Manitowoc J Service Manual

Ice Machines

J Model

Service

Manual

 1997 Manitowoc Ice, Inc.

Part No. 83-5631-9

Rev A 8/97

Safety Notices

As you work on a J-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.

Procedural Notices

As you work on a J-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:

WARNING

Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.

CAUTION

Text in a Caution box alerts you to a situation in
which you could damage the ice machine. Be sure
to read the Caution statement before proceeding,
and work carefully.

Throughout this manual, you will see the following
types of procedural notices:

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.

We reserve the right to make product improvements at any time.

Specifications and design are subject to change without notice.

Table of Contents

Section 1 - Warranty

Coverage..............................................................................................................................................................1-1

Section 2 - Installation References

(Refer to Installation Manual for complete Installation Guidelines)

Dimensions

Ice Machines...................................................................................................................................................2-1

Ice Storage Bins..............................................................................................................................................2-3

Remote Condensers........................................................................................................................................2-4

Location of Ice Machine ....................................................................................................................................2-5

Heat of Rejection................................................................................................................................................2-5

Electrical Fuse Size/Circuit Ampacity..............................................................................................................2-6

Electrical Wiring Connections

Self-Contained Electrical Connections ..........................................................................................................2-8

Remote Electrical Connections......................................................................................................................2-9

Water Connections and Drains.......................................................................................................................2-10

Cooling Tower Applications (Water-Cooled Models)...................................................................................2-11

Remote Condenser/Line Set Installation

Remote Ice Machines Refrigerant Charge....................................................................................................2-12

Routing Line Sets.........................................................................................................................................2-13

Calculating Remote Condenser Installation Distances ................................................................................2-14

Usage with Non-Manitowoc Multi-Circuit Condensers

Warranty.......................................................................................................................................................2-16

Line Set Routing and Sizing.........................................................................................................................2-16

Head Pressure Control Valve.......................................................................................................................2-16

Fan Motor.....................................................................................................................................................2-16

Internal Condenser Volume..........................................................................................................................2-17

Condenser ∆T...............................................................................................................................................2-17

Refrigerant Charge.......................................................................................................................................2-17

Quick-Connect Fittings................................................................................................................................2-17

i

Table of Contents (cont.)

Section 3 - Maintenance

Component Identification..................................................................................................................................3-1

Operational Checks

Water Level Check.........................................................................................................................................3-2

Ice Thickness Check.......................................................................................................................................3-2

Cleaning the Condenser

Air-Cooled Condenser (Self-Contained and Remote Models).......................................................................3-3

Water-Cooled Condenser and Water Regulating Valve.................................................................................3-4

Interior Cleaning and Sanitizing

General ...........................................................................................................................................................3-5

Cleaning Procedure........................................................................................................................................3-5

Sanitizing Procedure ......................................................................................................................................3-6

Procedure to Cancel a Self-Cleaning or Sanitizing Cycle After It Has Started..............................................3-6

AuCSä Accessory .........................................................................................................................................3-7

Removal of Parts for Cleaning/Sanitizing......................................................................................................3-8

Water Treatment/Filtration............................................................................................................................3-14

Removal from Service/Winterization

General .........................................................................................................................................................3-15

Self-Contained Air-Cooled Ice Machines....................................................................................................3-15

Water-Cooled Ice Machines.........................................................................................................................3-15

Remote Ice Machines...................................................................................................................................3-15

AuCSä Accessory .......................................................................................................................................3-15

Section 4 - Ice Machine Sequence of Operation

Self-Contained Air- and Water-Cooled............................................................................................................4-1

Remote.................................................................................................................................................................4-3

Section 5 - Water System Ice Making Sequence of Operation

Initial Start-Up or Start-Up After Automatic Shut-Off.................................................................................5-1

Freeze Cycle........................................................................................................................................................5-1

Harvest Cycle......................................................................................................................................................5-2

Automatic Shut-Off............................................................................................................................................5-2

ii

Table of Contents (cont.)

