Manitowoc QR0320A Service Manual

ICE MACHINES

-Mode

2004 Manitowoc Ice, Inc.

80-1597-3

6/04

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

Specifications and design are subject to change without notice.

Safety Notices

As you work on a Q-Series Ice Machine, be sure to pay close attention to the safety notices in this manual. Disregarding the notices may lead to serious injury and/ or damage to the ice machine.

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

Procedural Notices

As you work on a Q-Series Ice Machine, be sure to read the procedural notices in this manual. These notices supply helpful information which may assist you as you work.

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

NOTE: Text set off as a Note provides you with simple, but useful, extra information about the procedure you are performing.

Warning

PERSONAL INJURY POTENTIAL

Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications.

Warning

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

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.

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.

Attend A Manitowoc Factory Service School

• Improve Your Service Techniques

• Network with Your Peers

• 4 1/2 Days of Intensive Training on Manitowoc Ice Machines

• Extensive “Hands On” Training on a Variety of Equipment

• Breakfast, Lunch and Hotel Room Included with Tuition

• Contact Your Distributor or Manitowoc Ice, Inc. for Details OR

• Visit Our Website at www.manitowocice.com for School Dates

MANITOWOC ICE, INC.

2110 South 26th Street P.O. Box 1720

Manitowoc, WI 54221-1720

Phone: (920) 682-0161

Service Fax: (920) 683-7585

Web Site - www.manitowocice.com

Litho in U.S.A.

Part No. 80-1100-3 1

Table of Contents

Section 1 General Information

Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Authorized Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2 Installation Instructions

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Q320/Q370/Q420 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Q200 – Q1000 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Q1300/Q1600/Q1800 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Q1300/Q1600/Q1800 Ice Machines (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Ice Storage Bin Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

S170/S400/S570 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

S320/S420 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

S970 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Remote Condenser Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

JC0495/JC0895/JC1095/JC1395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

JC1895 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

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

Stacking Two Ice Machines on a Single Storage Bin . . . . . . . . . . . . . . . . . . . . 2-5

Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Leveling the Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Air-Cooled Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Fuse/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Self-Contained Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Self Contained Ice Machine

115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Self Contained Ice Machine

208-230/3/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Self Contained Ice Machine

230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

For United Kingdom Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Table of Contents (continued)

2 Part No. 80-1100-3

Remote Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Ice Machine With Single Circuit Model Condenser

115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Ice Machine With Single Circuit Model Condenser

208-230/3/60 or 380-415/3/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Ice Machine With Single Circuit Model Condenser

230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Water Supply and Drain Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cooling Tower Applications

(Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Water Supply and Drain Line Sizing/Connections . . . . . . . . . . . . . . . . . . . . . 2-12

Remote Condenser/Line Set Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Remote Ice Machines

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Guidelines for Routing Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Calculating Remote Condenser Installation Distances . . . . . . . . . . . . . . . . . 2-15

Lengthening or Reducing Line Set Lengths . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Connecting A Line Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Remote Receiver Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Remote Ice Machine Usage with Non-Manitowoc Multi-Circuit Condensers . 2-17

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Head Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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

Condenser DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

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

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

Non-Manitowoc Multi-Circuit Condenser Sizing Chart . . . . . . . . . . . . . . . . . 2-18

Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Additional Checks for Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Section 3 Maintenance

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

Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

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

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

Harvest Sequence Water Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Air-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Water-Cooled Condenser

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

Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

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

Manitowoc’s Patented Cleaning or Sanitizing Technology . . . . . . . . . . . . . . 3-5

Table of Contents (continued)

Part No. 80-1100-3

AlphaSan“ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Procedure To Cancel A Cleaning Or

Sanitizing Cycle After It Has Started . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Automatic Cleaning System (AuCS“) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8

Removal of Parts For Cleaning/Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9

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

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Filter Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-14

Removal from Service/Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

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

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

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

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

AuCS“ Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-15

Section 4 Ice Machine Sequence of Operation

Self-Contained Air- and Water-Cooled Q200/Q280/Q320/Q370/Q420/Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 . 4-1

Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . 4-1

Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2

Remote

Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . 4-3

Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3

Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4

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

Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

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

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

Section 6 Electrical System

Energized Parts Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

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

1. Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . 6-1

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

1. Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . 6-2

Wiring Diagram Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

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

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

Table of Contents (continued)

4 Part No. 80-1100-3

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

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

Q200/Q280/Q320 - Self Contained - 1 Phase With Terminal Board . . . . . . . 6-18

Q280/Q370 - Self Contained - 1 Phase Without Terminal Board . . . . . . . . . 6-19

