Manitowoc Ice BG0260A SERVICE MANUAL

Page 1
Manitowoc
BG0260
Technician’s
Handbook
This manual is updated as new information and models are released.
Visit our website for the latest manual. www.manitowocfsg.com
America’s #1 Selling Ice Machine
Part Number STH48 6/15
Page 2
Page 3
General Information
Model Numbers ...................................5
BG0260A .............................................5
Model/Serial Number ...........................5
Manitowoc Cleaner and Sanitizer ........ 5
Installation
Location of Ice Machine ......................7
Installation Requirements ....................7
Potable Water Requirements .............. 8
Drain Connections ...............................8
Ice Machine Clearance Requirements 8
Electrical Service .................................9
Operation
Ice Making Sequence of Operation .........11
Thermostat settings .............................13
Maintenance
Cleaning & Sanitizing Procedure ......... 16
Cleaning the Condenser .....................20
Removal from Service/Winterization ...21
Page 4
Troubleshooting
Electrical Flowcharts ................................23
Electrical Flowchart Ice Machine Will Not
Run ...................................................... 24
Will Not cycle Into Harvest ...................28
Prematurely Cycles Into Harvest .........31
Refrigeration Troubleshooting ................34
Ice Production/Quality Check ..............35
Component Specifications
Thermostat Settings ............................41
Fan Cycle Control Settings ..................41
Total System Refrigerant Charge ........41
Filter-Driers .......................................... 42
Suction Cleanup Filter-Drier ................42
Charts
Cycle Times/24-Hour Ice Production/
Refrigerant Pressure Charts ....................43
BG0260A .............................................44
Diagrams
Wiring Diagram .........................................45
BG0260 ...............................................46
Refrigeration Tubing Schematics ...........47
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General Information

MODEL NUMBERS BG0260A MODEL/SERIAL NUMBER
These numbers are required when requesting information from your local Manitowoc Distributor, or Manitowoc Ice. The model and serial number are listed on the MODEL/SERIAL NUMBER DECAL affixed to the ice machine.

MANITOWOC CLEANER AND SANITIZER

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

LOCATION OF ICE MACHINE

The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location.
The location must be free of airborne and other contaminants.
The location must not be near heat-generating equipment or in direct sunlight.
The location must be capable of supporting the weight of the ice machine and a full bin of ice.
The location must allow enough clearance for water, drain and electrical connections in the rear of the ice machine.
The location must not obstruct airflow through or around the ice machine.

INSTALLATION REQUIREMENTS

The air temperature must be at least 50°F (10°C), but must not exceed 110°F (43°C).
The water temperature must be at least 50°F (10°C), but must not exceed 100°F (38°C).
The ice machine and bin must be level
Vent the ice machine and bin drains separately
Bin drain termination must have an air gap
A back flow preventer is required on water inlet lines
Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.
Part Number STH48 6/15 7
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POTABLE WATER REQUIREMENTS

Plumbing must conform to local codes
Do not connect the ice machine to a hot water supply. Be sure all hot water restrictors installed for other equipment are working. (Check valves on sink faucets, dishwashers, etc.)
If water pressure exceeds maximum pressure (6 bar) obtain a water pressure regulator from your Manitowoc distributor.
A union for both the ice making and condenser water lines is required
Water inlet lines require insulation to prevent condensation.

DRAIN CONNECTIONS

Drain lines must have a 1.5 inch drop per 5 feet of run (2.5 cm per meter), and must not create traps
The floor drain must be large enough to accommodate drainage from all drains.
Separate insulated bin and water-cooled condenser drain lines are required
The bin and ice machine drains require a vent.

