SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 3. PRE-CHILL To pre-chill the evaporator, the compressor runs for 30 seconds prior to water flow. (21) (20) TB32 TB35 (55) HPR SOLENOID (61) (60) HIGH PRES CUTOUT (78) (77) 4 HARVEST SOLENOID (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 TRANS.
Section 6 Electrical System 4. FREEZE SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 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. (20) TB32 TB35 (55) (21) HPR SOLENOID (61) (60) HIGH PRES CUTOUT (78) (77) 4 HARVEST SOLENOID (57) TB31 TRANS.
Electrical System Section 6 Harvest Sequence SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 (20) 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 deenergizes (turns off) strictly by time. The water fill valve energizes for the last 15 seconds of the 45-second water purge.
Section 6 Electrical System 6. HARVEST SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 The harvest valve(s) and HPR solenoid valve remain 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. (21) (20) TB32 TB35 (55) HPR SOLENOID (61) (60) HIGH PRES CUTOUT (77) 4 HARVEST SOLENOID (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 TRANS.
Electrical System Section 6 Automatic Shut-Off SEE SERIAL PLATE FOR VOLTAGE L2 (N) L1 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. (21) (20) TB32 TB35 (55) HPR SOLENOID (61) (60) HIGH PRES CUTOUT (78) (77) 4 HARVEST SOLENOID (75) DUMP SOLENOID 5 (57) TB31 TRANS.
Section 6 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 Section 6 Q200/Q280/Q320 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE L1 SEE SERIAL PLATE FOR VOLTAGE (21) (20) (61) WATER VALVE (60) (55) TB32 2 TB35 (77) (80) HARVEST SOLENOID 4 1 HIGH PRES CUTOUT (76) 3 5 (75) (81) DUMP SOLENOID (57) TB31 (99) (98) TRANS.
Section 6 Electrical System Q280/Q370 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD L2 (N) SEE SERIAL PLATE FOR VOLTAGE (20) CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE L1 (21) (22) WATER VALVE (61) (60) (89) (55) (77) 2 HIGH PRES CUTOUT 3 (76) 1 (88) (80) HARVEST SOLENOID 4 5 (75) (81) DUMP SOLENOID FUSE (7A) (99) (98) (57) TRANS.
Electrical System Section 6 Q320 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. SEE SERIAL PLATE FOR VOLTAGE DIAGRAM SHOWN DURING FREEZE CYCLE L1 L2 (N) (20) WATER VALVE (61) (55) (89) (60) 2 4 (77) 1 (88) (80) HARVEST SOLENOID 3 HIGH PRES CUTOUT (22) (21) (75) (76) 5 DUMP SOLENOID (57) (99) (98) TRANS.
Section 6 Electrical System Q420/Q450/Q600/Q800/Q1000 - SELF CONTAINED 1 PHASE WITH TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING SEE SERIAL PLATE FOR VOLTAGE ON ELECTRICAL CIRCUITRY.
Electrical System Section 6 Q420/Q450/Q600/Q800/Q1000 - SELF CONTAINED 1 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING L1 L2 (N) ON ELECTRICAL CIRCUITRY. SEE SERIAL PLATE FOR VOLTAGE DIAGRAM SHOWN DURING FREEZE CYCLE (20) (61) (55) (89) HIGH PRES CUTOUT 2 (77) 4 (88) (22) (21) WATER VALVE HARVEST SOLENOID (60) 3 1 (80) (76) (75) DUMP SOLENOID 5 (57) TRANS.
Section 6 Electrical System Q800/Q1000 - SELF CONTAINED - 3 PHASE WITH TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. L1 L2 L3 DIAGRAM SHOWN DURING FREEZE CYCLE TB35 WATER VALVE (61) (60) HIGH PRES CUTOUT (77) 2 HARVEST SOLENOID 4 1 (55) (76) 5 DUMP SOLENOID (57) TB31 FUSE (7A) (80) (75) 3 TRANS.
