Manitowoc Ice S1800 Bedienungsanleitung

Thank you for selecting a Manito woc Ice Machine, the de pendability leader in ice making equipment and re lated products. With proper inst allation, care and maintenance, your new Manitowoc Ice Machin e will provide you with many years of reliable and economical perfor mance. S1800 Marine Model Ice Machines Service Manual Part Number 80-1634-3 9/2[...]

We rese rve the right to make product imp rovement s at any time. S pecifications and design are subject to change without n otice. Safety Notices As you work on a S-Series Ice Machine, be sure to pay close attention to the safe ty notices in this manual. Disregarding the notices may lead to serious injury and/ or damage t o the ice ma chine. Throu[...]

Part No. 80-1634-3 1 T able of Content s Section 1 General Information Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . .[...]

Table of Contents (continued) 2 Part No. 80-1634-3 Section 3 Ice Machine Operation Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2 Initial Start-Up or St art-Up After Automati[...]

Table of Contents (continue d) Part No. 80-1634-3 3 Section 6 Electrical System Energized Parts Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Self-Contained Water-Cooled Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 Wiring Diagram Sequence of Operat ion . . . . . . . . . . . . [...]

Table of Contents (continued) 4 Part No. 80-1634-3 Refrigerant Recove ry/Evacuation and Rechar ging . . . . . . . . . . . . . . . . . . . . . 7-21 Normal Self-Contained Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . 7-21 System Contamination Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 Replacing [...]

Section 1 General Information Part Number 80-1634-3 1-1 Section 1 General Information Model Numbers This manual co vers the following models: NOTE: Model numbers ending in 3 indicate a 3-phase unit. Example: SY1805WM3 How to Read a Model Number Ice Cube Sizes Self-Cont ained Wa t e r - C o o l e d SR1801WM SD1803WM SY1805WM ! Warning PERSONAL INJUR[...]

General Information Section 1 1-2 Part Number 80-1634-3 Accessories Contact your Manito woc distributor for these op tional accessories: BIN CASTER Replaces sta ndard legs. ICE BAGGER Maximize profits fro m bagged ice sales with this convenient accessory . This sturdy unit rest s on the bin door frame, and adapts for left or right side filling. GUA[...]

Section 1 General Information Part Number 80-1634-3 1-3 Model/Serial Number Location These numbers are requir ed when requesting information from your local Manitowoc distributor , or Manitowoc Ice, Inc. The model and seria l number are listed on the MODEL/ SERIAL NUMBER DEC AL affixed to the ice m achine, remote cond enser and storag e bin. Model/[...]

General Information Section 1 1-4 Part Number 80-1634-3 Owner W arranty Registration Card GENERAL The packet cont aining this manual also includes warranty information. W arranty coverage begins the day your new ice machine is inst alled. If you do not return your OWNER W ARRAN TY REGISTRA TION CARD, Manitowoc will use the date of sale to the Manit[...]

Section 2 Installation Instructions Part Number 80-1634-3 2-1 Section 2 Inst allation Instructions General These instructions are provided to assist the qu alified installer . Check your local Y ellow Pages for the name of the nearest Manitowoc distributor , or call Manitowoc Ice, Inc. for informatio n regarding start-up service s. Ice Machine Dime[...]

Installation Instru ctions Section 2 2-2 Part Number 80-1634-3 Location of Ice Machine The location selected for the ice machine must m eet the following criteria. If any of these criteria ar e not met, select another location. • The location must be free of airborne an d other contamin ants. • The air t emperature must be at least 35°F (1 .6?[...]

Section 2 Installation Instructions Part Number 80-1634-3 2-3 Electrical Service GENERAL VO L T A G E The maximum allowable voltag e variation is ±10% o f the rated volt age at ice machine st art-up (when the electrical load is highest). Fuse/Circuit Breaker A separa te fuse/circuit br eaker must be provid ed for each ice machine. Circuit br eaker[...]

Installation Instru ctions Section 2 2-4 Part Number 80-1634-3 Self-Cont ained Electri cal Wiring Connections SELF CONT AINED ICE MA CHINE 1 15/1/60 OR 208-230/1/60 SELF CONT AINED ICE MACHINE 208-230/3/60 SELF CONT AINED ICE MACHINE 230/1/50 ! Warning These diagrams are not in tended to show prope r wire routing, wire sizin g, disconnects, etc., o[...]

