Manitowoc Ice QYP0274A Manuel de service

ICE MACHINES

-Mode

2003 Manitowoc Ice, Inc.

80-1100-3

6/03

Safety Notices

Procedural Notices

As you work on a Q-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 manufact ured 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 Q-Series Ice Machine , be sur e to re ad 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, e xtra inf ormation about the procedure y ou are performing.

We reserve the right to make product improvements at any time.

Specifications and design are subject to change without notice.

Section 1 General Information

Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1

Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2

Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Section 2 Installation Instructions

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Ice Storage Bin Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

Remote Condenser Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Location of Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Stacking Two Ice Machines on a Single Storage Bin . . . . . . . . . . . . . . . . . . . . 2-5

Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5

Leveling the Ice Storage Bin . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Air-Cooled Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6

Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Self-Contained Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

For United Kingdom Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Table of Contents

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Authorized Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3

Q320/Q370/Q420 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1

Q200 – Q1000 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Q1300/Q1600/Q1800 Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2

Q1300/Q1600/Q1800 Ice Machines (Cont.) . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

S170/S400/S570 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

S320/S420 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3

S970 Ice Storage Bins . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

JC0495/JC0895/JC1095/JC1395 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

JC1895 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Fuse/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7

Self Contained Ice Machine

115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Self Contained Ice Machine

208-230/3/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Self Contained Ice Machine

230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-9

Part No. 80-1100-3 1

Table of Contents (continued)

Remote Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Ice Machine With Single Circuit Model Condenser

115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Ice Machine With Single Circuit Model Condenser

208-230/3/60 or 380-415/3/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Remote Ice Machine With Single Circuit Model Condenser

230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10

Water Supply and Drain Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Cooling Tower Applications

(Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-11

Water Supply and Drain Line Sizing/Connections . . . . . . . . . . . . . . . . . . . . . 2-12

Remote Condenser/Line Set Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

Remote Ice Machines

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Guidelines for Routing Line Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-14

Calculating Remote Condenser Installation Distances . . . . . . . . . . . . . . . . . 2-15

Lengthening or Reducing Line Set Lengths . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Connecting A Line Set . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Remote Receiver Service Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-16

Remote Ice Machine Usage with Non-Manitowoc Multi-Circuit Condensers . 2-17

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Head Pressure Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Fan Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Internal Condenser Volume . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Condenser DT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Quick Connect Fittings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17

Non-Manitowoc Multi-Circuit Condenser Sizing Chart . . . . . . . . . . . . . . . . . 2-18

Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

Additional Checks for Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-19

2 Part No. 80-1100-3

Section 3 Ice Machine Operation

Table of Contents (continued)

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1

Self-Contained Air- and Water-Cooled Q200/Q280/Q320/Q370/Q420/Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 . 3-2

Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . 3-2

Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2

Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3

Remote

Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800 . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . 3-4

Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4

Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5

Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6

Harvest Sequence Water Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7

Section 4 Maintenance

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Cleaning & Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1

Ice Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Cleaning the Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8

Water-Cooled Condenser and Water Regulat ing Valve . . . . . . . . . . . . . . . . 4-9

Removal from Service/Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Self-Contained Air-Cooled Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Water-Cooled Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Remote Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10

Section 5 Water System Ice Making Sequence of Operation

Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . . . 5-1

Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1

Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2

Part No. 80-1100-3

Section 6 Electrical System

Table of Contents (continued)

Energized Parts Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1

Self-Contained Air- And Water-Cooled Models . . . . . . . . . . . . . . . . . . . . . . . 6-1

Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2

Wiring Diagram Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Self-Contained Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3

Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Wiring Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-17

Q200/Q280/Q320 - Self Contained - 1 Phase With Terminal Board . . . . . . . 6-18

Q280/Q370 - Self Contained - 1 Phase Without Terminal Board . . . . . . . . . 6-19

Q320 - Self Contained - 1 Phase Without Terminal Board . . . . . . . . . . . . . . 6-20

Q420/Q450/Q600/Q800/Q1000 - Self Contained -

1 Phase With Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-21

Q420/Q450/Q600/Q800/Q1000 - Self Contained -

1 Phase Without Terminal Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-22

Q800/Q1000 - Self Contained - 3 Phase With Terminal Board . . . . . . . . . . . 6-23

Q800/Q1000 - Self Contained - 3 Phase Without Terminal Board . . . . . . . . 6-24

Q1300/Q1800 - Self Contained - 1 Phase With Terminal Board . . . . . . . . . . 6-25