ICE MACHINE CLEARANCE REQUIREMENTS

Air-Cooled Water-Cooled
Top/Sides 5" (13 cm) 5" (13 cm)
Back 8" (20 cm) 8" (20 cm)
8 Part Number STH48 6/15
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ELECTRICAL SERVICE

!
Warning
!
Warning
All wiring must conform to local and national codes.
Voltage
The maximum allowable voltage variation is ± 10% of the rated voltage on the ice machine model/serial number plate at compressor start-up.
Fuse/Circuit Breaker
A separate fuse/circuit breaker must be provided for each ice machine.
The ice machine must be grounded in accordance with national and local electrical codes.
Ground Fault Interrupter Circuit (GFIC)
A GFCI/GFI circuit protection is not recommended with our equipment. If a GFCI/GFI is required by code a GFCI/GFI breaker rather than outlet must be used to avoid intermittent nuisance trips.
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Operation

Ice Making Sequence of Operation

Priming the Water system
The water inlet valve on this machine energizes in the harvest sequence, therefore priming the system with water will allow the system to start up with a full reservoir of water. To prime system add 2 liters of water into the water trough.
1. Freeze Cycle
Turn the toggle switch to ON. The compressor, and water pump will energize, starting the freeze cycle. The pump sprays water into the inverted cups. The water freezes layer by layer, until an ice cube forms in each cup.
The freeze cycle continues and the evaporator thermostat reaches the adjusted se t po i nt .
The thermostat energizes the timer motor and the cam starts to turn. When the cam cycles through the preset freeze time the relays change position and the harvest cycle starts.
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2. Harvest Cycle
The compressor continues to operate and the water pump is de-energized. The harvest valve energizes, allowing hot gas to enter and warm the evaporator. The water valve is also energized, aiding with harvest, as well as filling up the sump with fresh water for a new freeze cycle.
The ice falls from the cups and drops into the bin. The harvest cycle continues until the preset harvest time expires.
The harvest valve and water valve de-energize. If ice cubes are not contacting the bin thermostat, a new freeze cycle is initiated and the water pump energizes and sprays water into the cups.
3. Automatic Shut-Off
When the storage bin is full, ice will contact the bin thermostat inside the bin. If the bin thermostat opens during a freeze cycle the ice machine will finish the freeze cycle and stop when it enters the harvest cycle.
The ice machine remains off until enough ice has been removed from the storage bin to allow the ice to fall clear of the bin thermostat probe. As the ice clears the probe, the bin thermostat warms up and the machine starts another freeze cycle.
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THERMOSTAT SETTINGS

1
2
3
4
5
6
7
1
2
3
4
5
6
7
Bin Thermostat
Small Numbers = Less ice in bin
Large Numbers = More ice in bin
Start at Chart Setting, then adjust as
required
Evaporator Thermostat
Small Numbers = Large dimple & lighter
cubes
Large Numbers = Small Dimple & heavier
cubes
Refer to chart for initial setting
Bin Thermostat:
The bin thermostat sensing bulb is located in holder on the right side of the bin on self storage models. The bin thermostat turns the ice machine on and off as the level of ice in the bin changes. Use the initial setting from the chart and adjust as required.
Evaporator Thermostat:
The evaporator thermostat energizes the timer motor. After the preset time on the timer expires the harvest cycle begins. Refer to chart for correct setting.
Thermostat Setting Chart
Model
Bin Thermostat
Setting
Evaporator
Thermostat Setting
BG0260 5 4
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Page 15

Maintenance

!
Caution
!
Warning
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.
An extremely dirty ice machine must be taken apart for cleaning and sanitizing.
Use only approved Ice Machine Cleaner and Sanitizer. Read and understand all labels printed on bottles before use. Do not mix Ice Machine Cleaner and Sanitizer solutions together.
Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer
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CLEANING & SANITIZING PROCEDURE

!
Caution
Ice machine cleaner is used to remove lime scale or other mineral deposits. Sanitizer is used to remove algae or slime.
Mix 4 liters of water with 500 ml of cleaner in a plastic or stainless container.
Cleaner Water
16 oz (500 ml) 1 gal (4L)
Step 1 Open the front door to access the evaporator compartment. Ice must not be on the evaporator during cleaning and sanitizing. Follow one of the methods below:
Press the power switch at the end of a harvest cycle after ice falls from the evaporator(s).
Press the power switch and allow the ice to melt.
Never use anything to force ice from the evaporator. Damage may result.
Step 2 Remove all ice from the bin and remove top
cover of ice machine
Step 3 Remove overflow tube and drain water sump. Step 4 Remove all parts for cleaning.
A. Remove two thumbscrews and shutter
assembly
B. Remove ice cube slide C. Remove spray bar and vinyl tubing D. Evaporator shield on top of evaporator
NOTE: The tubing, spray bar ends and nozzles can be removed when required for easier cleaning.
.
Mix a solution of cleaner and lukewarm water.
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Step 5 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.
Solution Type Water Mixed With
Cleaner 1 gal (4L) 16 oz (500 ml)
cleaner
Step 6
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. All parts except the ice thickness probe can be soaked when heavily scaled. Rinse all components with clean water.
Part Number STH48 6/15 17
Use 1/2 of the cleaner/water mixture to clean
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Step 7 While components are soaking, use 1/2 of the cleaner/water solution to clean all foodzone surfaces of the ice machine and bin. Use a nylon brush or cloth to thoroughly clean the following ice machine areas:
Evaporator top panel
Side walls
W ater trough interior / exterior
Evaporator and plastic parts - including top, bottom, and sides bin
Step 8 Rinse all areas thoroughly with clean water. Step 9 Mix a solution of sanitizer and lukewarm
water.
Solution Type Water Mixed With
Sanitizer 1 gal (4 L) 2 oz (60 Ml)
Sanitizer
Step 10 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.
Step 11
machine
the solution. When sanitizing, pay particular attention to the following areas:
Sanitize all foodzone surfaces of the ice
and bin. Use a spray bottle to liberally apply
Evaporator top panel
Side walls
W ater trough interior / exterior
Evaporator and plastic parts - including top, bottom, and sides
•Bin
Do not rinse the sanitized areas.
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Step 12 Replace all removed components. NOTE: Spray bar and nozzles.
If the nozzles were removed from the spray bar, take care to prevent cross threading when reassembling.
Verify the spray bar is correctly positioned and the nozzles are aligned to the evaporator cups.
Step 13 Reapply power to the ice machine and move the toggle switch to the on position. Step 14 Discard first batch of ice to remove any flavor transmission from the cleaning process.
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CLEANING THE CONDENSER

!
Warning
!
Warning
Disconnect electric power to the ice machine at the electric service switch before cleaning the condenser. The condenser fins are sharp. Use care when cleaning them.
Air-Cooled Condenser
Clean the condenser at least every six months. Follow the steps below.
1. Shine a flashlight through the condenser to check for dirt between the fins. Blow compressed air through the condenser fins from the inside or use a commercial condenser coil cleaner. Follow the directions and cautions supplied with the cleaner.
2. Straighten any bent condenser fins with a fin comb.
3. Carefully wipe of f the fan blades and motor with a soft cloth. Do not bend the fan blades. If the fan blades are excessively dirty, wash with warm, soapy water and rinse thoroughly.
If you are cleaning the condenser fan blades with water, cover the fan motor to prevent water damage.
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REMOVAL FROM SERVICE/WINTERIZATION

!
Caution
If water is allowed to remain in the ice machine in freezing temperatures, severe damage to some components could result. Damage of this nature is not covered by the warranty.
Follow the procedure below.
1. Disconnect the electric power at the circuit breaker or the electric service switch.
2. Turn off the water supply.
3. Disconnect and drain the incoming ice-making water line at the rear of the ice machine.
4. Disconnect drain tubing and drain water into container and discard.
5. Make sure water is not trapped in any of the water or drain lines.
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Troubleshooting

Electrical Flowcharts

Diagnostic troubleshooting for the ice machine involves following flowcharts that are dependant on symptoms of the failed machine.
Follow the flowcharts for the failure symptom and model you are working on.
NOTE: Refer to the sequence of operation to determine where in the sequence the ice machine has failed. An example would be an ice machine that energizes the gear motor, but the compressor does not energize. Following the electrical flowchart will quickly and easily eliminate non issues.
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ELECTRICAL FLOWCHART ICE MACHINE WILL NOT RUN

Start
Power Supplied to
Ice Machine?
YES
Toggle Switch in
ON Posion?
YES
Plug in Ice Machine, Reset BreakerNO
Move Switch to ON PosionNO
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Part Number STH48 6/15 25
YES
Switch
Illuminated?
YES
Bin Thermostat
Closed?
YES
NO
Remove Ice – Allow to warm and retest
Replace SwitchNO
Ice Contacng
Thermostat?
YES
NO
Verify New Seng
Cycles Machine On/
Adjusng Closes
Thermostat?
YES
Off
Replace Thermostat
NO
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26 Part Number STH48 6/15
YES
Line Voltage to
Compressor
Contactor?
Repair WiringNO
Contacts Closed? YES Replace ContactorNO
YES
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Part Number STH48 6/15 27
Line Voltage to
Compressor?
Repair WiringNO
Verify:
Compressor Overload is Closed, Start Components Funcon
YES
YES
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Part Number STH48 6/15 28
Start
Is the Evaporator
Temperature below
-7°F (-22°C)
Refer to Refrigeraon Diagnosis
(Long Freeze Cycle)
NO
Is the Evaporator Thermostat Contacts closed between #3 &
#2?
YES
Replace Evaporator
Thermostat
NO
Is there Voltage at
the Timer Motor
YES
Repair WiringNO
YES

WILL NOT CYCLE INTO HARVEST

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29 Part Number STH48 6/15
YES
Is the mer
motor turning
the cams?
YES
Aer 25 Minutes of the
Timer turning Cams
YES
Do the Cam Switches
Switch and send voltage to
Water Inlet valve and Hot
Gas Solenoid Valve?
YES
Replace the TimerNO
NO
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Part Number STH48 6/15 30
YES
Is the Water inlet
Valve and Hot Gas
Solenoid Valve
Energized?
NO
Repair Wiring
YES
Refer to: Ice Machine will not Harvest.
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31 Part Number STH48 6/15
Start
Is the Evaporator
Temperature below
-7°F (-22°C)
Refer to Refrigeraon Diagnosis
(Long Freeze Cycle)
NO
Is the Evaporator Thermostat Contacts closed between #3 &
#2?
YES
Replace Evaporator
Thermostat
NO
Is there Voltage at
the Timer Motor
YES
Repair WiringNO
YES

PREMATURELY CYCLES INTO HARVEST

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Part Number STH48 6/15 32
YES
Is the mer
motor turning
the cams?
YES
Aer 25 Minutes of the
Timer turning Cams
YES
Do the Cam Switches
Switch and send voltage to
Water Inlet valve and Hot
Gas Solenoid Valve?
YES
Replace the TimerNO
NO
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33 Part Number STH48 6/15
Is the Water inlet
Valve and Hot Gas
Solenoid Valve
Energized?
Repair Wiring
NO
YES
Refer to: Ice Machine will not Harvest.
YES
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34 Part Number STH48 6/15

Refrigeration Troubleshooting

If the compressor is not energized refer to Electrical Troubleshooting
Refer to Operational Pressure Charts for normal pressures and temperatures
Discharge Pressure Low High High Low
Suction Pressure Low High High Low
Evaporator Inlet Temperature Normal Low High Low
Evaporator Outlet Temperature High Normal High Low
Compressor Discharge Line Temperature
Normal Range =
> 158°F (70°C) @ 70°F (21°C)
>210°F (99°C) @ 110°F (43°C)
Low on
Refrigerant
High
Increases with
run time
Overcharge of
Refrigerant
Normal High
Non Condensible in
Increases with
System
run time
Restricted Capillary
Tube
High
Increases with
run time
Page 35

