Manitowoc Qr0320A Service Manual 1003440 ManualsLib Makes It Easy To Find Manuals Online! User
2017-02-23
User Manual: Manitowoc Manitowoc-Qr0320A-Service-Manual-1003440
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ICE MACHINES Q-Model Service Manual C 2004 Manitowoc Ice, Inc. 80-1597-3 6/04 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. Throughout this manual, you will see the following types of safety notices: Throughout this manual, you will see the following types of procedural notices: ! Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. ! Warning Text in a Warning box alerts you to a potential personal injury situation. Be sure to read the Warning statement before proceeding, and work carefully. Important Text in an Important box provides you with information that may help you perform a procedure more efficiently. Disregarding this information will not cause damage or injury, but it may slow you down as you work. NOTE: Text set off as a Note provides you with simple, but useful, extra information about the procedure you are performing. ! Caution Text in a Caution box alerts you to a situation in which you could damage the ice machine. Be sure to read the Caution statement before proceeding, and work carefully. We reserve the right to make product improvements at any time. Specifications and design are subject to change without notice. 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. Box 1720 Manitowoc, WI 54221-1720 Phone: (920) 682-0161 Service Fax: (920) 683-7585 Web Site - www.manitowocice.com © 2003 Manitowoc Ice, Inc. Litho in U.S.A. Table of Contents Section 1 General Information Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Authorized Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 1-1 1-1 1-2 1-3 1-3 1-3 1-3 1-3 1-3 Section 2 Installation Instructions General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q320/Q370/Q420 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q200 – Q1000 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1300/Q1600/Q1800 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1300/Q1600/Q1800 Ice Machines (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . Ice Storage Bin Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S170/S400/S570 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S320/S420 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . S970 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Condenser Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JC0495/JC0895/JC1095/JC1395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . JC1895 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Location of Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Stacking Two Ice Machines on a Single Storage Bin . . . . . . . . . . . . . . . . . . . . Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leveling the Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-Cooled Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuse/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Contained Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . Self Contained Ice Machine 115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Contained Ice Machine 208-230/3/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self Contained Ice Machine 230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . For United Kingdom Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 80-1100-3 2-1 2-1 2-1 2-2 2-2 2-3 2-3 2-3 2-3 2-4 2-4 2-4 2-4 2-5 2-5 2-5 2-6 2-6 2-7 2-7 2-7 2-7 2-7 2-9 2-9 2-9 2-9 2-9 1 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Supply and Drain Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cooling Tower Applications (Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Supply and Drain Line Sizing/Connections . . . . . . . . . . . . . . . . . . . . . Remote Condenser/Line Set Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Ice Machines Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Guidelines for Routing Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calculating Remote Condenser Installation Distances . . . . . . . . . . . . . . . . . Lengthening or Reducing Line Set Lengths . . . . . . . . . . . . . . . . . . . . . . . . . Connecting A Line Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Receiver Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Ice Machine Usage with Non-Manitowoc Multi-Circuit Condensers . Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Head Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Internal Condenser Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Condenser DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Quick Connect Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Non-Manitowoc Multi-Circuit Condenser Sizing Chart . . . . . . . . . . . . . . . . . Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Additional Checks for Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 2-10 2-10 2-10 2-11 2-11 2-11 2-11 2-11 2-12 2-13 2-13 2-14 2-14 2-15 2-16 2-16 2-16 2-17 2-17 2-17 2-17 2-17 2-17 2-17 2-17 2-18 2-19 2-19 Section 3 Maintenance Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Sequence Water Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Air-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-Cooled Condenser and Water Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manitowoc’s Patented Cleaning or Sanitizing Technology . . . . . . . . . . . . . . 2 3-1 3-2 3-2 3-2 3-2 3-3 3-3 3-3 3-4 3-5 3-5 3-5 Part No. 80-1100-3 Table of Contents (continued) AlphaSan“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Procedure To Cancel A Cleaning Or Sanitizing Cycle After It Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Cleaning System (AuCS“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal of Parts For Cleaning/Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . Water Treatment/Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Removal from Service/Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Contained Air-Cooled Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . Water-Cooled Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AuCS“ Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5 3-6 3-7 3-7 3-8 3-9 3-14 3-14 3-14 3-15 3-15 3-15 3-15 3-15 3-15 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 . . . . . . . . . . . . . . . . . . . Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 . . . . . . . . . . . . . . . . . . . . . . . . . . Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 4-1 4-1 4-2 4-2 4-3 4-3 4-3 4-4 4-4 Section 5 Water System Ice Making Sequence of Operation Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 5-1 5-1 5-2 5-2 Energized Parts Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Contained Air- And Water-Cooled Models . . . . . . . . . . . . . . . . . . . . . . 1. Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . Wiring Diagram Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Contained Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 6-1 6-1 6-2 6-2 6-3 6-3 6-10 Section 6 Electrical System Part No. 80-1100-3 3 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 . . . . . . . . . . . . . . Q420/Q450/Q600/Q800/Q1000 - Self Contained 1 Phase With Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q420/Q450/Q600/Q800/Q1000 - Self Contained 1 Phase Without Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q800/Q1000 - Self Contained - 3 Phase With Terminal Board . . . . . . . . . . . Q800/Q1000 - Self Contained - 3 Phase Without Terminal Board . . . . . . . . Q1300/Q1800 - Self Contained - 1 Phase With Terminal Board . . . . . . . . . . Q1300/Q1600/Q1800 - Self Contained - 1 Phase Without Terminal Board . Q1300/Q1800 - Self Contained - 3 Phase With Terminal Board . . . . . . . . . . Q1300/Q1600/Q1800 - Self Contained - 3 Phase Without Terminal Board . Q450/Q600/Q800/Q1000 - Remote - 1 Phase With Terminal Board . . . . . . Q450/Q600/Q800/Q1000 - Remote - 1 Phase Without Terminal Board . . . . Q800/Q1000 -Remote - 3 Phase With Terminal Board . . . . . . . . . . . . . . . . . Q800/Q1000 -Remote - 3 Phase Without Terminal Board . . . . . . . . . . . . . . Q1300/Q1800 - Remote - 1 Phase With Terminal Board . . . . . . . . . . . . . . . Q1300/Q1600/Q1800 - Remote - 1 Phase Without Terminal Board . . . . . . . Q1300/Q1800 - Remote - 3 Phase With Terminal Board . . . . . . . . . . . . . . . Q1300/Q1600/Q1800 - Remote - 3 Phase Without Terminal Board . . . . . . . Component Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PTCR Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ICE/OFF/CLEAN Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Board Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Thickness Probe (Harvest Initiation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How The Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest/Safety Limit Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freeze Time Lock-In Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Maximum Freeze Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing Ice Thickness Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . Water Level Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Level Probe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Freeze Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Diagnosing Freeze Cycle Potable Water Level Control Circuitry . . . . . . . . . Diagnosing An Ice Machine That Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . 4 6-17 6-17 6-18 6-19 6-20 6-21 6-22 6-23 6-24 6-25 6-26 6-27 6-28 6-29 6-30 6-31 6-32 6-33 6-34 6-35 6-36 6-38 6-38 6-38 6-40 6-41 6-44 6-44 6-45 6-47 6-47 6-47 6-47 6-47 6-47 6-48 6-50 6-50 6-50 6-50 6-50 6-51 6-54 Part No. 80-1100-3 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) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Before Beginning Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Production Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Installation/Visual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Water System Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Ice Formation Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Safety Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analyzing Discharge Pressure During Freeze or Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Analyzing Suction Pressure During Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Single Expansion Valve Ice Machines Comparing Evaporator Inlet and Outlet Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Valve Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Discharge Line Temperature Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . How to Use the Refrigeration System Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigeration System Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . Harvest Pressure Regulating (H.P.R.) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Headmaster Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pressure Control Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . Fan Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . High Pressure Cut-Out (HPCO) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts . . . . . . . . . Q200 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q280 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q320 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q370 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q420/450 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q450 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q600 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1000 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1300 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1600 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Q1800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Part No. 80-1100-3 7-1 7-1 7-3 7-6 7-8 7-8 7-9 7-9 7-10 7-10 7-11 7-13 7-17 7-18 7-20 7-21 7-22 7-24 7-25 7-27 7-29 7-31 7-31 7-31 7-32 7-32 7-33 7-34 7-35 7-36 7-37 7-37 7-39 7-40 7-42 7-43 7-44 5 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Total System Refrigerant Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Refrigerant Re-Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . HFC Refrigerant Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 7-46 7-46 7-48 7-52 7-54 7-56 7-56 7-57 7-58 7-59 Part No. 80-1100-3 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 QD0283W QY0285W QD0373W QY0375W QR0451W QD0453W QY0455W QR0601W QD0603W QY0605W QR0801W QD0803W QY0805W QR1001W QD1003W QY1005W QR1301W QD1303W QY1305W QD1603W QY1605W QR1801W QD1803W QY1805W Remote --- 9 REMO TE A IR -COOLED --------QR0490N QD0492N QY0494N QR0690N QD0692N QY0694N QR0890N QD0892N QY0894N QR1090N QD1092N QY1094N QR1390N QD1392N QY1394N QD1692N QY1694N QR1890N QD1892N QY1894N # C UB E SIZE CONDEN SER TY PE 0 1 2 3 4 5 A IR -COOLED W ATER -COOLED A IR -COOLED W ATER -COOLED A IR -COOLED W ATER -COOLED R EG U LAR R EG U LAR DICE DICE H A LF-DICE H A LF-DICE Q R 0450 A ICE M A CHINE MODEL ICE C UB E SIZE R R EG U LAR D DICE Y H A LF DICE ICE M A CHINE SER IES CONDEN SER TY PE A SEL F-CON TA INED AIR -COOLED W SEL F-CON TA INED W ATER -COOLED N R EMO TE AIR -COOLED Ice Cube Sizes Regular Dice Half Dice 1-1/8" x 1-1/8" x 7/8" 7/8" x 7/8" x 7/8" 3/8" x 1-1/8" x 7/8" 2.86 x 2.86 x 2.22 cm 2.22 x 2.22 x 2.22 cm 0.95 x 2.86 x 2.22 cm NOTE: Model numbers ending in 3 indicate a 3-phase unit. Example: QY1804A3 ! Warning PERSONAL INJURY POTENTIAL Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. Part No. 80-1100-3 1-1 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. 80-1100-3 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. No warranty is extended for personal, family, or household purposes. PARTS 1. Manitowoc warrants the ice machine against defects in materials and workmanship, under normal use and service for three (3) years from the date of original installation. 2. The evaporator and compressor are covered by an additional two (2) year (five years total) warranty beginning on the date of the original installation. LABOR 1. Labor required to repair or replace defective components is covered for three (3) years from the date of original installation. 2. The evaporator is covered by an additional two (2) year (five years total) labor warranty beginning on the date of the original installation. Part No. 80-1100-3 1. Normal maintenance, adjustments and cleaning. 2. Repairs due to unauthorized modifications to the ice machine or use of non-standard parts without prior written approval from Manitowoc Ice, Inc. 3. Damage caused by improper installation of the ice machine, electrical supply, water supply or drainage, or damage caused by floods, storms, or other acts of God. 4. Premium labor rates due to holidays, overtime, etc.; travel time; flat rate service call charges; mileage and miscellaneous tools and material charges not listed on the payment schedule. Additional labor charges resulting from the inaccessibility of equipment are also excluded. 5. Parts or assemblies subjected to misuse, abuse, neglect or accidents. 6. Damage or problems caused by installation, cleaning and/or maintenance procedures inconsistent with the technical instructions provided in this manual. 7. This product is intended exclusively for commercial application. No warranty is extended for personal, family, or household purposes. AUTHORIZED WARRANTY SERVICE To comply with the provisions of the warranty, a refrigeration service company qualified and authorized by a Manitowoc distributor, or a Contracted Service Representative must perform the warranty repair. 1-3 General Information Section 1 THIS PAGE INTENTIONALLY LEFT BLANK 1-4 Part No. 80-1100-3 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 (67.3 cm) 2-1 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. 80-1100-3 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 (111.7 cm) 2-3 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. Prior to using a non-Manitowoc ice storage system with other Manitowoc ice machines, contact the manufacturer to assure their ice deflector is compatible with Manitowoc ice machines. SV1301 2-4 Part No. 80-1100-3 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. • The location must not obstruct air flow through or around the ice machine. Refer to the chart below for clearance requirements. Q1300/Q1600/ Q1800 Top/Sides Back Self-Contained Air-Cooled 24" (61 cm) 12" (30.5 cm) Top/Sides Back Self-Contained Air-Cooled 12" (30.5 cm) 5" (127 mm) All other Q models Top/Sides Back Self-Contained Air-Cooled 8" (20.3 cm) 5" (12.7 cm) Q370 Water-Cooled and Remote 8" (20.3 cm) 5" (12.7 cm) Water-Cooled 5" (12.7 cm) 5" (12.7 cm) Water-Cooled and Remote 8" (20.3 cm) 5" (12.7 cm) There is no minimum clearance required. This value is recommended for efficient operation and servicing only. Q1600 is not available as an air-cooled model. ! Caution The ice machine must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization” on Page 314. Stacking Two Ice Machines on a Single Storage Bin A stacking kit is required for stacking two ice machines. Installation instructions are supplied with the stacking kit. Q450/Q600/ Q800/Q1000 Top/Sides Back Q1300/Q1600/ Q1800 Top/Sides Back Stacked Self-Contained Air-Cooled 16" (40.64 cm) 5" (12.70 cm) Stacked Water-Cooled and Remote* 5" (12.70 cm) 5" (12.70 cm) 48" (121.92 cm) 12" (30.48 cm) 24" (60.96 cm) 12" (30.48 cm) *There is no minimum clearance required. This value is recommended for efficient operation and servicing only. Q1600 is not available as an air-cooled model. Ice Machine Heat of Rejection Series Ice Machine Q320 Q370 Q420 Q200 Q280 Q450 Q600 Q800 Q1000 Q1300 Q1600 Q1800 Heat of Rejection Air Conditioning Peak 4,600 6,200 3,900 5,950 7,000 9,600 3,800 5,000 3,800 6,000 7,000 9,600 9,000 13,900 12,400 19,500 16,000 24,700 24,000 35,500 24,000 35,500 36,000 50,000 B.T.U./Hour Because the heat of rejection varies during the ice making cycle, the figure shown is an average. Ice machines, like other refrigeration equipment, reject heat through the condenser. It is helpful to know the amount of heat rejected by the ice machine when sizing air conditioning equipment where self-contained aircooled ice machines are installed. This information is also necessary when evaluating the benefits of using water-cooled or remote condensers to reduce air conditioning loads. The amount of heat added to an air conditioned environment by an ice machine using a water-cooled or remote condenser is negligible. Knowing the amount of heat rejected is also important when sizing a cooling tower for a water-cooled condenser. Use the peak figure for sizing the cooling tower. Part No. 80-1100-3 2-5 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. Move the bin into its final position. 4. Level the bin to assure that the bin door closes and seals properly. Use a level on top of the bin. Turn each foot as necessary to level the bin. NOTE: An optional caster assembly is available for use in place of the legs. Installation instructions are supplied with the casters. AIR BAFFLE SCREWS THREAD LEVELING LEG INTO BASE OF CABINET SV1607 THREAD ‘FOOT’ IN AS FAR AS POSSIBLE Figure 2-2. Air Baffle SV1606 Figure 2-1. Leveling Leg and Foot 2-6 Part No. 80-1100-3 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.) The maximum allowable voltage variation is ±10% of the rated voltage at ice machine start-up (when the electrical load is highest). The wire size (or gauge) is also dependent upon location, materials used, length of run, etc., so it must be determined by a qualified electrician. ! Warning The ice machine must be grounded in accordance with national and local electrical codes. Part No. 80-1100-3 2-7 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. Q200 - Q1000 Ice Machines Ice Machine Q200 Q280 Q450 Q600 Q800 Q1000 Q1300 Q1600 Q1800 2-8 Voltage Phase Cycle 115/1/60 208-230/1/60 230/1/50 115/1/60 208-230/1/60 230/1/50 115/1/60 208-230/1/60 230/1/50 208-230/1/60 230/1/50 208-230/1/60 208-230/3/60 230/1/50 208-230/1/60 208-230/3/60 230/1/50 208-230/1/60 208-230/3/60 230/1/50 380-415/3/50 208-230/1/60 208-230/3/60 230/1/50 380-415/3/50 208-230/1/60 208-230/3/60 230/1/50 380-415/3/50 Air-Cooled Maximum Minimum Fuse/Circuit Circuit Amps Breaker 15 11.6 15 5.4 15 5.2 20 12.6 15 5.7 15 5.7 20 12.8 15 7.8 15 6.1 15 9.2 15 9.2 20 12.1 15 8.9 20 12.0 20 14.3 15 9.8 20 15.6 30 19.5 20 13.1 30 15.7 N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 40 28.1 20 15.5 40 23.3 N/A N/A Water Cooled Maximum Minimum Fuse/Circuit Circuit Amps Breaker 15 10.9 15 4.8 15 4.9 20 11.7 15 5.2 15 5.2 20 11.9 15 7.4 15 5.7 15 8.7 15 8.8 20 11.4 15 8.2 20 10.6 20 13.2 15 8.8 20 14.2 30 18.1 20 11.6 30 14.3 N/A N/A 30 17.2 20 11.0 N/A N/A N/A N/A 40 26.7 20 14.1 40 21.9 N/A N/A Remote Maximum Minimum Fuse/Circuit Circuit Amps Breaker N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A 20 13.6 N/A N/A N/A N/A 15 9.3 15 9.4 20 11.9 15 8.9 20 11.2 20 14.2 15 9.9 20 14.6 30 19.8 20 12.7 30 14.7 15 7.3 30 18.2 20 12.0 N/A N/A N/A N/A 40 26.9 20 13.9 40 22.2 15 9.1 Part No. 80-1100-3 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. SELF CONTAINED ICE MACHINE 115/1/60 OR 208-230/1/60 L1 L1 L2 L2 L3 L3 GROUND SV1190 L1 TO SEPARATE FUSE/BREAKER L1 N=115V OR L2=208-230V GROUND SV1258 GROUND ICE MACHINE CONNECTIONS ICE MACHINE CONNECTIONS SELF CONTAINED ICE MACHINE 230/1/50 L1 GROUND L1 TO SEPARATE FUSE/BREAKER N N GROUND GROUND ICE MACHINE CONNECTIONS SV1191 TO SEPARATE FUSE/BREAKER. DISCONNECT ALL POLES. For United Kingdom Only As the colours of the wires in the mains lead of the appliance may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows: • The wire which is coloured green and yellow must be connected to the terminal in the plug which is marked with the letter E or by the earth ground symbol or coloured green or green and yellow. • The wire coloured blue must be connected to the terminal which is marked with the letter N or coloured black. • The wire coloured brown must be connected to the terminal which is marked with the letter L or coloured red. Part No. 80-1100-3 2-9 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. L1 SINGLE CIRCUIT REMOTE CONDENSER L2 GROUND Though wire nuts are shown in the drawings, the ice machine field wiring connections may use either wire nuts or screw terminals. GROUND F2 F1 REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 115/1/60 OR 208-230/1/60 SINGLE CIRCUIT L1 REMOTE CONDENSER L2 NOTE: FAN MOTOR IS 208-230V ICE MACHINE NOTE: CONDENSER FAN MOTOR VOLTAGE MATCHES ICE MACHINE VOLTAGE (115V OR 208-230V) L1 L1 L2 L2 L3 L3 GROUND GROUND TO SEPARATE FUSE/BREAKER SV1199 REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 230/1/50 F2 F1 ICE MACHINE L1 L1 N=115V OR L2=208-230V L2 GROUND SV1255 L2 L SINGLE CIRCUIT 1 REMOTE CONDENSER L2 NOTE: FAN MOTOR IS 220-240V GROUND TO SEPARATE FUSE/BREAKER F2 ICE MACHINE F1 L1 L1 N N GROUND SV1256 2-10 GROUND TO SEPARATE FUSE/BREAKER (220-240). DISCONNECT ALL POLES. Part No. 80-1100-3 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. Important If you are installing a Manitowoc water filter system, refer to the Installation Instructions supplied with the filter system for ice making water inlet connections. WATER INLET LINES • Drain lines must have a 1.5 inch drop per 5 feet of run (2.5 cm per meter), and must not create traps. • The floor drain must be large enough to accommodate drainage from all drains. • Run separate bin and ice machine drain lines. Insulate them to prevent condensation. • Vent the bin and ice machine drain to the atmosphere. Do not vent the condenser drain on water-cooled models. Follow these guidelines to install water inlet lines: • Do not connect the ice machine to a hot water supply. Be sure all hot water restrictors installed for other equipment are working. (Check valves on sink faucets, dishwashers, etc.) • If water pressure exceeds the maximum recommended pressure, obtain a water pressure regulator from your Manitowoc distributor. • Install a water shut-off valve for both the ice making and condenser water lines. • Insulate water inlet lines to prevent condensation. Part No. 80-1100-3 Cooling Tower Applications (Water-Cooled Models) A water cooling tower installation does not require modification of the ice machine. The water regulator valve for the condenser continues to control the refrigeration discharge pressure. It is necessary to know the amount of heat rejection, and the pressure drop through the condenser and water valves (inlet and outlet) when using a cooling tower on an ice machine. • Water entering the condenser must not exceed 90°F (32.2°C). • Water flow through the condenser must not exceed 5 gallons (19 liters) per minute. • Allow for a pressure drop of 7 psi (48 kPA) between the condenser water inlet and the outlet of the ice machine. • Water exiting the condenser must not exceed 110°F (43.3°C). 2-11 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. Condenser Water Drain --- --- Bin Drain --- --- Tubing Size Up to Ice Machine Fitting 3/8" (9.5 mm) minimum inside diameter 1/2" Female 1/2" (12.7 mm) minimum Pipe Thread inside diameter Q1300/Q1600/Q1800 - 1/2" Female Pipe Thread All Others - 3/8" Female Pipe Thread 1/2" Female 1/2" (12.7 mm) minimum Pipe Thread inside diameter 3/4" Female 3/4" (19.1 mm) minimum Pipe Thread inside diameter SV1626 Figure 2-3. Typical Water Supply Drain Installation 2-12 Part No. 80-1100-3 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. If additional refrigerant is required, an additional label located next to the Model/Serial Numbers decal states the amount of refrigerant to be added. IMPORTANT EPA CERTIFIED TECHNICIANS If remote line set length is between 50' and 100' (15.2530.5 m), add 1.5 lb. (24 oz) (0.68 kg) of refrigerant to the nameplate charge. Tubing length: ______________________________ Refrigerant added to nameplate: ________________ New total refrigerant charge: ___________________ *Line Set RT RL Discharge Line 1/2" (1.27 cm) 1/2" (1.27 cm) Liquid Line 5/16" (.79 cm) 3/8" (.95 cm) Air Temperature Around the Condenser Minimum Maximum -20°F (-28.9°C) 120°F (49°C) Figure 2-4. Typical Additional Refrigerant Label If there is no additional label, the nameplate charge is sufficient for line sets up to 100' (30.5 m). (See the chart below.) WARNING Potential Personal Injury Situation REMOTE ICE MACHINES REFRIGERANT CHARGE Each remote ice machine ships from the factory with a refrigerant charge appropriate for installation with line sets of up to 50' (15.25 m). The serial tag on the ice machine indicates the refrigerant charge. Ice Machine Q490 Q690 Q890 Q1090 Q1390 Q1690 Q1890 Part No. 80-1100-3 Nameplate Charge (Charge Shipped in Ice Machine) 6 lb. (96 oz.) 8 lb. (128 oz.) 8 lb. (128 oz.) 9.5 lb. (152 oz.) 12.5 lb. (200 oz.) 15 lb. (240 oz.) 15 lb. (240 oz.) The ice machine contains refrigerant charge. Installation of the line sets must be performed by a properly trained and EPA certified refrigeration technician aware of the dangers of dealing with refrigerant charged equipment. Refrigerant to be Added for 50'-100' Line Sets None None None None 1.5 lb. (24 oz) 2.0 lb. (32 oz) 2.0 lb. (32 oz) Maximum System Charge (Never Exceed) 6 lb. (96 oz.) 8 lb. (128 oz.) 8 lb. (128 oz.) 9.5 lb. (152 oz.) 14 lb. (224 oz.) 17 lb. (272 oz.) 17 lb. (272 oz.) 2-13 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. When combined, they must fit within approved specifications. The following guidelines, drawings and calculation methods must be followed to verify a proper remote condenser installation. ! Caution The 60 month compressor warranty (including the 36 month labor replacement warranty) will not apply if the remote ice machine is not installed according to specifications. This warranty also will not apply if the refrigeration system is modified with a condenser, heat reclaim device, or other parts or assemblies not manufactured by Manitowoc Ice, Inc., unless specifically approved in writing by Manitowoc Ice, Inc. 3 Follow these guidelines when routing the refrigerant lines. This will help insure proper performance and service accessibility. 