Q320 - Self Contained - 1 Phase Without Terminal Board . . . . . . . . . . . . . . 6-20

Q420/Q450/Q600/Q800/Q1000 - Self Contained -

1 Phase With Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Q420/Q450/Q600/Q800/Q1000 - Self Contained -

1 Phase Without Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Q800/Q1000 - Self Contained - 3 Phase With Terminal Board . . . . . . . . . . . 6-23

Q800/Q1000 - Self Contained - 3 Phase Without Terminal Board . . . . . . . . 6-24

Q1300/Q1800 - Self Contained - 1 Phase With Terminal Board . . . . . . . . . . 6-25

Q1300/Q1600/Q1800 - Self Contained - 1 Phase Without Terminal Board . 6-26

Q1300/Q1800 - Self Contained - 3 Phase With Terminal Board . . . . . . . . . . 6-27

Q1300/Q1600/Q1800 - Self Contained - 3 Phase Without Terminal Board . 6-28

Q450/Q600/Q800/Q1000 - Remote - 1 Phase With Terminal Board . . . . . . 6-29

Q450/Q600/Q800/Q1000 - Remote - 1 Phase Without Ter minal Board . . . . 6-30

Q800/Q1000 -Remote - 3 Phase With Terminal Board . . . . . . . . . . . . . . . . . 6-31

Q800/Q1000 -Remote - 3 Phase Without Terminal Board . . . . . . . . . . . . . . 6-32

Q1300/Q1800 - Remote - 1 Phase With Terminal Board . . . . . . . . . . . . . . . 6-33

Q1300/Q1600/Q1800 - Remote - 1 Phase Without Terminal Board . . . . . . . 6-34

Q1300/Q1800 - Remote - 3 Phase With Terminal Board . . . . . . . . . . . . . . . 6-35

Q1300/Q1600/Q1800 - Remote - 3 Phase Without Terminal Board . . . . . . . 6-36

Component Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Compressor Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

PTCR Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

ICE/OFF/CLEAN Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

Control Board Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

Electronic Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Ice Thickness Probe (Harvest Initiation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

How The Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Harvest/Safety Limit Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Freeze Time Lock-In Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Maximum Freeze Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Diagnosing Ice Thickness Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

Water Level Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Water Level Probe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Freeze Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Harvest Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Diagnosing Freeze Cycle Potable Water Level Control Circuitry . . . . . . . . . 6-51

Diagnosing An Ice Machine That Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

Table of Contents (continued)

Part No. 80-1100-3

Section 7 Refrigeration System

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

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

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

Q1300/Q1600/Q1800 Refrigeration Tubing Schematics . . . . . . . . . . . . . . . 7-6

Operational Analysis (Diagnostics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

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

Analyzing Discharge Pressure

During Freeze or Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Analyzing Suction Pressure

During Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Single Expansion Valve Ice Machines Comparing Evaporator Inlet and

Outlet Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Harvest Valve Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Discharge Line Temperature Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

How to Use the Refrigeration System

Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Refrigeration System Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . 7-25

Harvest Pressure Regulating

(H.P.R.) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Headmaster Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Pressure Control Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . 7-31

Fan Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

High Pressure Cut-Out (HPCO) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts . . . . . . . . . 7-32

Q200 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Q280 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Q320 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Q370 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Q420/450 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Q450 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Q600 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Q800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

Q1000 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Q1300 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Q1600 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

Q1800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Table of Contents (continued)

6 Part No. 80-1100-3

Refrigerant Recovery/Evacuation and Recharging . . . . . . . . . . . . . . . . . . . . . 7-46

Normal Self-Contained Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

Normal Remote Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

System Contamination Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Replacing Pressure Controls Without

Removing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

Total System Refrigerant Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

Refrigerant Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

Refrigerant Re-Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

HFC Refrigerant Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

Part No. 80-1100-3 1-1

Section 1

General Information

Model Numbers

This manual covers the following models:

