Manitowoc SD0302A, SY0324A, SY0304A, SY0325W, SY0424A Technician's Handbook

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America’s #1 Selling Ice Machine

S Model

Ice Machines

Part Number 80-1479-3 7/10

Manitowoc

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:

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:

Warning

Text in a Warning b ox alerts yo u to a p otential personal injury si tuation. Be su re to read the Warning statement before proceeding, a nd work carefully.

Caution

Text in a Caution box alerts you to a si tuation in which you could damage the equipment. Be sure to read the Caution statement before proceeding, and work carefully.

Important

Text in an Impo rtant b ox provid es you wi th information t hat ma y h elp yo u perform a procedure more ef ficiently. Di sregarding thi s 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 i nstallation, ca re and ma intenance are essential for maximum performance and troublefree op eration of you r Manitowo c eq uipment. If you en counter prob lems not covered by this handbook, do no t procee d, contact Ma nitowoc Foodservice. We wi ll b e happy to p rovide assistance.

Important

Routine ad justments and main tenance procedures outlin ed in thi s handbook are not covered by the warranty.

! Warning

PERSONAL INJURY POTENTIAL

Do n ot ope rate eq uipment that has b een misused, ab used, ne glected, d amaged, o r altered/modified from that of origi nal manufactured specifications.

We reserve the right to make product

improvements at any time. Specifications and

design are subject to change without notice.

Part Number 80-1479-3 7/10 5

Table of Contents

General Information

Model Numbers . . . . . . . . . . . . . . . . . . . . . 9

How to Read a Model Number . . . . . . 10

Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . 10

Model/Serial Number Location . . . . . . . . 11

Energy Efficient Ice Machine

Serial Breaks . . . . . . . . . . . . . . . . . . . . . . . 12

Ice Machine Warranty Information . . . . . 13

Owner Warranty Registration Card . . . 13

Commercial Warranty Coverage . . . . . 14

Residential Ice Machine Warranty . . . . 16

Installation

Location of Ice Machine . . . . . . . . . . . . . . 21

Ice Machine Clearance Requirements . . 22

Ice Machine Heat of Rejection . . . . . . . . . 23

Remote Condenser Line Set Installation

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

Calculating Remote Condenser

Installation Distances . . . . . . . . . . . . . 25

Lengthening or Reducing Line Sets . . 27

Connecting A Line Set . . . . . . . . . . . . 28

Component Identification

S Model Single Evaporator Models . . . . . 29

S Model Quad Evaporator Models . . . . . 30

Maintenance

General . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Cleaning / Sanitizing Procedure . . . . . . . 32

Cleaning Procedure . . . . . . . . . . . . . . 32

Parts Removal for Cleaning/Sanitizing 34

Procedure to Clean Heavily Scaled

Ice Machines . . . . . . . . . . . . . . . . . . . . . . . 40

General . . . . . . . . . . . . . . . . . . . . . . . . 40

Cleaning Procedure . . . . . . . . . . . . . . 40

Parts Removal for Cleaning/Sanitizing 43

6 Part Number 80-1479-3 7/10

Removal from Service/Winterization . . . 57

Self-Contained Air-Cooled Ice Machines 57

Water-Cooled Ice Machines . . . . . . . . 58

Remote Ice Machines . . . . . . . . . . . . . 58

Sequence of Operation

Self Contained Air or Water Cooled . . . . 59

Single & Quad Evaporator Models . . . 59

Safety Timers . . . . . . . . . . . . . . . . . . . . . . 64

Safety Limits . . . . . . . . . . . . . . . . . . . . . . 65

Remotes . . . . . . . . . . . . . . . . . . . . . . . 72

Troubleshooting

Safety Limits . . . . . . . . . . . . . . . . . . . . . . 81

Quad Evaporator Machines Only . . . . 82

Analyzing Why a Safety Limit Stopped the

Ice Machine . . . . . . . . . . . . . . . . . . . . 84

Safety Limit #1 . . . . . . . . . . . . . . . . . . 85

Safety Limit #2 . . . . . . . . . . . . . . . . . . 86

Safety Limit #3 . . . . . . . . . . . . . . . . . . 87

Control Board Testing . . . . . . . . . . . . . . . 88

Control Board Test Cycle . . . . . . . . . . 88

Troubleshooting By Symptom . . . . . . . . 89

Symptom #1 Ice Machine will not run . 90 Compressor Electrical Diagnostics . . . 92 Symptom #2 Low Productionand/or Long

Freeze Cycle . . . . . . . . . . . . . . . . . . . . 94

Symptom #2 - Freeze Cycle Refrigeration System Operational Analysis Tables . 96 Freeze Cycle Refrigeration System Opera-

tional Analysis Table Procedures . . . . 105

Harvest Problems . . . . . . . . . . . . . . . . . . 126

Symptom #3 Ice Will Not Harvest, Cubes

Are Not Melted . . . . . . . . . . . . . . . . . . 127

Symptom #3 - Traditional Remotes Only

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Symptom #4 Will Not Harvest, Cubes Are

Melted . . . . . . . . . . . . . . . . . . . . . . . . . 131

Part Number 80-1479-3 7/10 7

Component Check Procedures

Electrical Components . . . . . . . . . . . . . . . 135

Main Fuse . . . . . . . . . . . . . . . . . . . . . . 135

ICE/OFF/CLEAN Toggle Switch . . . . . 136

Bin Switch . . . . . . . . . . . . . . . . . . . . . . 137

Cleaning the Ice Thickness or Water Level

Probe . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Water Level Control Circuitry . . . . . . . 141

Ice Thickness Probe (Harvest Initiation)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Harvest Assist Air Pump . . . . . . . . . . . 151

Compressor Electrical Diagnostics . . . . 152

Diagnosing Start Components . . . . . . 154

Refrigeration Components . . . . . . . . . . . 158

High Pressure Cutout (HPCO) Control 158

Fan Cycle Control . . . . . . . . . . . . . . . . 159

Water Regulating Valve . . . . . . . . . . . 160

Harvest Pressure Regulating (HPR) System

Remotes Only . . . . . . . . . . . . . . . . . . . 161

Head Pressure Control Valve . . . . . . . 164

Low Pressure Cutout (LPCO) Control . 167

Harvest Pressure Solenoid Valve . . . . 168

Refrigerant Recovery/Evacuation . . . . . . 169

Normal Self-Contained Model Procedures

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Normal Remote Model Procedures . . . 173

System Contamination Clean-Up . . . . . . 178

Determining Severity Of Contamination 178

Cleanup Procedure . . . . . . . . . . . . . . . 180

Replacing Pressure Controls Without Re-

moving Refrigerant Charge . . . . . . . . . 183

Specifications

Main Fuse . . . . . . . . . . . . . . . . . . . . . . 185

Fan Cycle Control . . . . . . . . . . . . . . . . 185

High Pressure Cutout (HPCO) Control 185

Filter-Driers . . . . . . . . . . . . . . . . . . . . . 186

Total System Refrigerant Charge . . . . 187

8 Part Number 80-1479-3 7/10

Charts

Cycle Times/24-Hour Ice Production/

Refrigerant Pressure Charts . . . . . . . . . . 191

S300 Series . . . . . . . . . . . . . . . . . . . . 192

S320 Series . . . . . . . . . . . . . . . . . . . . 196

S420 Series . . . . . . . . . . . . . . . . . . . . 198

S450 Series . . . . . . . . . . . . . . . . . . . . 202

S500 Series . . . . . . . . . . . . . . . . . . . . 206

S600 Series . . . . . . . . . . . . . . . . . . . . 215

S850 Series . . . . . . . . . . . . . . . . . . . . 218

S1000 Series . . . . . . . . . . . . . . . . . . . 227

S1200 Series . . . . . . . . . . . . . . . . . . . 236

S1400 Series . . . . . . . . . . . . . . . . . . . 242

S1600 Series . . . . . . . . . . . . . . . . . . . 253

S1800 Series . . . . . . . . . . . . . . . . . . . 256

S3300 Series . . . . . . . . . . . . . . . . . . . 265

Diagrams

Wiring Diagrams . . . . . . . . . . . . . . . . . . . 267

Wiring Diagram Legend . . . . . . . . . . . 267

Wiring Diagrams Before Energy Efficient &

EnergyStar Machines . . . . . . . . . . . . . 268

Wiring Diagrams for Energy Efficient & En-

ergyStar Machines . . . . . . . . . . . . . . . 279

Electronic Control Board . . . . . . . . . . . . 290

Single and Twin Evaporator . . . . . . . . 290

Single and Twin Evaporator With Test But-

ton . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Quad Evaporator Ice Machines . . . . . 292

Refrigeration Tubing Schematics . . . . . 293

Self-Contained Air- or

Water -Cooled Models . . . . . . . . . . . . 293

Remote Models . . . . . . . . . . . . . . . . . 295

Part Number 80-1479-3 7/10 9

General Information

Model Numbers

This manual covers the following models:

NOTE: Model numbers ending in 3 indicate a 3

phase unit. Example: SY1004A3.