1. Optional - Make the service loop in the line sets (See Figure 2-5). This permits easy access to the ice machine for cleaning and service. Do not use hard rigid copper at this location. 2. Required - Do not form traps in the refrigeration lines (except the service loop). Refrigerant oil must be free to drain toward the ice machine or the condenser. Route excess tubing in a supported downward horizontal spiral (See Figure 2-5). Do not coil tubing vertically. 3. Required - Keep outdoor refrigerant line runs as short as possible. DOWNWARD HORIZONTAL SPIRAL 2 2 3 1 1 SV1204 Figure 2-5. Routing Line Sets 2-14 Part No. 80-1100-3 Section 2 Installation Instructions CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES Make the following calculations to make sure the line set layout is within specifications. 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. The receiver is designed to hold a charge sufficient to operate the ice machine in ambient temperatures between -20°F (-28.9°C) and 120°F (49°C), with line set lengths of up to 100' (30.5 m). 2. Insert the measured drop into the formula below. Multiply by 6.6 to get the calculated drop. (Example. A condenser located 10 feet below the ice machine has a calculated drop of 66 feet.) Line Set Rise/Drop 3. Insert the measured horizontal distance into the formula below. No calculation is necessary. The maximum rise is 35' (10.7 m). The maximum drop is 15' (4.5 m). 4. Add together the calculated rise, calculated drop, and horizontal distance to get the total calculated distance. If this total exceeds 150' (45.7 m), move the condenser to a new location and perform the calculations again. ! Caution If a line set has a rise followed by a drop, another rise cannot be made. Likewise, if a line set has a drop followed by a rise, another drop cannot be made. Calculated Line Set Distance The maximum distance is 150' (45.7 m). Line set rises, drops, horizontal runs (or combinations of these) in excess of the stated maximums will exceed compressor start-up and design limits. This will cause poor oil return to the compressor. Maximum Line Set Distance Formula Step 1. Step 2. Step 3. Step 4. Measured Rise (35' [10.7 m] Maximum) ______ x 1.7 Measured Drop (15' [4.5 m] Maximum) ______ x 6.6 Measured Horizontal Distance (100' [30.5 m] Maximum) Total Calculated Distance 150' (45.7 m) = = _______ _______ _______ _______ H H H R D D R SV1196 Figure 2-6. Combination of a Rise and a Horizontal Run Part No. 80-1100-3 Calculated Rise Calculated Drop Horizontal Distance Total Calculated Distance SV1195 Figure 2-7. Combination of a Drop and a Horizontal Run SV1194 Figure 2-8. Combination of a Rise, a Drop and a Horizontal Run 2-15 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. The quick connect fittings on the line sets are equipped with Schraeder valves. Use these valves to recover any vapor charge from the line set. When lengthening or shortening lines, follow good refrigeration practices and insulate new tubing. Do not change the tube sizes. Evacuate the lines and place about 5 oz (143g) of vapor refrigerant charge in each line. 1. Remove the top and left side panels. 2. Remove the receiver service valve cap. 3. Backseat (open) the valve. 4. Reinstall the cap and panels. REMOVE FRONT, TOP, AND LEFT SIDE PANEL FOR ACCESS TO RECEIVER VALVE CONNECTING A LINE SET 1. Remove the dust caps from the line set, condenser and ice machine. TURN COUNTERCLOCKWISE TO OPEN 2. Apply refrigeration oil to the threads on the quick disconnect couplers before connecting them to the condenser. 3. Carefully thread the female fitting to the condenser or ice machine by hand. 4. Tighten the couplings with a wrench until they bottom out. 5. Turn an additional 1/4 turn to ensure proper brassto-brass seating. Torque to the following specifications: Liquid Line 10-12 ft lb. (13.5-16.2 N•m) Discharge Line 35-45 ft lb. (47.5-61.0 N•m) SV1603 RECEIVER SERVICE VALVE CAP (TURN COUNTERCLOCKWISE TO REMOVE) Figure 2-9. Backseating the Receiver Service Valve 6. Check all fittings for leaks. 2-16 Part No. 80-1100-3 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. Performance may vary from Sales specifications. Q-Model ARI certified standard ratings only apply when used with a Manitowoc remote condenser. The condenser fan must be on during the complete ice machine freeze cycle (do not cycle on fan cycle control). The ice maker has a condenser fan motor circuit for use with a Manitowoc condenser. It is recommended that this circuit be used to control the condenser fan(s) on the multi-circuit condenser to assure it is on at the proper time. Do not exceed the rated amps for the fan motor circuit listed on the ice machine’s serial tag. If the design of the condenser meets the specifications, Manitowoc’s only approval is for full warranty coverage to be extended to the Manitowoc manufactured part of the system. Since Manitowoc does not test the condenser in conjunction with the ice machine, Manitowoc will not endorse, recommend, or approve the condenser, and will not be responsible for its performance or reliability.. Important Manitowoc warrants only complete new and unused remote packages. Guaranteeing the integrity of a new ice machine under the terms of our warranty prohibits the use of pre-existing (used) tubing or condensers. HEAD PRESSURE CONTROL VALVE Any remote condenser connected to a Manitowoc QModel Ice Machine must have a head pressure control valve #836809-3 (available from Manitowoc Distributors) installed on the condenser package. Manitowoc will not accept substitute “off the shelf” head pressure control valves. INTERNAL CONDENSER VOLUME The multi-circuit condenser internal volume must not be less than or exceed that used by Manitowoc (see chart on Page 2-18). Do not exceed internal volume and try to add charge to compensate, as compressor failure will result. CONDENSER ∆T ∆T is the difference in temperature between the condensing refrigerant and entering air. The ∆T should be 15 to 20°F (-9.4 to -6.6°C) at the beginning of the freeze cycle (peak load conditions) and drop down to 12 to 17°F (-11.1 to -8.3°C) during the last 75% of the freeze cycle (average load conditions). REFRIGERANT CHARGE Remote ice machines have the serial plate refrigerant charge (total system charge) located in the ice maker section. (Remote condensers and line sets are supplied with only a vapor charge.) ! Caution Never add more than nameplate charge to ice machine for any application. QUICK CONNECT FITTINGS ! Caution Do not use a fan cycling control to try to maintain discharge pressure. Compressor failure will result. Part No. 80-1100-3 The ice machine and line sets come with quick connect fittings. It is recommended that matching quick connects (available through Manitowoc Distributors) be installed in the multi-circuit condenser, and that a vapor “holding” charge (5 oz.) of proper refrigerant be added to the condenser prior to connection of the ice machine or line set to the condenser. 2-17 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 0.170 Type Charge Q450 Q600 R-404A R-404A Q800 Q1000 Q1300 Q1600 Q1800 R-404A R-404A R-404A R-404A R-404A Quick Connect StubsMale Ends Discharge Liquid Head Pressure Control Valve 500 psig safe working pressure coupling P/N 83-6035-3 coupling P/N 83-6034-3 Manitowoc P/N 83-6809-3 2,500 psig burst pressure mounting flange P/N 83-6006-3 mounting flange P/N 83-6005-3 no substitutes Design Pressure Amount reflects additional R-404A refrigerant added to nameplate charge for 50' to 100' line sets, to ensure proper operation at all ambient conditions. Q1300 has 1.5 lbs. additional R-404A. Q1600 and Q1800 has 2.0 lbs. additional R-404A SINGLE CIRCUIT REMOTE CONDENSER ELECTRICAL DISCONNECT DISCHARGE LINE LIQUID LINE ELECTRICAL DISCONNECT ICE MACHINE ELECTRICAL SUPPLY 36.00" (91.44 cm) DROP BIN DISCHARGE REFRIGERANT LINE LIQUID REFRIGERANT LINE SV1615 Figure 2-10. Typical Single Circuit Remote Condenser Installation 2-18 Part No. 80-1100-3 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? Have all of the electrical and water connections been made? Has the supply voltage been tested and checked against the rating on the nameplate? Is there proper clearance around the ice machine for air circulation? Has the ice machine been installed where ambient temperatures will remain in the range of 35° - 110°F (1.7° - 43.3°C)? Has the ice machine been installed where the incoming water temperature will remain in the range of 33° - 90°F (0.6° - 32.2°C)? Is there a separate drain for the water-cooled condenser? Is the water trough drain plug installed? (The drain plug is taped to the top of the water pump). Are all electrical leads free from contact with refrigeration lines and moving equipment? Has the owner/operator been instructed regarding maintenance and the use of Manitowoc Cleaner and Sanitizer? Has the owner/operator completed the warranty registration card? Has the ice machine and bin been sanitized? Is the toggle switch set to ice? (The toggle switch is located directly behind the front panel). Is the ice thickness control set correctly? (Refer to Operational Checks on page 3-4 of this manual to check/set the correct ice bridge thickness). Additional Checks for Remote Models Has the receiver service valve been opened? Does the remote condenser fan operate properly after start-up? Has the remote condenser been located where ambient temperatures will remain in the range of -20° - 120°F ( -6.6 - 49°C). Is the line set routed properly? Part No. 80-1100-3 2-19 Installation Instructions Section 2 THIS PAGE INTENTIONALLY LEFT BLANK 2-20 Part No. 80-1100-3 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. 80-1100-3 3-1 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. To ensure proper operation, always follow the Operational Checks: • when starting the ice machine for the first time • after a prolonged out of service period • after cleaning and sanitizing NOTE: Make sure the water curtain is in place when performing this check. It prevents water from splashing out of the water trough. 1. Inspect the bridge connecting the cubes. It should be about 1/8" (3.2 mm) thick. 2. If adjustment is necessary, turn the ice thickness probe adjustment screw clockwise to increase bridge thickness, counterclockwise to decrease bridge thickness. NOTE: Routine adjustments and maintenance procedures are not covered by the warranty. NOTE: Turning the adjustment 1/3 of a turn will change the ice thickness about 1/16" (1.5 mm). WATER LEVEL The water level sensor is set to maintain the proper water level above the water pump housing. The water level is not adjustable. ADJUSTING SCREW If the water level is incorrect, check the water level probe for damage (probe bent, etc.). Repair or replace the probe as necessary. 1/8” ICE BRIDGE THICKNESS SV1208 Figure 3-3. Ice Thickness Check 3. Make sure the ice thickness probe wire and the bracket do not restrict movement of the probe. SV1616 Figure 3-2. Water Level Probe 3-2 Part No. 80-1100-3 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. A shorter purge setting (with standard water supplies such as city water) is not recommended. This can increase water system cleaning and sanitizing requirements. • The harvest sequence water purge may be set to 15, 30, or 45 seconds. • During the harvest sequence water purge, the water fill valve energizes and de-energizes by time. The water purge must be at the factory setting of 45 seconds for the water fill valve to energize during the last 15 seconds of the water purge. If it is set to less than 45 seconds, the water fill valve will not energize during the water purge. AIR-COOLED CONDENSER (SELF-CONTAINED AND REMOTE MODELS) A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces ice production and shortens component life. Clean the condenser at least every six months. Follow the steps below. ! Caution The condenser fins are sharp. Use care when cleaning them. 1. The washable aluminum filter on self-contained ice machines is designed to catch dust, dirt, lint and grease. This helps keep the condenser clean. Clean the filter with a mild soap and water solution. CONTROL BOARD WATER PURGE ADJUSTMENT 30 45 15 AIR FILTER SV1608 Figure 3-5. Self-Contained Air-Cooled Filter SV1617 Figure 3-4. Water Purge Adjustment 2. Clean the outside of the condenser (bottom of a remote condenser) with a soft brush or a vacuum with a brush attachment. Clean from top to bottom, not side to side. Be careful not to bend the condenser fins. Continued on next page … Part No. 80-1100-3 3-3 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. • High water consumption • High operating temperatures 4. Straighten any bent condenser fins with a fin comb. • High operating pressures If the ice machine is experiencing any of these symptoms, the water-cooled condenser and water regulating valve may require cleaning due to scale build-up. CONDENSER The cleaning procedures require special pumps and cleaning solutions. Follow the manufacturer’s instructions for the specific cleaner being used. FIN COMB “COMB” DOWN ONLY SV1515 Figure 3-6. Straighten Bent Condenser Fins 5. Carefully wipe off the fan blades and motor with a soft cloth. Do not bend the fan blades. If the fan blades are excessively dirty, wash with warm, soapy water and rinse thoroughly. ! Caution If you are cleaning the condenser fan blades with water, cover the fan motor to prevent water damage. 3-4 Part No. 80-1100-3 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. ! Caution Use only Manitowoc approved Ice Machine Cleaner (part number 94-0546-3) and Sanitizer (part number 94-0565-3). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Read and understand all labels printed on bottles before use. ! Caution Do not mix Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. ! Warning Wear rubber gloves and safety goggles (and/or face shield) when handling ice machine Cleaner or Sanitizer. Part No. 80-1100-3 MANITOWOC’S PATENTED CLEANING OR SANITIZING TECHNOLOGY Manitowoc Ice Machines include technology that allows the initiation and completion of a cleaning or sanitizing cycle at the flip of a switch. This cycle will permit cleaning or sanitizing of all surfaces that come in contact with the water distribution system. Periodic maintenance must be performed that includes sanitizing the bin (or dispenser) and adjacent surface areas, which cannot be contacted by the water distribution system. This technology will also allow initiation and completion of a clean or sanitize cycle, after which the ice machine automatically starts ice making again. Refer to the cleaning or sanitizing procedure for complete details. The AuCS Accessory can be set to automatically start and finish a clean or sanitize cycle every 2, 4, or 12 weeks. This accessory monitors ice-making cycles and initiates a cleaning or sanitizing cycle automatically. Refer to Automatic Cleaning System (AuCS) Accessory for further details. ALPHASAN The goal of AlphaSan is to keep the plastic surfaces of an ice machine cleaner, by reducing or delaying the formation of bio-film. The active ingredient in AlphaSan is the element silver in the form of silver ions (Ag+). AlphaSan slowly releases silver ions via an ion exchange mechanism. When AlphaSan is compounded directly into a plastic part, a controlled release of silver ions from the surface is regulated to maintain an effective concentration at or near the surface of the plastic ice machine part. AlphaSan’s unique ability to effectively control the release of silver not only protects against undesired discoloration of the plastic, but also will last the life of the plastic part. Although AlphaSan helps prevent bio-film build up it does not eliminate the need for periodic cleaning and maintenance. AlphaSan has no adverse effect on the taste of the ice or beverage. 3-5 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. Step 2 To start cleaning, place the toggle switch in the CLEAN position. The water will flow through the water dump valve and down the drain. The Clean light will turn on to indicate the ice machine is in the Cleaning mode. Step 3 Wait about one minute or until water starts to flow over the evaporator. Step 4 Add the proper amount of Manitowoc Ice Machine Cleaner to the water trough. Model Q200 Q280 Q320 Q370 Q420 Q450 Q600 Q800 Q1000 Q1300 Q1600 Q1800 3-6 Amount of Cleaner 3 ounces (90 ml) 5 ounces (150 ml) 9 ounces (270 ml) Step 5 The ice machine will automatically time out a ten minute cleaning cycle, followed by six rinse cycles, and stop. The Clean light will turn off to indicate the Cleaning mode is completed. This entire cycle lasts approximately 25 minutes. Step 6 When the cleaning process stops, move the toggle switch to OFF position. Refer to “Sanitizing Procedure” on the next page. Step 7 A. The ice machine may be set to start and finish a cleaning procedure then automatically start ice making again. B. You must wait about one minute into the cleaning cycle (until water starts to flow over the evaporator) then move the switch from CLEAN to ICE position. C. When the cleaning cycle is completed, an ice making sequence will start automatically. Important After the toggle switch is moved to the ICE position, opening the curtain switch will interrupt the cleaning sequence. The sequence will resume from the point of interruption when the curtain switch closes. Part No. 80-1100-3 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. Side walls B. Base (area above water trough) C. Evaporator plastic parts ! Caution Never use anything to force ice from the evaporator. Damage may result. D. Bin or dispenser Step 5 Rinse all sanitized areas with clear water. Step 6 Install the removed parts, restore power and place toggle switch in the ice position. ! Warning Disconnect electric power to the ice machine (and dispenser if applicable) at the electric switch box before proceeding. Step 2 Refer to Removal of Parts For Cleaning/ Sanitizing and remove ice machine parts. Step 3 Mix a solution of water and sanitizer. Solution Type Sanitizer Part No. 80-1100-3 Water 4 gal. (15 l) Mixed With 3 oz (90 ml) sanitizer 3-7 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. ! Caution Refer to the AuCS Accessory Installation - Use and Care Manual for complete details on the installation, operation, maintenance and cautionary statements of this accessory. Automatic Operation The following occurs when the toggle switch is in the ICE position: • The ice machine control board counts the number of ice harvest cycles. • The AuCS accessory interrupts the ice making mode and starts the cleaning (or sanitizing) mode when the harvest count equals the “Frequency of Cleaning” setting of the AuCS. • When the automatic cleaning (or sanitizing) cycle is complete (approximately 25 minutes), ice making resumes automatically, and the “Harvest Count” is reset to zero. Important Opening the curtain switch will interrupt the cleaning or sanitizing sequence. The sequence will resume from the point of interruption when the curtain recloses. ! Caution Never use anything to force ice from the evaporator. Damage may result. Step 2 To start the automatic cleaning system, move the toggle switch to the CLEAN position. The water will flow through the water dump valve and down the drain. The Clean light will turn on to indicate the ice machine is in the Self Cleaning mode. The AuCS then automatically adds cleaner or sanitizer to the ice machine. Step 3 The ice machine will automatically time out a ten minute cleaning or sanitizing cycle, followed by six rinse cycles, (de-energize the Clean light) and stop. This entire cycle lasts approximately 25 minutes. Step 4 After the cleaning or sanitizing cycle stops, move the toggle switch to ICE position. Step 5 A. The ice machine may be set to start and finish a cleaning or sanitizing cycle, then automatically start ice making again. B. You must wait about one minute into the cleaning cycle (until water starts to flow over the evaporator), then move the toggle switch from CLEAN to ICE position. C. When the cleaning or sanitizing cycle is completed, the clean light will turn off and an ice making sequence will start automatically. 3-8 Part No. 80-1100-3 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. ! Warning Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer. 3. Soak the removed part(s) in a properly mixed solution. Solution Type Cleaner Sanitizer Water 1 gal. (4 l) 4 gal. (15 l) Mixed With 16 oz (500 ml) cleaner 1 oz (30 ml) sanitizer Do not mix Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. ! Caution Do not immerse the water pump motor in the cleaning or sanitizing solution. 5. Use the solution and a brush to clean the top, sides, and bottom evaporator extrusions; the inside of the ice machine panels; and the entire inside of the bin. 6. Thoroughly rinse all of the parts and surfaces with clean water. 7. Install the removed parts. NOTE: Incomplete rinsing of the ice thickness probe or water level probe may leave a residue. This could cause the ice machine to malfunction. For best results, brush or wipe the probes off while rinsing it. Thoroughly dry the probes before installing them. 8. Turn on the water and electrical supply. Part No. 80-1100-3 3-9 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. Figure 3-7. Dump Valve Removal Follow the procedure below to remove the dump valve. Important ! Warning Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply before proceeding. 1. If so equipped, remove the water dump valve shield from its mounting bracket. 2. Lift and slide the coil retainer cap from the top of the coil. 3. Note the position of the coil assembly on the valve for assembly later. Leaving the wires attached, lift the coil assembly off the valve body and the enclosing tube. 4. Press down on the plastic nut on the enclosing tube and rotate it 1/4 turn. Remove the enclosing tube, plunger, and plastic gasket from the valve body. NOTE: At this point, the water dump valve can easily be cleaned. If complete removal is desired, continue with step 5. The plunger and the inside of the enclosing tube must be completely dry before assembly. NOTE: During cleaning, do not stretch, damage or remove the spring from the plunger. If it is removed, slide the spring’s flared end into the plunger’s slotted top opening until the spring contacts the plunger spring stop. 5. Remove the valve body. 6. Remove the tubing from the dump valve by twisting the clamps off. 7. Remove the two screws securing the dump valve and the mounting bracket. CAP PLUNGER SPRING STOP COIL SPRING PLUNGER ENCLOSING TUBE DIAPHRAM VALVE BODY Figure 3-8. Dump Valve Disassembly 3-10 Part No. 80-1100-3 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. Ice Thickness Probe Removal NOTE: At this point, the ice thickness probe can easily be cleaned. If complete removal is desired, continue with step 2 below. PUMP OUTLET SV1618 ! Warning Disconnect the electric power to the ice machine at the electric service switch box. Figure 3-9. Water Pump Removal 2. Disconnect the hose from the pump outlet. 3. Loosen the screws securing the pump mounting bracket to the bulkhead. 4. Lift the pump and bracket assembly off the screws. 2. Disconnect the wire lead from the control board inside the electrical control box. Ice Thickness Probe Cleaning 1. Mix a solution of Manitowoc ice machine cleaner and water (2 ounces of cleaner to 16 ounces of water) in a container. 2. Soak ice thickness probe in container of cleaner/ water solution while disassembling and cleaning water circuit components (soak ice thickness probe for 10 minutes or longer). 3. Clean all ice thickness probe surfaces including all plastic parts (do not use abrasives). Verify the ice thickness probe cavity is clean. Thoroughly rinse ice thickness probe (including cavity) with clean water, then dry completely. Incomplete rinsing and drying of the ice thickness probe can cause premature harvest. 4. Reinstall ice thickness probe, then sanitize all ice machine and bin/dispenser interior surfaces. Part No. 80-1100-3 3-11 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. ! Warning Disconnect the electric power to the ice machine at the electric service switch box and turn off the water supply before proceeding. 1. Remove the valve shield if necessary. 2. Remove the filter access screws that hold the valve in place. NOTE: The water inlet valve can be disassembled and cleaned without disconnecting the incoming water supply line to the ice machine. 3. Remove, clean, and install the filter screen. SCREW 4. If necessary, remove the enclosure tube access screws to clean interior components. WATER LEVEL PROBE WATER TROUGH WIRE LEAD ICE MACHINE SIDE PANEL FILTER ACCESS SCREWS INCOMING WATER LINE WATER INLET VALVE SV1621 SV1622 Figure 3-11. Water Level Probe Removal Water Inlet Valve Figure 3-12. Water Inlet Valve Removal The water inlet valve normally does not require removal for cleaning. Follow the instructions below to determine if removal is necessary. ENCLOSURE TUBE ACCESS SCREWS ELECTRICAL SOLENOID 1. Set the ICE/OFF/CLEAN switch to OFF. Locate the water inlet valve (in the compressor area of the ice machine). It pours water into the water trough. 2. When the ice machine is off, the water inlet valve must completely stop water flow into the machine. Watch for water flow. If water flows, remove, disassemble and clean the valve. 3. When the ice machine is on, the water inlet valve must allow the proper water flow through it. Set the toggle switch to ON. Watch for water flow into the ice machine. If the water flow is slow or only trickles into the ice machine, remove, disassemble, and clean the valve. 