Q1300/Q1600/Q1800 - Self Contained - 1 Phase Without Terminal Board . 6-26

Q1300/Q1800 - Self Contained - 3 Phase With Terminal Board . . . . . . . . . . 6-27

Q1300/Q1600/Q1800 - Self Contained - 3 Phase Without Terminal Board . 6-28

Q450/Q600/Q800/Q1000 - Remote - 1 Phase With Terminal Board . . . . . . 6-29

Q450/Q600/Q800/Q1000 - Remote - 1 Phase With out Terminal Board . . . . 6-30

Q800/Q1000 -Remote - 3 Phase With Terminal Board . . . . . . . . . . . . . . . . . 6-31

Q800/Q1000 -Remote - 3 Phase Without Terminal Board . . . . . . . . . . . . . . 6-32

Q1300/Q1800 - Remote - 1 Phase With Terminal Board . . . . . . . . . . . . . . . 6-33

Q1300/Q1600/Q1800 - Remote - 1 Phase Without Terminal Board . . . . . . . 6-34

Q1300/Q1800 - Remote - 3 Phase With Terminal Board . . . . . . . . . . . . . . . 6-35

Q1300/Q1600/Q1800 - Remote - 3 Phase Without Terminal Board . . . . . . . 6-36

Component Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-38

Compressor Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-40

PTCR Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-41

ICE/OFF/CLEAN Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

Control Board Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-44

Electronic Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-45

Ice Thickness Probe (Harvest Initiation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

How The Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Harvest/Safety Limit Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Freeze Time Lock-In Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Maximum Freeze Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-47

Diagnosing Ice Thickness Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48

Water Level Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Water Level Probe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Freeze Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Harvest Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-50

Diagnosing Freeze Cycle Potable Water Level Control Circuitry . . . . . . . . . 6-51

Diagnosing An Ice Machine That Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . 6-54

6-47

4 Part No. 80-1100-3

Section 7 Refrigeration System

Table of Contents (continued)

Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Self-Contained Air or Water -Cooled Models . . . . . . . . . . . . . . . . . . . . . . . . 7-1

Remote Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3

Q1300/Q1600/Q1800 Refrigeration Tubing Schematics . . . . . . . . . . . . . . . 7-6

Operational Analysis (Diagnostics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8

Before Beginning Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Ice Production Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9

Installation/Visual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Water System Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-10

Ice Formation Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-11

Safety Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-13

Analyzing Discharge Pressure

During Freeze or Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17

Analyzing Suction Pressure

During Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-18

Single Expansion Valve Ice Machines Comparing Evaporator Inlet and

Outlet Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

Harvest Valve Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21

Discharge Line Temperature Analysis . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22

How to Use the Refrigeration System

Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-24

Refrigeration System Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . 7-25

Harvest Pressure Regulating

(H.P.R.) System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27

Headmaster Control Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-29

Pressure Control Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . 7-31

Fan Cycle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

High Pressure Cut-Out (HPCO) Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31

Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts . . . . . . . . . 7-32

Q200 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-32

Q280 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

Q320 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-34

Q370 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-35

Q420/450 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-36

Q450 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Q600 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-37

Q800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-39

Q1000 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-40

Q1300 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-42

Q1600 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-43

Q1800 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-44

Part No. 80-1100-3

Table of Contents (continued)

Refrigerant Recovery/Evacuation and Recharging . . . . . . . . . . . . . . . . . . . . . 7-46

Normal Self-Contained Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . 7-46

Normal Remote Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-48

System Contamination Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-52

Replacing Pressure Controls Without

Removing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-54

Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

Total System Refrigerant Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-56

Refrigerant Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-57

Refrigerant Re-Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-58

HFC Refrigerant Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-59

6 Part No. 80-1100-3

Section 1

General Information

Model Numbers

This manual covers the following models:

