Manitowoc Ice QC0700 Service Manual
Flake / Chiplet Model
Revised 8/2003
Ice Machines
Flake Models QF0400/QF0800/
QF2200/QF2300
Chiplet Models QC0700
Service
Manual
Part Number 80-1214-3
07/03
Safety Notices
Revised 8/2003
Procedural Notices
As you work on a Flake / Chiplet Series Ice Machine, be
sure to pay close attention to the safety notices in this
manual. Disregarding the notices may lead to serious
injury and/or damage to the ice machine.
Throughout this manual, you will see the following types
of safety notices:
!
Warning
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
Warning
!
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
Caution
!
Text in a Caution box alerts you to a situation in
which you could damage the ice machine. Be sure
to read the Caution statement before proceeding,
and work carefully.
As you work on a Flake / Chiplet Series Ice Machine, be
sure to read the procedural notices in this manual.
These notices supply helpful information which may
assist you as you work.
Throughout this manual, you will see the following types
of procedural notices:
Important
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will
not cause damage or injury, but it may slow you
down as you work.
NOTE: Text set off as a Note provides you with simple,
but useful, extra information about the procedure you are
performing.
Read These Before Proceeding:
Caution
!
Proper installation, care and maintenance are
essential for maximum ice production and troublefree operation of you Manitowoc Ice Machine.
Read and understand this manual. It contains
valuable care and maintenance information. If you
encounter problems not covered by this manual, do
not proceed, contact Manitowoc Ice, Inc. We will be
happy to provide assistance.
Important
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
We reserve the right to make product improvements at any time.
Specifications and design are subject to change without notice.
Section 1
Revised 8/2003
General Information
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Remote Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Owner Warranty Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2
Installation Instructions
Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Ice Machine Head Section and Remote Condensing Unit Dimensions . . . . . 2-2
Location of Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Ice Machine Head Section Clearance Requirements . . . . . . . . . . . . . . . . . . . . 2-3
Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Location of Remote Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Leveling the Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Condenser Air Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
For United Kingdom Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
Ice Machine Head Section Electrical Wiring Connections . . . . . . . . . . . . . . . 2-7
Remote Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Table of Contents
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Bin Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Ice Bagger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Arctic Pure Water Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
Manitowoc Cleaner and Sanitizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
QF400 Air Cooled Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
QC700/QF800 Water Cooled Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
QC700/QF800 Air Cooled Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
QF2200/QF2300 and RFC2085/RFC2385 Remote Condensing Unit . . . . . 2-2
Condensing Unit Clearance Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Fuse/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
QC700/QF800 Ice Machine Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
QF2200 Ice Machine Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
QF2300 Ice Machine Head Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
RFC2085 Remote Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
RFC2385 Remote Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-8
Part No. 80-1214-3 1
Section 3
Revised 8/2003
Maintenance
Table of Contents (continued)
Ice Machine Head Section Water Supply and Drains . . . . . . . . . . . . . . . . . . . 2-9
Potable Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Potable Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Cooling Tower Applications
(Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9
Water Supply and Drain Line Sizing/Connections . . . . . . . . . . . . . . . . . . . . 2-10
Refrigeration System Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
(QF2200/RFC2085 and QF2300/RFC2385 Only) . . . . . . . . . . . . . . . . . . . . 2-11
Usage with Non-Manitowoc
Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11
Refrigeration Line Set Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
A. Line Set Length . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
B. Line Set Rise or Drop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-12
C. Suction Line Oil Traps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Ice Machine Head Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1
Remote Condensing Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Water Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4
Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Air-Cooled Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6
Manitowoc’s Cleaning Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Preventative Maintenance Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . 3-7
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-9
Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-10
Procedure to Clean Heavily Scaled Flake/Chiplet Ice Machines . . . . . . . . . 3-11
Removal of Parts For Cleaning/Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . 3-12
Removal from Service/Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
Water Cooled Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-19
2 Part No. 80-1214-3
Table of Contents (continued)
Revised 8/2003
Section 4
Ice Machine Sequence of Operation
QF400/QC700/QF800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Prior to Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Flush Sequence in the “ICE” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
QF2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Prior to Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Flush Sequence in the “ICE” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
QF2300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Prior to Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Initial Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Flush Sequence in the “ICE” Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Section 5
Troubleshooting
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1
Safeguard Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Reset Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Standby Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SafeGuard Indicator Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
SafeGuard Modes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Gear Box Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
QF400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
QC700/QF800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7
Evaporator Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-9
Section 6
Electrical System
Energized Parts Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
Wiring Diagram Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