ICE PRODUCTION/QUALITY CHECK

The amount of ice a machine produces directly relates to the operating water and air temperatures. This means an ice machine with a 68°F
(20°C) outdoor
ambient temperature and 50°F (10.0°C) water produces more ice than the same model ice machine with a 90°F (32°C) outdoor ambient and 70°F (21°C) water.
1. Determine the ice machine operating conditions: Air temp entering condenser: ____° Air temp around ice machine: ____° Water temp entering sump trough: ____°
2. Refer to the appropriate 24-Hour Ice Production Chart.
3. Use the operating conditions determined in Step 1 to find published 24 hr. ice production: ____
Times are in minutes.
Example: 1 min., 15 sec. converts to 1.25 min. (15 seconds ÷ 60 seconds = .25 minutes)
Weights are in grams.
4. Perform an ice production check using the formula below.
1. _________
Freeze Time
2. 1440
_________
Minutes in
24 Hrs.
3. _________
Weight of One
Harvest
+ _________
Harvest Time
_________
Total Cycle
Time
× _________
Cycles per Day
= _________
Total Cycle
Time
_________
Cycles per Day
= _________
Actual 24-Hour
Production
Weighing the ice is the only 100% accurate check. Compare the results of Step 3 with Step 2. Ice
production is normal when these numbers match closely. If they match closely, determine if:
Another ice machine is required.Relocating the existing equipment to lower the load
conditions is required.
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WATER SYSTEM CHECKLIST
A water-related problem often causes the same symptoms as a refrigeration system component malfunction.
Water system problems must be identified and eliminated prior to replacing refrigeration components.
Water area (evaporator) is dirty
Clean as needed
Water inlet pressure not between 1.4 and 5.5 bar
Install a water regulator valve or increase the water
pressure
Incoming water temperature is not between
1.7°C and 32.2°C
If too hot, check the hot water line check valves in
other store equipment
Water filtration is plugged (if used)
Install a new water filter
Hoses, fittings, etc., are leaking water
Repair/replace as needed
Water inlet valve is stuck open or closed
Clean/replace as needed
Water is spraying out of the sump trough area
Stop the water spray
Uneven water flow across the evaporator
Clean the ice machine
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DISCHARGE PRESSURE HIGH CHECKLIST Improper Installation
Refer to Installation section of this manual
Restricted Condenser Air Flow
High inlet air temperatureCondenser discharge air re-circulationDirty condenser finsDefective fan motor
Improper Refrigerant Charge
OverchargedNon-condensable in systemWrong type of refrigerant
Other
High side refrigerant lines/component restricted
(before mid-condenser)
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FREEZE CYCLE DISCHARGE PRESSURE LOW CHECKLIST
Improper Installation
Refer to Installation section of this manual
Improper Refrigerant Charge
UnderchargedWrong type of refrigerant
Other
High side refrigerant lines/component restricted
(before mid-condenser)
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SUCTION PRESSURE HIGH CHECKLIST Improper Installation
Refer to Installation section of this manual
Discharge Pressure
Discharge pressure is too high, and is affecting
suction pressure
Improper Refrigerant Charge
OverchargedWrong type of refrigerantNon Condensible in system
Other
Harvest valve leakingDefective compressor
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SUCTION PRESSURE LOW CHECKLIST Discharge Pressure
Discharge pressure (ambient temperature) is too
low, and is affecting suction pressure - Refer to Installation section of this manual
Improper Refrigerant Charge
UnderchargedWrong type of refrigerant
Other
Restricted capillary tubeCollapsed/restricted suction tubingHarvest valve not opening in harvest cycle
40 Part Number STH48 6/15
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Component Specifications

Important

THERMOSTAT SETTINGS

Model
BG0260A 5 4
Bin
Thermostat
Setting
Evaporator Thermostat
Setting

FAN CYCLE CONTROL SETTINGS

Model Cut-In (Close) Cut-Out (Open)
BG0260A
215 psi
1482 kPa
230 psi
1586 kPa

T OTAL SYSTEM REFRIGERANT CHARGE

This information is for reference only. Refer to the ice machine serial number tag to verify the system charge. Serial plate information overrides information listed on this page.
Model R404A Refrigerant Charge
BG0260A 22 oz (620 g)
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FILTER-DRIERS

Important
The size of the filter-drier is important. The refrigerant charge is critical. Using an improperly sized filter-drier will cause the ice machine to be improperly charged with refrigerant.
Driers are covered as a warranty part. The drier must be replaced any time the system is opened for repairs.