Section 6 - Electrical System

Energized Parts Charts

Self-Contained Air- and Water-Cooled Models.............................................................................................6-1

Remote Models ..............................................................................................................................................6-2

Wiring Diagram Sequence of Operation

Self-Contained Models...................................................................................................................................6-3

Remote Models ............................................................................................................................................6-10

Wiring Diagrams

Wiring Diagram Legend...............................................................................................................................6-17

Old Style Self-Contained - J200/J250/J320 - 1 Phase..................................................................................6-18

Old Style Self-Contained - J420/J450/J600/J800/J1000 - 1 Phase..............................................................6-19

Old Style Self-Contained - J800/J1000 - 3 Phase........................................................................................6-20

Old Style Self-Contained - J1300/J1800 - 1 Phase......................................................................................6-21

Old Style Self-Contained - J1300/J1800 - 3 Phase......................................................................................6-22

Old Style Remote - J450/J600/J800/J1000 - 1 Phase...................................................................................6-23

Old Style Remote - J800/J1000 - 3 Phase....................................................................................................6-24

Old Style Remote - J1300/J1800 - 1 Phase..................................................................................................6-25

Old Style Remote - J1300/J1800 - 3 Phase..................................................................................................6-26

New Style Self-Contained - J200/J250/J320 - 1 Phase................................................................................6-27

New Style Self-Contained - J420/J450/J600/J800/J1000 - 1 Phase.............................................................6-28

New Style Self-Contained - J800/J1000 - 3 Phase.......................................................................................6-29

New Style Self-Contained - J1300/J1800 - 1 Phase.....................................................................................6-30

New Style Self-Contained - J1300/J1800 - 3 Phase.....................................................................................6-31

New Style Remote - J450/J600/J800/J1000 - 1 Phase.................................................................................6-32

New Style Remote - J800/J1000 - 3 Phase ..................................................................................................6-33

New Style Remote - J1300/J1800 - 1 Phase ................................................................................................6-34

New Style Remote - J1300/J1800 - 3 Phase ................................................................................................6-35

iii

Table of Contents (cont.)

Section 6 - Electrical System (cont.)

Component Specifications and Diagnostics

Fuses.............................................................................................................................................................6-36

Bin Switch....................................................................................................................................................6-36

Compressor Electrical Diagnostics ..............................................................................................................6-38

PTCR Diagnostics........................................................................................................................................6-39

Discharge Line Thermistor...........................................................................................................................6-43

Ice/Off/Clean Toggle Switch........................................................................................................................6-44

Control Board Relays...................................................................................................................................6-45

Electronic Control Board (Old Style)...........................................................................................................6-46

Electronic Control Board (New Style).........................................................................................................6-47

Ice Thickness Probe (Harvest Initiation)

General .........................................................................................................................................................6-50

How the Probe Works..................................................................................................................................6-50

Freeze Time Lock-In Feature.......................................................................................................................6-50

Maximum Freeze Time................................................................................................................................6-50

Installation of New Probe on Old Style Control Board................................................................................6-50

Diagnosing Probe Control Circuitry

Ice Machine Cycles Into Harvest Before Water Contact with Probe.....................................................6-51

Ice Machine Does Not Cycle Into Harvest When Water Contacts Probe ..............................................6-52

Diagnosing Ice Machine That Will Not Run..................................................................................................6-53

iv

Table of Contents (cont.)

Section 7 - Refrigeration System

Sequence of Operation

Self-Contained Air- or Water-Cooled Models...............................................................................................7-1

Remote Models ..............................................................................................................................................7-3

J1300/J1800 Refrigeration Tubing Schematics..............................................................................................7-6

Operational Analysis (Diagnostics)

General ...........................................................................................................................................................7-8

Before Beginning Service...............................................................................................................................7-9

Ice Production Check.....................................................................................................................................7-9

Installation/Visual Inspection Checklist.......................................................................................................7-10

Water System Checklist...............................................................................................................................7-10

Ice Formation Pattern...................................................................................................................................7-11

Safety Limits................................................................................................................................................7-13

Hot Gas Valve Temperature Check..............................................................................................................7-17

Single Expansion Valve Ice Machines - Comparing Evaporator Inlet and Outlet Temperatures................7-18

Analyzing Discharge Pressure During Freeze or Harvest Cycle

Procedure................................................................................................................................................7-19

Freeze Cycle Discharge Pressure High Checklist..................................................................................7-19

Freeze Cycle Discharge Pressure Low Checklist...................................................................................7-19

Analyzing Suction Pressure During Freeze Cycle

Procedure................................................................................................................................................7-20

Freeze Cycle Suction Pressure High Checklist......................................................................................7-21

Freeze Cycle Suction Pressure Low Checklist.......................................................................................7-21

How to Use the Refrigeration System Operational Analysis Tables............................................................7-22

Refrigeration System Operational Analysis Tables

Single TXV ............................................................................................................................................7-24

Dual TXV...............................................................................................................................................7-25

Remotes Only

Harvest Pressure Regulating (H.P.R.) System.......................................................................................7-26

Headmaster Control Valve.....................................................................................................................7-28

v

Table of Contents (cont.)