Section 2 Installation Instructions Part Number 80-1634-3 2-5 W ater Supply and Drain Requirement s W ATER SUPPLY Local water conditions may require treatm ent of the water to inh ibit scale forma tion, filter sed iment, and remove chlor ine odor and t aste. W ATER INLET LINES Follow these guidelines to inst all w ater inlet lines: • Do not conne[...]

Installation Instru ctions Section 2 2-6 Part Number 80-1634-3 W ATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS T ypical W ater Supply Drain Inst allation ! Caution Plumbing must conform to state and local codes. Locatio n Wa t e r T e m p e r a t u r e W ate r Pressure Ice Machine Fitting T ubing Size Up to Ice Machine Fitting Ice Making W ater Inl[...]

Section 2 Installation Instructions Part Number 80-1634-3 2-7 Inst allation Check List F Is the Ice Machine level? F Has all of the interna l packing been removed? F Have all of the e lectrical and water connection s been made? F Has the su pply voltage been t ested and checked against the r ating on the nameplate? F Is there proper clear ance arou[...]

Installation Instru ctions Section 2 2-8 Part Number 80-1634-3 Before St arting the Ice Machine All Manitowoc ice machines are factory-operated an d adjusted before shipmen t. No rmally , new installations do not require any adjustment. T o ensure prop er operation , follow the Op erational Checks in Section 3 of this manual. S tarting the ice mach[...]

Section 3 Ice Machine Operation Part Number 80-1634-3 3-1 Section 3 Ice Machine Operation Component Identification sv3150 sv3149 Check V alve Ice Thickness Probe Dump V alve T oggle Switch W ater Curtain W ater Distribution T ube W a ter Level Probe W a ter Pump W ater Inlet Location W ater Inlet V alve (Located in Refrig eration Co mpartment) Bin [...]

Ice Machine Operation Section 3 3-2 Part Number 80-1634-3 Sequence Of Operation NOTE: The toggle switch must be in the ice position and the water curta in must be in place on the evaporator before the ice machine will start. INITIAL ST ART-UP OR START-UP AF TER AUTOMATIC SHUT-OFF 1. W a ter Purg e Before the compresso r start s, the water pump and [...]

Section 3 Ice Machine Operation Part Number 80-1634-3 3-3 HARVEST SEQUENCE 5. W a ter Purge The harvest valve(s) op ens at the beginning of the water purge to divert hot refrigerant gas into the evaporator . The water pump co ntinues to run, and th e water dump valve energizes for 45 seconds to pur ge the water in the sump trough. The water fi ll v[...]

Ice Machine Operation Section 3 3-4 Part Number 80-1634-3 Operational Checks GENERAL Manitowoc ice machines are factory-operated and adjusted before shipmen t. No rmally , new installations do not require any adjustment. T o ensure prop er operation , always follow th e Operational Checks: • when st arting the ice machine fo r the first time • [...]

Section 3 Ice Machine Operation Part Number 80-1634-3 3-5 HARVEST SEQUENCE W ATER PURGE The harvest sequence water purge ad justment may be used when the ice mach ine is hooked up to special water systems, such as a de-ionized water treatment system. • The harve st sequence w ate r purge is factory set for 45 seconds. Repositioning the jumper wil[...]

Ice Machine Operation Section 3 3-6 Part Number 80-1634-3 THIS P A GE INTENTIONALL Y LEFT BLANK[...]

Section 4 Maintenance Part Number 80-1634-3 4-1 Section 4 Maintenance General Y ou are responsib le for main ta ining the ic e machine in accordance with the instru ctions in this manual. Maintenance procedures ar e not covered by the warranty . We recommend th at you perfor m the follow ing maintenance procedures a minimum of once every six months[...]

Maintenance Section 4 4-2 Part Number 80-1634-3 Guardian ™ Slime is a leading cause of ice machine brea kdowns a nd biological growth is a health concern. The Guardia n ™ system releases chlorine dioxide on a controlled basis to inhi bit the growth of bacteria a nd fungi that form slime and cause malodo rs in the food zone of ice mac hines. The[...]