SUCTION CLEANUP FILTER-DRIER

Contaminated systems must have a suction line filter­drier installed to remove contamination. An access valve must be installed on the inlet side of the suction filter to allow pressure drop readings to be obtained.
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Charts

Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts

These charts are used as guidelines to verify correct ice machine operation.
Accurate collection of data is essential to obtain the correct diagnosis.
Ice production checks that are within 10% of the
chart are considered normal.This is due to three factors:
1. The data listed is an average obtained from testing a group of ice machines.
2. Freeze/harvest times have been rounded to the nearest whole number
3. Air and water temperatures will seldom match the charts exactly.
Zero out manifold gauge set before obtaining pressure readings to avoid misdiagnosis.
Discharge and suction pressure are highest at the beginning of the cycle and drop throughout the freeze cycle.
Water temperature will affect suction and discharge pressure 50°F (10°C) water temperature will result in pressures on the lower end of the ranges specified. 90°F (32°C) water temperatures will result in pressures on the upper end of the range specified.
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BG0260A

SELF STORAGE AIR-COOLED
Averages are used for calculations, characteristics will vary depending on your operating conditions.
CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time
Air Temp.
Entering
Condenser
70°F/21°C 30-32 31-38 34-45 90°F/32°C 33-42 40-50 37-60
100°F/38°C 38-44 40-56 42-70
110°F/43°C 40-46 49-60 65-75
1 Times in minutes NOTE: In addition to air/water temperatures, freeze cycle times will
increase/decrease significantly depending on cube weight
24 HOUR ICE PRODUCTION
Air Temp. Entering
Condenser F
1 Based on average ice weight of one Freeze/Harvest cycle 7.5 lbs
(3600 grams) 60 cubes @ 2 oz (60 grams)
70°F 21°C
90°F 32°C
100°F
38°C
110°F
43°C
°/°C
OPERATING PRESSURES
Air
Temperature
Entering
Condenser
50°F 10°C
70°F 21°C
90°F 32°C
100°F
38°C
110°F
43°C
Suction
Pressure
psig/kPa
18-48
124-331
20-50
138-345
25-60
172-414
25-65
172-448
30-65
207-448
Freeze Time
Water Temperature F°/°C
50/10 70/21 90/32
Water Temperature F°/°C
50/10 70/21 90/32
315 lbs
143 kgs
260 lbs
118 kgs
250 lbs
113 kgs
240 lbs
109 kgs
Freeze Cycle Harvest Cycle
Discharge
Pressure
psig/kPa
215-265
1482-1827
215-295
1482-2034
255-355
1758-2448
290-400
1999-2758
330-440
2275-3034
290 lbs
132 kgs
255 lbs
116 kgs
230 lbs
104 kgs
200 lbs
91 kgs
Suction
Pressure
psig/kPa
75-145
517-1000
75-145
517-1000
80-160
552-1103
85-175
586-1207
170-185
1172-1276
Harvest
270 lbs
122 kgs
230 lbs
104 kgs
200 lbs
91 kgs
150 lbs
68 kgs
Discharge
Pressure
psig/kPa
125-150
862-1034
125-150
1862-1034
140-240
965-1655
150-260
1034-1793
170-280
1172-1931
Time
2:45
to
4:00
1
1
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Diagrams

!
Warning

Wiring Diagram

The following pages contain electrical wiring diagrams. Be sure you are referring to the correct diagram for the ice machine you are servicing.
Always disconnect power before working on electrical circuitry.
Part Number STH48 6/15 45
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BG0260

Refer to Nameplate for Voltage Rating
46 Part Number STH48 6/15
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Refrigeration Tubing Schematics

1
7
6
5
4
3
2
1 Compressor 2 Condenser (air or water cooled) 3 Liquid Line Drier 4 Capillary tube 5 Accumulator 6 Heat Exchanger 7Evaporator
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2110 South 26th Street, P.O. Box 1720
Ph: 920-682-0161 Fax: 920-683-7589
Visit us online at: www.manitowocfsg.com
© 2015 Manitowoc Part Number STH48 6/15
Manitowoc Ice
Manitowoc, WI 54221-1720 , USA
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