Manitowoc J250, J200, J320, J420, J450 Service Manual

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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

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

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

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

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

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

14.25

0.63

6.50

SV1270

23.50

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

3.00

10.13

29.75

SV1500

23.50

48.25

1.56

1.25

1.56

0.75

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

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

ICE STORAGE BINS

C730 Ice Storage Bin

C170/C400/C470/C570 Ice Storage Bins

30.00

42.00

40.00

6.75

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

17.00

52.00

4.25

SV1296

17.00

11.00

NOTE: All measurements are in inches.

Bin Model Dimension A Dimension B

C320 34.00 32.00 C420 34.00 44.00

6.50

SV1272

WARNING

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

This clearance is not required, but it is recommended

for efficient operation and servicing.

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

B.T.U./Hour

Because the heat of rejection varies during the ice

making cycle, the figure shown is an average.

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

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

GROUND

ICE MACHINE

N = 115V

L2 = 208-230

TO SEPARATE

GROUND

Self Contained Ice Machine

208-230/3/60

GROUND

ICE MACHINE

Self Contained Ice Machine 208-240/1/50

TO SEPARATE

GROUND

SV1190

SV1258

GROUND

ICE MACHINE

GROUND

TO SEPARATE

FUSE/BREAKER.

SV1191

2-8

Section 2 Installation References

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

SINGLE

CIRCUIT

REMOTE

CONDENSER

ICE

GROUND

NOTE: FAN MOTOR IS 208-230

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

GROUND

NOTE: CONDENSER FAN MOTOR VOLTAGE MATCHES ICE MACHINE

N = 115V OR L2 = 208-230V

TO SEPARATE

SINGLE CIRCUIT

REMOTE

CONDENSER

ICE

GROUND

SV1255

GROUND

TO SEPARATE

GROUND

SV1199

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

SINGLE

CIRCUIT

REMOTE

CONDENSER

ICE

GROUND

NOTE: FAN MOTOR IS 220-240 VOLT

GROUND

TO SEPARATE

FUSE/BREAKER (220-240).

GROUND

SV1256

2-9

Water Connections and Drains

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.)

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”

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

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

Combination of a Rise

and a Horizontal Run

2-14

SV1195SV1196

Combination of a Drop

and a Horizontal Run

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 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

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

Component Identification (Typical Q450 Shown)

BIN SWITCH

FLOAT VALVE

SV1205

3-1

Operational Checks

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

Section 3Maintenance

B. Raise or lower the float valve assembly as

necessary, then tighten the screws.

C. If further adjustment is required, carefully

bend the float arm to achieve the correct water level.

ICE THICKNESS CHECK

The ice thickness probe is factory-set to maintain the ice bridge thickness at 1/8” (3.2 mm).

NOTE: Routine adjustments and maintenance procedures are not covered by the warranty.

WATER LEVEL CHECK

1. Check the water level while the ice machine is in

the freeze mode and the water pump is running. The correct water level is 1/8”-1/2” (3-12.5 mm) above the water pump impeller housing.

WATER

PUMP

OUTLET

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: Turning the adjustment 1/3 of a turn will change the ice thickness about 1/16” (1.5 mm).

ADJUSTING

SCREW

WATER LEVEL

1/8”-1/2” ABOVE

HOUSING

WATER PUMP

IMPELLER

HOUSING

Water Level Check

2. The float valve is factory-set for the proper water

level. If adjustments are necessary: A. Loosen the two screws on the float valve

bracket.

3-2

SV1331

SV1208

1/8” ICE

THICKNESS

Ice Thickness Check

3. Make sure the ice thickness probe wire and the

bracket do not restrict movement of the probe.

Section 3 Maintenance

Cleaning the Condenser

3. Shine a flashlight through the condenser to check

WARNING

Disconnect electric power to the ice machine and the remote condenser at the electric service switch before cleaning the condenser.

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.

for dirt between the fins. If dirt remains: A. Blow compressed air through the condenser

fins from the inside. Be careful not to bend the fan blades.

B. Use a commercial condenser coil cleaner.

Follow the directions and cautions supplied with the cleaner.

4. Straighten any bent condenser fins with a fin

comb.

CONDENSER

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.

AIR

FILTER

SV1608

FIN COMB

“COMB”

DOWN

ONLY

SV1515

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.

Self-Contained Air-Cooled Filter

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...

3-3

Section 3Maintenance

WATER-COOLED CONDENSER AND WATER REGULATING VALVE

Symptoms of restrictions in the condenser water circuit include:

• Low ice production

• High water consumption

• High operating temperatures

• 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.

The cleaning procedures require special pumps and cleaning solutions. Follow the manufacturer’s instructions for the specific cleaner being used.

3-4

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 take 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.

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 self-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 Self-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 Amount of Cleaner

Q200 Q320 Q420 3 ounces (90 ml) Q450 Q600 Q800 5 ounces (150 ml)

Q1000 Q1300 Q1800 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 Self-Cleaning mode is completed. This entire cycle lasts approximately 25 minutes.

Step 6 When the self-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

self-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 self-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.

3-5

Section 3Maintenance

SELF SANITIZING PROCEDURE

Use sanitizer to remove algae or slime. Do not use it to remove lime scale or other mineral deposits.

CAUTION

Never use anything to force ice from the evaporator. Damage may result.

Step 2 To start self-sanitizing, 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 Self-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 Sanitizer to the water trough.

Model Amount of Sanitizer

Q200 Q320 Q420 3 ounces (90 ml)

Q450 Q600 Q800 Q1000 3 ounces (90 ml)

Q1300 Q1800 6 ounces (180 ml)

Step 5 The ice machine will automatically time out a ten minute sanitizing cycle, followed by six rinse cycles, and stop. The Clean light will turn off to indicate the Self-Cleaning mode is completed. This entire cycle lasts approximately 25 minutes.

Step 7

A. The ice machine may be set to start and finish a

self-sanitizing procedure then automatically start ice making again.

B. You must wait about one minute into the

sanitizing cycle (until water starts to flow over the evaporator) then move the switch from CLEAN to ICE position.

C. When the self-sanitizing cycle is completed, the

clean light will turn off and a ice making sequence will start automatically.

Important

After the toggle switch is moved to the ICE position, opening the curtain switch will interrupt the sanitizing sequence. The sequence will resume from the point of interruption when the curtain switch closes.

PROCEDURE TO CANCEL A SELF-CLEANING OR SANITIZING CYCLE AFTER IT HAS STARTED

If less than 45 seconds into cycle:

Move the toggle switch to the OFF position. The cycle is now canceled.

If more than 45 seconds into cycle:

Step 1 Move toggle switch to OFF position. Step 2 Move toggle switch to ICE position. Step 3 Move toggle switch to OFF position.

The cycle is now canceled.

If the bin requires sanitizing, remove all the ice and sanitize it with a solution of one ounce (30ml) of sanitizer with up to 4 gallons (15 L)of water.

Step 6 When the self-sanitizing process stops, move the toggle switch to ICE position to start ice making again.

3-6

Section 3 Maintenance

AUCS ACCESSORY MANUAL START OPERATION

This accessory monitors ice making cycles and initiates self-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.

CAUTION

Refer to the AuCS Accessory Installation - Use and Care Guide 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 automatic 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. (New style circuit boards will also energize the Clean light.) The AuCS then automatically adds cleaner of 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

self-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 self-cleaning cycle or sanitizing is

completed, an ice making sequence will start automatically.

3-7

Section 3Maintenance

REMOVAL OF PARTS FOR CLEANING/SANITIZING

1. Turn off the water supply to the ice machine at

the water service valve.

WARNING

Disconnect electric power to the ice machine at the electric switch box before proceeding.

2. Remove the following parts:

• water trough

• water curtain

• water pump

• water distribution tube

• ice thickness probe

(See the following pages for removal procedures for these parts.)

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 Cleaner or Sanitizer solution.

3. Soak the removed parts in a properly mixed

solution.

Solution Type Water Mixed With

Cleaner 1 gal. (4 l) 16 oz (500 ml) cleaner Sanitizer 4 gal. (15 l) 1 oz (30 ml) sanitizer

4. Use a soft-bristle brush or sponge (NOT a wire

brush) to carefully clean the parts.

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

may leave a residue. This could cause the ice machine to go into the harvest cycle prematurely. For best results, brush or wipe the probe off while rinsing it. Thoroughly dry the probe before installing it.

8. Turn on the water and electrical supply.

3-8

Section 3 Maintenance

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.

DUMP VALVE

OUTLET

DRAIN HOSE

Follow the procedure below to remove the dump valve.

WARNING

Disconnect the electric power to the ice machine at the electric service switch box.

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.

PLUNGER

SPRING STOP

CAP

SV1456

Dump Valve Outlet Drain Hose

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.

COIL

ENCLOSING

TUBE

SPRING

PLUNGER

PLASTIC GASKET

VALVE BODY

Dump Valve Disassembly

NOTE: At this stage, the water dump valve can easily be cleaned. If complete removal is desired, continue with step 5 on the next page.

Important

The plunger and the inside of the enclosing tube must be completely dry before assembly.

3-9

Section 3Maintenance

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 tubing from the dump valve by

twisting the clamps off.

6. Remove the two screws securing the dump valve

and the mounting bracket.

DO NOT

DISCONNECT

WIRES AT COIL

DRAIN

HOSE

VALVE SHIELD

WATER

DUMP

VALVE

COIL

WATER PUMP

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.

LOOSEN SCREWS

WATER

PUMP

OUTLET

POWER

CORD

Dump Valve Removal

SV1218

SV1209

Water Pump Removal

2. Disconnect the hose from the pump outlet.

3. Loosen the two screws securing the pump

mounting bracket to the bulkhead.