Section 4 Maintenance Part Number 80-1634-3 4-3 Interior Cleani ng and Sanitizing GENERAL Clean and san itize the ice machine every six months fo r efficient oper ation. If the ice machine requires more frequent cleaning and saniti zing, consu lt a qualified service company to test the water quality and recommend appropria te water treatment. An ex[...]

Maintenance Section 4 4-4 Part Number 80-1634-3 SANITIZING PROCEDURE Use sanitizer to remove algae or slime. Do not use it to remove lime scale or other mineral depo sits. Ste p 1 Set the toggle switch to the OFF positio n 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[...]

Section 4 Maintenance Part Number 80-1634-3 4-5 REMOVAL OF PARTS FOR CLEANING/SANITIZING 1. Turn of f the electrical and water supply to the ice machine (and disp ense r when applicable). 2. Remove all ice from the bin. 3. Remove the water curtain and the component s you want to clean or sanitize. See the followin g pages for removal pr ocedures fo[...]

Maintenance Section 4 4-6 Part Number 80-1634-3 1. Water Curt ain A. Gently flex the curt ain in the center a nd remove it from the right side. B. Slide the left pin ou t. W ater Curtain Removal 2. Ice Thickness Probe A. Compress the hinge pi n on the top of the ice thickness probe. Ice Thickness Probe Remo val B. Pivot the ice thickness pr obe to [...]

Section 4 Maintenance Part Number 80-1634-3 4-7 3. Water Distribution T ube NOTE: Distribution tube thumbscrews are ret ained by o- rings to prevent loss. Loosen thumbscre ws but do not pull thumbscre ws out of distributio n tube. W ater Distribution T ube Removal A. Remove outer half of distribution tube by loosening the four (4) thumbscrews (o- r[...]

Maintenance Section 4 4-8 Part Number 80-1634-3 W ater Level Probe 1. Remove t he water trou gh. 2. T he water level probe no rmally does not requ ire removal for cleaning. The p robe can be wiped and cleaned in place or proceed to step 3. 3. Pull the water level pr obe straight down to disengage . 4. Lower the water level probe until the wiring co[...]

Section 4 Maintenance Part Number 80-1634-3 4-9 W a ter Dump V alve The water dump va lve normally does not requ ire removal for cleaning. T o determine if removal is necessary: 1. Locate t he water dum p valve. 2. Set the toggle switch to ICE. 3. While the ice machine is in the freeze mode, c heck the dump valve’s clear plastic outlet drain hose[...]

Maintenance Section 4 4-10 Part Number 80-1634-3 Evaporator T ray Re moval 1. Remove t he water trou gh. 2. Remove thumbscrew on left side of tray . 3. Allow left side of tray to drop as you pull the tray to the left side. Continue un til the outlet tube disengages fro m the right side. Drain Line Check V alve The drain line check valve no rmally d[...]

Section 4 Maintenance Part Number 80-1634-3 4-11 W a ter Inlet V alve The water inlet valve norma lly does not require removal for cleaning. Refer to Sectio n 5 for a list of ca uses for “No W ater Entering W ater T rough” or “W ater Overflows W ater Tr ough. 1. When the ice machine is off, the water inlet valve must completely stop wate r fl[...]

Maintenance Section 4 4-12 Part Number 80-1634-3 Removal from Service/Winterization GENERAL S pecial precautions must be taken if the ice machine is to be removed from service for an extended period of time or exp osed to ambie nt temper atures of 3 2°F (0°C) or below . Follow the applicable pro cedure below . SELF-CONT AINED W ATER-COOLED ICE MA[...]

Section 5 Before Calling For Service Part Number 80-1634-3 5-1 Section 5 Before Calling For Service Checklist If a problem arises during operation of your ice machine, follow the checklis t below before calling service. Routine adjustment s and maintenance proced ures are not co vered by the wa rranty . Problem Possible Cau se T o Correct Ice machi[...]

Before Calling For Service Section 5 5-2 Part Number 80-1634-3 Safety Limit Feature In addition to the standard sa fety controls, such as the high pressure cutout, your Manitowoc ice machine features built-in safety lim its which will stop the ice machine if conditions arise which could cause a ma jor component failure. Before calling for service, [...]