NOTE: Model numbers ending in 3 indicate a 3-phase unit. Example: QY1804A3

How to Read a Model Number

Ice Cube Sizes

Self-Contained

Air-Cooled

Self-Contained

Water-Cooled

Remote

QR0320A QD0322A QY0324A

QR0321W QD0323W QY0325W

QR0420A QD0422A QY0424A

QR0421W QD0423W QY0425W

QR0200A QD0202A QY0204A

QR0201W QD0203W QY0205W

QR0280A QD0282A QY0284A

QR0281W QD0283W QY0285W

QD0372A QY0374A

QD0373W QY0375W

QR0450A QD0452A QY0454A

QR0451W QD0453W QY0455W

QR0490N QD0492N QY0494N

QR0600A QD0602A QY0604A

QR0601W QD0603W QY0605W

QR0690N QD0692N QY0694N

QR0800A QD0802A QY0804A

QR0801W QD0803W QY0805W

QR0890N QD0892N QY0894N

QR1000A QD1002A QY1004A

QR1001W QD1003W QY1005W

QR1090N QD1092N QY1094N

QR1300A QD1302A QY1304A

QR1301W QD1303W QY1305W

QR1390N QD1392N QY1394N

QD1603W QY1605W

QD1692N QY1694N

QR1800A QD1802A QY1804A

QR1801W QD1803W QY1805W

QR1890N QD1892N QY1894N

Warning

PERSONAL INJURY POTENTIAL

Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications.

Regular

1-1/8" x 1-1/8" x 7/8"

2.86 x 2.86 x 2.22 cm

Dice

7/8" x 7/8" x 7/8"

2.22 x 2.22 x 2.22 cm

Half Dice

3/8" x 1-1/8" x 7/8"

0.95 x 2.86 x 2.22 cm

Q R 0450 A

ICE M A CHINE

MODEL

ICE CUBE SIZE R REG ULAR

D DICE Y HALF DICE

# C UB E SIZE 0 REG ULAR

1 R E G U L AR 2 DICE 3 DICE 4 H A LF-DICE 5 H A LF-DICE

CONDEN SER TY PE AIR-COOLED

W ATER-COOLED AIR-COOLED W ATER-COOLED AIR-COOLED W ATER-COOLED

A SELF-CON TAINED AIR-COOLED W SELF-CON TAINED W ATER-COOLED N REMO TE AIR-COOLED

9 REMO TE

AIR-COOLED

CONDEN SER TY PE

ICE M A CHINE

SERIES

General Information Section 1

1-2 Part No. 80-1100-3

Model/Serial Number Location

These numbers are required when requesting information from your local Manitowoc distributor, or Manitowoc Ice, Inc.

The model and serial number are listed on the MODEL/ SERIAL NUMBER DECAL affixed to the ice machine, remote condenser and storage bin.

Figure 1-1. Model/Serial Number Location

SV1600

Section 1 General Information

Part No. 80-1100-3 1-3

Warranty Coverage

GENERAL

The following Warranty outline is provided for your convenience. For a detailed explanation, re ad the warranty bond shipped with each product.

Contact your local Manitowoc Distributor 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.

2. Repairs due to unauthorized modifications to the ice machine or use of non-standard parts without prior written approval from Manitowoc Ice, Inc.

3. Damage caused by improper installation of the ice machine, electrical supply , water supply or drainage, or damage caused by floods, storms, or other acts of God.

4. Premium labor rates due to holidays, overtime, etc.; travel time; flat rate service call charges; mileage and miscellaneous tools and material charges not listed on the payment schedule. Additional labor charges resulting from the inaccessibility of equipment are also excluded.

5. Parts or assemblies subjected to misuse, abuse, neglect or accidents.

6. Damage or problems caused by installation, cleaning and/or maintenance procedures inconsistent with the technical instructions provided in this manual.

7. This product is intended exclusively for commercial application. No warranty is extended for personal, family, or household purposes.

AUTHORIZED WARRANTY SERVICE

To comply with the provisions of the warranty, a refrigeration service company qualified and authorized by a Manitowoc distributor, or a Contracted Service Representative must perform the warranty repair.

Important

This product is intended exclusively for commercial application. No warranty is extended for personal, family, or household purposes.

General Information Section 1

1-4 Part No. 80-1100-3

THIS PAGE INTENTIONALLY LEFT BLANK

Part No. 80-1100-3 2-1

Section 2

Installation Instructions

General

Refer to Installation Manual for complete installation guidelines.

Ice Machine Dimensions

Q320/Q370/Q420 ICE MACHINES

Important

Failure to follow these installation guidelines may affect warranty coverage.