Electrical System Section 6 Q800/Q1000 - SELF CONTAINED - 3 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY.
Section 6 Electrical System Q1300/Q1800 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE L1 L2(N) WATER VALVE (21) (20) (22) (55) TB32 RH HARVEST SOLENOID TB35 (61) (88) HIGH PRES CUTOUT (87) (60) (77) 2 4 LH HARVEST SOLENOID 1 (75) (76) 3 (57) (98) TB31 TRANS.
Electrical System Section 6 Q1300/Q1600/Q1800 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING SEE SERIAL PLATE FOR VOLTAGE ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE L1 L2 (N) (20) WATER VALVE (55) (89) (22) (21) (61) HIGH PRES CUTOUT (60) (77) 2 (88) (80) HARVEST SOLENOID 4 3 1 5 (75) (76) DUMP SOLENOID (81) (98) (99) (42) (57) TRANS.
Section 6 Electrical System Q1300/Q1800 - SELF CONTAINED - 3 PHASE WITH TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE L2 L1 L3 CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY.
Electrical System Section 6 Q1300/Q1600/Q1800 - SELF CONTAINED - 3 PHASE WITHOUT TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE L3 L2 L1 CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE (89) (20) (21) WATER VALVE (55) RH HARVEST SOLENOID (88) (61) (88) (60) HIGH PRES CUTOUT 2 (77) 4 (42) 3 1 (76) (57) N - 50HZ ONLY (75) DUMP SOLENOID TRANS.
Section 6 Electrical System Q450/Q600/Q800/Q1000 - REMOTE - 1 PHASE WITH TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE L1 SEE SERIAL PLATE FOR VOLTAGE L2 (N) (21) (20) (22) WATER VALVE TB32 (55) HPR SOLENOID (61) TB35 (60) HIGH PRES CUTOUT (78) (79) 2 (77) 4 HARVEST SOLENOID (80) 1 (75) (76) 3 5 (57) TB31 FUSE (7A) (99) (98) TRANS.
Electrical System Section 6 Q450/Q600/Q800/Q1000 - REMOTE - 1 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING SEE SERIAL PLATE FOR VOLTAGE ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE L1 L2 (N) (20) (89) (55) (21) (22) WATER VALVE HPR SOLENOID (61) (78) HIGH PRES CUTOUT (79) 2 (88) (60) 4 (88) (80) HARVEST SOLENOID 1 3 (77) DUMP SOLENOID 5 (81) (57) (99) TRANS.
Section 6 Electrical System Q800/Q1000 -REMOTE - 3 PHASE WITH TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE L3 L2 L1 CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE HPR SOLENOID (60) HIGH PRES CUTOUT (78) (79) HARVEST SOLENOID (80) (77) 2 4 1 DUMP SOLENOID 5 (57) TB31 TRANS.
Electrical System Section 6 Q800/Q1000 -REMOTE - 3 PHASE WITHOUT TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE L3 L2 L1 CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE (21) (22) WATER VALVE (20) (55) (89) (61) (60) HIGH PRES CUTOUT (88) HPR SOLENOID (78) 2 (77) 4 HARVEST SOLENOID 3 1 (42) (98) (57) TRANS.
Section 6 Electrical System Q1300/Q1800 - REMOTE - 1 PHASE WITH TERMINAL BOARD SEE SERIAL PLATE FOR VOLTAGE CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE WATER VALVE (21) (20) L2 (N) (22) HPR SOLENOID L1 RH HARVEST SOLENOID (55) TB32 TB35 (61) HIGH PRES CUTOUT (78) (79) (88) (87) (60) (77) 2 4 LH HARVEST SOLENOID 1 (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 (98) (99) TRANS.
Electrical System Section 6 Q1300/Q1600/Q1800 - REMOTE - 1 Phase Without Terminal Board CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE L2 (N) (20) (21) (22) WATER VALVE HPR SOLENOID L1 (89) (78) (79) (88) (87) RH HARVEST SOLENOID (55) (61) HIGH PRES CUTOUT (77) 2 (80) LH HARVEST SOLENOID (60) 4 (88) 1 (76) 3 (57) TRANS.