Section 6 Electrical System Part Number 80-1634-3 6-1 Section 6 Electrical System Energized Part s Charts SELF-CONT AINED W ATER-COOLED MODELS 1. Initial S tart-Up or S tart-Up After Automatic Shut-Off * Not Used on all Models Condenser Fan Motor The fan motor is wired through a fan cycle pressure control, therefore, it may cycle on and off. Harves[...]

Electrical System Section 6 6-2 Part Number 80-1634-3 Wiring Diagram Sequence of Operation SELF-CONT AINED MODELS Initial St art-Up or St art-U p Af ter Automatic Shut -Off 1. W A TER PURGE Before the compressor starts, the water pump and wate r dump solenoid are energ ized for 45 seconds to purge old w ater from the ice machine. This ensu res that[...]

Section 6 Electrical System Part Number 80-1634-3 6-3 2. REFRIGERA TION SYSTEM ST ART -UP The compre ssor starts after the 45- second water purge, and it remains on throughou t the Freeze and Harvest cycles. The water fill valve is energized at the same t ime as the c ompressor . The harvest valve(s) remains on for the first 5 seconds of the initia[...]

Electrical System Section 6 6-4 Part Number 80-1634-3 Freeze Sequence 3. PRE-CHILL T o pre-chill the evaporator , the compressor runs for 30 seconds (60 seconds initial cycl e) prior to water flow . The water fill valve remains on until the water level probe is satisfied. Self-Contained — Pre-Chill T able 6-3. Self-Contained Mode ls 3. Pre-Chill [...]

Section 6 Electrical System Part Number 80-1634-3 6-5 4. FREEZE The water pump starts after the pre- chill. An even flow of water is directed across the evaporator an d into each cube cell, where it freezes. The water fill valve will cycle off then on one more time to refill the water trough. When sufficient ice has formed, the water flow (not the [...]

Electrical System Section 6 6-6 Part Number 80-1634-3 Harvest Sequence 5. W A TER PURGE The harvest valve(s) opens at the beginning of th e water purge to divert hot refrigerant ga s into the evaporator . The water pump continues to ru n, and the water dump valve energizes for 45 seconds to purge the water in the sump trough. The water fill valve e[...]

Section 6 Electrical System Part Number 80-1634-3 6-7 6. HARVEST The harvest valve(s) remains open and the refrigerant gas war ms the evaporator . This causes the cube s to slide, as a sheet, of f the evaporator and into the storage bin. The sliding sheet of cubes swings th e water curt ain out, opening the bin switch. This moment ary opening and c[...]

Electrical System Section 6 6-8 Part Number 80-1634-3 Automatic Shut -Off 7. AUTOMATIC SHUT-OFF When the storage bin is full at the end of a harvest cycle, the sheet of cubes fails to clear the w ater curtain and holds it open. Af ter the water curtain is held ope n for 30 seconds, the ice machine shuts off. The ice machine remains of f until enoug[...]

Section 6 Electrical System Part Number 80-1634-3 6-9 Wiring Diagra ms The following pages cont ain electrical wiring diagrams. Be sure you are referring to th e correct diagram for the ice machine whic h you are servicin g. WIRING DIAGRAM LEGEN D The following symbo ls are used on all of the wiring diag rams: * Internal Compressor Overload (Some m[...]

Electrical System Section 6 6-10 Part Number 80-1634-3 S1800 - SELF-CONTAINED - 1 PHASE (2) (1) R S CLEAN OFF ICE RUN CAPACITOR (50) (45) R (46) PTCR (AIR COOLED ONLY) FAN MOTOR RUN CAPACITOR** (86) (85) (51) (BLACK) *OVERLOAD C R COMPRESSOR (YELLOW) (RED) CONTACTOR L1 CONTACTS FAN CYCLE CONTROL (59) CLEAN LEFT BIN RIGHT BIN RMT BIN WTR PROBE ICE P[...]

Section 6 Electrical System Part Number 80-1634-3 6-11 S1800 - SELF-CONTAINED - 3 PHASE (42) CONTROL BOARD CLEAN OFF ICE BIN SWITCH (8) LOW D.C. VOLTAGE PLUG CONTACTOR COIL (56) TERMINATES AT PIN CONNECTION (74) PUMP WATER (58) ICE THICKNESS PROBE WATER LEVEL PROBE SOLENOID DUMP (81) (75) (76) LH HARVEST SOLENOID (87) (77) VALVE WATER (60) (61) (22[...]

Electrical System Section 6 6-12 Part Number 80-1634-3 Component Specifications and Diagnostics MAIN FUSE Function The control board fuse stop s ice machine operation if electrical c omponents fail ca using high a mp draw . Specifications The main fuse is 250 V olt, 7 amp. Check Procedure 1. If the bin switch light is on with the w ater curtain clo[...]

Section 6 Electrical System Part Number 80-1634-3 6-13 Symptoms Bin Switch Fails Open • The ice machine will not star t with the toggle switch in the ice position, bu t runs normally with the to ggle switch in the clean po sition. Bin Switch Fails Closed • Safety limit 2 is record ed in the control boar d memory and the har vest cycle continues[...]

Electrical System Section 6 6-14 Part Number 80-1634-3 COMPRESSOR ELECTRI CAL DIAGNOSTICS The compressor will not start or will trip repeatedly on overload. Check Resist ance (Ohm) V alues NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter . Perform the resist ance test after the compressor cool s. The compresso[...]

Section 6 Electrical System Part Number 80-1634-3 6-15 PTCR DIAGNOSTICS What is a PTCR? A PTCR (or Positive T emperatur e Coefficient Resistor) is made from high-purity , semi-conducting ceramics. A PTCR is useful because of it s resistance versus temperature characteri stic. The P TCR has a low resistance over a wide ( low) temperature ra nge, but[...]

Electrical System Section 6 6-16 Part Number 80-1634-3 S-Model Auto matic Shut-O ff and Restart When the storage bin is full at the end of a h arvest cycle, the sheet of cubes fails to clear the water curtain and will hold it open . After the water cu rtain is held open f or 30 seconds, the ice machine shuts of f. T o assure the P TCR has cooled, t[...]

Section 6 Electrical System Part Number 80-1634-3 6-17 There are other pr oblems that may cause compr essor start-up fa ilure with a good P TCR in a new , properly wired ice machine. • The voltage at th e compressor during st art-up is too low . Manitowoc ice machines ar e rated at ±1 0% of nameplate volta ge at comp ressor start-up . (Ex: An ic[...]

Electrical System Section 6 6-18 Part Number 80-1634-3 DIAGNOSING ST ART COMPONEN T S If the compressor attempts to st art, or hums and trips the overload protector , check the st art components before replacing th e compressor . Cap acitor Visual evidence of capacitor fa ilure can include a bulged terminal end or a ruptured membrane. Do not assume[...]

Section 6 Electrical System Part Number 80-1634-3 6-19 ICE/OFF/CLEAN T OGGLE SWITCH Function The switch is used to place the ice machine in ICE, OFF or CLEAN mode of operation. Specifications Single-pole, single-thro w switch. The switch is connected into a varying low D.C. voltage circuit. Check Procedure NOTE: Becaus e of a wide variatio n in D.C[...]

Electrical System Section 6 6-20 Part Number 80-1634-3 ELECTRONIC CONTROL BOARD Control Board SV3129 AC LINE VOL T AGE ELECTRIC AL PLUG (NUMBERS MARKED ON WIRES) MAIN FUSE (7A) AUTOMA TIC CLEANING SYSTEM (AuCS) PLUG ICE THICKNESS PROBE (3/16'' CONNECTION) W A TER LEVEL PROBE DC LOW VOL T AGE ELECTRICAL PLUG (NUMBERS MARKED ON WIRES) W A T[...]

Section 6 Electrical System Part Number 80-1634-3 6-21 General S-Model control boards use a dual volt age transformer . This means only one control bo ard is needed for both 1 15V and 208-230V use. Safety Limits In addition to standar d safety controls, such as the high pressure cut-out, the control board has built- in safety limits. These safety l[...]

Electrical System Section 6 6-22 Part Number 80-1634-3 Ice Thickness Probe (H arvest Initiation) HOW THE PROBE WORKS Manitowoc’s electro nic sensing circuit does not rely on refrigerant pressure, e vaporator temperatu re, water levels or timers to produce co nsistent ice formation. As ice forms on the evaporator , water (not ice) cont acts the ic[...]

Section 6 Electrical System Part Number 80-1634-3 6-23 DIAGNOSING ICE THICKN ESS CONTROL CIRCUITRY Ice Machin e Does Not Cy cle Into Harv est When Water Contact s The I ce Thickness Control Pro be Ste p 1 Bypass the freeze time lock-in fe ature by moving the ICE/OFF/C LEAN switch to OFF and back to ICE. Ste p 2 Wait until the water starts to flow o[...]

Electrical System Section 6 6-24 Part Number 80-1634-3 W ater Level Control Circuitry W ATER LEVEL PROBE LIGHT The water lev el probe cir cuit can be mo nitored by watching the water level light. The water level light is on when water contact s the probe, and off when no water is in contact with the probe. The water level light functions any time p[...]

Section 6 Electrical System Part Number 80-1634-3 6-25 DIAGNOSING W ATER LEVEL CONTROL CIRCUITRY Problem: W ater T rough Overfilling During The Freeze Cycle Ste p 1 S tart a new freeze seque nce by moving the ICE/ OFF/CLEAN toggle switch to OFF , then back to I CE. (if water flows with the switch off, check the water inlet valve). Step 2 W ait unti[...]

Electrical System Section 6 6-26 Part Number 80-1634-3 Problem: W ater Will Not Run Into The Sump T rough During The Freeze Cycle Ste p 1 V erify water is supplied to the ice machine, and then start a ne w freeze sequence by movin g the ICE/ OFF/CLEAN toggle switch to OF F then back to ICE. Ste p 2 Wait until the freeze cycle st arts (approximately[...]

Section 6 Electrical System Part Number 80-1634-3 6-27 Diagnosing An Ice Mach ine That Will Not Run ! Warning High (line) voltage is app lied 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. Ste p Check Notes 1 V erify p[...]

Electrical System Section 6 6-28 Part Number 80-1634-3 SELF CONT AINED - 1 PHASE WITH T ERMINAL BOARD SV2071 2 1 3 4 5 6[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-1 Section 7 Refrigeration System Sequence of Operation SELF-CONT AINED W ATER -COOLED MODELS Figure 7-1. Self-Cont ained Prechill and Freeze Cycle Prechill Refrig eration Sequence No water flows over the evapo rator during the prechill. The refrigerant absor bs heat (picked up duri ng the harve[...]

Refrigeration System Section 7 7-2 Part Number 80-1634-3 Figure 7-2. Self-Cont ained Harvest Cycle Harvest Cycle Refrigeration Sequence Hot gas flows through the energized harvest valve, heating the evaporato r . The harvest valve is sized to allow the pr oper amount of refrigeran t into the evaporator . This specific si zing (along with the proper[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-3 S1800 SELF-CONT AINED T UBING SCHEMATIC NOTE: The refrigeration sequence for self-cont ained dual expansion valve ice machines is identical to self- contained single expansion valve ice mach ines. See Pages 7-1 and 7-2 for sequence of operatio n. x x HARVEST SOLENOID VALVE AIR OR WATER COOLED[...]

Refrigeration System Section 7 7-4 Part Number 80-1634-3 Operational Analys is (Diagnostics) GENERAL When analyzing the refrigerat i on system, it is important to underst and that dif ferent refrigeration component malfunctions may cause ve ry similar symptoms. Also, many ex ternal factors c an make good refrigeration component s appear bad. These [...]

Section 7 Refrigeration System Part Number 80-1634-3 7-5 BEFORE BEGINNING SERVICE Ice machines may experience operational prob lems only during cert ain 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 star t in the right directio[...]

Refrigeration System Section 7 7-6 Part Number 80-1634-3 INSTALLATION/V ISUAL INSPECTION CHECKLIST W ATER SYSTEM CHECKLIST A water-related problem ofte n causes the same symptoms as a refrigeration system co mponent malfunction. W ater system problems must be identified and eliminated prior to replacin g refrigeration components. Possible Pr oblem [...]

Section 7 Refrigeration System Part Number 80-1634-3 7-7 ICE FORMATION PATTERN Evaporator ice formation p atter n analysis is helpful in ice machine diagnostics. Analyzing the ice form ation pattern alon e cannot diagnose an ice machine malfunction. However , when this analysis is used along with Manitowoc’ s Refrigeration System Operational Anal[...]

Refrigeration System Section 7 7-8 Part Number 80-1634-3 3. Extremely Thin at Evaporator Inlet There is no ice, or a considerable lack of ice formation at the inlet of the evap orator . Exampl es: The ice at the outlet of the evaporator reaches 1/8" to initiate a harvest, but there is no ice forma tion at all at the inlet of the evaporator . P[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-9 SAFETY LIMITS General In addition to standar d safe ty controls, such as high pressure cu t-out, the con trol board ha s two built in saf ety limit controls which protect the ice machine from major component failures. Safety Limit #1: If the freeze time reaches 60 minutes, the control board a[...]

Refrigeration System Section 7 7-10 Part Number 80-1634-3 Safety Limit # 1 Refer to previous p age for safety limit operation. Freeze time exce eds 60 minutes for 6 consec utive freeze cy cles . SAFETY LIMIT NOTES • Because there are man y possible external pr oblems, do not limit your diagnosis to only the items listed in this chart. • A conti[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-11 Safety Limit # 2 Refer to page 7-1 1 for safety limit o peration. Harvest time exceeds 3.5 m inutes for 500 consec utive harves t cycles. SAFETY LIMIT NOTES • Because there are man y possible external pr oblems, do not limit your diagnosis to only the items listed in this chart. • A cont[...]

Refrigeration System Section 7 7-12 Part Number 80-1634-3 ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE Procedure 1. Determine the ice machine operating conditions: Air temp. entering co ndenser ______ Air temp. aroun d ice machine ______ W ater temp. entering sump tro ugh ______ 2. Refer to Operating Pressu re Chart for ice ma chine [...]

Section 7 Refrigeration System Part Number 80-1634-3 7-13 ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE The suction pressure gradu ally drops throug hout the freeze cycle . The actual s uction press ure (and dr op rate) changes as the air and wate r temperatures enteri ng the ice machine cha nge. This af fects freeze cycle times. T o analyze and i[...]

Refrigeration System Section 7 7-14 Part Number 80-1634-3 Freeze Cycle Suction Pressure Hig h Checklist Freeze Cycle Suction Pressure Low Che cklist NOTE: Do not limit your diagnosis to on ly the items listed in the checklists. Possible Cause Check/Correct Improper installation See “Installation/Visual Inspection Checklist” Discharge pressure D[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-15 HARVEST V ALVE T EMPERATURE CHECK General NOTE: This procedure requires ch ecking both harvest valves. A harvest valve requires a critical orifice size. This meters the amount of hot gas flowing into the e vaporator during the harvest cycle. If the orifice is e ven slightly too large or too [...]

Refrigeration System Section 7 7-16 Part Number 80-1634-3 DISCHARGE LINE T EMPERATURE ANALYSIS General Knowing if the discharge line tempera ture is increasing, decreasing or remaining const ant can be an important diagnostic tool. Maximum compr essor discharge line temperature on a normally opera ting ice machine steadily increases throughout the [...]

Section 7 Refrigeration System Part Number 80-1634-3 7-17 HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS T ABLES General These tables must be used with charts, checklist s and other references to eliminate refrigeration comp onents not listed on the t ables and external items and problems which can ca use good ref rigeration com ponents t[...]

Refrigeration System Section 7 7-18 Part Number 80-1634-3 REFRIGERATION SYSTEM OPER ATIONAL ANALYSIS T ABLES S Models Dual Exp ansion V alve - Ice Machine Model Number___ ___________ ___ This table must be used with charts, checklist s and other references to eliminate refrigeration components not listed on th e table and extern al items and proble[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-19 Pressure Control Specifications and Diagnostics HIGH PRESSURE CUT-OU T (HPCO) CONTROL Function S tops the ice machine if s ubjected t o excessive high- side pressure. The HPCO control is normally closed, and opens on a rise in discharge pressur e. Specifications Cut-out: 450 p sig ±10 (3103[...]