QF400/QC700/QF800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1
QF2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
QF2300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
QF400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-4
QC700/QF800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10
QF2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
QF2300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-26
Wiring Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-36
QF400 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-37
QC700/QF800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38
QF2200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40
RFC2085 (230V/60Hz/1Ph - 230/50/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41
RFC2085 (208-230V/60Hz/3Ph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-42
QF2300 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-43
RFC2385 (230V/60Hz/1Ph - 230/50/1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44
RFC2385 (208-230V/60Hz/3Ph) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45
Part No. 80-1214-3
3
Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-46
Revised 8/2003
Component Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Diagnosing An Ice Machine That Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . 6-59
Diagnosing A Condensing Unit That Will Not Run . . . . . . . . . . . . . . . . . . . . . 6-59
Section 7
Refrigeration System
Tubing Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
Refrigeration System Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4
Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts . . . . . . . . . 7-11
Table of Contents (continued)
ICE/OFF/CLEAN Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Bin Level Probe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47
Motor Speed Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-49
Water Level Probes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Temperature/Resistance Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-52
Control Board Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-53
Water Float Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
Water Level Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-54
High Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Low Pressure Cut-Out Control (LPCO)
RFC2085/RFC2385 (QF2200/QF2300) Only . . . . . . . . . . . . . . . . . . . . . . . . 6-55
Fan Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-56
Compressor Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-57
QF400/QC700/QF800 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1
QF2200/RFC2085 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
QF2300/RFC2385 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Before Beginning Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Ice Production/Quality Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Installation/Visual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Water System Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
SafeGuards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
Analyzing Discharge Pressure
During Freeze or Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7
Analyzing Suction Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Equalization Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Water Regulating Valve (Water-Cooled Models Only) . . . . . . . . . . . . . . . . . 7-9
Headmaster Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
Freeze Cycle Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10
QF400 Self-Contained Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11
QC700 Self-COntained Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
QC700 Self-Contained Water Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12
QF800 Self-Contained Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
QF800 Self-Contained Water Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13
QF2200/RFC2085 Remote Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
QF2300/RFC2385 Remote Air Cooled . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14
4 Part No. 80-1214-3
Table of Contents (continued)
Revised 8/2003
Refrigerant Recovery/Evacuation and Recharging . . . . . . . . . . . . . . . . . . . . . . 7-15
Refrigerant Recovery/Evacuation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-15
System Contamination Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-19
Replacing Pressure Controls Without
Removing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Suction Clean-Up Filter/DRier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Total System Refrigerant Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-23
Refrigerant Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24
Refrigerant Re-Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Part No. 80-1214-3
5
Table of Contents (continued)
Revised 8/2003
6 Part No. 80-1214-3
Section 1
D
G
Revised 8/2003
General Information
Model Numbers
This manual covers the following models:
Condensing
Unit
Undercounter
Self-Contained
Air-Cooled
Self-Contained
Air-Cooled
Self-Contained
Water Cooled
Remote
Air-Cooled
Flake Ice Chiplet Ice
QF0406A NA NA
QF0806A QC0708A NA
QF0807W QC0709W NA
QF2296N NA RFC2085
QF2396N NA RFC2385
Warning
!
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
How to Read a Model Number
9 REMOTE
AIR-COOLED
# CUBE SIZE
6 FLAKE
7 FLAKE
8 CHIPLET
9 CHIPLET
CONDENSER TYPE
AIR-COOLED
WATER-COOLED
AIR-COOLED
WATER-COOLED
Accessories
BIN CASTER
Replaces standard legs.
ICE BAGGER
Maximize profits from bagged ice sales with this
convenient accessory. This sturdy unit rests on the bin
door frame, and adapts for left or right side filling.
ARCTIC PURE™ WATER FILTER SYSTEM
Engineered specifically for Manitowoc ice machines,
This water filter is an efficient, dependable, and
affordable method of inhibiting scale formation, filtering
sediment, and removing chlorine taste and odor.
MANITOWOC CLEANER AND SANITIZER
Manitowoc Ice Machine Cleaner and Sanitizer are
available in convenient 16 oz. (473 ml) and 1 gal (3.78 l)
bottles. These are the only cleaner and sanitizer
approved for use with Manitowoc products.
Cleaner Part Number Sanitizer Part Number
16 oz. 94-0456-3 16 oz. 94-0565-3
1 gallon 94-0580-3 1 gallon 94-0581-3
NOTE: The Manitowoc Automatic Cleaning System
(AuCS) accessory cannot be used with Flake/Chiplet Ice
Machines.
Remote Condensing Unit
Part No. 80-1214-3 1-1
ICE MACHINE
MODEL
ICE CUBE SIZE
F FLAKE
C CHIPLET
CONDENSING
UNIT MODEL
Q F 0807 W
ICE MACHINE
SERIES
CONDENSER TYPE
A SELF-CONTAINED AIR-COOLED
W SELF-CONTAINED WATER-COOLE
N REMOTE AIR-COOLED
RFC 2385
CONDENSIN
UNIT SERIES
SV3106
SV3107
General Information Section 1
Revised 8/2003
Model/Serial Number Location
These numbers are required when requesting
information from your local Manitowoc distributor,
service representative, or Manitowoc Ice, Inc.
SV2019
(QF800/QC700/QF2200/
The model and serial number are listed on the OWNER
WARRANTY REGISTRATION CARD. They are also
listed on the MODEL/SERIAL NUMBER DECAL affixed
to the ice machine head section and condensing unit.
Both model/serial numbers must be referenced to obtain
warranty or service information.
MODEL / SERIAL
NUMBERS DECAL
QF2300)
1-2
MODEL / SERIAL
NUMBERS DECAL
(QF400)
SV2047
Model/Serial Number Location
Part No. 80-1214-3
Section 1 General Information
Revised 8/2003
Owner Warranty Registration Card
GENERAL
Warranty coverage begins the day the ice machine is
installed.
Important
Complete and mail the OWNER WARRANTY
REGISTRATION CARD as soon as possible to
validate the installation date.