3-12 RESTRICTOR (FLAT SIDE MUST FACE OUT) MOUNTING PLATE FILTER ACCESS SCREWS ENCLOSURE TUBE SPRING FITTING O-RING VALVE BODY FILTER SCREEN PIN RUBBER SEAL SV1623 Figure 3-13. Exploded View of Water Inlet Valve Part No. 80-1100-3 Section 3 Maintenance Water Distribution Tube Water Curtain 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. Lift the right side of the distribution tube up off the locating pin, then slide it back and to the right. ! Caution Do not force this removal. Be sure the locating pin is clear of the hole before sliding the distribution tube out. 3. Disassemble for cleaning. A. Twist both of the inner tube ends until the tabs line up with the keyways. B. Pull the inner tube ends outward. INNER TUBE TAB INNER TUBE KEYWAY SV1211 Figure 3-15. Water Distribution Tube Disassembly Part No. 80-1100-3 3-13 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. FILTER REPLACEMENT PROCEDURE Tri-Liminator systems include a pre-filter and a primary filter. For maximum filtration efficiency, replace the primary filter cartridge every six months. If the filter gauge reading drops below 20 psig prior to six months usage, replace the pre-filter first. 1. Turn off the water supply at the inlet shutoff valve. PRESSURE RELEASE BUTTON CAP 5. Remove the O-ring from the housing groove. Wipe the housing groove and the O-ring clean. 6. Lubricate the O-ring with petroleum jelly. 7. Press the O-ring into the housing groove. 8. Insert a new filter cartridge into the housing. Make sure it slips down over the housing standpipe. 9. Screw the housing on to the cap and carefully handtighten it. ! Caution Hand-tighten only. Do not overtighten. Do not use a spanner wrench. 10. Repeat steps 3-9 for each filter housing. 11. Turn on the water supply to allow the housing and filter to slowly fill with water. SHUT OFF VALVE SEAL CARTRIDGE 12. Depress the pressure release button to release trapped air from the housing. O-RING 13. Check for leaks. OUTLET SIDE INLET SIDE PRE-FILTER HOUSING PRIMARY FILTER SEAL Figure 3-17. Typical Tri-Liminator Water Filtration System 2. Depress the pressure release button to relieve the pressure. 3-14 Part No. 80-1100-3 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. Insert a large screwdriver between the bottom spring coils of the water regulating valve. Pry upward to open the valve. If water is allowed to remain in the ice machine in freezing temperatures, severe damage to some components could result. Damage of this nature is not covered by the warranty. Follow the applicable procedure below. SELF-CONTAINED AIR-COOLED ICE MACHINES 1. Disconnect the electric power at the circuit breaker or the electric service switch. 2. Turn off the water supply. 3. Remove the water from the water trough. 4. Disconnect and drain the incoming ice-making water line at the rear of the ice machine. 5. Blow compressed air in both the incoming water and the drain openings in the rear of the ice machine until no more water comes out of the inlet water lines or the drain. 6. Make sure water is not trapped in any of the water lines, drain lines, distribution tubes, etc. SV1624 Figure 3-18. Pry Open the Water Regulating Valve 4. Hold the valve open and blow compressed air through the condenser until no water remains. REMOTE ICE MACHINES 1. Move the ICE/OFF/CLEAN switch to OFF. 2. “Frontseat” (shut off) the receiver service valves. Hang a tag on the switch as a reminder to open the valves before restarting. 3. Perform steps 1-6 under “Self-Contained Air-Cooled Ice Machines.” AUCS Accessory Refer to the AuCS Accessory manual for winterization of the AuCS Accessory. Part No. 80-1100-3 3-15 Maintenance Section 3 THIS PAGE INTENTIONALLY LEFT BLANK 3-16 Part No. 80-1100-3 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. The harvest valve(s) is also energized during water purge, although it stays on for an additional 5 seconds (50 seconds total on time) during the initial refrigeration system start-up. 2. Refrigeration System Start-Up The compressor starts after the 45 second water purge, and it remains on throughout the entire Freeze and Harvest Sequences. The water fill valve is energized at the same time as the compressor. It remains on until the water level sensor closes for 3 continuous seconds, or until a six-minute time period has expired. (See “Water Inlet Valve Safety Shutoff,” Page 6-50.) The harvest valve(s) remains on for 5 seconds during initial compressor start-up and then shuts off. FREEZE SEQUENCE 3. Prechill The compressor is on for 30 seconds prior to water flow, to prechill the evaporator. 4. Freeze The water pump restarts after the 30 second prechill. An even flow of water is directed across the evaporator and into each cube cell, where it freezes. The water fill valve will cycle on and then off one more time to refill the water trough. When sufficient ice has formed, the water flow (not the ice) contacts the ice thickness probe. After approximately 7 seconds of continual water contact, the harvest sequence is initiated. The ice machine cannot initiate a harvest sequence until a 6 minute freeze lock has been surpassed. At the same time the compressor starts, the condenser fan motor (air-cooled models) is supplied with power throughout the entire Freeze and Harvest Sequences. The fan motor is wired through a fan cycle pressure control, therefore it may cycle on and off. (The compressor and condenser fan motor are wired through the contactor. As a result, anytime the contactor coil is energized, the compressor and fan motor are supplied with power.) Figure 4-1. Freeze Sequence (Typical Q450 Shown) Continued on next page … Part No. 80-1100-3 4-1 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. The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge. If set at less than 45 seconds the water fill valve does not energize during the water purge. When the storage bin is full at the end of a harvest sequence, 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. The ice machine remains off for 3 minutes before it can automatically restart. After the 45 second water purge, the water fill valve, water pump and dump valve de-energize. (Refer to “Water Purge Adjustment” on Page 3-3 for details.) The harvest valve also opens at the beginning of the water purge to divert hot refrigerant gas into the evaporator. The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain. As the water curtain swings back to the operating position, the bin switch re-closes and the ice machine restarts (steps 1 - 2), provided the 3 minute delay period is complete. 6. Harvest The harvest valve(s) remains open and the refrigerant gas warms the evaporator causing the cubes to slide, as a sheet, off the evaporator and into the storage bin. The sliding sheet of cubes swings the water curtain out, opening the bin switch. The momentary opening and reclosing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence (Step 3 - 4.) Figure 4-3. Automatic Shut-Off (Typical Q450 Shown) Figure 4-2. Harvest Sequence (Typical Q450 Shown) 4-2 Part No. 80-1100-3 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. The harvest valve and harvest pressure regulating (HPR) solenoid valves also energize during water purge, although they stay on for an additional 5 seconds (50 seconds total on time) during the initial refrigeration system start-up. 2. Refrigeration System Start-Up The compressor and liquid line solenoid valve energize after the 45 second water purge and remain on throughout the entire Freeze and Harvest Sequences. The water fill valve is energized at the same time as the compressor. It remains on until the water level sensor closes for 3 continuous seconds, or until a six-minute time period has expired. (See “Water Inlet Valve Safety Shutoff,” Page 6-50.). The harvest valve and HPR solenoid valves remain on for 5 seconds during initial compressor start-up and then shut off. FREEZE SEQUENCE 3. Prechill The compressor is on for 30 seconds prior to water flow, to prechill the evaporator. 4. Freeze The water pump restarts after the 30 second prechill. An even flow of water is directed across the evaporator and into each cube cell, where it freezes. The water fill valve will cycle on and then off one more time to refill the water trough. (See Page 4-1.) When sufficient ice has formed, the water flow (not the ice) contacts the ice thickness probe. After approximately 7 seconds of continual water contact, the harvest sequence is initiated. The ice machine cannot initiate a harvest sequence until a 6 minute freeze lock has been surpassed. The remote condenser fan motor starts at the same time the compressor starts and remains on throughout the entire Freeze and Harvest Sequences. (The compressor and condenser fan motor are wired through the contactor, therefore, anytime the contactor coil is energized, the compressor and fan motor are on.) Figure 4-4. Freeze Sequence (Typical Q450 Shown) Continued on next page … Part No. 80-1100-3 4-3 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. The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge. If set at less than 45 seconds the water fill valve does not energize during the water purge. When the storage bin is full at the end of a harvest sequence, 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. The ice machine remains off for 3 minutes before it can automatically restart. After the 45 second water purge, the water fill valve, water pump and dump valve de-energize. (Refer to “Water Purge Adjustment” on Page 3-3 for details.) The harvest valve(s) and HPR solenoid valve also open at the beginning of the water purge. The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to drop clear of the water curtain. As the water curtain swings back to the operating position, the bin switch re-closes and the ice machine restarts (steps 1 - 2) provided the 3 minute delay period is complete. 6. Harvest The HPR valve and the harvest valve(s) remain open and the refrigerant gas warms the evaporator causing the cubes to slide, as a sheet, off the evaporator and into the storage bin. The sliding sheet of cubes swings the water curtain out, opening the bin switch. The momentary opening and re-closing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence (Step 3 - 4.) Figure 4-6. Automatic Shut-Off (Typical Q450 Shown) Figure 4-5. Harvest Sequence (Typical Q450 Shown) 4-4 Part No. 80-1100-3 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. The water fill valve energizes after the 45second water purge, and remains on until the water level probe is satisfied. FREEZE CYCLE 3. The water pump starts after the 30-second pre-chill. An even flow of water is directed across the evaporator and into each cube cell. During the first 45 seconds of the Freeze Cycle, the water fill valve cycles on and off as many times as needed to refill the water trough. After the 45 seconds, the water fill valve cycles on and off one more time to refill the water trough. The water fill valve then remains off for the duration of the Freeze Cycle. WATER INLET VALVE SAFETY SHUT-OFF 2. To pre-chill the evaporator, there is no water flow over the evaporator for the first 30 seconds of the freeze cycle. This feature limits the water inlet valve to a six-minute on time. Regardless of the water level probe input, the control board automatically shuts off the water inlet valve if it remains on for 6 continuous minutes. WATER INLET VALVE TO DISTRIBUTION TUBE WATER PUMP WATER DUMP VALVE TO DRAIN SV1677 Figure 5-1. Water Flow Over the Evaporator Part No. 80-1100-3 5-1 Water System Ice Making Sequence of Operation HARVEST CYCLE Section 5 AUTOMATIC SHUT-OFF 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. WATER INLET VALVE TO DISTRIBUTION TUBE WATER PUMP WATER DUMP VALVE TO DRAIN SV1677 Figure 5-2. Water Flow Down the Drain 5-2 Part No. 80-1100-3 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. Freeze 1 Water Pump Control Board Relays 3 4 Water Water Fill Harvest Dump Valve Valve(s) Valve 2 Contactor 5 5A 5B Contactor Coil Compressor Condenser Fan Motor Length Of Time On Off On On Off Off Off 45 Seconds Off On On Off On On May Cycle On/Off 5 Seconds Off Off On On May Cycle On/Off 30 Seconds Until 7 sec. water contact with ice thickness probe Off On May cycle On/ Off during first 45 sec. ----------Cycles On, then Off 1 more time Off Off On On May Cycle On/Off Locked Out After Six Minutes HARVEST SEQUENCE 5. Water Purge On 30 sec. Off, 15 sec. On On On On On May Cycle On/Off Factory-set at 45 Seconds 6. Harvest Off Off On Off On On May Cycle On/Off 7. AUTOMATIC SHUT-OFF Off Off Off Off Off Off Off Bin switch activation Until bin switch re-closes 1. Initial Start-Up or Start-Up After Automatic Shut-Off Condenser Fan Motor FREEZE SEQUENCE The fan motor is wired through a fan cycle pressure control, therefore, it may cycle on and off. • The ice machine is locked into the freeze cycle for the first 6 minutes, not allowing the ice thickness probe to initiate a harvest sequence. • The maximum freeze time is 60 minutes, at which time the control board automatically initiates a harvest sequence (steps 5-6). Harvest Water Purge The circuit board has an adjustable water purge in the harvest cycle. This permits a 15, 30 or 45 second purge cycle. Auto Shut-Off The ice machine remains off for 3 minutes before it can automatically restart. The ice machine restarts (steps 12) immediately after the delay period, if the bin switch recloses prior to 3 minutes. Safety Timers HARVEST SEQUENCE The maximum harvest time is 3-1/2 minutes, at which time the control board automatically terminates the harvest sequence. If the bin switch is open, the ice machine will go to automatic shut-off (step 7). If the bin switch is closed, the ice machine will go to the freeze sequence (steps 3-4). The control board has the following non-adjustable safety timers: Part No. 80-1100-3 6-1 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. water contact with ice thickness probe Off 4. Freeze On HARVEST SEQUENCE 5. Water Purge On 6. Harvest 7. AUTOMATIC SHUT-OFF May cycle On/Off during first 45 sec. -----------Cycles On, then Off 1 more time Locked Out After Six Minutes b. HPR Solenoid Off Off On On On 30 sec. Off, 15 sec. On On On On On On Off Off On Off On On On Off Off Off Off Off Off Off Factory-set at 45 Seconds Bin switch activation Until bin switch recloses 1. Initial Start-Up or Start-Up After Automatic Shut-Off Auto Shut-Off FREEZE SEQUENCE The ice machine remains off for 3 minutes before it can automatically restart. The ice machine restarts (steps 12) immediately after the delay period, if the bin switch recloses prior to 3 minutes. • The ice machine is locked into the freeze cycle for the first 6 minutes, not allowing the ice thickness probe to initiate a harvest sequence. • The maximum freeze time is 60 minutes, at which time the control board automatically initiates a harvest sequence (steps 5-6). Harvest Water Purge The circuit board has an adjustable water purge in the harvest cycle. This permits a 15, 30 or 45 second purge cycle. Safety Timers The control board has the following non-adjustable safety timers: 6-2 HARVEST SEQUENCE • The maximum harvest time is 3-1/2 minutes, at which time the control board automatically terminates the harvest sequence. If the bin switch is open, the ice machine will go to automatic shut-off (step 7). If the bin switch is closed, the ice machine will go to the freeze sequence (steps 3-4). Part No. 80-1100-3 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 (76) 3 (57) (58) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C 1G CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL (62) The harvest valve(s) is also energized during the water purge. In the case of an initial refrigeration start-up, it stays on for an additional 5 seconds (50 seconds total). BIN SWITCH LIGHT (63) (64) BIN SWITCH TB30 TB30 1F NOT USED (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 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. (80) HARVEST SOLENOID 4 1 1. WATER PURGE (22) (21) (20) (55) TB32 TB35 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) (66) (62) VIEW FOR WIRING ICE 68 INTERNAL WORKING VIEW OFF 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) C (48) TB30 (45) L1 (51) (52) (85) (86) TB33 PTCR (53) TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-1 Figure 6-1. Self-Contained — Water Purge Table 6-1. Self-Contained Models 1. Water Purge (45 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Closed Closed / ON Open / OFF Closed / ON Closed / ON Open / OFF OFF OFF Closed Closed 6-3 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. VOLTAGE PLUG WATER LEVEL (62) BIN SWITCH LIGHT (63) (64) BIN SWITCH TB30 TB30 1F 1G (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 At the same time the compressor starts, the condenser fan motor (aircooled models) is supplied with power. It continues to be supplied with power throughout the Freeze and Harvest cycles. The fan motor is wired through a fan cycle pressure control, and may cycle on and off. (The compressor and the condenser fan motor are wired through the contactor. Any time the contactor coil is energized, these components are supplied with power.) (76) 3 The harvest valve(s) remains on for the first 5 seconds of the initial compressor start-up. (80) HARVEST SOLENOID 4 The water fill valve is energized at the same time as the compressor. It remains on until the water level sensor closes for 3 continuous seconds. (22) (21) (20) (55) TB32 TB35 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) 68 INTERNAL WORKING VIEW OFF (66) (62) VIEW FOR WIRING ICE 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) TB30 C (48) (45) L1 (51) (52) (85) (86) PTCR (53) TB33 TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-2 Figure 6-2. Self-Contained — Refrigeration System Start-Up Table 6-2. Self-Contained Models 2. Refrigeration System Start Up (5 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-4 ICE Closed Open / OFF Closed / ON Closed / ON Open / OFF Closed / ON ON ON Closed Closed Part No. 80-1100-3 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. (22) (21) (20) (55) TB32 TB35 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) BIN SWITCH LIGHT (63) (64) BIN SWITCH TB30 TB30 1F 1G (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) 68 INTERNAL WORKING VIEW OFF (66) (62) VIEW FOR WIRING ICE 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) C (48) TB30 (45) L1 (51) (52) (85) (86) TB33 PTCR (53) TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-3 Figure 6-3. Self-Contained — Pre-Chill Table 6-3. Self-Contained Models 3. Pre-Chill (30 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Closed Open / OFF Closed / ON Open / OFF Open / OFF Closed / ON ON ON Closed Closed 6-5 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. VOLTAGE PLUG WATER LEVEL (62) BIN SWITCH LIGHT (63) (64) BIN SWITCH TB30 TB30 1F 1G (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP (58) TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 NOTE: The ice machine cannot initiate a harvest cycle until a 6minute freeze lock has expired. (80) HARVEST SOLENOID 4 When sufficient ice has formed, the water flow (not the ice) contacts the ice thickness probes. After approximately 7 seconds of continual contact, a harvest cycle is initiated. (22) (21) (55) TB32 TB35 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) (66) (62) VIEW FOR WIRING ICE 68 INTERNAL WORKING VIEW OFF 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) C (48) TB30 (45) L1 (51) (52) (85) (86) TB33 PTCR (53) TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-4 Figure 6-4. Self-Contained — Freeze Table 6-4. Self-Contained Models 4. Freeze (Until 7 Seconds of Water Contact with Ice Thickness Probe) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-6 ICE Closed Closed / ON Cycles ON then OFF Open / OFF Open / OFF Closed / ON ON ON Closed Closed Part No. 80-1100-3 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. The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge. If set at less than 45 seconds, the water fill valve does not energize during the water purge. (20) (61) WATER VALVE (60) HIGH PRES CUTOUT (77) 2 1 (76) 3 (57) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL (62) BIN SWITCH LIGHT (63) BIN SWITCH TB30 TB30 1F 1G (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP (58) TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 (64) (80) HARVEST SOLENOID 4 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) After the 45 second water purge, the water fill valve, water pump and dump valve de-energize. (Refer to “Water Purge Adjustment” on Page 3-3 for details.) The harvest valve also opens at the beginning of the water purge to divert hot refrigerant gas into the evaporator. (22) (21) (55) TB32 TB35 (66) (66) (62) VIEW FOR WIRING ICE 68 INTERNAL WORKING VIEW OFF 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) C (48) TB30 (45) L1 (51) (52) (85) (86) TB33 PTCR (53) TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-5 Figure 6-5. Self-Contained — Water Purge Table 6-5. Self-Contained Models 5. Water Purge (45 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Closed Closed / ON Cycles OFF then ON Closed / ON Closed / ON Closed / ON ON ON Closed Closed 6-7 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. This momentary opening and closing of the bin switch terminates the Harvest Cycle and returns the ice machine to the Freeze Cycle (steps 3-4). (22) (21) (61) TB35 (57) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL (62) BIN SWITCH LIGHT (63) (64) BIN SWITCH TB30 TB30 1F 1G (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP (58) TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) (66) (62) VIEW FOR WIRING ICE 68 INTERNAL WORKING VIEW OFF 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) C (48) TB30 (45) L1 (51) (52) (85) (86) PTCR (53) TB33 TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-6 Figure 6-6. Self-Contained — Harvest Table 6-6. Self-Contained Models 6. Harvest (Until Bin Switch Activation) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-8 ICE Closed Open / OFF Open / OFF Closed / ON Open / OFF Closed / ON ON ON Closed Closed Part No. 80-1100-3 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) (59) TERMINATES AT PIN CONNECTION (73) ICE THICKNESS PROBE 1C NOT USED CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL (62) BIN SWITCH LIGHT (63) (64) BIN SWITCH TB30 TB30 1F 1G (74) CONTACTOR COIL (56) WATER LEVEL PROBE TB30 WATER PUMP (58) TB37 TB30 (99) (98) TB31 TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 NOTE: The ice machine must remain off for 3 minutes before it can automatically restart. (80) HARVEST SOLENOID 4 The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain. As the water curtain swings back to the operating position, the bin switch closes and the ice machine restarts (steps 1-2). (22) (21) (20) (55) TB32 TB35 HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) (66) (62) VIEW FOR WIRING ICE 68 INTERNAL WORKING VIEW OFF 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD (42) S RUN CAPACITOR (46) R R (50) C (48) TB30 (45) L1 (51) (52) (85) (86) PTCR (53) TB33 TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646-7 Figure 6-7. Self-Contained — Automatic Shut-Off Table 6-7. Self-Contained Models 7. Automatic Shut-Off (Until Bin Switch Closes) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid #4 Water Dump Valve #5 Contactor Coil Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Open Open / OFF Open / OFF Open / OFF Open / OFF Open / OFF OFF OFF Closed Closed 6-9 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. (78) (77) 4 HARVEST SOLENOID (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 TRANS. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 (64) (79) 2 1 NOTE: The harvest valve and harvest pressure regulating (HPR) solenoid valve are also energized during the water purge. In the case of an initial refrigeration start-up, they stay on for an additional 5 seconds (50 seconds total). (22) WATER VALVE (66) (62) VIEW FOR WIRING ICE OFF INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-1 RUN CAPACITOR Figure 6-8. Remote — Water Purge Table 6-8. Remote Models 1. Water Purge (45 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-10 ICE Closed Closed / ON Open / OFF Closed / ON Closed / ON Closed / ON Open / OFF De-energized OFF OFF Closed Closed Part No. 80-1100-3 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) HIGH PRES CUTOUT (78) (77) 4 HARVEST SOLENOID (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 TRANS. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 (64) (79) 2 1 The harvest valve and harvest pressure regulating (HPR) solenoid valve remain on for the first 5 seconds of the initial compressor start-up. (22) WATER VALVE HPR SOLENOID (61) (60) The water fill valve is energized at the same time as the compressor. It remains on until the water level sensor closes for 3 continuous seconds. VIEW FOR WIRING ICE OFF (66) (62) NOTE: (The compressor and the condenser fan motor are wired through the contactor. Any time the contactor coil is energized, these components are supplied with power.) (21) INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-2 RUN CAPACITOR Figure 6-9. Remote — Refrigeration System Start-Up Table 6-9. Remote Models 2. Refrigeration System Start-Up (5 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Closed Open / OFF Closed / ON Closed / ON Closed / ON Open / OFF Closed / ON Energized ON ON Closed Closed 6-11 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. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 (64) (79) 2 1 NOTE: The water fill valve remains on until the water level sensor closes for three continuous seconds. (22) WATER VALVE (66) (62) VIEW FOR WIRING ICE OFF INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-3 RUN CAPACITOR Figure 6-10. Remote — Pre-Chill Table 6-10. Remote Models 3. Pre-Chill (30 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-12 ICE Closed Open / OFF Closed / ON Open / OFF Open / OFF Open / OFF Closed / ON Energized ON ON Closed Closed Part No. 80-1100-3 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. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 (64) (75) DUMP SOLENOID 5 NOTE: The ice machine cannot initiate a harvest cycle until a 6minute freeze lock has expired. (80) (76) 3 When sufficient ice has formed, the water flow (not the ice) contacts the ice thickness probes. After approximately 7 seconds of continual contact, a harvest cycle is initiated. (79) 2 1 After six minutes the water inlet valve is locked out and can not add additional water. (22) WATER VALVE (66) (62) VIEW FOR WIRING ICE OFF INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-4 RUN CAPACITOR Figure 6-11. Remote — Freeze Table 6-11. Remote Models 4. Freeze (Until 7 Seconds of Water Contact with Ice Thickness Probe) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Closed Closed / ON Cycles / ON then OFF Open / OFF Open / OFF Open / OFF Closed / ON Energized ON ON Closed Closed 6-13 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. The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge. If set at less than 45 seconds the water fill valve does not energize during the water purge. TB32 TB35 (55) (60) HIGH PRES CUTOUT (78) (79) 2 (77) 4 HARVEST SOLENOID 1 (80) (75) (76) 3 DUMP SOLENOID 5 (57) TB31 TRANS. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 (64) (22) WATER VALVE HPR SOLENOID (61) (68) (69) (67) NOTE: After the 45 second water purge, the water fill valve, water pump and dump valve de-energize. (Refer to “Water Purge Adjustment” on Page 3-3 for details.) The harvest valve and HPR solenoid also open at the beginning of the water purge to divert hot refrigerant gas into the evaporator. (21) (66) (62) VIEW FOR WIRING ICE OFF INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-5 RUN CAPACITOR Figure 6-12. Remote — Water Purge Table 6-12. Remote Models 5. Water Purge (45 Seconds) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-14 ICE Closed Closed / ON Cycles / OFF then ON Closed / ON Closed / ON Closed / ON Closed / ON Energized ON ON Closed Closed Part No. 80-1100-3 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. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 (64) (79) (78) 2 1 The sliding sheet of cubes swings the water curtain out, opening the bin switch. This momentary opening and closing of the bin switch terminates the Harvest Cycle and returns the ice machine to the Freeze Cycle (steps 3-4). (22) WATER VALVE (66) (62) VIEW FOR WIRING ICE OFF INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-6 RUN CAPACITOR Figure 6-13. Remote — Harvest Table 6-13. Remote Models 6. Harvest (Until Bin Switch Activation) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) Part No. 80-1100-3 ICE Closed Open / OFF Open / OFF Closed / ON Closed / ON Open / OFF Closed / ON Energized ON ON Closed Closed 6-15 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. FUSE (7A) (99) (59) 1C (83) (82) LIQUID LINE SOLENOID WATER LEVEL PROBE WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) TB30 TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G NOT USED BIN SWITCH (74) CONTACTOR COIL (56) 1F TB30 WATER PUMP (73) ICE THICKNESS PROBE TB30 (81) (98) (58) TB37 NOTE: The ice machine must remain off for 3 minutes before it can automatically restart. (80) (76) 3 (64) (79) 2 1 The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain. As the water curtain swings back to the operating position, the bin switch closes and the ice machine restarts. (22) WATER VALVE (66) (62) VIEW FOR WIRING ICE OFF INTERNAL WORKING VIEW 68 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER SV1648-7 RUN CAPACITOR Figure 6-14. Remote — Automatic Shut-Off Table 6-14. Remote Models 7. Automatic Shut-Off (Until Bin Switch Closes) Toggle Switch Bin Switch Control Board Relays #1 Water Pump #2 Water Fill Valve #3 Harvest Solenoid Harvest Pressure Regulating (HPR) Solenoid #4 Water Dump Valve #5 Contactor Coil Liquid Line Solenoid Compressor Condenser Fan Motor Safety Controls (Which could stop ice machine operation) High Pressure Cut-Out Main Fuse (On Control Board) 6-16 ICE Open Open / OFF Open / OFF Open / OFF Open / OFF Open / OFF Open / OFF De-energized ON ON Closed Closed Part No. 80-1100-3 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. WIRING DIAGRAM LEGEND The following symbols are used on all of the wiring diagrams: * Internal Compressor Overload (Some models have external compressor overloads) ** Fan Motor Run Capacitor (Some models do not incorporate fan motor run capacitor) TB Terminal Board Connection (Terminal board numbers are printed on the actual terminal board) ( ) Wire Number Designation (The number is marked at each end of the wire) —>>— Multi-Pin Connection (Electrical Box Side) —>>— (Compressor Compartment Side) Part No. 80-1100-3 6-17 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. (58) TB37 (59) TERMINATES AT PIN CONNECTION (73) 1C WATER LEVEL PROBE TB30 TB30 WATER PUMP FUSE (7A) ICE THICKNESS PROBE L2 (N) (22) (56) 1F (74) TB30 CONTACTOR COIL TB30 CLEAN LIGHT NOT USED 1G LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT BIN SWITCH LIGHT (62) (63) (64) BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (67) (69) OFF (66) (66) VIEW FOR WIRING ICE (62) 68 INTERNAL WORKING VIEW 66 67 62 CLEAN 69 (49) TB30 COMPRESSOR (47) R CONTACTOR CONTACTS TB35 *OVERLOAD S (50) TB30 C PTCR (48) (42) L1 (51) TB33 (52) (85) (86) FAN CYCLE CONTROL (53) TB34 FAN MOTOR (AIR COOLED ONLY) TB30 RUN CAPACITOR** SV1654 6-18 Part No. 80-1100-3 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. WATER PUMP (58) (59) TERMINATES AT PIN CONNECTION ICE THICKNESS PROBE 1C WATER LEVEL PROBE 1F NOT USED 1G CONTACTOR COIL (56) CLEAN LIGHT (42) LOW D.C. VOLTAGE PLUG BIN SWITCH LIGHT (62) (63) (64) BIN SWITCH (74) WATER LEVEL HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) (68) (67) ICE 66 (69) OFF (66) (66) VIEW FOR WIRING 67 62 69 CLEAN (62) 68 COMPRESSOR R CONTACTOR CONTACTS OVERLOAD INTERNAL {230V 50/60 HZ} S C (47) S R (49) L1 C (48) 5 2 4 1 (46) (51) POTENTIAL RELAY (44) START CAPACITOR COMPRESSOR TERMINAL LAYOUT VIEWED FROM END OF COMPRESSOR (45) (50) (85) (86) FAN MOTOR (AIR COOLED ONLY) FAN CYCLE CONTROL RUN CAPACITOR** SV3018 Part No. 80-1100-3 6-19 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. (81) WATER PUMP TERMINATES AT PIN CONNECTION (59) FUSE (7A) ICE THICKNESS PROBE (58) 1C WATER LEVEL PROBE (56) 1F CLEAN LIGHT 1G NOT USED LOW D.C. VOLTAGE PLUG (42) (74) WATER LEVEL BIN SWITCH LIGHT (62) BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (63) (64) CONTACTOR COIL (65) TOGGLE SWITCH (68) (69) (67) VIEW FOR WIRING 68 ICE 66 OFF (66) CLEAN 67 62 69 (62) (49) COMPRESSOR (47) S R C CONTACTOR CONTACTS (50) *OVERLOAD PTCR (48) L1 FAN MOTOR (AIR COOLED ONLY) (51) (85) (86) FAN CYCLE CONTROL RUN CAPACITOR** COMPRESSOR (49) (47) RUN CAPACITOR R R OVERLOAD (50) (46) (48) (45) PTCR SV2070 6-20 Part No. 80-1100-3 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. DIAGRAM SHOWN DURING FREEZE CYCLE L1 L2 (N) (61) TB35 WATER VALVE (60) HIGH PRES CUTOUT (22) (21) (20) (55) TB32 (77) 2 (80) HARVEST SOLENOID 4 1 (76) 3 (57) FUSE (7A) TB30 WATER PUMP (58) TB37 (59) TERMINATES AT PIN CONNECTION (74) (73) TB30 1C ICE THICKNESS PROBE CONTACTOR COIL (56) 1G NOT USED (64) TB30 1F WATER LEVEL PROBE CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT BIN SWITCH (65) (67) (66) TB30 (99) (98) TB31 TRANS. (75) (81) DUMP SOLENOID 5 TOGGLE SWITCH (68) ICE VIEW FOR WIRING 68 (69) INTERNAL WORKING VIEW OFF (66) (62) 66 67 62 CLEAN 69 (49) COMPRESSOR (47) R CONTACTOR CONTACTS TB35 (42) *OVERLOAD RUN CAPACITOR R R S (46) (50) TB30 C (45) (48) L1 (51) PTCR (52) (85) (86) TB33 (53) TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1646 Part No. 80-1100-3 6-21 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) (55) (89) HIGH PRES CUTOUT 2 (77) 4 (88) (22) (21) WATER VALVE (61) HARVEST SOLENOID (60) 3 1 (80) (76) (75) DUMP SOLENOID 5 (57) TRANS. (98) (81) (99) WATER PUMP FUSE (7A) (59) TERMINATES AT PIN CONNECTION (58) ICE THICKNESS PROBE 1C CONTACTOR COIL (56) 1F WATER LEVEL PROBE LOW D.C. VOLTAGE PLUG 1G NOT USED (74) CLEAN LIGHT WATER LEVEL (62) BIN SWITCH (64) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (69) (67) (66) VIEW FOR WIRING ICE 68 OFF 66 CLEAN 67 62 (62) 69 (49) COMPRESSOR (50) S R (42) (50) (47) CONTACTOR CONTACTS *Overload C (48) L1 (45) (46) PTCR (51) (85) (86) FAN MOTOR (AIR COOLED ONLY) FAN CYCLE CONTROL RUN CAPACITOR** 6-22 SV2071 Part No. 80-1100-3 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) 3 (76) 5 DUMP SOLENOID (57) TB31 TRANS. FUSE (7A) (80) (75) TB30 (81) (99) (98) TB30 WATER PUMP (58) TB37 (59) ICE THICKNESS PROBE TERMINATES AT PIN CONNECTION (73) (74) TB30 1C (56) CONTACTOR COIL TB30 1F WATER LEVEL PROBE 1G NOT USED CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) (64) (22) (21) (20) TB32 BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) (67) (66) TOGGLE SWITCH (68) ICE (69) OFF (66) (62) VIEW FOR WIRING 68 INTERNAL WORKING VIEW 66 62 CLEAN 67 69 (96) TB30 (42) TB35 L3 L2 L1 TB33 (52) (85) (86) (53) TB34 FAN MOTOR (AIR COOLED ONLY) TB30 FAN CYCLE CONTROL T2 COMPRESSOR RUN CAPACITOR** T3 T1 SV1647a Part No. 80-1100-3 6-23 Electrical System Section 6 Q800/Q1000 - SELF CONTAINED - 3 PHASE WITHOUT TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE SEE SERIAL PLATE FOR VOLTAGE L3 L2 L1 (20) (89) (61) HIGH PRES CUTOUT (60) 2 (88) (77) HARVEST SOLENOID 4 3 (76) 5 DUMP SOLENOID (57) FUSE (7A) (59) CONTACTOR COIL (56) 1F NOT USED WATER LEVEL (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) (67) TOGGLE SWITCH (68) ICE (66) OFF VIEW FOR WIRING 68 66 (69) 62 (62) CLEAN L2 (74) CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G L3 TERMINATES AT PIN CONNECTION (58) 1C (64) (99) WATER PUMP ICE THICKNESS PROBE (75) (81) (98) TRANS. BIN SWITCH (80) 1 (42) WATER LEVEL PROBE (22) (21) WATER VALVE (55) 67 69 L1 FAN MOTOR (AIR COOLED ONLY) CONTACTOR CONTACTS (51) T2 (85) (86) FAN CYCLE CONTROL RUN CAPACITOR** T3 T1 SV2072 6-24 Part No. 80-1100-3 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) (99) (98) TB31 TRANS. TB30 (81) DUMP SOLENOID 5 TB30 WATER PUMP FUSE (7A) (58) TB37 ICE THICKNESS PROBE (80) 1C (59) TERMINATES AT PIN CONNECTION (73) (74) TB30 1F CONTACTOR COIL (56) WATER LEVEL PROBE TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G AUCS DISPENSE TIME WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) (64) BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (67) (66) VIEW FOR WIRING ICE 68 (69) INTERNAL WORKING VIEW OFF (66) (62) 66 67 62 CLEAN 69 CRANKCASE HEATER (94) (95) TB35 TB30 (49) COMPRESSOR (47) R CONTACTOR CONTACTS *OVERLOAD RUN CAPACITOR R (46) R (50) CONTACTOR CONTACTS C (48) (42) TB35 S (45) (96) L2 L1 (51) PTCR (52) (85) (86) (53) TB30 (44) TB34 TB33 FAN CYCLE CONTROL RUN CAPACITOR** FAN MOTOR (AIR COOLED ONLY) SV1652 Part No. 80-1100-3 6-25 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) (55) (89) (22) (21) WATER VALVE (61) HIGH PRES CUTOUT (60) (77) 2 (80) HARVEST SOLENOID 4 (88) 3 1 5 (75) (76) DUMP SOLENOID (81) (98) (99) (42) (57) TRANS. WATER PUMP FUSE (7A) (59) 1C ICE THICKNESS PROBE (58) CONTACTOR COIL 1F (56) WATER LEVEL PROBE AUCS DISPENSE TIME BIN SWITCH (64) CLEAN LIGHT 1G LOW D.C. VOLTAGE PLUG (74) WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) (67) (69) (66) (62) VIEW FOR WIRING 68 ICE OFF 66 CLEAN 62 67 69 CRANKCASE HEATER (95) (94) COMPRESSOR (49) S (47) R *OVERLOAD TERMINATES AT PIN CONNECTION RUN CAPACITOR (50) (46) C (48) (96) (45) L1 L2 CONTACTOR CONTACTS CONTACTOR CONTACTS PTCR (51) (85) (86) FAN MOTOR (AIR COOLED ONLY) FAN CYCLE CONTROL RUN CAPACITOR** SV2075 6-26 Part No. 80-1100-3 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. DIAGRAM SHOWN DURING FREEZE CYCLE (20) WATER VALVE (21) (22) TB32 TB35 RH HARVEST SOLENOID (61) HIGH PRES CUTOUT (88) 2 (76) 3 (57) TB31 (58) TB37 (59) ICE THICKNESS PROBE 1F (56) WATER LEVEL PROBE 1G AUCS DISPENSE TIME TB30 TERMINATES AT PIN CONNECTION (74) (73) 1C TB30 TB30 (99) WATER PUMP (98) TRANS. FUSE (7A) (75) (81) DUMP SOLENOID 5 TB30 CONTACTOR COIL TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) BIN SWITCH (80) LH HARVEST SOLENOID 1 (55) N - 50HZ ONLY (77) 4 (64) (87) (60) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) (67) (66) (66) TOGGLE SWITCH (68) ICE (69) OFF (62) VIEW FOR WIRING 68 INTERNAL WORKING VIEW 62 CLEAN CRANKCASE HEATER (95) 66 69 (94) TB35 67 TB30 (96) TB30 (42) NOTE: WIRE (96) IS NOT USED ON 50HZ TB35 L3 L2 L1 TB33 (52) (85) (86) FAN CYCLE CONTROL T2 COMPRESSOR (53) TB34 FAN MOTOR (AIR COOLED ONLY) RUN CAPACITOR** TB30 SV1653 T3 T1 Part No. 80-1100-3 6-27 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. (87) (80) LH HARVEST SOLENOID 5 (22) (98) (81) (99) WATER PUMP FUSE (7A) (59) ICE THICKNESS PROBE TERMINATES AT PIN CONNECTION (58) 1C CONTACTOR COIL (56) 1F WATER LEVEL PROBE BIN SWITCH (64) CLEAN LIGHT 1G LOW D.C. VOLTAGE PLUG AUCS DISPENSE TIME WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) TOGGLE SWITCH (68) ICE (69) OFF (66) (67) (62) CLEAN VIEW FOR WIRING 68 66 62 (95) 67 69 (94) CRANKCASE HEATER NOTE: WIRE (96) IS NOT USED ON 50HZ L3 L2 (96) L1 CONTACTOR CONTACTS FAN MOTOR (AIR COOLED ONLY) (51) (85) (86) FAN CYCLE CONTROL T2 RUN CAPACITOR** T3 T1 COMPRESSOR SV3008 6-28 Part No. 80-1100-3 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. (58) (59) (83) (82) LIQUID LINE SOLENOID (74) (73) 1C 1G NOT USED (64) TB30 CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT BIN SWITCH (65) TOGGLE SWITCH (68) (67) (66) TB30 CONTACTOR COIL (56) 1F WATER LEVEL PROBE TB30 WATER PUMP TB37 ICE THICKNESS PROBE TB30 (81) DUMP SOLENOID VIEW FOR WIRING ICE (69) OFF (66) (62) 68 INTERNAL WORKING VIEW 66 67 62 CLEAN 69 (49) COMPRESSOR R CONTACTOR CONTACTS TB35 *OVERLOAD (47) S RUN CAPACITOR (46) (48) (42) R R (50) TB30 C (45) L1 (51) PTCR (52) TERMINATES AT PIN CONNECTION TB33 (53) TB34 (F2) (F1) TB30 REMOTE FAN MOTOR REMOTE CONDENSER RUN CAPACITOR Part No. 80-1100-3 SV1648 6-29 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) (22) (21) 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. (42) (98) WATER PUMP FUSE (7A) (59) (83) (82) LIQUID LINE SOLENOID (58) 1C CONTACTOR COIL ICE THICKNESS PROBE (56) 1F CLEAN LIGHT WATER LEVEL PROBE LOW D.C. VOLTAGE PLUG 1G AUCS DISPENSE TIME (74) WATER LEVEL LIGHT BIN SWITCH LIGHT (62) BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (63) (64) (75) (65) TOGGLE SWITCH (68) (67) (66) (69) VIEW FOR WIRING ICE 68 OFF 66 (62) CLEAN 67 62 COMPRESSOR (49) R (47) 69 (94) RUN CAPACITOR S R (46) CONTACTOR CONTACTS *OVERLOAD R (50) C (48) (45) L1 PTCR (51) F1 F2 REMOTE FAN MOTOR REMOTE CONDENSER RUN CAPACITOR** 6-30 SV2073 Part No. 80-1100-3 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. FUSE (7A) (98) (81) (99) WATER PUMP (58) TB37 (59) TB30 TB30 (82) (83) LIQUID LINE SOLENOID ICE THICKNESS PROBE (73) 1C (56) (74) CONTACTOR COIL CLEAN LIGHT LOW D.C. VOLTAGE PLUG 1G AUCS DISPENSE TIME WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT BIN SWITCH (65) TB30 TB30 1F WATER LEVEL PROBE (64) (75) (76) 3 (55) (22) WATER VALVE (61) TB32 TB35 (21) (20) TOGGLE SWITCH (68) ICE (67) (69) OFF (66) (62) VIEW FOR WIRING INTERNAL WORKING VIEW 68 66 62 CLEAN 67 69 (96) TB30 (42) TB35 L3 L2 (F1) (F2) L1 TB30 CONTACTOR CONTACTS TB33 T2 (52) TERMINATES AT PIN CONNECTION (53) TB34 REMOTE FAN MOTOR COMPRESSOR T3 T1 REMOTE CONDENSER SV1649 RUN CAPACITOR Part No. 80-1100-3 6-31 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. (59) 1F (65) (66) TOGGLE SWITCH (68) ICE (69) OFF (62) (85) L1 CONTACTOR CONTACTS (56) CONTACTOR COIL (74) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (67) L3 L2 (82) BIN SWITCH LIGHT (63) (64) (83) (58) WATER LEVEL LIGHT (62) BIN SWITCH (99) CLEAN LIGHT 1G LOW D.C. VOLTAGE PLUG NOT USED (75) LIQUID LINE SOLENOID 1C WATER LEVEL PROBE (81) WATER PUMP FUSE (7A) ICE THICKNESS PROBE (80) (76) DUMP SOLENOID 5 (79) INTERNAL WORKING VIEW VIEW FOR WIRING 68 66 CLEAN 67 62 69 (F1) (F2) (51) REMOTE FAN MOTOR T2 REMOTE CONDENSER T3 T1 COMPRESSOR RUN CAPACITOR SV2074 6-32 Part No. 80-1100-3 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. (58) TB37 LIQUID LINE SOLENOID (74) (73) 1C 1F TB30 CONTACTOR COIL (56) WATER LEVEL PROBE (82) (83) (59) ICE THICKNESS PROBE TB30 1G AUCS DISPENSE TIME CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT BIN SWITCH (65) VIEW FOR WIRING TOGGLE SWITCH (68) (67) (66) ICE 68 (69) INTERNAL WORKING VIEW OFF (66) 66 CRANKCASE HEATER (95) 67 62 CLEAN (62) TB35 TB30 WATER PUMP FUSE (7A) (64) TB30 (81) 69 (94) TB30 (49) COMPRESSOR (47) R *OVERLOAD CONTACTOR CONTACTS (42) TB35 RUN CAPACITOR S R R (46) (50) CONTACTOR CONTACTS C (48) (45) (96) L1 L2 (51) TB33 PTCR (52) TERMINATES AT PIN CONNECTION (53) TB30 (44) (F2) TB34 (F1) REMOTE FAN MOTOR REMOTE CONDENSER RUN CAPACITOR Part No. 80-1100-3 SV1650 6-33 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. (98) (99) WATER PUMP TB37 FUSE (7A) (59) 1C ICE THICKNESS PROBE (82) (83) LIQUID LINE SOLENOID (58) 1F CONTACTOR COIL (56) WATER LEVEL PROBE CLEAN LIGHT 1G LOW D.C. VOLTAGE PLUG AUCS DISPENSE TIME (75) (81) DUMP SOLENOID 5 WATER LEVEL LIGHT (74) BIN SWITCH LIGHT (62) BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (63) (64) (65) TOGGLE SWITCH (68) (67) OFF (66) (62) INTERNAL WORKING VIEW 68 COMPRESSOR 67 66 CLEAN 62 CRANKCASE HEATER (95) (42) VIEW FOR WIRING ICE (69) 69 (94) (F2) (49) RUN CAPACITOR R S (47) (46) *OVERLOAD CONTACTOR CONTACTS R R (96) (50) CONTACTOR CONTACTS C (48) (45) L1 L2 (44) PTCR (51) (F1) (F2) REMOTE FAN MOTOR REMOTE CONDENSER SV2076 RUN CAPACITOR 6-34 Part No. 80-1100-3 Section 6 Electrical System Q1300/Q1800 - REMOTE - 3 PHASE WITH TERMINAL BOARD CAUTION: DISCONNECT POWER BEFORE WORKING ON ELECTRICAL CIRCUITRY. DIAGRAM SHOWN DURING FREEZE CYCLE WATER VALVE (21) (22) SEE SERIAL PLATE FOR VOLTAGE (20) L3 L2 N - 50HZ ONLY HPR SOLENOID L1 (78) (79) (88) (87) 2 (77) 4 LH HARVEST SOLENOID (80) RH HARVEST SOLENOID TB32 TB35 (61) HIGH PRES CUTOUT (60) 1 (55) 3 (76) 5 DUMP SOLENOID (57) TB31 TB30 TB30 WATER PUMP (58) TB37 (59) (82) LIQUID LINE SOLENOID (74) (83) ICE THICKNESS PROBE (73) 1C 1F (56) CONTACTOR COIL AUCS DISPENSE TIME CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT BIN SWITCH LIGHT (62) (63) (64) BIN SWITCH HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (65) (67) (66) (66) TOGGLE SWITCH (68) ICE (69) OFF (62) VIEW FOR WIRING 68 INTERNAL WORKING VIEW 66 67 62 CLEAN CRANKCASE HEATER (95) TB35 TB30 TB30 WATER LEVEL PROBE 1G TB30 (99) (98) TRANS. FUSE (7A) (75) (81) 69 (94) TB30 (96) (42) TB35 L3 L2 TB30 NOTE: WIRE (96) IS NOT USED ON 50HZ (F1) L1 CONTACTOR CONTACTS (51) T2 (F2) TB33 (52) TERMINATES AT PIN CONNECTION (53) TB34 REMOTE FAN MOTOR COMPRESSOR T3 T1 REMOTE CONDENSER RUN CAPACITOR SV1651 Part No. 80-1100-3 6-35 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 (98) WATER PUMP (57) FUSE (7A) (59) 1F (83) LOW D.C. VOLTAGE PLUG CONTACTOR COIL CLEAN LIGHT WATER LEVEL LIGHT BIN SWITCH (74) (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT (64) (65) (67) (82) LIQUID LINE SOLENOID (56) 1G NOT USED (99) (58) 1C WATER LEVEL PROBE (75) DUMP SOLENOID TRANS. ICE THICKNESS PROBE (80) (81) (76) 5 (42) (87) (88) HIGH PRES CUTOUT TOGGLE SWITCH (68) (69) VIEW FOR WIRING ICE OFF (66) (62) INTERNAL WORKING VIEW 67 62 CLEAN (95) 68 66 69 (94) NOTE: WIRE (96) IS NOT USED ON 50HZ (96) (96) (F1) L3 L2 L1 CONTACTOR CONTACTS (F2) (51) REMOTE FAN MOTOR T2 T3 T1 REMOTE CONDENSER COMPRESSOR RUN CAPACITOR SV2077 6-36 Part No. 80-1100-3 Section 6 Electrical System THIS PAGE INTENTIONALLY LEFT BLANK Part No. 80-1100-3 6-37 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: Specifications 1. Terminating the harvest cycle and returning the ice machine to the freeze cycle. The main fuse is 250 Volt, 7 amp. This occurs when the bin switch is opened and closed again within 7 seconds during the harvest cycle. Check Procedure ! Warning High (line) voltage is applied to the control board (terminals #55 and #56) at all times. Removing the control board fuse or moving the toggle switch to OFF will not remove the power supplied to the control board. 1. If the bin switch light is on with the water curtain closed, the fuse is good. ! Warning 2. Automatic ice machine shut-off. If the storage bin is full at the end of a harvest cycle, the sheet of cubes fails to clear the water curtain and holds it open. After the water curtain is held open for 7 seconds, the ice machine shuts off. The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain. As the water curtain swings back to the operating position, the bin switch closes and the ice machine restarts, provide the three-minute delay has expired. Disconnect electrical power to the entire ice machine before proceeding. 2. Remove the fuse. Check the resistance across the fuse with an ohm meter. Reading Open (OL) Closed (O) Result Replace fuse Fuse is good Important The water curtain must be ON (bin switch(s) closed) to start ice making. Specifications The bin switch is a magnetically operated reed switch. The magnet is attached to the lower right corner of the water curtain. The switch is attached to the evaporatormounting bracket. The bin switch is connected to a varying D.C. voltage circuit. (Voltage does not remain constant.) NOTE: Because of a wide variation in D.C. voltage, it is not recommended that a voltmeter be used to check bin switch operation. 6-38 Part No. 80-1100-3 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 Water Curtain Removal Notes The water curtain must be on (bin switch closed) to start ice making. While a freeze cycle is in progress, the water curtain can be removed and installed at any time without interfering with the electrical control sequence. If the ice machine goes into harvest sequence while the water curtain is removed, one of the following will happen: • Water curtain remains off: When the harvest cycle time reaches 3.5 minutes and the bin switch is not closed, the ice machine stops as though the bin were full. • Water curtain is put back on: If the bin switch closes prior to reaching the 3.5minute point, the ice machine immediately returns to another freeze sequence prechill. OHM Test 1. Disconnect the bin switch wires to isolate the bin switch from the control board. 2. Connect an ohmmeter to the disconnected bin switch wires. 3. Cycle the bin switch open and closed numerous times by opening and closing the water curtain. NOTE: To prevent misdiagnosis: • Always use the water curtain magnet to cycle the switch (a larger or smaller magnet will affect switch operation). • Watch for consistent readings when the bin switch is cycled open and closed (bin switch failure could be erratic). Part No. 80-1100-3 6-39 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: • Defective starting component Perform the resistance test after the compressor cools. The compressor dome should be cool enough to touch (below 120°F/49°C) to assure that the overload is closed and the resistance readings will be accurate. • Mechanically seized compressor To determine which you have: 1. Install high and low side gauges. SINGLE PHASE COMPRESSORS 2. Try to start the compressor. 1. Disconnect power from the cuber and remove the wires from the compressor terminals. 3. Watch the pressures closely. A. If the pressures do not move, the compressor is seized. Replace the compressor. 2. The resistance values must be within published guidelines for the compressor. The resistance values between C and S and between C and R, when added together, should equal the resistance value between S and R. 3. If the overload is open, there will be a resistance reading between S and R, and open readings between C and S and between C and R. Allow the compressor to cool, then check the readings again. THREE PHASE COMPRESSORS 1. Disconnect power from the cuber and remove the wires from the compressor terminals. 2. The resistance values must be within published guidelines for the compressor. The resistance values between L1 and L2, between L2 and L3, and between L3 and L1 should all be equal. 3. If the overload is open, there will be open readings between L1 and L2, between L2 and L3, and between L3 and L1. Allow the compressor to cool, then check the readings again. B. If the pressures move, the compressor is turning slowly and is not seized. Check the capacitors and start relay. COMPRESSOR DRAWING HIGH AMPS The continuous amperage draw on start-up should not be near the maximum fuse size indicated on the serial tag. The voltage when the compressor is trying to start must be within ±10% of the nameplate voltage. Diagnosing Capacitors • If the compressor attempts to start, or hums and trips the overload protector, check the starting components before replacing the compressor. • Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane. Do not assume a capacitor is good if no visual evidence is present. • A good test is to install a known good substitute capacitor. • Use a capacitor tester when checking a suspect capacitor. Clip the bleed resistor off the capacitor terminals before testing. Check Motor Windings to Ground Check continuity between all three terminals and the compressor shell or copper refrigeration line. Scrape metal surface to get good contact. If continuity is present, the compressor windings are grounded and the compressor should be replaced. 6-40 Part No. 80-1100-3 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. The PTCR has a low resistance over a wide (low) temperature range, but upon reaching a certain higher temperature, its resistance greatly increases, virtually stopping current flow. When the source of heat is removed, the PTCR returns to its initial base resistance. In severe duty cycles, it can be used to repeatedly switch (virtually stop) large currents at line voltages. PTCR’s have been used for many years in millions of HVAC applications. In place of using the conventional start relay/start capacitor, a simple PTCR provides the starting torque assistance to PSC (Permanent Split Capacitor) single-phase compressors, which can equalize pressures before starting. 1. It is important for the refrigerant discharge and suction pressures to be somewhat equalized prior to the compressor starting. To assure equalization of pressures the harvest valve (and HPR valve on remotes) will energize for 45 seconds prior to compressor starting. The harvest valve (and HPR valve on remotes) remains on for an additional 5 seconds while the compressor is starting. 2. When starting the compressor, the contactor closes and the PTCR, which is at a low resistance value, allows high starting current to flow in the start winding. 3. The current passing through the PTCR causes it to rapidly heat up, and after approximately .25-1 second it abruptly “switches” to a very high resistance, virtually stopping current flow through it. 4. At this point the motor is up to speed and all current going through the start winding will now pass through the run capacitor. 5. The PTCR remains hot and at a high resistance as long as voltage remains on the circuit. 6. It is important to provide time between compressor restarts to allow the PTCR to cool down to near its initial temperature (low resistance). When the contactor opens to stop the compressor, the PTCR cools down to its initial low resistance and is again ready to provide starting torque assistance. To assure the PTCR has cooled down, during an automatic shut-off, the Q model ice machines have a built-in 3-minute off time before it can restart. Part No. 80-1100-3 6-41 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. WHY A GOOD PTCR MAY FAIL TO START THE COMPRESSOR The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the water curtain. As the water curtain swings back to operating position, the bin switch closes and the ice machine restarts, provided the three-minute delay period is complete. L1 L2 CONTACTOR CONTACTS C R For example, if the PTCR is properly cooled, say 60°F (15.6°C) when the compressor starts, it will take .25 to 1.0 seconds before its temperature reaches 260°F (126.6°C), and current flow is stopped. If the PTCR is still warm, say 160°F (71.1°C) when the compressor starts, it will take only .125 to .50 seconds before its temperature reaches 260°F (126.6°C), and current flow is stopped. This decreased time may be insufficient to start the compressor. A good PTCR may be too hot to operate properly at start-up because: RUN CAPACITOR R The PTCR must be cooled before attempting to start the compressor, otherwise the high starting torque may not last long enough. R • The ice machine’s 3-minute delay has been overridden. Opening and closing the service disconnect or cycling the toggle switch from OFF to ICE will override the delay period. • The control box temperature is too high. Though rare, very high air temperatures (intense sunlight, etc.) can greatly increase the temperature of the control box and its contents. This may require a longer off time to allow the PTCR to cool. • The compressor has short-cycled, or the compressor overload has opened. Move the toggle switch to OFF and allow the compressor and PTCR to cool. S COMPRESSOR SV1506 PTCR Figure 6-15. During Start-Up (First .25 - 1.0 Seconds) L2 L1 CONTACTOR CONTACTS C R RUN CAPACITOR R Continued on next page … R S COMPRESSOR PTCR SV1507 Figure 6-16. After Start-Up (Current Flows Through Run Capacitor) 6-42 Part No. 80-1100-3 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. These two pressures must be somewhat equalized before attempting to start the compressor. The harvest valve (and HPR valve on remotes) energizes for 45 seconds before the compressor starts, and remains on 5 seconds after the compressor starts. Make sure this is occurring and the harvest valve (and HPR solenoid) coil is functional before assuming that the PTCR is bad. Model Q200 Q280 Q320 Q420 Q450 Q600 Q800 Q1000 Q1300 Q1600 Q1800 Room Manitowoc Cera-Mite Temperature Part Number Part Number Resistance 8505003 305C20 22-50 Ohms 8504993 305C19 18-40 Ohms 8504913 305C9 8-22 Ohms CHECKING THE PTCR ! Warning Disconnect electrical power to the entire ice machine at the building electrical disconnect box before proceeding. SV1540 1. Visually inspect the PTCR. Check for signs of physical damage. Figure 6-17. Manitowoc PTCR’s 8505003 & 8504993 NOTE: The PTCR case temperature may reach 210°F (100°C) while the compressor is running. This is normal. Do not change a PTCR just because it is hot. 2. Wait at least 10 minutes for the PTCR to cool to room temperature. 