Self-Contained

Air-Cooled

Self-Contained

Water-Cooled

Remote

SD0302A SY0304A

SD0303W SY0305W

---

SD0322A SY0324A

SD0323W SY0325W

---

SR0420A SD0422A SY0424A

SR0421W SD0423W SY0425W

---

SD0452A SY0454A

SD0453W SY0455W

---

SR0500A SD0502A SY0504A

SR0501W SD0503W SY0505W

SD0592N SY0594N

SD0602A SY0604A

SD0603W SY0605W

SD0692N SY0694N

SR0850A SD0852A SY0854A

SR0851W SD0853W SY0855W

SR0890N SD0892N SY0894N

SR1000A SD1002A SY1004A

SR1001W SD1003W SY1005W

SR1090N SD1092N SY1094N

SD1202A SY1204A

SD1203W SY1205W

---

SD1402A SY1404A

SD1403W SY1405W

SD1492N SY1494N

SR1600A SD1602A SY1604A

SR1601W SD1603W SY1605W

SR1690N SD1692N SY1694N

SR1800A SD1802A SY1804A

SR1801W SD1803W SY1805W

SR1890N SD1892N SY1894N

---

SD3303W

SD3303WHP

SY3305W

SY3305WHP

---

10 Part Number 80-1479-3 7/10

HOW TO READ A MODEL NUMBER

Ice Cube Sizes

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 x2.22 cm

Half Dice

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

0.95 x 2.86 x 2.22 cm

! Warning

Personal Injury Potential

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

S Y 1094 N SI

ICE MACHINE

MODEL

ICE CUBE SIZE R REGULAR

D DICE Y HALF DICE

# CUBE SIZE 0 REGULAR

1 REGULAR 2 DICE 3 DICE 4 HALF-DICE 5 HALF-DICE

CONDENSER TYPE AIR-COOLED

WATER-COOLED AIR-COOLED WATER-COOLED AIR-COOLED WATER-COOLED

A SELF-CONTAINED AIR-COOLED W SELF-CONTAINED WATER-COOLED N REMOTE AIR-COOLED

9 REMOTE

AIR-COOLED

CONDENSER TYPE

ICE MACHINE

SERIES

ADDITIONAL SPECS

3 PHASE M MARINE UNIT HP HIGH PRESSURE WATER VALVE SI AUCS-SI INCLUDED

Part Number 80-1479-3 7/10 11

Model/Serial Number Location

These numbers are required when requesting information from your local Manitowoc Distributor, service representative, or Manitowoc Ice, Inc. The model and serial number are listed on the OWNER WARRANTY REGISTRATION CARD. They are also listed on the MODEL/SERIAL NUMBER DECAL affixed to the ice machine.

! Warning

All Man itowoc ice ma chines re quire th e ice storage system (bin, dispenser, etc.) to incorporate an ice deflector.

48” w ide S Model ice mach ines re quire add ing Manitowoc Ice Deflector Kit K00 349 w hen installing wi th non-Manitowoc ice sto rage systems.

30” w ide S Model ice mach ines re quire add ing Manitowoc Ice Deflector Kit K00 347 w hen installing wi th non-Manitowoc ice sto rage systems.

Prior to using a non -Manitowoc ice sto rage system with other Manitowoc ice machin es, contact th e manufacturer to assu re th eir ice deflector is comp atible wi th Mani towoc ice machines.

12 Part Number 80-1479-3 7/10

Energy Efficient Ice Machine Serial Breaks

Some specifications have changed with our release of more Energy Efficient machines. The following machines have a serial break to indicate when they became more Energy Efficient.

Series Ice

Machine

Serial Break/Manufacture Date for

Energy Efficient Machines

S300 110704351

S420 110667970

S450 110670157

S500 110684316

S850 110683282

S1000 110697023

S1200 110707329

S1400W

Manufacture Date After 0711

(November 2007)

S1400W

Manufacture Date Between

0711 & 0905

(November 2007 & May 2009)

S1400A

S1400W

S1400N

Manufacture Date After 0905

(May 2009)

S1800A

S1800W

S1800N

Manufacture Date After 0910

(October 2009)

Part Number 80-1479-3 7/10 13

Ice Machine Warranty Information

OWNER WARRANTY REGISTRATION CARD

Warranty coverage begins the day the ice machine is installed.

If the OWNER WARRANTY REGISTRATION CARD is not returned, Manitowoc will use the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice machine.

Important

Complete and mail the OW NER WARRANTY REGISTRATION C ARD as soon as p ossible to validate the installation date.

14 Part Number 80-1479-3 7/10

COMMERCIAL WARRANTY COVERAGE

Manitowoc Ice, (hereinafter referred to as the "COMPANY") warrants for a period of thirty-six months from the installation date (except as limited below) that new ice machines manufactured by the COMPANY shall be free of defects in material or workmanship under normal and proper use and maintenance as specified by the COMPANY and upon proper installation and start-up in accordance with the instruction manual supplied with the ice machine.

The COMPANY'S warranty hereunder with respect to the compressor shall apply for an additional twentyfour months, excluding all labor charges, and with respect to the evaporator for an additional twenty-four months, including labor charges.

The obligation of the COMPANY under this warranty is limited to the repair or replacement of parts, components, or assemblies that in the opinion of the COMPANY are defective. This warranty is further limited to the cost of parts, components or assemblies and standard straight time labor charges at the servicing location. Time and hourly rate schedules, as published from time to time by the COMPANY, apply to all service procedures.

Additional expenses including without limitation, travel time, overtime premium, material cost, accessing or removal of the ice machine, or shipping are the responsibility of the owner, along with all maintenance, adjustments, cleaning, and ice purchases.

Labor covered under this warranty must be performed by a COMPANY Contracted Service Representative or a refrigeration service agency as qualified and authorized by the COMPANY'S local Distributor.

The COMPANY'S liability under this warranty shall in no event be greater than the actual purchase price paid by customer for the ice machine.

Part Number 80-1479-3 7/10 15

The foregoing warranty shall not apply to (1) any part or assembly that has been altered, modified, or changed; (2) any part or assembly that has been subjected to misuse, abuse, neglect, or accidents; (3) any ice machine that has been installed and/or maintained inconsistent with the technical instructions provided by the COMPANY; or (4) any ice machine initially installed more than five years from the serial number production date. This warranty shall not apply if the Ice Machine's refrigeration system is modified with a condenser, heat reclaim device, or parts and assemblies other than those manufactured by the COMPANY, unless the COMPANY approves these modifications for specific locations in writing.

THIS WARRANTY IS IN LIEU OF ALL OTHER WARRANTIES OR GUARANTEES OF ANY KIND, EXPRESSED OR IMPLIED, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE.

In no event shall the COMPANY be liable for any special, indirect, incidental or consequential damages. Upon the expiration of the warranty period, the COMPANY'S liability under this warranty shall terminate. The foregoing warranty shall constitute the sole liability of the COMPANY and the exclusive remedy of the customer or user.

To secure prompt and continuing warranty service, the warranty registration card must be completed and sent to the COMPANY within five (5) days from the installation date.

To obtain warranty service or information regarding your Product, please contact us at:

MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.manitowocice.com

16 Part Number 80-1479-3 7/10

RESIDENTIAL ICE MACHINE LIMITED WARRANTY

WHAT DOES THIS LIMITED WARRANTY COVER?

Subject to the exclusions and limitations below, Manitowoc Ice, Inc. (“Manitowoc”) warrants to the original consumer that any new ice machine manufactured by Manitowoc (the “Product”) shall be free of defects in material or workmanship for the warranty period outlined below under normal use and maintenance, and upon proper installation and startup in accordance with the instruction manual supplied with the Product.

HOW LONG DOES THIS LIMITED WARRANTY LAST?

WHO IS COVERED BY THIS LIMITED WARRANTY?

This limited warranty only applies to the original consumer of the Product and is not transferable.

Product Covered Warranty Period

Ice Machine

Twelve months from the

sale date

Part Number 80-1479-3 7/10 17

WHAT ARE MANITOWOC ICE’S OBLIGATIONS UNDER THIS LIMITED WARRANTY?

If a defect arises and Manitowoc receives a valid warranty claim prior to the expiration of the warranty period, Manitowoc shall, at its option: (1) repair the Product at Manitowoc’s cost, including standard straight time labor charges, (2) replace the Product with one that is new or at least as functionally equivalent as the original, or (3) refund the purchase price for the Product. Replacement parts are warranted for 90 days or the balance of the original warranty period, whichever is longer. The foregoing constitutes Manitowoc’s sole obligation and the consumer’s exclusive remedy for any breach of this limited warranty. Manitowoc’s liability under this limited warranty is limited to the purchase price of Product. Additional expenses including, without limitation, service travel time, overtime or premium labor charges, accessing or removing the Product, or shipping are the responsibility of the consumer.

HOW TO OBTAIN WARRANTY SERVICE

To obtain warranty service or information regarding your Product, please contact us at:

MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.manitowocice.com

18 Part Number 80-1479-3 7/10

WHAT IS NOT COVERED?

This limited warranty does not cover, and you are solely responsible for the costs of: (1) periodic or routine maintenance, (2) repair or replacement of the Product or parts due to normal wear and tear, (3) defects or damage to the Product or parts resulting from misuse, abuse, neglect, or accidents, (4) defects or damage to the Product or parts resulting from improper or unauthorized alterations, modifications, or changes; and (5) defects or damage to any Product that has not been installed and/or maintained in accordance with the instruction manual or technical instructions provided by Manitowoc. To the extent that warranty exclusions are not permitted under some state laws, these exclusions may not apply to you.

XCEPT AS STATED IN THE FOLLOWING SENTENCE, THIS

IMITED WARRANTY IS THE SOLE AND EXCLUSIVE

ARRANTY OF MANITOWOC WITH REGARD TO THE

RODUCT. ALL IMPLIED WARRANTIES ARE STRICTLY

IMITED TO THE DURATION OF THE LIMITED WARRANTY

PPLICABLE TO THE PRODUCTS AS STATED ABOVE,

NCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF

ERCHANTABILITY OR OF FITNESS FOR A PARTICULAR

URPOSE.

Some states do not allow limitations on how long an implied warranty lasts, so the above limitation may not apply to you.

Part Number 80-1479-3 7/10 19

IN NO EVENT SHALL MANITOWOC OR ANY OF ITS A

FFILIATES BE LIABLE TO THE CONSUMER OR ANY

THER PERSON FOR ANY INCIDENTAL, CONSEQUENTIAL

R SPECIAL DAMAGES OF ANY KIND (INCLUDING,

ITHOUT LIMITATION, LOSS OF PROFITS, REVENUE OR

USINESS) ARISING FROM OR IN ANY MANNER

ONNECTED WITH THE PRODUCT, ANY BREACH OF THIS

IMITED WARRANTY, OR ANY OTHER CAUSE

HATSOEVER, WHETHER BASED ON CONTRACT, TORT

R ANY OTHER THEORY OF LIABILITY.

Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation or exclusion may not apply to you.

HOW STATE LAW APPLIES

This limited warranty gives you specific legal rights, and you may also have rights that vary from state to state or from one jurisdiction to another.

REGISTRATION CARD

To secure prompt and continuing warranty service, this warranty registration card must be completed and sent to Manitowoc within thirty (30) days from the sale date. Complete the registration card and send it to Manitowoc.

20 Part Number 80-1479-3 7/10

This Page Intentionally Left Blank

Part Number 80-1479-3 7/10 21

Installation

Location of Ice Machine

The location selected for the ice machine head section 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.