If the OWNER WARRANTY REGISTRATION CARD is
not returned, Manitowoc will use the date of sale to the
Manitowoc Distributor as the first day of warranty
coverage for your new ice machine.
Warranty Coverage
GENERAL
The following Warranty outline is provided for your
convenience. For a detailed explanation, read the
warranty bond shipped with each product.
Contact your local Manitowoc Distributor or Manitowoc
Ice, Inc. if you need further warranty information.
Important
This product is intended exclusively for commercial
application. No warranty is extended for personal,
family, or household purposes.
EXCLUSIONS
The following items are not included in the ice machine’s
warranty coverage:
1. Normal maintenance, adjustments and cleaning as
outlined in this manual.
2. Repairs due to unauthorized modifications to the ice
machine or use of non-standard parts without prior
written approval from Manitowoc Ice, Inc.
3. Damage caused by improper installation of the ice
machine, electrical supply, water supply or drainage,
or damage caused by floods, storms, or other acts of
God.
4. Premium labor rates due to holidays, overtime,
etc.; travel time; flat rate service call charges;
mileage and miscellaneous tools and material
charges not listed on the payment schedule.
Additional labor charges resulting from the
inaccessibility of equipment are also excluded.
5. Parts or assemblies subjected to misuse, abuse,
neglect or accidents.
6. Damage or problems caused by installation,
cleaning and/or maintenance procedures
inconsistent with the technical instructions provided
in this manual.
7. This product is intended exclusively for commercial
application. No warranty is extended for personal,
family, or household purposes.
PARTS
1. Manitowoc warrants the ice machine against defects
in materials and workmanship, under normal use
and service for two (2) years from the date of original
installation.
2. The compressor is covered by an additional three
(3) year (five years total) warranty beginning on the
date of the original installation.
LABOR
1. Labor required to repair or replace defective
components is covered for two (2) years from the
date of original installation.
Part No. 80-1214-3 1-3
General Information Section 1
Revised 8/2003
THIS PAGE INTENTIONALLY LEFT BLANK
1-4
Part No. 80-1214-3
Ice Machine Dimensions
Revised 8/2003
Section 2
Installation Instructions
QF400 AIR COOLED ICE MACHINE
19”
(48.2 CM)
(82.55 CM)
3.03”
(7.7 CM)
(15.24 CM)
26.5”
(67.3 CM)
26”
(66 CM)
1.36”
(3.5 CM)
(18.2 CM)
3.04”
(7.72 CM)
7.2”
Important
Failure to follow these installation guidelines may
affect warranty coverage.
32.5”
6”
SV2050
QC700/QF800 AIR COOLED ICE MACHINE
22”
(55.88 CM)
5.9”
(15 CM)
2.9”
(7.3 CM)
1.6”
(4 CM)
3”
(7.6 CM)
(62.23 CM)
24.5”
26.5”
(67.3 CM)
SV2003
QC700/QF800 WATER COOLED ICE MACHINE
11.13”
(28.3 CM)
5.6”
(14.3 CM)
1.9”
(4.8 CM)
2”
(5.1 CM)
13.5”
(34.3 CM)
11.5”
(29.2 CM)
26.5”
(67.3 CM)
SV2004
Part No. 80-1214-3 2-1
Installation Instructions Section 2
Revised 8/2003
Ice Machine Head Section and Remote Condensing Unit Dimensions
QF2200/QF2300 AND RFC2085/RFC2385 REMOTE CONDENSING UNIT
30”
(76.2 CM)
2.8”
(7.12 CM)
1.8”
(4.6 CM)
9.8”
(24.89 CM)
24.5”
(62.23 CM)
2.25”
(5.72 CM)
4.5”
(11.43 CM)
23.5”
(67.3 CM)
SV1784
25.75”
14.5”
(36.8 CM)
34”
(86.4 CM)
14.5”
(36.8 CM)
9.5”
(24.1 CM)
10.75”
(27.3 CM)
24.13”
(53.7 CM)
SV1758
2-2
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Location of Ice Machine
The location selected for the ice machine must meet the
following criteria. If any of these criteria are not met,
select another location.
• The location must be free of airborne and other
contaminants.
• The air temperature must be at least 45°F (7°C), but
must not exceed 110°F (43.4°C).
• The water temperature must be at least 45°F (7°C),
but must not exceed 90°F (32.2°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. QF400 airflow is in and out
of the front of the ice machine. Refer to below for
clearance requirements.
Ice Machine Head Section Clearance
Requirements
QF400
Top/Sides 5” (12.7 mm) NA
Back 5” (12.7 mm) NA
QC700/QF800
Top/Sides 8” (20.3 mm) 5” (12.7 mm)
Back 5” (12.7 mm) 5” (12.7 mm)
QF2200/QF2300
Top/Sides 8” (20.3 mm) 5” (12.7 mm)
Back 5” (12.7 mm) 5” (12.7 mm)
Self-Contained
Air-Cooled
Self-Contained
Air-Cooled
Self-Contained
Air-Cooled
Self-Contained
Water-Cooled
Self-Contained
Water-Cooled
Remote
Air-Cooled
Ice Machine Heat of Rejection
Series
Condensing Unit
QF400 4000
QF700 7800
QF800 7800
QF2200/RFC2085 21000
QF2300/RFC2385 21000
*B.T.U. / Hour
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
the air conditioning equipment where self-contained aircooled ice machines are installed. QF2200/QF2300 ice
machines add an insignificant amount of load to a
conditioned space.