3. Remove the PTCR from the ice machine. 4. Measure the resistance of the PTCR as shown below. If the resistance falls outside of the acceptable range, replace it. SV1541 Figure 6-18. Manitowoc PTCR 8504913 Part No. 80-1100-3 6-43 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. There are five relays on the control board: Check Procedure NOTE: Because of a wide variation in D.C. voltage, it is not recommended that a volt meter be used to check toggle switch operation. 1. Inspect the toggle switch for correct wiring. 2. Isolate the toggle switch by disconnecting all wires from the switch, or by disconnecting the Molex connector and removing wire #69 from the toggle switch. Relay #1 #2 #3 #4 #5 Controls Water Pump Water Inlet Valve Harvest Valve / HPR Valve (Remotes) Water Dump Valve Contactor (Self-Contained) Contactor / Liquid Line Solenoid (Remotes) 3. Check across the toggle switch terminals using a calibrated ohm meter. Note where the wire numbers are connected to the switch terminals, or refer to the wiring diagram to take proper readings. Switch Setting ICE CLEAN OFF Terminals 66-62 67-68 67-69 66-62 67-68 67-69 66-62 67-68 67-69 Ohm Reading Open Closed Open Closed Open Closed Open Open Open 4. Replace the toggle switch if ohm readings do not match all three switch settings. 6-44 Part No. 80-1100-3 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. Control Board Part No. 80-1100-3 6-45 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. Safety Limits In addition to standard safety controls, such as the high pressure cut-out, the control board has built-in safety limits. These safety limits protect the ice machine from major component failures. For more information, see “Safety Limits” on Page 7-13. Refer to specific component specifications (inputs), wiring diagrams and ice machine sequence of operation sections for details. As an example, refer to “Ice Thickness Probe” on the next page for information relating to how the probe and control board function together. This section will include items such as: 6-46 • How a harvest cycle is initiated • How the harvest light functions with the probe • Freeze time lock-in feature • Maximum freeze time • Diagnosing ice thickness control circuitry Part No. 80-1100-3 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. After the water completes this circuit across the probe continuously for 6-10 seconds, a harvest cycle is initiated. ICE THICKNESS CHECK The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8" (3.2 mm). NOTE: Make sure the water curtain is in place when performing this check. It prevents water from splashing out of the water trough. 1. Inspect the bridge connecting the cubes. It should be about 1/8" (3.2 mm) thick. 2. If adjustment is necessary, turn the ice thickness probe adjustment screw clockwise to increase bridge thickness, or counterclockwise to decrease bridge thickness. NOTE: Turning the adjustment 1/3 of a turn will change the ice thickness about 1/16" (1.5 mm). SV1730A ADJUSTING SCREW Figure 6-20. Ice Thickness Probe HARVEST/SAFETY LIMIT LIGHT 1/8” ICE BRIDGE THICKNESS This light’s primary function is to be on as water contacts the ice thickness probe during the freeze cycle, and remain on throughout the entire harvest cycle. The light will flicker as water splashes on the probes. SV1208 Figure 6-21. Ice Thickness Check The light’s secondary function is to continuously flash when the ice machine is shut off on a safety limit, and to indicate which safety limit shut off the ice machine. Make sure the ice thickness probe wire and the bracket do not restrict movement of the probe. FREEZE TIME LOCK-IN FEATURE Ice Thickness Probe Cleaning The ice machine control system incorporates a freeze time lock-in feature. This prevents the ice machine from short cycling in and out of harvest. 1. Mix a solution of Manitowoc ice machine cleaner and water (2 ounces of cleaner to 16 ounces of water) in a container. The control board locks the ice machine in the freeze cycle for six minutes. If water contacts the ice thickness probe during these six minutes, the harvest light will come on (to indicate that water is in contact with the probe), but the ice machine will stay in the freeze cycle. After the six minutes are up, a harvest cycle is initiated. This is important to remember when performing diagnostic procedures on the ice thickness control circuitry. 2. Soak ice thickness probe in container of cleaner/ water solution while disassembling and cleaning water circuit components (soak ice thickness probe for 10 minutes or longer). To allow the service technician to initiate a harvest cycle without delay, this feature is not used on the first cycle after moving the toggle switch OFF and back to ICE. 3. Clean all ice thickness probe surfaces including all plastic parts (do not use abrasives). Verify the ice thickness probe cavity is clean. Thoroughly rinse ice thickness probe (including cavity) with clean water, then dry completely. Incomplete rinsing and drying of the ice thickness probe can cause premature harvest. 4. Reinstall ice thickness probe, then sanitize all ice machine and bin/dispenser interior surfaces. Part No. 80-1100-3 6-47 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. ICE THICKNESS PROBE CLEAN LIGHT WATER LEVEL LIGHT BIN SWITCH LIGHT HARVEST/SAFETY LIMIT LIGHT EVAPORATOR GROUND SV3010 JUMPER WIRE SV1588A Figure 6-22. Step 2 Step 2 Jumper wire connected from probe to ground Monitoring of Harvest Light Correction The harvest light comes on, and 6-10 seconds later, ice The ice thickness control circuitry is functioning properly. Do machine cycles from freeze to harvest. not change any parts. The harvest light comes on but the ice machine stays in the The ice thickness control circuitry is functioning properly. The freeze sequence. ice machine is in a six-minute freeze time lock-in. Verify step 1 of this procedure was followed correctly. The harvest light does not come on. Proceed to Step 3, below. Step 3 Disconnect the ice thickness probe from the control board at terminal 1C. Clip the jumper wire leads to terminal 1C on the control board and any cabinet ground. Monitor the harvest light. ICE THICKNESS PROBE CLEAN LIGHT WATER LEVEL LIGHT EVAPORATOR BIN SWITCH LIGHT JUMPER WIRE HARVEST/SAFETY LIMIT LIGHT 1C GROUND SV3011 SV1588G Figure 6-23. Step 3 Step 3 Jumper wire connected from control board terminal 1C to ground Monitoring of Harvest Light Correction The harvest light comes on, and 6-10 seconds later, ice The ice thickness probe is causing the malfunction. machine cycles from freeze to harvest. The harvest light comes on but the ice machine stays in the The control circuitry is functioning properly. The ice machine is freeze sequence. in a six-minute freeze time lock-in (verify step 1 of this procedure was followed correctly). The harvest light does not come on. The control board is causing the malfunction. 6-48 Part No. 80-1100-3 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. Step 2 Step 2 Disconnect probe from control board terminal 1C. Monitoring of Harvest Light Correction The harvest light stays off and the ice machine remains in the The ice thickness probe is causing the malfunction. freeze sequence. Verify that the Ice Thickness probe is adjusted correctly. The harvest light comes on, and 6-10 seconds later, the ice The control board is causing the malfunction. machine cycles from freeze to harvest. Part No. 80-1100-3 6-49 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. The water level light is on when water contacts the probe, and off when no water is in contact with the probe. The water level light functions any time power is applied to the ice machine, regardless of toggle switch position. During the first 45 seconds of the Freeze Cycle: • The water inlet valve is on when there is no water in contact with the water level probe. • The water inlet valve turns off after water contacts the water level probe for 3 continuous seconds. • The water inlet valve will cycle on and off as many times as needed to fill the water trough. After 45 seconds into the Freeze Cycle: The water inlet valve will cycle on, and then off one more time to refill the water trough. The water inlet valve is now off for the duration of the freeze sequence. HARVEST CYCLE CIRCUITRY The water level probe does not control the water inlet valve during the harvest cycle. During the harvest cycle water purge, the water inlet valve energizes (turns on) and de-energizes (turns off) strictly by time. The harvest water purge adjustment dial may be set at 15, 30 or 45 seconds. CONTROL BOARD SV1616 HARVEST WATER PURGE ADJUSTMENT 30 45 Figure 6-25. Freeze Cycle Water Level Setting During the freeze cycle, the water level probe is set to maintain the proper water level above the water pump housing. The water level is not adjustable. If the water level is incorrect, check the water level probe for damage (probe bent, etc.). Repair or replace the probe as necessary. 15 SV1617 WATER INLET VALVE SAFETY SHUT-OFF In the event of a water level probe failure, this feature limits the water inlet valve to a six-minute on time. Regardless of the water level probe input, the control board automatically shuts off the water inlet valve if it remains on for 6 continuous minutes. This is important to remember when performing diagnostic procedures on the water level control circuitry. 6-50 NOTE: The water purge must be at the factory setting of 45 seconds for the water inlet valve to energize during the last 15 seconds of the Water Purge. If set at 15 or 30 seconds the water inlet valve will not energize during the harvest water purge. Part No. 80-1100-3 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. Important This restart must be done prior to performing diagnostic procedures. This assures the ice machine is not in a freeze cycle water inlet valve safety shut-off mode. You must complete the entire diagnostic procedure within 6 minutes of starting. Important For the test to work properly you must wait until the freeze cycle starts, prior to connecting the jumper wire. If you restart the test you must disconnect the jumper wire, restart the ice machine, (step 1) and then reinstall the jumper wire after the compressor starts. YELLOW GR EE N GR EE N CLEAN LIGHT WATER LEVEL LIGHT BIN SWITCH LIGHT R ED HARVEST/SAFETY LIMIT LIGHT 1C 1F GR O U N D JUMP ER SV1621a Figure 6-26. Step 2 Is water flowing into the water trough? no Step 2 Jumper wire connected from probe to ground The Water Inlet Valve The Water Level Light is: Solenoid Coil is: on De-Energized yes on De-Energized yes off Energized Cause This is normal operation. Do not change any parts. The water inlet valve is causing the problem. Proceed to step 3. Continued on next page … Part No. 80-1100-3 6-51 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. If past 6 minutes you must restart this test by disconnecting the jumper wire, restarting the ice machine, (step 1) and then reinstalling the jumper wire to terminal 1F, after the compressor starts. YELLOW GREEN WATER LEVEL LIGHT GREEN BIN SWITCH LIGHT RED G R O U ND JUMPER CLEAN LIGHT HARVEST/SAFETY LIMIT LIGHT 1C 1F SV1588b Figure 6-27. Step 3 Is water flowing into the water trough? no yes yes 6-52 Step 3 Jumper wire connected from control board terminal 1F to ground The Water Level The Water Inlet Valve Cause Light is: Solenoid Coil is: The water level probe is causing the problem. on De-Energized Clean or replace the water level probe. off Energized The control board is causing the problem. on De-Energized The water fill valve is causing the problem. Part No. 80-1100-3 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. This assures the ice machine is not in a freeze cycle water inlet valve safety shutoff mode. You must complete the entire diagnostic procedure within 6 minutes of starting. Is water flowing into the water trough? yes no Step 2 Checking for normal operation The Water Level The Water Inlet Valve Cause Light is: Solenoid Coil is: off Energized This is Normal Operation don’t change any parts on or off Energized Or De-Energized Proceed to step 3 Step 3 Leave the ice machine run, then disconnect the water level probe from control board terminal 1F. Important For the test to work properly you must wait until the freeze cycle starts, prior to disconnecting the water level probe. If you restart the test you must reconnect the water level probe, restart the ice machine, (step 1) and then disconnect the water level probe after the compressor starts. YELLOW DISCONNECT WATER LEVEL PROBE FROM TERMINAL 1F CLEAN LIGHT GREEN WATER LEVEL LIGHT GREEN BIN SWITCH LIGHT RED HARVEST/SAFETY LIMIT LIGHT 1C 1F SV1621G SV1588 Figure 6-28. Step 3 Is water flowing into the water trough? yes no no Part No. 80-1100-3 Step 3 Disconnect water level probe from control board terminal 1F The Water Level The Water Inlet Valve Cause Light is: Solenoid Coil is: off Energized The water level probe is causing the problem. Clean or replace the water level probe. off Energized The water inlet valve is causing the problem. on or off De-Energized The control board is causing the problem. 6-53 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. Verify ICE/OFF/CLEAN toggle switch functions properly. Verify low DC voltage is properly grounded. Replace the control board. Notes Verify that the fuse or circuit breaker is closed. The H.P.C.O. is closed if primary power voltage is present at terminals #55 and #56 on the control board. If the bin switch light functions, the fuse is OK. A defective bin switch can falsely indicate a full bin of ice. A defective toggle switch may keep the ice machine in the OFF mode. Loose DC wire connections may intermittently stop the ice machine. Be sure Steps 1-6 were followed thoroughly. Intermittent problems are not usually related to the control board. NOTE: Refer to wiring diagram on Page 6-55 for component and sequence identification. 6-54 Part No. 80-1100-3 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. DIAGRAM SHOWN DURING FREEZE CYCLE L1 L2 (N) 1 (61) TB35 WATER VALVE (60) HIGH PRES CUTOUT (77) 2 (80) HARVEST SOLENOID 4 2 (22) (21) (20) (55) TB32 1 (76) 3 (57) FUSE (7A) TB30 WATER PUMP (58) TB37 3 (59) TERMINATES AT PIN CONNECTION (74) (73) TB30 1C ICE THICKNESS PROBE 1G (64) TB30 1F NOT USED 4 CLEAN LIGHT LOW D.C. VOLTAGE PLUG WATER LEVEL LIGHT (62) BIN SWITCH LIGHT (63) HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT BIN SWITCH (65) (67) 6 (66) TOGGLE SWITCH (68) ICE (66) (47) R (42) 66 67 62 CLEAN 69 (49) COMPRESSOR *OVERLOAD 68 INTERNAL WORKING VIEW OFF 5 CONTACTOR CONTACTS VIEW FOR WIRING (69) (62) TB35 CONTACTOR COIL (56) WATER LEVEL PROBE TB30 (99) (98) TB31 TRANS. (75) (81) DUMP SOLENOID 5 RUN CAPACITOR R R S (46) (50) TB30 C (45) (48) L1 (51) PTCR (52) (85) (86) TB33 (53) TB34 FAN CYCLE CONTROL TB30 RUN CAPACITOR** Part No. 80-1100-3 FAN MOTOR (AIR COOLED ONLY) SV2071 6-55 Electrical System Section 6 THIS PAGE INTENTIONALLY LEFT BLANK 6-56 Part No. 80-1100-3 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. Self-Contained Prechill and Freeze Cycle (Models Q200/Q280/Q320/Q370/Q420/Q450/Q600/Q800/Q1000) Prechill Refrigeration Sequence Freeze Cycle Refrigeration Sequence No water flows over the evaporator during the prechill. The refrigerant absorbs heat (picked up during the harvest cycle) from the evaporator. The suction pressure decreases during the prechill. The refrigerant absorbs heat from water running over the evaporator surface. The suction pressure gradually drops as ice forms. Part No. 80-1100-3 7-1 Refrigeration System Section 7 E VA P O R A T O R H EA T E X C H A N GE R E XP A N S I O N V A LV E H AR VE S T S O LE N O I D V A LV E C O M PR E S S O R S T R A IN ER A I R O R WA T E R C O N D EN S E R DRI ER R EC EI V E R ( WA T E R C OO L ED O N LY ) H I G H PR ES SUR E V A P O R H I G H PR ES S U R E LI Q U I D LO W P R E S SU R E L I Q U I D L O W P R E S S U R E VA P O R 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. The harvest valve is sized to allow the proper amount of refrigerant into the evaporator. This specific sizing (along with the proper system refrigerant charge) assures proper heat transfer, without the refrigerant condensing and slugging the compressor. 7-2 Part No. 80-1100-3 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. Remote Pre-Chill and Freeze Cycle (Models Q450/Q600/Q800/Q1000) Prechill Refrigeration Sequence Freeze Cycle Refrigeration Sequence No water flows over the evaporator during the prechill. The refrigerant absorbs heat (picked up during the harvest cycle) from the evaporators. The suction pressure decreases during the prechill. The refrigerant absorbs heat from the water running over the evaporator surface. The suction pressure gradually drops as ice forms. Part No. 80-1100-3 The headmaster control valve maintains discharge pressure in ambient temperatures below 70°F (21.1°C). (See “Headmaster Control Valve” on Page 7-30.) 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. Remote Harvest Cycle (Models Q450/Q600/Q800/Q1000) Harvest Cycle Refrigeration Sequence Hot gas flows through the energized harvest valve, heating the evaporator. The harvest valve is sized to allow the proper amount of hot gas into the evaporator. This specific harvest valve sizing, along with the harvest pressure regulating (H.P.R.) system, assures proper heat transfer, without the hot gas condensing to liquid and slugging the compressor. The harvest pressure regulating (H.P.R.) valve helps maintain the suction pressure during the harvest cycle. (See “H.P.R. System” on Page 7-27.) 7-4 Part No. 80-1100-3 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. Remote Automatic Shut-Off (Models Q450/Q600/Q800/Q1000) Automatic Shut-Off The compressor and liquid line solenoid valve are deenergized simultaneously when the contactor contacts open. During the off cycle, the check valve prevents refrigerant from migrating back into the high side, and the liquid line solenoid prevents refrigerant from migrating back into the low side. This protects the compressor from refrigerant migration during the off cycle, preventing refrigerant slugging upon start-up. Part No. 80-1100-3 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. See Pages 7-1 and 7-2 for sequence of operation. 7-6 Part No. 80-1100-3 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. Q1300/Q1600/Q1800 Remote Models NOTE: The refrigeration sequence for remote dual expansion valve ice machines is identical to remote single expansion valve ice machines. See Pages 7-3, 7-4 and 7-5 for sequence of operation. Part No. 80-1100-3 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. The following two examples illustrate how similar symptoms can result in a misdiagnosis. 1. An expansion valve bulb that is not securely fastened to the suction line and/or not insulated will cause a good expansion valve to flood. If a service technician fails to check for proper expansion valve bulb mounting, he may replace the expansion valve in error. The ice machine now functions normally. The technician erroneously thinks that the problem was properly diagnosed and corrected by replacing the expansion valve. Actually, the problem (loose bulb) was corrected when the technician properly mounted the bulb of the replacement expansion valve. Section 7 2. An ice machine that is low on charge may cause a good expansion valve to starve. If a service technician fails to verify the system charge, he may replace the expansion valve in error. During the replacement procedure, recovery, evacuation and recharging are performed correctly. The ice machine now functions normally. The technician erroneously thinks that the problem was properly diagnosed and corrected by replacing the expansion valve. The service technician’s failure to check the ice machine for a low charge condition resulted in a misdiagnosis and the needless replacement of a good expansion valve. When analyzing the refrigeration system, use the Refrigeration System Operational Analysis Table. This table, along with detailed checklists and references, will help prevent replacing good refrigeration components due to external problems. The service technician’s failure to check the expansion valve bulb for proper mounting (an external check) resulted in a misdiagnosis and the needless replacement of a good expansion valve. 7-8 Part No. 80-1100-3 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. (These charts begin on Page 7-33.) Use the operating conditions determined in Step 1 to find published 24 hour ice production: ______ 3. Perform an actual ice production check. Use the formula below. __________ 1. When does the ice machine malfunction? (night, day, all the time, only during the freeze cycle, etc.) 2. When do you notice low ice production? (one day a week, every day, on weekends, etc.) Minutes in 24 Hours 3. Weight of One Harvest • Can you describe exactly what the ice machine seems to be doing? • Has anyone been working on the ice machine? • Is anything (such as boxes) usually stored near or on the ice machine which could obstruct airflow around the machine? • During “store shutdown,” is the circuit breaker, water supply or air temperature altered? • Is there any reason why incoming water pressure might rise or drop substantially? ICE PRODUCTION CHECK The amount of ice a machine produces directly relates to the operating water and air temperatures. This means an ice machine in a 70°F (21.1°C) room with 50°F (10.0°C) water produces more ice than the same model ice machine in a 90°F (32.2°C) room with 70°F (21.1°C) water. 1. Determine the ice machine operating conditions: Air temp. entering condenser: _______ ° Air temp. around ice machine: _______ ° Water temp. entering sump trough: _______ ° + Freeze Time 1440 __________ __________ = Harvest Time ÷ __________ = Total Cycle Time x __________ __________ Total Cycle Time __________ Cycles Per Day = Cycles Per Day __________ Actual 24 Hour Ice Production Important Times are in minutes. Example: 1 min., 15 sec. converts to 1.25 min. (15 seconds ÷ 60 seconds = .25 minutes) Weights are in pounds. Example: 2 lb., 6 oz. converts to 2.375 lb. (6 oz. ÷ 16 oz. = .375 lb.) Weighing the ice is the only 100% accurate check. However, if the ice pattern is normal and the 1/8" thickness is maintained, the ice slab weights listed with the 24 Hour Ice Production Charts may be used. 4. Compare the results of step 3 with step 2. Ice production is normal when these numbers match closely. If they match closely, determine if: • another ice machine is required. • more storage capacity is required. • relocating the existing equipment to lower the load conditions is required. Contact the local Manitowoc distributor for information on available options and accessories. Part No. 80-1100-3 7-9 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 Clean the condenser filter and/or condenser Reinstall according to the Installation Manual Install a new water filter Run and vent drains according to the Installation Manual Reinstall according to the Installation Manual WATER SYSTEM CHECKLIST A water-related problem often causes the same symptoms as a refrigeration system component malfunction. Example: A water dump valve leaking during the freeze cycle, a system low on charge, and a starving TXV have similar symptoms. Water system problems must be identified and eliminated prior to replacing refrigeration components. Possible Problem Water area (evaporator) is dirty Water inlet pressure not between 20 and 80 psi Incoming water temperature is not between 35°F (1.7°C) and 90°F (32.2°C). Water filtration is plugged (if used) Water dump valve leaking during the freeze cycle Vent tube is not installed on water outlet drain Hoses, fittings, etc., are leaking water Water fill valve is stuck open Water is spraying out of the sump trough area Uneven water flow across the evaporator Water is freezing behind the evaporator Plastic extrusions and gaskets are not secured to the evaporator Water does not flow over the evaporator (not trickle) immediately after the prechill Corrective Action Clean as needed Install a water regulator valve or increase the water pressure If too hot, check the hot water line check valves in other store equipment Install a new water filter Clean/replace dump valve as needed See Installation Instructions Repair/replace as needed Clean/replace as needed Stop the water spray Clean the ice machine Correct the water flow Remount/replace as needed Clean/replace water level probe as needed Part No. 80-1100-3 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. However, when this analysis is used along with Manitowoc’s Refrigeration System Operational Analysis Table, it can help diagnose an ice machine malfunction. Examples: No ice at all on the outlet of the evaporator, but ice forms on the intlet half of the evaporator. Or, the ice at the outlet of the evaporator reaches 1/8" to initiate a harvest, but the intlet of the evaporator already has 1/2" to 1" of ice formation. Improper ice formation can be caused by any number of problems. Example: An ice formation that is “extremely thin on outlet” could be caused by a hot water supply, a dump valve leaking water, a faulty water fill valve, a low refrigerant charge, etc. Important ICE OUTLET Keep the water curtain in place while checking the ice formation pattern to ensure no water is lost. 1. Normal Ice Formation Ice forms across the entire evaporator surface. ICE At the beginning of the freeze cycle, it may appear that more ice is forming on the intlet of the evaporator than on the outlet. At the end of the freeze cycle, ice formation on the outlet will be close to, or just a bit thinner than, ice formation on the intlet. The dimples in the cubes at the outlet of the evaporator may be more pronounced than those on the intlet. This is normal. The ice thickness probe must be set to maintain the ice bridge thickness at approximately 1/8". If ice forms uniformly across the evaporator surface, but does not reach 1/8" in the proper amount of time, this is still considered normal. INLET SV1576 Figure 7-8. Extremely Thin Ice Formation at Evaporator Outlet Part No. 80-1100-3 7-11 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. Important The Q1300 Q1600 and Q1800 model machines have left and right expansion valves and separate evaporator circuits. These circuits operate independently from each other. Therefore, one may operate properly while the other is malfunctioning. Example: If the left expansion valve is starving, it may not affect the ice formation pattern on the entire right side of the evaporator. OUTLET ICE OUTLET INLET OUTLET INLET SV1571 INLET SV1575 Figure 7-9. Extremely Thin Ice Formation at Evaporator Inlet Figure 7-11. Q1300/Q1600/Q1800 Evaporator Tubing 4. Spotty Ice Formation There are small sections on the evaporator where there is no ice formation. This could be a single corner, or a single spot in the middle of the evaporator. This is generally caused by loss of heat transfer from the tubing on the back side of the evaporator. OUTLET ICE SV1577 INLET Figure 7-10. Spotty Ice Formation 7-12 Part No. 80-1100-3 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. In addition to standard safety controls, such as high pressure cut-out, the control board has two built in safety limit controls which protect the ice machine from major component failures. There are two control boards with different safety limit sequences. Original production control boards have a black micro-processor. Current production and replacement control boards have an orange label on the control board microprocessor. Safety Limit #1: If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle. Control Board with black microprocessor If 3 consecutive 60-minute freeze cycles occur, the ice machine stops. Control Board with orange label on microprocessor. 