• Self contained air and water cooled - The air temperature must be at least 35°F (1.6°C), but must not exceed 110°F (43.4°C).

• Remote air cooled - The air temperature must be at least -20°F (-29°C), but must not exceed 120°F (49°C)

• Ice Making Water Inlet - Water Pressure must be at least 20 psi (1.38 bar), but must not exceed 80 psi (5.52 bar).

• Condenser Water Inlet - Water Pressure must be at least 20 psi (1.38 bar), but must not exceed 150 psi (10.34 bar). S3300W-HP units allow water pressure up to 350 psig (24.13 bar)

• The location must not be near heat-generating equipment or in direct sunlight and protected from weather.

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

• 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”

Warning

PERSONAL INJURY POTENTIAL

Remove a ll i ce machi ne p anels before lifting a nd installing.

22 Part Number 80-1479-3 7/10

Ice Machine Clearance Requirements

S300

Self-Contained

Air-Cooled

Self-Contained

Water-Cooled

Top/Sides 16" (40.6 cm) 8" (20.3 cm)

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

S320/S450/S500/

S600/S850/S1000

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)

S420

Self-Contained

Air-Cooled

Water-Cooled and

Remote*

Top/Sides 12" (30.5 cm) 8" (20.3 cm)

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

S1200

Self-Contained

Air-Cooled

Water-Cooled and

Remote*

To p 8" (20.3 cm) 8" (20.3 cm)

Sides 12" (30.5 cm) 8" (20.3 cm)

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

S1400/S1600/

S1800

Self-Contained

Air-Cooled

Water-Cooled

and Remote*

Top/Sides 24" (61.0 cm) 8" (20.3 cm)

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

* There is no minimum clearance required for water-cooled or

remote ice machines. This value is recommended for efficient operation and servicing only.

S3300

** S3300 - 24” on all sides is recommended to allow access without

moving the bin/ice machine.

Water-Cooled

Top/Sides 8" (20.3 cm)

Back 24" (61.0 cm)

Part Number 80-1479-3 7/10 23

Ice Machine Heat of Rejection

Series Ice

Machine

Heat of Rejection

Air

Conditioning*

Peak

S300 3,800 6,000

S320 3,800 6,000

S420/S450 7,000 9,600

S500 7,000 9,600

S600 9,000 13,900

S850 12,000 18,000

S1000 16,000 22,000

S1200 19,000 28,000

S1400 19,000 28,000

S1600 21,000 31,000

S1800 24,000 36,000

Energy Efficient Machines

S300 5,000 6,000

S420/S450 5,900 6,900

S500 6,100 6,900

S850 13,000 16,000

S1000 17,700 21,000

S1200 20,700 24,500

S1400W 25,000 28,000

S1400A/

S1400N

23,500 27,000

S1800 31,000 36,000

S3300 45,000 51,000

*BTU/Hour Because the heat of rejection varies during the ice making

cycle, the figure shown is an average.

24 Part Number 80-1479-3 7/10

REMOTE CONDENSER LINE SET INSTALLATION

Ice Machine

Remote Single

Circuit

Condenser

Line Set*

S500 JC0495

RT-20-R404A RT-35-R404A

RT-50-R404A S600 S800

S1000

JC0895

RT-20-R404A

RT-35-R404A

RT-50-R404A

S1400 S1600 S1800

JC1395

RL-20-R404A

RL-35-R404A

RL-50-R404A

*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 (-29°C) 120°F (49°C)

Important

Manitowoc remote systems are only approved and warranted as a complete new package. Warranty on the refrigeration system will be void if a new ice machine head section is connected to pre-existing (used) tubing or remote condenser s or vice versa.

Part Number 80-1479-3 7/10 25

CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES

NOTE: Manitowoc warrants only complete new and

unused remote packages. Warranty on the refrigeration system will be void if a new ice machine head section is connected to existing (used) tubing or condensers.

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).

Caution

If a li ne se t h as a rise fo llowed by a drop , a nother rise cann ot be mad e. Likew ise, if a li ne se t h as a drop fo llowed by a rise, another drop cannot be made.

26 Part Number 80-1479-3 7/10

Calculated Line Set Distance

The maximum calculated 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.

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 dist ance 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.

Part Number 80-1479-3 7/10 27

Maximum Line Set Distance Formula Step 1

Measured Rise ____ X 1.7 = ______Calculated Rise (35 ft. Max)

Step 2

Measured Drop ____ X 6.6 = ______Calculated Drop (15 ft. Max.)

Step 3

Measured Horizontal Distance = _________Horizontal (100 ft. Max.) Distance

Step 4

Total Calculated Distance = ________Total Calculated (150 ft. Max.) Distance

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, purge with nitrogen and insulate all tubing. Do not change the tube sizes. Evacuate the lines and place about 5 oz (143g) of vapor refrigerant charge in each line.

28 Part Number 80-1479-3 7/10

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 couplings with a wrench until they bottom out.

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

6. Check all fittings and valve caps for leaks.

7. Make sure Schraeder cores are seated and Schraeder caps are on and tight.

Liquid Line Discharge Line

10-12 ft lb.

(13.5-16.2 N•m)

35-45 ft lb.

(47.5-61.0 N•m)

Part Number 80-1479-3 7/10 29

Component Identification

S Model Single Evaporator Models

WATER CURTAIN

CONTROL BOX

WATER

DISTRIBUTION

TUBE

TOGGLE

SWITCH

WATER

TROUGH

REFRIGERATION ACCESS VALVES

ICE

THICKNESS

CONTROL

EVAPORATOR

WA TER LEVE L

PROBE

WATER PUMP

WATER INLET

LOCATION, THE

WA TER INLET V AL VE

IS LOCATED IN THE

REFRIGERATION

COMP ARTMENT

30 Part Number 80-1479-3 7/10

S Model Quad Evaporator Models

WATER

PUMPS

WA TER LEVEL

PROBE

EVAPORATORS

WATER

TROUGH

CONTROL

BOX

ICE DAMPERS

Part Number 80-1479-3 7/10 31

Maintenance

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 water care professional to test the water quality and recommend appropriate water treatment. An extremely dirty ice machine must be taken apart for cleaning and sanitizing.

Manitowoc Ice Machine Cleaner and Sanitizer are the only products approved for use in Manitowoc ice machines.

This Manitowoc Ice Machine has two separate cleaning procedures.

Cleaning/Sanitizing Procedure

This procedure must be performed a minimum of once every six months.

• The ice machine and bin must be disassembled

cleaned and sanitized

• All ice produced during the cleaning and sanitizing

procedures must be discarded

• Removes mineral deposits from areas or surfaces

that are in direct contact with water

Heavily Scaled Cleaning Procedure

Perform this procedure if you have some or all of these symptoms.

• Ice machine stops on Safety Shutdown

• Your water has a high concentration of minerals

• The ice machine has not been on a regular

maintenance schedule.

32 Part Number 80-1479-3 7/10

Cleaning / Sanitizing Procedure

CLEANING PROCEDURE

Ice machine cleaner is used to remove lime scale and mineral deposits. Ice machine sanitizer disinfects and removes algae and slime.

Step 1 Remove front door and top cover. This will

allow easiest access for adding cleaning and sanitizing solutions.

Step 2 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

Use on ly Mani towoc app roved Ice Machi ne Cleaner and Sanitize r fo r this application (Manitowoc Clea ner part n umber 9 4-0546-3 a nd Manitowoc Sanitizer part number 94-0565-3). It is a violation of Federal law to use these solutions in a man ner inconsistent with the ir la beling. Re ad and und erstand a ll l abels prin ted on bo ttles before use.

Caution

Do n ot mi x Clea ner a nd Sa nitizer sol utions together. It is a viol ation of Fe deral law to use these solutions in a manner inconsistent with their labeling.

Warning

Wear rubbe r gloves an d safe ty go ggles (and/or face sh ield) when handling ice machin e Clea ner or Sanitizer.

Caution

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

Part Number 80-1479-3 7/10 33

Step 3 Remove all ice from the bin. Step 4 Place the toggle switch in the CLEAN

position. The water will flow through the water dump valve and down the drain. Wait until the water trough refills and water flows over the evaporator, then add the proper amount of ice machine cleaner.

Step 5 Wait until the clean cycle is complete (approximately *35 minutes). then place the toggle

switch in the OFF position and disconnect power to the ice machine (and dispenser when used).

NOTE: *S3300 Only - 80 minutes..

Step 6 Remove parts for cleaning. Please refer to the proper parts removal for your

ice machine. Single Evaporator Ice Machines - page 34. Quad Evaporator Ice Machines - page 35.

Model Amount of Cleaner

S300/S320/S420 3 ounces (90 ml)

S450/S500/S600/S850/

S1000/S1200

5 ounces (150 ml)

S1400/S1600/S1800 9 ounces (265 ml)

S3300 16 ounces (475 ml)

Warning

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

34 Part Number 80-1479-3 7/10

PARTS REMOVAL FOR CLEANING/SANITIZING Single Evaporator Ice Machines

A. Remove the water curtain

• Gently flex the curtain in the center and remove it from the right side.

• Slide the left pin out.

B. Remove the ice thickness probe

• Compress the hinge pin on the top of the ice thickness probe.

• Pivot the ice thickness probe to disengage one pin then the other. The ice thickness probe can be cleaned at this point without complete removal. If complete removal is desired, disconnect the ice thickness control wiring from the control board.

C. Remove the water trough

• Depress tabs on right and left side of the water trough.

• Allow front of water trough to drop as you pull forward to disengage the rear pins.

NOTE: Proceed to page 37, Step 7.

Part Number 80-1479-3 7/10 35

Quad Evaporator Ice Machines A.Remove the water trough shield.

• Grasp the water trough shield in the center and the left end.

• Flex the water trough shield in the center and pull the left end forward until clear of the side wall. Repeat for the right end.

• Pull water trough shield forward to remove.

B. Remove Splash Shields.

• Grasp the top center of splash shields.

• Lift up and then out.

C. Remove ice thickness probe.

• Compress the hinge pin on the top of the ice thickness probe.

D. Remove the water pump assembly

• Disconnect the vinyl distribution tube from both water pumps.

• Disconnect the water pump and water level probe electrical connections.

• Remove two thumbscrews and lift the water pump assembly out of the ice machine.

E. Remove the water trough.

• Depress the two tabs on the top of the water trough.

• Turn left and right ice dampers down to clear water trough.

• Pull forward on the water trough to remove.

NOTE: Proceed to page 37, Step 7.

Continued on next page …

36 Part Number 80-1479-3 7/10

Part Number 80-1479-3 7/10 37

Step 7 Mix a solution of cleaner and warm water.

Depending upon the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly clean all parts.

Step 8 Use 1/2 of the cleaner/water mixture to clean

all components. The cleaner solution will foam when it contacts lime scale and mineral deposits; once the foaming stops use a soft-bristle nylon brush, sponge or cloth (NOT a wire brush) to carefully clean the parts. Soak parts for 5 minutes (15 - 20 minutes for heavily scaled parts). Rinse all components with clean water.

Step 9 While components are soaking, use 1/2 of the

cleaner/water solution to clean all foodzone surfaces of the ice machine and bin (or dispenser). Use a nylon brush or cloth to thoroughly clean the following ice machine areas:

• Side walls

• Base (area above water trough)

• Evaporator plastic parts - including top, bottom, and sides

• Bin or dispenser

Rinse all areas thoroughly with clean water.

Continued on next page …

Step 10 Mix a solution of sanitizer and warm water.

Step 11 Use 1/2 of the sanitizer/water solution to

sanitize all removed components. Use a spray bottle to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution. Do not rinse parts after sanitizing.

Solution Type Water Mixed With

Cleaner 1 gal. (4 l)

16 oz (500 ml)

cleaner

Solution Type Water Mixed With

Sanitizer 6 gal. (23 l)

4 oz (120 ml)

sanitizer

38 Part Number 80-1479-3 7/10

Step 12 Use 1/2 of the sanitizer/water solution to

sanitize all foodzone surfaces of the ice machine and bin (or dispenser). Use a spray bottle to liberally apply the solution. When sanitizing, pay particular attention to the following areas:

• Side walls

• Base (area above water trough)

• Evaporator plastic parts - including top, bottom and sides

• Bin or dispenser

Do not rinse the sanitized areas.

Step 13 Replace all removed components. Step 14 Wait 30 minutes.

Part Number 80-1479-3 7/10 39

Step 15 Reapply power to the ice machine and place

the toggle switch in the CLEAN position.

Step 16 Wait until the water trough refills and water

flows over the evaporator (approximately 3 minutes). Add the proper amount of Manitowoc Ice Machine Sanitizer to the water trough by pouring between the water curtain/splash shields and evaporator..

Step 17 Move the toggle switch to the ICE position

and replace the front panel. The ice machine will automatically start ice making after the sanitize cycle is complete (approximately 35 minutes, S3300 - 80 minutes).

Model Amount of Sanitizer

S300/S320/S420 3 ounces (90 ml)

S450/S500/S600/S850/

S1000/S1200

3 ounces (90 ml)

S1400/S1600/S1800 6 ounces (180 ml)

S3300 25 ounces (740 ml)

40 Part Number 80-1479-3 7/10

Procedure to Clean Heavily Scaled Ice Machines

Ice machines that are heavily scaled or have not been cleaned on a regular basis will need to run this procedure.

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. The ice machine must be taken apart for cleaning and sanitizing.

CLEANING PROCEDURE

Caution

Use o nly Ma nitowoc approved Ice Machine Cleaner and Sanitizer fo r this app lication (Manitowoc Cleaner part number 94-0546-3 and Manitowoc Sanitizer part number 94-0565-3). It is a violation of Federal law to use these solutions in a manne r inconsistent wit h thei r la beling. Read and u nderstand a ll labels printed on b ottles before use.

Caution

Do n ot mix Cle aner and Sani tizer solu tions together. It is a vi olation of F ederal l aw to u se these solu tions in a ma nner in consistent with their labeling.

Warning

Wear rubb er gl oves an d safety gog gles (a nd/or face shie ld) when handling ice machine Cleaner or Sanitizer.

Part Number 80-1479-3 7/10 41

Ice machine cleaner is used to remove lime scale and mineral deposits. Ice machine sanitizer disinfects and removes 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.

Step 2 Remove top cover. This will allow easiest

access for adding cleaning and sanitizing solutions.

Step 3 Remove all ice from the bin. Step 4 Place the toggle switch in the CLEAN

Continued on next page …

Caution

Never use anythin g to fo rce ice fro m the evaporator. Damage may result.

Model Amount of Cleaner

S300/S320/S420 3 ounces (90 ml)

S450/S500/S600/S850/

S1000/S1200

5 ounces (150 ml)

S1400/S1600/S1800 9 ounces (265 ml)

S3300 16 ounces (475 ml)

42 Part Number 80-1479-3 7/10

Step 5 Wait until the clean cycle is complete (approximately *35 minutes). then place the toggle

switch in the OFF position and disconnect power to the ice machine (and dispenser when used)

NOTE: *S3300 Only - 80 minutes..

Step 6 Remove parts for cleaning.

Please refer to the proper parts removal for your ice machine.

Single Evaporator Ice Machines - page 43. Quad Evaporator Ice Machines - page 46.

Warning

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

Part Number 80-1479-3 7/10 43

PARTS REMOVAL FOR CLEANING/SANITIZING Single Evaporator Ice Machines

A. Remov e the water curtain

• Gently flex the curtain in the center and remove it from the right side.

• Slide the left pin out.

B. Remove the ice thickness probe

• Compress the hinge pin on the top of the ice thickness probe.

C. Remove the water distribution tube

NOTE: Distribution tube thumbscrews are retained to prevent loss. Loosen thumbscrews but do not pull thumbscrews out of distribution tube.

• Loosen the two outer screws (do not remove screws completely they are retained to prevent loss) and pull forward on the distribution tube to release from slip joint.

• Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing the distribution tube into two pieces.

D. Remov e the water trough

• Depress tabs on right and left side of the water trough.

• Allow front of water trough to drop as you pull forward to disengage the rear pins.

44 Part Number 80-1479-3 7/10

E. Remove the water level probe

• Pull the water level probe straight down to disengage.

• Lower the water level probe until the wiring connector is visible.

• Disconnect the wire lead from the water level probe.

• Remove the water level probe from the ice machine.

F. Remove the water pump.

• Grasp pump and pull straight down on pump assembly until water pump disengages and electrical connector is visible.

• Disconnect the electrical connector.

• Remove the water pump assembly from ice machine.

• Do not soak the water pump motor in cleaner or sanitizer solution.

G. Remove the evaporator tray or water diverter

from the bottom of the evaporator.

• Loosen thumbscrew on left side of tray.

• Allow left side of tray to drop as you pull the tray to the left side. Continue until the outlet tube disengages from the right side.

NOTE: Proceed to page 49, Step 7.

Part Number 80-1479-3 7/10 45

46 Part Number 80-1479-3 7/10

Quad Evaporator Ice Machines A. Remove panels

• Remove both front panels

• Remove top panel

B. Remove front evaporator shield.

• Remove four quarter turn connectors

• Remove splash shield

C. Remove left and right evaporator top covers.

• Remove two thumbscrews from the front of each evaporator top cover.

• Lift front of cover, pull forward to remove.

D. Remove Splash Shields.

• Grasp the top center of splash shields.

• Lift up and then out.

NOTE: Each evaporator has a splash shield that must be removed - total of four splash shields.

E. Remove ice thickness probe.

• Compress the hinge pin on the top of the ice thickness probe.

Part Number 80-1479-3 7/10 47

F. Remove distribution tubes.

• Distribution tube thumbscrews are retained to prevent loss. Loosen thumbscrews but do not pull thumbscrews out of distribution tube.

• Loosen the two outer screws and pull forward on the distribution tube to release from slip joint.

• Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing the distribution tube into two pieces.

NOTE: Each evaporator has a distribution tube that must be removed - total of four distribution tubes.

G. Remove ice dampers.

• Grasp ice damper and apply pressure toward the back mounting bracket.

• Apply pressure to the front mounting bracket with thumb.

• Pull ice damper downward when the front ice damper pin disengages.

NOTE: Each evaporator has an ice damper that must be removed - total of four ice dampers.

H. Remove the water pump assembly.

• Disconnect the vinyl distribution tube from both water pumps.

• Disconnect the water pump and water level probe electrical connections.

• After the wires are disconnected remove the two thumbscrews and lift the water pump assembly out of the ice machine.

• Remove the thumbscrews securing the water pumps (2 each pump) and remove water pumps. Do not immerse the water pump motor in cleaner or sanitizer solutions.

• Remove the water level probe from the assembly housing.

I. Remove the water trough.

• Pull forward on the water trough to remove.

NOTE: Proceed to page 49, Step 7.

48 Part Number 80-1479-3 7/10

Part Number 80-1479-3 7/10 49

Step 7 Mix a solution of cleaner and warm water.

Depending upon the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly clean all parts.

Step 8 Use 1/2 of the cleaner/water mixture to clean

Step 9 While components are soaking, use 1/2 of the

cleaner/water solution to clean all foodzone surfaces of the ice machine and bin (or dispenser). Use a nylon brush or cloth to thoroughly clean the following ice machine areas:

• Side walls

• Base (area above water trough)

• Evaporator plastic parts - including top, bottom, and sides

• Bin or dispenser

Rinse all areas thoroughly with clean water.

Step 10 Mix a solution of sanitizer and warm water.

Step 11 Use 1/2 of the sanitizer/water solution to

sanitize all removed components. Use a cloth or sponge to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution. Do not rinse parts after sanitizing.

Step 12 Use 1/2 of the sanitizer/water solution to

sanitize all foodzone surfaces of the ice machine and

Solution Type Water Mixed With

Cleaner 1 gal. (4 l) 16 oz (500 ml) cleaner

Solution Type Water Mixed With

Sanitizer 6 gal. (23 l)

4 oz (120 ml)

sanitizer

50 Part Number 80-1479-3 7/10

bin (or dispenser). Use a cloth or sponge to liberally apply the solution. When sanitizing, pay particular attention to the following areas:

• Side walls

• Base (area above water trough)

• Evaporator plastic parts - including top, bottom and sides

• Bin or dispenser

Do not rinse the sanitized areas.

Step 13 Replace all removed components. Step 14 Reapply power to the ice machine and place

the toggle switch in the CLEAN position.

Step 15 Wait about two minutes or until water starts

to flow over the evaporator. Add the proper amount of Manitowoc Ice Machine Sanitizer to the water trough by pouring between the water curtain/splash shields and evaporator.

Step 16 The ice machine will stop after the sanitize

cycle (approximately *35 minutes). Place the toggle switch in the OFF position and disconnect power to the ice machine.

*S3300 Only - 80 minutes.

Step 17 Refer to step 6 and disassemble

components. After dissembling proceed to step 18.

Step 18 Mix a solution of sanitizer and warm water.

Model Amount of Sanitizer

S300/S320/S420 3 ounces (90 ml)

S450/S500/S600/S850/

S1000/S1200

3 ounces (90 ml)

S1400/S1600/S1800 6 ounces (180 ml)

S3300 25 ounces (740 ml)

Warning

Disconnect the ele ctric po wer to th e ice machine at the electric service switch box.

Part Number 80-1479-3 7/10 51

Step 19 Use 1/2 of the sanitizer/water solution to

Step 20 Use 1/2 of the sanitizer/water solution to

sanitize all foodzone surfaces of the ice machine and bin (or dispenser). Use a cloth or sponge to liberally apply the solution. When sanitizing, pay particular attention to the following areas:

• Side walls

• Base (area above water trough)

• Evaporator plastic parts - including top, bottom and sides

• Bin or dispenser

Do not rinse the sanitized areas.

Step 21 Install the removed parts, restore power and

place the toggle switch in the ICE position.

Solution

Type

Water Mixed With

Sanitizer 6 gal. (23 l) 4 oz (120 ml) sanitizer

52 Part Number 80-1479-3 7/10

Ice Thickness Probe & Water Level Probe

Clean the probes using the following procedure.

1. Mix a solution of Manitowoc ice machine cleaner and water (2 ounces of cleaner to 16 ounces of water) in a container.

2. Soak probes in container of cleaner/water solution while disassembling and cleaning water circuit components (soak probes for 10 minutes or longer).

3. Clean all probe surfaces including all plastic parts (do not use abrasives). Verify all cavities are clean. Thoroughly rinse probes (including cavity)

with clean water, then dry completely. Incomplete

rinsing and drying of the ice thickness probe can cause premature harvest.

4. Reinstall probes, then sanitize all ice machine and bin/dispenser interior surfaces.

Part Number 80-1479-3 7/10 53

Water Inlet Valve

The water inlet valve normally does not require removal for cleaning. Refer to “Water System Checklist” page 109, if you are troubleshooting water related problems.

1. When the ice machine is off, the water inlet valve must completely stop water flow into the machine. Watch for water flow.

When the ice machine is on, the water inlet valve must allow the proper water flow through it. Set the toggle switch to ON. Watch for water flow into the ice machine. If the water flow is slow or only trickles into the ice machine, refer to water system checklist.

Follow the procedure below to remove the water inlet valve.

1. Remove the 1/4” hex head screws.

2. Remove, clean, and install the filter screen.

Warning

Disconnect the el ectric power to the ice machi ne and dispenser at the electric service switch box and turn off the water supply before proceeding.

4 Hex Head

Screws

54 Part Number 80-1479-3 7/10

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 water trough to determine if the dump valve is leaking. If there is no or little water in the water trough (during the freeze cycle) the dump valve is leaking.

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 “Ice Machine Cleaning Procedure”.

Follow the procedure below to remove the dump valve.

4. If so equipped, remove the water dump valve shield from its mounting bracket.

5. Leaving the wires attached, twist coil and rotate it counter-clockwise1/4 turn.

6. Lift the coil assembly off the valve body.

7. Remove the spring, plunger, and nylon gasket from the valve body.

NOTE: At this point, the water dump valve can easily

be cleaned. If complete removal is desired, continue with step 5.

Warning

Disconnect the electric power to the ice ma chine at the electric service switch bo x and turn of f the water supply before proceeding.

Important

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

Part Number 80-1479-3 7/10 55

NOTE: During cleaning, do not stretch or damage the

spring.

1. Remove the tubing from the dump valve by twisting the clamps off.

2. Remove the valve body, twist off.

Dump Valve Disassembly

SPRING

PLUNGER

DIAPHRAM

VALVE BODY

COIL

MOUNTING BRACKET

NYLON GASKET

56 Part Number 80-1479-3 7/10

Drain Line Check Valve

The drain line check valve (not used on all models) should be inspected and cleaned, whenever the ice machine is cleaned.

1. Remove check valve and tube assembly. A. Tip assembly to right until tubing disengages. B. Lift up on assembly to remove.

2. Remove insulation from check valve assembly.

3. Remove vinyl tubing from top of check valve.

4. Soak in cleaner solution 10 minutes, and then

flush with water to remove debris.

CHECK VALVE

ASSEMBLY

CHECK VALVE

Part Number 80-1479-3 7/10 57

Removal from Service/Winterization

General

Special precautions must be taken if the ice machine is to be removed from service for an extended period of time or exposed to ambient temperatures of 32°F (0°C) or below.

Follow the applicable procedure below.

SELF-CONTAINED AIR-COOLED ICE MACHINES

1. Move the ICE/OFF/CLEAN switch ot OFF.

2. Disconnect the electric power at the circuit breaker or the electric service switch.

3. Turn off the water supply.

4. Remove the water from the water trough.

5. Disconnect and drain the incoming ice-making water line at the rear of the ice machine.

6. Energize the ice machine and wait one minute for the water inlet valve to open.

7. 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 water inlet lines or the drain.

8. Make sure water is not trapped in any of the water lines, drain lines, distribution tubes, etc.

Caution

If water is al lowed to remain in the ice machine in freezing temperatures, se vere damag e to some components could resu lt. Damage of thi s na ture is not covered by the warranty.

58 Part Number 80-1479-3 7/10

WATER-COOLED ICE MACHINES

1. Perform steps 1-6 under “Self-Contained AirCooled Ice Machines.”

2. Disconnect the incoming water and drain line 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.

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 valve. Hang a tag on the switch as a reminder to open the valves before restarting.

3. Perform steps 1-6 under “Self-Contained AirCooled Ice Machines.”

SV1624

Part Number 80-1479-3 7/10 59

Sequence of Operation

Self Contained Air or Water Cooled

SINGLE & QUAD EVAPORATOR MODELS

NOTE: The toggle switch must be in the ice position

and the water curtain/ice dampers must be in place on the evaporator before the ice machine will start.

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

1. Water Purge

Before the refrigerant compressor starts, the water pump and water dump solenoid energize to purge the ice machine of old water. This feature ensures that the ice making cycle starts with fresh water.

Single evaporator models energize the harvest valve(s) and air compressor (when used) at the end of the water purge and they remain energized during refrigeration startup.

Energized Control Board LightsSingle Evaporators = Left Bin (green) Quad Evaporators = All Curtain Switches (green),

Dump Valve (red), Water Pump (red)

2. Refrigeration System Start-Up

The compressor, condenser fan motor and water fill valve energize and 5 seconds later the harvest valve(s) and air compressor(s) de-energize.

The fan motor is wired through a fan cycle pressure control and will cycle on and off when the room temperatures is below 70°F (21°C) .

Energized Control Board LightsSingle Evaporators = Left Bin (green) Quad Evaporators = All Curtain Switches (green),

Water Solenoid (red), Liquid Solenoid (red)

60 Part Number 80-1479-3 7/10

Freeze Sequence

3. Prechill

The compressor lowers the temperature of the evaporator(s) before the water pump is energized. The water fill valve will remain energized until water contacts the water level probe.

Energized Control Board LightsSingle Evaporators = Left Bin (green) Quad Evaporators = All Curtain Switches (green),

Water Solenoid (red), Liquid Solenoid (red)

4. Freeze

The water pump(s) energizes and water flows over the evaporator. After water contacts the water level probe the water fill valve de-energizes. The water fill valve will cycle on and off one more time.

The freeze cycle continues until the six minute freeze lock expires and enough ice has formed to allow water to contact the ice thickness probe. After approximately 10 seconds of continual water contact, the harvest sequence is initiated.

NOTE: Freeze lock is bypassed after moving the toggle switch from OFF to ICE position for the first cycle only.

Energized Control Board LightsSingle Evaporators = Left Bin (green), water probe

(green), Harvest (red when water contacts the ice thickness probe)

Quad Evaporators = All Curtain Switches (green), Water Level (green), Water Solenoid (red), Liquid

Solenoid (red), Water Pump (red), Harvest (red when water contacts the ice thickness probe)

Part Number 80-1479-3 7/10 61

Harvest Sequence

5. Water Purge

The air compressor (when used) and the harvest valve(s) open at the beginning of the water purge to divert hot refrigerant gas into the evaporator.

The water pump continues to run, and the water dump valve energizes to purge the water in the water trough.

Single evaporator models energize the water fill valve for the last 15 seconds of the water purge cycle.

Energized Control Board LightsSingle Evaporators = Left Bin (green), Harvest (red) Quad Evaporators = All Curtain Switches (green),

Liquid Solenoid (red), Dump Valve (red), Water Pump (red), Harvest (red), All Harvest Valves (red)

62 Part Number 80-1479-3 7/10

6. Harvest

The air compressor (when used) remains energized and the harvest valve(s) remains open. The refrigerant gas warms the evaporator causing the cubes to slide, as a sheet, off the evaporator and into the storage bin.

Energized Control Board LightsSingle Evaporators = Left Bin (green), Harvest (red) Quad Evaporators = All Curtain Switches (green),

Liquid Solenoid (red), Harvest (red), All Harvest Valves (red)

Single evaporator models - The sliding sheet of

cubes opens the water curtain and bin switch. The momentary opening and re-closing of the bin

switch terminates the harvest sequence and return to the freeze sequence (Step 3 - 4.)

Quad evaporator models - The sliding sheet of

cubes opens the ice damper and bin switch. The momentary opening and re-closing of the bin switch de-energized the harvest valve for the evaporator. When all of the bin switches have opened and closed the ice machine will terminate the harvest sequence and return to the freeze sequence (Step 3 - 4.)

Energized Control Board Lights (once ice drops)-

Single Evaporators = Left Bin (green flashes once)

Quad Evaporators = All Curtain Switches (green

flashes once), Liquid Solenoid (red)

Part Number 80-1479-3 7/10 63

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/ice damper and will hold it open. After the water curtain/ice damper is held open for 30 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 or all of the ice dampers. As the water curtain/ice dampers swing back to the closed position, the bin switch re-closes and the ice machine restarts (steps 1 - 2), provided the 3 minute delay period is complete.

Energized Control Board LightsSingle Evaporators = No Lights Quad Evaporators = Depending on which damper is

open, the closed dampers will be lit (green)

64 Part Number 80-1479-3 7/10

Safety Timers

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

• The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated. Freeze lock is bypassed after moving the toggle switch from OFF to ICE position for the first cycle only.

• The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence (steps 5 & 6).

• The maximum harvest time is 3.5 minutes for single evaporators and 7 minutes for Quad evaporator model. The control board automatically initiates a freeze sequence (steps 3 & 4) when these times are exceeded.

Part Number 80-1479-3 7/10 65

Safety Limits

Safety limits are stored and indicated by the control board after three cycles. The number of cycles required to stop the ice machine varies for each safety limit.

• Safety Limit 1 - If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle. If 6 consecutive 60-minute freeze cycles occur, the ice machine stops

• Safety Limit 2 single evaporator models - If the harvest time reaches 3.5 minutes, the control board automatically returns the ice machine to the freeze cycle. If three 500 consecutive 3.5 minute harvest cycles occur, the ice machine stops.

• Safety Limit 2 Quad evaporator models - If the harvest time reaches 7 minutes, the control board automatically returns the ice machine to the freeze cycle. If 500 consecutive 7 minute harvest cycles occur, the ice machine stops.

• Safety Limit 3 Quad evaporator models - If the low refrigerant pressure control opens, the ice machine shuts off and starts a 5 minute delay period. If 3 consecutive low pressure events occur the ice machine stops and flashes the safety/ harvest light.

Use the following procedures to determine if the

control board contains a safety limit indication.

1. Move the toggle switch to OFF.

2. Move the toggle switch back to ICE. Watch the safety limit/harvest lights on the control board. If a safety limit has been recorded, the corresponding light will flash once, twice or three times to indicate which safety limit stopped the ice machine.

66 Part Number 80-1479-3 7/10

Safety Limit Stand-By Mode (Quad Evaporators Only)

The first time a safety limit shut down occurs, (three consecutive long freeze or harvest cycles) the ice machine will turn off for 60 minutes (Stand-By Mode).

During the Stand-By Mode the harvest light will be flashing continuously and a safety limit indication can be viewed. After 60 minutes the ice machine will automatically restart to see if the problem re-occurs. If the same safety limit is reached a second time (three more consecutive long freeze or harvest cycles) the ice machine will initiate a safety limit shut down and remain off until it is manually restarted. During a safety limit shut down the harvest light will be flashing continuously.

Part Number 80-1479-3 7/10 67

Warm Water Rinse Cycle

Single evaporator models only - Closing the back of the evaporator allows ice to build up on the rear of the evaporator and the plastic evaporator frame parts. After 200 freeze/harvest cycles have been completed the control board will initiate a warm water rinse.

After the 200th harvest cycle ends:

• The Clean and Harvest LEDs energize to indicate the ice machine is in a warm water rinse.

• The compressor and harvest valve remain energized.

• The water pump energizes.

• The water inlet valve energizes until water contacts the water level probe.

• The compressor and harvest valve warm the water for 5 minutes, then de-energize.

• The water pump remains energized for an additional 5 minutes (10 minute total on time) then de-energizes.

NOTE: The warm water rinse cycle can be terminated by moving the toggle switch to the OFF position, then back to ICE.

68 Part Number 80-1479-3 7/10

Self Contained Air & Water-Cooled

Single Evaporator Model Energized Parts Chart

Ice Making

Sequence of

Operation

Water Pump

Harvest Valve(s)

Air

Pump(s)*

Water

Inlet

Valve

Water Dump

Valve

Contactor

Coil

Compressor

Condenser

Fan Motor

Length

of Time

Start-Up

1. Water Purge

On On

35 sec.

Off

10 sec.

Off On Off Off Off

45 Seconds

2. Refrigeration System Start-up

Off On Off On Off On On

May Cycle

On/Off

5 Seconds

Freeze Sequence

3. Prechill

Off Off Off

May

Cycle

On/Off

during

pre-chill

Off On On

May Cycle

On/Off

Initial Start-Up is

60 Seconds

30 Seconds thereafter

4. Freeze

On Off Off

Cycles

Off then

On one

time

Off On On

May Cycle

On/Off

Unil 10 Sec.

Water Contact

w/Ice Thickness Probe

Part Number 80-1479-3 7/10 69

Harvest Sequence

5. Water Purge

On On On

30 sec.

Off

15 sec.

On On On

May Cycle

On/Off

Factory

Set at

45 Seconds

6. Harvest

Off On On Off Off On On

May Cycle

On/Off

Bin Switch

Activation

7. Automatic Shut-Off

Off Off Off Off Off Off Off Off

Until Bin Switch

Re-closes & 3 min.

delay

* NOT USED ON ALL MODELS

Self Contained Air & Water-Cooled

Single Evaporator Model Energized Parts Chart (Continued)

Ice Making

Sequence of

Operation

Water Pump

Harvest Valve(s)

Air

Pump(s)*

Water

Inlet

Valve

Water Dump

Valve

Contactor

Coil

Compressor

Condenser

Fan Motor

Length

of Time

70 Part Number 80-1479-3 7/10

Self Contained Water-Cooled

Quad Evaporator Model Energized Parts Chart

Ice Making

Sequence of

Operation

Water

Pumps

Harvest

Valves

Air

Pumps

Water

Inlet Valve

Water Dump

Valves

Contactor

Coil

Compressor

Length

of Time

Start-Up

1. Water Purge

On Off Off Off On Off Off

Initial Start-Up is

45 Seconds

30 Seconds thereafter

2. Refrigeration System Start-up

Off Off Off On Off On On

5 Seconds

Freeze Sequence

3. Prechill

Off Off Off

May Cycle

On/Off

during

pre-chill

Off On On

30 Seconds thereafter

4. Freeze

On Off Off

Cycles Off

then On

up to two

times

Off On On

Unil 10 Sec.

Water Contact

w/Ice Thickness Probe

Part Number 80-1479-3 7/10 71

Harvest Sequence

5. Water Purge

On On On

from 30-45

seconds

On On On

Factory

Set at

30 Seconds

6. Harvest

Off On On Off Off On On

Bin Switch

Activation

7. Automatic Shut-Off

Off Off Off Off Off Off Off

Until Bin Switch

Re-closes & 3 min. delay

expires

Self Contained Water-Cooled

Quad Evaporator Model Energized Parts Chart (Continued)

Ice Making

Sequence of

Operation

Water

Pumps

Harvest

Valves

Air

Pumps

Water

Inlet Valve

Water Dump

Valves

Contactor

Coil

Compressor

Length

of Time

72 Part Number 80-1479-3 7/10

REMOTES Single Evaporator Models

NOTE: The toggle switch must be in the ice position

and the water curtain must be in place on the evaporator before the ice machine will start.

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

1. Water Purge

Before the compressor starts, the water pump and water dump solenoid are energized for 45 seconds, to completely purge the ice machine of old water. This feature ensures that the ice making cycle starts with fresh water.

The harvest valve and harvest pressure regulating (HPR) solenoid valves also energize during water purge, although they stay on for an additional 5 seconds (50 seconds total on time) during the initial refrigeration system start-up.

When Used - The air pump energizes for the last 10

seconds of the cycle. Energized Control Board LightsLeft Bin (green)

Part Number 80-1479-3 7/10 73

2. Refrigeration System Start-Up

The compressor and liquid line solenoid valve energize after the 45 second water purge and remain on throughout the entire Freeze and Harvest Sequences. The water fill valve is energized at the same time as the compressor. It remains on until the water level sensor closes for 3 continuous seconds, or until a six-minute time period has expired. The harvest valve and HPR solenoid valves remain on for 5 seconds during initial compressor start-up and then shut off.

The remote condenser fan motor starts at the same time the compressor starts and remains on throughout the entire Freeze and Harvest Sequences.

Energized Control Board LightsLeft Bin (green)

74 Part Number 80-1479-3 7/10

Freeze Sequence

3. Prechill

The compressor is on for 30 seconds (60 seconds initial cycle) prior to water flow, to prechill the evaporator.

Energized Control Board LightsLeft Bin (green)

4. Freeze

The water pump restarts after the prechill. An even flow of water is directed across the evaporator and into each cube cell, where it freezes. The water fill valve will cycle on and then off one more time to refill the water trough.

When sufficient ice has formed, the water flow (not the ice) contacts the ice thickness probe. After approximately 10 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.

Energized Control Board LightsLeft Bin (green), water probe (green), Harvest (red

when water contacts the ice thickness probe)

Part Number 80-1479-3 7/10 75

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. The water fill valve energizes (turns on) and de-energizes (turns off) strictly by time. The water fill valve energizes for the last 15 seconds of the 45-second water purge. The water purge must be at the factory setting of 45 seconds for the fill valve to energize during the last 15 seconds of the Water Purge. If set at less than 45 seconds the water fill valve does not energize during the water purge.

After the 45 second water purge, the water fill valve, water pump and dump valve de-energize. (Refer to “Water Purge Adjustment”) The harvest valve(s) and HPR solenoid valve also open at the beginning of the water purge.

Energized Control Board LightsLeft Bin (green), Harvest (red)

6. Harvest

The HPR valve and the harvest valve(s) remain open and the refrigerant gas warms the evaporator causing the cubes to slide, as a sheet, off the evaporator and into the storage bin. The sliding sheet of cubes swings the water curtain out, opening the bin switch. The momentary opening and re-closing of the bin switch terminates the harvest sequence and returns the ice machine to the freeze sequence (Step 3 - 4.)

When Used - The air pump energizes after 35 seconds

and remains energized throughout the entire harvest cycle. The air pump will automatically energize after 60 seconds when the harvest cycle time exceeded 75 seconds the previous cycle

Energized Control Board LightsLeft Bin (green), Harvest (red) - when the ice drops the

harvest light turns off

76 Part Number 80-1479-3 7/10

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 30 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 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.

Energized Control Board LightsNo Lights

Part Number 80-1479-3 7/10 77

Remote Air-Cooled

Single Evaporator Model Energized Parts Chart

Ice Making

Sequence of

Operation

Water Pump

Harvest

Val ve (Left)

HPR

Val ve

Harvest

Val ve (Right) (When

Used)

Air Comp. (When

Used)

Water

Inlet

Val ve

Water Dump

Val ve

Contactor

Coil

Liquid Line

Solenoid

Compressor

Condenser

Fan Motor

Length

of Time

Initial Start-Up

1. Water Purge

On On On

35 sec.

Off

10 sec.

On.

Off On Off Off Off

45 Seconds

2. Refrigeration System Startup

Off On On On On Off On On On

5 Seconds

Freeze Sequence

3. Prechill

Off Off Off Off

May

Cycle On/Off during

pre-chill

Off On On On

Initial Start-Up is

60 Seconds

30 Seconds thereafter

4. Freeze

On Off Off Off

Cycles

Off

Then On

one

time

Off On On On

Unil 10 Sec.

Water Contact

w/Ice Thickness Probe

78 Part Number 80-1479-3 7/10

Harvest Sequence

5. Water Purge

On On On

After

35 sec.

30 sec.

Off

15 sec.

On On On On

Factory

Set at

45 Seconds

6. Harvest Off On On On Off Off On On On

Bin Switch

Activation

7. Automatic Shut-Off

Off Off Off Off Off Off Off Off Off

Until Bin Switch

Re-closes & 3 min.

delay

Remote Air-Cooled

Single Evaporator Model Energized Parts Chart (Continued)

Ice Making

Sequence of

Operation

Water Pump

Harvest

Val ve (Left)

HPR

Val ve

Harvest

Val ve (Right) (When

Used)

Air Comp. (When

Used)

Water

Inlet

Val ve

Water Dump

Val ve

Contactor

Coil

Liquid Line

Solenoid

Compressor

Condenser

Fan Motor

Length

of Time

Part Number 80-1479-3 7/10 79

This Page Intentionally Left Blank

80 Part Number 80-1479-3 7/10

This Page Intentionally Left Blank

Part Number 80-1479-3 7/10 81

Troubleshooting

Safety Limits

In addition to standard safety controls, the control board has built in safety limit controls which protect the ice machine from major component failures.

Use the following procedures to determine if the control board contains a safety limit indication.

1. Move the toggle switch to OFF.

2. Move the toggle switch back to ICE.

3. Watch the safety limit lights/harvest light on the control board. If a safety limit has been recorded, the corresponding light will flash once, twice or three times to indicate which safety limit stopped the ice machine.

Safety limits are stored and indicated by the control board after three cycles. The number of cycles required to stop the ice machine varies for each safety limit.

• Safety Limit 1 all models - If the freeze time

reaches 60 minutes, the control board automatically initiates a harvest cycle. If 6 consecutive 60-minute freeze cycles occur, the ice machine stops

• Safety Limit 2 single evaporator models - If the

harvest time reaches 3.5 minutes, the control board automatically returns the ice machine to the freeze cycle. If 500 consecutive 3.5 minute harvest cycles occur, the ice machine stops.

• Safety Limit 2 quad evaporator models - If the

harvest time reaches 7 minutes, the control board automatically returns the ice machine to the freeze cycle. If 500 consecutive 7 minute harvest cycles occur, the ice machine stops.

• Safety Limit 3 quad evaporator models - If the

low refrigerant pressure control opens, the ice machine shuts off and starts a 5 minute delay period. If 3 consecutive low pressure events occur the ice machine stops and flashes the harvest light.

82 Part Number 80-1479-3 7/10

QUAD EVAPORATOR MACHINES ONLY

When a safety limit condition causes the ice machine to stop, the harvest light on the control board continually flashes on and off. Use the following procedures to determine which safety limit has stopped the ice machine.

1. Move the toggle switch to OFF.

2. Move the toggle switch back to ICE.

3. Watch the harvest light. It will flash one or two times, corresponding to safety limits 1 and 2, to indicate which safety limit stopped the ice machine.

After safety limit indication, the ice machine will restart and run until a safety limit is exceeded again.

When a safety limit condition is exceeded for 3 consecutive cycles the control board enters the limit to memory and the ice machine continues to run. Use the following procedure to determine if the control board contains a safety limit indication.

1. Move the toggle switch to OFF.

2. Move the toggle switch back to ICE.

3. Watch the harvest light. It will flash one or two times, corresponding to safety limits 1 and 2, to indicate which safety limit stopped the ice machine.

When a safety limit condition is exceeded (6 consecutive cycles for safety limit #1 or 500 cycles for safety limit #2) the ice machine stops, and the harvest light on the control board flashes on and off. Use the following procedure to determine which safety limit has stopped the ice machine.

1. Move the toggle switch to OFF.

2. Move the toggle switch back to ICE.

3. Watch the harvest light. It will flash one or two times, corresponding to safety limits 1 and 2, to indicate which safety limit stopped the ice machine.

After safety limit indication, the ice machine will restart and run until a safety limit is exceeded again.

Part Number 80-1479-3 7/10 83

Safety Limit Stand-By Mode:

The first time a safety limit shut down occurs, (three consecutive long freeze or harvest cycles) the ice machine will turn off for 60 minutes (Stand-By Mode).

84 Part Number 80-1479-3 7/10

ANALYZING WHY A SAFETY LIMIT STOPPED THE ICE MACHINE

According to the refrigeration industry, a high percentage of compressors fail as a result of external causes. These can include: flooding or starving expansion valves, dirty condensers, water loss to the ice machine, etc. The safety limits protect the ice machine (primarily the compressor) from external failures by stopping ice machine operation before major component damage occurs.

The safety limit system is similar to a high pressure cut-out control. It stops the ice machine, but does not tell what is wrong. The service technician must analyze the system to determine what caused the high pressure cut-out, or a particular safety limit, to stop the ice machine.

The safety limits are designed to stop the ice machine prior to major component failures, most often a minor problem or something external to the ice machine. This may be difficult to diagnose, as many external problems occur intermittently.

Example: An ice machine stops intermittently on safety limit #1 (long freeze times). The problem could be a low ambient temperature at night, a water pressure drop, the water is turned off one night a week, etc.

Refrigeration and electrical component failures will cause a safety limit trip. Eliminate all electrical components and external causes first. If it appears that the refrigeration system is causing the problem, use Manitowoc’s Freeze Cycle Refrigeration System Operational Analysis Table, along with detailed charts, checklists, and other references to determine the cause.

The following checklists are designed to assist the service technician in analysis. However, because there are many possible external problems, do not limit your diagnosis to only the items listed.

Part Number 80-1479-3 7/10 85

SAFETY LIMIT #1 Water System

1. Water supply to machine is being interrupted

2. Water leaking down the drain during freeze (dump valve or water tracking into condensate tray)

3. Water tracking into bin

4. Uneven water flow over evaporator

5. Water pump not pumping

Electrical System

1. Improper voltage (low)

2. Ice thickness probe adjustment too thick

3. Water level probe open / dirty

4. Water inlet valve failure

5. Contactor failure

6. Compressor failure / start component failure page 146

Refrigeration System

1. Dirty condenser

2. Low on Refrigerant

3. Starving TXV

4. Head Pressure Control Valve stuck in Bypass

5. Harvest valve leaking through or stuck open

6. Inefficient compressor

86 Part Number 80-1479-3 7/10

SAFETY LIMIT #2 Water System

1. Ice thickness control probe is dirty causing a premature harvest with no ice on the plate. page 149

2. Dirty evaporator causing a long harvest and ice melt out. page 131

Electrical System

1. Ice thickness probe adjustment too close

2. Bin switch failed closed

3. Harvest valve not energizing

4. Quad Evaporator Only - Harvest pressure solenoid valve not energizing.

Refrigeration System

1. Non-Manitowoc components

2. Incorrect refrigerant charge

3. TXV flooding

4. Defective harvest valve

5. Defective fan cycle control - will not open (page 167)

6. Defective Head Pressure Control Valve - will not bypass (page 164)

7. Quad Evaporator Only - Harvest pressure solenoid valve not energizing.

Part Number 80-1479-3 7/10 87

SAFETY LIMIT #3 Water System

1. Water supply to machine is being interrupted

2. Water leaking down the drain during freeze (dump valve or water tracking into condensate tray)

3. Water tracking into bin

4. Uneven water flow over evaporator

5. Water pump not pumping

Electrical System

1. Water level probe prematurely statisfied

2. Water inlet valve failure

3. Water pump failure

Refrigeration System

1. Low on Refrigerant

2. Starving TXV

88 Part Number 80-1479-3 7/10

Control Board Testing

All replacement S Model control boards and ice machines with serial numbers larger than 110924847 have a control board that includes a diagnostic test cycle. The control board can be identified by the blue printed circuit board and a push button switch on the bottom left corner labeled “service mode”.

CONTROL BOARD TEST CYCLE

1. Place the toggle switch in the ice position.

2. Press and hold the test button for 5 seconds.

3. The control board memory is cleared. A. All safety limits are cleared B. Resets to factory default settings

C. Calibration is cleared for ice thickness &

water level probe.

4. The control board relays close at 1 second

intervals and energize the corresponding control board light.

5. The relays remain closed and the lights remain

energized for 3.5 minutes to allow time to test voltage at components.

6. After 3.5 minutes the ice machine automatically

exits the test cycle.

7. An ice making cycle will automatically start

(unless the toggle switch is moved to OFF).

8. Water level and ice thickness probe calibration

are processed and stored in control board memory during the second

ice making cycle.

The test cycle can be terminated at anytime by moving the toggle switch from ICE to OFF, or by disconnecting and reapplying line voltage to the ice machine.

Part Number 80-1479-3 7/10 89

Troubleshooting By Symptom

The troubleshooting procedures follow flow charts. There are four symptoms, the symptom that you are experiencing will determine which flow chart to use. The flow chart asks yes and no questions to determine the problem. The flow chart will direct you to a procedure to correct the problem. Traditional remote and self contained models use seperate charts.