4. Lift the pump and bracket assembly off the

screws.

3-10

Section 3 Maintenance

ICE THICKNESS PROBE

1. Compress the side of the ice thickness probe near

the top hinge pin and remove it from the bracket.

DISCONNECT

WIRE LEADS

COMPRESS

HINGE PIN

ICE THICKNESS

PROBE

SV1212

Ice Thickness Probe Removal

NOTE: At this stage, the ice thickness probe can easily be cleaned. If complete removal is desired, continue with step 2 below.

WARNING

Disconnect the electric power to the ice machine at the electric service switch box.

WATER TROUGH

Water trough removal varies slightly by model. The following procedure is typical.

1. Remove the push-in screws holding the trough in

place.

1. REMOVE

3. REMOVE TROUGH FROM PEGS

2. LOWER RIGHT SIDE OF TROUGH

PUSH-IN SCREWS

SV1216

Water Trough Removal

2. Lower the right side of the trough into the bin.

3. Disengage the left side of the trough from its

holding pegs and remove the trough.

2. Disconnect the wire leads from the control board

inside the electrical control box.

3-11

Section 3Maintenance

FLOAT VALVE

1. Turn off the water supply to the ice machine at

the water service valve.

2. Turn the splash shield counterclockwise one or

two turns.

WATER INLET

COMPRESSION

FITTING

FILTER SCREEN

AND CAP

TUBE

SPLASH

SHIELD

WATER CURTAIN

1. Gently flex the curtain in the center and remove it

from the right side.

STEP 1

STEP 2

SV1213

Water Curtain Removal

2. Slide the left pin out.

SV1217

Float Valve Removal

3. Pull the float valve forward and off the mounting

bracket.

4. Disconnect the water inlet tube from the float

valve at the compression fitting.

5. Remove the filter screen and cap for cleaning.

3-12

Section 3 Maintenance

WATER DISTRIBUTION TUBE

1. Disconnect the water hose from the distribution

tube.

THUMBSCRE

DISTRIBUTION

TUBE

THUMBSCRE

LOCATING PIN

LOCATING HOLE

SV1210

Water Distribution Tube Removal

2. Loosen the two thumbscrews which secure the

distribution tube.

3. Lift the right side of the distribution tube up off

the locating pin, then slide it back and to the right.

4. Disassemble for cleaning.

INNER

TUBE

Water Distribution Tube Disassembly

A. Twist both of the inner tube ends until the

tabs line up with the keyways.

B. Pull the inner tube ends outward.

KEYWAY

INNER

TUBE

TAB

SV1211

CAUTION

Do not force this removal. Be sure the locating pin is clear of the hole before sliding the distribution tube out.

3-13

Water Treatment/Filtration

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 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

OUTLET

SIDE

SEAL

O-RING

CAP

CARTRIDGE

INLET

SIDE

SHUT OFF

ALVE

Section 3Maintenance

3. Unscrew the housing from the cap.

4. Remove the used filter cartridge from the housing

and discard it.

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

hand-tighten 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.

12. Depress the pressure release button to release

trapped air from the housing.

13. Check for leaks.

PRE-FILTER

HOUSING

SEAL

PRIMARY

FILTER

Typical Tri-Liminator Water Filtration System

2. Depress the pressure release button to relieve the

pressure.

3-14

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 or below.

CAUTION

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 float valve or the drain.

6. Make sure water is not trapped in any of the water

lines, drain lines, distribution tubes, etc.

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.

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.

3-15

THIS PAGE INTENTIONALLY LEFT BLANK

Section 3Maintenance

3-16

Section 4 Ice Machine Sequence of Operation

Section 4 Basic Ice Machine Sequence of Operation

Self-Contained Air- and Water-Cooled

J200/J250/J320/J420/J450/J600/J800/J1000/J1300/J1800

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 hot gas 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 hot gas 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.

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 fan condenser 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.)

Freeze Sequence (Typical J450 Shown)

Continued on next page...

4-1

Section 4Ice Machine Sequence of Operation

HARVEST SEQUENCE

5. Water Purge

The water pump continues to run and the water dump valve energizes for 45 seconds, to purge the water in the sump trough. After the 45 second water purge, the water pump and dump valve de-energize. The hot gas valve(s) also opens at the beginning of the water purge, to divert hot refrigerant gas into the evaporator.

New style circuit boards have an adjustable water purge in the harvest cycle. This permits a 0 (off), 15, 30 or 45 second purge cycle.

6. Harvest

The hot gas 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 re-closing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence (Step 3 - 4.)

AUTOMATIC SHUT-OFF

7. Automatic Shut-Off

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.

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.

Harvest Sequence (Typical J450 Shown)

Automatic Shut-Off (Typical J450 Shown)

4-2

Section 4 Ice Machine Sequence of Operation

Remote

J450/J600/J800/J1000/J1300/J1800

INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF

1. Water Purge

The hot gas 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 hot gas 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 remote condenser fan motor starts at the same time the compressor starts and remain 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.)

Freeze Sequence (Typical J450 Shown)

Continued on next page...

4-3

Section 4Ice Machine Sequence of Operation

HARVEST SEQUENCE

5. Water Purge

The water pump continues to run and the water dump valve energizes for 45 seconds, to purge the water in the sump trough. After the 45 second water purge, the water pump and dump valve de-energize. The hot gas valve(s) and HPR solenoid valve also open at the beginning of the water purge.

New style circuit boards have an adjustable water purge in the harvest cycle. This permits a 0 (off), 15, 30 or 45 second purge cycle.

6. Harvest

The HPR valve and the hot gas 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.)

AUTOMATIC SHUT-OFF

7. Automatic Shut-Off

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.

Harvest Sequence (Typical J450 Shown)

Automatic Shut-Off (Typical J450 Shown)

4-4

Section 5 Water System Ice Making Sequence of Operation

Section 5

Water System Ice Making Sequence of Operation

NOTE: The sequence of operation is the same for self-contained 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.

TO DISTRIBUTION TUBE

WATER DUMP VALVE

FREEZE CYCLE

2. To pre-chill the evaporator, there is no water flow

over the evaporator for the first 30 seconds of the 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.

WATER PUMP

TO DRAIN

SV1457

Water Flow Over the Evaporator

5-1

Section 5Water System Ice Making Sequence of Operation

HARVEST CYCLE

4. The water pump and water dump solenoid are

energized for 45 seconds to purge the water from the water trough.

5. After the 45-second purge, the water pump and

water dump valve de-energize.

TO DISTRIBUTION TUBE

WATER DUMP VALVE

NOTE: New style control boards have an adjustable water purge in the harvest cycle. This permits a 0 (off), 15, 30 or 45 second purge cycle.

AUTOMATIC SHUT-OFF

There is no water flow during an automatic shut-off.

WATER PUMP

TO DRAIN

5-2

SV1456

Water Flow Down the Drain

Section 6 Electrical System

Energized Parts Charts

SELF-CONTAINED AIR- AND WATER-COOLED MODELS

Ice Making Control Board Relays Contactor

Sequence

Operation

Start-Up

1. Water Purge

2. Refrigeration

System Start-Up

Freeze Sequence

3. Pre-Chill

4. Freeze

Harvest Sequence

5. Water Purge

6. Harvest

7. Automatic

Shut-Off

Initial Start-Up or Start-Up After Automatic Shut-Off

1 2 3 4 4A 4B Length

Water Pump

On On On Off Off Off 45 Seconds

Off On Off On On

Off Off Off On On

On Off Off On On

On On On On On

Off On Off On On

Off Off Off Off Off Off

Hot Gas

Valve

Water Dump Valve

Contactor

Coil

Compressor

Condenser

Fan Motor

May Cycle

On/Off

May Cycle

On/Off

May Cycle

On/Off

May Cycle

On/Off

May Cycle

On/Off

Until 7 sec. water

contact with ice

thickness probe

Until bin switch

Time

5 Seconds

30 Seconds

Factory-set at

45 Seconds

Bin switch

activation

re-closes

Condenser Fan Motor

The fan motor is wired through a fan cycle pressure control, therefore, it may cycle on and off.

Harvest Water Purge

New style circuit boards have an adjustable water purge in the havest cycle. This permits a 0 (off), 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 1-2) immediately after the delay period, if the bin switch re-closes prior to 3 minutes.

Safety Timers

The control board has the following non-adjustable safety timers:

FREEZE SEQUENCE

• 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 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 (step7). If the bin switch is closed, the ice machine will go to the freeze sequence (steps 3-4).

6-1

REMOTE MODELS

Ice Making Control Board Relays Contactor

Sequence

Operation

Start-Up

1. Water Purge

2. Refrigeration

System Start-Up

1 2 3 4 4A 4B Length

Water Pump

On On On Off Off Off 45 Seconds

Off On Off On On On 5 Seconds

Hot Gas

Valve

HPR

Solenoid

Water Dump Valve

Contactor

Coil

Liquid Line

Solenoid

Compressor

Freeze Sequence

3. Pre-Chill

4. Freeze

Off Off Off On On On 30 Seconds

On Off Off On On On

Harvest Sequence

5. Water Purge

6. Harvest

7. Automatic

Shut-Off

Initial Start-Up or Start-Up After Automatic Shut-Off

On On On On On On

Off On Off On On On

Off Off Off Off Off Off

Condenser

Fan Motor

Section 6Electrical System

Time

Until 7 sec. water

contact with ice

thickness probe

Factory-set at

45 Seconds

Bin switch

activation

Until bin switch

re-closes

Auto Shut-Off

The ice machine remains off for 3 minutes before it can automatically restart. The ice machine restarts (steps 1-2) immediately after the delay period, if the bin switch re-closes prior to 3 minutes.