Self-Contained

Air-Cooled

QR0320A QD0322A QY0324A

QR0420A QD0422A QY0424A

QR0200A QD0202A QY0204A

QR0280A QD0282A QY0284A

QD0372A QY0374A

QR0450A QD0452A QY0454A

QR0600A QD0602A QY0604A

QR0800A QD0802A QY0804A

QR1000A QD1002A QY1004A

QR1300A QD1302A QY1304A

QR1800A QD1802A QY1804A

Self-Contained

Water-Cooled

QR0321W QD0323W QY0325W

QR0421W QD0423W QY0425W

QR0201W QD0203W QY0205W

QR0281W QD0283W QY0285W

QD0373W QY0375W

QR0451W QD0453W QY0455W

QR0601W QD0603W QY0605W

QR0801W QD0803W QY0805W

QR1001W QD1003W QY1005W

QR1301W QD1303W QY1305W

QD1603W QY1605W

QR1801W QD1803W QY1805W

Remote

QR0490N QD0492N QY0494N

QR0690N QD0692N QY0694N

QR0890N QD0892N QY0894N

QR1090N QD1092N QY1094N

QR1390N QD1392N QY1394N

QD1693N QY1694N

QR1890N QD1892N QY1894N

How to Read a Model Number

9 REMOTE

AIR-COOLED

# CU BE SIZ E 0 REGULAR

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

CONDENSER TYPE AIR-COOLED

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

Q R 0450 A

ICE MACHINE

MODEL

ICE CUBE SIZE R REGULAR

D DICE Y HALF DICE

ICE MACHINE

SERIES

CONDENSER TYPE A SELF-CONTAINED AIR-COOLED

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

Ice Cube Sizes

Regular

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

2.86 x 2.86 x 2.22 cm

Dice

7/8" x 7/8" x 7/8"

2.22 x 2.22 x 2.22 cm

Half Dice

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

0.95 x 2.86 x 2.22 cm

NOTE: Model numbers ending in 3 indicate a 3-phase unit. Example: QY1804A3

Warning

PERSONAL INJURY POTENTIAL

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

Part No. 80-1100-3 1-1

General Information Section 1

Model/Serial Number Location

These numbers are required when requesting information from your local Manitowoc distributor, or Manitowoc Ice, Inc.

The model and serial number are listed on the MODEL/ SERIAL NUMBER DECAL affixed to the ice machine, remote condenser and storage bin.

1-2

SV1600

Figure 1-1. Model/Serial Number Location

Part No. 80-1100-3

Section 1 General Information

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.

PARTS

1. Manitowoc warrants the ice machine a gainst def ects in materials and workmanship, under normal use and service for three (3) years from the date of original installation.

2. The evaporator and compressor are covered by an additional two (2) 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 three (3) years from the date of original installation.

2. The evaporator is covered by an additional two (2) year (five years total) labor warranty beginning on the date of the original installation.

EXCLUSIONS

The following items are not included in the ice machine’s warranty coverage:

1. Normal maintenance, adjustments and cleaning.

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, w ater 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.

AUTHORIZED WARRANTY SERVICE

To comply with the provisions of the warranty, a refrigeration service company qualified and authorized by a Manitowoc distributor, or a Contracted Service Representative must perform the warranty repair.

Part No. 80-1100-3 1-3

General Information Section 1

THIS PAGE INTENTIONALLY LEFT BLANK

1-4

Part No. 80-1100-3

Section 2

Installation Instructions

General

Refer to Installation Manual f or complete installation guidelines.

Ice Machine Dimensions

Q320/Q370/Q420 ICE MACHINES

WATER COOLED AIR COOLED

Failure to follow these installation guidelines may affect warranty coverage.

Important

SV1602 SV1611

Ice Machine Dimension H

Q320 21.5 in (54.6 cm) Q370 21.5 in (54.6 cm) Q420 26.5 in (67.3 cm)

Part No. 80-1100-3 2-1

Installation Instructions Section 2

Q200 – Q1000 ICE MACHINES Q1300/Q1600/Q1800 ICE MACHINES

WATER-COOLED SELF CONTAINED

SV1612 SV1628

AIR-COOLED

SELF CONTAINED

WATER-CO OLED

2-2

SV1613

Ice Machine Dimension H

Q200 – Q280 16.5 in (41.9 cm)

Q450 21.5 in (54.6 cm) Q600 21.5 in (54.6 cm) Q800 26.5 in (67.3 cm)

Q1000 29.5 in (74.9 cm)

SV1627

Ice Machine Dimension H

Q1300/Q1600 29.5 in (74.9 cm)

Q1800 29.5 in (74.9 cm)

Part No. 80-1100-3

Section 2 Installation Instructions

Q1300/Q1600/Q1800 ICE MACHINES (CONT.)

REMOTE AIR-COOLED

SV1629

Ice Storage Bin Dimensions

S170/S400/S570 ICE STORAGE BINS

SV1609

Bin Model Dimension A Dimension B

S170 29.5 in (74.9 cm) 19.1 in (48.5 cm) S400 34.0 in (86.3 cm) 32.0 in (81.3 cm) S570 34.0 in (86.3 cm) 44.0 in (111.7 cm)

S320/S420 ICE STORAGE BINS

SV1614

Bin Model Dimension A Dimension B

S320 34.0 in (86.3 cm) 32.0 in (81.3 cm) S420 34.0 in (86.3 cm) 44.0 in (111.7 cm)

Part No. 80-1100-3 2-3

Installation Instructions Section 2

S970 ICE STORAGE BINS

Warning

All Manitowoc ice machines require the ice storage system (bin, dispenser, etc.) to incorporate an ice deflector.

The Q1300, Q1600 and Q 1 80 0 series ice machines require adding Manitowoc Ice Deflector Kit K00139 when installing with non-Manitowoc ice storage systems.

Prior to using a non-Manitowoc ice storage system with other Manitowoc ice machines, contact the manufacturer to assure their ice deflector is compatible with Manitowoc ice machines.

Remote Condenser Dimensions

JC0495/JC0895/JC1095/JC1395

SV1610 SV1297

JC1895

2-4

SV1301

Part No. 80-1100-3

Section 2 Installation Instructions

Location of Ice Machine

The location selected for the ice machin e 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 35°F (1. 6°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 not obstruct air flow through or around the ice machine. Refer to the chart below for clearance requirements.

Q1300/Q1600/

Q1800

Top/Sides 24" (61 cm) 8" (20.3 cm)

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

Q370

Top/Sides 12" (30.5 cm) 5" (12.7 cm)

Back 5" (127 mm) 5" (12.7 cm)

All other

Q models

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. This value is

recommended for efficient operation and servicing only. Q1600 is not available as an air-cooled model.

The ice machine must be protected if it will be subjected to temperatures belo w 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization” on Page 3-14.

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Caution

Water-Cooled

and Remote

Water-Cooled

and Remote

Stacking Two Ice Machines on a Single Storage Bin

A stacking kit is required for stacking two ice machines. Installation instructions are supplied with the stac king kit.

Q450/Q600/

Q800/Q1000

Top/Sides 16" (40.64 cm) 5" (12.70 cm)

Back 5" (12.70 cm) 5" (12.70 cm)

Q1300/Q1600/

Q1800

Top/Sides 48" (121.92 cm) 24" (60.96 cm)

Back 12" (30.48 cm) 12" (30.48 cm)

*There is no minimum clearance required. This value is

recommended for efficient operation and servicing only. Q1600 is not available as an air-cooled model.

Stacked

Self-Contained

Air-Cooled

Stacked

Water-Cooled

and Remote*

Ice Machine Heat of Rejection

Series

Ice Machine

Q320 4,600 6,200 Q370 3,900 5,950 Q420 7,000 9,600 Q200 3,800 5,000 Q280 3,800 6,000 Q450 7,000 9,600 Q600 9,000 13,900

Q800 12,400 19,500 Q1000 16,000 24,700 Q1300 24,000 35,500 Q1600 24,000 35,500 Q1800 36,000 50,000

B.T.U./Hour Because the heat of rejection varies during the ice making cycle,

the figure shown is an average.

Air Conditioning

Heat of Rejection

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 -c on ta ine d aircooled ice machines are installed.

This information is also necessary when evaluating the benefits of using water-cooled or remote condensers to reduce air conditioning loads . The am ount of heat add ed to an air conditioned environment by an ice machine using a water-cooled or remote condenser is negligible.

Knowing the amount of heat rejected is also important when sizing a cooling tower for a water-cooled condenser. Use the peak figure for sizing the cooling tower.

Peak

Part No. 80-1100-3 2-5

Installation Instructions Section 2

Leveling the Ice Storage Bin

1. Screw the leveling legs onto th e 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 i nstructions are supp lied with the casters.

Air-Cooled Baffle

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 LEVELING LEG INTO BASE OF

THREAD ‘FOOT’ IN AS

FAR AS POSSIBLE

Figure 2-1. Leveling Leg and Foot

CABINET

SV1607

Figure 2-2. Air Baffle

SV1606

2-6

Part No. 80-1100-3

Section 2 Installation Instructions

Electrical Service

GENERAL

Warning

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

VOLTA G E

The maximum allowabl e voltag e variation is ±10% of the rated voltage at i ce machine 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 break er must be provided for each ice machine. Circuit breakers must be H.A.C.R. rated (does not apply in Canada).

MINIMUM CIRCUIT AMPACITY

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.

Part No. 80-1100-3 2-7

Installation Instructions Section 2

Table 2-1. Q320/370/420 Ice Machines

Vol tag e

Ice Machine

Q320

Q370

Q420

Phase

Cycle

115/1/60 15 11.2 15 10.5

208-230/1/60 15 4.8 15 4.2

230/1/50 15 5.2 15 4.7 115/1/60 20 12.9 20 12.2

208-230/1/60 15 6.2 15 5.8

230/1/50 15 6.2 15 5.8 115/1/60 20 12.3 20 11.4

208-230/1/60 15 7.8 15 7.4

230/1/50 15 6.3 15 5.9

Table 2-2. Q200 - Q1000 Ice Machines

Ice Machine

Q200

Q280

Q450

Q600

Q800

Q1000

Q1300

Q1600

Q1800

Voltage

Phase

Cycle

115/1/60 15 11.6 15 10.9 N/A N/A

208-230/1/60 15 5.4 15 4.8 N/A N/A

230/1/50 15 5.2 15 4.9 N/A N/A 115/1/60 20 12.6 20 11.7 N/A N/A

208-230/1/60 15 5.7 15 5.2 N/A N/A

230/1/50 15 5.7 15 5.2 N/A N/A 115/1/60 20 12.8 20 11.9 20 13.6

208-230/1/60 15 7.8 15 7.4 N/A N/A

230/1/50 15 6.1 15 5.7 N/A N/A

208-230/1/60 15 9.2 15 8.7 15 9.3

230/1/50 15 9.2 15 8.8 15 9.4 208-230/1/60 20 12.1 20 11.4 20 11.9 208-230/3/60 15 8.9 15 8.2 15 8.9

230/1/50 20 12.0 20 10.6 20 11.2 208-230/1/60 20 14.3 20 13.2 20 14.2 208-230/3/60 15 9.8 15 8.8 15 9.9

230/1/50 20 15.6 20 14.2 20 14.6 208-230/1/60 30 19.5 30 18.1 30 19.8 208-230/3/60 20 13.1 20 11.6 20 12.7

230/1/50 30 15.7 30 14.3 30 14.7 380-415/3/50 N/A N/A N/A N/A 15 7.3 208-230/1/60 N/A N/A 30 17.2 30 18.2 208-230/3/60 N/A N/A 20 11.0 20 12.0

230/1/50 N/A N/A N/A N/A N/A N/A 380-415/3/50 N/A N/A N/A N/A N/A N/A 208-230/1/60 40 28.1 40 26.7 40 26.9 208-230/3/60 20 15.5 20 14.1 20 13.9

230/1/50 40 23.3 40 21.9 40 22.2 380-415/3/50 N/A N/A N/A N/A 15 9.1

Maximum

Fuse/Circuit

Breaker

Maximum Fuse/

Circuit Breaker

Air-Cooled Water Cooled Remote

Circuit Amps

Air-Cooled Water Cooled

Minimum

Circuit Amps

Maximum

Fuse/Circuit

Breaker

Maximum Fuse/

Circuit Breaker

Minimum

Circuit Amps

Maximum

Fuse/Circuit

Breaker

Minimum

Circuit Amps

Minimum

Circuit Amps

2-8

Part No. 80-1100-3

Section 2 Installation Instructions

Self-Contained 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 sho wn in the drawings, the ice machine field wiring connections may use either wire nuts or screw terminals.

SELF CONTAINED ICE MACHINE 115/1/60 OR 208-230/1/60

N=115V

L2=208-230V

GROUND

SELF CONTAINED ICE MACHINE 208-230/3/60

GROUND

ICE MACHINE

SV1190

CONNECTIONS

TO SEPARATE

FUSE/BREAKER

GROUND

SELF CONTAINED ICE MACHINE 230/1/50

SV1258

ICE MACHINE

CONNECTIONS

TO SEPARATE

FUSE/BREAKER

SV1191

GROUND

ICE MACHINE

CONNECTIONS

GROUND

TO SEPARATE

FUSE/BREAKER.

DISCONNECT ALL

POLES.

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 yello w 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

Part No. 80-1100-3 2-9

Installation Instructions Section 2

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 sho wn in the drawings, the ice machine field wiring connections may use either wire nuts or screw terminals.

REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 115/1/60 OR 208-230/1/60

SINGLE CIRCUIT

REMOTE

CONDENSER

GROUND

NOTE: CONDENSER FAN MOTOR VOLTAGE MATCHES ICE MACHINE VOLTAGE (115V OR 208-230V)

REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 208-230/3/60 OR 380-415/3/50

GROUND

NOTE: FAN MOTOR IS 208-230V

TO SEPARATE

FUSE/BREAKER

GROUND

SINGLE CIRCUIT

REMOTE

CONDENSER

ICE

MACHINE

SV1199

ICE

MACHINE

SV1255

GROUND

N=115V OR L2=208-230V

TO SEPARATE

FUSE/BREAKER

GROUND

REMOTE ICE MACHINE WITH SINGLE CIRCUIT MODEL CONDENSER 230/1/50

SINGLE CIRCUIT

REMOTE

CONDENSER

ICE

MACHINE

SV1256

GROUND

TO SEPARATE

FUSE/BREAKER

DISCONNECT ALL

NOTE: FAN MOTOR IS 220-240V

(220-240).

POLES.

GROUND

2-10

Part No. 80-1100-3

Section 2 Installation Instructions

Water Supply and Drain Requirements

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.

WATER INLET LINES

Follow these guidelines to install water inlet lines:

• Do not connect the ice machine to a hot wate r 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 recommended pressure, obtain a water pressure regulator from your Manitowoc distributor.

• Install a water shut-off valve for both the ice making and condenser water lines.

• Insulate water inlet lines to prevent condensation.

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 ice machine drain lines. Insulate them to prevent condensation.

• Vent the bin and ice machine drain to the atmosphere. Do not vent the condenser drain on water-cooled models.

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 co ndenser must not exceed 90°F (32.2°C).

• Water flow th rough the condenser m ust not e xceed 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. 80-1100-3 2-11

Installation Instructions Section 2

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

Ice Making

Water Drain

Condenser Water Inlet

Condenser

Water Drain

Bin Drain --- ---

33°F (0.6°C) Min.

90°F (32.2°C) Max.

--- ---

33°F (0.6°C) Min.

90°F (32.2°C) Max.

--- ---

20 psi (137.9 kPA) Min.

80 psi (551.5 kPA) Ma x.

20 psi (137.9 kPA) Min.

150 psi (1034.2 kPA) Max.

3/8" Female Pipe Thread

1/2" Female Pipe Thread

Q1300/Q1600/Q1800 - 1/2" Female Pipe Thread

All Others - 3/8" Female Pipe Thread

1/2" Female Pipe Thread

3/4" 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

3/4" (19.1 mm) minimum

inside diameter

2-12

SV1626

Figure 2-3. Typical Water Supply Drain Installation

Part No. 80-1100-3

Section 2 Installation Instructions

Remote Condenser/Line Set Installation

Remote Single

Ice Machine

Q490 JC0495 RT-20-R404A Q690 JC0895

Q890 Q1090 JC1095 Q1390 JC1395 RL-20-R404A Q1690 JC1695 Q1890 JC1895

*Line Set Discharge Line Liquid Line

RT 1/2" (1.27 cm) 5/16" (.79 cm) RL 1/2" (1.27 cm) 3/8" (.95 cm)

Air Temperature Around the Condenser

Minimum Maximum

-20°F (-28.9°C) 120°F (49°C)

REMOTE ICE MACHINES REFRIGERANT CHARGE

Each remote ice machine ships from the factory with a refrigerant charge appropriate for installation with line sets of up to 50' (15.25 m). The serial tag on the ice machine indicates the refrigerant charge.

Circuit

Condenser

Line Set*

RT-35-R404A RT-50-R404A

RL-35-R404A RL-50-R404A

Additional refrigerant may be required for installations using line sets between 50' and 100' (15.25-30.5 m) long. If additional refrigerant is required, an additional label located next to the Model/Serial Numbers decal states the amount of refrigerant to be added.

IMPORTANT

EPA CERTIFIED TECHNICIANS

If remote line set length is between 50' and 100' (15.25-

30.5 m), add nameplate charge.

Tubing length: _______________________________ Refrigerant added to nameplate: ________________ New total refrigerant charge: ___________________

1.5 lb. (24 oz) (0.68 kg) of refrigerant to the

Figure 2-4. Typical Additional Refrigerant Label

If there is no additional label, the nameplate charge is sufficient for line set s up to 100' (30. 5 m). (See the chart below.)

WARNING

Potential Personal Injury Situation

The ice machine contains refrigerant charge. Installation 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.

Ice Machine

Q490 6 lb. (96 oz.) None 6 lb. (96 oz.) Q690 8 lb. (128 oz.) None 8 lb. (128 oz.)

Q890 8 lb. (128 oz.) None 8 lb. (128 oz.) Q1090 9.5 lb. (152 oz.) None 9.5 lb. (152 oz.) Q1390 12.5 lb. (200 oz.) 1.5 lb. (24 oz) 14 lb. (224 oz.) Q1690 15 lb. (240 oz.) 2.0 lb. (32 oz) 17 lb. (272 oz.) Q1890 15 lb. (240 oz.) 2.0 lb. (32 oz) 17 lb. (272 oz.)

Nameplate Charge

(Charge Shipped in Ice Machine)

Refrigerant to be Added for

50'-100' Line Sets

Maximum System Charge

(Never Exceed )

Part No. 80-1100-3 2-13

Installation Instructions Section 2

GENERAL

Condensers must be mounted horizontally with the fan motor on top.

Remote condenser installations consist of v ertical and horizontal line sets between the ice machine and the condenser. When combined, they must fit within approved specifications. The following guidelines, drawings and calculation methods must be followed to verify a proper remote condenser installa tion.

Caution

The 60 month compressor warranty (including the 36 month labor replacement warranty) will not apply if the remote ice machine is 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., unless specifically approved in writing by Manitowoc Ice, Inc.

GUIDELINES FOR ROUTING LINE SETS

First, cut a 2.5" (6.35 cm) circular hole in the wall or roof for tubing routing. The line set en d with the 90° bend will connect to the ice machine. The straight end will connect to the remote condenser.

Follow these guidelines when routing the refrigerant lines. This will help insure proper performance and service accessibility.

1. Optional - Make the service loop in the line sets (See Figure 2-5). This permits easy access to the ice machine for cleaning and service. Do not use hard rigid copper at this location.

2. Required - Do not form traps in the refrigeration lines (except the service loop). Refrigerant oil must be free to drain toward the ice machine or the condenser. Route excess tubing in a supported downward horizontal spiral (See Figure 2-5). Do not coil tubing vertically.

3. Required - Keep outdoor refrigerant line runs as short as possible.

SV1204

DOWNWARD

HORIZONTAL

SPIRAL

Figure 2-5. Routing Line Sets

2-14

Part No. 80-1100-3

Section 2 Installation Instructions

CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES

Line Set Length

The maximum length is 100' (30.5 m). The ice machine compressor must have the proper oil

return. The receiver is designed to hold a char ge sufficient to operate the ice machine in ambient temperatures between -20°F (-28.9°C) and 120°F (49°C), with line set lengths of up to 100' (30.5 m).

Line Set Rise/Drop

The maximum rise is 35' (10.7 m). The maximum drop is 15' (4.5 m).

Caution

If a 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.

Calculated Line Set Distance

The maximum distance is 150' (45.7 m). Line set rises, drops, ho rizontal runs (or combina tions of

these) in excess of the stated maximums will exceed compressor start-up and design limits. This will cause poor oil return to the compressor.

Make the following calculations to mak e sure the line set layout is within specifications.

1. Insert the measured rise into the formula below. Multiply by 1.7 to get the calculated rise. (Example: A condenser located 10 feet above the ice machine has a calculated rise of 17 feet.)

2. Insert the measured drop into the formula below. Multiply by 6.6 to get the calculated drop. (Example. A condenser located 10 f eet below t he ice machine has a calculated drop of 66 feet.)

3. Insert the measured horizontal distance into the formula below. No calculation is necessary.

4. Add together the calculated rise, calculated drop, and horizontal distance to get t he total calculated distance. If this total exceeds 150' (45.7 m), move the condenser to a new location and perform the calculations again.