Heat of Rejection*
Location of Remote Condensing Unit
The location selected for the Remote Condensing Unit
must meet the following criteria. If any of these criteria
are not met, select another location.
• The air temperature must be at least -20°F (-28.9°C)
but must not exceed 120°F (49°C).
• The location must not allow exhaust fan heat and/or
grease to enter the condenser.
• The location must not obstruct airflow through or
around the condensing unit. Refer to the chart below
for clearance requirements.
CONDENSING UNIT CLEARANCE REQUIREMENTS
Ice Machine Condensing Unit
Top/Sides There is no minimum clearance required,
although 6” (12.7 cm) is recommended for
efficient operation and servicing only.
Front/Back 4’ (1.2)
Part No. 80-1214-3 2-3
Caution
!
The ice machine head section must be protected if it
will be subjected to temperatures below 32°F (0°C).
Failure caused by exposure to freezing
temperatures is not covered by the warranty. See
“Removal from Service/Winterization”.
Installation Instructions Section 2
Revised 8/2003
Leveling the Ice Storage Bin
1. Screw the leveling legs onto the bottom of the bin.
2. Screw the foot of each leg in as far as possible.
Caution
!
The legs must be screwed in tightly to prevent them
from bending.
3. Move the bin into its final position.
4. Level the bin to assure that the bin door closes and
seals properly. Use a level on top of the bin. Turn
each foot as necessary to level the bin.
NOTE: An optional caster assembly is available for use
in place of the legs. Installation instructions are supplied
with the casters.
Condenser Air Baffle
(QC700/QF800 Air-Cooled Ice Machines Only)
The air-cooled baffle prevents condenser air from
recirculating. To install:
1. Remove the back panel screws next to the
condenser.
2. Align the mounting holes in the air baffle with the
screw holes and reinstall the screws.
SCREWS
AIR
BAFFLE
THREAD ‘FOOT’ IN AS
FAR AS POSSIBLE
Leveling Leg and Foot
THREAD LEVELING
LEG INTO BASE OF
CABINET
SV1606
SV1607
Air Baffle
2-4
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Electrical Service
GENERAL
Warning
!
All wiring must conform to local, state and national
codes.
VOLT AG E
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).
Warning
!
The ice machine must be grounded in accordance
with national and local electrical codes.
FUSE/CIRCUIT BREAKER
A separate fuse/circuit breaker must be provided for
each ice machine. Circuit breakers must be H.A.C.R.
rated (does not apply in Canada).
QF400 115/60/1 ice machines are factory pre-wired
with a power cord and 5-15P plug confirmation.
QF400 230/50/1 ice machines are factory pre-wired
with a power cord, no plug is supplied.
QF2200/QF2300 with Remote Condensing Unit the
ice machine head section and remote condensing unit
are wired independent of each other. A separate
dedicated fuse/circuit breaker must be provided
section. Circuit breakers must be H.A.C.R. rated (does
not apply in Canada).
MINIMUM CIRCUIT AMPACITY
QC700/QF800/QF2200/QF2300 Only
The minimum circuit ampacity is used to help select the
wire size of the electrical supply. (Minimum circuit
ampacity is not the ice machine’s running amp load.)
The wire size (or gauge) is also dependent upon
location, materials used, length of run, etc., so it must be
determined by a qualified electrician.
for each
Part No. 80-1214-3 2-5
Installation Instructions Section 2
Revised 8/2003
Electrical Requirements
Ice Machine Head Section
Fuse/
Circuit
Remote
Air-Cooled
Minimum
Circuit
Amps
Water Cooled
Maximum
Fuse/Circuit
Breaker
Minimum
Circuit
Amps
Air-Cooled
Ice
Machine
QF400
QC700
QF800
QF2200
QF2300
Interconnecting wiring (115/60/1) is required between the ice machine and condensing unit to energize the contactor coil.
* Indicates preliminary data
Vol tag e
Phase
Cycle
115/1/60 15 NA 9.8 NA NA NA NA
230/1/50 15 NA 4.2 NA NA NA NA
115/1/60 30 18.9 NA NA NA 30 17.9
230/1/50 20 8.8 NA NA NA 20 8.4
230/1/60 15 8.7 NA NA NA 15 8.3
115/1/60 30 18.9 NA NA NA 30 17.9
230/1/50 20 8.8 NA NA NA 20 8.4
230/1/60 15 8.7 NA NA NA 15 8.3
115/1/60 NA NA NA 15 4.3 NA NA
230/1/50 NA NA NA NA NA NA NA
230/1/60 NA NA NA NA NA NA NA
115/1/60 NA NA NA 15 5.5* NA NA
230/1/50 NA NA NA NA NA NA NA
230/1/60 NA NA NA NA NA NA NA
Maximum
Fuse/Circuit
Breaker
Minimum
Circuit
Amps
Total
Circuit
Amps
Maximum
Breaker
Remote Condensing Unit
Condensing Unit
RFC2085
RFC2385
* Indicates preliminary data
Voltage Phase
Cycle
208-230/1/60
208-230/3/60
208-230/1/60
208-230/3/60
Maximum Fuse/Circuit
Breaker
30 15.6
20 11.2
30 18.5*
20 11.2*
Minimum Circuit Amps
For United Kingdom Only
As the colours of the wires in the mains lead of the appliance may not correspond with the coloured markings
identifying the terminals in your plug, proceed as follows:
• The wire which is coloured green and yellow
the letter E or by the earth ground symbol or coloured green or green and yellow.