1. Move the toggle switch to OFF. 2. Move the toggle switch back to ICE. 3. Watch the harvest light. If a safety limit has been recorded, the harvest light will flash one or two times, corresponding to safety limit 1 or 2. When a safety limit condition is exceeded (6 consecutive cycles for Safety Limit #1 or 500 cycles for Safety Limit #2) the ice machine stops and the harvest light on the control board continually flashes on and off. Use the following procedures to determine which safety limit has stopped the machine. If 6 consecutive 60-minute freeze cycles occur, the ice machine stops. 1. Move the toggle switch to OFF. Safety Limit #2: If the harvest time reaches 3.5 minutes, the control board automatically returns the ice machine to the freeze cycle. 3. Watch the harvest light. It will flash one or two times, corresponding to safety limit 1 or 2 to indicate which safety limit stopped the ice machine. Control Board with black microprocessor If three consecutive 3.5 minute harvest cycles occur, the ice machine stops. 2. Move the toggle switch back to ICE. After safety limit indication, the ice machine will restart and run until a safety limit is exceeded again. Control Board with orange label on microprocessor. If 500 consecutive 3.5 minute harvest cycles occur, the ice machine stops. Safety Limit Indication Control Board with Black Microprocessor When a safety limit condition is exceeded for 3 consecutive cycles the ice machine stops and the harvest light on the control board continually flashes on and off. Use the following procedures to determine which safety limit has stopped the ice machine. 1. Move the toggle switch to OFF. 2. Move the toggle switch back to ICE. After safety limit indication, the ice machine will restart and run until a safety limit is exceeded again. Part No. 80-1100-3 Orange Label 3. Watch the harvest light. It will flash one or two times, corresponding to safety limits 1 and 2, to indicate which safety limit stopped the ice machine. 7-13 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. The safety limit system is similar to a high pressure cutout control. It stops the ice machine, but does not tell what is wrong. The service technician must analyze the system to determine what caused the high pressure cutout, or a particular safety limit, to stop the ice machine. The safety limits are designed to stop the ice machine prior to major component failures, most often a minor problem or something external to the ice machine. This may be difficult to diagnose, as many external problems occur intermittently. Example: An ice machine stops intermittently on safety limit #1 (long freeze times). The problem could be a low ambient temperature at night, a water pressure drop, the water is turned off one night a week, etc. When a high pressure cut-out or a safety limit stops the ice machine, they are doing what they are supposed to do. That is, stopping the ice machine before a major component failure occurs. Refrigeration and electrical component failures may also trip a safety limit. Eliminate all electrical components and external causes first. If it appears that the refrigeration system is causing the problem, use Manitowoc’s Refrigeration System Operational Analysis Table, along with detailed charts, checklists, and other references to determine the cause. The following checklists are designed to assist the service technician in analysis. However, because there are many possible external problems, do not limit your diagnosis to only the items listed. 7-14 Part No. 80-1100-3 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. Possible Cause Improper installation Water system Electrical system Restricted condenser air flow (air-cooled models) Restricted condenser water flow (water-cooled models) Refrigeration system SAFETY LIMIT NOTES • Because there are many possible external problems, do not limit your diagnosis to only the items listed in this chart. • A continuous run of 100 harvests automatically erases the safety limit code. • The control board will store and indicate only one safety limit – the last one exceeded. Part No. 80-1100-3 Check/Correct See “Installation/Visual Inspection Checklist” on Page 7-10 Low water pressure (20 psi min.) High water pressure (80 psi max.) High water temperature (90°F/32.2°C max.) Clogged water distribution tube Dirty/defective water fill valve Dirty/defective water dump valve Defective water pump Ice thickness probe out of adjustment Harvest cycle not initiated electrically Contactor not energizing Compressor electrically non-operational High inlet air temperature (110°F/43.3°C max.) Condenser discharge air recirculation Dirty condenser filter Dirty condenser fins Defective fan cycling control Defective fan motor Low water pressure (20 psi min.) High water temperature (90°F/32.2°C max.) Dirty condenser Dirty/defective water regulating valve Water regulating valve out of adjustment Non-Manitowoc components Improper refrigerant charge Defective head pressure control (remotes) Defective harvest valve Defective compressor TXV starving or flooding (check bulb mounting) Non-condensables in refrigeration system Plugged or restricted high side refrigerant lines or component • If the toggle switch is moved to the OFF position and then back to the ICE position prior to reaching the 100-harvest point, the last safety limit exceeded will be indicated. • If the harvest light did not flash prior to the ice machine restarting, then the ice machine did not stop because it exceeded a safety limit. 7-15 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. Possible Cause Improper installation Water system Electrical system Refrigeration system SAFETY LIMIT NOTES • Because there are many possible external problems, do not limit your diagnosis to only the items listed in this chart. • A continuous run of 100 harvests automatically erases the safety limit code. • The control board will store and indicate only one safety limit – the last one exceeded. 7-16 Check/Correct See “Installation/Visual Inspection Checklist” on Page 7-10 Water area (evaporator) dirty Dirty/defective water dump valve Vent tube not installed on water outlet drain Water freezing behind evaporator Plastic extrusions and gaskets not securely mounted to the evaporator Low water pressure (20 psi min.) Loss of water from sump area Clogged water distribution tube Dirty/defective water fill valve Defective water pump Ice thickness probe out of adjustment Ice thickness probe dirty Bin switch defective Premature harvest Non-Manitowoc components Water regulating valve dirty/defective Improper refrigerant charge Defective head pressure control valve (remotes) Defective harvest pressure control (HPR) valve (remotes) Defective harvest valve TXV flooding (check bulb mounting) Defective fan cycling control • If the toggle switch is moved to the OFF position and then back to the ICE position prior to reaching the 100-harvest point, the last safety limit exceeded will be indicated. • If the harvest light did not flash prior to the ice machine restarting, then the ice machine did not stop because it exceeded a safety limit. Part No. 80-1100-3 Section 7 Refrigeration System ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE 3. Perform an actual discharge pressure check. 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.) Use the operating conditions determined in step 1 to find the published normal discharge pressures. Freeze Cycle _______ Beginning of Cycle Middle of Cycle End of Cycle Freeze Cycle PSIG __________ __________ __________ Harvest Cycle PSIG __________ __________ __________ 4. Compare the actual discharge pressure (step 3) with the published discharge pressure (step 2). The discharge pressure is normal when the actual pressure falls within the published pressure range for the ice machine’s operating conditions. Harvest Cycle_______ Freeze Cycle Discharge Pressure High Checklist Possible Cause Improper installation Restricted condenser air flow (air-cooled models) Restricted condenser water flow (water-cooled models) Improper refrigerant charge Other Check/Correct See “Installation/Visual Inspection Checklist” on Page 7-10 High inlet air temperature (110°F/43.3°C max.) Condenser discharge air recirculation Dirty condenser filter Dirty condenser fins Defective fan cycling control Defective fan motor Low water pressure (20 psi min.) High inlet water temperature (90°F/32.2°C max.) Dirty condenser Dirty/defective water regulating valve Water regulating valve out of adjustment Overcharged Non-condensables in system Wrong type of refrigerant Non-Manitowoc components in system High side refrigerant lines/component restricted (before mid-condenser) Defective head pressure control valve (remote models) Freeze Cycle Discharge Pressure Low Checklist Possible Cause Improper installation Improper refrigerant charge Water regulating valve (water-cooled condensers) Other Check/Correct See “Installation/Visual Inspection Checklist” on Page 7-10 Undercharged Wrong type of refrigerant Out of adjustment Defective Non-Manitowoc components in system Defective head pressure control valve (remote models) Defective fan cycle control NOTE: Do not limit your diagnosis to only the items listed in the checklists. Part No. 80-1100-3 7-17 Refrigeration System Section 7 ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE NOTE: Analyze discharge pressure before analyzing suction pressure. High or low discharge pressure may be causing high or low suction pressure. 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. To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time. “Operating Pressure” and “Freeze Cycle Time” charts can be found later in this section. Procedure Step 1. Determine the ice machine operating conditions. 2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice machine model being checked. Using operating conditions from Step 1, determine published freeze cycle time and published freeze cycle suction pressure. Example Using QY0454A Model Ice Machine Air temp. entering condenser: 90°F/32.2°C Air temp. around ice machine: 80°F/26.7°C Water temp. entering water fill valve: 70°F/21.1°C Published freeze cycle time: 13.7 - 14.1 minutes Published freeze cycle suction pressure: 55-36 PSIG Published Freeze Cycle Time (minutes) 1 3 5 7 9 12 14 2B. Compare the published freeze cycle time and published freeze cycle suction pressure. Develop a chart. 55 52 48 44 41 38 36 Published Freeze Cycle Suction Pressure (psig) 3. Perform an actual suction pressure check at the beginning, middle and end of the freeze cycle. Note the times at which the readings are taken. 4. Compare the actual freeze cycle suction pressure (Step 3) to the published freeze cycle time and pressure comparison (Step 2B). Determine if the suction pressure is high, low or acceptable. 7-18 Beginning of freeze cycle: Middle of freeze cycle: End of freeze cycle: Time Into Freeze Cycle 1 minutes 7 minutes 14 minutes Published Pressure 55 PSIG 44 PSIG 36 PSIG 59 PSIG at 1 minute 48 PSIG at 7 minutes 40 PSIG at 14 minutes Actual Pressure 59 PSIG 48 PSIG 40 PSIG Result High High High Part No. 80-1100-3 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. solenoid leaking harvest valve stuck open TXV flooding (check bulb mounting) Defective compressor Freeze Cycle Suction Pressure Low 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 low, and is affecting low side (See “Freeze Cycle Discharge Pressure Low Checklist” on Page 7-16) Undercharged Wrong type of refrigerant Non-Manitowoc components in system Improper water supply over evaporator (See “Water System Checklist” on page 7-10) Loss of heat transfer from tubing on back side of evaporator Restricted/plugged liquid line drier Restricted/plugged tubing in suction side of refrigeration system TXV starving NOTE: Do not limit your diagnosis to only the items listed in the checklists. Part No. 80-1100-3 7-19 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. The actual temperatures entering and leaving the evaporator vary by model, and change throughout the freeze cycle. This makes documenting the “normal” inlet and outlet temperature readings difficult. The key to the diagnosis lies in the difference between the two temperatures five minutes into the freeze cycle. These temperatures must be within 7° of each other. Section 7 Use this procedure to document freeze cycle inlet and outlet temperatures. 1. Use a quality temperature meter, capable of taking temperature readings on curved copper lines. 2. Attach the temperature meter sensing device to the copper lines entering and leaving the evaporator. Important Do not simply insert the sensing device under the insulation. It must be attached to and reading the actual temperature of the copper line. 3. Wait five minutes into the freeze cycle. 4. Record the temperatures below and determine the difference between them. 5. Use this with other information gathered on the Refrigeration System Operational Analysis Table to determine the ice machine malfunction. ______________ ______________ Inlet Temperature Outlet Temperature _______________ Difference Must be within 7° at 5 minutes into freeze cycle 7-20 Part No. 80-1100-3 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. A too-large orifice causes refrigerant to condense to liquid in the evaporator during the harvest cycle. This liquid will cause compressor damage. A too-small orifice does not allow enough hot gas into the evaporator. This causes low suction pressure, and insufficient heat for a harvest cycle. Refer to the Parts Manual for proper valve application. If replacement is necessary, Use only “original” Manitowoc replacement parts. Harvest Valve Analysis Symptoms of a harvest valve remaining partially open during the freeze cycle can be similar to symptoms of either an expansion valve or compressor problem. The best way to diagnose a harvest valve is by using Manitowoc’s Ice Machine Refrigeration System Operational Analysis Table. Use the following procedure and table to help determine if a harvest valve is remaining partially open during the freeze cycle. 1. Wait five minutes into the freeze cycle. 3. Feel the compressor discharge line. ! Warning The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand. Just touch them momentarily. 4. Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line. Findings The inlet of the harvest valve is cool enough to touch and the compressor discharge line is hot. Comments This is normal as the discharge line should always be too hot to touch and the harvestharvest valve inlet, although too hot to touch during harvest, should be cool enough to touch after 5 minutes into the freeze cycle. The inlet of the This is an indication something is harvest valve is hot wrong, as the harvest valve inlet did and approaches the not cool down during the freeze cycle. temperature of a hot If the compressor dome is also entirely compressor hot, the problem is not a harvest valve discharge line. leaking, but rather something causing the compressor (and the entire ice machine) to get hot. Both the inlet of the This is an indication something is harvest valve and wrong, causing the compressor the compressor discharge line to be cool to the touch. discharge line are This is not caused by a harvest valve cool enough to leaking. touch. 2. Feel the inlet of the harvest valve(s). Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison. The harvest valve outlet is on the suction side (cool refrigerant). It may be cool enough to touch even if the valve is leaking. Part No. 80-1100-3 7-21 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. Comparing the temperatures over several cycles will result in a consistent maximum discharge line temperature. Ambient air temperatures affect the maximum discharge line temperature. Higher ambient air temperatures at the condenser = higher discharge line temperatures at the compressor. Lower ambient air temperatures at the condenser = lower discharge line temperatures at the compressor. Regardless of ambient temperature, the freeze cycle discharge line temperature will be higher than 160°F (71.1°C) on a normally operating ice machine. Observe the discharge line temperature for the last three minutes of the freeze cycle and record the maximum discharge line temperature. Discharge Line Temperature Above 160°F (71.1°C) At End Of Freeze Cycle: Ice machines that are operating normally will have consistent maximum discharge line temperatures above 160°F (71.1°C). Discharge Line Temperature Below 160°F (71.1°C) At End Of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that decreases each cycle. Verify the expansion valve sensing bulb is 100% insulated and sealed airtight. Condenser air contacting an incorrectly insulated sensing bulb will cause overfeeding of the expansion valve. Verify the expansion valve sensing bulb is positioned and secured correctly. 7-22 Part No. 80-1100-3 Section 7 Refrigeration System THIS PAGE INTENTIONALLY LEFT BLANK Part No. 80-1100-3 7-23 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. NOTE: A low-on-charge ice machine and a starving expansion valve have very similar characteristics and are listed under the same column. NOTE: Before starting, see “Before Beginning Service” on Page 7-9 for a few questions to ask when talking to the ice machine owner. Procedure Step 1 Complete the “Operation Analysis” column. Read down the left “Operational Analysis” column. Perform all procedures and check all information listed. Each item in this column has supporting reference material to help analyze each step. While analyzing each item separately, you may find an “external problem” causing a good refrigerant component to appear bad. Correct problems as they are found. If the operational problem is found, it is not necessary to complete the remaining procedures. Step 2 Enter check marks (√) in the small boxes. Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a check mark. Example: Freeze cycle suction pressure is determined to be low. Enter a check mark in the “low” box. Step 3 Add the check marks listed under each of the four columns. Note the column number with the highest total and proceed to “Final Analysis.” NOTE: If two columns have matching high numbers, a procedure was not performed properly and/or supporting material was not analyzed correctly. 7-24 Section 7 Final Analysis The column with the highest number of check marks identifies the refrigeration problem. COLUMN 1 - HARVEST VALVE LEAKING A leaking harvest valve must be replaced. COLUMN 2 - LOW CHARGE/TXV STARVING Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures. A low refrigerant charge normally affects both pressures. Verify the ice machine is not low on charge before replacing an expansion valve. 1. Add refrigerant charge in 2 to 4 oz. increments as a diagnostic procedure to verify a low charge. If the problem is corrected, the ice machine is low on charge. Find the refrigerant leak. The ice machine must operate with the nameplate charge. If the leak cannot be found, proper refrigerant procedures must still be followed Change the liquid line drier. Then, evacuate and weigh in the proper charge. 2. If the problem is not corrected by adding charge, the expansion valve is faulty. On dual expansion valve ice machines, change only the TXV that is starving. If both TXV’s are starving, they are probably good, and are being affected by some other malfunction, such as low charge. COLUMN 3 - TXV FLOODING A loose or improperly mounted expansion valve bulb causes the expansion valve to flood. Check bulb mounting, insulation, etc., before changing the valve. On dual expansion valve machines, the service technician should be able to tell which TXV is flooding by analyzing ice formation patterns. Change only the flooding expansion valve. COLUMN 4 - COMPRESSOR Replace the compressor and start components. To receive warranty credit, the compressor ports must be properly sealed by crimping and soldering them closed. Old start components must be returned with the faulty compressor. Part No. 80-1100-3 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. Operational Analysis Ice Production Installation and Water System Ice Formation Pattern Safety Limits Refer to “Analyzing Safety Limits” to eliminate all nonrefrigeration problems. Freeze Cycle Discharge Pressure _____ ______ ______ 1 minute Middle End into cycle Freeze Cycle Suction Pressure _____ ______ ______ 1 minute Middle End Wait 5 minutes into the freeze cycle. Compare temperatures of evaporator inlet and evaporator outlet. Inlet ____ ° F (° C) Outlet ____ ° F (° C) Difference ____ ° F (° C) Wait 5 minutes into the freeze cycle. Compare temperatures of compressor discharge line and harvest valve inlet. Discharge Line Temperature Record freeze cycle discharge line temperature at the end of the freeze cycle 1 2 3 4 Air-Temperature Entering Condenser_____________ Water Temperature Entering Ice Machine_________ Published 24 hour ice production________________ Calculated (actual) ice production_______________ NOTE: The ice machine is operating properly if the ice fill patterns is normal and ice production is within 10% of charted capacity. All installation and water related problems must be corrected before proceeding with chart. Ice formation is extremely thin on outlet of evaporator -orNo ice formation on the entire evaporator Ice formation is extremely thin on outlet of evaporator -orNo ice formation on entire evaporator Ice formation normal -orIce formation is extremely thin on inlet of evaporator -orNo ice formation on entire evaporator Ice formation normal -orNo ice formation on entire evaporator Stops on safety limit: 1 Stops on safety limit: 1 Stops on safety limit: 1 or 2 Stops on safety limit: 1 If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist to eliminate problems and/or components not listed on this table before proceeding. If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist to eliminate problems and/or components not listed on this table before proceeding. Suction pressure is High Suction pressure is Low or Normal Suction pressure is High Suction pressure is High Inlet and outlet within 7° of each other Inlet and outlet not within 7° of each other -andInlet is colder than outlet Inlet and outlet within 7° of each other -orInlet and outlet not within 7° of each other -andInlet is warmer than outlet Inlet and outlet within 7° of each other The harvest valve inlet is Hot -andapproaches the temperature of a Hot compressor discharge line. The harvest valve inlet is Cool enough to hold hand on -andthe compressor discharge line is Hot. The harvest valve inlet is Cool enough to hold hand on -andthe compressor discharge line is Cool enough to hold hand on. The harvest valve inlet is Cool enough to hold hand on -andthe compressor discharge line is Hot. Discharge line temperature 160°F (71.1°C) or higher at the end of the freeze cycle Discharge line temperature 160°F (71.1°C) or higher at the end of the freeze cycle Discharge line temperature less than 160°F (71.1°C) at the end of the freeze cycle Discharge line temperature 160°F (71.1°C) or higher at the end of the freeze cycle Harvest Valve Leaking Low On Charge -OrTXV Starving TXV Flooding Compressor _________°F (°C) Final Analysis Enter total number of boxes checked in each column. Part No. 80-1100-3 7-25 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. Operational Analysis Ice Production Ice Formation Pattern Left side _____________ ___________________ Right side ___________ ___________________ 1 2 3 4 Air-Temperature Entering Condenser____________ Water Temperature Entering Ice Machine_________ Published 24 hour ice production________________ Calculated (actual) ice production________________ NOTE: The ice machine is operating properly if the ice production and ice formation pattern is normal and ice production is within 10% of charted capacity. Ice formation is Ice formation is Ice formation normal Ice formation normal extremely thin on extremely thin on -or-oroutet of one side of outlet of one or both Ice formation is No ice formation on evaporator sides of evaporator extremely thin on inlet entire evaporator -or-orof one side of No ice formation on No ice formation on evaporator one side of entire evaporator -orevaporator No ice formation on entire evaporator Stops on safety limit: Stops on safety limit: Stops on safety limit: Stops on safety limit: 1 1 1 or 2 1 Safety limits Refer to “Analyzing Safety Limits” to eliminate problems and/or components not listed on this table Freeze Cycle If discharge pressure is High or Low refer to a freeze cycle high or low discharge pressure DISCHARGE pressure problem checklist to eliminate problems and/or components not listed on this table before _____ ______ ______ proceeding. 1 minute Middle End into cycle Freeze Cycle If suction pressure is High or Low refer to a freeze cycle high or low suction pressure problem SUCTION pressure checklist to eliminate problems and/or components not listed on this table before proceeding. _____ ______ ______ Suction pressure is Suction pressure is Suction pressure is Suction pressure is Beginning Middle End High Low or Normal High High Harvest Valve One harvest valve Both harvest valve Both harvest valve Both harvest valve Wait 5 minutes into the freeze inlet is Hot inlets are inlets are Cool inlets are Cool cycle. -andCool enough enough enough Compare temperatures of approaches the to hold hand on to hold hand on to hold hand on compressor discharge line temperature of a Hot -and-and-andand both harvest valve inlets. compressor the compressor the compressor the compressor discharge line. discharge line is Hot. discharge line is discharge line is Hot. Cool enough to hold hand on. Discharge Line Temperature Discharge line Discharge line Discharge line Discharge line Record freeze cycle discharge temperature temperature temperature temperature line temperature at the end of 160°F (71.1°C) 160°F (71.1°C) less than 160°F (71.1°C) the freeze cycle 160°F (71.1°C) or higher or higher or higher at the end of the at the end of the at the end of the at the end of the freeze cycle freeze cycle _________°F (°C) freeze cycle freeze cycle Final Analysis Enter total number of boxes checked in each column. 7-26 Harvest Valve Leaking Low On Charge -OrTXV Starving TXV Flooding Compressor Part No. 80-1100-3 Section 7 Refrigeration System HARVEST PRESSURE REGULATING (H.P.R.) SYSTEM Figure 7-13. H.P.R. Valve 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). This is a non-adjustable pressure regulating valve which modulates open and closed, based on the refrigerant pressure at the outlet of the valve. The valve closes completely and stops refrigerant flow when the pressure at the outlet rises above the valve setting. INLET SV3053 OUTLET Part No. 80-1100-3 7-27 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. solenoid is opened (energized) during the harvest cycle, allowing refrigerant gas from the top of the receiver to flow into the H.P.R. valve. The H.P.R. valve modulates open and closed, raising the suction pressure high enough to sustain heat for the harvest cycle, without allowing refrigerant to condense to liquid in the evaporator. In general, harvest cycle suction pressure rises, then stabilizes in the range of 75-100 psig (517-758 kPA). Exact pressures vary from model to model. These can be found in the “Operational Refrigerant Pressures” charts, beginning on Page 7-32. 7-28 Part No. 80-1100-3 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. Freeze time normal? (Refer to Cycle Times/Refrigerant Pressures/24 Hour Ice Production Charts) Refrigeration System 6. Freeze cycle Head Pressure 220 psig or higher? If the head pressure is lower than 220 psig refer to headmaster diagnostics. 7. Freeze cycle Suction Pressure normal? Refer to analyzing suction pressure if suction pressure is high or low. 8. Discharge line temperature is 160°F (71.1°C) or higher at end of freeze cycle? If less than 160°F (71.1°C) check expansion valve bulb mounting and insulation. 9. Harvest cycle suction and discharge pressures are lower than indicated in the cycle times/refrigerant pressures/24 hour ice production chart? Replace Harvest Pressure Regulating system (HPR Valve and HPR solenoid valve). Shorter freeze cycles - Refer to headmaster diagnostics. Longer freeze cycles - Refer to water system checklist, then refer to Refrigeration Diagnostic Procedures. 4. Harvest time is longer than normal and control board indicates safety limit #2? (Refer to Cycle Times/Refrigerant Pressures/24 Hour Ice Production Charts) Connect refrigeration manifold gauge set to the access valves on the front of the ice machine, and a thermometer thermocouple on the discharge line within 6" of the compressor (insulate thermocouple). 5. Establish baseline by recording suction and discharge pressure, discharge line temperature and freeze & harvest cycle times. (Refer to section 7 “Operational Analysis” for data collection detail). Part No. 80-1100-3 7-29 Refrigeration System Section 7 HEADMASTER CONTROL VALVE Diagnosing 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. At temperatures below this (or at higher temperatures if it is raining), the head pressure control dome’s nitrogen charge closes the condenser port and opens the bypass port from the compressor discharge line. In this modulating mode, the valve maintains minimum head pressure by building up liquid in the condenser and bypassing discharge gas directly to the receiver. 1. Determine the air temperature entering the remote condenser. 2. Determine if the head pressure is high or low in relationship to the outside temperature. (Refer to the proper “Operational Pressure Chart” later in this section.) If the air temperature is below 70°F (21.1°C), the head pressure should be modulating about 225 PSIG. 3. Determine the temperature of the liquid line entering the receiver by feeling it. This line is normally warm; “body temperature.” 4. Using the information gathered, refer to the chart below. NOTE: A headmaster that will not bypass, will function properly with condenser air temperatures of approximately 70°F (21.1°C) or above. When the temperature drops below 70°F (21.1°C), the headmaster fails to bypass and the ice machine malfunctions. Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle. Symptom Valve not maintaining pressures Probable Cause Non-approved valve Discharge pressure extremely high; Liquid line entering receiver feels hot Discharge pressure low; Liquid line entering receiver feels extremely cold Discharge pressure low; Liquid line entering receiver feels warm to hot Valve stuck in bypass Corrective Measure Install a Manitowoc Headmaster control valve with proper setting Replace valve Valve not bypassing Replace valve Ice machine low on charge See “Low on Charge Verification” on 7-30 Page 7-31 Part No. 80-1100-3 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. The fan cycle control is not capable of bypassing the condenser coil and keeping the liquid line temperature and pressure up. If you cannot verify that the ice machine is low on charge: 1. Add refrigerant in 2 lb. increments, but do not exceed 6 lbs. 2. If the ice machine was low on charge, the headmaster function and discharge pressure will return to normal after the charge is added. Do not let the ice machine continue to run. To assure operation in all ambient conditions, the refrigerant leak must be found and repaired, the liquid line drier must be changed, and the ice machine must be evacuated and properly recharged. This is very apparent when it rains or the outside temperature drops. When it rains or the outside temperature drops, the fan begins to cycle on and off. At first, everything appears normal. But, as it continues raining or getting colder, the fan cycle control can only turn the fan off. All the refrigerant must continue to flow through the condenser coil, being cooled by the rain or low outside temperature. This causes excessive sub-cooling of the refrigerant. As a result, the liquid line temperature and pressure are not maintained for proper operation. 3. If the ice machine does not start to operate properly after adding charge, replace the headmaster. Part No. 80-1100-3 7-31 Refrigeration System Section 7 Pressure Control Specifications and Diagnostics HIGH PRESSURE CUT-OUT (HPCO) CONTROL FAN CYCLE CONTROL 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. Specifications Function The HPCO control is normally closed, and opens on a rise in discharge pressure. Specifications Cut-out: 450 psig ±10 Cut-in: Manual or automatic reset (Must be below 300 psig to reset). Check Procedure Model Q200/Q280 Q320/Q370/Q420 Q450/Q600 Q800/Q1000 Q1300/ Q1800 Cut-In (Close) Cut-Out (Open) 250 psig ±5 200 psig ±5 275 psig ±5 225 psig ±5 1. Set ICE/OFF/CLEAN switch to OFF, (Manual reset HPCO reset if tripped). 2. Connect manifold gauges. 3. Hook voltmeter in parallel across the HPCO, leaving wires attached. 1. Verify fan motor windings are not open or grounded, and fan spins freely. 4. On water-cooled models, close the water service valve to the water condenser inlet. On self-contained air-cooled and remote models, disconnect the fan motor. 2. Connect manifold gauges to ice machine. 5. Set ICE/OFF/CLEAN switch to ICE. 3. Hook voltmeter in parallel across the fan cycle control, leaving wires attached. 6. No water or air flowing through the condenser will cause the HPCO control to open because of excessive pressure. Watch the pressure gauge and record the cut-out pressure. Check Procedure 4. Refer to chart below. At: above cut-in below cut-out Reading Should Be: 0 volts line voltage Fan Should Be: running off ! Warning If discharge pressure exceeds 460 psig and the HPCO control does not cut out, set ICE/OFF/ CLEAN switch to OFF to stop ice machine operation. Replace the HPCO control if it: 7-32 • Will not reset (below 300 psig) • Does not open at the specified cut-out point Part No. 80-1100-3 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 90/32.2 100/37.8 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 11.5-13.5 13.8-16.1 16.1-18.7 19.8-23.0 13.8-16.1 15.6-18.2 18.6-21.6 23.6-27.4 15.2-17.8 17.0-19.8 20.5-23.8 25.5-29.6 Harvest Time 1.0-2.5 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 11.5-13.5 12.0-14.1 12.6-14.7 13.1-15.4 12.8-15.0 13.5-15.7 14.1-16.5 14.8-17.3 14.5-16.9 15.2-17.8 16.1-18.7 17.0-19.8 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Times in minutes 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 270 230 200 165 230 205 175 140 210 190 160 130 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Freeze Cycle Harvest Cycle Air Temp. Entering Discharge Suction Discharge Suction Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 195-260 60-28 120-190 85-110 50/10.0 70/21.1 195-260 60-28 120-190 85-110 80/26.7 210-270 65-28 160-190 90-110 90/32.2 240-290 70-30 190-210 100-120 100/37.8 270-330 70-35 220-240 120-140 110/43.3 310-390 85-40 250-270 120-150 Suction pressure drops gradually throughout the freeze cycle 50/10.0 70/21.1 90/32.2 270 260 250 240 245 235 225 215 220 210 200 190 Based on average ice slab weight of 2.44 - 2.81 lb Regular cube derate is 7% Based on average ice slab weight of 2.44 - 2.81 lb Regular cube derate is 7% Operating Pressures Water Temperature °F/°C Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 240 480 2100 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Around Ice Discharge Suction Discharge Suction Machine Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 225-235 60-28 170-200 90-110 50/10.0 70/21.1 225-235 60-28 170-200 90-110 80/26.7 225-240 60-28 175-205 90-110 90/32.2 225-245 65-30 175-205 90-115 100/37.8 225-250 70-32 180-210 90-115 110/43.3 225-260 75-34 185-215 90-120 Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-33 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 90/32.2 10.6-12.5 11.5-13.5 12.6-14.7 14.5-16.9 11.8-13.8 12.8-15.0 14.1-16.5 16.5-19.3 12.6-14.7 13.8-16.1 15.2-17.8 18.0-21.0 Harvest Time 1.0-2.5 Times in minutes Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 10.6-12.5 10.8-12.7 11.0-13.0 11.3-13.2 12.0-14.1 12.3-14.4 12.6-14.7 12.8-15.0 12.3-14.4 13.8-16.1 14.1-16.5 14.5-16.9 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 290 270 250 220 265 245 225 195 250 230 210 180 Based on average ice slab weight of 2.44 - 2.81 lb Regular cube derate is 7% Operating Pressures Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG 50/10.0 195-250 60-20 70/21.1 195-250 60-20 80/26.7 220-280 60-26 90/32.2 250-310 66-30 100/37.8 280-350 70-32 110/43.3 310-390 85-40 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 150-190 70-90 150-190 70-90 180-220 70-90 190-220 80-100 220-250 80-110 250-270 80-120 Suction pressure drops gradually throughout the freeze cycle Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 290 285 280 275 260 255 250 245 255 230 225 220 Based on average ice slab weight of 2.44 - 2.81 lb Regular cube derate is 7% Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 250 490 3400 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Freeze Cycle Harvest Cycle Around Discharge Suction Discharge Suction Ice Pressure Pressure Pressure Pressure Machine PSIG PSIG PSIG PSIG °F/°C 225-235 60-28 190-200 75-90 50/10.0 70/21.1 225-235 60-28 190-200 80-90 80/26.7 225-240 60-28 190-200 80-90 90/32.2 225-245 62-28 190-200 80-90 100/37.8 225-250 62-30 190-200 80-90 110/43.3 225-260 64-32 195-205 80-95 Suction pressure drops gradually throughout the freeze cycle 7-34 Part No. 80-1100-3 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 90/32.2 12.2-13.9 13.6-15.5 16.1-18.4 19.7-22.3 13.1-14.9 14.8-16.817.7-20.2 22.0-25.0 14.2-16.2 16.1-18.4 19.7-22.3 25.0-28.3 Harvest Time 1-2.5 Times in minutes Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 12.6-14.4 13.1-14.9 13.6-15.5 14.2-16.2 13.6-15.5 14.2-16.2 14.8-16.8 15.4-17.6 15.4-17.6 16.1-18.4 16.9-19.2 17.7-20.2 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 310 280 240 200 290 260 220 180 270 240 200 160 Based on average ice slab weight of 2.94 - 3.31lb Regular cube derate is 7% Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 50/10.0 200-250 50-36 150-180 75-90 70/21.1 200-250 50-36 160-190 80-100 80/26.7 220-280 50-36 170-200 90-110 90/32.2 230-320 54-38 180-220 90-120 100/37.8 270-360 56-40 200-250 95-140 110/43.3 280-380 58-42 210-260 95-150 Suction pressure drops gradually throughout the freeze cycle Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 300 290 280 270 280 270 260 250 250 240 230 220 Based on average ice slab weight of 2.94 - 3.31 lb Regular cube derate is 7% Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 270 560 3200 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Cycle Harvest Cycle Discharg Suction Discharge Suction e Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 225-235 50-36 160-180 80-110 225-235 50-36 170-190 85-115 225-240 50-36 170-200 85-115 225-250 50-36 170-210 90-120 225-260 52-36 170-210 90-120 225-265 54-36 175-215 95-125 Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-35 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 90/32.2 10.3-11.7 11.3-12.9 12.9-14.7 14.5-16.5 11.7-13.4 12.6-14.4 13.9-15.8 16.1-18.4 12.6-14.4 13.9-15.8 15.4-17.6 17.3-19.7 Harvest Time 1-2.5 Times in minutes Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 10.3-11.7 10.6-12.1 11.0-12.5 11.3-12.9 11.0-12.5 11.3-12.9 11.7-13.4 12.2-13.9 12.2-13.9 12.6-14.4 13.1-14.4 13.6-15.5 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 24 Hour Ice Production Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 360 330 295 265 320 300 275 240 300 275 250 225 Based on average ice slab weight of 2.94 - 3.31lb Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 360 350 340 330 340 330 320 310 310 300 290 280 Based on average ice slab weight of 2.94 - 3.31lb Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 50/10.0 200-250 60-34 145-165 75-95 70/21.1 215-250 60-36 150-170 85-100 80/26.7 250-290 65-38 165-185 90-110 90/32.2 260-330 70-40 175-195 100-120 100/37.8 300-380 80-41 195-220 130-150 110/43.3 310-390 80-42 200-225 135-155 Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 220 490 3700 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C Suction pressure drops gradually throughout the freeze cycle 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Cycle Harvest Cycle Discharg Suction Discharge Suction e Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 225-235 60-32 150-170 85-100 225-235 60-33 150-170 85-105 225-240 65-36 155-175 90-110 225-240 68-38 155-175 90-110 235-260 75-40 175-200 100-120 240-265 85-40 185-205 105-125 Suction pressure drops gradually throughout the freeze cycle 7-36 Part No. 80-1100-3 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 70/21.1 90/32.2 9.7-11.4 10.9-12.8 12.3-14.4 14.5-17.0 10.9-12.8 12.3-14.4 14.1-16.5 16.5-19.2 12.0-14.0 13.3-15.6 15.5-18.0 18.3-21.3 Harvest Time 1-2.5 Times in minutes Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 9.9-11.7 10.1-11.9 10.4-12.2 10.6-12.5 11.4-13.4 11.7-13.7 12.0-14.0 12.3-14.4 12.6-14.8 13.0-15.2 13.3-15.6 13.7-16.0 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 530 480 430 370 480 430 380 330 440 400 350 300 Based on average ice slab weight of 4.12 - 4.75lb Regular cube derate is 7% Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 50/10.0 195-260 45-30 150-170 75-90 70/21.1 200-260 47-33 165-180 80-100 80/26.7 230-265 50-35 165-185 80-100 90/32.2 260-290 55-36 190-210 90-110 100/37.8 290-340 60-38 215-235 105-125 110/43.3 195-260 45-30 235-255 125-140 Suction pressure drops gradually throughout the freeze cycle Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 520 510 500 490 460 450 440 430 420 410 400 390 Based on average ice slab weight of 4.12 - 4.75 lb. Regular cube derate is 7% Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 400 740 2400 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Cycle Harvest Cycle Discharg Suction Discharge Suction e Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 235-245 50-35 165-180 85-100 235-245 50-35 165-180 85-100 235-245 50-35 165-180 85-100 235-245 52-35 165-180 85-100 235-245 52-35 165-185 85-100 240-250 55-36 165-185 85-100 Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-37 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 90/32.2 10.6-12.5 12.0-14.0 13.3-15.6 10.9-12.8 11.1-13.1 12.0-14.0 13.3-15.6 12.3-14.4 12.6-14.8 13.7-16.0 15.5-18.0 13.7-16.0 14.1-16.5 15.5-18.0 17.6-20.6 Harvest Time 1-2.5 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 7.1-8.4 7.8-9.2 8.6-10.1 9.5-11.2 7.8-9.2 8.6-10.1 9.5-11.2 10.6-12.5 8.6-10.1 9.5-11.2 10.4-12.2 12.0-14.0 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Times in minutes 24 Hour Ice Production 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 Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 490 440 400 480 470 440 400 430 420 390 350 390 380 350 310 Based on average ice slab weight of 4.12- 4.75lb Regular cube derate is 7% Ratings with JC0495 condenser, dice or half dice cubes Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG -20/-28.9 to 225-245 50-32 175-190 85-100 50/10.0 70/21.1 230-250 50-32 175-190 85-100 80/26.7 240-260 52-32 180-195 85-100 90/32.2 245-270 54-35 185-200 85-100 100/37.8 280-310 57-37 190-205 90-105 110/43.3 290-325 64-39 190-205 95-110 Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 690 640 590 540 640 590 540 490 590 540 500 440 Based on average ice slab weight of 4.12- 4.75lb Regular cube derate is 7% Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 50/10.0 195-260 42-22 155-180 75-95 70/21.1 220-290 44-22 160-185 85-100 80/26.7 220-305 52-22 160-190 90-110 90/32.2 250-325 52-23 175-195 95-115 100/37.8 280-355 54-30 195-210 95-125 110/43.3 300-385 56-32 200-225 100-135 Suction pressure drops gradually throughout the freeze cycle Suction pressure drops gradually throughout the freeze cycle 7-38 Part No. 80-1100-3 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 7.8-9.2 7.9-9.4 8.2-9.7 8.4-9.9 8.7-10.3 8.9-10.5 9.5-11.2 9.7-11.4 9.9-11.7 10.1-11.9 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 50/10.0 70/21.1 90/32.2 670 660 640 630 610 600 580 570 540 530 520 510 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 600 1250 6800 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 50/10.0 70/21.1 90/32.2 7.9-9.4 8.9-10.5 9.5-11.2 8.0-9.4 8.1-9.5 8.4-9.9 8.9-10.5 9.0-10.6 9.1-10.7 9.5-11.2 10.1-11.9 9.6-11.3 9.7-11.4 10.1-11.9 10.9-12.8 Harvest Time 1-2.5 24 Hour Ice Production Based on average ice slab weight of 4.12 - 4.75 lb Regular cube derate is 7% Gal/24 hours Freeze Time Water Temperature °F/°C Times in minutes Water Temperature °F/°C Condenser Water Consumption 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 Cycle Discharg Suction e Pressure Pressure PSIG PSIG 225-235 46-25 225-235 46-26 225-235 48-26 225-240 48-26 225-245 50-28 225-250 52-28 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 140-184 80-102 148-184 82-104 154-186 86-108 154-190 86-108 162-194 86-112 165-200 86-115 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 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 630 570 540 625 620 600 570 565 560 540 510 535 530 510 480 Based on average ice slab weight of 4.12- 4.75 lb Regular cube derate is 7% Ratings with JC0895 condenser, dice or half dice cubes Operating Pressures Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG -20/-28.9 to 220-250 42-26 50/10.0 70/21.1 225-260 44-26 80/26.7 245-265 46-26 90/32.2 250-265 48-26 100/37.8 265-295 52-26 110/43.3 300-335 52-28 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 152-170 75-100 155-172 156-174 157-174 158-176 158-176 82-100 82-100 84-100 84-100 84-105 Suction pressure drops gradually throughout the freeze cycle Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-39 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 90/32.2 8.9-10.2 9.3-10.7 10.3-11.9 12.1-13.8 9.7-11.1 10.2-11.7 11.4-13.1 13.3-15.2 10.3-11.9 10.9-12.5 12.3-14.1 14.4-16.5 Harvest Time 1-2.5 Times in minutes Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 8.7-10.1 8.9-10.2 9.0-10.3 9.1-10.5 9.5-11.0 9.7-11.1 9.8-11.3 10.0-11.5 10.9-12.5 11.0-12.7 11.2-12.9 11.4-13.1 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 800 770 700 610 740 710 640 560 700 670 600 520 Based on average ice slab weight of 5.75- 6.50 lb Regular cube derate is 7% Operating Pressures Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG 50/10.0 220-280 31-18 70/21.1 220-280 32-18 80/26.7 225-280 36-20 90/32.2 260-295 38-22 100/37.8 300-330 40-24 110/43.3 320-360 44-26 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 135-180 65-90 140-180 70-90 140-180 70-95 150-200 80-100 210-225 80-100 210-240 85-120 Suction pressure drops gradually throughout the freeze cycle Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 810 800 790 780 750 740 730 720 670 660 650 640 Based on average ice slab weight of 5.75- 6.50lb Regular cube derate is 7% Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 640 1420 6000 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Cycle Discharg Suction e Pressure Pressure PSIG PSIG 225-235 33-20 225-235 34-20 225-235 34-20 225-235 36-22 225-235 36-22 225-240 38-24 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 160-185 65-85 165-185 70-85 165-185 70-85 165-185 70-85 165-185 70-85 170-190 75-90 Suction pressure drops gradually throughout the freeze cycle 7-40 Part No. 80-1100-3 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 90/32.2 9.5-11.0 10.6-12.2 11.6-13.4 9.7-11.1 9.8-11.3 10.6-12.2 11.9-13.6 10.8-12.4 11.0-12.6 11.9-13.6 13.4-15.4 11.9-13.6 12.1-13.8 13.2-15.1 14.7-16.9 Harvest Time 1-2.5 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 9.9-10.6 10.2-11.0 10.9-11.7 12.1-13.0 10.6-11.4 11.2-12.0 11.9-12.8 13.2-14.1 11.3-12.2 11.9-12.8 12.8-13.7 14.2-15.2 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Times in minutes 24 Hour Ice Production 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 Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 750 685 630 740 730 685 620 675 665 620 555 620 610 565 510 Based on average ice slab weight of 5.75- 6.50lb Regular cube derate is 7% Ratings with JC0895 condenser, dice or half dice cubes Operating Pressures Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG -20/-28.9 to 220-250 30-22 50/10.0 70/21.1 225-250 32-22 80/26.7 240-260 33-22 90/32.2 255-265 34-22 100/37.8 275-295 38-24 110/43.3 280-320 40-26 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 180-200 65-90 190-200 190-205 195-205 200-210 200-225 70-90 70-90 70-90 70-90 75-100 Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 980 950 900 820 920 880 830 760 870 830 780 710 Based on average ice slab weight of 7.75 - 8.25lb Regular cube derate is 7% Operating Pressures Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG 50/10.0 220-280 38-18 70/21.1 220-280 40-18 80/26.7 225-280 42-20 90/32.2 260-295 42-22 100/37.8 300-330 42-24 110/43.3 320-360 44-24 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 135-180 65-90 140-180 70-90 140-180 70-95 150-200 80-100 210-225 80-100 210-240 85-120 Suction pressure drops gradually throughout the freeze cycle Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-41 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 10.1-10.9 10.2-11.0 10.4-11.1 10.6-11.4 10.8-11.6 10.9-11.7 11.0-11.8 12.1-13.0 12.3-13.2 12.5-14.3 12.6-14.4 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 50/10.0 70/21.1 90/32.2 970 960 950 940 920 910 900 890 820 810 800 790 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 750 1500 6200 Water regulating valve set to maintain 230 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 50/10.0 70/21.1 90/32.2 10.5-11.3 11.3-12.2 12.1-13.0 10.7-11.5 10.8-11.6 11.5-12.3 12.3-13.2 11.5-12.3 11.6-12.5 12.5-13.4 13.4-14.3 12.3-13.2 12.5-13.4 13.4-14.3 14.4-15.5 Harvest Time 1-2.5 24 Hour Ice Production Based on average ice slab weight of 7.75- 8.25lb Regular cube derate is 7% Gal/24 hours Freeze Time Water Temperature °F/°C Times in minutes Water Temperature °F/°C Condenser Water Consumption 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 Cycle Discharg Suction e Pressure Pressure PSIG PSIG 225-235 36-18 225-235 38-18 225-235 40-18 225-235 40-20 225-235 40-20 225-240 42-20 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 160-185 65-85 165-185 70-85 165-185 70-85 165-185 70-85 165-185 70-85 170-190 75-90 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 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 930 870 820 915 906 860 810 860 850 800 750 810 800 750 700 Based on average ice slab weight of 7.75- 8.25lb Regular cube derate is 7% Ratings with JC1095 condenser, dice or half dice cubes Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG -20/-28.9 to 220-250 40-22 180-200 65-90 50/10.0 70/21.1 225-250 40-22 190-200 70-90 80/26.7 240-260 42-22 190-205 70-90 90/32.2 255-265 44-22 195-205 70-90 100/37.8 275-295 44-24 200-210 70-90 110/43.3 280-320 46-26 200-225 75-100 Suction pressure drops gradually throughout the freeze cycle Suction pressure drops gradually throughout the freeze cycle 7-42 Part No. 80-1100-3 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 90/32.2 9.4-10.5 9.9-11.1 11.0-12.3 12.3-13.7 9.9-11.1 10.6-11.8 11.5-12.8 13.2-14.7 10.9-12.2 11.6-12.9 12.8-14.2 14.7-16.3 Harvest Time 1-2.5 Times in minutes Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 9.0-10.1 9.1-10.1 9.2-10.3 9.4-10.5 9.8-10.9 9.8-11.0 10.0-11.2 10.1-11.3 11.4-12.6 11.6-12.9 12.0-13.3 12.2-13.6 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production 24 Hour Ice Production Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1320 1260 1150 1040 1260 1190 1110 980 1160 1100 1010 890 Based on average ice slab weight of 10.0- 11.0 lb Regular cube derate is 7% Operating Pressures Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG 50/10.0 220-280 40-20 70/21.1 220-280 40-20 80/26.7 220-280 42-22 90/32.2 245-300 48-26 100/37.8 275-330 50-26 110/43.3 280-360 52-28 