Section 6 Electrical System Q1300/Q1800 - REMOTE - 3 PHASE WITH TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY.
Electrical System Section 6 Q1300/Q1600/Q1800 - REMOTE - 3 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. SEE SERIAL PLATE FOR VOLTAGE L3 L2 DIAGRAM SHOWN DURING FREEZE CYCLE (21) (22) WATER VALVE (20) N - 50 HZ ONLY HPR SOLENOID L1 (79) (78) (89) (55) LH HARVEST SOLENOID (61) (77) 2 4 (88) (60) RH HARVEST SOLENOID 3 1 (76) 5 (42) (57) (59) 1F (83) LOW D.C.
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Electrical System Section 6 Component Specifications and Diagnostics MAIN FUSE BIN SWITCH Function Function The control board fuse stops ice machine operation if electrical components fail causing high amp draw. Movement of the water curtain controls bin switch operation. 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.
Section 6 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. 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.
Electrical System Section 6 COMPRESSOR ELECTRICAL DIAGNOSTICS Determine if the Compressor is Seized The compressor will not start or will trip repeatedly on overload. Check the amp draw while the compressor is trying to start. Check Resistance (Ohm) Values COMPRESSOR DRAWING LOCKED ROTOR NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter. The two likely causes of this are: Perform the resistance test after the compressor cools.
Section 6 Electrical System PTCR DIAGNOSTICS Compressor Start Sequence What is a PTCR? PTCR’s provide additional starting torque by increasing the current in the auxiliary (start) winding during starting. The PTCR is wired across the run capacitor (in series with the start winding). A PTCR (or Positive Temperature Coefficient Resistor) is made from high-purity, semi-conducting ceramics. A PTCR is useful because of its resistance versus temperature characteristic.
Electrical System Section 6 Q-Model Automatic Shut-Off and Restart Troubleshooting PTCR’s 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.
Section 6 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.) • The compressor discharge and suction pressures are not matched closely enough or equalized.
Electrical System Section 6 ICE/OFF/CLEAN TOGGLE SWITCH CONTROL BOARD RELAYS Function Function The switch is used to place the ice machine in ICE, OFF or CLEAN mode of operation. The control board relays energize and de-energize system components. Specifications Specifications Double-pole, double-throw switch. The switch is connected into a varying low D.C. voltage circuit. Relays are not field replaceable.
Section 6 Electrical System ELECTRONIC CONTROL BOARD AC LINE VOLTAGE ELECTRICAL PLUG (NUMBERS MARKED ON WIRES) CLEAN LIGHT YELLOW 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 JUMPER USED ON Q1300/Q1600/ Q1800 ONLY 1G 67 68 62 DC LOW VOLTAGE ELECTRICAL PLUG (NUMBERS MARKED ON WIRES) 63 65 SV1588 Figure 6-19.
Electrical System Section 6 General Inputs Q-Model control boards use a dual voltage transformer. This means only one control board is needed for both 115V and 208-230V use. The control board, along with inputs, controls all electrical components, including the ice machine sequence of operation. Prior to diagnosing, you must understand how the inputs affect the control board operation.
Section 6 Electrical System Ice Thickness Probe (Harvest Initiation) MAXIMUM FREEZE TIME HOW THE PROBE WORKS The control system includes a built-in safety which will automatically cycle the ice machine into harvest after 60 minutes in the freeze cycle. 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.
Electrical System Section 6 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.
Section 6 Electrical System Ice Machine Cycles Into Harvest Before Water Contact With The Ice Thickness 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, then monitor the harvest light. Step 2 Disconnect the ice thickness probe from the control board at terminal 1C. ICE THICKNESS PROBE CLEAN LIGHT WATER LEVEL LIGHT BIN SWITCH LIGHT HARVEST/SAFETY LIMIT LIGHT SV3011 SV1588 Figure 6-24.