Section 7 - Refrigeration System (cont.)

Pressure Control Specifications and Diagnostics

Fan Cycle Control ........................................................................................................................................7-30

High Pressure Cutout (HPCO) Control........................................................................................................7-30

Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts

J200 ..............................................................................................................................................................7-31

J250 ..............................................................................................................................................................7-32

J320 ..............................................................................................................................................................7-33

J420/J450......................................................................................................................................................7-34

J600 ..............................................................................................................................................................7-35

J800 ..............................................................................................................................................................7-37

J1000 ............................................................................................................................................................7-38

J1300 ............................................................................................................................................................7-40

J1800 ............................................................................................................................................................7-41

Refrigerant Recovery/Evacuating and Recharging

Normal Self-Contained Model Procedures ..................................................................................................7-44

Normal Remote Model Procedures..............................................................................................................7-46

System Contamination Cleanup...................................................................................................................7-50

Replacing Pressure Controls Without Removing Refrigerant Charge.........................................................7-52

Filter-Driers..................................................................................................................................................7-54

Total System Refrigerant Charges................................................................................................................7-54

Refrigerant Definitions.................................................................................................................................7-55

Refrigerant Re-Use Policy............................................................................................................................7-56

HFC Refrigerant Questions and Answers....................................................................................................7-57

vi

Section 1 Warranty

Section 1
Warranty

Coverage

GENERAL

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 representative or
Manitowoc Ice, Inc. if you need further warranty
information.

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.

EXCLUSIONS

The following items are not included in the ice
machine’s warranty coverage:

1. Normal maintenance, adjustments and cleaning as

outlined in the Owner/Operator Use and Care
Guide.

2. Repairs due to unauthorized modifications to the

ice machine or the use of non-standard parts
without prior written approval 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 the ice machine 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 the Installation Manual and the
Owner/Operator Use and Care Guide.

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.

1-1

Warranty Section 1

THIS PAGE INTENTIONALLY LEFT BLANK

1-2

Section 2 Installation References

Section 2

Installation References

Refer to Installation Manual for complete installation guidelines

Dimensions

ICE MACHINES

J320/J420 Ice Machine

7.00

15.00

3.00

1.50

4.00

2.25

30.00

J250 Ice Machine

28.00

4.50

0.75

1.75

NOTE: All measurements are in inches.

10.00

3.50

32.50

6.50

SV1319

22.00

H

14.25

0.63

6.50

SV1270

23.50

1.56

H

1.56

0.63

4.63

1.25

10.00

NOTE: All measurements are in inches.

Ice Machine Dimension H

J320 20.00
J420 25.00

SV1271

2-1

Section 2Installation References

J200-J1000 Ice Machines

30.00

17.50

10.00

23.50

2.75

SV1181SV1181

3.25

4.00

6.25

5.00

J1300/J1800 Ice Machines

23.50

48.25

H

3.00

10.13

29.75

H

SV1500

23.50

48.25

1.56

1.25

1.56

0.75

C

1.75

SV1180SV1180

NOTE: All measurements are in inches.

Ice Machine Dimension H Dimension C

J200 16.50 7.25
J450 20.00 10.50
J600 20.00 10.50
J800 25.00 10.50

J1000 28.00 10.50

H

19.25

2.88

9.88

SV1501

NOTE: All measurements are in inches.

Ice Machine Dimension H

J1300 28.00
J1800 28.00

2-2

Section 2 Installation References

A

A

ICE STORAGE BINS

C730 Ice Storage Bin

C170/C400/C470/C570 Ice Storage Bins

30.00

B

42.00

40.00

6.75

14.00

14.00

SV1187

Bin Model Dimension A Dimension B

C170 28.25 19.06
C400 34.00 31.37
C470 29.50 44.00
C570 34.00 44.00

C320/C420 Ice Storage Bins

22.00

6.50

16.00

31.50

4.25

SV1497

C970 Ice Storage Bin

48.25

44.00

6.75

B

17.00

52.00

4.25

SV1296

6.50

17.00

11.00

WARNING

All Manitowoc ice machines require an ice storage

SV1272

system with an ice deflector. The J1300 and J1800
require a Manitowoc Ice Deflector Kit (K00092)
when installing with a non-Manitowoc ice storage

NOTE: All measurements are in inches.