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 140-170 65-80 145-170 70-80 150-185 70-80 160-190 70-85 160-210 70-90 165-225 75-100 Suction pressure drops gradually throughout the freeze cycle Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1370 1360 1340 1320 1280 1270 1250 1240 1120 1100 1070 1050 Based on average ice slab weight of 10.0 - 11.0 lb Regular cube derate is 7% Condenser Water Consumption Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1150 2220 7400 Water regulating valve set to maintain 240 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 70/21.1 80/26.7 90/32.2 100/37.8 110/43.3 Freeze Cycle Harvest Cycle Discharg Suction Discharge Suction e Pressure Pressure Pressure Pressure PSIG PSIG PSIG PSIG 235-245 40-18 150-180 70-80 235-245 40-18 150-180 70-80 235-245 40-20 150-180 70-80 235-250 42-20 150-180 70-80 235-255 44-20 150-180 70-80 240-265 46-20 150-180 70-80 Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-43 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 70/21.1 90/32.2 9.9-11.1 10.9-12.2 11.7-13.0 10.0-11.2 10.1-11.3 10.8-12.0 11.7-13.0 11.0-12.3 11.1-12.4 11.8-13.2 12.9-14.3 11.1-12.4 10.7-11.9 12.8-14.2 13.8-15.4 Harvest Time 1-2.5 Freeze Time Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 7.2-8.1 7.3-8.2 7.4-8.2 7.4-8.3 8.0-9.0 8.1-9.1 8.2-9.1 8.4-9.4 8.9-9.9 9.2-10.2 9.6-10.7 9.7-10.8 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Times in minutes 24 Hour Ice Production 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 Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1260 1160 1090 1250 1240 1170 1090 1150 1140 1080 1000 1140 1180 1010 940 Based on average ice slab weight of 10.0- 11.0 lb Ratings with JC1395 condenser, dice or half dice cubes Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 70/21.1 50/10.0 70/21.1 90/32.2 1650 1635 1625 1620 1650 1510 1500 1490 1450 1510 1390 1350 1300 1290 1390 Based on average ice slab weight of 13.0 -14.12 lb Condenser Water Consumption Gal/24 hours Operating Pressures Water Temperature °F/°C 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1400 2235 6500 Water regulating valve set to maintain 240 PSIG discharge pressure Freeze Cycle Air Temp. Discharg Entering Suction e Condenser Pressure Pressure °F/°C PSIG PSIG -20/-28.9 to 220-250 40-22 50/10.0 70/21.1 240-260 40-22 80/26.7 240-270 41-22 90/32.2 250-290 42-22 100/37.8 280-320 46-22 110/43.3 310-360 48-24 Harvest Cycle Discharge Pressure PSIG Suction Pressure PSIG 135-170 75-95 140-180 140-190 140-200 140-210 140-220 80-95 80-95 80-95 80-95 85-100 Suction pressure drops gradually throughout the freeze cycle Operating Pressures Freeze Cycle Air Temp. Entering Discharge Suction Condenser Pressure Pressure °F/°C PSIG PSIG -20/-28.9 to 235-245 48-24 50/10.0 70/21.1 235-265 52-26 80/26.7 235-270 52-26 90/32.2 235-280 52-28 100/37.8 240-285 52-28 110/43.3 240-290 54-28 Harvest Cycle Discharge Suction Pressure Pressure PSIG PSIG 145-170 70-90 150-175 150-175 155-180 155-180 155-185 70-90 75-95 75-95 80-100 80-100 Suction pressure drops gradually throughout the freeze cycle 7-44 Part No. 80-1100-3 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 7.5-8.4 8.2-9.2 9.0-10.1 8.0-8.9 8.4-9.3 9.2-10.3 8.6-9.6 9.2-10.2 10.0-11.2 9.2-10.3 9.7-10.8 10.4-11.6 Harvest Time 1 - 2.5 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 90/32.2 8.5-9.3 9.0-9.9 9.6-10.5 10.6-11.6 9.4-10.3 9.8-10.8 10.4-11.5 11.5-12.6 9.9-10.9 10.5-11.5 11.1-12.2 12.4-13.6 Harvest Time 1-2.5 Times in minutes Times in minutes 24 Hour Ice Production 24 Hour Ice Production Air Temp. Entering Condenser °F/°C -20 to 70 -29 to 21.1 90/32.2 100/37.8 110/43.3 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1600 1478 1370 1523 1460 1343 1425 1350 1250 1340 1290 1213 Based on average ice slab weight of 13.0- 14.12lb Ratings with JC1895 condenser, dice or half dice cubes Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG -20 to 50/-29 220-255 52-26 100-120 70-85 to 10.0 70/21.1 250-270 56-28 110-120 75-90 80/26.7 250-275 56-28 110-120 75-90 90/32.2 255-285 56-28 110-120 80-90 100/37.8 270-310 56-30 115-130 80-95 110/43.3 305-350 58-32 120-135 80-100 Air Temp. Entering Condenser °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1880 1780 1690 1550 1720 1650 1570 1440 1640 1560 1480 1350 Based on average ice slab weight of 13.0 - 14.12lb Regular cube derate is 7% Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG 50/10.0 220-280 40-20 155-190 60-80 70/21.1 220-280 40-20 160-190 65-80 80/26.7 230-290 42-20 160-190 65-80 90/32.2 260-320 44-22 185-205 70-90 100/37.8 300-360 46-24 210-225 75-100 110/43.3 320-400 48-26 215-240 80-100 Suction pressure drops gradually throughout the freeze cycle Suction pressure drops gradually throughout the freeze cycle Part No. 80-1100-3 7-45 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 9.0-9.9 9.1-10.1 9.2-10.1 9.6-10.5 9.6-10.6 9.7-10.7 9.8-10.7 10.8-11.9 10.8-11.9 10.9-12.0 11.1-12.1 Harvest Time 1-2.5 Times in minutes 24 Hour Ice Production Air Temp. Around Ice Machine °F/°C 70/21.1 80/26.7 90/32.2 100/37.8 50/10.0 70/21.1 90/32.2 1840 1780 1760 1750 1690 1680 1670 1660 1520 1520 1510 1490 Based on average ice slab weight of 13.0- 14.12lb Regular cube derate is 7% Gal/24 hours 90/32.2 Air Temperature Around Ice Machine Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 2000 2670 7750 Water regulating valve set to maintain 240 PSIG discharge pressure Operating Pressures Air Temp. Around Ice Machine °F/°C 50/10.0 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 90/32.2 9.1-10.0 9.8-10.8 10.7-11.7 9.3-10.2 9.5-10.5 10.1-11.1 11.0-12.1 10.1-11.1 10.3-11.4 11.1-12.2 12.1-13.2 10.9-12.0 11.1-12.2 11.9-13.0 12.7-13.9 Harvest Time 1-2.5 Times in minutes Water Temperature °F/°C Condenser Water Consumption 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 Cycle Discharg Suction e Pressure Pressure PSIG PSIG 235-245 36-20 235-245 38-20 235-245 40-20 235-250 42-22 235-255 44-22 235-260 46-22 Harvest Cycle Discharg Suction e Pressure Pressure PSIG PSIG 170-190 65-80 170-190 65-80 170-190 65-80 175-190 65-80 175-190 65-80 175-190 65-80 24 Hour Ice Production 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 Water Temperature °F/°C 50/10.0 70/21.1 90/32.2 1770 1650 1540 1735 1700 1620 1500 1615 1580 1480 1380 1510 1480 1400 1320 Based on average ice slab weight of 13.0 - 14.12lb Regular cube derate is 7% Ratings with JC1895 condenser, dice or half dice cubes Operating Pressures Freeze Cycle Harvest Cycle Air Temp. Discharg Entering Suction Discharge Suction e Condenser Pressure Pressure Pressure Pressure °F/°C PSIG PSIG PSIG PSIG -20/-28.9 to 220-250 38-24 160-180 60-80 50/10.0 70/21.1 220-260 40-24 170-180 60-80 80/26.7 250-270 48-24 175-190 70-90 90/32.2 250-280 50-24 180-200 80-90 100/37.8 270-300 52-28 205-215 80-95 110/43.3 300-350 54-28 205-230 80-100 Suction pressure drops gradually throughout the freeze cycle Suction pressure drops gradually throughout the freeze cycle 7-46 Part No. 80-1100-3 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. 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. OPEN LOW SIDE SERVICE VALVE BACKSEATED OPEN BACKSEATED HIGH SIDE SERVICE VALVE Important Replace the liquid line drier before evacuating and recharging. Use only a Manitowoc (O.E.M.) liquid line filter drier to prevent voiding the warranty. CONNECTIONS 1. Suction side of the compressor through the suction service valve. 2. Discharge side of the compressor through the discharge service valve. VACUUM PUMP/ RECOVERY UNIT OPEN CLOSED SV1404A Figure 7-14. Recovery/Evacuation Connections 3. Open (backseat) the high and low side ice machine service valves, and open high and low side on manifold gauges. 4. Perform recovery or evacuation: A. Recovery: Operate the recovery unit as directed by the manufacturer’s instructions. B. Evacuation prior to recharging: Pull the system down to 250 microns. Then, allow the pump to run for an additional half hour. Turn off the pump and perform a standing vacuum leak check. NOTE: Check for leaks using a halide or electronic leak detector after charging the ice machine. 5. Refer to Charging Procedures. Part No. 80-1100-3 7-47 Refrigeration System Section 7 Self-Contained Charging Procedures 2. Close the vacuum pump valve, the low side service valve, and the low side manifold gauge valve. 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. Let the system “settle” for 2 to 3 minutes. 6. Place the toggle switch in the ICE position. MANIFOLD SET LOW SIDE SERVICE VALVE 3. Open the high side manifold gauge valve, and backseat the high side service valve. CLOSED OPEN FRONTSEATED BACKSEATED 7. Close the high side on the manifold gauge set. Add any remaining vapor charge through the suction service valve (if necessary). NOTE: Manifold gauges must be removed properly to ensure that no refrigerant contamination or loss occurs. HIGH SIDE SERVICE VALVE 8. Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses. A. Run the ice machine in freeze cycle. B. Close the high side service valve at the ice machine. CHARGING CYLINDER VACUUM PUMP/ RECOVERY UNIT D. Open the high and low side valves on the manifold gauge set. Any refrigerant in the lines will be pulled into the low side of the system. CLOSED OPEN SV1404B Figure 7-15. Charging Connections C. Open the low side service valve at the ice machine. E. Allow the pressures to equalize while the ice machine is in the freeze cycle. F. Close the low side service valve at the ice machine. Remove the hoses from the ice machine and install the caps. 7-48 Part No. 80-1100-3 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. NOTE: Manitowoc recommends using an access valve core removal and installation tool on the discharge line quick-connect fitting. This permits access valve core removal. This allows for faster evacuation and charging, without removing the manifold gauge hose. REMOTE RECOVERY/EVACUATION 1. Place the toggle switch in the OFF position. 2. Install manifold gauges, charging cylinder/scale, and recovery unit or two-stage vacuum pump. 3. Open (backseat) the high and low side ice machine service valves. 4. Open the receiver service valve halfway. Important Replace the liquid line drier before evacuating and recharging. Use only a Manitowoc (O.E.M.) liquid line filter drier to prevent voiding the warranty. CONNECTIONS Important Recovery/evacuation of a remote system requires connections at four points for complete system evacuation. See the drawing on next page. 5. Open high and low side on the manifold gauge set. 6. Perform recovery or evacuation: A. Recovery: Operate the recovery unit as directed by the manufacturer’s instructions. B. Evacuation prior to recharging: Pull the system down to 250 microns. Then, allow the pump to run for an additional hour. Turn off the pump and perform a standing vacuum leak check. NOTE: Check for leaks using a halide or electronic leak detector after charging the ice machine. 7. Refer to Charging Procedures. Make these connections: • Suction side of the compressor through the suction service valve. • Discharge side of the compressor through the discharge service valve. • Receiver outlet service valve, which evacuates the area between the check valve in the liquid line and the pump down solenoid. • Access (Schrader) valve on the discharge line quickconnect fitting, located on the outside of the compressor/evaporator compartment. This connection evacuates the condenser. Without it, the magnetic check valves would close when the pressure drops during evacuation, preventing complete evacuation of the condenser. Part No. 80-1100-3 7-49 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 E R C HEAD PRESS U RE C O NTR O L V A LV E M ANIFO LD SET O PEN TEE O PEN O PEN V AC UU M PU M P/ REC O V ER Y U NIT SCA LE C LO SED SV1461 Figure 7-16. Recovery/Evacuation Connections 7-50 Part No. 80-1100-3 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. If the access valve core removal and installation tool is used on the discharge quick-connect fitting, reinstall the Schraeder valve core before disconnecting the access tool and hose. 3. Open the charging cylinder and add the proper refrigerant charge (shown on nameplate) into the system high side (receiver outlet valve and discharge lines quick-connect fitting). 6. Run the ice machine in freeze cycle. 4. If the high side does not take the entire charge, close the high side on the manifold gauge set, and backseat (open) the low side service valve and receiver outlet service valve. Start the ice machine and add the remaining charge through the low side (in vapor form) until the machine is fully charged. 9. Open the high and low side valves on the manifold gauge set. Any refrigerant in the lines will be pulled into the low side of the system. 5. Ensure all vapor in charging hoses is drawn into the machine, then disconnect the manifold gauges. Part No. 80-1100-3 7. Close the high side service valve at the ice machine. 8. Open the low side service valve at the ice machine. 10. Allow the pressures to equalize while the ice machine is in the freeze cycle. 11. Close the low side service valve at the ice machine. 12. Remove the hoses from the ice machine and install the caps. 7-51 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 LV E R C HEAD PRESS U RE C O NTR O L V A LV E M ANIFO LD SET TEE C LO SED O PEN C LO SED SCA LE V AC UU M PU M P/ REC O V ER Y U NIT SV1462 O PEN Figure 7-17. Remote Charging Connections 7-52 Part No. 80-1100-3 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. These devices sample refrigerant, eliminating the need to take an oil sample. Follow the manufacturer’s directions. If a refrigerant test kit indicates harmful levels of contamination, or if a test kit is not available, inspect the compressor oil. 1. Remove the refrigerant charge from the ice machine. 2. Remove the compressor from the system. Determining Severity Of Contamination 3. Check the odor and appearance of the oil. System contamination is generally caused by either moisture or residue from compressor burnout entering the refrigeration system. 4. Inspect open suction and discharge lines at the compressor for burnout deposits. Inspection of the refrigerant usually provides the first indication of system contamination. Obvious moisture or an acrid odor in the refrigerant indicates contamination. 5. If no signs of contamination are present, perform an acid oil test. Check the chart below to determine the type of cleanup required. Contamination/Cleanup Chart Required Cleanup Procedure Normal evacuation/recharging procedure Symptoms/Findings No symptoms or suspicion of contamination Moisture/Air Contamination symptoms Refrigeration system open to atmosphere for longer than 15 minutes Mild contamination cleanup procedure Refrigeration test kit and/or acid oil test shows contamination Leak in water-cooled condenser No burnout deposits in open compressor lines Mild Compressor Burnout symptoms Oil appears clean but smells acrid Mild contamination cleanup procedure Refrigeration test kit or acid oil test shows harmful acid content No burnout deposits in open compressor lines Severe Compressor Burnout symptoms Oil is discolored, acidic, and smells acrid Severe contamination cleanup procedure Burnout deposits found in the compressor and lines, and in other components Part No. 80-1100-3 7-53 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. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation. Do not position heat lamps too close to plastic components, or they may melt or warp. 4. Wipe away any burnout deposits from suction and discharge lines at compressor. 5. Sweep through the open system with dry nitrogen. Important Dry nitrogen is recommended for this procedure. This will prevent CFC release. 4. Follow the normal evacuation procedure, except replace the evacuation step with the following: A. Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi. B. Pull vacuum to 500 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi. C. Change the vacuum pump oil. D. Pull vacuum to 250 microns. Run the vacuum pump for 1/2 hour on self-contained models, 1 hour on remotes. Important Refrigerant sweeps are not recommended, as they release CFC’s into the atmosphere. 6. Install a new compressor and new start components. 7. Install a suction line filter-drier with acid and moisture removal capability (P/N 89-3028-3). Place the filter drier as close to the compressor as possible. 8. Install an access valve at the inlet of the suction line drier. 9. Install a new liquid line drier. Continued on next page … NOTE: You may perform a standing vacuum test to make a preliminary leak check. You should use an electronic leak detector after system charging to be sure there is no leak. 5. Charge the system with the proper refrigerant to the nameplate charge. 6. Operate the ice machine. 7-54 Part No. 80-1100-3 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. • Fan cycle control (air-cooled only) • Water regulating valve (water-cooled only) • High pressure cut-out control B. Change the vacuum pump oil. • High side service valve C. Pull vacuum to 500 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi. • Low side service valve A. Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi. Important D. Change the vacuum pump oil. This is a required in-warranty repair procedure. E. Pull vacuum to 250 microns. Run the vacuum pump for 1/2 hour on self-contained models, 1 hour on remotes. 1. Disconnect power to the ice machine. NOTE: You may perform a standing vacuum test to make a preliminary leak check. You should use an electronic leak detector after system charging to be sure there is no leak. 11. Charge the system with the proper refrigerant to the nameplate charge. 12. Operate the ice machine for one hour. Then, check the pressure drop across the suction line filter-drier. A. If the pressure drop is less than 1 psi, the filterdrier should be adequate for complete cleanup. B. If the pressure drop exceeds 1 psi, change the suction line filter-drier and the liquid line drier. Repeat until the pressure drop is acceptable. 13. Operate the ice machine for 48-72 hours. Then, remove the suction line drier and change the liquid line drier. 14. Follow normal evacuation procedures. 2. Follow all manufacturer’s instructions supplied with the pinch-off tool. Position the pinch-off tool around the tubing as far from the pressure control as feasible. (See the figure on next page.) Clamp down on the tubing until the pinch-off is complete. ! Warning Do not unsolder a defective component. Cut it out of the system. Do not remove the pinch-off tool until the new component is securely in place. 3. Cut the tubing of the defective component with a small tubing cutter. 4. Solder the replacement component in place. Allow the solder joint to cool. 5. Remove the pinch-off tool. 6. Re-round the tubing. Position the flattened tubing in the proper hole in the pinch off tool. Tighten the wingnuts until the block is tight and the tubing is rounded. (See the drawing on next page.) NOTE: The pressure controls will operate normally once the tubing is re-rounded. Tubing may not re-round 100%. Part No. 80-1100-3 7-55 Refrigeration System Section 7 SV1406 Figure 7-18. Using Pinch-Off Tool 7-56 Part No. 80-1100-3 Section 7 Refrigeration System FILTER-DRIERS TOTAL SYSTEM REFRIGERANT CHARGES 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. These filter-driers have a very high moisture removal capability and a good acid removal capability. The size of the filter-drier is important. The refrigerant charge is critical. Using an improperly sized filter-drier will cause the ice machine to be improperly charged with refrigerant. Listed below are the recommended O.E.M. field replacement driers: Model Self-Contained Air and Water Cooled Q200 /Q280/Q320 Q370/Q420/Q450 Q600/Q800/Q1000 Remote Air Cooled Q450/Q600 Q800/Q1000 All Condenser Type Q1300/Q1600 Q1800 Suction Filter Drier Size UK-032S Important This information is for reference only. Refer to the ice machine serial number tag to verify the system charge. Serial plate information overrides information listed on this page. Series Q200 Q210 Q280 Q320 Q370 End Connection Size Part Number 1/4" 89-3025-3 Q420/Q450 Q600 UK-083S 3/8" 89-3027-3 Q800 UK-083S 3/8" 89-3027-3 Q1000 UK-165S 5/8" 89-3028-3 Suction Filter used when cleaning up severely contaminated systems Important Driers are covered as a warranty part. The drier must be replaced any time the system is opened for repairs. Q1300 Q1600 Q1800 Version Air-Cooled Water-Cooled Air-Cooled Water-Cooled Air-Cooled Water-Cooled Air-Cooled Water-Cooled Air-Cooled Water-Cooled Air-Cooled Water-Cooled Remote Air-Cooled Water-Cooled Remote Air-Cooled Water-Cooled Remote Air-Cooled Water-Cooled Remote Air-Cooled Water-Cooled Remote Water-Cooled Remote Air-Cooled Water-Cooled Remote Charge 18 oz. 15 oz. 15 oz 11 oz 18 oz 15 oz 20 oz. 16 oz. 20 oz. 17 oz. 24 oz. 22 oz. 6 lb. 28 oz. 22 oz. 8 lb. 36 oz. 25 oz. 8 lb. 38 oz. 32 oz. 9.5 lb. 48 oz. 44 oz. 12.5 lb. * 46 oz. 15 lb.* 56 oz. 46 oz. 15 lb.* *For remote line sets with lengths between 50' and 100' refer to chart on Page 2-13 NOTE: All ice machines on this list are charged using R-404A refrigerant. Part No. 80-1100-3 7-57 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. To remove refrigerant, in any condition, from a system and store it in an external container, without necessarily testing or processing it in any way. Recycle To clean refrigerant for re-use by oil separation and single or multiple passes through devices, such as replaceable core filter-driers, which reduce moisture, acidity and particulate matter. This term usually applies to procedures implemented at the field job site or at a local service shop. Chemical analysis is the key requirement in this definition. Regardless of the purity levels reached by a reprocessing method, refrigerant is not considered “reclaimed” unless it has been chemically analyzed and meets ARI Standard 700 (latest edition). New Product Specifications This means ARI Standard 700 (latest edition). Chemical analysis is required to assure that this standard is met. 7-58 Part No. 80-1100-3 Section 7 Refrigeration System REFRIGERANT RE-USE POLICY Manitowoc recognizes and supports the need for proper handling, re-use, and disposal of, CFC and HCFC refrigerants. Manitowoc service procedures require recapturing refrigerants, not venting them to the atmosphere. It is not necessary, in or out of warranty, to reduce or compromise the quality and reliability of your customers’ products to achieve this. Important Manitowoc Ice, Inc. assumes no responsibility for use of contaminated refrigerant. Damage resulting from the use of contaminated, recovered, or recycled refrigerant is the sole responsibility of the servicing company. 3. Recovered or Recycled Refrigerant • Must be recovered or recycled in accordance with current local, state and federal laws. • Must be recovered from and re-used in the same Manitowoc product. Re-use of recovered or recycled refrigerant from other products is not approved. • Recycling equipment must be certified to ARI Standard 740 (latest edition) and be maintained to consistently meet this standard. • Recovered refrigerant must come from a “contaminant-free” system. To decide whether the system is contaminant free, consider: – Type(s) of previous failure(s) – Whether the system was cleaned, evacuated and recharged properly following failure(s) Manitowoc approves the use of: – Whether the system has been contaminated by this failure 1. New Refrigerant • – Compressor motor burnouts and improper past service prevent refrigerant re-use. Must be of original nameplate type. 2. Reclaimed Refrigerant • Must be of original nameplate type. • Must meet ARI Standard 700 (latest edition) specifications. Part No. 80-1100-3 – Refer to “System Contamination Cleanup” to test for contamination. 4. “Substitute” or “Alternative” Refrigerant • Must use only Manitowoc-approved alternative refrigerants. • Must follow Manitowoc-published conversion procedures. 7-59 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. What are some of the characteristics of POE oils? They are hygroscopic, which means they have the ability to absorb moisture. POE oils are 100 times more hygroscopic than mineral oils. Once moisture is absorbed into the oil, it is difficult to remove, even with heat and vacuum. POE oils are also excellent solvents, and tend to “solvent clean” everything inside the system, depositing material where it is not wanted. 3. What do these POE oil characteristics mean to me? You must be more exacting in your procedures. Take utmost care to prevent moisture from entering the refrigeration system. Refrigeration systems and compressors should not be left open to the atmosphere for more than 15 minutes. Keep oil containers and compressors capped at all times to minimize moisture entry. Before removing the system charge to replace a faulty component, be sure you have all of the needed components at the site. Remove new system component plugs and caps just prior to brazing. Be prepared to connect a vacuum pump immediately after brazing. 7-60 Section 7 4. Are there any special procedures required if a POE system is diagnosed with a refrigerant leak? For systems found with positive refrigerant system pressure, no special procedures are required. For systems found without any positive refrigerant pressure, assume that moisture has entered the POE oil. After the leak is found and repaired, the compressor oil must be changed. The compressor must be removed and at least 95% of the oil drained from the suction port of the compressor. Use a “measuring cup” to replace the old oil with exactly the same amount of new POE oil, such as Mobil EAL22A. Remember, care must be taken to prevent moisture from getting into the refrigeration system during refrigeration repairs. 5. How do I leak-check a system containing HFC refrigerant? Use equipment designed for HFC detection. Do not use equipment designed for CFC detection. Consult leak detection equipment manufacturers for their recommendations. Also, standard soap bubbles will work with HFC refrigerants. 6. Does Manitowoc use a special liquid line filter-drier with HFC refrigerants? Yes. Manitowoc uses an ALCO “UK” series filterdrier for increased filtration and moisture removal. During a repair, Manitowoc recommends installing the drier just before hooking up a vacuum pump. Continued on next page … Part No. 80-1100-3 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. Do I have to recover HFC refrigerants? Yes. Like other refrigerants, government regulations require recovering HFC refrigerants. 9. Will R-404A or R-134A separate if there is a leak in the system? No. Like R-502, the degree of separation is too small to detect. 10. How do I charge a system with HFC refrigerant? The same as R-502. Manitowoc recommends charging only liquid refrigerant into the high side of the system. 7-61 Refrigeration System Section 7 THIS PAGE INTENTIONALLY LEFT BLANK 7-62 Part No. 80-1100-3 Section 7 Refrigeration System THIS PAGE INTENTIONALLY LEFT BLANK Part No. 80-1100-3 7-63
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