Electrical System Section 6 Water Level Control Circuitry FREEZE CYCLE CIRCUITRY WATER LEVEL PROBE LIGHT Manitowoc’s electronic sensing circuit does not rely on float switches or timers to maintain consistent water level control. During the freeze cycle, the water inlet valve energizes (turns on) and de-energizes (turns off) in conjunction with the water level probe located in the water trough. The water level probe circuit can be monitored by watching the water level light.
Section 6 Electrical System DIAGNOSING FREEZE CYCLE POTABLE WATER LEVEL CONTROL CIRCUITRY Problem: Water Trough Overfilling During The Freeze Cycle Step 2 Wait until the freeze cycle starts (approximately 45 seconds, the freeze cycle starts when the compressor energizes) then connect a jumper from the water level probe to any cabinet ground. Step 1 Start a new freeze sequence by moving the ICE/ OFF/CLEAN toggle switch to OFF, then back to ICE.
Electrical System Section 6 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. 1 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.
Section 6 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. Step 2 Wait until the freeze cycle starts (approximately 45 seconds, the freeze cycle starts when the compressor energizes), and then refer to chart. Important This restart must be done prior to performing diagnostic procedures.
Electrical System Section 6 Diagnosing An 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 1 2 3 4 5 6 7 Check Verify primary voltage supply to ice machine. Verify the high-pressure cutout is closed. Verify control board fuse is OK. Verify the bin switch functions properly.
Section 6 Electrical System Q0420/Q0450/Q0600/Q0800/Q1000 - SELF CONTAINED 1 PHASE WITH TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING SEE SERIAL PLATE FOR VOLTAGE ON ELECTRICAL CIRCUITRY.
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Section 7 Refrigeration System Sequence of Operation SELF-CONTAINED AIR OR WATER -COOLED MODELS EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HARVEST SOLENOID VALVE X AIR OR WATER CONDENSER COMPRESSOR STRAINER DRIER RECEIVER (WATER COOLED ONLY) HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR SV1569 Figure 7-1.
Refrigeration System Section 7 E V A P O R A TO R HEAT EXCH A N G E R EXPANSION VALVE HARVEST SOLENOID VALVE COMPRESSOR STRAINER AIR OR WATER CONDENSER DRI ER RECEIVER ( WA T E R C O O L E D O N L Y ) HIGH PRESSURE VAP O R HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR SV1570 Figure 7-2. Self-Contained Harvest Cycle (Models Q200/Q280/Q320/Q370/Q420/Q450/Q600/Q800/Q1000) Harvest Cycle Refrigeration Sequence Hot gas flows through the energized harvest valve, heating the evaporator.
Section 7 Refrigeration System REMOTE MODELS EVAPORATOR HEAT EXCHANGER EXPANSION VALVE STRAINER X COMPRESSOR HARVEST SOLENOID VALVE REMOTE CONDENSER CHECK VALVE LIQUID LINE SOLENOID VALVE HARVEST PRESSURE REGULATING VALVE HEAD PRESSURE CONTROL VALVE X DRIER H.P.R. SOLENOID VALVE R CHECK VALVE B C RECEIVER SERVICE VALVE RECEIVER HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR SV1566 Figure 7-3.
Refrigeration System Section 7 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE STRAINER COMPRESSOR HARVEST SOLENOID VALVE REMOTE CONDENSER CHECK VALVE LIQUID LINE SOLENOID VALVE HEAD PRESSURE CONTROL VALVE HARVEST PRESSURE REGULATING VALVE DRIER RECEIVER SERVICE VALVE B H.P.R. SOLENOID VALVE R CHECK VALVE C RECEIVER HIGH PRESSURE VAPOR HIGH PRESSURE LIQUID LOW PRESSURE LIQUID LOW PRESSURE VAPOR SV1567 Figure 7-4.