Bin Model Dimension A Dimension B

C320 34.00 32.00
C420 34.00 44.00

system.
For other Manitowoc Ice Machines, do not use a

non-Manitowoc ice storage system before
confirming with the manufacturer that their ice

2-3

deflector is compatible with Manitowoc ice
machines.

Section 2Installation References

2-4

Section 2 Installation References

REMOTE CONDENSERS

JC0495/JC0895/JC1095/JC1395 Condensers

OPTIONAL

29.16

38.00

34.00

6.00

29.50

3.50

4.00

6.50

14.62

27.94

1.50

OPTIONAL

20.00

16.00

SV1297

Dual Circuit Condenser - DC0862

OPTIONAL

47.25

43.25

39.25

35.25

31.25

3.91

8.56

29.16

6.34

8.50

14.69

29.30

22.40

3.38

24.00

6.34

8.50

SV1578

OPTIONAL

19.69

15.69

JC1895 Remote Condenser

OPTIONAL

29.16

47.25

43.25

39.25

35.25

31.25

8.56

3.91

29.50

6.34

8.50

14.69

27.94

SV1301

NOTE: All measurements are in inches.

1.60

OPTIONAL

19.69

15.69

11.69

7.69

3.69

2-5

Location of Ice Machine

A Manitowoc ice machine operates most efficiently
when it is:

1. Located Away From Heat Sources

Do not install the ice machine near heat­generating equipment or in an area of direct
sunlight.

Air Temperature Around Ice Machine

Minimum Maximum

35°F (1.7°C) 110°F (43.3°C)

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
“Winterization” in the Owner/Operator Use and
Care Guide.

2. Located in a Contaminant-Free Area

Airborne contaminants can damage ice machines.
Air-cooled models are particularly vulnerable.

3. Provided with Sufficient Air Clearance

Adequate airflow through and around the ice
machine is essential for maximum ice production
and long component life.

Air Clearance Around Ice Machine

Model Area Clearance

Self-Contained Top 8” (20 cm)

Air-Cooled Sides 8” (20 cm)

Back 5” (12 cm)

Water-Cooled Top

or Remote Sides 5” (12 cm)

Back

1

This clearance is not required, but it is recommended

for efficient operation and servicing.

1

Section 2Installation References

Heat of Rejection

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 you are sizing air conditioning
equipment for the ice machine installation area.

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 with a water-cooled
or remote condenser is negligible.

Knowing the amount of heat rejected is also
important when sizing a cooling tower for a water­cooled condensing unit. The peak figure is used for
sizing the cooling tower.

Series Heat of Rejection

Ice Machine Air Conditioning

J250 4,000 5,200
J320 4,600 6,200
J420 7,000 9,600
J200 3,800 5,000
J450 7,000 9,600
J600 9,000 13,900

J800 12,400 19,500
J1000 16,000 24,700
J1300 24,000 35,500
J1800 36,000 50,000

1

B.T.U./Hour

2

Because the heat of rejection varies during the ice

making cycle, the figure shown is an average.

2

1

Peak

Important

Two stacked ice machines may share a single ice
storage bin. A stacking kit is required for stacking
two ice machines. Follow the instructions supplied
with the stacking kit.

2-6

Section 2 Installation References

Electrical Fuse Size/Circuit Ampacity

MINIMUM CIRCUIT AMPACITY

WARNING

All electrical work, including wire routing and
grounding, must conform to local, state and
national electrical codes.

VOLTAGE

The maximum allowable voltage variation is +/- 10%
of the rated voltage, at start-up (when the electrical
load is the highest).

FUSE/CIRCUIT BREAKER

A separate fuse/circuit breaker must be provided for
each ice machine. Circuit breakers must be H.A.C.R.
rated. (H.A.C.R. rating does not apply in Canada.)

The minimum circuit ampacity is used to help select
the wire size of the electrical supply. (It is NOT the
ice machine’s running amp load.)