Harvest Water Purge

New style circuit boards have an adjustable water purge in the havest cycle. This permits a 0 (off), 15, 30 or 45 second purge cycle.

Safety Timers

The control board has the following non-adjustable safety timers:

FREEZE SEQUENCE

• 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 SEQUENCE

• The maximum harvest time is 3-1/2 minutes, at

6-2

Section 6 Electrical System

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

Wiring Diagram Sequence of Operation

SELF-CONTAINED MODELS

SEE SERIAL PLATE FOR VOLTAGE

Initial Start-Up or Start-Up After Automatic Shut-Off

1. WATER PURGE Before the compressor starts, the water pump and water dump solenoid are energized for 45 seconds to purge old water from the ice machine. This ensures that the ice-making cycle starts with fresh water.

The hot gas 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).

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE

3 1 2 4

TRANS. FUSE

FUSE

1D 1C 1B 1

COMPRESSOR RUN CAPACITOR

CONTROL

RUN CAPACITO R**

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIE

CLEAN

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

TB30

68 67

TB30

(Old Style Control Board Shown)

Self-Contained Models

1. Water Purge (45 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Closed

Water Pump ON

#2 Closed

Hot Gas Solenoid ON

#3 Closed

Water Dump Valve ON

#4 Open

Contactor Coil OFF Compressor OFF Condenser Fan Motor OFF

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-3

Section 6Electrical System

SV1560

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

Initial Start-Up Or Start-Up After Automatic Shut-Off (cont.)

2. REFRIGERATION SYSTEM START-UP The compressor starts after the 45-second water purge, and it remains on throughout the Freeze and Harvest cycles.

The hot gas valve(s) remains on for the first 5 seconds of the initial compressor start-up.

At the same time the compressor starts, the condenser fan motor (air-cooled 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.)

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE

(Old Style Control Board Shown)

3 1 2 4

TRANS. FUSE

FUSE

1D 1C 1B 1

COMPRESSOR RUN CAPACITOR

CONTROL

RUN CAPACITO R**

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIE

CLEAN

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

TB30

68 67

TB30

Self-Contained Models

2. Refrigeration System Start-Up (5 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Closed

Hot Gas Solenoid ON

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-4

Section 6 Electrical System

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

Freeze Sequence

3. PRE-CHILL To pre-chill the evaporator, the compressor runs for 30 seconds prior to water flow.

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE

CONTROL

(Old Style Control Board Shown)

3 1 2 4

TRANS. FUSE

FUSE

1D 1C 1B 1

COMPRESSOR RUN CAPACITOR

ICE OFF

CLEAN

RUN CAPACITO R**

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIE

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

68 67

SV1561

TB30

Self-Contained Models

3. Pre-Chill (30 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Open

Hot Gas Solenoid OFF

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-5

Section 6Electrical System

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

Freeze Sequence (cont.)

4. FREEZE 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, where it freezes.

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.

NOTE: The ice machine cannot initiate a harvest cycle until a 6-minute freeze lock has expired.

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE

CONTROL

3 1 2 4

TRANS. FUSE

FUSE

1D 1C 1B 1

COMPRESSOR RUN CAPACITOR

ICE OFF

CLEAN

RUN CAPACITO R**

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIE

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

SV1562

TB30

68 67

TB30

(Old Style Control Board Shown)

Self-Contained Models

4. Freeze (Until 7 Seconds of Water Contact with Ice Thickness Probe)

Toggle Switch Bin Switch Control Board Relays

#1 Closed

Water Pump ON

#2 Open

Hot Gas Solenoid OFF

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-6

Section 6 Electrical System

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

Harvest Sequence

5. WATER PURGE The water pump continues to run as the water dump valve energizes for 45 seconds to purge the water from the water trough.

The hot gas valve(s) opens at the beginning of the water purge. Hot refrigerant gas is diverted into the evaporator throughout the 45-second water purge.

After the 45-second water purge, the water pump and dump valve de-energize. New style control boards have an adjustable water purge. This permits a 0 (off), 15, 30 or 45 second water purge.

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE

CONTROL

3 1 2 4

TRANS. FUSE

FUSE

COMPRESSOR RUN CAPACITOR

ICE OFF CLEAN

RUN CAPACITO R**

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIE

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

68 67

SV1563

TB30

(Old Style Control Board Shown)

Self-Contained Models

5. Water Purge (45 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Closed

Water Pump ON

#2 Closed

Hot Gas Solenoid ON

#3 Closed

Water Dump Valve ON

#4 Closed

Contactor Coil ON Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-7

Section 6Electrical System

SV156

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

Harvest Sequence (cont.)

6. HARVEST The hot gas valve(s) remains open, allowing refrigerant gas to warm the evaporator. This causes the cubes to slide, as a sheet, off the evaporator and into the storage bin.

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).

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

(Old Style Control Board Shown)

3 1 2 4

TRANS. FUSE

FUSE

COMPRESSOR RUN CAPACITOR

FAN CYCLE

CONTROL

RUN CAPACITO R**

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIE

CLEAN

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

TB30

68 67

TB30

Self-Contained Models

6. Harvest (Until Bin Switch Activation)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Closed

Hot Gas Solenoid ON

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-8

Section 6 Electrical System

(N)

)

(61)

(60)

(77)

(80)

(76)

(75)

(98)

(99)

(59)

(73)

(74)

(56)

(58)

(57)

(7A)

(62)

(63)

(65)

(64)

(66)

(67)

(62)

(69)

(68)

(49)

(47)

(46)

(45)

(50)

(42)

(48)

(52)

(85)

(86)

(53)

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.

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).

NOTE: The ice machine must remain off for 3 minutes before it can automatically restart.

TB35

TB32(55

HIGH

PRESSURE

CUTOUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

BIN SWITCH

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE

(Old Style Control Board Shown)

3 1 2 4

TRANS. FUSE

FUSE

COMPRESSOR RUN CAPACITOR

CONTROL

RUN CAPACITO R**

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

TB3

TB37

HARVEST LIGHT/ SAFETY CODE LIMIT LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIE

CLEAN

PTCR

FAN MOTOR (AIR-COOLED ONLY )

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR COIL

VIEW FOR WIRING

66 62

68 67

SV1565

TB30

Self-Contained Models

7. Automatic Shut-Off (Until Bin Switch Closes)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Open

Hot Gas Solenoid OFF

#3 Open

Water Dump Valve OFF

#4 Open

Contactor Coil OFF Compressor OFF Condenser Fan Motor OFF

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-9

REMOTE MODELS

Initial Start-Up Or Start-Up After Automatic Shut-Off

The hot gas 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).

TB35

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

CONTACTOR

CONTACTS

TB32 (55)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1A

LOW D.C. VOLTAGE

(62) (63)

BIN SWITCH

(65)(64)

(66)

*OVERLOAD

(48)(42)

(51)

(52)

TB33 TB34

TERMINATES AT

PIN CONNECTION

(F1) (F2)

PLUG

(68)

(67)

(69)

(66)

(62)

(49)

COMPRESSOR RUN CAPACITOR

(47)

(53)

(61) (60)

(57)

TB31

(58)

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIEW

CLEAN

(46)

PTCR

REMOTE FAN

MOTOR

RUN CAPACITO R

Section 6Electrical System

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(79)(78)

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONTACTOR

VIEW FOR WIRING

66 62

REMOTE

CONDENSER

COIL

(80)

(81)

WATER

PUMP

LIQUID LINE

(50)

L2 (N)

(75)

SOLENOID

(74)

68 67

SV1552

TB30

(Old Style Control Board Shown)

Remote Models

1. Water Purge (45 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Closed

Water Pump ON

#2 Closed

Hot Gas Solenoid ON Harvest Pressure Regulating (HPR) Solenoid ON

#3 Closed

Water Dump Valve ON

#4 Open

Contactor Coil OFF Liquid Line Solenoid De-Energized Compressor OFF Condenser Fan Motor OFF

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-10

Section 6 Electrical System

Initial Start-Up Or Start-Up After Automatic Shut-Off (cont.)

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.

The hot gas valve and harvest pressure regulating (HPR) solenoid valve remain on for the first 5 seconds of the initial compressor start-up.

(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.)

TB35

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

CONTACTOR

CONTACTS

TB32 (55)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1

LOW D.C.

VOLTAGE

(62) (63)

BIN SWITCH

(65)(64)

(66)

*OVERLOAD

(48)(42)

(51)

(52)

TB33 TB34

TERMINATES AT

PIN CONNECTION

(F1) (F2)

PLUG

(67) (66)

COMPRESSOR RUN CAPACITOR

(53)

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE

(69)

OFF CLEAN

(62)

(49)

(47)

(61) (60)

(57)

TB31

(58)

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIEW

(46)

PTCR

REMOTE FAN

MOTOR

RUN CAPACITO R

(Old Style Control Board Shown)

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONTACTOR

COIL

VIEW FOR WIRING

66 62

REMOTE

CONDENSER

(80)

(81)

WATER

PUMP

(50)

(79)(78)

(75)

LIQUID LINE

SOLENOID

(74)

68 67

SV1553

L2 (N)

TB30

Remote Models

2. Refrigeration System Start-Up (5 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Closed

Hot Gas Solenoid ON Harvest Pressure Regulating (HPR) Solenoid ON

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-11

Section 6Electrical System

Freeze Sequence

3. PRE-CHILL To pre-chill the evaporator, the compressor runs for 30 seconds prior to water flow.

TB35

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

CONTACTOR

CONTACTS

TB32 (55)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1A

LOW D.C.