Section 7 Refrigeration System EVAPORATOR HEAT EXCHANGER EXPANSION VALVE STRAINER X COMPRESSOR HARVEST SOLENOID VALVE REMOTE CONDENSER CHECK VALVE X LIQUID LINE SOLENOID VALVE HEAD PRESSURE CONTROL VALVE HARVEST PRESSURE REGULATING VALVE DRIER X RECEIVER SERVICE VALVE H.P.R. SOLENOID VALVE B R CHECK VALVE C RECEIVER LIQUID/VAPOR EQUALIZED TO AMBIENT CONDITIONS SV1568 Figure 7-5.
Refrigeration System Section 7 Q1300/Q1600/Q1800 REFRIGERATION TUBING SCHEMATICS EVAPORATOR HEAT EXCHANGE HARVEST SOLENOID VALVE EXPANSION VALVE x x EXPANSION VALVE HARVEST SOLENOID VALVE STRAINER COMPRESSOR AIR OR WATER COOLED CONDENSER DRIER RECEIVER SV1512 Figure 7-6. Q1300/Q1600/Q1800 Self-Contained Air- or Water-Cooled Models NOTE: The refrigeration sequence for self-contained dual expansion valve ice machines is identical to selfcontained single expansion valve ice machines.
Section 7 Refrigeration System EVAPORATOR HEAT EXCHANGE EXPANSION VALVE x x EXPANSION VALVE HARVEST SOLENOID VALVE HARVEST SOLENOID VALVE X COMPRESSOR STRAINER LIQUID LINE SOLENOID VALVE REMOTE CONDENSER CHECK VALVE DRIER HARVEST PRESSURE REGULATING VALVE RECEIVER SERVICE VALVE X HEAD PRESSURE CONTROL VALVE B R CHECK VALVE C H.P.R. SOLENOID VALVE RECEIVER SV1513 Figure 7-7.
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.
Section 7 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. Ask these questions before beginning service: • • Refrigeration System 2. Refer to the appropriate 24 Hour Ice Production Chart.
Refrigeration System Section 7 INSTALLATION/VISUAL INSPECTION CHECKLIST Possible Problem Ice machine is not level Improper clearance around top, sides and/or back of ice machine Air-cooled condenser filter is dirty 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 Remote condenser line set is improperly installed 7-10 Corrective Action Level the ice machine Reinstall according to the Installation Manual
Section 7 Refrigeration System ICE FORMATION PATTERN 2. Extremely Thin at Evaporator Outlet Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. There is no ice, or a considerable lack of ice formation on the outlet of the evaporator (tubing outlet). Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction.
Refrigeration System Section 7 3. Extremely Thin at Evaporator Inlet 5. No Ice Formation There is no ice, or a considerable lack of ice formation on the intlet of the evaporator (tubing inlet). Examples: The ice at the outlet of the evaporator reaches 1/8" to initiate a harvest, but there is no ice formation at all on the intlet of the evaporator. The ice machine operates for an extended period, but there is no ice formation at all on the evaporator.
Section 7 Refrigeration System SAFETY LIMITS Control Board with Orange Label General When a safety limit condition is exceeded for 3 consecutive cycles the control board enters the limit into memory and the ice machine continues to run. Use the following procedures to determine if the control board contains a safety limit indication.
Refrigeration System Section 7 Analyzing Why Safety Limits May Stop the Ice Machine According to the refrigeration industry, a high percentage of compressors fail as a result of external causes. These can include: flooding or starving expansion valves, dirty condensers, water loss to the ice machine, etc. The safety limits protect the ice machine (primarily the compressor) from external failures by stopping ice machine operation before major component damage occurs.
Section 7 Refrigeration System Safety Limit #1 Refer to page 7-13 for control board identification and safety limit operation. Control Board with Black Microprocessor - Freeze Time exceeds 60 minutes for 3 consecutive freeze cycles or Control Board with Orange Label on Microprocessor - Freeze time exceeds 60 minutes for 6 consecutive freeze cycles.