• The wire coloured blue
• The wire coloured brown
must be connected to the terminal which is marked with the letter N or coloured black.
must be connected to the terminal which is marked with the letter L or coloured red.
must be connected to the terminal in the plug which is marked with
2-6
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Ice Machine Head Section Electrical Wiring Connections
QF2200 ICE MACHINE HEAD SECTION
!
Warning
These diagrams are not intended to show proper
wire routing, wire sizing, disconnects, etc., only the
correct wire connections.
All electrical work, including wire routing and
grounding, must conform to local, state and national
electrical codes.
Though wire nuts are shown in the drawings, the ice
machine field wiring connections may use either
wire nuts or screw terminals.
QC700/QF800 ICE MACHINE HEAD SECTION
115/1/60 or 208-230/1/60
115/60/1
ICE MACHINE
CONNECTIONS
N = 115V
GROUND
L
1
TO FUSE/BREAKER.
DISCONNECT ALL
LINE VOLTAGE DO
NOT DISCONNECT
GROUND.
L
N = 115V
GROUND
1
230/1/50
L
1
GROUND
L
1
N
GROUND
ICE MACHINE
CONNECTIONS
N=115V
OR
L2=208-230V
GROUND
GROUND
L
1
SV1258
L
1
N
QF2300 ICE MACHINE HEAD SECTION
115/60/1
ICE MACHINE
CONNECTIONS
N = 115V
C
1
C
2
L
1
GROUND
CONDENSING UNIT
CONNECTIONS
C
1
C
2
L
1
N = 115V
GROUND
TO FUSE/BREAKER.
DISCONNECT ALL
LINE VOLTAGE DO
NOT DISCONNECT
GROUND.
Part No. 80-1214-3 2-7
ICE MACHINE
CONNECTIONS
TO SEPARATE
FUSE/BREAKER.
DISCONNECT ALL
POLES.
SV1191
Installation Instructions Section 2
Revised 8/2003
Remote Electrical Wiring Connections
!
Warning
These diagrams are not intended to show proper
wire routing, wire sizing, disconnects, etc., only the
correct wire connections.
All electrical work, including wire routing and
grounding, must conform to local, state and national
electrical codes.
Though wire nuts are shown in the drawings, the ice
machine field wiring connections may use either
wire nuts or screw terminals.
RFC2085 REMOTE CONDENSING UNIT
208-230/1/60
CONDENSING UNIT
CONNECTIONS
L
1
RFC2385 REMOTE CONDENSING UNIT
208-230/1/60
CONDENSING UNIT
CONNECTIONS
C
1
C
2
L
1
L
2
GROUND
L
1
ICE MACHINE
CONNECTIONS
C
1
C
2
L
1
L
2
GROUND
TO FUSE/BREAKER.
DISCONNECT ALL
LINE VOLTAGE DO
NOT DISCONNECT
GROUND.
L
2
GROUND
L
2
GROUND
TO FUSE/BREAKER.
DISCONNECT ALL
LINE VOLTAGE DO
NOT DISCONNECT
GROUND.
2-8
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Ice Machine Head Section Water Supply
and Drains
POTABLE WATER SUPPLY
Local water conditions may require treatment of the
water to inhibit scale formation, filter sediment, and
remove chlorine odor and taste.
Important
If you are installing a Manitowoc water filter system,
refer to the Installation Instructions supplied with the
filter system for ice making water inlet connections.
POTABLE WATER INLET LINES
Follow these guidelines to install water inlet lines:
• Do not connect the ice machine to a hot water supply.
Be sure all hot water restrictors installed for other
equipment are working. (Check valves on sink
faucets, dishwashers, etc.)
• If water pressure exceeds the maximum (80 psig
551.5 kPA) recommended pressure, obtain a water
pressure regulator from your Manitowoc distributor.
• Install a water shut-off valve and union for both the
ice making and condenser water lines.
DRAIN CONNECTIONS
Follow these guidelines when installing drain lines to
prevent drain water from flowing back into the ice
machine and storage bin:
• Drain lines must have a 1.5 inch drop per 5 feet of
run (2.5 cm per meter), and must not create traps.
• The floor drain must be large enough to
accommodate drainage from all drains.
• Run separate bin and water-cooled condenser drain
lines. Insulate them to prevent condensation.
• Vent the bin and ice machine drain to the
atmosphere. The ice machine drain requires an 18”
vent. Do not vent the condenser drain on watercooled models.
• Drains must have a union or other suitable means to
allow in place disconnection from the ice machine
when servicing is required.
• Insulate water inlet lines and drain lines to prevent
condensation.
Cooling Tower Applications
(Water-Cooled Models)
A water cooling tower installation does not require
modification of the ice machine. The water regulator
valve for the condenser continues to control the
refrigeration discharge pressure.