VOLTAGE

(62) (63)

BIN SWITCH

(65)(64)

(66)

*OVERLOAD

(48)(42)

(51)

(52)

TB33 TB34

TERMINATES AT

PIN CONNECTION

(F1) (F2)

PLUG

(68)

(67)

(69)

(66)

(62)

(49)

COMPRESSOR RUN CAPACITOR

(47)

(53)

(61) (60)

(57)

TB31

(58)

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIEW

CLEAN

(46)

PTCR

REMOTE FAN

MOTOR

RUN CAPACITO R

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(79)(78)

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONTACTOR

COIL

VIEW FOR WIRING

66 62

REMOTE

CONDENSER

(80)

(81)

WATER

PUMP

LIQUID LINE

(50)

SV1554

(75)

SOLENOID

(74)

68 67

L2 (N)

TB30

(Old Style Control Board Shown)

Remote Models

3. Pre-Chill (30 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Open

Hot Gas Solenoid OFF Harvest Pressure Regulating (HPR) Solenoid OFF

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-12

Section 6 Electrical System

Freeze Sequence (cont.)

4. FREEZE 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, where it freezes.

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.

NOTE: The ice machine cannot initiate a harvest cycle until a 6-minute freeze lock has expired.

TB35

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

CONTACTOR

CONTACTS

TB32 (55)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1A

LOW D.C.

VOLTAGE

(62) (63)

BIN SWITCH

(65)(64)

(66)

*OVERLOAD

(48)(42)

(51)

(52)

TB33 TB34

TERMINATES AT

PIN CONNECTION

(F1) (F2)

PLUG

(67) (66)

COMPRESSOR RUN CAPACITOR

(53)

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE

(69)

OFF CLEAN

(62)

(49)

(47)

RUN CAPACITO R

(61) (60)

(57)

(58)

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIEW

(46)

PTCR

REMOTE FAN

MOTOR

TB31

(Old Style Control Board Shown)

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONDENSER

CONTACTOR

COIL

VIEW FOR WIRING

66 62

(50)

REMOTE

(80)

(81)

WATER

PUMP

SV1555

(79)(78)

(75)

LIQUID LINE

SOLENOID

(74)

68 67

L2 (N)

TB30

Remote Models

4. Freeze (Until 7 Seconds of Water Contact with Ice Thickness Probe)

Toggle Switch Bin Switch Control Board Relays

#1 Closed

Water Pump ON

#2 Open

Hot Gas Solenoid OFF Harvest Pressure Regulating (HPR) Solenoid OFF

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-13

Section 6Electrical System

Harvest Sequence

5. WATER PURGE The water pump continues to run as the water dump valve energizes for 45 seconds to purge the water from the water trough.

The hot gas valve(s) and HPR solenoid valve open at the beginning of the water purge. Hot refrigerant gas is diverted into the evaporator throughout the 45-second water purge.

After the 45-second water purge, the water pump and dump valve de-energize. New style control boards have an adjustable water purge. This permits a 0 (off), 15, 30 or 45 second water purge.

TB35

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

CONTACTOR

CONTACTS

TB32 (55)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1A

LOW D.C. VOLTAGE

(62) (63)

BIN SWITCH

(65)(64)

(66)

*OVERLOAD

(48)(42)

(51)

(52)

TB33 TB34

TERMINATES AT

PIN CONNECTION

(F1) (F2)

PLUG

(67) (66)

COMPRESSOR RUN CAPACITOR

(53)

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE

(69)

OFF

CLEAN

(62)

(49)

(47)

RUN CAPACITO R

(61) (60)

(57)

(58)

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIEW

(46)

PTCR

REMOTE FAN

MOTOR

TB31

(Old Style Control Board Shown)

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(79)(78)

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONTACTOR

COIL

VIEW FOR WIRING

66 62

REMOTE

CONDENSER

(50)

(80)

(81)

WATER

PUMP

LIQUID LINE

SV1556

(75)

SOLENOID

(74)

68 67

L2 (N)

TB30

Remote Models

5. Water Purge (45 Seconds)

Toggle Switch Bin Switch Control Board Relays

#1 Closed

Water Pump ON

#2 Closed

Hot Gas Solenoid ON Harvest Pressure Regulating (HPR) Solenoid ON

#3 Closed

Water Dump Valve ON

#4 Closed

Contactor Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-14

Section 6 Electrical System

Harvest Sequence (cont.)

6. HARVEST The hot gas 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.

TB35

TB32 (55)

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

(66)

CONTACTOR

CONTACTS

(48)(42)

(51)

TB33 TB34

(62) (63)

BIN SWITCH

*OVERLOAD

(52)

TERMINATES AT

PIN CONNECTION

(F1) (F2)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1A

LOW D.C. VOLTAGE

PLUG

(65)(64)

(68)

(67)

(69)

(66)

(62)

(49)

COMPRESSOR RUN CAPACITOR

(47)

(53)

(61) (60)

(57)

TB31

(58)

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←←INTERNAL

OFF

WORKING VIEW

CLEAN

(46)

PTCR

REMOTE FAN

MOTOR

RUN CAPACITO R

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONTACTOR

VIEW FOR WIRING

66 62

REMOTE

CONDENSER

COIL

(80)

(81)

WATER

PUMP

(50)

SV1557

(79)(78)

(75)

LIQUID LINE

SOLENOID

(74)

68 67

L2 (N)

TB30

(Old Style Control Board Shown)

Remote Models

6. Harvest (Until Bin Switch Activation)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Closed

Hot Gas Solenoid ON Harvest Pressure Regulating (HPR) Solenoid ON

#3 Open

Water Dump Valve OFF

#4 Closed

Contactor Coil ON Liquid Line Solenoid Energized Compressor ON Condenser Fan Motor ON

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-15

Section 6Electrical System

7. Automatic Shut-Off

NOTE: The ice machine must remain off for 3 minutes before it can automatically restart.

TB35

HIGH

PRESSURE

CUT-OUT

ICE THICKNESS PROBE

DISCHARGE LINE THERM ISTOR

CONTACTOR

CONTACTS

TB32 (55)

3 1

2 4

TRANS. FUSE

FUSE (7A)

1D 1C 1B 1A

LOW D.C.

VOLTAGE

(62) (63)

BIN SWITCH

(65)(64)

(66)

*OVERLOAD

(48)(42)

(51)

(52)

TB33 TB34

TERMINATES AT

PIN CONNECTION

(F1) (F2)

PLUG

(67) (66)

COMPRESSOR RUN CAPACITOR

(53)

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE

(69)

OFF CLEAN

(62)

(49)

(47)

RUN CAPACITO R

(61) (60)

(57)

(58)

TB37

TOGGLE SWITCH

←←←←INTERNAL WORKING VIEW

(46)

PTCR

REMOTE FAN

MOTOR

TB31

(Old Style Control Board Shown)

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

(71)

HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98) (99)

(59) (82)(83)

(73)

(56)

(45)

CONDENSER

CONTACTOR

COIL

VIEW FOR WIRING

66 62

(50)

REMOTE

(80)

(81)

WATER

PUMP

(79)(78)

(75)

LIQUID LINE

SOLENOID

(74)

68 67

SV1558

L2 (N)

TB30

Remote Models

7. Automatic Shut-Off (Until Bin Switch Closes)

Toggle Switch Bin Switch Control Board Relays

#1 Open

Water Pump OFF

#2 Open

Hot Gas Solenoid OFF Harvest Pressure Regulating (HPR) Solenoid OFF

#3 Open

Water Dump Valve OFF

#4 Open

Contactor Coil OFF Liquid Line Solenoid De-Energized Compressor OFF Condenser Fan Motor OFF

Safety Controls (Which could stop ice machine operation)

High Pressure Cut-Out Closed Main Fuse (On Control Board) Closed Transformer Fuse (On Control Board) Closed Thermistor Operation OK

ICE Closed

6-16

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)

6-17

OLD STYLE SELF-CONTAINED - J200/J250/J320 - 1 PHASE

(74)

(49)

(48)

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(62)

(47)

(42)

(51)

(52)

(85)

(86)

(53)

(50)

Section 6Electrical System

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

CONTACTOR

CONTACTS

TB33 TB34

WORKING ON ELECTRICAL CIRCUITRY.

3 1

2 4

TRANS.

FUSE (7A

1D 1C 1B

LOW D.C.

VOLTAGE

BIN SWITCH

COMPRESSOR

*OVERLOAD

FAN CYCLE CONTROL RUN CAPACITOR**

FUSE

HOT GAS

SOLENOID

TB31

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←← INTERNAL

OFF CLEAN

WORKING VIE

PTCR

FAN MOTOR (AIR-COOLED ONLY)

SEE SERIAL PLATE FOR VOLTAGE

DUMP

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

66 62

L2 (N)

TB30

6-18

SV1543

Section 6 Electrical System

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

)

(62)

(63)

(64)

(65)

(66)

(67)

(69)

(49)

(47)

(48)

(42)

(51)

(52)

(85)

(86)

(53)

(50)

(

)

(46)

OLD STYLE SELF-CONTAINED - J420/J450/J600/J800/J1000 - 1 PHASE

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

WORKING ON ELECTRICAL CIRCUITRY.

BIN SWITCH

3 1

2 4

TRANS.

1D 1C 1B

FUSE

FUSE (7A

LOW D.C.