Refrigeration System Section 7 Safety Limit #2 Refer to page 7-13 for control board identification and safety limit operation. Control Board with Black Microprocessor - Harvest time exceeds 3.5 minutes for 3 consecutive harvest cycles. or Control Board with Orange Label on Microprocessor - Harvest time exceeds 3.5 minutes for 500 consecutive harvest cycles.
Section 7 Refrigeration System 3. Perform an actual discharge pressure check. ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE Procedure 1. Determine the ice machine operating conditions: 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. (These charts begin on Page 7-33.
Refrigeration System Section 7 NOTE: Analyze discharge pressure before analyzing suction pressure. High or low discharge pressure may be causing high or low suction pressure. ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperatures entering the ice machine change. This affects freeze cycle times.
Section 7 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” on Page 7-10 Discharge pressure is too high, and is affecting low side (See “Freeze Cycle Discharge Pressure High Checklist” on Page 7-16) Overcharged Wrong type of refrigerant Non-Manitowoc components in system H.P.R.
Refrigeration System SINGLE EXPANSION VALVE ICE MACHINES COMPARING EVAPORATOR INLET AND OUTLET TEMPERATURES NOTE: This procedure will not work on the dual expansion valve Q1300 Q1600 and Q1800 ice machines. The temperatures of the suction lines entering and leaving the evaporator alone cannot diagnose an ice machine. However, comparing these temperatures during the freeze cycle, along with using Manitowoc’s Refrigeration System Operational Analysis Table, can help diagnose an ice machine malfunction.
Section 7 Refrigeration System HARVEST VALVE TEMPERATURE CHECK NOTE: This procedure requires checking both harvest valves on dual expansion valve Q1300 and Q1800 ice machines. General A harvest 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.
Refrigeration System Section 7 DISCHARGE LINE TEMPERATURE ANALYSIS Procedure General Connect a temperature probe on the compressor discharge line with-in 6" of the compressor and insulate. Knowing if the discharge line temperature is increasing, decreasing or remaining constant can be an important diagnostic tool. Maximum compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle.
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Refrigeration System HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES General These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear defective. The tables list five different defects that may affect the ice machine’s operation.
Section 7 Refrigeration System REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES Q, J and B Model Single Expansion Valve 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 Section 7 Q and J Model Dual Expansion Valve 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.
Section 7 Refrigeration System Figure 7-13. H.P.R. Valve HARVEST PRESSURE REGULATING (H.P.R.) SYSTEM Remotes Only GENERAL The harvest pressure regulating (H.P.R.) system includes: • Harvest pressure regulating solenoid valve (H.P.R. solenoid). This is an electrically operated valve which opens when energized, and closes when deenergized. INLET OUTLET FLOW SV1427 Figure 7-12. H.P.R. Solenoid • Harvest pressure regulating valve (H.P.R. valve).
Refrigeration System Section 7 FREEZE CYCLE The H.P.R. system is not used during the freeze cycle. The H.P.R. solenoid is closed (de-energized), preventing refrigerant flow into the H.P.R. valve. HARVEST CYCLE During the harvest cycle, the check valve in the discharge line prevents refrigerant in the remote condenser and receiver from backfeeding into the evaporator and condensing to liquid. The H.P.R.
Section 7 HPR DIAGNOSTICS Steps 1 through 4 can be quickly verified without attaching a manifold gauge set or thermometer. All questions must have a yes answer to continue the diagnostic procedure. 1. Liquid line warm? (Body temperature is normal) If liquid line is warmer or cooler than body temperature, refer to headmaster diagnostics. 2. Ice fill pattern normal? Refer to “Ice Formation Pattern” if ice fill is not normal. 3.
Refrigeration System Section 7 Diagnosing HEADMASTER CONTROL VALVE Manitowoc remote systems require headmaster control valves with special settings. Replace defective headmaster control valves only with “original” Manitowoc replacement parts. Operation The R404A headmaster control valve is non adjustable. At ambient temperatures of approximately 70°F (21.1°C) or above, refrigerant flows through the valve from the condenser to the receiver inlet.