SV1602 SV1611

WATER COOLED AIR COOLED

Ice Machine Dimension H

Q320 21.5 in (54.6 cm) Q370 21.5 in (54.6 cm) Q420 26.5 in (67.3 cm)

Installation Instructions Section 2

2-2 Part No. 80-1100-3

Q200 – Q1000 ICE MACHINES Q1300/Q1600/Q1800 ICE MACHINES

SV1612 SV1628

WATER-COOLED SELF CONTAINED

AIR-COOLED

Ice Machine Dimension H

Q200 – Q280 16.5 in (41.9 cm)

Q450 21.5 in (54.6 cm) Q600 21.5 in (54.6 cm) Q800 26.5 in (67.3 cm)

Q1000 29.5 in (74.9 cm)

SV1613

AIR-COOLED

Ice Machine Dimension H

Q1300/Q1600 29.5 in (74.9 cm)

Q1800 29.5 in (74.9 cm)

SV1627

SELF CONTAINED

WATER-COOLED

Section 2 Installation Instructions

Part No. 80-1100-3 2-3

Q1300/Q1600/Q1800 ICE MACHINES (CONT.)

Ice Storage Bin Dimensions

S170/S400/S570 ICE STORAGE BINS

S320/S420 ICE STORAGE BINS

SV1629

REMOTE AIR-COOLED

Bin Model Dimension A Dimension B

S170 29.5 in (74.9 cm) 19.1 in (48.5 cm) S400 34.0 in (86.3 cm) 32.0 in (81.3 cm) S570 34.0 in (86.3 cm) 44.0 in (111.7 cm)

Bin Model Dimension A Dimension B

S320 34.0 in (86.3 cm) 32.0 in (81.3 cm) S420 34.0 in (86.3 cm) 44.0 in (111.7 cm)

SV1609

SV1614

Installation Instructions Section 2

2-4 Part No. 80-1100-3

S970 ICE STORAGE BINS

Remote Condenser Dimensions

JC0495/JC0895/JC1095/JC1395

JC1895

Warning

All Manitowoc ice machines require the ice storage system (bin, dispenser, etc.) to incorporate an ice deflector.

The Q1300, Q1600 and Q1800 series ice machines require adding Manitowoc Ice Deflector Kit K 00139 when installing with non-Manitowoc ice storage systems.

Prior to using a non-Manitowoc ice storage system with other Manitowoc ice machines, contact the manufacturer to assure their ice deflector is compatible with Manitowoc ice machines.

SV1610 SV1297

SV1301

Section 2 Installation Instructions

Part No. 80-1100-3 2-5

Location of Ice Machine

The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location.

• The location must be free of airborne and other contaminants.

• The air temperature must be at least 35°F (1.6°C), but must not exceed 110°F (43.4°C).

• The location must not be near h eat-generating equipment or in direct sunlight.

• The location must not obstruct air flow through or around the ice machine. Refer to the chart below for clearance requirements.

Stacking Two Ice Machines on a Single Storage Bin

A stacking kit is required for stacking two ice machines. Installation instructions are supplied with the stacking kit.

Ice Machine 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 sizing air conditioning equipment where self-contained aircooled ice machines are installed.

This information is also necessary when evaluating the benefits of using water-cooled or remote condensers to reduce air conditioning loads. The amount of heat added to an air conditioned environment by an ice machine using a water-cooled or remote condenser is negligible.

Knowing the amount of heat rejected is also important when sizing a cooling tower for a water-cooled condenser. Use the peak figure for sizing the cooling tower.

Q1300/Q1600/

Q1800

Self-Contained

Air-Cooled

Water-Cooled

and Remote

Top/Sides 24" (61 cm) 8" (20.3 cm)

Back 12" (30.5 cm) 5" (12.7 cm)

Q370

Self-Contained

Air-Cooled

Water-Cooled

Top/Sides 12" (30.5 cm) 5" (12.7 cm)

Back 5" (127 mm) 5" (12.7 cm)

All other

Q models

Self-Contained

Air-Cooled

Water-Cooled

and Remote

Top/Sides 8" (20.3 cm) 8" (20.3 cm)

Back 5" (12.7 cm) 5" (12.7 cm)

There is no minimum clearance required. This value is

recommended for efficient operation and servicing only. Q1600 is not available as an air-cooled model.

Caution

The ice machine must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization” on Page 3-

14.

Q450/Q600/

Q800/Q1000

Stacked

Self-Contained

Air-Cooled

Stacked

Water-Cooled

and Remote*

Top/Sides 16" (40.64 cm) 5" (12.70 cm)

Back 5" (12.70 cm) 5" (12.70 cm)

Q1300/Q1600/

Q1800

Top/Sides 48" (121.92 cm) 24" (60.96 cm)

Back 12" (30.48 cm) 12" (30.48 cm)

*There is no minimum clearance required. This value is

recommended for efficient operation and servicing only. Q1600 is not available as an air-cooled model.

Series

Ice Machine

Heat of Rejection

B.T.U./Hour

Air Conditioning

Because the heat of rejection varies during the ice making cycle,

the figure shown is an average.

Peak

Q320 4,600 6,200 Q370 3,900 5,950 Q420 7,000 9,600 Q200 3,800 5,000 Q280 3,800 6,000 Q450 7,000 9,600 Q600 9,000 13,900

Q800 12,400 19,500 Q1000 16,000 24,700 Q1300 24,000 35,500 Q1600 24,000 35,500 Q1800 36,000 50,000

Installation Instructions Section 2

2-6 Part No. 80-1100-3

Leveling the Ice Storage Bin

1. Screw the leveling legs onto the bottom of the bin.

2. Screw the foot of each leg in as far as possible.

3. Move the bin into its final position.

4. Level the bin to assure that the bin door closes and seals properly. Use a level on top of the bin. Turn each foot as necessary to level the bin.

NOTE: An optional caster assembly is available for use in place of the legs. Installation instructions are supplied with the casters.

Figure 2-1. Leveling Leg and Foot

Air-Cooled Baffle

The air-cooled baffle prevents condenser air from recirculating. To install:

1. Remove the back panel screws next to the condenser.

2. Align the mounting holes in the air baffle with the screw holes and reinstall the screws.

Figure 2-2. Air Baffle

Caution

The legs must be screwed in tightly to prevent them from bending.

SV1606

THREAD LEVELING LEG INTO BASE OF

CABINET

THREAD ‘FOOT’ IN AS

FAR AS POSSIBLE

SV1607

AIR

BAFFLE

SCREWS

Section 2 Installation Instructions

Part No. 80-1100-3 2-7

Electrical Service

GENERAL

VOLTAGE

The maximum allowable voltage variation is ±1 0% of the rated voltage at ice machine start-up (wh en the electrical load is 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 (does not apply in Canada).

MINIMUM CIRCUIT AMPACITY

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

The wire size (or gauge) is also dependent upon location, materials used, length of run, etc., so it must be determined by a qualified electrician.

Warning

All wiring must conform to local, state and national codes.

Warning

The ice machine must be grounded in accordance with national and local electrical codes.

Installation Instructions Section 2

2-8 Part No. 80-1100-3

Table 2-1. Q320/370/420 Ice Machines

Table 2-2. Q200 - Q1000 Ice Machines

Ice Machine

Voltage

Phase

Cycle

Air-Cooled Water Cooled

Maximum Fuse/

Circuit Breaker

Minimum

Circuit Amps

Maximum Fuse/

Circuit Breaker

Minimum

Circuit Amps

Q320

115/1/60 15 11.2 15 10.5

208-230/1/60 15 4.8 15 4.2

230/1/50 15 5.2 15 4.7

Q370

115/1/60 20 12.9 20 12.2

208-230/1/60 15 6.2 15 5.8

230/1/50 15 6.2 15 5.8

Q420

115/1/60 20 12.3 20 11.4

208-230/1/60 15 7.8 15 7.4

230/1/50 15 6.3 15 5.9

Ice Machine

Voltage

Phase

Cycle

Air-Cooled Water Cooled Remote

Maximum

Fuse/Circuit

Breaker

Minimum

Circuit Amps

Maximum

Fuse/Circuit

Breaker

Minimum

Circuit Amps

Maximum

Fuse/Circuit

Breaker

Minimum

Circuit Amps

Q200

115/1/60 15 11.6 15 10.9 N/A N/A

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

230/1/50 15 5.2 15 4.9 N/A N/A

Q280

115/1/60 20 12.6 20 11.7 N/A N/A

208-230/1/60 15 5.7 15 5.2 N/A N/A

230/1/50 15 5.7 15 5.2 N/A N/A

Q450

115/1/60 20 12.8 20 11.9 20 13.6

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

230/1/50 15 6.1 15 5.7 N/A N/A

Q600

208-230/1/60 15 9.2 15 8.7 15 9.3

230/1/50 15 9.2 15 8.8 15 9.4

Q800

208-230/1/60 20 12.1 20 11.4 20 11.9 208-230/3/60 15 8.9 15 8.2 15 8.9

230/1/50 20 12.0 20 10.6 20 11.2

Q1000

208-230/1/60 20 14.3 20 13.2 20 14.2 208-230/3/60 15 9.8 15 8.8 15 9.9

230/1/50 20 15.6 20 14.2 20 14.6

Q1300

208-230/1/60 30 19.5 30 18.1 30 19.8 208-230/3/60 20 13.1 20 11.6 20 12.7

230/1/50 30 15.7 30 14.3 30 14.7

380-415/3/50 N/A N/A N/A N/A 15 7.3

Q1600

208-230/1/60 N/A N/A 30 17.2 30 18.2 208-230/3/60 N/A N/A 20 11.0 20 12.0

230/1/50 N/A N/A N/A N/A N/A N/A

380-415/3/50 N/A N/A N/A N/A N/A N/A

Q1800

208-230/1/60 40 28.1 40 26.7 40 26.9 208-230/3/60 20 15.5 20 14.1 20 13.9

230/1/50 40 23.3 40 21.9 40 22.2

380-415/3/50 N/A N/A N/A N/A 15 9.1

Section 2 Installation Instructions

Part No. 80-1100-3 2-9

Self-Contained Electrical Wiring Connections

SELF CONTAINED ICE MACHINE 115/1/60 OR 208-230/1/60

SELF CONTAINED ICE MACHINE 208-230/3/60

SELF CONTAINED ICE MACHINE 230/1/50

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.

Though wire nuts are shown in the drawings, the ice machine field wiring connections may use either wire nuts or screw terminals.

N=115V

L2=208-230V

GROUND

ICE MACHINE

CONNECTIONS

SV1258

GROUND

ICE MACHINE

CONNECTIONS

TO SEPARATE

FUSE/BREAKER

SV1190

GROUND

ICE MACHINE

CONNECTIONS

TO SEPARATE

FUSE/BREAKER.

DISCONNECT ALL

POLES.

SV1191

For United Kingdom Only

As the colours of the wires in the mains lead of the appliance may not correspond with the coloured markings identifying the terminals in your plug, proceed as follows:

• The wire which is colour ed green and yello w

must be connected to the terminal in the plug which is marked with

the letter E or by the earth ground symbol or coloured green or green and yellow.

• The wire coloured blue

must be connected to the terminal which is marked with the letter N or coloured black.

• The wire coloured brown

must be connected to the terminal which is marked with the letter L or coloured red.

TO SEPARATE

FUSE/BREAKER

Installation Instructions Section 2

2-10 Part No. 80-1100-3

Remote Electrical Wiring Connections

REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 115/1/60 OR 208-230/1/60

REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 208-230/3/60 OR 380-415/3/50

REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 230/1/50

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.

Though wire nuts are shown in the drawings, the ice machine field wiring connections may use either wire nuts or screw terminals.

NOTE: CONDENSER FAN MOTOR VOLTAGE MATCHES ICE MACHINE VOLTAGE (115V OR 208-230V)

GROUND

SINGLE CIRCUIT

REMOTE

CONDENSER

ICE

MACHINE

SV1255

GROUND

TO SEPARATE

FUSE/BREAKER

GROUND

N=115V OR L2=208-230V

GROUND

ICE

MACHINE

SV1199

GROUND

TO SEPARATE

FUSE/BREAKER

GROUND

NOTE: FAN MOTOR IS 208-230V

SINGLE CIRCUIT

REMOTE

CONDENSER

SINGLE CIRCUIT

REMOTE

CONDENSER

NOTE: FAN MOTOR IS 220-240V

ICE

MACHINE

GROUND

TO SEPARATE

FUSE/BREAKER

(220-240).

DISCONNECT ALL

POLES.

SV1256

Section 2 Installation Instructions

Part No. 80-1100-3 2-11

Water Supply and Drain Requirements

WATER SUPPLY

Local water conditions may require treatment of the water to inhibit scale formation, filter sediment, and remove chlorine odor and taste.

WATER INLET LINES

Follow these guidelines to install water inlet lines:

• Do not connect the ice machine to a hot water supply. Be sure all hot water restrictors installed for other equipment are working. (Check valves on sink faucets, dishwashers, etc.)

• If water pressure exceeds the maximum recommended pressure, obtain a water pressure regulator from your Manitowoc distributor.

• Install a water shut-off valve for both the ice making and condenser water lines.

• Insulate water inlet lines to prevent condensation.

DRAIN CONNECTIONS

Follow these guidelines when installing drain lines to prevent drain water from flowing back into the ice machine and storage bin:

• Drain lines must have a 1.5 inch drop per 5 feet of run (2.5 cm per meter), and must not create traps.

• The floor drain must be large enough to accommodate drainage from all drains.

• Run separate bin and ice machine drain lines. Insulate them to prevent condensation.

• Vent the bin and ice machine dr ain to the atmosphere. Do not vent the condenser drain on water-cooled models.

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, a nd 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 condense r must not exceed 5 gallons (19 liters) per minute.

• Allow for a pressure drop of 7 psi (48 kPA) between the condenser water inlet and the outlet of the ice machine.

• Water exiting the condenser must not exceed 110°F (43.3°C).

Important

If you are installing a Manitowoc water filter system, refer to the Installation Instructions supplied with the filter system for ice making water inlet connections.

Installation Instructions Section 2

2-12 Part No. 80-1100-3

WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS

Figure 2-3. Typical Water Supply Drain Installation

Caution

Plumbing must conform to state and local codes.

Location Water Temperature Water Pressure Ice Machine Fitting

Tubing Size Up to Ice

Machine Fitting

Ice Making Water Inlet

33°F (0.6°C) Min.

90°F (32.2°C) Max.

20 psi (137.9 kPA) Min.

80 psi (551.5 kPA) Max.

3/8" Female Pipe Thread

3/8" (9.5 mm) minimum

inside diameter

Ice Making

Water Drain

--- ---

1/2" Female Pipe Thread

1/2" (12.7 mm) minimum

inside diameter

Condenser Water Inlet

33°F (0.6°C) Min.

90°F (32.2°C) Max.

20 psi (137.9 kPA) Min.

150 psi (1034.2 kPA) Max.

Q1300/Q1600/Q1800 - 1/2" Female Pipe Thread

All Others - 3/8" Female Pipe Thread

Condenser

Water Drain

--- ---

1/2" Female Pipe Thread

1/2" (12.7 mm) minimum

inside diameter

Bin Drain --- ---

3/4" Female Pipe Thread

3/4" (19.1 mm) minimum

inside diameter

SV1626

Section 2 Installation Instructions

Part No. 80-1100-3 2-13

Remote Condenser/Line Set Installation

REMOTE ICE MACHINES REFRIGERANT CHARGE

Each remote ice machine ships from the factory with a refrigerant charge appropriate for installation with line sets of up to 50' (15.25 m). The serial tag on the ice machine indicates the refrigerant charge.

Additional refrigerant may be required for installations using line sets between 50' and 100' (15.25-30.5 m) long. If additional refrigerant is required, an additional label located next to the Model/Serial Numbers decal states the amount of refrigerant to be added.

Figure 2-4. Typical Additional Refrigerant Label

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

Ice Machine

Remote Single

Circuit

Condenser

Line Set*

Q490 JC0495 RT-20-R404A

RT-35-R404A RT-50-R404A

Q690 JC0895

Q890 Q1090 JC1095 Q1390 JC1395 RL-20-R404A

RL-35-R404A RL-50-R404A

Q1690 JC1695 Q1890 JC1895

*Line Set Discharge Line Liquid Line

RT 1/2" (1.27 cm) 5/16" (.79 cm) RL 1/2" (1.27 cm) 3/8" (.95 cm)

Air Temperature Around the Condenser

Minimum Maximum

-20°F (-28.9°C) 120°F (49°C)

IMPORTANT

EPA CERTIFIED TECHNICIANS

If remote line set length is 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: ___________________

WARNING

Potential Personal Injury Situation

The ice machine contains refrigerant charge. Installation of the line sets must be performed by a properly trained and EPA certified refrigeration technician aware of the dangers

of dealing with refrigerant charged equipment.

Ice Machine

Nameplate Charge

(Charge Shipped in Ice Machine)

Refrigerant to be Added for

50'-100' Line Sets

Maximum System Charge

(Never Exceed) Q490 6 lb. (96 oz.) None 6 lb. (96 oz.) Q690 8 lb. (128 oz.) None 8 lb. (128 oz.) Q890 8 lb. (128 oz.) None 8 lb. (128 oz.)