VOLTAGE

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE

←←←← INTERNAL

OFF CLEAN

(62)

TB31

TB37

TOGGLE SWITCH

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

L2 (N)

TB30

TB35

CONTACTOR

CONTACTS

TB33

*OVERLOAD

FAN CYCLE CONTROL

COMPRESSOR

TB34

RUN CAPACITOR**

RUN CAPACITOR

PTCR

FAN MOTOR

AIR-COOLED ONLY

TB30

SV1544

6-19

OLD STYLE SELF-CONTAINED - J800/J1000 - 3 PHASE

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

(7A)

(62)

(63)

(64)

(65)

(66)

(67)

(69)

(42)

(51)

(52)

(85)

(86)

(53)

(

)

(96)

Section 6Electrical System

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

CAUTION: DISCONNECT POWER BEFORE

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

WORKING ON ELECTRICAL CIRCUITRY.

TB32

BIN SWITCH

3 1

2 4

TRANS.

1D 1C 1B

FUSE

LOW D.C. VOLTAGE

FUSE

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE

←←←← INTERNAL

OFF CLEAN

(62)

HOT GAS

SOLENOID

DUMP

SOLENOID

TB31

TB37

TOGGLE SWITCH

WORKING VIE

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

66 62

TB30

TB35

L2L3

COMPRESSOR*

CONTACTOR

CONTACTS

TB33

FAN CYCLE CONTROL

TB34

FAN MOTOR

AIR-COOLED ONLY

RUN CAPACITOR**

TB30

SV1545

6-20

Section 6 Electrical System

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

)

(62)

(63)

(64)

(65)

(66)

(67)

(69)

(49)

(47)

(48)

(42)

(51)

(52)

(85)

(86)

(53)

(50)

(46)

(87)

(88)

(44)

(95)

(94)

(96)

(45)

OLD STYLE SELF-CONTAINED - J1300/J1800 - 1 PHASE

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

WORKING ON ELECTRICAL CIRCUITRY.

BIN SWITCH

3 1

2 4

TRANS.

1D 1C 1B

FUSE (7A

LOW D.C. VOLTAGE

FUSE

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

(68)

ICE OFF CLEAN

(62)

TB31

TB37

TOGGLE SWITCH

←←←← INTERNAL

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

RH HOT

GAS

LH HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

L2 (N)

TB30

TB35

CRANKCASE HEATER

COMPRESSOR

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE CONTROL

RUN CAPACITOR**

RUN CAPACITOR

PTCR

FAN MOTOR (AIR-COOLED ONLY)

TB30

CONTACTOR

CONTACTS

TB30

SV1548

6-21

OLD STYLE SELF-CONTAINED - J1300/J1800 - 3 PHASE

(99)

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(81)

(58)

(59)

(73)

(56)

(74)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(42)

(51)

(52)

(85)

(86)

(53)

(

)

(96)

(88)

(87)

(95)

(94)

Section 6Electrical System

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

DISCHARGE LINE THERMISTOR

TB35

CAUTION: DISCONNECT POWER BEFORE

TB32

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

3 1 2

TRANS.

FUSE

FUSE (7A

1D 1C

LOW D.C.

VOLTAGE

CRANKCASE HEATER

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

ICE OFF CLEAN

(62)

LH HOT GAS

SOLENOID

TB31

TB37

TOGGLE SWITCH

←←←← INTERNAL

WORKING VIE

RH HOT

GAS

DUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

WATER

PUMP

IEW FOR WIRING

67 69

TB30 TB30

TB30

N - 50HZ

ONLY

L2L3

CONTACTOR

COMPRESSOR*

CONTACTS

TB33

TB35

NOTE: WIRE (96) IS NOT USED ON 50HZ

FAN CYCLE CONTROL

TB34

RUN CAPACITOR**

FAN MOTOR

AIR-COOLED ONLY

TB30

SV1549

6-22

Section 6 Electrical System

(69)

(49)

(47)

(48)

(42)

(51)

(52)

(53)

(50)

(46)

(45)

(F1)

(F2)

OLD STYLE REMOTE - J450/J600/J800/J1000 - 1 PHASE

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32 (55)

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

(64) (65)

(66) (66)

WORKING ON ELECTRICAL CIRCUITRY.

BIN SWITCH

(62) (63)

3 1

2 4

TRANS.

1D 1C 1B

FUSE

FUSE (7A)

LOW D.C. VOLTAGE

PLUG

(67)

(68)

(62)

(61) (60)

(57)

TB31

(58)

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE OFF CLEAN

←←←← INTERNAL

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

HPR

(77) HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98)

(59)

(73)

(56)

SOLENOID

(83) (82)

CONTACTOR

66 62

(79)(78)

(80)

(81)

WATER

PUMP

(74)

COIL

IEW FOR WIRING

(75)

(99)

LIQUID LINE

SOLENOID

68 67

L2 (N)

TB30

TB35

CONTACTOR

CONTACTS

TB33

*OVERLOAD

TERMINATES AT

PIN CONNECTION

COMPRESSOR

TB34

RUN CAPACITOR

PTCR

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

TB30

SV1546

6-23

OLD STYLE REMOTE - J800/J1000 - 3 PHASE

(99)

(55)

(61)

(60)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(42)

(77)

(76)

(80)

(75)

(98)

(57)

(81)

(58)

(59)

(73)

(56)

(74)

(79)

(78)

(83)

(82)

(51)

(52)

(53)

(96)

(F1)

(F2)

Section 6Electrical System

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

CAUTION: DISCONNECT POWER BEFORE

TB32

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

3 1 2

TRANS.

FUSE (7A

1D 1C

1B 1

FUSE

LOW D.C.

VOLTAGE

(62)

ICE OFF CLEAN

HOT GAS

SOLENOID

DUMP

SOLENOID

TB31

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

←←←← INTERNAL

WORKING VIE

HPR

SOLENOID

WATER

PUMP

CONTACTOR

IEW FOR WIRING

LIQUID LINE

SOLENOID

67 69

TB30

L2L3

COMPRESSOR*

CONTACTOR

CONTACTS

TB33

TERMINATES AT

PIN CONNECTION

TB34

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

TB35

TB30

SV1547

6-24

Section 6 Electrical System

(55)

(61)

(60)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

(79)

(78)

(83)

(82)

(87)

(88)

(49)

(47)

(48)

(42)

(51)

(52)

(53)

(50)

(46)

(44)

(95)

(94)

(96)

(45)

(F1)

(F2)

OLD STYLE REMOTE - J1300/J1800 - 1 PHASE

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

WORKING ON ELECTRICAL CIRCUITRY.

BIN SWITCH

3 1

2 4

TRANS.

FUSE (7A

1D 1C

1B 1

FUSE

LOW D.C.

VOLTAGE

(62)

TB31

TB37

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

TOGGLE SWITCH

ICE

←←←← INTERNAL

OFF CLEAN

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

RH HOT

GAS

LH HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

CONTACTOR

IEW FOR WIRING

PUMP

LIQUID LINE

SOLENOID

67 69

L2 (N)

TB30

TB35

CONTACTOR

CONTACTS

TB33

*OVERLOAD

TERMINATES AT

PIN CONNECTION

CRANKCASE HEATER

COMPRESSOR

TB34

RUN CAPACITOR

PTCR

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

CONTACTOR

CONTACTS

TB30

SV1550

6-25

OLD STYLE REMOTE - J1300/J1800 - 3 PHASE

(75)

(99)

(62)

(55)

(61)

(60)

(77)

(76)

(80)

(98)

(57)

(81)

(58)

(59)

(73)

(56)

(74)

(7A)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(42)

(51)

(52)

(53)

(96)

(88)

(87)

(95)

(94)

(78)

(79)

(F1)

(F2)

Section 6Electrical System

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

CAUTION: DISCONNECT POWER BEFORE

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

DISCHARGE LINE THERMISTOR

WORKING ON ELECTRICAL CIRCUITRY.

TB32

BIN SWITCH

3 1 2

TRANS. FUSE

FUSE

1D 1C

LOW D.C.

VOLTAGE

CRANKCASE HEATER

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

BIN SWITCH LIGHT

ICE

←←←← INTERNAL

OFF CLEAN

(62)

HPR

SOLENOID

RH HOT

GAS

LH HOT GAS

SOLENOID

DUMP

SOLENOID

TB31

TB37

TOGGLE SWITCH

WORKING VIE

WATER

PUMP

CONTACTOR

IEW FOR WIRING

LIQUID LINE

68 67

N - 50HZ

ONLY

TB30 TB30

TB30

L2L3

CONTACTOR

CONTACTS

COMPRESSOR*

TB33

TB35

NOTE: WIRE (96) IS NOT USED ON 50HZ

TERMINATES AT

PIN CONNECTION

TB34

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

TB30

SV1551

6-26

Section 6 Electrical System

(52)

(74)

(49)

(48)

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(62)

(47)

(42)

(51)

(85)

(86)

(53)

(50)

NEW STYLE SELF-CONTAINED - J200/J250/J320 - 1 PHASE

CAUTION: DISCONNECT POWER BEFORE

WORKING ON ELECTRICAL CIRCUITRY.

SEE SERIAL PLATE FOR VOLTAGE

L2 (N)

TB35

HIGH

PRESSUR

E CUT-

TB32

ICE THICKNESS PROBE

CONNECTION NOT USED

CONTACTOR

CONTACTS

TB33

BIN SWITCH

*OVERLOAD

FAN CYCLE CONTROL

3 1

2 4

TRANS.