Section 7 Refrigeration System LOW ON CHARGE VERIFICATION FAN CYCLE CONTROL VS. HEADMASTER The remote ice machine requires more refrigerant charge at lower ambient temperatures than at higher temperatures. A low on charge ice machine may function properly during the day, and then malfunction at night. Check this possibility. A fan cycle control cannot be used in place of a headmaster.
Refrigeration System Section 7 Pressure Control Specifications and Diagnostics FAN CYCLE CONTROL HIGH PRESSURE CUT-OUT (HPCO) CONTROL Function Stops the ice machine if subjected to excessive highside pressure. (Self-Contained Air-Cooled Models Only) Function Cycles the fan motor on and off to maintain proper operating discharge pressure. The fan cycle control closes on an increase, and opens on a decrease in discharge pressure.
Section 7 Refrigeration System Cycle Time/24 Hour Ice Production/ Refrigerant Pressure Charts Q200 SERIES Q200 SERIES NOTE: These characteristics may vary depending on operating conditions. Self-Contained Water-Cooled Self-Contained Air-Cooled NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Cycle Times Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.
Refrigeration System Section 7 Q280 SERIES Q280 SERIES Self-Contained Air-Cooled Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Section 7 Refrigeration System Q320 SERIES Q320 SERIES Self-Contained Air-Cooled Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Refrigeration System Section 7 Q370 SERIES Q370 SERIES Self-Contained Air-Cooled Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Section 7 Refrigeration System Q420/450 SERIES Q420/450 SERIES Self-Contained Air-Cooled Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.
Refrigeration System Section 7 Q450 SERIES Q600 SERIES Remote Self-Contained Air-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C -20/-28.9 to 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Section 7 Refrigeration System Q600 SERIES Q600 SERIES Self-Contained Water-Cooled Remote NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 7.4-8.7 7.5-8.9 7.
Refrigeration System Section 7 Q800 SERIES Q800 SERIES Self-Contained Air-Cooled Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Section 7 Refrigeration System Q800 SERIES Q1000 SERIES Remote Self-Contained Air-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C -20/-28.9 to 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Refrigeration System Section 7 Q1000 SERIES Q1000 SERIES Self-Contained Water-Cooled Remote NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 10.0-10.7 10.
Section 7 Refrigeration System Q1300 SERIES Q1300 SERIES Self-Contained Air-Cooled Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.
Refrigeration System Section 7 Q1300 SERIES Q1600 SERIES Remote Self-Contained Water-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C -20/-28.9 to 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Time Water Temperature °F/°C 50/10.0 70/21.
Section 7 Refrigeration System Q1600 SERIES Q1800 SERIES Remote Self-Contained Air-Cooled NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °F/°C -20 to 70 -29 to 21.1 90/32.2 100/37.8 110/43.3 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 7.
Refrigeration System Section 7 Q1800 SERIES Q1800 SERIES Self-Contained Water-Cooled Remote NOTE: These characteristics may vary depending on operating conditions. NOTE: These characteristics may vary depending on operating conditions. Cycle Times Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time + Harvest Time = Total Cycle Time Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 8.7-9.6 9.0-9.
Section 7 Refrigeration System Refrigerant Recovery/Evacuation and Recharging NORMAL SELF-CONTAINED MODEL PROCEDURES SELF-CONTAINED RECOVERY/EVACUATION Refrigerant Recovery/Evacuation 1. Place the toggle switch in the OFF position. Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. 2. Install manifold gauges, charging cylinder/scale, and recovery unit or two-stage vacuum pump. MANIFOLD SET Important Manitowoc Ice, Inc.
Refrigeration System Section 7 2. Close the vacuum pump valve, the low side service valve, and the low side manifold gauge valve. 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. 4. Open the charging cylinder and add the proper refrigerant charge (shown on nameplate) through the discharge service valve. 5.
Section 7 Refrigeration System NORMAL REMOTE 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 Section 7 EV A PO RAT O R HEAT E X CHANGER EX PANSIO N V A LV E x H O T GAS SO LEN O ID V A LV ES LO W SIDE SER V ICE V A LV E (BAC K SEATED ) C O M PRESS O R STRAINER HAR V EST PRESS U RE SO LEN O ID V A LV E CHEC K V A LV E x HAR V EST PRESS U RE REG U LATING V A LV E x HIGH SIDE SER V ICE V A LV E (BAC K SEATED ) LIQU ID LINE SO LEN O ID DISCHARGE LINE QU ICK CO NNECT SCHRAEDER FITTING DRIER RE M O TE CO NDENSER RECEI V ER SER V ICE V A LV E 1/2 O PEN B CHEC K V A LV
Section 7 Remote Charging Procedures 1. Be sure the toggle switch is in the OFF position. 2. Close the vacuum pump valve, the low and high side service valves (frontseat), and the low side manifold gauge valve. Refrigeration System NOTE: Backseat the receiver outlet service valve after charging is complete and before operating the ice machine.
Refrigeration System Section 7 EV A PO RAT O R HEAT E X CHANGER EX PANSIO N V A LV E H O T GAS SO LEN O ID V A LV ES x LO W SIDE SER V ICE V A LV E (BAC K SEATED ) STRAINER C O M PRESS O R HAR V EST PRESS U RE SO LEN O ID V A LV E CHEC K V A LV E x HAR V EST PRESS U RE REG U LATING V A LV E x HIGH SIDE SER V ICE V A LV E (BAC K SEATED ) LIQU ID LINE SO LEN O ID DISCHARGE LINE QU ICK CO NNECT SCHRAEDER FITTING DRIER RE M O TE CO NDENSER RECEI V ER SER V ICE V A LV E 1/2 O PEN B CHEC K V A L
Section 7 Refrigeration System SYSTEM CONTAMINATION CLEAN-UP 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. If either condition is found, or if contamination is suspected, use a Total Test Kit from Totaline or a similar diagnostic tool.
Refrigeration System Mild System Contamination Cleanup Procedure Section 7 Severe System Contamination Cleanup Procedure 1. Replace any failed components. 1. Remove the refrigerant charge. 2. If the compressor is good, change the oil. 2. Remove the compressor. 3. Replace the liquid line drier. 3. Disassemble the harvest solenoid valve. If burnout deposits are found inside the valve, install a rebuild kit, and replace manifold strainer, TXV and harvest pressure regulating valve.
Section 7 Refrigeration System 10. 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. REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE This procedure reduces repair time and cost. Use it when any of the following components require replacement, and the refrigeration system is operational and leak-free.
Refrigeration System Section 7 SV1406 Figure 7-18. Using Pinch-Off Tool 7-56 Part No.
Section 7 Refrigeration System TOTAL SYSTEM REFRIGERANT CHARGES FILTER-DRIERS The filter-driers used on Manitowoc ice machines are manufactured to Manitowoc specifications. The difference between Manitowoc driers and off-theshelf driers is in filtration. Manitowoc driers have dirtretaining filtration, with fiberglass filters on both the inlet and outlet ends. This is very important because ice machines have a back-flushing action which takes place during every harvest cycle.
Refrigeration System Section 7 REFRIGERANT DEFINITIONS Reclaim Recover To reprocess refrigerant to new product specifications (see below) by means which may include distillation. A chemical analysis of the refrigerant is required after processing to be sure that product specifications are met. This term usually implies the use of processes and procedures available only at a reprocessing or manufacturing facility.
Section 7 Refrigeration System REFRIGERANT RE-USE POLICY 3. Recovered or Recycled Refrigerant 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. • Must be recovered or recycled in accordance with current local, state and federal laws.
Refrigeration System HFC REFRIGERANT QUESTIONS AND ANSWERS 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. Part No. 80-1100-3 Refrigeration System 8.
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