Refrigeration System Section 7 7-20 Part Number 80-1634-3 Cycle Time/24 Hour Ice Production/ Refrigerant Pressure Chart s These charts a re used as guidelines to verify correct ice machine opera tion. Accurate collection of dat a is essential to obtain the correct diagnosis. • Refer to “OPERA TIONAL ANAL YSIS T ABLE” for the list of data that[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-21 Refrigerant Recovery/Ev acuation and Recharging NORMAL SELF-CONTAINED MODEL PROCEDURES Refrigerant Recovery/Eva cuation Do not purge refrig erant to the atmosp here. Captur e refrigerant usin g recovery equipm ent. Follow the manufacturer’s recommendation s. CONNECTIONS Manifold gauge sets[...]

Refrigeration System Section 7 7-22 Part Number 80-1634-3 Self-Cont ained Charging Procedures 1. Be sure the toggle switch is in the OFF position. Figure 7-9. Charging Connections 2. Close the vacuum pump valve, the low side service valve, and the low side manifold gauge valve. 3. Open the high side manifo ld gauge valve, an d backseat the high sid[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-23 SYSTEM CONT AMI NATION CLEAN-UP General This section describes the basic requ irements for restoring conta minated systems to reliable service. Determining Severity Of Cont amination System contam ination is generally caused by ei ther moisture or res idue from compre ssor burnout ente ring [...]

Refrigeration System Section 7 7-24 Part Number 80-1634-3 Mild System Cont amination Cleanup Procedure 1. Replace any failed component s. 2. If th e compressor is good, change the oil. 3. Replace th e liquid line drier. NOTE: If the contamination is fr om moisture, use heat lamps du ring evacuation. Position them at the compressor , condenser and e[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-25 10. Follow t he normal ev acuation proc edure, excep t replace the evacuatio n step with the following: A. Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system . Pressurize to a minimum of 5 p si (35 kPa .35 bar) . B. Change the vacu um pump oil. C. Pull vacuu[...]

Refrigeration System Section 7 7-26 Part Number 80-1634-3 Figure 7-10. Usin g Pinch-Off T ool SV1406[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-27 FILTER-DRIERS The filter-driers used on Manitowoc ice machines are manufactured to Manitowoc sp ecifications. The dif ference between Manitowoc dr iers and of f-the- shelf driers is in filtration . Manitowoc driers have dirt- retaining filtration, with fiberg lass filters on both the inlet a[...]

Refrigeration System Section 7 7-28 Part Number 80-1634-3 T O T AL SY STEM REFRIGERANT CHARGES NOTE: All ice machines ar e charged using R-404A refrigerant. Important This information is for re ference only . Refer to the ice machine serial number tag to verify the system charge. Serial pla te information ov errides information listed on this p age[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-29 REFRIGERANT DEFINITIONS Recover T o remove refrigerant, in any condition, from a system and store it in an extern al container , without necessarily testing or processing it in any way . Recycle T o clean refrigerant for re-use by oil separation and single or multiple passes through devices,[...]

Refrigeration System Section 7 7-30 Part Number 80-1634-3 REFRIGERANT RE-USE POLICY Manitowoc recognizes and support s the need for pr oper handling, re-use, and disp osal of, CFC and HCFC refrigerant s. Manitowoc ser vice procedures require recapturing refr igerant s, not venting them to the atmosphere. It is not necessary , in or ou t of warranty[...]

Section 7 Refrigeration System Part Number 80-1634-3 7-31 HFC REFRIGERANT QUESTIONS A ND ANSWERS Manitowoc ice machines use R-404A HF C refrigerant with ozone depletion pote ntial (ODP) factors of zero (0.0). 1. What compressor oil does Manitowoc require for use with HFC refrigerants? Manitowoc product s use Polyol Ester (POE) type compressor o il.[...]

Refrigeration System Section 7 7-32 Part Number 80-1634-3 THIS P A GE INTENTIONALL Y LEFT BLANK[...]

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Attend A Manitowoc Factory Service School • Improve Y our Service T echniques • Network with Y our Peers • 4 1/2 Days of Intensive T rai ning on Manitowoc Ice Machines • Extensive “Hands On” T raining on a V ariety of Equipm ent • Breakfast, Lunch and Hotel Room Included with T uition • Contact Y our Distributor or Manitowoc Ice, In[...]