FUSE (7A

LOW D.C. VOLTAGE

COMPRESSOR

CLEAN LIGHT

LIGHT NOT USED

BIN SWITCH LIGHT HARVEST LIGHT/

SAFETY LIMIT CODE LIGHT

ICE

←←←← INTERNAL

OFF CLEAN

TB34

RUN CAPACITOR**

TB31

TB37

TOGGLE SWITCH

WORKING VIE

PTCR

FAN MOTOR (AIR-COOLED ONLY)

HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

66 62

TB30

SV1579

6-27

NEW STYLE SELF-CONTAINED - J420/J450/J600/J800/J1000 - 1 PHASE

(74)

(49)

(48)

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(62)

(47)

(42)

(51)

(85)

(86)

(53)

(50)

(

)

(46)

(45)

(52)

CAUTION: DISCONNECT POWER BEFORE

WORKING ON ELECTRICAL CIRCUITRY.

SEE SERIAL PLATE FOR VOLTAGE

Section 6Electrical System

L2 (N)

TB35

HIGH

PRESSUR

E CUT-

TB32

ICE THICKNESS PROBE

CONNECTION NOT USED

BIN SWITCH

3 1

2 4

TRANS.

FUSE (7A

LOW D.C.

VOLTAGE

TB31

TB37

CLEAN LIGHT

LIGHT NOT USED

BIN SWITCH LIGHT HARVEST LIGHT/

SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

ICE

←←←← INTERNAL

OFF CLEAN

WORKING VIE

HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

66 62

TB30

TB35

CONTACTOR

CONTACTS

TB33

*OVERLOAD

FAN CYCLE CONTROL

COMPRESSOR

TB34

RUN CAPACITOR**

RUN CAPACITOR

PTCR

FAN MOTOR

AIR-COOLED ONLY

TB30

SV1580

6-28

Section 6 Electrical System

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

)

(62)

(63)

(64)

(65)

(66)

(67)

(69)

(42)

(51)

(52)

(85)

(86)

(53)

(

)

(96)

NEW STYLE SELF-CONTAINED - J800/J1000 - 3 PHASE

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

CONNECTION NOT USED

CAUTION: DISCONNECT POWER BEFORE

TB32

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

3 1

2 4

TRANS.

FUSE (7A

LOW D.C.

VOLTAGE

(68)

ICE OFF CLEAN

(62)

HOT GAS

SOLENOID

DUMP

SOLENOID

TB31

TB37

CLEAN LIGHT LIGHT NOT USED

BIN SWITCH LIGHT HARVEST LIGHT/

SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

←←←← INTERNAL

WORKING VIE

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

66 62

TB30

TB35

L2L3

COMPRESSOR*

CONTACTOR

CONTACTS

TB33

FAN CYCLE CONTROL

TB34

FAN MOTOR

AIR-COOLED ONLY

RUN CAPACITOR**

TB30

SV1581

6-29

NEW STYLE SELF-CONTAINED - J1300/J1800 - 1 PHASE

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

(7A)

(62)

(63)

(64)

(65)

(66)

(67)

(69)

(49)

(47)

(48)

(42)

(51)

(52)

(85)

(86)

(53)

(50)

(

)

(46)

(87)

(88)

(44)

(95)

(94)

(96)

(45)

Section 6Electrical System

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32

ICE THICKNESS PROBE

CONNECTION NOT USED

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

3 1

2 4

TRANS.

FUSE

LOW D.C.

VOLTAGE

(68)

(62)

TB31

TB37

CLEAN LIGHT

LIGHT NOT USED

BIN SWITCH LIGHT

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

ICE

←←←← INTERNAL

OFF CLEAN

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

RH HOT

GAS

LH HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

66 62

L2 (N)

TB30

TB35

CRANKCASE HEATER

COMPRESSOR

CONTACTOR

CONTACTS

TB33 TB34

*OVERLOAD

FAN CYCLE CONTROL

RUN CAPACITOR**

RUN CAPACITOR

PTCR

FAN MOTOR

AIR-COOLED ONLY

TB30

CONTACTOR

CONTACTS

TB30

SV1584

6-30

Section 6 Electrical System

(55)

(61)

(60)

(77)

(76)

(80)

(75)

(98)

(57)

(81)

(58)

(59)

(73)

(56)

(74)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(42)

(51)

(52)

(85)

(86)

(53)

(

)

(96)

(88)

(87)

(95)

(94)

NEW STYLE SELF-CONTAINED - J1300/J1800 - 3 PHASE

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

ICE THICKNESS PROBE

CONNECTION NOT USED

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

TB32

3 1 2

TRANS.

FUSE (7A

LOW D.C.

VOLTAGE

CRANKCASE HEATER

TB37

CLEAN LIGHT LIGHT NOT USED

BIN SWITCH LIGHT HARVEST LIGHT/

SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

ICE

←←←← INTERNAL

(62)

OFF CLEAN

WORKING VIE

LH HOT GAS

TB31

SOLENOID

DUMP

SOLENOID

RH HOT

GAS

WATER

PUMP

TERMINATES AT

PIN CONNECTION

CONTACTOR

IEW FOR WIRING

N - 50HZ

ONLY

TB30 TB30

TB30

67 69

TB30

L2L3

CONTACTOR

CONTACTS

COMPRESSOR*

TB33

TB35

NOTE: WIRE (96) IS NOT USED ON 50HZ

FAN CYCLE CONTROL

TB34

RUN CAPACITOR**

FAN MOTOR

AIR-COOLED ONLY

TB30

SV1585

6-31

NEW STYLE REMOTE - J450/J600/J800/J1000 - 1 PHASE

(68)

(69)

(49)

(47)

(48)

(42)

(51)

(52)

(53)

(50)

(46)

(45)

(F1)

(F2)

Section 6Electrical System

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32 (55)

ICE THICKNESS PROBE

CONNECTION NOT USED

BIN SWITCH

(64)

(66)

WORKING ON ELECTRICAL CIRCUITRY.

3 1

2 4

TRANS.

FUSE (7A)

LOW D.C. VOLTAGE

PLUG

(62) (63)

(65)

(67) (66)

(62)

(61) (60)

(57)

TB31

(58)

TB37

CLEAN LIGHT

LIGHT NOT USED

BIN SWITCH LIGHT

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

ICE OFF CLEAN

←←←← INTERNAL

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

HPR

(77) HOT GAS

SOLENOID

(76)

DUMP

SOLENOID

(98)

(59)

(73)

(56)

SOLENOID

(83) (82)

CONTACTOR

66 62

(79)(78)

(80)

(81)

WATER

PUMP

LIQUID LINE

(74)

COIL

IEW FOR WIRING

(75)

(99)

SOLENOID

68 67

L2 (N)

TB30

TB35

CONTACTOR

CONTACTS

TB33

*OVERLOAD

TERMINATES AT

PIN CONNECTION

COMPRESSOR

TB34

RUN CAPACITOR

PTCR

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

TB30

SV1582

6-32

Section 6 Electrical System

(55)

(61)

(60)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(42)

(77)

(76)

(80)

(75)

(98)

(57)

(81)

(58)

(59)

(73)

(56)

(74)

(79)

(78)

(83)

(82)

(51)

(52)

(53)

(96)

(F1)

(F2)

NEW STYLE REMOTE - J800/J1000 - 3 PHASE

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

CONNECTION NOT USED

CAUTION: DISCONNECT POWER BEFORE

TB32

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

3 1 2

TRANS.

FUSE (7A

LOW D.C.

VOLTAGE

ICE OFF CLEAN

(62)

HOT GAS

SOLENOID

DUMP

SOLENOID

TB31

TB37

CLEAN LIGHT LIGHT NOT USED

BIN SWITCH LIGHT HARVEST LIGHT/

SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

←←←← INTERNAL

WORKING VIE

HPR

SOLENOID

WATER

PUMP

CONTACTOR

IEW FOR WIRING

LIQUID LINE

SOLENOID

67 69

TB30

L2L3

COMPRESSOR*

CONTACTOR

CONTACTS

TB33

TERMINATES AT

PIN CONNECTION

TB34

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

TB35

TB30

SV1583

6-33

NEW STYLE REMOTE - J1300/J1800 - 1 PHASE

(55)

(61)

(60)

)

(62)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(77)

(76)

(80)

(75)

(98)

(57)

(99)

(81)

(58)

(59)

(73)

(56)

(74)

(79)

(78)

(83)

(82)

(87)

(88)

(49)

(47)

(48)

(42)

(51)

(52)

(53)

(50)

(46)

(44)

(95)

(94)

(96)

(45)

(F1)

(F2)

Section 6Electrical System

TB35

HIGH

PRESSUR

E CUT-

CAUTION: DISCONNECT POWER BEFORE

TB32

ICE THICKNESS PROBE

CONNECTION NOT USED

BIN SWITCH

WORKING ON ELECTRICAL CIRCUITRY.

3 1

2 4

TRANS.

FUSE (7A

LOW D.C.

VOLTAGE

(62)

TB31

TB37

CLEAN LIGHT

LIGHT NOT USED BIN SWITCH LIGHT

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

TOGGLE SWITCH

ICE

←←←← INTERNAL

OFF CLEAN

WORKING VIE

SEE SERIAL PLATE FOR VOLTAGE

HPR

SOLENOID

RH HOT

GAS

LH HOT GAS

SOLENOID

DUMP

SOLENOID

WATER

CONTACTOR

IEW FOR WIRING

PUMP

LIQUID LINE

SOLENOID

67 69

L2 (N)

TB30

TB35

CONTACTOR

CONTACTS

TB33

*OVERLOAD

TERMINATES AT

PIN CONNECTION

CRANKCASE HEATER

COMPRESSOR

TB34

RUN CAPACITOR

PTCR

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

CONTACTOR

CONTACTS

TB30

SV1586

6-34

Section 6 Electrical System

(55)

(61)

(60)

(77)

(76)

(80)

(98)

(57)

(81)

(58)

(59)

(73)

(56)

(74)

)

(63)

(64)

(65)

(66)

(67)

(68)

(69)

(42)

(51)

(52)

(53)

(96)

(88)

(87)

(95)

(94)

(78)

(79)

(F1)

(F2)

(83)

(75)

NEW STYLE REMOTE - J1300/J1800 - 3 PHASE

SEE SERIAL PLATE FOR VOLTAGE

L2L3

TB35

CONNECTION NOT USED

TB35

CAUTION: DISCONNECT POWER BEFORE

HIGH

PRESSUR

E CUT-

ICE THICKNESS PROBE

WORKING ON ELECTRICAL CIRCUITRY.