It is necessary to know the amount of heat rejection, and
the pressure drop through the condenser and water
valves (inlet and outlet) when using a cooling tower on
an ice machine.
• Water entering the condenser must not exceed 90°F
(32.2°C).
• Water flow through the condenser must not exceed 5
gallons (19 liters) per minute.
• Allow for a pressure drop of 7 psi (48 kPA) between
the condenser water inlet and the outlet of the ice
machine.
• Water exiting the condenser must not exceed 110°F
(43.3°C).
Part No. 80-1214-3 2-9
Installation Instructions Section 2
5
Revised 8/2003
WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS
Caution
!
Plumbing must conform to state and local codes.
Location Water Temperature Water Pressure Ice Machine Fitting
Ice Making
Water Inlet
Condenser
Water Inlet
Condenser
Water Drain
45°F (6°C) Min.
90°F (32.2°C) Max.
33°F (0.6°C) Min.
90°F (32.2°C) Max.
--- ---
Bin Drain --- ---
20 psi (137.9 kPA) Min.
80 psi (551.5 kPA) Max.
20 psi (137.9 kPA) Min.
150 psi (1034.2 kPA) Max.
3/8" Female
Pipe Thread
1/2" Female
Pipe Thread
1/2" Female
Pipe Thread
1/2" Female
Pipe Thread
Tubing Size Up to Ice
Machine Fitting
3/8" (9.5 mm) minimum
inside diameter
1/2" (12.7 mm) minimum
inside diameter
1/2" (12.7 mm) minimum
inside diameter
1/2" (12.7 mm) minimum
inside diameter
VENT TUBE
8” (20CM)
LONG
BIN DRAIN
SV1626
Typical Water Supply Drain Installation
ICE MAKING
WATER INLET
TUBING 3/8” MIN.
I.D. (.95 SM)
WATER
SHUT-OFF
VALV E
SV211
2-10
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Refrigeration System Installation
(QF2200/RFC2085 AND QF2300/RFC2385 ONLY)
QuietQube®
Ice Machine
QF2200
QF2300
Line Set Suction Line Liquid Line
RC 20/30/50
USAGE WITH NON-MANITOWOC
CONDENSING UNITS
Manitowoc Condensing Units are specifically designed
for usage with a Manitowoc Flake/Chiplet Ice Machine
Head Sections. Manitowoc Flake/Chiplet Ice Machines
will not operate with non-Manitowoc condensing units.
Installation of a Remote Condensing Unit may require
the use of special equipment for placement. Trained
and qualified personnel are required for proper
rigging and lifting.
The 60-month compressor warranty (including the 24month labor replacement warranty) will not apply if
the Manitowoc Ice Machine and remote Manitowoc
Condensing Unit are not installed according to
specifications. This warranty also will not apply if the
refrigeration system is modified with a condenser,
heat reclaim device, or other parts or assemblies not
manufactured by Manitowoc Ice, Inc.
Remote Single
Condenser
RFC2085
RFC2385
3/4 inch
(19.1 mm)
!
!
Circuit
(12.7 mm)
Warning
Caution
1/2 inch
Line Set*
RC-20
RC-30
RC-50
Insulation
Thickness
1/2”(13mm)
Suction Line
1/4” (7mm)
Liquid Line
Factory Equipment Refrigeration Amounts
ICE MACHINE HEAD SECTION
Each ice machine head section ships from the factory
with a R-404A refrigerant charge appropriate for line
sets up to 50’ in length (12.5 lbs.). The serial tag on the
ice machine indicates the refrigerant charge. Additional
refrigerant must be added for line set lengths between
50’ and 100’ (1.5 lbs.).
Caution
!
Never add more than nameplate charge to the
refrigeration system for any application.
!
Warning
Potential Personal Injury Situation
The ice machine head section contains the refrigerant
charge. Installation and brazing of the line sets must be
performed by a properly trained and EPA certified
refrigeration technician aware of the dangers of dealing
with refrigerant charged equipment.
REMOTE CONDENSING UNIT
Each condensing unit ships from the factory pressurized
with 50/50 nitrogen helium mixture that must be removed
during the installation process (approximately 20 psig).
REFRIGERATION LINE SETS/TRAPS KIT
Refrigeration Rated Tubing and Trap Kits are shipped
capped with atmospheric pressure.
Part No. 80-1214-3 2-11
Installation Instructions Section 2
Revised 8/2003
Refrigeration Line Set Installation
GENERAL
Refrigeration line set installations consist of vertical and
horizontal line set distances between the ice machine
and the condensing unit. The following guidelines,
drawings and calculation methods must be followed to
assure proper oil return and condensing unit/ice
machine operation
!
Warning
The following instructions are provided as a general
overview of a typical installation. Refer to the
Installation, Use and Care Manual for step by step
installation instructions.
!
Warning
Disconnect electrical power to the ice machine head
section and the remote condensing unit before
proceeding.
!
Warning
The ice machine head section contains refrigerant
charge. The ice machine head section contains three
(3) refrigeration valves that must remain closed until
proper installation of the line set is completed.
A. LINE SET LENGTH
100 feet (30.5 m) Length: The maximum measured
length the line set can be.