SYMPTOM #1

Ice Machine Stops Running

Toggle Switch is in the ICE position or Has a History of Shutting Down

• Refer to Ice Machine Stops Running Flow Chart (page 90)

SYMPTOM #2

Ice Machine has a Long Freeze Cycle.

Ice Formation is Thick or Thin Ice Fill on Top or Bottom of Evaporator or Low Production

Safety Limit #1 (possible)

• Refer to Freeze Cycle Refrigeration System

Operational Analysis Table (page 105)

SYMPTOM #3

Ice Machine Will Not Harvest - Freeze Cycle is Normal and Ic e Cub es are No t Mel ted After Harvest

Safety Limit #2 (possible)

• Refer to Refrigeration Harvest Flow Chart

(page 127)

Symptom #4 Ice Machine Will Not Harvest - Freeze Cycle is

Normal and Ice Cubes are Melted After Harvest

• Refer to Ice Meltout Flow Chart

(page 131)

90 Part Number 80-1479-3 7/10

SYMPTOM #1 ICE MACHINE WILL NOT RUN

Ice Machine Stops Running or Has a History of Shutting Down

YES

Control board has

energized lights?

Does ice machine run in CLEAN?

Does the

ice machine start when toggle switch is

moved to ICE?

Refer to

“Diagnosing an

Ice Machine that Will Not Run”

Continued on Next Page...

Part Number 80-1479-3 7/10 91

YES

Are

Water Curtain/Ice Dampers

in place?

YES

SL1/

Harvest (once)

Run machine &

check for

Normal Operation

Refer to Bin

Switch Diagnostics

Are

Water Curtain/Ice Damper

magnets attached?

Install

Water Curtain/

Ice Dampers

Replace the Water Curtain/

Ice Dampers

SL2/

Harvest (twice)

Harvest (3 times)

Which light flashed immediately after

resetting the toggle switch?

Refer to Safety Limit #1

Long Freeze Cycle

Refer to Safety Limit #2

Long Harvest Cycle

Refer to Safety Limit #3

Low Pressure

92 Part Number 80-1479-3 7/10

COMPRESSOR ELECTRICAL DIAGNOSTICS

The compressor does 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. 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 then remove the wires from the compressor terminals.

2. 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 and remove the wires from the compressor terminals.

2. 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.

Part Number 80-1479-3 7/10 93

CHECK MOTOR WINDINGS TO GROUND

Check continuity between all three terminals and the compressor shell or copper refrigeration line. Scrape metal surface to get good contact. If continuity is present, the compressor windings are grounded and the compressor should be replaced.

COMPRESSOR DRAWING LOCKED ROTOR

To determine if the compressor is seized, check the amp draw while the compressor is trying to start.

The two likely causes of this are a defective starting component and a mechanically seized compressor.

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 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.

94 Part Number 80-1479-3 7/10

SYMPTOM #2 LOW PRODUCTION, LONG FREEZE Ice Machine has a Long Freeze Cycle.

Ice Formation is Thick or Thin Ice Fill on Top or Bottom of Evaporator or Low Production

How to Use the Freeze Cycle Refrigeration System Operational Analysi s Table

GENERAL

These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear defective.

The tables list five different defects that may affect the ice machine’s operation.

NOTE: A low-on-charge ice machine and a starving

expansion valve have very similar characteristics and are listed under the same column.

NOTE: Before starting, see “Before Beginning

Service” for a few questions to ask when talking to the ice machine owner.

Part Number 80-1479-3 7/10 95

PROCEDURE

Step 1 Complete the “Operation Analysis” column.

Read down the left “Operational Analysis” column. Perform all procedures and check all information listed. Each item in this column has supporting reference material to help analyze each step.

While analyzing each item separately, you may find an “external problem” causing a good refrigerant component to appear bad. Correct problems as they are found. If the operational problem is found, it is not necessary to complete the remaining procedures.

Step 2 Enter check marks (

).

Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a check mark.

Example: Freeze cycle suction pressure is determined to be low. Enter a check mark in the “low” column.

Step 3 Add the check marks listed under each of the four columns. Note the column number with the highest total and proceed to “Final Analysis.”

NOTE: If two columns have matching high numbers,

a procedure was not performed properly, supporting material was not analyzed correctly or the problem component is not covered by the analysis table.

96 Part Number 80-1479-3 7/10

SYMPTOM #2 - FREEZE CYCLE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

S MODELS SINGLE EXP ANSION VALV E

Operational Analysis 1 2 3 4

Ice Production

Air-Temperature Entering Condenser_____________ Water Temperature Entering Ice Machine_________ Published 24 hour ice production________________ Calculated (actual) ice production_______________ NOTE: The ice machine is operating properly if the ice fill patterns is normal and ice production is within 10% of charted capacity.

Installation and Water System

All installation and water related problems must be corrected before proceeding with chart.

Ice Formation Pattern

Ice formation is extremely

thin on outlet of

evaporator

-or-

No ice formation on the

entire evaporator

Ice formation is

extremely thin on outlet

of evaporator

-or-

No ice formation on

entire evaporator

Ice formation normal

-or-

Ice formation is

extremely thin on inlet of

evaporator

-or-

No ice formation on

entire evaporator

Ice formation normal

-or-

No ice formation on

entire evaporator

Freeze Cycle Discharge Pressure _______ ______ ______ 1 minute Middle End into cycle

If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist page 112 to eliminate problems and/or components not listed on this table before proceeding.

Part Number 80-1479-3 7/10 97

Freeze Cycle Suction Pressure _______ ______ _____ 1 minute Middle End

If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist page 115 to eliminate problems and/or components not listed on this table before proceeding.

Suction pressure is High

Suction pressure is

Low or Normal

Suction pressure is

High

Suction pressure is

High

Wait 5 minutes into the freeze cycle. Compare temperatures of

evaporator inlet and evaporator outlet.

Inlet _____________° F (°C) Outlet ___________ ° F (°C) Difference________ ° F (°C)

Inlet and outlet

within 7° F (4°C)

of each other

Inlet and outlet

not

within 7° F (4°C)

of each other

-and-

Inlet is colder than

outlet

Inlet and outlet

within 7°F (4°C)

of each other

-or-

Inlet and outlet

not

within 7°F (4°C)

of each other

-and-

Inlet is warmer than

outlet

Inlet and outlet

within 7°F (4°C)

of each other

S MODELS SINGLE EXP ANSION VALV E

Operational Analysis 1 2 3 4

98 Part Number 80-1479-3 7/10

Wait 5 minutes into the freeze cycle. Compare temperatures of

compressor discharge line

and harvest valve inlet.

The harvest valve inlet is

Hot

-and-

approaches the

temperature of a Hot

compressor discharge

line.

The harvest valve inlet

is Cool enough to hold

hand on

-and-

the compressor

discharge line is Hot.

The harvest valve inlet is Cool enough to hold

hand on

-and-

the compressor

discharge line is Cool

enough to hold hand on.

The harvest valve inlet is Cool enough to hold

hand on

-and-

the compressor

discharge line is Hot.

Discharge Line Temperature

Record freeze cycle discharge line temperature at the end of the freeze cycle

_________°F (°C)

Discharge line temp.

150°F (65°C)

or higher at the end of the

freeze cycle

-------------------------------S850/S1000

Air & Water Only

Discharge line temp.

140°F (60°C) or higher at

the end of the freeze

cycle

Discharge line temp.

150°F (65°C)

or higher at the end of

the freeze cycle

-----------------------------S850/S1000

Air & Water Only

Discharge line temp.

140°F (60°C)

or higher at the end of

the freeze cycle

Discharge line temp.

less than

150°F (65°C) at the end

of the freeze cycle

-------------------------------S850/S1000

Air & Water Only

Discharge line temp.

less than

140°F (60°C) at the end

of the freeze cycle

Discharge line temp.

150°F (65°C) or higher

at the end of the freeze

cycle

-------------------------------S850/S1000

Air & Water Only

Discharge line temp.

140°F (60°C)

or higher at the end of

the freeze cycle

Final Analysis

Enter total number of boxes checked in each column.

Harvest Valve

Leaking

Low On Charge

-Or-

TXV Starving

TXV Flooding Compressor

S MODELS SINGLE EXP ANSION VALV E

Operational Analysis 1 2 3 4

Part Number 80-1479-3 7/10 99

Freeze Cycle Refrigeration System Operational Analysis Tables

S MODELS DUAL EXPANSION VALVE

Operational Analysis 1 2 3 4

Ice Production

Installation and Water System

All installation and water related problems must be corrected before proceeding with table.

Ice Formation Pattern

Left Side_______________

Right Side______________

Ice formation is extremely

thin on outlet of

evaporator

-or-

No ice formation on the

one side of evaporator

Ice formation is

extremely thin on outlet

of one side of

evaporator

-or-

No ice formation on

entire evaporator

Ice formation normal

-or-

Ice formation is

extremely thin at inlet of

one side of evaporator

-or-

No ice formation on

entire evaporator

Ice formation normal

-or-

No ice formation on

entire evaporator

Freeze Cycle Discharge Pressure _______ ______ ______ 1 minute Middle End into cycle

If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist

page 112 to eliminate problems and/or components not listed on this table before proceeding.

100 Part Number 80-1479-3 7/10

Freeze Cycle Suction Pressure _______ ______ _____ 1 minute Middle End

If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist

page 115 to eliminate problems and/or components not listed on this table before proceeding.

Suction pressure is High Suction pressure is Low

or Normal

Suction pressure is

High

Suction pressure is

High

Wait 5 minutes into the

freeze cycle.

Compare temperatures of

compressor discharge line

and both harvest valve

inlets.

The harvest valve inlet is

Hot

-and-

approaches the

temperature of a Hot

compressor discharge

line.

The harvest valve inlet is Cool enough to hold

hand on

-and-

the compressor

discharge line is Hot.

The harvest valve inlet is Cool enough to hold

hand on

-and-

the compressor

discharge line is Cool

enough to hold hand on.

The harvest valve inlet

is Cool enough to hold

hand on

-and-

the compressor

discharge line is Hot.

S MODELS DUAL EXPANSION VALVE

Operational Analysis 1 2 3 4

Manitowoc SD0302A, SY0324A, SY0304A, SY0325W, SY0424A Technician's Handbook

Specifications and Main Features

Frequently Asked Questions

User Manual