TB32

BIN SWITCH

3 1 2

TRANS.

FUSE (7A

LOW D.C. VOLTAGE

CRANKCASE HEATER

CLEAN LIGHT LIGHT NOT USED BIN SWITCH LIGHT

HARVEST LIGHT/ SAFETY LIMIT CODE LIGHT

ICE

←←←← INTERNAL

OFF CLEAN

(62)

HPR

SOLENOID

RH HOT

GAS

LH HOT GAS

SOLENOID

DUMP

SOLENOID

TB31

TB37

TOGGLE SWITCH

WORKING VIE

WATER

PUMP

CONTACTOR

IEW FOR WIRING

LIQUID LINE

N - 50HZ

ONLY

TB30 TB30

TB30

L2L3

CONTACTOR

CONTACTS

COMPRESSOR*

TB33

TB35

NOTE: WIRE (96) IS NOT USED ON 50HZ

TERMINATES AT

PIN CONNECTION

TB34

REMOTE

FAN MOTOR

RUN CAPACITOR

REMOTE

CONDENSER

TB30

SV1587

6-35

Component Specifications and Diagnostics

Section 6Electrical System

FUSES

Function

The control board fuse(s) stops ice machine operation if electrical components fail causing high amp draw.

Specifications

Fuse Specifications

Main Fuse 250 Volt, 7 Amp

Transformer Fuse

The transformer fuse is not used on new style dual voltage control boards.

250 Volt, 60 Hz, .125 Amp 250 Volt, 50 Hz, .100 Amp

Check Procedure

WARNING

High (line) voltage is applied to the control board (terminals #55 and #56) at all times. Removing control board fuses 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, both fuses are good.

WARNING

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 Result

Open (OL) Replace fuse

Closed (O) Fuse is good

BIN SWITCH

Function

Bin switch operation is controlled by movement of the water curtain. The bin switch has two main functions:

1. Terminating the harvest cycle and returning the

ice machine to the freeze cycle.

This occurs when the bin switch is opened and closed

again within 7 seconds during the harvest cycle.

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.

Important

The water curtain must be ON (bin switch 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 evaporator mounting bracket.

The bin switch is connected to a varying D.C. voltage circuit. (Voltage does not remain constant.)

6-36

NOTE: Because of a wide variation in D.C. voltage, it is not recommended that a voltmeter be used to check bin switch operation.

Section 6 Electrical System

Check Procedure

1. Set the toggle switch to OFF.

2. Watch the bin switch light on the control board.

3. Move the water curtain toward the evaporator.

The bin switch must close. The bin switch light “on” indicates the bin switch has closed properly.

4. Move the water curtain away from the evaporator.

The bin switch must open. The bin switch light “off” indicates the bin switch has opened properly.

Ohm Test

1. Disconnect the bin switch wires to isolate the bin

switch from the control board.

2. Connect an ohmmeter to the disconnected bin

switch wires. Set the ohmmeter to the 10,000 ohm scale.

3. Cycle the bin switch by opening and closing the

water curtain.

4. With the bin switch open: Resistance readings of

more than 30,000 ohms indicate a correctly operating bin switch.

5. With the bin switch closed: Resistance readings

of less than 70 ohms indicates a correctly operating bin switch.

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 3.5 minute point, the ice machine immediately returns to another freeze sequence prechill.

Important

Any reading between 70 and 30,000 ohms, regardless of curtain position, indicates a defective bin switch

GOOD

INFINITE

OHMS METER READS

(OL)

0 OHMS

70 OHMS

SWITCH CLOSED

GOOD

30,000 OHMS

SWITCH OPEN

BAD

Bin Switch Resistance Readings

6-37

COMPRESSOR ELECTRICAL DIAGNOSTICS

The compressor will not start or will trip repeatedly on overload.

Check Resistance (Ohm) Values

NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter.

Section 6Electrical System

Determine if the Compressor is Seized

Check the amp draw while the compressor is trying to start.

COMPRESSOR DRAWING LOCKED ROTOR The two likely causes of this are:

• Defective starting component

• Mechanically seized compressor

Perform the resistance test after the compressor cools. The compressor dome should be cool enough to touch (below 120°F/49°C) to assure that the overload is closed and the resistance readings will be accurate.

SINGLE PHASE COMPRESSORS

1. 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 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.

Check Motor Windings to Ground

Check continuity between all three terminals and the compressor shell or copper refrigeration line.

NOTE: Scrape the metal surface to get good contact.

To determine which you have:

1. Install high and low side gauges.

2. Try to start the compressor.

3. Watch the pressures closely. A. If the pressures do not move, the compressor

is seized. Replace the compressor.

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.

Diagnosing PTCR’s

See “PTCR Diagnostics” on the next page.

If continuity is present, the compressor windings are grounded and the compressor should be replaced.

6-38

Section 6 Electrical System

Compressor Start Sequence

PTCR DIAGNOSTICS

What is a PTCR?

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.

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).

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 hot gas valve (and HPR valve on remotes) will energize for 45 seconds prior to compressor starting. The hot gas 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 J model ice machines have a built-in 3-minute off time before it can restart.

6-39

J-Model Automatic Shut-Off and Res tart

When the storage bin is full at the end of a harvest cycle, the sheet of cubes fails to clear the water curtain and will hold it open. After the water curtain is held open for 7 seconds, the ice machine shuts off. To assure the PTCR has cooled, the ice machine remains off for 3 minutes before it can automatically restart.

Section 6Electrical System

L1 L2

CONTACTOR

CONTACTS

COMPRESSOR

RUN CAPACITOR

PTCR

SV1506

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.

During Start-Up (First .25 - 1.0 Seconds)

L1 L2

CONTACTOR

CONTACTS

COMPRESSOR

RUN CAPACITOR

PTCR

SV1507

After Start-Up

(Current Flows Through Run Capacitor)

6-40

Section 6 Electrical System

There are other problems that may cause compressor

Troubleshooting PTCR’s

WHY A GOOD PTCR MAY FAIL TO START THE COMPRESSOR

The PTCR must be cooled before attempting to start the compressor, otherwise the high starting torque may not last long enough.

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:

• 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.

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 hot gas 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 before assuming that the PTCR is bad.

6-41

CHECKING THE PTCR

WARNING

Disconnect electrical power to the entire ice machine at the building electrical disconnect box before proceeding.

MEASURE OHMS

BETWEEN END TABS

Section 6Electrical System

1. Visually inspect the PTCR. Check for signs of

physical damage.

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.

Room

Temperature

Resistance

Model

J200 J250 J320 J420 J450 J600

J800 J1000 J1300 J1800

Manitowoc

Part Number

8505003 305C20 22-50 Ohms

8504993 305C19 18-40 Ohms

8504913 305C9 8-22 Ohms

Cera-Mite

Part Number

SV1540

Manitowoc PTCR’s 8505003 & 8504993

MEASURE OHMS BETWEEN

CENTER TAB AND END TAB

LEAVE JUMPER

WIRE IN PLACE

Manitowoc PTCR 8504913

SV1541

6-42

Section 6 Electrical System

Verify that the thermistor resistance is accurate and

DISCHARGE LINE THERMISTOR

NOTE: The discharge line thermistor is not used on later production J-model ice machines. The part has been removed due to the redundancy of safety limits 3 and 4. Any fault that would stop the ice machine on safety limit 3 or 4 would also stop the ice machine on safety limit 1 or 2.

As an example, consider an expansion valve that is overfeeding refrigerant, causing low discharge line temperatures in the harvest cycle. This would stop the ice machine on safety limit 3. But, due to decreased harvest temperatures, the ice machine will stop on safety limit 2 (harvest cycle exceeds 3.5 minutes) with safety limit 3 removed.

When replacing an old style control board with a new style control board, the thermistor will no longer be used.

Function

The discharge line thermistor senses the compressor discharge line temperature. This is used in conjunction with the control board safety limits to stop the ice machine if the discharge line temperature falls below 85°F (29.4°C) or rises above 255°F (123.9°C).

Specifications

100,000 Ohms ±2% at 77°F (25°C)

CAUTION

Use only Manitowoc thermistors.

Check Procedure

Thermistors generally fail because of moisture or physical damage. Manitowoc J-Model discharge line thermistors are encased in a specially-designed, moisture sealed aluminum block. This eliminates physical damage and moisture concerns.

corresponding to the high and low temperature ranges.

1. Disconnect the thermistor from terminals 1A and

1B on the control board.

2. Connect the ohm meter to the isolated thermistor

wire leads.

3. Acquire a temperature meter capable of taking

readings on curved copper lines. Attach the sensing device to the compressor discharge line next to the thermistor aluminum block.

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.

4. With the ice machine running, verify that the

temperature of the discharge line corresponds to the thermistor resistance reading as stated in the chart on the next page.