The wire size, or gauge, is also dependent upon the
location, materials used, length of run, etc., and
therefore must be determined by a qualified
electrician.

J250 Ice Machines with Power Cord (Cord is 6’ long, with NEMA 5-15P plug configuration.)

Air-Cooled Water-Cooled

Ice

Machine

J250 115/1/60 15 8.8 15 8.0

Voltage, Phase,

Cycle

Maximum

Fuse/Circuit

Breaker

Total

Amps

Maximum

Fuse/Circuit

Breaker

J250 Ice Machines Requiring Direct Wiring

Air-Cooled Water-Cooled

Ice

Machine

J250 208-230/1/60 15 4.8 15 4.2

Voltage, Phase,

Cycle

230/1/50 15 4.8 15 4.2

Maximum

Fuse/Circuit

Breaker

Minimum

Circuit

Amps

Maximum

Fuse/Circuit

Breaker

Total

Amps

Minimum

Circuit

Amps

2-7

Section 2 Installation References

J320/J420 Ice Machines

Air-Cooled Water-Cooled

Ice

Machine

J320 208-230/1/60 15 4.8 15 4.2

J420 208-230/1/60 15 7.8 15 7.4

J200 - J1000 Ice Machines

Ice

Machine

J200 208-230/1/60 15 5.4 15 4.8 N/A N/A

J450 208-230/1/60 15 7.8 15 7.4 N/A N/A

J600 208-230/1/60 15 7.4 15 6.9 15 8.2

J800 208-230/3/60 15 7.7 15 6.7 15 7.6

J1000 208-230/3/60 15 10.1 15 9.1 15 10.3

J1300 208-230/3/60 20 12.9 20 11.3 20 10.6

J1800 208-230/3/60 20 17.0 20 15.4 20 15.1

Voltage,

Phase, Cycle

115/1/60 15 11.3 15 10.9

230/1/50 15 4.6 15 4.0
115/1/60 20 12.7 20 11.8

230/1/50 15 5.7 15 5.4

Voltage,

Phase, Cycle

115/1/60 15 10.5 15 10.0 N/A N/A

230/1/50 15 4.8 15 4.2 N/A N/A
115/1/60 20 12.7 20 11.8 20 13.7

230/1/50 15 5.7 15 5.4 N/A N/A

230/1/50 15 6.4 15 6.1 15 6.5

208-230/1/60 20 11.8 20 11.1 20 12.1

230/1/50 15 10.7 15 9.9 15 9.7

208-230/1/60 20 13.3 20 12.3 20 12.8

230/1/50 15 13.6 15 12.1 15 12.9

208-230/1/60 30 19.0 30 17.4 30 18.4

230/1/50 30 19.9 30 18.7 30 18.1
380-415/3/50 N/A N/A N/A N/A 15 7.3
208-230/1/60 35 23.8 35 22.2 35 22.3

230/1/50 35 23.0 35 21.5 35 20.6
380-415/3/50 N/A N/A N/A N/A 15 9.1

Maximum

Fuse/Circuit

Breaker

Air-Cooled Water-Cooled Remote

Maximum

Fuse/

Circuit

Breaker

Minimum

Circuit

Amps

Minimum Circuit

Amps

Maximum

Fuse/

Circuit

Breaker

Maximum

Fuse/Circuit

Breaker

Minimum

Circuit

Amps

Maximum

Fuse/

Circuit

Breaker

Minimum Circuit

Amps

Minimum

Circuit

Amps

2-7

Electrical Wiring Connections

V

Section 2Installation References

SELF-CONTAINED ELECTRICAL CONNECTIONS

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.

Self Contained Ice Machine
115/1/60 or 208-230/1/60

L

1

GROUND

ICE MACHINE

N = 115V

OR

L2 = 208-230

TO SEPARATE

GROUND

L

1

Self Contained Ice Machine

L

208-230/3/60

1

L

2

L

3

GROUND

ICE MACHINE

Self Contained Ice Machine
208-240/1/50

L

1

TO SEPARATE

GROUND

SV1190

L

1

L

2

L

3

L

1

SV1258

GROUND

N

ICE MACHINE

N

GROUND

TO SEPARATE

FUSE/BREAKER.

SV1191

2-8

Section 2 Installation References

V

Remote Ice Machine

REMOTE ELECTRICAL CONNECTIONS

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.