The receiver is designed to hold a charge sufficient to
operate the ice machine in ambient temperatures
between -20°F (-28.9°C) and 120°F (49°C), with line set
lengths of up to 100 feet (30.5 m).
Important
The ice machines will not function with line sets
greater than 100 feet (30.5 m). Do not attempt to go
beyond this distance and add refrigerant charge to
compensate!
B. LINE SET RISE OR DROP
35’ (10.7 M)
MAX.
DISTANCE
Step 1 Verify Ice Machine and Remote Condensing
Unit Locations Are Within Guidelines.
Prior to installation of the ice machine head section and
remote condensing unit be sure that the distance
between then is within the line set routing guidelines
outlined in this manual.
Roof/Wall Penetration
If required, cut a 3-inch (76.2 mm) circular hole in the
wall or roof for routing of refrigeration tubing. A qualified
person must perform all roof penetrations.
Step 2 Route Refrigeration Tubing
Properly route refrigeration tubing between the ice
machine head section and the remote condensing unit.
SV1751
35 feet (10.7 m) Rise: The maximum distance the
remote condensing unit can be above the ice machine.
15’ (4.5 M)
MAX.
DISTANCE
SV1750
15 feet (4.5 m) Drop: The maximum distance the
remote condensing unit can be below the ice machine.
2-12
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
C. SUCTION LINE OIL TRAPS
Caution
!
Do not form unwanted traps in refrigeration lines.
Never coil excess refrigeration tubing.
0 to 20 feet (0 to 6.1 m) Rise: The ice machine head
section has one oil trap built in which allows for a
maximum condenser rise of 20 feet (6.1 m) without
additional traps in the suction line.
21 to 35 feet (6.4 to 10.7 m) Rise: The suction line
requires an additional Oil Trap (“S” type) to be installed.
Install the trap as close as possible to midpoint between
the ice machine head section and remote condensing
unit. S-Trap Kits are available from Manitowoc (refer to
chart).
21’ OR MORE
RISE
ADDITIONAL
TRAP KIT
REQUIRED
Service Loop
A service loop in the line set permits easy access to the
ice machine for cleaning and service.
• The supplied service loop is an installation
requirement.
• A service loop is not considered an oil trap.
• The service loop is not included when calculating
length, rise or drop of the tubing run.
• Do not use hard rigid copper for the service loop.
Caution
!
If a line set has a rise followed by a drop, another rise
cannot be made. Likewise, if a line set has a drop
followed by a rise, another drop cannot be made.
Step 3 Lengthening or Reducing Line Set Lengths
Caution
!
Do not form unwanted traps in refrigeration lines.
Never coil excess refrigeration tubing.
When the line set required shortening or lengthening, do
so before connecting the line set to the ice machine
head section or the remote condensing unit.
Manitowoc S-Trap Kit
Model
QF2200
QF2300
S-Trap Kit
Number
K00166
Continued on Next Page...
SV1751
SV1760
Tu b in g Si ze
3/4 inch
(19.1 mm)
Part No. 80-1214-3 2-13
Installation Instructions Section 2
Revised 8/2003
Step 4 Connecting the line set.
To prevent oxidation of the copper, purge line set and
condensing unit with dry nitrogen while brazing.
Connect The Line Set To The Ice Machine Head
Section
!
Warning
The ice machine head section contains refrigerant
charge. The ice machine head section contains three
(3) refrigeration valves that must remain closed until
proper installation of the line sets is completed.
The line set shut off valves at the back of the ice
machine must remain closed and be protected from heat
during the brazing process. Wrap the valves in a wet rag
or other type of heat sink prior to brazing. Cool braze
joint with water immediately after brazing to prevent heat
migration to the valve.
Connect The Line Set To The Remote Condensing
Unit
The compressor oil rapidly absorbs moisture. Be
prepared to complete line set installation and start your
evacuation process in order to minimize the time the
compressor is exposed to the atmosphere. (Maximum
amount of time the system can be exposed to the
atmosphere is 15 minutes).
The line set can be routed for entry through the front or
left side of the condensing unit.
• Remove knockout for preferred location.
• Insert supplied plastic bushings in knockout holes to
prevent tubing from contacting sheet metal.
• Use the supplied 90° elbows to route tubing.
• Cut the tubing ends of the suction and liquid lines
and braze the line sets to the condensing unit.
SUCTION
FILTER
VALVES MUST REMAIN
CLOSED AND BE
PROTECTED FROM
HEAT WHEN BRAZING
(WRAP WITH WET RAG)
SV1757
Warning
!
The condensing unit ships from the factory
pressurized with a 50/50 mixture of nitrogen/helium.
Bleed off pressure from both suction and liquid line
access ports prior to cutting into refrigeration lines.
SUCTION
LINE
MINIMIZE THE TIME THE REFRIGERATION
SYSTEM IS EXPOSED TO THE ATMOSPHERE
(15 MINUTES MAXIMUM)
SV2100
2-14
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Step 5 Pressure Test and Evacuate The Line Set
and Remote Condensing Unit
Schrader valve core removal tools that allow for removal
and installation of the valve cores without removing
manifold gauge set hoses are recommended to
decrease the evacuation time.
Leave the line set shut off valves closed (front seated).
Pressure test the line sets and remote condensing unit
with 150 psig of dry nitrogen. Add nitrogen at the line set
shut off valves located at the back of the ice machine.
Complete the pressure test, verify no leaks are present
and remove the nitrogen from the system before
connecting the vacuum pump. Connect a vacuum pump
to both of the line set shut off valves located at the back
of the ice machine head section. Evacuate to 500
microns (or less). To completely evacuate the Remote
condensing unit, continue the evacuation for 30 minutes
after reaching the 500 micron point.
CONNECT
VACUUM PUMP TO
LINE SET SHUT
OFF VALVES
Step 6 Open The Valves Prior To Starting The Ice
Machine.
A. Slowly backseat (open-turn counterclockwise)
the suction line shut off valve.
B. Slowly backseat (open-turn counterclockwise)
the liquid line shut off valve.
C. Slowly backseat (open-turn counterclockwise)
the receiver service valve.
SV1757
If required, the line set and condensing unit can be
evacuated from the schrader valves located in the
remote condensing unit. Schrader valve core removal
tools (that allow for putting the cores back in without
removing vacuum pump hoses) must be used if
evacuating from the condensing unit side.
Isolate the vacuum pump from the line set shut off valves
and/or condensing unit access ports prior to proceeding.
Open refrigeration system shut off valves.
The suction line, liquid line and receiver service valves
are closed during shipment and installation.
ALTERNATE CONNECTIONS AT
CONDENSING UNIT SCHRADER VALVES
USE ALLEN WRENCH TO OPEN
(TURN COUNTERCLOCKWISE)
LIQUID AND SUCTION LINE
SHUT-OFF VALVES
OPEN SUCTION AND LIQUID LINE SHUT OFF VALVES
SV1784
Part No. 80-1214-3 2-15
SV2100
Installation Instructions Section 2
Revised 8/2003
Verify O-ring in schrader valve caps are intact and
reinstall on shut off valves to prevent refrigerant leakage.
Replace shut off valve access caps and torque to the
following specifications.
Torque Value’s
Stem 18-20 ft. lbs.
Caps 12-15 ft. lbs.
Schrader Core 1.5-3 in. lbs.
Replace cap on receiver service valve and tighten.
TURN
COUNTERCLOCKWISE
RECEIVER SERVICE VALVE CAP
(TURN COUNTERCLOCKWISE
TO REMOVE)
SV1756
Open Receiver Service Valve
There is a liquid line solenoid valve at the outlet of the
receiver; refrigerant will not flow to the condensing unit
until the ice machine head section is started. Connect
power to both the ice machine head section and the
Remote condensing unit. Place the ICE/OFF/CLEAN
toggle switch into the ICE position, this will allow
refrigerant to enter the line set and condensing unit.
Important
All refrigeration valve caps must be reinstalled to
prevent future refrigeration leaks.
Step 7 Leak Check The Refrigeration System
Leak check the new line set connections at the ice
machine head section, condensing unit and S trap as
well as all factory joints throughout the entire system.
Disconnect power to the remote condensing unit. Place
the ICE/OFF/CLEAN toggle switch into the ICE position.
This allows the low side and high side pressures to
equalize. Place the ICE/OFF/CLEAN toggle switch in the
OFF position. Connect power to the remote condensing
unit and allow system to pump down.
Step 8 Insulation Requirements
To prevent condensation the entire suction line including
the shut-off valve must be insulated. All insulation must
be airtight and sealed at both ends.
The following insulation requirements prevent
condensation at 90°F (32.2°C) ambient 70% Relative
Humidity. If higher humidity is expected, increase
insulation thickness.
The entire line set, including the suction service valve
located on the back of the ice machine requires:
Suction Line Liquid Line
3/4 inch
(19.1 mm)
1/2 inch
(12.7 mm)
Min. Insulation
Thickness
1/2”(13mm)
Suction Line
1/4” (7mm)
Liquid Line
Important
To prevent condensation the entire suction line
including the shut off valve must be insulated. All
insulation must be airtight and sealed at both ends.
The minimum requirements are for conditions at or
below 70% humidity and 90°F (32.2°C) ambient.
When higher humidity will be experienced, insulation
wall thickness will need to be increased.
2-16
Part No. 80-1214-3
Section 2 Installation Instructions
Revised 8/2003
Suction Shut Off Valve Insulation
The pre-formed suction shut-off valve insulation is
located in the plastic bag taped to the water curtain.
A. Verify valve and schrader caps are tightened to
specifications (see Step 6).
PRE-FORMED
INSULATION
TIGHTEN VALVE CAPS TO
SPECIFICATIONS
SV3084
B. Place insulation over schrader valve cap and left
side of valve. Position the tab between the
mounting bracket and rear panel.
PLACE TAB BETWEEN
VALVE BODY AND PANEL
SV3085
C. Fold insulation and hold against right hand side
of valve while securing with electrical tape. Seal
the line set insulation to the shut off valve
insulation with electrical tape.
FOLD INSULATION OVER
RIGHT SIDE OF VALVE AND
SECURE WITH
ELECTRICAL TAPE
Part No. 80-1214-3 2-17
SV3086
Installation Instructions Section 2
Revised 8/2003
THIS PAGE INTENTIONALLY LEFT BLANK
2-18
Part No. 80-1214-3
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