Check the thermistor at high temperatures (during the

freeze cycle) and at low temperatures (during the harvest cycle). It is normal for the compressor discharge line temperature to rise during the freeze cycle and drop during the harvest cycle.

NOTE: If the ice machine is inoperable, remove the thermistor and place it (for a short time) in an ice water bath, and then in a boiling water bath, to verify its accuracy. See the chart on the next page.

5. If the thermistor would fail closed, the ice

machine would stop on safety limit #4 15 seconds after contact #4 on the control board closes (compressor starts).

6. If the thermistor would fail open, the ice

machine would start and run through two normal freeze and harvest sequences. During the third harvest sequence, the ice machine would stop on safety limit #3.

6-43

Section 6Electrical System

Temperature/Resistance Chart

As the temperature rises at the thermistor block, the resistance drops.

Important

If the ohm meter reads “OL”, check the scale setting on the meter before assuming the thermistor is bad.

Temperature of Thermistor Resistance

°°°°F °°°°C K ohms (x 1000)

32° 0° 376.7 - 283.6

(ice water bath) 50° - 60° 10.0° - 15.6° 198.9 - 153.1 60° - 70° 15.6° - 21.1° 153.1 - 118.8 70° - 80° 21.1° - 26.7° 118.8 - 92.9 80° - 90° 26.7° - 32.2° 92.9 - 73.3

90° - 100° 32.2° - 37.8° 73.3 - 58.2 100° - 110° 37.8° - 43.3° 58.2 - 46.6 110° - 120° 43.3° - 48.9° 46.6 - 37.5 120° - 130° 48.9° - 54.4° 37.5 - 30.5 130° - 140° 54.4° - 60.0° 30.5 - 24.9 140° - 150° 60.0° - 65.6° 24.9 - 20.4 150° - 160° 65.6° - 71.1° 20.4 - 16.8 160° - 170° 71.1° - 76.7° 16.8 - 14.0 170° - 180° 76.7° - 82.2° 14.0 - 11.7 180° - 190° 82.2° - 87.8° 11.7 - 9.8 190° - 200° 87.8° - 93.3° 9.8 - 8.2 200° - 210° 93.3° - 98.9° 8.2 - 7.0

212° 100° 7.3 - 6.2

(boiling water bath) 220° - 230° 104.4° - 110.0° 5.9 - 5.1 230° - 240° 110.0° - 115.6° 5.1 - 4.3 240° - 250° 115.6° - 121.1° 4.3 - 3.7 250° - 260° 121.1° - 126.7° 3.7 - 3.3

ICE/OFF/CLEAN TOGGLE SWITCH

Function

The switch is used to place the ice machine in ICE, OFF or CLEAN mode of operation.

Specifications

Double-pole, double-throw switch. The switch is connected into a varying low D.C. voltage circuit.

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.

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 Terminals Ohm Reading

66-62 Open

ICE 67-68 Closed

67-69 Open 66-62 Closed

CLEAN 67-68 Open

67-69 Closed 66-62 Open

OFF 67-68 Open

67-69 Open

6-44

4. Replace the toggle switch if ohm readings do not

match all three switch settings.

Section 6 Electrical System

For example, a service technician turns the toggle

CONTROL BOARD RELAYS

Function

The control board relays energize and de-energize system components.

Specifications

Relays are not field replaceable. Old and new style control boards use four control board relays. New style control boards have a fifth relay which is not used.

Check Procedure

To increase relay life, there is a capacitor and a resistor mounted across the relay contacts to reducing arcing. Keep this in mind when measuring voltage through open relay contacts.

When measuring voltage through open contacts with a component disconnected from the relay, the current flows through the capacitor and resistor. This results in a “line voltage” reading. The current through the capacitor and resistor is milliamps. Always measure voltage with the component connected to the relay contacts which result in a “0” reading when the contacts are open.

switch OFF (relay contact open) and unplugs the water pump (component disconnected). The service technician places the voltmeter leads into the water pump plug (taking voltage through open contacts with the component disconnected). He reads 208 volts (“line voltage” for the model being worked on).

The service technician mistakenly replaces the control board, thinking that the relay is stuck closed. Actually, there is nothing wrong with the relay, as the technician was reading milliamp current flow through the capacitor and resistor.

Remember to leave components connected to the relays when taking voltage measurements. Otherwise, the reading will always be “line voltage”, whether the relay contacts are open or closed.

6-45

ELECTRONIC CONTROL BOARD (OLD STYLE)

(

)

(

)

AC LINE VOLTAGE

ELECTRICAL PLUG

NUMBERS MARKED ON WIRES

Section 6Electrical System

MAIN FUSE (7A)

AUTOMATIC CLEANING SYSTEM

DISCHARGE LINE THERMISTOR

(AuCS)

ACCESSORY PLUG

ICE THICKNESS PROBE

(3/16” CONNECTION)

(1/4” CONNECTION)

60 61

67 62

57 58

TRANSFORMER FUSE

(.125A - 60HZ)

PRIMARY

POWER SUPPLY N 115V

208-230V

HARVEST LIGHT/

BIN SWITCH LIGHT

DC LOW VOLTAGE

ELECTRICAL PLUG

NUMBERS MARKED ON WIRES

Old Style Control Board

General

The control board controls all electrical components, including the ice machine sequence of operation. Prior to diagnosing, you must understand how the control board functions, and what it is supposed to do.

SV1542

Refer to wiring diagrams and ice machine sequence of operation sections for details, including:

• Initial Start-Up or

Start-Up After Automatic Shut-Off

• Freeze Sequence

• Harvest Sequence

• Automatic Shut-Off

• Self-Cleaning

Refer to pages 6-48 and 6-49 for additional control board information.

6-46

Section 6 Electrical System

(

)

(

)

ELECTRONIC CONTROL BOARD (NEW STYLE)

AC LINE VOLTAGE

ELECTRICAL PLUG

NUMBERS MARKED ON WIRES

MAIN FUSE (7A)

AUTOMATIC CLEANING SYSTEM

(AuCS)

ACCESSORY PLUG

ICE THICKNESS PROBE

(3/16” CONNECTION)

NOT USED

DC LOW VOLTAGE

ELECTRICAL PLUG

NUMBERS MARKED ON WIRES

60 61

67 62 63

57 58 55

PRIMARY

POWER SUPPLY N 115V

208-230V

CLEAN LIGHT -- YELLOW

LIGHT NOT USED -- GREEN

BIN SWITCH LIGHT -- GREEN

HARVEST LIGHT/

SAFETY LIMIT CODE LIGHT -- RED

WATER PURGE ADJUSTMENT

SV1588

New Style Control Board

New Style Control Board Improvements

• A dual voltage transformer means only one

control board for both 115V and 208-230V use.

• One 7-amp fuse - no separate transformer fuse.

• A single ice thickness probe provides improved

ice thickness control by eliminating the possibility of scale or slime bridging the probes, causing premature harvests.

• A yellow “Clean” light energizes when a SeCS or AuCS cycle is in progress.

CAUTION

J model control boards that have only terminal 1C (no terminal 1D on board), must use the new single probe ice thickness control

• An adjustable harvest cycle water purge can be

set to 15, 30 or 45 seconds. This will not affect clean cycle purge time.

CAUTION

This control is factory-set to 45 seconds. A reduced setting will increase cleaning frequency.

• Safety limits 3 and 4 have been eliminated; no

thermistor is required.

• Exact control board replacement when replacing

an old style control board with a new style control board. Electrical sequence of operation is identical to the old style control board.

6-47

Control Board

HARVEST INITIATION (ICE THICKNESS PROBE) Manitowoc’s patented solid state electronic sensing circuit assures consistent ice formation. It does not rely on the refrigeration system (pressure), the temperature of the evaporator, or timers.

The ice machine must be in the freeze cycle six minutes prior to harvest cycle initiation. See “Freeze Time Lock-In Feature” for details.

As the ice forms on the evaporator, water (not ice) will contact the ice thickness probe. After the water completes this circuit for six to ten continuous seconds, a harvest sequence is initiated.

Section 6Electrical System

HARVEST/SAFETY LIMIT LIGHT 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.

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.

CLEAN LIGHT This light is only on the new style control board. It is on whenever a SeCS or AuCS (cleaning) cycle is in progress.

Freeze Time Lock-In Feature

This feature prevents the ice machine from short cycling in and out of harvest.

L.E.D. Lights

BIN SWITCH LIGHT The light is on when the bin switch (water curtain) is closed, and off when the bin switch is open.

This light functions any time power is supplied to the ice machine, even when the toggle switch is in the OFF or CLEAN position. This indicates the primary power supply (line voltage) at the control board is functioning, without having to take a voltage reading.

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 probes), but the ice machine will stay in the freeze cycle. After the six minutes are up, a harvest sequence is initiated.

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.

6-48

Section 6 Electrical System

SAFETY LIMITS

Water Curtain Removal

The water curtain must be on (bin switch closed) to start ice making. The water curtain can be removed and installed at any time during a freeze cycle without interfering with the electrical control sequence.

In addition to standard safety controls, such as the high pressure cut-out, the control board has built-in safety limits. Old style control boards have four safety limits, while new style control boards have two.

If the ice machine goes into a 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 3.5 minute point, the ice machine immediately returns to another freeze sequence prechill.

Fuses

The main fuse stops ice machine operation if electrical components fail cauing high amp draw.

The old style circuit board has an additional fuse. The transformer fuse protects the primary of the transformer only.

These safety limits protect the ice machine from major component failures. For more information, see “Safety Limits” in Section 7.

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Manitowoc J250, J200, J320, J420, J450 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual