Manitowoc RF0388, RF0399, RF0385, RF0244A, RNS0308 Technician's Handbook

...
R Model
Flake & Nugget Ice Machine
Technician’s Handbook
Part Number 000007661 11/16
Safety Notices
As you work on Manitowoc equipment, be sure to pay close attention to the safety notices in this handbook. Disregarding the notices may lead to serious injury and/ or damage to the equipment.
Throughout this handbook, you will see the following types of safety notices:
Warning
n
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 equipment. Be sure to read the Caution statement before proceeding, and work carefully.

Procedural Notices

As you work on Manitowoc equipment, be sure to read the procedural notices in this handbook. These notices supply helpful information which may assist you as you work.
Throughout this handbook, 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.
Read These Before Proceeding:
Caution
,
Proper installation, care and maintenance are essential for maximum performance and trouble-free operation of your equipment. Visit our website www. manitowocfsg.com for manual updates, translations, or contact information for service agents in your area.
Important
Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty.
Warning
n
Read this manual thoroughly before operating, installing or performing maintenance on the equipment. Failure to follow instructions in this manual can cause property damage, injury or death.
Warning
n
Do not use electrical appliances or accessories other than those supplied by Manitowoc for your ice machine model.
Warning
n
Two or more people or a lifting device are required to lift this appliance.
Warning
n
This equipment contains high voltage electricity and refrigerant charge. Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.The technician must also be certified in proper refrigerant handling and servicing procedures. All lockout and tag out procedures must be followed when working on this equipment.
Warning
n
Do not damage the refrigeration circuit when installing, maintaining or servicing the unit.
Warning
n
Do not operate equipment that has been misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision concerning use of the appliance by a person responsible for their safety. Do not allow children to play with this appliance.
Warning
n
All covers and access panels must be in place and properly secured, before operating this equipment.
Warning
n
Do not obstruct machine vents or openings.
Warning
n
Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
Warning
n
Do not clean with water jet.
Warning
n
It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.
Warning
n
Two or more people are required to move this equipment to prevent tipping.
Warning
n
When using electric appliances, basic precautions must always be followed, including the following:
a. Read all the instructions before using the
appliance.
b. To reduce the risk of injury, close supervision
is necessary when an appliance is used near
children. c. Do not contact moving parts. d. Only use attachments recommended or sold
by the manufacturer. e. Do not use outdoors. f. For a cord-connected appliance, the
following must be included:
• Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.
• Unplug from outlet when not in use and before servicing or cleaning.
• Do not operate any appliance with a damaged cord or plug, or after the appliance malfunctions or is dropped or damaged in any manner. Contact the nearest authorized service facility for examination, repair, or electrical or mechanical adjustment.
g. Follow applicable lock out tag out procedures
before working on equipment.
h. Connect to a properly grounded outlet only.
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Table of Contents
Safety Notices ....................................2
Procedural Notices ...............................2
General Information
Model Numbers ................................ 15
Self Contained................................ 15
Air & Water-Cooled Models ................... 15
Nugget Models............................... 16
QuietQube Models with Remote Condensing
Units .........................................16
Rack Units.................................... 17
Model/Serial Number........................... 17
Manitowoc Cleaner and Sanitizer ..............17
Ice Machine Warranty Information ............. 17
Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . . . 18
Installation
Installation Requirements...................... 21
Potable Water Requirements . . . . . . . . . . . . . . . . . . . 22
Drain Connections.............................. 22
Ice Machine Clearance Requirements ..........23
Cooling Tower Applications .................... 24
Electrical Service ............................... 25
Voltage ......................................25
Fuse/Circuit Breaker ..........................25
Ground Fault Interrupter Circuit (GFIC) ........ 25
Maintenance
Cleaning and Sanitizing ........................ 27
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
RF/RFS/RNS Models Cleaning/Sanitizing
Procedures ...................................27
Parts removal for Cleaning/Sanitizing .........32
Ice Chute Removal - RFS & RNS Models ........33
Ice Chute Removal - RF Models................ 34
Ice Chute Switch Actuator Removal ...........35
Cleaning sanitizing Procedure RN0400 ........36
Cleaning the Air filter and Condenser .........39
Removal from Service/Winterization........... 40
Part Number 000007661 11/16 9
Sequence of Operation
Ice Making Sequence of Operation .............41
RF0244/RNS0244/RF0266/RF0385/RFS0385/
RNS0385/RF0388/RF0399 ..................... 41
RF0300....................................... 42
RFS0300/RNS0308 ............................ 43
RF0644/RF0650/RF1200/RFS1200/RF2300/
RFS2300...................................... 44
RF1200C/RF2300C............................ 45
RF1200C/RF2300C............................ 46
RN0400 ...................................... 47
RN1000/RN1400.............................. 54
RN1000C/RN1200C ...........................57
Thermostat Settings............................ 61
Troubleshooting
RF0244/ RNS0244/RF0266/RF0385/RFS0385/
RF0388/RF0399/RNS0385 Troubleshooting ....63
Self-Contained Air-Cooled .................... 63
RF0300 Troubleshooting .......................69
Self-Contained Air-Cooled .................... 69
RFS0300/RNS0300 Troubleshooting ...........75
Self-Contained Air-Cooled .................... 75
RF0644/RF0650/RNS0600/RNS1000/RF1200
RFS1200 Troubleshooting ......................81
Self-Contained Air-Cooled .................... 81
Rotation Sensor Operation.................... 81
RNS1000/RF1200C/RFS1200C Troubleshooting 87
QuietQube Remote Air-cooled Models with
Remote Condensing Unit ..................... 87
RF1200R/RFS1200R Troubleshooting ..........94
Head Section For Rack Refrigeration Systems ..94
Rotation Sensor Operation.................... 94
10 Part Number 000007661 11/16
RF2300/RFS2300 Troubleshooting ............101
Self-Contained Air-Cooled ...................101
Rotation Sensor Operation...................101
RF2300C/RFS2300C Troubleshooting .........108
QuietQube Remote Air-cooled Models with
Remote Condensing Unit ....................108
RF2300R/RFS2300R Troubleshooting .........116
Head Section For Rack Refrigeration systems . 116
Rotation Sensor Operation...................116
RN0400 Troubleshooting......................124
Over-Torque Failure..........................124
Water Loss Failure ...........................127
RN1000/RN1400 Troubleshooting.............133
Indicator Light Operation ....................133
Control Board Errors .........................137
RN1000C/RN1200C Troubleshooting..........147
Indicator Light Operation ....................147
Control Board Errors .........................151
Refrigeration Troubleshooting ................163
Capillary Tube Models .......................163
Thermostatic Expansion Valve Models ........164
Component Specifications
Bin Thermostat ..............................165
Low Temperature Thermostat
Evaporator safety thermostat)................165
High Pressure Cutout (HPCO) Control.........166
Rotation Sensor .............................167
Low Pressure Cutout (LPCO) Control..........167
Fan Cycle Control ............................168
Total System Refrigerant Charge .............169
Filter-Driers..................................171
Suction Cleanup Filter-Drier..................171
Part Number 000007661 11/16 11
Charts
Total System Refrigerant Charge ..............173
Ice Production & Refrigerant Pressure.........173
RF Flake Models ...............................174
RF0244A ....................................174
RF0266A ....................................175
RF0300A ....................................176
RF0385A ....................................177
RF0388A ....................................178
RF0399A ....................................179
RF0644A ....................................180
RF0650A ....................................181
RF0650W....................................182
RF1200A ....................................183
RF1200W....................................184
RF1278C With RCU1075......................185
RF2300A ....................................186
RF2300W....................................187
RF2378C with RCU2375......................188
RFS Flake Models ..............................189
RFS0244A ...................................189
RFS0300A ...................................190
RFS0650A ...................................191
RFS0650W...................................192
RFS1200A ...................................193
RFS1200W...................................194
RFS1278C With RCU1075 ....................195
RFS2300A ...................................196
RFS2300W...................................197
RFS2378C with RCU2375.....................198
RN Nugget Models ............................199
RN0408A ....................................199
RN1008A ....................................200
RN1009W ...................................201
RN1408A ....................................202
RN1409W ...................................203
RN1078C With RCU1075 .....................204
RN1278C With RCU1275 .....................205
12 Part Number 000007661 11/16
RNS Nugget Models ...........................206
RNS0244A...................................206
RNS0308A...................................207
RNS0385A...................................208
RNS0608A...................................209
RNS0609W ..................................210
RNS1000A...................................211
RNS1009W ..................................212
RNS1078C With RCU1098 ....................213
Rack Models ...................................214
RF1279R ....................................214
RFS1279R ...................................215
RF2379R ....................................216
RFS2379R ...................................217
Diagrams
Wiring Diagrams...............................219
Flake Models ..................................220
RF0244/RF0266/RF0385/RF0388/RF0399 Air-
Cooled ......................................220
RF0300 Air-Cooled...........................222
RFS0300 Air-Cooled .........................224
RF0650/RF1200 Air-Cooled ..................226
RFS1200A Air-Cooled ........................228
RF1200 Water-Cooled........................230
RFS1200W Water-Cooled ....................232
RF1200C/RFS1200C QuietQube Head Section 234 RF2300/RFS2300 Air-Cooled & Water-cooled..236 RF2378C/RFS2378C QuietQube Head Section 238
Condensing Units .............................240
RCU Condensing Unit 1ph ...................240
RCU Condensing Unit 3ph ...................241
Part Number 000007661 11/16 13
Rack Models ...................................242
RF1279R/RFS1279R Head Section ............242
RF2379R/RFS2379R Head Section ............244
Nugget Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 246
RNS0244/RNS0385 Air-Cooled ...............246
RNS0308 Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . . 248
RN0400 115v/60hz/1ph......................250
RN0400 230v/60hz/1ph......................251
RNS0600A Air-Cooled........................252
RNS0600W Water-Cooled ....................254
RNS1000 Air-Cooled . . . . . . . . . . . . . . . . . . . . . . . . . 256
RNS1009 Water-cooled ......................258
RNS1078C...................................260
RN1000/RN1400 Air & Water Cooled..........262
RN1000C/RN1200C QuietQube Head Section. 263
Refrigeration Tubing Schematics ..............264
Flake Models ..................................264
RF0244/RFS0244/RF0266/RF0300/RF0385/
RF0388/RF0399/RF0644/RF0650 .............264
RF1200/RFS1200 Air-cooled..................265
RF1200/RFS1200 Water-cooled...............266
RF2300/RFS2300 Air-cooled..................268
RF2300/RFS2300 Water-cooled...............270
RF1200C/RFS1200C QuietQube Head Section &
RCU1075 Condensing Unit...................272
RF2300C/RFS2300 QuietQube Head Section &
RCU2375 Condensing Unit...................274
Nugget Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
RN0244/RNS0244/RN0385/RNS0385 .........276
RNS0308 ....................................277
RN0400/RN1000/RN1400 Air & Water-cooled . 278 RN1000C/RN1200C QuietQube Head Section &
RCU1075/RCU1275 Condensing Unit.........280
14 Part Number 000007661 11/16

General Information

Model Numbers

SELF CONTAINED

AIR & WATERCOOLED MODELS
Flake Models
Self Storage
Air-Cooled
RF0244A
RF0266A
RF0385A
RF0388A
RF0399A
RF0300A
RFS0300A
RF0644A
RF0650A RF0650W
RFS0650A RFS0650W
RF1200A RF1200W
RFS1200A RFS1200W
RF2300A RF2300W
Self Storage
Water-
Cooled
Modular Air-
Cooled
Modular
Water-
Cooled
Part Number 000007661 11/16 15

NUGGET MODELS

Self Storage
Air-Cooled
RNS0244A
-- RNS0308A
RNS0385A
RN0408A
RNS1008A
RN1008A RN1009W
RN1408A RN1409W
Self Storage
Water-
Cooled
Modular Air-
Cooled
Modular
Water-
Cooled

QUIETQUBE MODELS WITH REMOTE CONDENSING UNITS

Flake Models
QuietQube Head RCU Remote Condensing
Unit
RF1278C RCU1075
RFS1278C RCU1075
RF2378C RCU2375
RFS2378C RCU2375
Nugget Models
QuietQube Head RCU Remote Condensing
Unit
RN1078C RCU1075
RN1278C RCU1275
16 Part Number 000007661 11/16

RACK UNITS

Flake Models
Head Section Rack Remote Condensing
Unit
RF1279R Supplied by Others
RFS1279R Supplied by Others
RF2379R Supplied by Others
RFS2379R Supplied by Others
NOTE: Rack units share a common refrigeration circuit with other equipment, such as display cases and glass door freezer displays. Rack units have been modified to function with rack systems and will not function correctly with RCU condensing units.

Model/Serial Number

These numbers are required when requesting information from your local Manitowoc Distributor, or Manitowoc Ice. The model and serial number are listed on the MODEL/SERIAL NUMBER DECAL affixed to the ice machine.

Manitowoc Cleaner and Sanitizer

Manitowoc Ice Machine Cleaner and Sanitizer are available in 16 oz. (473 ml) bottles. These are the only cleaner and sanitizer approved for use with Manitowoc products.
Cleaner Part Number Sanitizer Part Number
16 oz. 000000084 16 oz. 9405653
1 gal N/A 1 gal. 9405813

Ice Machine Warranty Information

Warranty information for all ice machine models is available on our website at www.manitowocice.com.
Part Number 000007661 11/16 17

Ice Machine Heat of Rejection

Series Ice
Machine
RF Flake Models
RF0244A 2400 5000
RF0266A 2400 5000
RF0300A 2400 2400
RF0385A 3500 5200
RF0388A 3500 5200
RF0399A 3500 5200
RF0644A 7700 10250
RF0650A 5200 7700
RF0650W 5200 7700
RF1200A 7500 14000
RF1200W 7500 14000
RF1200C 7500 1400
RF2300A 15700 29500
RF2300W 15700 29500
RF2300C 15700 29500
RFS Flake Models
RFS0300A 2400 5000
RFS0650A 5200 7700
RFS0650W 5200 7700
RFS1200A 7500 14000
RFS1200W 7500 14000
RFS1200C 7500 14000
RFS2300C 15700 19500
Air Conditioning* Peak
Heat of Rejection
18 Part Number 000007661 11/16
Ice Machine Heat of Rejection
Series Ice
Machine
RN Nugget Models
RN0408A 3800 5400
RN1008A 11300 12800
RN1009W 11300 12800
RN1078C 11300 12800
RN1278C 7500 14000
RN1408A 16000 16400
RN1409W 16000 16400
RNS Nugget Models
RNS0244A 2400 5000
RNS0308A 3075 4100
RNS0385 3500 4600
RNS0608A 5200 7700
RNS0609W 5200 7700
RNS1008A 7500 10900
RNS1009W 7500 10900
RNS1078C 7500 14000
Air Conditioning* Peak
Heat of Rejection
*BTU/Hour
NOTE: Because the heat of rejection varies during the ice making cycle, the figure shown is an average.
Part Number 000007661 11/16 19
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20 Part Number 000007661 11/16

Installation

Installation Requirements

The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location.
• Air temperature:
• RF or RFS Flake Models - Minimum 50°F (10°C), Maximum 110°F (43°C)
• RN Nugget Models - Minimum 50°F (10°C), Maximum 100°F (38°C)
• RNS Nugget Models - Minimum 45°F (7°C), Maximum 110°F (43°C)
• The location must be free of airborne and other contaminants.
• The location must not be near heat-generating equipment or in direct sunlight.
• The location must be capable of supporting the weight of the ice machine and a full bin of ice.
• The location must allow enough clearance for water, drain and electrical connections in the rear of the ice machine.
• The location must not obstruct airflow through or around the ice machine.
• The ice machine and bin must be level.
• Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.
Part Number 000007661 11/16 21

Potable Water Requirements

• Plumbing must conform to local codes.
• Water temperature: Minimum 40°F (4°C), Maximum 90°F (32°C).
• 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 maximum pressure (70 psig [483 kPa] RN1000; 80 psig [552 kPa] for all other models) obtain a water pressure regulator from your Manitowoc distributor.
• A water shut-off valve is required to clean the ice machine.
• A union for both the ice making and condenser water lines is required.
• Water inlet lines require insulation to prevent condensation.
• RF/RFS/RFN Models: A back flow preventer is required on water inlet lines.

Drain Connections

• 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.
• Bin drain termination must have an air gap.
• Separate insulated bin and water-cooled condenser drain lines are required.
• The bin and ice machine drains require a vent.
22 Part Number 000007661 11/16

Ice Machine Clearance Requirements

Head
Sections
Back 5” (12.7 cm) 5” (12.7 cm) 5” (12.7 cm)
Sides/Top 8” (20.3 cm) 8” (20.3 cm) 8” (20.3 cm)
RCU Units Remote Condensing Unit*
Front/Back 24” (61.0 cm)
Sides/Top 6” (15.2 cm)*
Self­Contained Air-Cooled
Self-
Contained
Water-
Cooled*
QuietQube Air-Cooled
NOTE: Allowance must be made for removal when the ice machine is built-in. Monthly removal of the top panel is required for cleaning and sanitizing.
Part Number 000007661 11/16 23

Cooling Tower Applications

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 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 be lower than 37°F (3°C) or exceed 90°F (32°C).
• Water flow through the condenser must not exceed 5 gal. (19 L) 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°C).
24 Part Number 000007661 11/16

Electrical Service

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

VOLTAGE

The maximum allowable voltage variation is ± 10% of the rated voltage on the ice machine model/serial number plate at compressor start-up.

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

GROUND FAULT INTERRUPTER CIRCUIT (GFIC)

A GFCI/GFI circuit protection is not recommended with our equipment. If a GFCI/GFI is required by code a GFCI/ GFI breaker rather than outlet must be used to avoid intermittent nuisance trips.
Part Number 000007661 11/16 25
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26 Part Number 000007661 11/16

Maintenance

Cleaning and Sanitizing

Maintenance procedures covered in this manual are not covered by the warranty.
Caution
,
Use only Manitowoc approved Ice Machine Cleaner (part number 000000084) and Sanitizer (part number
9405653). 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. Read and understand all labels printed on bottles before use.
Warning
n
Wear rubber gloves and safety goggles (and/or face shield) when handling ice machine Cleaner or Sanitizer.

EXTERIOR CLEANING

Remove dust and dirt off exterior surfaces with mild household dish-washing detergent and warm water. Wipe dry with a clean, soft cloth.

RF/RFS/RNS MODELS CLEANING/SANITIZING PROCEDURES

Cleaning/Sanitizing Procedure
This procedure must be performed once every month.
• All ice must be removed from the bin
• The ice machine and bin must be disassembled cleaned and sanitized
• The ice machine produces ice with the cleaner and sanitizer solutions
• All ice produced during the cleaning and sanitizing procedure must be discarded
Part Number 000007661 11/16 27
Procedure to Clean/Sanitize
Use Ice Machine Cleaner part number 000000084.
Use Ice Machine Sanitizer part number 9405653.
Step 1 Remove front and top covers and set the toggle switch to the OFF position.
Step 2 Remove all ice from the bin.
Step 3 Turn off the ice making water supply and drain
water from evaporator and reservoir.
Step 4 Remove the top cover from water reservoir.
Step 5 Follow the chart and premix cleaner and water.
Amount of Water Amount of Cleaner
Part Number 000000084
1 gallon (4 Liters) 3 ounces (90 ml)
Step 6 Fill the evaporator and reservoir with cleaning solution.
Prop Float Up to Prevent Low
Water Level Shutdown
28 Part Number 000007661 11/16
Step 7 Move the toggle switch to the ON position. The ice machine will make ice with the cleaning solution and deposit the ice in the bin. Add the remaining cleaner/ water solution as the water level in the reservoir drops.
NOTE: Do not allow the cleaner/water level to drop below the minimum water level. The ice machine will discontinue the cleaning cycle if the water float switch opens.
Step 8 After all of the cleaner/water solution has been added turn on the ice making water supply. Continue the freeze cycle for 10 minutes to remove the cleaning solution from the water circuit.
Step 9 Place the toggle switch in the OFF position.
Step 10 Refer to disassembly for cleaning/sanitizing
and remove parts for hand cleaning/sanitizing.
• Hand clean all parts
• Rinse all parts with clear potable water
• Sanitize all parts - do not rinse after sanitizing
• Spray all interior bin surfaces with sanitizer (do not rinse sanitized areas).
• Spray evaporator discharge spout
Step 11 Reassemble ice machine.
Step 12 Turn off the ice making water supply.
Part Number 000007661 11/16 29
Step 13 Refer to chart and premix water and sanitizer.
Amount of Water Amount of Sanitizer
1 Gallons (4 L) Water 1/2 ounce (15 ml)
Step 14 Fill the evaporator and reservoir with sanitizer/ water solution.
Step 15 Move the toggle switch to the ON position. The ice machine will make ice with the sanitizer/water solution and deposit the ice in the bin. Add the remaining sanitizer/water solution when the water level in the reservoir drops.
NOTE: Do not allow the sanitizer/water level to drop below the minimum water level. The ice machine will discontinue the cleaning cycle if the water float switch opens.
Step 16 After all of the sanitizer/water solution has been added to the reservoir, turn on the ice making water supply.
Step 17 Continue the freeze cycle for 30 minutes and then discard all ice produced.
Heavily Scaled Cleaning Procedure
Perform this procedure if you have some or all of these symptoms.
• Excessive grinding, popping or squealing noises from the evaporator
• Grinding noise from gearbox
• Ice machine trips speed sensor
NOTE: A Cleaning/Sanitizing Procedure must be performed after this procedure.
Procedure to Clean Heavily Scaled Flake Ice Machines
Step 1 Remove front and top covers and set the
toggle switch to the OFF position.
Step 2 Remove all ice from the bin.
30 Part Number 000007661 11/16
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