Q1090 9.5 lb. (152 oz.) None 9.5 lb. (152 oz.) Q1390 12.5 lb. (200 oz.) 1.5 lb. (24 oz) 14 lb. (224 oz.) Q1690 15 lb. (240 oz.) 2.0 lb. (32 oz) 17 lb. (272 oz.) Q1890 15 lb. (240 oz.) 2.0 lb. (32 oz) 17 lb. (272 oz.)

Installation Instructions Section 2

2-14 Part No. 80-1100-3

GENERAL

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

Remote condenser installations consist of vertical and horizontal line sets between the ice machine and the condenser. When combin ed, they must fit within approved specifications. The following guidelines, drawings and calculation methods must be followed to verify a proper remote condenser installation.

GUIDELINES FOR ROUTING LINE SETS

First, cut a 2.5" (6.35 cm) circular hole in the wall or ro of for tubing routing. The line set end with the 90° bend will connect to the ice machine. The straight end will connect to the remote condenser.

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

1. Optional - Make the service loop in the line sets (See Figure 2-5). This permits easy access to the ice machine for cleaning and service. Do not use hard rigid copper at this location.

2. Required - Do not form traps in the refrigeration lines (except the service loop). Refrigerant oil must be free to drain toward the ice machine or the condenser. Route excess tubing in a supported downward horizontal spiral (See Figure 2-5). Do not coil tubing vertically.

3. Required - Keep outdoor refrigerant line runs as short as possible.

Figure 2-5. Routing Line Sets

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.

DOWNWARD

HORIZONTAL

SPIRAL

SV1204

Section 2 Installation Instructions

Part No. 80-1100-3 2-15

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 120°F (49°C), with line set lengths of up to 100' (30.5 m).

Line Set Rise/Drop

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

Calculated Line Set Distance

The maximum distance is 150' (45.7 m). Line set rises, drops, horizontal runs (o r 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.

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.)

3. Insert the measured horizontal distance into the formula below. No calculation is necessary.

4. Add together the calculated rise, calculated drop, and horizontal d istance to get the tot al calc ulated distance. If this total exceeds 150' (45.7 m), move the condenser to a new location and perform the calculations again.

Maximum Line Set Distance Formula

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.

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

Figure 2-6. Combination of a Rise

and a Horizontal Run

Figure 2-7. Combination of a Drop

and a Horizontal Run

Figure 2-8. Combination of a

Rise, a Drop and a Horizontal Run

SV1196 SV1195 SV1194

Installation Instructions Section 2

2-16 Part No. 80-1100-3

LENGTHENING OR REDUCING LINE SET LENGTHS

In most cases, by routing the line set properly, shortening will not be necessary. When shortening or lengthening is required, do so before connecting the line set to the ice machine or the remote condenser. This prevents the loss of refrigerant in the ice machine or condenser.

The quick connect fittings on the line sets are equipped with Schraeder valves. Use these valves to recover any vapor charge from the line set. When lengthening or shortening lines, follow good refrigeration practices and insulate new tubing. Do not change the tube sizes. Evacuate the lines and place about 5 oz (143g) of vapor refrigerant charge in each line.

CONNECTING A LINE SET

1. Remove the dust caps from the line set, condenser and ice machine.

2. Apply refrigeration oil to the threads on the quick disconnect couplers before connecting them to the condenser.

3. Carefully thread the female fitting to the condenser or ice machine by hand.

4. Tighten the coup lings with a wrench until they bottom out.

5. Turn an additional 1/4 turn to ensure proper brassto-brass seating. Torque to the following specifications:

6. Check all fittings for leaks.

REMOTE RECEIVER SERVICE VALVE

The receiver service valve is closed during shipment. Open the valve prior to starting the ice machine.

1. Remove the top and left side panels.

2. Remove the receiver service valve cap.

3. Backseat (open) the valve.

4. Reinstall the cap and panels.

Figure 2-9. Backseating the Receiver Service Valve

Liquid Line Discharge Line

10-12 ft lb.

(13.5-16.2 N•m)

35-45 ft lb.

(47.5-61.0 N•m)

SV1603

REMOVE FRONT, TOP, AND LEFT SIDE PANEL FOR ACCESS TO RECEIVER VALVE

TURN COUNTERCLOCKWISE TO OPEN

RECEIVER SERVICE VALVE CAP (TURN COUNTERCLOCKWISE TO REMOVE)

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