NOTE: The single circuit condenser should be wired
directly to the ice machine’s electrical panel. The
condenser fan runs only when the ice machine is
operating.

With Single Circuit Model Condenser
208-230/3/60 or 380-415/3/50

L

1

SINGLE

CIRCUIT

REMOTE

CONDENSER

ICE

F

F

L

L

L

2

1

1

2

2

GROUND

NOTE:
FAN MOTOR
IS 208-230

L

1

L

2

Remote Ice Machine
With Single Circuit Model Condenser
115/1/60 or 208-230/1/60

L

F

F

L

L

1

L

2

2

1

1

2

GROUND

GROUND

NOTE:
CONDENSER FAN
MOTOR VOLTAGE
MATCHES ICE MACHINE

N = 115V OR L2 = 208-230V

TO SEPARATE

SINGLE
CIRCUIT

REMOTE

CONDENSER

ICE

L

L

GROUND

SV1255

L

3

GROUND

TO SEPARATE

L

GROUND

3

SV1199

Remote Ice Machine
With Single Circuit Model Condenser
230/1/50

L

1

SINGLE

CIRCUIT

REMOTE

1

2

CONDENSER

ICE

L

2

GROUND

F

2

F

1

L

1

NOTE:
FAN MOTOR IS
220-240 VOLT

L

1

N

GROUND

TO SEPARATE

FUSE/BREAKER (220-240).

N

GROUND

SV1256

2-9

Water Connections and Drains

V

V

V

CAUTION

Plumbing must conform to local and state
codes.

Section 2Installation References

Location

Ice making

water inlet

Ice making

water drain

Condenser

water inlet

Condenser

Water Drain

Water

Temperature

33°F (0.6°C) min.

90°F (32.2°C) max

- - 1/2” F.P.T. 1/2”

33°F (0.6°C) min.

90°F (32.2°C) max

- - 1/2” F.P.T. 1/2”

Water

Pressure

20 psi min.
80 psi max

20 psi min.

150 psi max

Female Pipe Fitting

(F.P.T.)

1

Size

3/8” F.P.T. 3/8”

J1300/J1800 - 1/2” F.P.T.

All Others - 3/8” F.P.T.

Bin Drain - - 3/4” F.P.T. 3/4”

1

F.P.T. - Female Pipe Thread

CONDENSER WATER

INLET FITTING

1/2” F.P.T.

CONDENSER WATER

DRAIN FITTING

1/2” F.P.T.

ICE MAKING WATER

INLET TUBING

3/8” MIN. I.D.

CONDENSER WATER

DRAIN TUBING

1/2” MIN. I.D.

CONDENSER WATER

Tube Size Up to Ice

Machine Fitting

INLET TUBING

1/2” MIN. I.D.

BIN DRAIN

FITTING

3/4” F.P.T.

ICE MAKING WATER

INLET FITTING

3/8” F.P.T.

3/4” MIN. I.D.

BIN DRAIN

TUBING

18”

ENT

ICE MAKING WATER

DRAIN FITTING

1/2” F.P.T.

VENT

SLOPE

WATER

SHUT OFF

ALVE

ICE MAKING WATER

DRAIN TUBING

1/2” MIN. I.D.

OPEN, TRAPPED OR

ENTED DRAIN

SV1304

2-10

Section 2 Installation References

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 per minute.

• Allow for a pressure drop of 7 psi 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

Remote Condenser/Line Set Installation

Section 2Installation References

Ice Machine

J490 JC0495 RT-20-R404A
J690 JC0895 RT-35-R404A

J890 RT-50-R404A
J1090 JC1095
J1390 JC1395 RL-20-R404A
J1890 JC1895 RL-35-R404A

*Line Set Discharge Line Liquid Line

RT 1/2” (12.7 mm) 5/16” (7.9 mm)
RL 1/2” (12.7 mm) 3/8” (9.5 mm)

Air Temperature Around the Condenser

Minimum Maximum

-20°F (-28.9°C) 130°F (54.4°C)

Remote Single

Circuit Condenser

Line Set*

RL-50-R404A

REMOTE ICE MACHINES
REFRIGERANT CHARGE

Each remote ice machines 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.

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 serial
tag states the amount of refrigerant to be added.

Typical Additional Refrigerant Label

IMPORTANT

EPA CERTIFIED TECHNICIANS

If remote line set length i s between 50’ and 100’
(15.25-30.5 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: _________________

If there is no additional label, the nameplate charge is
sufficient for line sets up to 100’ (30.5 m). (See the
chart below.)

Ice

Machine

J490 6 lb. (96 oz.) None 6 lb. (96 oz.)
J690 8 lb. (128 oz.) None 8 lb. (128 oz.)

J890 8 lb. (128 oz.) None 8 lb. (128 oz.)
J1090 9.5 lb. (152 oz.) None 9.5 lb. (152 oz.)
J1390 12.5 lb. (200 oz.) 1.5 lb (24 oz) 14 lb. (224 oz.)
J1890 15 lb. (240 oz.) 2.0 lb (32 oz) 17 lb. (272 oz.)

(Total Charge Shipped in Ice Machine)

Nameplate Charge

Refrigerant to be Added

for 50’-100’ Line Sets

Maximum System Charge

(Never Exceed)

2-12

Section 2 Installation References

ROUTING LINE SETS

General

Condensers must be mounted horizontally with the
fan motor on top.

Remote condenser installations consist of vertical and
horizontal line set distances between the 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.

Guidelines for Routing Line Sets

First, cut a 2.5” (63.5 mm) circular hole in the wall or
roof for tubing routing. Connect the line set end with
the 90° bend to the ice machine. Connect the straight
end to the remote condenser.

Then, follow these guidelines when routing the
refrigerant lines. This will help insure proper
performance and service accessibility.

1. Make the service loop in the line sets as shown

below. This permits easy access to the ice
machine for cleaning and service. Do not use hard
rigid copper at this location.

2. 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 as shown below. Do
not coil tubing vertically.

3. Keep outdoor refrigerant line runs as short as

possible.

DOWNWARD

HORIZONTAL

SPIRAL

3

2

2

1

1

3

SV1204

2-13

CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES

Line Set Length

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 130°F
(54.4°C), with line set lengths of up to 100’ (30.5 m).

Section 2Installation References

Make the following calculations to make sure the line
set layout is within specifications.

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.)

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

The maximum rise is 35’ (10.7 m).
The maximum drop is 15’ (4.5 m).

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.

3. Insert the measured horizontal distance into the

formula below. No calculation is necessary.

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.

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. Measured Rise (35’ [10.7 m] Maximum) ______ x 1.7 = _______ Calculated Rise
Step 2. Measured Drop (15’ [4.5 m] Maximum) ______ x 6.6 = _______ Calculated Drop
Step 3. Measured Horizontal Distance (100’ [30.5 m] Maximum) = _______ Horizontal Distance
Step 4. Total Calculated Distance 150’ (45.7 m) = _______ Total Calculated Distance

H

H

H

2-14

R

Combination of a Rise

and a Horizontal Run

D

SV1195SV1196

Combination of a Drop

and a Horizontal Run

R

D

SV1194

Combination of a Rise, a Drop

and a Horizontal Run

Section 2 Installation References

SINGLE CIRCUIT

REMOTE

CONDENSER

ELECTRICAL

DISCONNECT

DISCHARGE

LINE

LIQUID

LINE

NOTE:
BORE A 2.5” DIAMETER HOLE IN
THE ROOF OR WALL FOR
TUBING.

SEAL WITH TAR OR PITCH.
SLOPE TO PREVENT ENTRANCE

ELECTRICAL

DISCONNECT

ELECTRICAL

SUPPLY

BIN

ICE

MACHINE

DISCHARGE

REFRIGERANT

LINE

36.00”
DROP

LIQUID

REFRIGERANT

LINE

Typical Single Circuit Remote Condenser Installation

SV1184

2-15

Usage With Non-Manitow oc Multi-Circuit Condensers

Section 2Installation References

WARRANTY

1. The sixty (60) month compressor warranty,

including the thirty-six (36) month labor
replacement warranty, shall not apply when the
remote ice machine is not installed within the
remote specifications outlined in the Installation
Manual.

2. The foregoing warranty shall not apply to any ice

machine installed and/or maintained inconsistent
with the technical instructions provided by
Manitowoc Ice, Inc..

3. Performance may vary from sales specification.

4. J Model ARI certified standard ratings only apply

when used with a Manitowoc remote condenser.

5. Manitowoc ice machines are UL listed with

Manitowoc condensers only.

6. If the design of the condenser meets the

specifications laid out, Manitowoc will only
approve warranty coverage on the Manitowoc­manufactured portion of the system.

7. Since Manitowoc does not test the condenser in

conjunction with the ice machine, Manitowoc
will not endorse, recommend, or approve of the
condenser, and will not be responsible for its
performance or reliability.

LINE SET ROUTING AND SIZING

Remote condenser installations consist of vertical and
horizontal line set distances to the condenser that,
when combined, must fit within approved guidelines.
The line set sizing guidelines, drawings, and length
calculation methods must be followed to verify a
proper remote condenser installation. Refer to the
Installation Instructions for specifications for remote
line sets and maximum remote condenser location.

HEAD PRESSURE CONTROL VALVE

Any remote condenser connected to a Manitowoc
J-model ice machine must have a head pressure
control valve (P/N 836809-3), available from
Manitowoc distributors, installed on the condenser
package. Manitowoc will not accept substitute off­the-shelf head pressure control valves.

CAUTION

Do not use a fan cycle control to maintain discharge
pressure. Compressor failure will result.

FAN MOTOR

The condenser fan must be on during the complete
ice machine freeze cycle. Do not cycle with a fan
cycle control.

2-16

The ice machine has a condenser fan motor circuit
designed 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. This
will assure it is on at the proper time.

Do not exceed the rated amps for the fan motor
circuit listed on the ice machine serial tag.

Section 2 Installation References

INTERNAL CONDENSER VOLUME

The multi-circuit condenser internal volume must not
be less, nor greater, than that used by Manitowoc.

CAUTION

Do not exceed internal volume and try to add
charge to compensate. Compressor failure will
result.

CONDENSER

∆∆∆∆

T

∆T is the difference in temperature between the
condensing refrigerant and the entering air. The ∆T
should be 15-20°F at the beginning of the freeze
cycle (peak load conditions) and drop to 12-17°F
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 reason.

QUICK-CONNECT FITTINGS

The ice machine and the line sets come with quick­connect fittings. It is recommended that matching
quick-connects (available from Manitowoc
distributors) be installed in the multi-circuit
condenser, and a vapor “holding” charge (5 oz.) of
refrigerant be added.

Internal

Refrigerant

Model

Type Charge

J450 R404-A 6 lb. 7,000 9,600 0.020 0.035 500 psig coupling coupling Manitowoc
J600 R404-A 8 lb. 9,000 13,900 0.045 0.060

J800 R404-A 8 lb. 12,400 19,500 0.045 0.060 pressure, mounting mounting NO SUBSTITUTES
J1000 R404-A 9.5 lb. 16,000 24,700 0.065 0.085 2500 psig flange flange
J1300 R404-A 14 lb.124,000 35,500 0.085 0.105 burst P/N 83-6006-3 P/N 83-6005-3
J1800 R404-A 17 lb.136,000 50,000 0.130 0.170 pressure

1

Amount reflects additional refrigerant added to nameplate charge to ensure proper operation at all ambient conditions.

J1300 has an additional 1.5 lb., J1800 has an additional 2.0 lb.

Heat of

Rejection

Avg.

BTU/Hr

Peak

BTU/Hr

Condenser

Volume

(cu. ft.)

Min. Max. Discharge Liquid

Design

Pressure

safe

working

P/N 83-6035-3 P/N 83-6034-3 P/N 83-6809-3

Quick-Connect

Stubs-Male Ends

Head Pressure

Control

Valve

2-17

THIS PAGE INTENTIONALLY LEFT BLANK

Section 2Installation References

2-18

Section 3 Maintenance

Section 3

Maintenance

Component Identification

CONDENSER FAN

(AIR-COOLED MODELS)

HOT GAS

VALVE

AIR

CONDENSER

CONDENSER WATER
REGULATING VALVE

WATER DUMP

VALVE

WATER

CURTAIN

WATER

TROUGH

DRAIN
HOSE

DISTRIBUTION

TUBE

COMPRESSOR

ICE THICKNESS

REMOTE

COUPLINGS

WATER

CONDENSER

PROBE EVAPORATOR

WATER COOLED

MODEL

HIGH PRESSURE CUTOUT/

MANUAL RESET

ICE/OFF/CLEAN

SV1206

SWITCH

WATER

PUMP

BIN SWITCH

Component Identification (Typical Q450 Shown)

FLOAT
VALVE

SV1205

3-1