Manitowoc Ice K-0250 SERVICE MANUAL

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KOOLAIRE

Ice Machines

Technician’s

Handbook

This manual is updated as new information and models are

released. Visit our website for the latest manual. www.kool-aire.com

Part Number STH045 8/15

Safety Notices

Warning

Caution

As you work on Koolaire 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:

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

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

Procedural Notices

Important

As you work on Koolaire 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:

Text in an Important box provides you with information that may help you perform a procedure more efficiently. Disregarding this information will not cause damage or injury, but it may slow you down as you work.

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

Read These Before Proceeding:

Caution

Important

! Warning

Warning

Proper installation, care and maintenance are essential for maximum performance and troublefree operation of your equipment. Visit our website www.kool-aire.com for manual updates, translations, or contact information for service agents in your area.

Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty.

Read this manual thoroughly before operating, installing or performing maintenance on the equipment. Failure to follow instructions in this manual can cause property damage, injury or death.

Do not use electrical appliances or accessories other than those supplied by Koolaire for your ice machine model.

Two or more people or a lifting device are required to lift this appliance.

! Warning

This equipment contains high voltage electricity

Warning

and refrigerant charge. Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.The technician must also be certified in proper refrigerant handling and servicing procedures. All lockout and tag out procedures must be followed when working on this equipment.

Do not damage the refrigeration circuit when installing, maintaining or servicing the unit.

Do not operate equipment that has b een misused, abused, neglected, damaged, or altered/modified from that of original manufactured specifications. This appliance is not intended for use by persons (including children) with reduced physical, sensory or mental capabilities, or lack of experience and knowledge, unless they have been given supervision concerning use of the appliance by a person responsible for their safety. Do not allow children to play with this appliance.

All covers and access panels must be in place and properly secured, before operating this equipment.

Warning

Do not obstruct machine vents or openings.

! Warning

Warning

! Warning

Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.

Do not clean with water jet.

It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.

Two or more people are required to move this equipment to prevent tipping.

! Warning

When using electric appliances, basic

We reserve the right to make product

improvements at any time. S pecifications and

design are subject to change without notice.

precautions must always be followed, including the following:

a. Read all the instructions before using

the appliance.

b. To reduce the risk of injury, close

supervision is necessary when an appliance is used near children.

c. Do not contact moving parts.

d. Only use attachments recommended or

sold by the manufacturer.

e. Do not use outdoors.

f. For a cord-connected appliance, the

following must be included:

• Do not unplug by pulling on cord. To unplug, grasp the plug, not the cord.

• Unplug from outlet when not in use and before servicing or cleaning.

• Do not operate any appliance with a damaged cord or plug, or after the appliance malfunctions or is dropped or damaged in any manner. Contact the nearest authorized service facility for examination, repair, or electrical or mechanical adjustment.

g. Follow applicable lock out tag out

procedures before working on equipment.

h. Connect to a properly grounded outlet

only.

Table of Contents

GENERAL INFORMATION

Model Numbers . . . . . . . . . . . . . . . . . . . . . 13

How to Read a Model Number . . . . . . . . .14

Ice Machine Warranty Information . . . . .15

Commercial Warranty Coverage . . . . .15

Residential Warranty Coverage . . . . .18

Limited Warranty for Ice Storage Bins . .21

Limited Warranty . . . . . . . . . . . . . . . . .21

INSTALLATION

Location of Ice Machine . . . . . . . . . . . . . .25

Ice Machine Clearance Requirements . .26

Clearance Requiremen ts . . . . . . . . . . . . .26

Ice Machine Heat of Rejection . . . . . . . . .27

Leveling the Ice Machine . . . . . . . . . . . . .27

Electrical Requirements . . . . . . . . . . . . . .28

Water Service/Drains . . . . . . . . . . . . . . . .29

Water Supply . . . . . . . . . . . . . . . . . . . .29

Water Inlet Lines . . . . . . . . . . . . . . . . .29

Drain Connections . . . . . . . . . . . . . . . .30

Cooling Tower Applications . . . . . . . . . 30

MAINTENANCE

Interior Cleaning and Sanitizing . . . . . . .33

General . . . . . . . . . . . . . . . . . . . . . . . .33

Cleaning and Sanitizing Procedure . . . 33

Toggle switch Operation . . . . . . . . . . .34

Remove Parts for Cleaning . . . . . . . . .38

Preventative Maintenance Cleaning . . . .40

Ice Machine Inspection . . . . . . . . . . . . . .41

Cleaning the Condenser . . . . . . . . . . . . . 42

Removal from Service/Winterization . . .43

Air-cooled Models . . . . . . . . . . . . . . . .43

Water-cooled Models . . . . . . . . . . . . .43

Part Number STH045 8/15 9

OPERATION

Ice Making Sequence of Operation . . . . 45

Control Board Timers . . . . . . . . . . . . 46

Energized Parts Chart . . . . . . . . . . . . 48

Operational Checks . . . . . . . . . . . . . . . . . 50

Ice Thickness Check . . . . . . . . . . . . . 50

TROUBLESHOOTING

Control Board Test Mode . . . . . . . . . . . . 51

Diagnosing an Ice Machine that Will Not Run

Ice Machine Does Not Cycle Into Harvest when Water Loses Contact with the Harvest

Float Switch . . . . . . . . . . . . . . . . . . . . . . . 53

Ice Machine Cycles Into Harvest Before Water loses Contact with the Harvest Float Switch

Ice Production Check . . . . . . . . . . . . . . . 56

Installation/Visual Inspection Checklist 57

Water System Checklist . . . . . . . . . . . . . 58

Ice Formation Pattern . . . . . . . . . . . . . . . 59

Safety Limits . . . . . . . . . . . . . . . . . . . . 61

Analyzing Discharge Pressure . . . . . . . . 68

Analyzing Suction Pressure . . . . . . . . . . 70

Harvest Valve . . . . . . . . . . . . . . . . . . . . . . 74

Comparing Evaporator Inlet/Outlet

Temperatures . . . . . . . . . . . . . . . . . . . . . . 78

Discharge Line Temperature Analysis . 79 Refrigeration Component Diagnostics . 81

Final Analysis . . . . . . . . . . . . . . . . . . . 83

Refrigeration Component Diagnostic Chart

10 Part Number STH045 8/15

COMPONENT CHECK PROCEDURES

Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . .87

Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . .88

Float Switch . . . . . . . . . . . . . . . . . . . . . . . 90

Compressor Electrical Diagnostics . . . . 92

Fan Cycle Control . . . . . . . . . . . . . . . . . . .94

High Pressure Cutout (HPCO) Control . .95

Refrigeration Components . . . . . . . . . . .96

Head Pressure Control Valve . . . . . . . 96

Harvest Pressure Regulating (HPR) System

Remote Condenser Only . . . . . . . . . . . 100

Water Regulating Valve . . . . . . . . . . .103

Refrigerant Recovery/Evacuation . . . . . .104

Definitions . . . . . . . . . . . . . . . . . . . . . .104

Refrigerant Re-use Policy . . . . . . . . . .105

Recovery and Recharging Procedures 107 Remote Condenser Model Procedure .110

System Contamination Cleanup . . . . . . . 113

Determining Severity of Contamination 113 Mild System Contamination Cleanup

Procedure . . . . . . . . . . . . . . . . . . . . . .115

Severe System Contamination Cleanup

Procedure . . . . . . . . . . . . . . . . . . . . . .116

Replacing Pressure Controls without

Removing Refrigerant Charge . . . . . . .117

Refrigerant Amount . . . . . . . . . . . . . . . . .119

Part Number STH045 8/15 11

YCHARTS

Cycle Times, 24 Hr. Ice Production and

Refrigerant Pressure Charts . . . . . . . . . . 121

K0250A Self-contained Air-cooled . . . 122 K0350A Self-contained Air-cooled . . . 123 K0350W Self-contained Water-cooled 124 K0420A Self-contained Air-cooled . . . 125 K0420W Self-contained Water-cooled 126 K0500A Self-contained Air-cooled . . . 127 K0500W Self-contained Water-cooled 128 K0600A Self-contained Air-cooled . . . 129 K0600W Self-contained Water-cooled 130 K1000A Self-contained Air-cooled . . . 131 K1000W Self-contained Water-cooled 132

K1000N Remote Air-cooled . . . . . . . . 133

K1350A Self-contained Air-cooled . . . 134 K1350W Self-contained Water-cooled 135

K1350N Remote Air-cooled . . . . . . . . 136

DIAGRAMS

Wiring Diagrams . . . . . . . . . . . . . . . . . . . 137

Wiring Diagram Legend . . . . . . . . . . . 137

K0250, K0350, K0420, K0500, K0600, K1000  Self contained Air OR Water-cooled . . 138

K1000 Remote Air-cooled . . . . . . . . . 139

K13500 - K1800 Air or Water-cooled . 140 K13500 - K1800 Air or Water-cooled . 141 K13500 - K1800 remote Air-cooled . . 142 K13500 - K1800 remote Air-cooled . . 143

Electronic Control Board . . . . . . . . . . . 144

Refrigeration Tubing Schematics . . . . . 145

Self-contained Air or Water-cooled . . . 145

Remote Air-cooled . . . . . . . . . . . . . . . 146

12 Part Number STH045 8/15

General Information

Model Numbers

This manual covers the following models:

Self-Contained

Air-Cooled

KD0250A KY0250A KD0350A KY0350A KD0420A KY0420A KD0500A KY0500A KD0600A KY0600A KD1000A KY1000A KD1350A KY1350A

Self-Contained

Water-Cooled

----

---KD0350W KY0350W KD0420W KY0420W KD0500W KY0500W KD0600W KY0600W KD1000W KY1000W KD1350W KY1350W

Remote

----

---KY1000N KD1000N KY1350N KD1350N

Part Number STH045 8/15 13

How to Read a Model Number

! Warning

A - Air-cooled W - Water-cooled N - Remote Air-cooled

Series

Condenser

Type

Model

K D 0350 A E

D - Dice Y - Half-dice

Cube Size

E - WRAS 50Hz

An ice machine contains high voltage electricity and refrigerant charge. Repairs are to be performed by properly trained refrigeration technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.

14 Part Number STH045 8/15

Ice Machine Warranty Information

Important

Owner Warranty Registration Card General

Warranty coverage begins the day the ice machine is installed.

Complete and mail the OWNER WARRANTYREGISTRATION CARD as soon as possible to validate the installation date.

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

COMMERCIAL WARRANTY COVERAGE

The Koolaire brand warranty is administered through Manitowoc Ice (hereinafter referred to as the “COMPANY”) warrants for a period of 36 months from the installation date (except as limited below) that new ice machines manufactured by the C OMP ANY 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 and evaporator shall apply for an additional tenty four months, excluding all 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.

Part Number STH045 8/15 15

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 Factory Authorized Service Company 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.

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.

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.

In no event shall the

16 Part Number STH045 8/15

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.

Warranty Service

To comply with the provisions of the warranty, a refrigeration service company qualified and authorized by your Koolaire distributor, or a Factory Authorized Servicer must perform the warranty repair.

Service Calls

Normal maintenance, adjustments and cleaning as outlined in this manual are not covered by the warranty.

For factory assistance Contact: Manitowoc Foodservice Ice Machine Division

2110 South 26th Street, PO Box 1720,

Manitowoc WI, 54221-1720 T elephone: 920-682-0161 Fax: 920-683-7585

Website: www.kool-aire.com

Authorized

Part Number STH045 8/15 17

RESIDENTIAL WARRANTY COVERAGE WHAT DOES THIS LIMITED WARRANTY COVER?

Subject to the exclusions and limitations below, Manitowoc Foodservice (“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?

Product CoveredWarranty Period Ice MachineTwelve (12) months from the sale date

WHO IS COVERED BY THIS LIMITED WARRANTY? This limited warranty only applies to the original

consumer of the Product and is not transferable.

WHAT ARE MANITOWOC’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.

18 Part Number STH045 8/15

HOW TO OBTAIN WARRANTY SERVICE To obtain warranty service or information regarding

your Koolaire product, please contact: MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.kool-aire.com 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.

Except As Stated In The Following Sentence, This Limited Warranty Is The Sole And Exclusive Warranty Of Manitowoc With Regard T o The Product. All Implied Warranties Are S trictly Limited To The Duration Of The Limited Warranty Applicable To The Products As Stated Above, Including But Not Limited To, Any Warranty Of Merchantability Or Of Fitness For A Particular Purpose.

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

Continued on next page …

Part Number STH045 8/15 19

In No Event Shall Manitowoc Or Any Of Its Affiliates Be Liable To The Consumer Or Any Other Person For Any Incidental, Consequential Or Special Damages Of Any Kind (Including, Without Limitation, Loss Profits, Revenue Or Business) Arising From Or In Any Manner Connected With The Product, Any Breach Of This Limited Warranty, Or Any Other Cause Whatsoever, Whether Based On Contract, Tort Or 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 T o 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 following registration card and send it to Manitowoc.

For factory assistance Contact: Manitowoc Foodservice Ice Machine Division

2110 South 26th Street, PO Box 1720,

Manitowoc WI, 54221-1720 T elephone: 920-682-0161 Fax: 920-683-7585

Website: www.kool-aire.com

20 Part Number STH045 8/15

Limited Warranty for Ice Storage Bins

LIMITED WARRANTY

Koolaire®, a division of Manitowoc FSG Operations, LLC (“Company”), warrants the new Ice Storage Bin sold by 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.

WHAT IS COVERED

Parts and Labor for a period of twelve (12) months. The Ice Storage Bin Warranty begins on the date of

the original installation. This Warranty shall not apply to any Ice Storage Bin initially installed more than five (5) years from the serial number production date.

The obligation of the Company under this Warranty is limited to the repair or replacement of parts, components, or assemblies that in the sole 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 costs, accessing or removal of the Ice Storage Bin or shipping are the responsibility of the Purchasers, along with all maintenance, adjustments, cleaning and ice purchase. Labor covered under this Warranty must be performed by an approved Company contracted Service Representative or a refrigeration service agency as qualified and authorized by the Company’s local Distributor. Company’s liability under this Warranty shall in no event be greater than the actual purchase price paid by the purchaser for the Ice Storage Bin.

Part Number STH045 8/15 21

EXCLUSIONS FROM COVERAGE

Repair or replacement of parts required because of misuse, improper care or storage, negligence, alteration, use of incompatible supplies or lack of specified maintenance shall be excluded.

• Normal maintenance items. Failures caused by adverse environmental, water conditions or improper drainage.

• Improper or unauthorized repair

• Any Ice Storage Bin that has been installed and or maintained inconsistent with the instructions provided by the Company

• Parts subject to damage beyond the control of the Company, or to the Ice Storage Bin’s which have been subject to accidents, damage in shipment, fire, floods, other hazards acts of God that are beyond the control of the Company.

• This Limited Warranty shall not apply if the Ice Storage Bin is modified with parts and assemblies other than those manufactured by the Company, unless the Company approves these modifications for specific locations in writing prior to the commencement of the modification.

22 Part Number STH045 8/15

LIMITATIONS OF LIABILITY

The preceding paragraphs set forth the exclusive remedy for all claims based on failure of, or defect in, Ice Storage Bins sold hereunder, whether the failure or defect arises before or during the Warranty period and whether a claim, however instituted , is based on contract, indemnity, Warranty, tort (including negligence), strict liability ,implied by stat ute, common law or otherwise, and Company and agents shall not be liable for any claims for personal injuries or consequential damages or loss, howsoever caused. Upon the expiration of the Warranty period, all such liability shall terminate. THE FOREGOING WARRANTIES ARE EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, IMPLIED OR STATUTORY. NO IMPLIED WARRANTY OF MERCANTABILITY OR FITNESS FOR PARTICULAR PURPOSE SHALL APPLY; COMPANY DOES NOT WARRANTY ANY PRODUCTS OR SERVICES OF OTHERS.

REMEDIES

The liability of Company for breach of any Warranty obligation

hereunder is limited to: (i) the repair or replacement of the Ice Storage Bin on which the liability is based, or with respect to services, re-performance of the services; or (ii) at Company’s option, the refund of the amount paid for the said equipment or services, Any breach by Company with respect to any item or unit or equipment or services shall be deemed a breach with respect to any item or unit of equipment or services shall be deemed a breach with respect to that item or unit or service only.

Part Number STH045 8/15 23

WARRANTY CLAIM PROCEDURE

Customer shall be responsible to: Complete and return Warranty registration card or

All Warranty service must be performed by an approved Koolaire contracted or authorized Service Representative.

To schedule a service appointment contact your local Koolaire Service Representative or visit us at www.kool-aire.com to find a Service Representative near you.

GOVERNING LAW

This Limited Wa rranty shall be governed b y the laws of the state of Wisconsin, USA, excluding their conflicts of law principles. The United Nations Convention on Contracts for the International Sale of Goods is hereby excluded in its entirety from application to this Limited Warranty.

For factory assistance contact: Manitowoc Ice Machine Division 21 10 South 26th Street, P.O. Box 1720 Manitowoc, WI 54221-1720 Telephone: 844-724-2273 Website:www.kool-aire.com

24 Part Number STH045 8/15

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 indoors.

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

• Air temperature: Must be at least 40°F (4°C) but must not exceed 110°F (43.4°C).

• 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 condenser air flow is in the back and out the sides. Refer to the chart 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.

Part Number STH045 8/15 25

Ice Machine Clearance Requirements

! Warning

Caution

Clearance Requirements

Do not obstruct ice machine vents or openings

K0250

Top/Sides 12" (30.5 cm) n/a

Back 5" (12.7 cm)* n/a

K0350 - K0420 K0500 - K0600 K1000 - K1350

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

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

*There is no minimum clearance required for water-cooled or remote ice machines. This value is recommended for efficient operation and servicing only.

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Self-Contained

Water-Cooled*

Water-Cooled

and Remote*

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 co vered by the warranty.

26 Part Number STH045 8/15

Ice Machine Heat of Rejection

Caution

Series

Ice Machine

K0250 4600 5450 K0350 3800 6000 K0420 5400 6300 K0500 5300 6100 K0600 9000 13900 K1000 16250 18600 K1350 28300 34300

1 B.T.U./Hour 2 Because the heat of rejection varies during the ice making

cycle, the figure shown is an average.

Ice machines, like other refrigeration equipment, reject heat through the condenser. It is helpful to know the amount of heat rejected by the ice machine when sizing air conditioning equipment where self-contained air-cooled ice machines are installed.

Heat of Rejection Air

Conditioning

Peak

Leveling the Ice Machine

1. The leveling legs must be screwed into the bottom of the bin as far as possible.

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

2. Move the bin into its final position.

3. Use a level on top of the bin. Adjust each foot as necessary and level from front to back and side to side.

Part Number STH045 8/15 27

Electrical Requirements

! Warning

Voltage

The maximum allowable voltage variation is ±10% of the rated voltage on the ice machine model/serial number plate at start-up (when the electrical load is highest).

Fuse/Circuit Breaker

A separate fuse/circuit breaker must be provided for each ice machine.

Total Circuit Ampacity

The total circuit ampacity is used to help select the wire size of the electrical supply.

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

Refer to ice machine data plate, for electrical requirements. The ice machine data plate information overrides all other published data.

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

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

28 Part Number STH045 8/15

Water Service/Drains

Important

! Warning

WATER SUPPLY

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

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

For ice making, connect to a potable water supply only.

WATER INLET LINES

Follow these guidelines to install water inlet lines:

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

• If water pressure exceeds the maximum recommended pressure, 80 psig (5.5 bar) obtain a water pressure regulator from your Koolaire distributor.

• Install a water shut-off valve for ice making potable water.

• Insulate water inlet lines to prevent condensation.

Part Number STH045 8/15 29

DRAIN CONNECTIONS

Caution

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

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

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

• Install a tee to vent the ice machine drain to the atmosphere.

• Insulate drain lines to prevent condensation.

COOLING TOWER APPLICATIONS Water Cooled Models Only

A water-cooling tower installation does not require modification of the ice machine. The water regulator valve for the condenser continues to control the refrigeration discharge pressure.

It is necessary to know the amount of heat rejected, and the pressure drop through the condenser and water valves (inlet to outlet) when using a cooling tower on an ice machine.

• Water entering the condenser must not exceed 90°F (32.2°C).

• Water flow through the condenser must not exceed 5 gallons (19 liters) per minute.

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

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

Plumbing must conform to state and local codes

30 Part Number STH045 8/15

WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS

Fitting

Ice Machine

Tubing Size Up to

Fitting

Ice Machine

Water

Pressure

Water

Temperature

Drain

inside diameter

1/2”(1.27 mm) min

3/8" (9.5 mm) min.

Drain 1/2”

3/8" Female

Pipe Thread

Potable water

80 psi (5.5 bar) max.

20 psi (1.38 bar) min.

33°F (0.6°C) min.

90°F (32.2°C) max.

Drain

inside diameter

1/2”(1.27 mm) min

3/8" (9.5 mm) min.

Drain 1/2”

3/8" Female

Pipe Thread

20 psi (1.38 bar) min.

150 psi (10.3 bar) max.

33°F (0.6°C) min.

90°F (32.2°C) max.

Drain

inside diameter

1/2”(1.27 mm) min

3/8" (9.5 mm) min.

Drain 1/2”

3/8" Female

Pipe Thread

—

Location

Part Number STH045 8/15 31

Water Inlet

Ice Making

Water Inlet

Condenser

Water Drain

32 Part Number STH045 8/15

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Maintenance

Caution

Interior Cleaning and Sanitizing

GENERAL

Clean and sanitize the ice machine every six months for efficient operation. If the ice machine requires more frequent cleaning and sanitizing, consult a qualified service company to test the water quality and recommend appropriate water treatment.

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

Use only Manitowoc approved Ice Machine Cleaner and Sanitizer. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Read and understand all labels printed on bottles before use.

CLEANING AND SANITIZING PROCEDURE

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

Part Number STH045 8/15 33

TOGGLE SWITCH OPERATION

Caution

! Warning

Moving the toggle switch to clean will start a Clean cycle.

• Setting the ice machine to stop after the clean cycle: Place the toggle switch in the clean position. The ice machine will stop after the clean cycle.

• Setting the ice machine to start ice making after the clean cycle: Place the toggle switch in the Ice position more than 2 minutes into the clean cycle.

Step 1 Place the toggle switch in the clean position after ice falls from the evaporator at the end of a Harvest cycle. Or, place the toggle switch in the off position and allow the ice to melt off the evaporator.

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

Step 2 Remove all ice from the bin.

Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer.

34 Part Number STH045 8/15

Caution

Do not mix Ice Machine Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.

Step 3 To start a cleaning cycle, move the toggle switch to Clean. Water will flow through the water dump valve and down the drain. Wait until the water trough refills, then add the proper amount of ice machine cleaner to the water trough.

Model Amount of Cleaner

K0250 K0350 K0420 3 ounces (90 ml) K0500 K0600 K1000 5 ounces (150 ml)

K1350 9 ounces (265 ml)

Step 4 Wait until the clean cycle is complete (approximately 24 minutes) then place the toggle switch in the off position and disconnect power and water supplies to the ice machine.

Step 5 Remove parts for cleaning. Refer to the proper parts removal for your machine. Continue with step 6 when the parts have been removed.

Part Number STH045 8/15 35

Step 6 Mix a solution of cleaner and lukewarm water. Depending on 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. (4 l) 16 oz (500 ml) cleaner

Step 7 Use half of the cleaner/water solution 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 brush, sponge or cloth (not a wire brush) to carefully clean the parts. Soak the parts for 5 minutes (15 – 20 minutes for heavily scaled parts). Rinse all components with clean water.

Step 8 While components are soaking, use half 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 plastic parts – including top, bottom and sides

• Bin bottom, sides and top

• Rinse all areas thoroughly with clean water.

36 Part Number STH045 8/15

Step 9 Mix a solution of sanitizer and warm water.

Solution Type Water Mixed With

Sanitizer 3 gal. (12 l) 2 oz (60 ml) sanitizer

Step 10 Use half 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 Use half of the sanitizer/water solution to sanitize all foodzone surfaces of the ice machine and bin. Use a spray bottle to liberally apply the solution. When sanitizing, pay particular attention to the following areas:

• Evaporator plastic parts - including top, bottom and sides

• Bin bottom, sides and top

Do not rinse the sanitized areas. Step 12 Replace all removed compon ents.

Step 13 Wait 25 minutes. Step 14 Reapply power and water to the ice machine

and place the toggle switch in the ice position. Step 15 Water will flow through the water dump valve

and down the drain. Wait until the water trough refills, then add the proper amount of ice machine sanitizer to the water trough.

K0250 K0350 K0420 K0500 K0600 K1000



Model Amount of Sanitizer

3 ounces (90 ml)

K1350 6 ounces (180 ml)

Wait until the sanitize cycle is complete (approximately 24 minutes) then place the toggle switch in the ice position to start ice making.

Part Number STH045 8/15 37

REMOVE PARTS FOR CLEANING

! Warning

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

1. Remove the water curtain

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

• Slide the left pin out.

2. 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.

3. Remove the ice thickness and harvest float switches

• Pull the float switch straight down to disengage.

• Lower the float switch until the wiring connector is visible.

• Disconnect the wire lead from the float switch.

• Remove the float switch from the ice machine.

4. 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.

• Proceed to page 36 Step 6.

38 Part Number STH045 8/15

5. 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.

• Remove the water trough from the bin area.

Part Number STH045 8/15 39

Preventative Maintenance Cleaning

Caution

Warning

This cleaning procedure can be performed between the bi-annual cleaning and saniti zing cycles. This procedure does not require removing the ice from the bin.

Step 1 Place the toggle switch in the off position after ice falls from the evaporator at the end of a Harvest cycle. Or, place the toggle switch in the off position and allow the ice to melt off the evaporator.

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

Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer.

Step 2 To start a cleaning cycle, place the toggle switch in the clean position. Water will flow through the water dump valve and down the drain. Wait until the water trough refills, then add the proper amount of ice machine cleaner to the water trough.

Model Amount of Cleaner

K0250 K0350 K0420 3 ounces (90 ml) K0500 K0600 K1000 5 ounces (150 ml)

K1350 9 ounces (265 ml)

Step 3 Wait until the clean cycle is complete (approximately 24 minutes) then place the toggle switch in the off position.

40 Part Number STH045 8/15

Ice Machine Inspection

Check all water fittings and lines for leaks. Also, make sure the refrigeration tubing is not rubbing or vibrating against other tubing, panels, etc.

There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life.

Exterior Cleaning

Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation.

Sponge any dust and dirt off the outside of the ice machine with mild soap and water. Wipe dry with a clean, soft cloth.

Cleanup any fallen ice or water spills as they occur.

Part Number STH045 8/15 41

Cleaning the Condenser

! Warning

Warning

General

Disconnect electric power to the ice machine head section and the remote condensing unit at the electric service switches before cleaning the condenser.

A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces ice production and shortens component life.

• Clean the condenser at least every six months.

The condenser fins are sharp. Use care when cleaning them.

• Shine a flashlight through the condenser to check for dirt between the fins.

• Blow compressed air or rinse with water from the inside out (opposite direction of airflow).

• If dirt still remains call a service agent to clean the condenser.

42 Part Number STH045 8/15

Removal from Service/Winterization

AIR-COOLED MODELS

1. Clean and sanitize the ice machine.

2. Place the toggle switch in the off position to turn off the ice machine.

3. Turn off the water supply, disconnect and drain the incoming ice-making water line at the rear of the ice machine and drain the water trough.

4. Energize the ice machine, wait one minute for the water inlet valve to open and blow compressed air in both the incoming water and the drain openings in the rear of the ice machine to remove all water.

5. Place the toggle switch in the off posi tion and disconnect the electric power at the circui t breaker or the electric service switch.

6. Fill spray bottle with sanitizer and spray all interior food zone surfaces. Do not rinse and allow to air dry.

7. Replace all panels.

WATER-COOLED MODELS

1. Perform steps 1-6 under “ Air-Cooled Models.”

2. Disconnect the incoming water and drain line from the water-cooled condenser.

3. Energize the ice machine in the freeze cycle. The increasing refrigerant pressure will open the water regulating valve.

4. Blow compressed air through the condenser until no water remains.

Part Number STH045 8/15 43

44 Part Number STH045 8/15

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Operation

Ice Making Sequence of Operation

NOTE: The toggle switch must be in the ON position and the water curtain must be closed before the ice machine will start.

Water Purge Cycle

The ice machine purges any remaining water from the water trough down the drain.

Freeze Cycle

Prechill - The refrigeration system chills the evaporator before water flow over the evaporator starts. The water inlet valve energizes during the pre-chill and remains on until the ice thickness float switch is satisfied.

Freeze - Water flowing across the evaporator freezes and builds ice on the evaporator. After a sheet of ice has formed, the Harvest float switch signals the control board to start a harvest cycle.

Harvest Cycle

Any remaining water is purged down the drain as refrigerant gas warms the evaporator. When the evaporator warms, the sheet of cubes slides off the evaporator and into the storage bin. If all cubes fall clear of the water curtain, the ice machine starts another freeze cycle.

Full Bin Cycle

If the water curtain is held open by ice cubes the ice machine shuts off. When the water curtain closes the ice machine starts a new cycle at the water purge.

Part Number STH045 8/15 45

CONTROL BOARD TIMERS

• The ice machine is locked into the freeze cycle for 6 minutes before a harvest cycle can be initiated. The freeze time lock in feature is bypassed on the initial cycle (manual start or after a full bin/safety limit condition).



During the initial cycle, if the Harvest float Switch is in the down position for 10 continuous seconds during the start of a freeze cycle, a harvest sequence is initiated. In all subsequent cycles if the harvest float switch is in the down position for 10 continuous seconds a safety limit 1 will be indicated.

• The maximum freeze time is 60 minutes at which time the control board automatically initiates a harvest sequence.

• The maximum harvest time is 3.5 minutes. The control board automatically initiates a freeze sequence when these times are exceeded.

• The ice machine will continue to fill with water for up to six minutes, or until the high water float opens for 5 continuous seconds. The control board will energize the water inlet valve one more time 3 minutes into the freeze cycle.Safety Limits

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

Safety limits can be reset by cycling the toggle switch Off/On and starting a new ice making cycle.

A safety limit is indicated by a flashing light on the control board.

Safety Limit 1

If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle.

• After 3 consecutive 60 minute cycles control board light SL#1 light will flash on/off at 1 second intervals.

• If 6 consecutive 60-minute freeze cycles occur, the ice machine stops and the SL#1 light on the control board will be on continuously.



46 Part Number STH045 8/15

Safety Limit 2

If the harvest time reaches 3.5 minutes, the control board automatically returns the ice machine to the freeze cycle.

• If three consecutive 3.5 minute harvest cycles occur the SL#2 light on the control board will flash on/off at 1 second intervals.

• If 100 consecutive 3.5 minute harvest cycles occur, the ice machine stops and the SL#2 light on the control board will be on continuously.

Safety Limit 3 - No water or water loss

If the harvest float switch hasn’t opened for 10 continuous seconds within 4 minutes of the water inlet valve energizing the ice machine stops.

• Safety Limit 3 is bypassed on the initial cycle (manual start or after a full bin/safety limit condition). For all subsequent cycles the ice machine stops for 30 minutes when the water inlet valve is energized for 4 minutes and the harvest float valve didn’t open. Control board lights SL#1 and SL#2 will flash on/off at 1 second intervals.

• The ice machine automatically restarts at the end of the 30 minute delay period and stops flashing the control board lights.

• If 100 consecutive failures occur the ice machine stops and the SL#1 & SL#2 lights flash on/off at 1 second intervals.

• SL#1 & SL#2 will flash 3 times on startup and automatically erase after 100 normal cycles.

Part Number STH045 8/15 47

48 Part Number STH045 8/15

ENERGIZED PARTS CHART Self-Contained Ice Machines

ICE MAKING

SEQUENCE OF

OPERATION

Initial Start-up

1a. Water purge

1b. Delay period

2. Refrigeration System Start-up

2a. Equalize

Pressure

2b. Compressor

Start-up

Freeze Sequence

3. Pre chill

Water Pump

OFF OFF OFF OFF OFF CLOSED CLOSED 5 seconds

OFF ON OFF OFF OFF CLOSED CLOSED 5 seconds OFF ON OFF OFF ON CLOSED CLOSED 5 seconds

OFF OFF ON OFF ON OPEN MAY BE OPEN

Compressor

Harvest

Valve

ON OFF OFF ON OFF CLOSED CLOSED 45 seconds

Water Inlet

Valve

Dump

Valve

(Contactor) &

Condenser Fan

Motor*

Harvest

Float Switch

Ice Thickness

Float Switch

Length of

Time

120

Seconds

OR CLOSED

initial cycle

Thereafter

60 seconds

Part Number STH045 8/15 49

4. Freeze

Harvest

Sequence

ON OFF ON OFF ON OPEN THEN

CLOSED

CLOSED THEN

OPEN

Until

Harvest

Float Switch

closes for

10 continual

seconds

5. Water Purge

6. Harvest

ON ON OFF ON ON CLOSED CLOSED 45 seconds

OFF ON OFF OFF ON CLOSED CLOSED

OFF OFF OFF OFF OFF CLOSED CLOSED

7. Automatic Shut-off

* Condenser Fan Motor: The fan motor is wired through a fan cycle pressure control; therefore, it may cycle on and off.

Bin switch

activation

Until 3 Minute

delay

expires and

bin switch

re-closes

Operational Checks

Ice Thickness Float

Switch Adjustment

ICE THICKNESS CHECK

After a harvest cycle, inspect the ice cubes in the ice storage bin. The ice bridge connects the ice cubes and must be set to maintain an ice bridge thickness of 1/8" (3.2 mm). To adjust the thickness of the bridge refer to ice thickness adjustment.

The ice thickness float switch is factory-set to maintain the ice bridge thickness at 1/8" (3 mm).

NOTE: Make sure the water curtain is in place when performing this check. It prevents water from splashing out of the water trough.

1. Inspect the bridge connecting the cubes. It should be about 1/8" (3 mm) thick.

2. If adjustment is necessary, turn the ice thickness float switch clockwise to increase bridge thickness, counterclockwise to decrease bridge thickness. Adjust to achieve a 1/8" (3 mm) bridge thickness.

NOTE: The float can be adjusted with a 3/4" wrench while the water trough is in-place.Test run two cycles to verify ice bridge thickness.

50 Part Number STH045 8/15

Troubleshooting

Control Board Test Mode

NOTE: The water curtain/bin switch can be open or closed and does not effect the operation of the test mode.

To enter the test mode move the toggle switch to off, then press and hold the test button on the control board for 3 seconds. The control board test mode performs the following functions for a 2 minute time period:

• Energizes all control board relays

• Energizes all control board lights During test mode, all relays will energize in 1 second

intervals. The relays shall energize in the following order:

1. Harvest valve solenoid

2. Water pump

3. Dump valve solenoid

4. Water inlet solenoid

5. Compressor contactor

After 2 minutes the control board will automatically initiate and complete one ice making cycle, then stop.

Canceling a test cycle:

To cancel a test cycle press the test button a second time.

Restarting a test cycle:

The test cycle will restart each time the test button is pressed for a 3 second time period.

Part Number STH045 8/15 51

Diagnosing an Ice Machine

! Warning

that Will Not Run

High (line) voltage is applied to the control board at all times. Removing the control board fuse or cycling the toggle switch Off/On will not remove the power supplied to the control board.

1. Verify primary voltage is supplied to ice machine and the fuse/circuit breaker is closed.

2. Verify control board fuse is okay.

NOTE: If any control board lights are on, the fuse is okay.

3. Verify the bin switch functions properly. A defective bin switch can falsely indicate a full bin of ice.

4. Verify toggle switch functions properly. A defective toggle switch may keep the ice machine in the OFF mode. Refer to toggle switch diagnostics when steps 1-3 test good.

5. Be sure Steps 1 – 4 were followed thoroughly. Intermittent problems are not usually related to the control board. Replace control board if toggle switch operation is correct.

52 Part Number STH045 8/15

Ice Machine Does Not Cycle Into Harvest

HARVEST FLOAT SWITCH

ICE THICKNESS FLOAT

SWITCH

when Water Loses Contact with the Harvest Float Switch

NOTE: The ice machine will make a thick or double slab when a new freeze cycle is started with ice already present on the evaporator.  Two of the most common scenarios are:

• Power is cycled off/on with ice on the evaporator.

• The water curtain/bin switch is opened/closed in

the harvest cycle before the ice releases.

Remove all ice from the evaporator before starting diagnostic procedures.

Freeze Time Lock-In Feature

The ice machine control system incorporates a freeze time lock-in feature. This prevents the ice machine from short cycling in and out of harvest. The control board locks the ice machine in the freeze cycle for six minutes. After six minutes a harvest cycle can be initiated. To allow the service technician to initiate a harvest cycle without delay, this feature is not used on the first cycle after moving the toggle switch to OFF and back to ON.

Part Number STH045 8/15 53

Step 1 Disconnect power to the ice machine, remove the electrical panel to allow viewing of the control board lights. Disconnect the harvest float switch wire from the control board and place a jumper on the control board harvest switch terminals.

Step 2 Bypass the freeze time lock-in feature by moving the toggle switch Off/On to cycle the ice machine on. Wait until water flows over the evaporator, then refer to chart.

Result Correction

10 seconds into the freeze cycle the ice machine cycles from freeze to harvest and the control board harvest light energizes.

The harvest light comes on, but the ice machine remains in the freeze cycle.

The harvest light stays off and the ice machine remains in freeze.

The ice thickness float switch, connectors or wiring are causing the malfunction.

The ice machine is in a 6 minute freeze lock - Cycle on/off and retest.

Replace the control board.

54 Part Number STH045 8/15

Ice Machine Cycles Into Harvest Before

HARVEST FLOAT SWITCH

ICE THICKNESS FLOAT

SWITCH

Water loses Contact with the Harvest Float Switch

Step 1 Disconnect power to the ice machine, remove

the electrical panel to allow viewing of the control board lights and disconnect the harvest float switch from the control board.

Step 2 Reapply power and move the toggle switch to ice to bypass the freeze time lock-in feature. Wait until water flows over the evaporator, then refer to chart.

Result Correction

The harvest light does not come on and the ice machine stays in freeze.

10 seconds into the freeze cycle the ice machine cycles from freeze to harvest and the control board harvest light energizes.

The ice thickness float switch, connectors or wiring are causing the malfunction. Refer to float switch diagnostics.

Replace the control board.



Part Number STH045 8/15 55

Ice Production Check

The amount of ice a machine produces directly relates to the operating water and air temperatures. This means an ice machine with a 70°F (21°C) ambient temperature and 50°F (10°C) water produces more ice than the same ice machine with 90°F (32°C) 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. 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 pounds. Example: 2 lb., 6 oz. converts to 2.375 lb. (6 oz. 16 oz. = .375 lb.)

3. Perform an ice production check using the formula below.

1. _______ + _______ = _______

Freeze Time Harvest Time Total Cycle Time

2. 1440  _______ = _______

Mins in 24 hrs Total Cycle T ime Cycles Per Day

3. _______ x _______ = _______

Weight of One Cycles Per Day Actual 24 Hr

Harvest Production

Weighing the ice is the only 100% accurate check.

4. 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 larger ice machine is required. Relocating the existing equipment to lower the load

conditions is required.

Contact the local distributor for information on available options and accessories.

56 Part Number STH045 8/15

Installation/Visual Inspection Checklist

Ice machine is not level

• Level the ice machine

Condenser is dirty

• Clean the condenser

Water filtration is plugged (if used)

• Install a new water filter

Water drains are not run separately and/or are not vented

• Run and vent drains according to the Installation

Manual

Part Number STH045 8/15 57

Water System Checklist

A water-related problem often causes the same symptoms as a refrigeration system component malfunction.

Example: A water dump valve leaking during the freeze cycle, a system low on charge, and a starving TXV have similar symptoms.

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 20 and 80 psig (1–5 bar, 138–552 kPa)

• Install a water regulator valve or increase the water pressure

Incoming water temperature is not between 35°F (1.7°C) and 90°F (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

Vent tube is not installed on water outlet drain

• See Installation Instructions

Hoses, fittings, etc., are leaking water

• Repair/replace as needed

Water valve is stuck open, closed or is leaking

• 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

Water is freezing behind the evapora tor

• Correct the water flow

Plastic extrusions and gaskets are not secured to the evaporator

• Remount/replace as needed

58 Part Number STH045 8/15

Ice Formation Pattern

INLET

OUTLET

Evaporator ice formation pattern analysis is helpful in ice machine diagnostics.

Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction. However, when this analysis is used along with the Refrigeration System Operational Analysis Table, it can help diagnose an ice machine malfunction.

Example of Evaporator Tubing Routing

Normal Ice Formation

Ice forms across the entire evaporator surface. At the beginning of the Freeze cycle, it may appear

that more ice is forming on the inlet of the evaporator than at the outlet. At the end of the Freeze cycle, ice formation at the outlet will be close to, or just a bit thinner than, ice formation at the inlet. The dimples in the cubes at the outlet of the evaporator may be more pronounced than those at the inlet. This is normal.

If ice forms uniformly across the evaporator surface, but does not do so in the proper amount of time, this is still considered a normal ice fill pattern.

Part Number STH045 8/15 59

Extremely Thin at Evaporator Outlet

There is no ice, or a considerable lack of ice formation on the outlet of the evaporator.

Examples: No ice at all at the outlet of the evaporator, but ice forms at the inlet half of the evaporator. Or, the ice at the outlet of the evaporator reaches the correct thickness, but the outlet of the evaporator already has 1/2" to 1" of ice formation.

Possible cause: Water loss, low on refrigerant, starving TXV, faulty water inlet valve, etc.

Extremely Thin at Evaporator Inlet

There is no ice, or a considerable lack of ice formation at the inlet of the evaporator. Examples: The ice at the outlet of the evaporator reaches the correct thickness, but there is no ice formation at all at the inlet of the evaporator.

Possible cause: Insufficient water flow, flooding TXV, etc.

No Ice Formation

The ice machine operates for an extended period, but there is no ice formation at all on the evaporator.

Possible cause: water inlet valve, water pump, starving expansion valve, low refrigerant charge, compressor, etc.

60 Part Number STH045 8/15

SAFETY LIMITS

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

Safety limits can be reset by cycling the toggle switch Off/On and starting a new ice making cycle.

A safety limit is indicated by a flashing light on the control board.

Safety Limit 1

If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle.

• After 3 consecutive 60 minute cycles control board light SL#1 light will flash on/off at 1 second intervals.

• If 6 consecutive 60-minute freeze cycles occur, the ice machine stops and the SL#1 light on the control board will be on continuously.

Safety Limit 2

If the harvest time reaches 3.5 minutes, the control board automatically returns the ice machine to the freeze cycle.

• If three consecutive 3.5 minute harvest cycles occur the SL#2 light on the control board will flash on/off at 1 second intervals.

• If 100 consecutive 3.5 minute harvest cycles occur, the ice machine stops and the SL#2 light on the control board will be on continuously.

Part Number STH045 8/15 61

Safety Limit 3

If the harvest float switch hasn’t opened for 10 continuous seconds within 4 minutes of the water inlet valve energizing the ice machine stops.

• The ice machine automatically restarts at the end of the 30 minute delay period and stops flashing the control board lights.

• If 100 consecutive failures occur the ice machine stops and the SL#1 & SL#2 lights flash on/off at 1 second intervals.

• SL#1 & SL#2 will flash 3 times on startup and automatically erase after 100 normal cycles.

62 Part Number STH045 8/15

Determining Which Safety Limit Stopped the

Ice Machine:

1. Cycle the toggle switch Off.

2. Cycle the toggle switch On to start ice making.

3. Watch the safety limit lights.

• One will flash corresponding to safety limits 1 or 2.

4. Safety limit 3 is indicated by both SL#1 & SL#2 flashing.

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

Safety Limit Notes

• A continuous run of 100 harvests automatically erases the safety limit code.

• The control board will store and indicate only one safety limit – the last one exceeded.

• If the toggle switch is cycled OFF and then ON prior to reaching the 100-harvest point, the last safety limit exceeded will be indicated.

Part Number STH045 8/15 63

Safety Limit Checklist

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.

Safety Limit #1 Freeze time exceeds 60 minutes for 3 consecutive

freeze cycles.

Possible Cause Checklist

Improper installation

• Refer to “Installation/Visual Inspection Checklist” on page 57

Water System

• Float switch or water escaping water trough

• Low water pressure (20 psig min.)

• High water pressure (80 psig max.)

• High water temperature (90°F/3 2. 2°C max.)

• Clogged water distribution tube

• Dirty/defective water inlet valve

• Defective water pump

Electrical System

• Harvest cycle not initiated electrically

• Contactor not energizing

• Compressor electrically non-operational

• Restricted condenser air flow

• High inlet air temperature (110°F/43.3°C max.)

• Condenser discharge air re-circulation

• Dirty condenser fins

• Defective fan cycling control

• Defective fan motor

• Dirty condenser

64 Part Number STH045 8/15

Refrigeration System

• Non- OEM components

• Improper refrigerant charge

• Defective compressor

• TXV starving or flooding (check bulb mounting)

• Non-condensible in refrigeration system

• Plugged or restricted high side refrigerant lines or component

• Defective harvest valve

Part Number STH045 8/15 65

Safety Limit #2 Harvest time exceeds 3.5 minutes for 100

Consecutive harvest cycles.

Possible Cause Checklist

Improper installation

• Refer to “Installation/Visual Inspection Checklist” on page 57.

Water System

• Water area (evaporator) dirty

• Dirty/defective water dump valve

• Vent tu be not installed on water outlet drain

• Water freezing behind evaporator

• Plastic extrusions and gaskets not securely mounted to the evaporator

Electrical system

• Bin switch defective

• Premature harvest

Refrigeration system

• Non-OEM components

• Improper refrigerant charge

• Defective harvest valve

• TXV flooding (check bulb mounting)

• Defective fan cycling control

66 Part Number STH045 8/15

Safety Limit 3 The harvest float switch hasn’t opened for 10

continuous seconds within 4 minutes of the wat er inlet valve energizing.

Possible Cause Checklist

Improper installation

• Refer to “Installation/Visual Inspection Checklist” on page 57.

Water System

• Water dump valve

• Harvest float valve dirty or defective

• Low water pressure (20 psig min.)

• Dirty defective water filter (when used)

• Loss of water from sump area

• Dirty/defective water inlet valve

Electrical system

• Water inlet valve coil defective

• Harvest float valve defective

Part Number STH045 8/15 67

Analyzing Discharge Pressure

1. Determine the ice machine operating conditions: Air temp. entering condenser ______ Air temp. around ice machine ______ Water temp. entering sump trough ______

2. Refer to “Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts” on page 121 for ice machine being checked.

Use the operating conditions determined in step 1 to find the published normal discharge pressures.

Freeze Cycle ______ Harvest Cycle ______

3. Perform an actual discharge pressure check.

Beginning of

Cycle

Middle of

Cycle

End of

Cycle

Freeze

Cycle PSIG

__________ __________

Harvest

Cycle PSIG

4. Compare the actual discharge pressure (step 3) with the published discharge pressure (step 2).

The discharge pressure is normal when the actual pressure falls within the published pressure range for the ice machine’s operating conditions. It is normal for the discharge pressure to be higher at the beginning of the freeze cycle (when load is greatest), then drop through out the freeze cycle.

68 Part Number STH045 8/15

Discharge Pressure High Checklist

Improper Installation

• Refer to “Installation/Visual Inspection Checklist”

on page 57.

Condenser Air Flow

• High inlet air temperature

• Condenser discharge air re-circulation

• Dirty condenser fins

• Defective fan cycling control

• Defective fan motor

Improper Refrigerant Charge

• Overcharged

• Non-condensible in system

• Wrong type of refrigerant

Other

• Non-OEM components in system

• High side refrigerant lines/component restricted

(before mid-condenser)

Freeze Cycle Discharge Pressure Low Checklist

Improper Installation

• Refer to “Installation/Visual Inspection Checklist”

on page 57.

Improper Refrigerant Charge

• Undercharged

• Wrong type of refrigerant

Other

• Non-OEM components in system

• High side refrigerant lines/component restricted

(before mid-condenser)

• Defective fan cycle control NOTE: Do not limit your diagnosis to only the items

listed in the checklists.

Part Number STH045 8/15 69

Analyzing Suction Pressure

The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times.

To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time.

NOTE: Analyze discharge pressure before analyzing suction pressure. High or low discharge pressure may be causing high or low suction pressure.

70 Part Number STH045 8/15

Procedure

Step

1. Determine the ice machine operating conditions.

Example: Air temp. entering condenser: 90°F/32.2°C Air temp. around ice machine: 80°F/26.7°C Water temp. entering water fill valve: 70°F/21.1°C

2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice machine model being checked. Using operating conditions from Step 1, determine published freeze cycle time and published freeze cycle suction pressure.

Example: Published freeze cycle time: 14.8 - 15.9 minutes Published freeze cycle suction pressure: 65 - 26 psig

2B. Compare the published freeze cycle time and published freeze cycle suction pressure. Develop a chart.

Example: Published Freeze Cycle Time (minutes)

1247101214

|||||||

65 55 47 39 34 30 26

Published Freeze Cycle Suction Pressure (psig) In the example, the proper suction pressure should be approximately 39 minutes; etc.

3. Perform an actual suction pressure check at the beginning, middle and end of the freeze cycle. Note the times at which the readings are taken.

Example: Manifold gauges were connected to the example ice machine and suction pressure readings taken as follows: ________ PSIG Beginning of Freeze cycle: 79 (at 1 min.) Middle of freeze cycle: 48 (at 7 min.) End of freeze cycle: 40 (at 14 min.)

4. Compare the actual freeze cycle suction pressure (Step

3) to the published freeze cycle time and pressure comparison (Step 2B). Determine if the suction pressure is high, low or acceptable.

Example: In this example, the suction pressure is considered high throughout the freeze cycle. It should have been: Approximately 65 psig (at 1 minute) – not 79 Approximately 39 psig (at 7 minutes) – not 48 Approximately 26 psig (at 14 minutes) – not 40

psig at 7 minutes; 30 psig at 12

Part Number STH045 8/15 71

Suction Pressure High Checklist

Improper Installation

• Refer to “Installation/Visual Inspection Checklist” on page 57.

Discharge Pressure

• Discharge pressure is too high, and is affecting suction pressure, refer to

“Discharge Pressure

High Checklist” on page 69.

Improper Refrigerant Charge

• Overcharged

• Wrong type of refrigerant

• Non-condensible in system

Other

• Non-OEM components in system

• Harvest valve leaking

• TXV flooding (check bulb mounting)

• Defective compressor

72 Part Number STH045 8/15

Suction Pressure Low Checklist

Improper Installation

• Refer to “Installation/Visual Inspection Checklist” on page 57.

Discharge Pressure

• Discharge pressure is too low, and is affecting suction pressure, refer to “Freeze Cycle Discharge Pressure Low Checklist”

Improper Refrigerant Charge

• Undercharged

• Wrong type of refrigerant

Other

• Non-OEM components in system

• Improper water supply over evaporator refer to “Water System Checklist” on page 58.

• Loss of heat transfer from tubing on back side of evaporator

• Restricted/plugged liquid line drier

• Restricted/plugged tubing in suction side of refrigeration system

• TXV starving

NOTE: Do not limit your diagnosis to only the items listed in the checklists.

Part Number STH045 8/15 73

Harvest Valve

General

The harvest valve is an electrically operated valve that opens when energized, and closes when de-energized.

Normal Operation

The valve is de-energized (closed) during the freeze cycle and energized (open) during the harvest cycle. The valve is positioned between the compressor discharge line and the evaporator and performs two functions:

1. Prevents refrigerant from entering the evaporator during the freeze cycle.

The harvest valve is not used during the freeze cycle. The harvest valve is de-energized (closed) preventing refrigerant flow from the discharge line into the evaporator.

2. Allows refrigerant vapor to enter the evaporator in the harvest cycle.

During the harvest cycle, the harvest valve is energized (open) allowing refrigerant gas from the discharge line of the compressor to flow into the evaporator. The heat is absorbed by the evaporator and allows release of the ice slab.

Exact pressures vary according to ambient temperature and ice machine model. Harvest pressures can be found in the Cycle Time/24 Hour Ice Production/ Refrigerant Pressure Charts in this book.



74 Part Number STH045 8/15

Harvest Valve Analysis

The valve can fail in two positions:

• Valve will not open in the harvest cycle.

• Valve remains open during the freeze cycle. VALVE WILL NOT OPEN IN THE HARVEST CYCLE Although the circuit board has initiated a harvest cycle,

the evaporator temperature remains unchanged from the freeze cycle.

VALVE REMAINS OPEN IN THE FREEZE CYCLE: Symptoms of a harvest valve remaining partially open

during the freeze cycle can be similar to symptoms of an expansion valve or compressor problem. Symptoms are dependent on the amount of leakage in the freeze cycle.

A small amount of leakage will cause increased freeze times and an ice fill pattern that is “Thin at the Outlet”, but fills in at the end of the cycle.

As the amount of leakage increases the length of the freeze cycle increases and the amount of ice at the outlet of the evaporator decreases.

Refer to the Parts Manual for proper valve application. If replacement is necessary, use only “original” replacement parts.

Part Number STH045 8/15 75

Use the following procedure and table to help

Important

! Warning

determine if a harvest valve is remaining partially open during the freeze cycle.

1. Wait five minutes into the freeze cycle.

2. Feel the inlet of the harvest valve(s).

Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison.

The harvest valve outlet is on the suction side (cool refrigerant). It may be cool enough to touch even if the valve is leaking.

3. Feel the compressor discharge line.

The inlet of the harvest valve and the compressor discharge line could be hot enough to burn your hand. Just touch them momentarily.

4. Compare the temperature of the inlet of the harvest valves to the temperature of the compressor discharge line.

76 Part Number STH045 8/15

Findings Comments

The inlet of the harvest valve is cool enough to

touch and the compressor

discharge line is hot.

Cool & Hot

The inlet of the harvest

valve is hot and approaches

the temperature of a hot

compressor discharge line.

Hot & Hot

Both the inlet of the harvest

valve and the compressor

discharge line are cool

enough to touch.

Cool & Cool

This is normal as the

discharge line should

always be too hot to touch

and the harvest valve inlet,

although too hot to touch

during harvest, should be

cool enough to touch after 5

minutes into the freeze

This is an indication

something is wrong, as the

harvest valve inlet did not

cool down during the freeze

cycle. If the compressor

dome is also entirely hot,

the problem is not a harvest

valve leaking, but rather

something causing the

compressor (and the entire

ice machine) to get hot.

This is an indication

something is wrong, causing

the compressor discharge

line to be cool to the touch.

This is not caused by a

harvest valve leaking.

5. Record your findings on the table.

cycle.

Part Number STH045 8/15 77

Comparing Evaporator Inlet/Outlet

Important

Temperatures

The temperatures of the suction lines entering and leaving the evaporator alone cannot diagnose an ice machine. However, comparing these temperatures during the freeze cycle, along with the Refrigeration System Operational Analysis T able, can help diagnose an ice machine malfunction.

The actual temperatures entering and leaving the evaporator vary by model, and change throughout the freeze cycle. This makes documenting the “normal” inlet and outlet temperature readings difficult. The key to the diagnosis lies in the difference between the two temperatures five minutes into the freeze cycle. These temperatures must be within 7°F (4°C) of each other.

Use this procedure to document freeze cycle inlet and outlet temperatures.

1. Use a quality temperature meter, capable of taking temperature readings on curved copper lines.

2. Attach the temperature meter sensing device to the copper lines entering and leaving the evaporator.

Do not simply insert the sensing device under the insulation. It must be attached to and reading the actual temperature of the copper line.

3. Wait five minutes into the freeze cycle.

4. Record the temperatures below and determine the difference between them.

___________ ___________ ___________

Inlet

Temperature

Difference must be

within 7°F (4°C) at 5

minutes into the

freeze cycle

Outlet

Temperature

5. Use this with other information gathered on the Refrigeration System Operational Analysis Table to determine the ice machine malfunction.

78 Part Number STH045 8/15

Discharge Line Temperature Analysis

GENERAL Knowing if the discharge line temperature is

increasing, decreasing or remaining constant can be an important diagnostic tool. Maximum compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle. Comparing the temperatures over several cycles will result in a consistent maximum discharge line temperature.

Ambient air temperatures affect the maximum discharge line temperature.

Higher ambient air temperatures at the condenser = higher discharge line temperatures at the compressor.

Lower ambient air temperatures at the condenser = lower discharge line temperatures at the compressor.

Regardless of ambient temperature, the freeze cycle discharge line temperature will be higher than 150°F (66°C) on a normally operating ice machine.

PROCEDURE Connect a temperature probe on the compressor

discharge line within 6" (15 cm) of the compressor. Observe the discharge line temperature for the last three minutes of the freeze cycle and record the maximum discharge line temperatur e.

Part Number STH045 8/15 79

Discharge Line Temperature Above 150°F (66°C) at End of Freeze Cycle:

Ice machines that are operating normally will have consistent maximum discharge line temperatures above 150°F (66°C).

Verify the expansion valve sensing bulb is positioned and secured correctly.

Discharge Line Temperature Below 150°F (66°C) at End of Freeze Cycle

Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that decreases each cycle.

Verify the expansion valve sensing bulb is 100% insulated and sealed airtight. Condenser air contacting an incorrectly insulated sensing bulb will cause overfeeding of the expansion valve.

80 Part Number STH045 8/15

Refrigeration Component Diagnostics

All electrical and water related problems must be corrected before these charts will work properly. These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed and external items and problems that will cause good refrigeration components to appear defective.

The tables list four 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.

Part Number STH045 8/15 81

PROCEDURE Step 1 Complete each item individually in the

“Operational Analysis” column. Enter check marks (✓) in the boxes. 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” box.

Perform the procedures and check all information listed. Each item in this column has supporting reference material.

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 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 and/or supporting material was not analyzed correctly.

82 Part Number STH045 8/15

FINAL ANALYSIS

The column with the highest number of check marks identifies the refrigeration problem.

Column 1 – Harvest Valve Leaking

A leaking harvest valve must be replaced.

Column 2 – Low Charge/TXV Starving

Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures. A low refrigerant charge normally affects both pressures. Verify the ice machine is not low on charge before replacing an expansion valve.

Add refrigerant charge in 2 oz. increments as a diagnostic procedure to verify a low charge. (Do not add more than the total charge of refrigerant). If the problem is corrected, the ice machine is low on charge. Find the refrigerant leak.

The ice machine must operate with the nameplate charge. If the leak cannot be found, proper refrigerant procedures must still be followed. Change the liquid line drier, evacuate the system and weigh in the proper charge.

If the problem is not corrected by adding charge, the expansion valve is faulty.

Column 3 – TXV Flooding

A loose or improperly mounted expansion valve bulb causes the expansion valve to flood. Check bulb mounting, insulation, etc., before changing the valve.

Column 4 – Compressor

Replace the compressor and start components. To receive warranty credit, the compress or port s must be properly sealed by crimping and soldering them closed. Old start components must be returned with the faulty compressor.

Part Number STH045 8/15 83

Refrigeration Component Diagnostic Chart

Ice formation is

before proceeding with chart.

production is within 10% of charted capacity.

Published 24 hour ice production ____________

Calculated (actual) 24 hour ice production ____________

All installation and water related problems must be corrected

Note: The ice machine is operating properly if the ice fill patterns is normal and ice

-or-

normal

on entire

Ice formation is

No ice formation

-or-

normal

ice formation is

the bottom of the

extremely thin on

-or-

outlet of

evaporator

Ice formation is

extremely thin on

Ice formation is

extremely thin on

-or-

outlet of evaporator

No ice formation

evaporator

evaporator or

on evaporator

No ice formation

on entire

evaporator

on entire

evaporator

Analysis

Operational

84 Part Number STH045 8/15

Ice Production

Installation and

Water system

Pattern

Ice Formation

within 7°

of each other

Inlet and outlet

High

Suction

pressure is

Inlet and outlet

within 7° of each

Inlet and

outlet not

Inlet and

Operational Analysis

Wait 5 minutes into the freeze

cycle.Compare temperatures of

other or Inlet

within 7° and

and outlet not

-and Inlet

each other

within 7° of

outlet

of each

within 7°

evaporator outlet.

evaporator inlet and

than outlet

Inlet is warmer

outlet

is colder than

other

Freeze cycle

If discharge pressure is High or Low, refer to freeze cycle high or

Discharge Pressure

and/or components not listed on this table before proceeding.

low discharge pressure problem checklist to eliminate problems

_______

_______ _______

1 minute Middle End

components not listed on this table before proceeding.

suction pressure problem checklist to eliminate problems and/or

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

Freeze cycle

Suction Pressure

_______ _______

High

Suction

pressure is

Low

Suction

pressure is

High

Suction

pressure is

_______

1 minute Middle End

Part Number STH045 8/15 85

inlet is

The harvest valve

COOL

and

discharge line is

The compressor

HOT

temp 150°F

Discharge line

freeze cycle

at the end of

(66°C) or higher

Compressor

inlet is

The harvest valve

inlet is

The harvest valve

inlet is

The harvest valve

Operational Analysis

and

COOL

and

COOL

and

HOT

Harvest Valve

The compressor

COOL

Discharge line

temp less than

discharge line is

HOT

discharge line is

HOT

discharge line is

150°F (66°C) at

temp 150°F

Discharge line

(66°C) or higher

temp 150°F

Discharge line

(66°C) or higher

Record freeze cycle

Discharge Line Temp.

cycle

the end of freeze

freeze cycle

at the end of

freeze cycle

at the end of

end of freeze cycle.

discharge line temp at the

TXV Flooding

-or-

Low On Charge

Harvest Valve

Final Analysis

Enter total number of

TXV Starving

Leaking

each column.

boxes checked in

86 Part Number STH045 8/15

Component Check Procedures

! Warning

Main Fuse

Function

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

Specifications

• The main fuse is 250 Volt, 3.15 amp.

High (line) voltage is applied to the control board at all times. Removing the control board fuse or cycling the toggle switch Off/On will not remove the power supplied to the control board.

Check Procedure

1. If the curtain light is on with the water curtain closed, the fuse is good.

Disconnect electrical power to the entire ice machine before proceeding.

2. Remove the fuse. Check the resistance across the fuse with an ohmmeter.

Reading Result

Open (OL) Replace fuse Closed (O) Fuse is good

Part Number STH045 8/15 87

Bin Switch

Important

Function

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

1. Terminating the harvest cycle and returning the ice machine to the freeze cycle.

This occurs when the bin switch is opened and closed again within 30 seconds of opening during the harvest cycle.

2. Automatic ice machine shut-off. If the storage bin is full at the end of a harvest

cycle, the sheet of cubes fails to clear the water curtain and holds it open. After the water curtain is held open for 30 seconds, the ice machine shuts off.

The ice machine remains off until enough ice is removed from the storage bin to allow the sheet of cubes to drop clear of the water curtain. As the water curtain swings back to the operating position, the bin switch closes and the ice machine restarts.

The water curtain must be closed (bin switch closed) to start ice making.

Check Procedure

1. Cycle the toggle switch OFF.

2. Watch the curtain light on the control board.

3. Move the water curtain upward, toward the evaporator. The bin switch must close. The curtain light “on” indicates the bin switch has closed properly.

4. Close the water curtain. The bin switch must open. The curtain light “off” indicates the bin switch has opened properly.

88 Part Number STH045 8/15

Ohm Test

1. Disconnect the bin switch wires from the control board.

2. Connect an ohmmeter to the disconnected bin switch.

3. Cycle the bin switch open and closed numerous times by opening and closing the water curtain.

NOTE: To prevent misdiagnosis:

• Always use the water curtain magnet to cycle the switch (a larger or smaller magnet will affect switch operation).

• Watch for consistent readings when the bin switch is cycled open and closed (bin switch failure could be erratic).

Part Number STH045 8/15 89

Float Switch

Function

Open and close to indicate to the control board the level of water in the water trough.

Specifications

Normally closed, float operated magnetic reed switch. The float switch contacts are closed in the down

position. When water raises the float to the up position the magnet in the float opens the contacts.

Check Procedure

The ice machine uses two float switches. Ice Thickness Float -Indicates the water level has

been reached. Harvest Float - Indicates a harvest cycle needs to be

initiated. Initial testing can be performed by viewing the control

board light(s) while raising and lowering the float. The corresponding control board light must turn on and off when the float is raised and lowered.

Harvest Float switch:

A. The light must be on in the up position. B. The light must be off in the down position.

Ice Thickness Float Switch:

A. The light must be on in the up position. B. The light must be off in the down position.

90 Part Number STH045 8/15

If the control board light does not respond to the float

ICE

THICKNESS

FLOAT

HARVEST

FLOAT

SWITCH

proceed with step 1 below.

1. Disconnect power to the ice machine and pull the float switch and connector through the ice machine base and disconnect.

2. Attach an ohm meter lead to each float switch wire.

3. Place the float in the down position - The float switch must be closed.

4. Place the float in the up position - The float switch must be open.

5. If the float tests good, ohm the interconnecting wires to the control board and inspect connectors.

NOTE: Make adjustments with the ice machine in the off position. Making adjustments during the freeze cycle may produce an initial sheet of ice that is thicker than future cycles.

Part Number STH045 8/15 91

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 ensure that the overload is closed and the resistance readings will be accurate.

Single Phase Compressors

1. Disconnect power and 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.

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.

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

92 Part Number STH045 8/15

Compressor Drawing Locked Rotor

The two likely causes of this are:

• Defective starting component

• Mechanically seized compressor To determine which you have:

1. Install high and low side gauge.

2. Try to start the compressor.

3. Watch the pressures closely.

• If the pressures do not move, the compressor is seized. Replace the compressor.

• If the pressures move, the compressor is turning slowly and is not seized. Check the start components.

Compressor Drawing High Amps

The continuous amperage draw on start-up should not be near the maximum fuse size indicated on the serial tag.

The wiring must be correctly sized to minimize voltage drop at compressor start-up. The voltage when the compressor is trying to start must be within 10% of the nameplate voltage.

Part Number STH045 8/15 93

Fan Cycle Control

Function

Cycles the fan motor on and off to maintain proper operating discharge pressure.

The fan cycle control closes on an increase, and opens on a decrease in discharge pressure.

Specifications

Cut-In

(Close)

335 psig 5 275 psig 5

Cut-Out

(Open)

Check Procedure

Disconnect electrical power to the ice machine at the electrical service disconnect.

Verify fan motor windings are not open or grounded, and fan spins freely.

Connect manifold gauge to ice machine. Hook voltmeter in parallel across the fan cycle control,

leaving wires attached. Reconnect electrical power to the ice machine and

Cycle the toggle switch On. Wait until water flows over the evaporator then refer to

chart below.

System

Pressure:

above cut-in 0 volts running

below cut-out line voltage off

Reading

Should Be:

Fan Should

Be:

94 Part Number STH045 8/15

High Pressure Cutout (HPCO) Control

Warning

Function

Stops the ice machine if subjected to excessive highside pressure.

The HPCO control is normally closed, and opens on a rise in discharge pressure.

Specifications

Cut-out: 600 psig 10 Cut-in: 450 psig 10 (Must be below 450 psig to reset).

Check Procedure

1. Move toggle switch to OFF.

2. Connect manifold gauge.

3. Hook voltmeter in parallel across the HPCO, leaving wires attached.

4. On water-cooled models, close the water service valve to the water condenser inlet. On selfcontained air-cooled models, disconnect the fan motor.

5. Move toggle switch to ON.

6. No water or air flowing through the condenser will cause the HPCO control to open because of excessive pressure. Watch the pressure gauge and record the cut-out pressure.

If discharge pressure exceeds 600 psig and the HPCO control does not cut out, cycle the toggle switch Off to stop ice machine operation.

Replace the HPCO control if it:

• Will not reset (below 450 psig)

• Does not open at the specified cut-out point

Part Number STH045 8/15 95

Refrigeration Components

HEAD PRESSURE CONTROL VALVE

Manitowoc remote systems require head pressure control valves with special settings. Replace defective head pressure control valves only with “original” Manitowoc replacement parts.

Refrigerant Charge Verification

The correct amount of refrigerant (name plate charge) is required to operate correctly at all ambient conditions.

An ice machine with an overcharge or undercharge of refrigerant may function properly at higher ambient temperatures and fails at lower ambient temperatures. Symptoms of incorrect refrigerant amount are:

• Works during the day and malfunctions at night, and/or fails whenever the outdoor temperature drops.

• A Safety limit is stored in control board memory.

Refrigerant loss and ambient temperature are directly related to each other. As the ambient temperature drops, more refrigerant is stored in the condenser.

When the refrigerant charge and ambient temperature create an undercharge of refrigerant in the freeze cycle, the receiver dip tube will lose it’s liquid seal. Without liquid refrigerant to the TXV, the ice machine fails to make a full sheet of ice in 60 minutes and a safety limit #1 results.

NOTE: When a head pressure control valve is being replaced or refrigerant charge is suspected, verify the refrigerant charge is correct by recovering the refrigerant, weighing and comparing to the nameplate amount. Refer to Refrigerant Recovery/Evacuation for recovery procedures.

96 Part Number STH045 8/15

Freeze Cycle Operation All Models

The head pressure control valve is non adjustable. At ambient temperatures of approximately 70°F (21°C)

or above, refrigerant flows through the valve from the condenser to the receiver inlet. At temperatures below this (or at higher temperatures if it is raining), the head pressure control dome’s nitrogen charge closes the condenser port and opens the bypass port from the compressor discharge line.

In this modulating mode, the valve maintains minimum head pressure by building up liquid in the condenser and bypassing discharge gas directly to the receiver.

Harvest Cycle Operation Remote Condenser Models

The head pressure control cycles into full bypass due to the pressure drop when the harvest valve opens. Refrigerant flows from the compressor to the evaporator through the harvest valve and the head pressure valve is out of the circuit.

Diagnostics

FREEZE CYCLE - REMOTE CONDENSER

1. Determine if the coil is clean.

2. Determine the air temperature entering the condenser.

3. Determine if the head pressure is high or low in relationship to the outside temperature. (Refer to the proper “Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts”).

4. Determine the temperature of the liquid line entering the receiver by feeling it. This line is normally warm; “body temperature.”

5. Using the information gathered, refer to the chart.

Part Number STH045 8/15 97

NOTE: A head pressure control valve that will not bypass, will function properly with condenser air temperatures of approximately 70°F (21°C) or above. When the temperature drops below 70°F (21°C), the head pressure control valve fails to bypass and the ice machine malfunctions. Lower ambient conditions can be simulated by rinsing the condenser with cool water during the freeze cycle.

Condition

Discharge Pressure - High

Liquid Line Temperature -

Hot

Discharge Pressure - Low

Liquid Line Temperature -

Cold

Discharge Pressure - Low

Liquid Line Temperature -

Hot

Probable

Cause

Valve stuck in

bypass

Valve not

bypassing

Ice Machine

Low on Charge

Corrective

Measure

Replace

valve

Replace

valve

Refrigerant

Charge

Verification

98 Part Number STH045 8/15

Harvest Cycle

REMOTE CONDENSER The head pressure control cycles into full bypass due

to the pressure drop when the harvest valve opens. Refrigerant flows from the compressor to the evaporator through the harvest valve and the head pressure valve is out of the circuit.

Undercharge Symptoms

• Safety limit #1 or Safety limit #2 in control board memory, a flashing triangle alert and after pressing left arrow Long Freeze or Long Harvest is displayed.

• Harvest cycle suction pressure is low.

• Harvest cycle discharge pressure is low.

• Liquid line entering receiver feels warm to hot in the freeze cycle.

Overcharge Symptoms

• Safety limit #2 in control board memory, a flashing triangle alert and after pressing left arrow Long Harvest is displayed.

• Harvest cycle discharge pressure is normal.

• Freeze cycle time, suction and discharge pressure are normal and the ice machine will not harvest. The sheet of ice cubes show little or no sign of melting when removed from the evaporator after the harvest cycle has been completed. (If the cubes are melted you have a release problem, clean the ice machine).

Part Number STH045 8/15 99

HARVEST PRESSURE REGULATING (HPR)

INLET

OUTLET

FLOW

HPR SOLENOID

OUTLET

INLET

HPR VALVE

SYSTEM REMOTE CONDENSER ONLY

GENERAL The harvest pressure regulating (HPR) system

includes:

• Harvest pressure regulating solenoid valve (HPR solenoid). This is an electrically operated valve which opens when energized, and closes when de-energized.

• Harvest pressure regulating valve (HPR valve). This is a pressure regulating valve which modulates open and closed, based on the refrigerant pressure at the outlet of the valve. The valve closes completely and stops refrigerant flow when the pressure at the outlet rises above the valve setting.

100 Part Number STH045 8/15

Manitowoc Ice K-0250 SERVICE MANUAL

Specifications and Main Features

Frequently Asked Questions

User Manual

General Information

Model Numbers

How to Read a Model Number

Ice Machine Warranty Information

COMMERCIAL WARRANTY COVERAGE

Service Calls

Limited Warranty for Ice Storage Bins

LIMITED WARRANTY

Installation

Location of Ice Machine

Ice Machine Clearance Requirements

Clearance Requirements

Ice Machine Heat of Rejection

Leveling the Ice Machine

Electrical Requirements

Voltage

Fuse/Circuit Breaker

Total Circuit Ampacity

Water Service/Drains

WATER SUPPLY

WATER INLET LINES

DRAIN CONNECTIONS

Maintenance

Interior Cleaning and Sanitizing

GENERAL

CLEANING AND SANITIZING PROCEDURE

TOGGLE SWITCH OPERATION

REMOVE PARTS FOR CLEANING

Preventative Maintenance Cleaning

Ice Machine Inspection

Exterior Cleaning

Cleaning the Condenser

General

Removal from Service/Winterization

AIR-COOLED MODELS

WATER-COOLED MODELS

Operation

Ice Making Sequence of Operation

Water Purge Cycle

Freeze Cycle

Harvest Cycle

Full Bin Cycle

CONTROL BOARD TIMERS

Safety Limit 1

Safety Limit 2

Safety Limit 3 - No water or water loss

Operational Checks

ICE THICKNESS CHECK

Troubleshooting

Control Board Test Mode

Canceling a test cycle:

Restarting a test cycle:

Freeze Time Lock-In Feature

Ice Production Check

Installation/Visual Inspection Checklist

Water System Checklist

Ice Formation Pattern

Normal Ice Formation

Extremely Thin at Evaporator Outlet

Extremely Thin at Evaporator Inlet

No Ice Formation

SAFETY LIMITS

Safety Limit 1

Safety Limit 2

Safety Limit 3

Safety Limit Notes

Safety Limit Checklist

Analyzing Discharge Pressure

Discharge Pressure High Checklist

Freeze Cycle Discharge Pressure Low Checklist

Analyzing Suction Pressure

Procedure

Suction Pressure High Checklist

Suction Pressure Low Checklist

Harvest Valve

General