Maximum Line Set Distance Formula

Step 1. Measured Rise (35' [10.7 m] Maximum) ______ x 1.7 = _______ Calculated Rise Step 2. Measured Drop (15' [4.5 m] Maximum) ______ x 6.6 = _______ Calculated Drop Step 3. Measured Horizontal Distance (100' [30.5 m] Maximum) _______ Horizontal Distance Step 4. Total Calculated Distance 150' (45.7 m) _______ Total Calculated Distance

SV1196 SV1195 SV1194

Figure 2-6. Combination of a Rise

and a Horizontal Run

Figure 2-7. Combination of a Drop

and a Horizontal Run

Figure 2-8. Combination of a

Rise, a Drop and a Horizontal Run

Part No. 80-1100-3 2-15

Installation Instructions Section 2

LENGTHENING OR REDUCING LINE SET LENGTHS

In most cases, b y routing the line set properly, shortening will not be necessary. When shortening or lengthening is required, do so bef ore con necting the lin e set to the ice machine or the remote condenser. This prevents the loss of refrigerant in the ice machine or condenser.

The quick connect fittings on the line sets are equipped with Schraeder valves. Use these valves to recover any vapor charge from the line set. When lengthening or shortening lines, follow good refrigeration practices and insulate new tubing. Do not change the tube sizes. Evacuate the lines and place a bo ut 5 oz (1 43 g) of vapor refrigerant charge in each line.

CONNECTING A LINE SET

1. Remove the dust caps from the line set, condenser and ice machine.

2. Apply refr ig eratio n oil to the thr e ad s on the quick disconnect couplers before connecting them to the condenser.

3. Carefully thread the female fitting to the condenser or ice machine by hand.

4. Tighten the couplings with a wrench until they bottom out.

REMOTE RECEIVER SERVICE VALVE

The receiver service valve is closed during shipment. Open the valve prior to starting the ice machine.

1. Remove the top and left side panels.

2. Remove the receiver service valve cap.

3. Backseat (open) the valve.

4. Reinstall the cap and panels.

REMOVE FRONT, TOP, AND LEFT SIDE PANEL FOR ACCESS TO RECEIVER VALVE

TURN COUNTERCLOCKWISE TO OPEN

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

Liquid Line Discharge Line

10-12 ft lb.

(13.5-16.2 N•m)

35-45 ft lb.

(47.5-61.0 N•m)

6. Check all fittings for leaks.

RECEIVER SERVICE VALVE CAP (TURN

SV1603

COUNTERCLOCKWISE TO REMOVE)

Figure 2-9. Backseating the Receiver Service Valve

2-16

Part No. 80-1100-3

Section 2 Installation Instructions

Remote Ice Machine Usage with Non-Manitowoc Multi-Circuit Condensers

WARRANTY

The sixty (60) month compressor warranty, including thirty six (36) month labor replacement warranty, shall not apply when the remote ice machine is not installed within the remote specifications. The foregoing warranty shall not apply to any ice machine installed and/or maintained inconsistent with the technical instructions provided by Manitowoc Ice, Inc. Performance may vary from Sales specifications. Q-Model ARI certified standard ratings only apply when used with a Manito woc remote condenser.

If the design of the condenser meets the specificatio ns, Manitowoc’ s only be extended to the Manitowoc manufactured part of the system. Since Manitowoc does not conjunction with the ice machine, Manitowoc will not endorse, recommend, or approve the condenser, and will not be responsible for its performance or reliability..

approval is f or full w arranty cov erage to

test the condenser in

Important

Manitowoc warrants only complete new and unused remote packages. Guaranteeing the integrity of a new ice machine under the terms of our warranty prohibits the use of pre-existing (used) tubing or condensers.

HEAD PRESSURE CONTROL VALVE

Any remote condenser connected to a Manitowoc QModel Ice Machine must have a head pressure control valve #836809 -3 (a v ailab le from Ma nitow oc Distributors) installed on the condenser package. Manitowoc will not accept substitute “off the shelf” head pressure control valves.

FAN MOTOR

The condenser fan must be on during the complete ice machine freeze cycle (do not cycle on fan cycle control). The ice maker has a condenser fan motor circuit for use with a Manitowoc condenser . It is recommended that this circuit be used to control the condenser fan(s) on the multi-circuit condenser to assure it is on at the proper time. Do not exceed the rated amps for the fan motor

circuit listed on the ice machine’s serial tag.

INTERNAL CONDENSER VOLUME

The multi-circuit condenser internal volume must not be less than or exceed that used by Manitowoc (see chart on Page 2-18). Do not exceed internal volume and try

to add charge to compensate, as compressor failure will result.

CONDENSER ∆T

∆T is the difference in temperature between the condensing refrigerant and entering air. The ∆T should be 15 to 20°F (-9.4 to -6.6°C) at the beginning of the freeze cycle (peak load conditions) and dr op down to 12 to 17°F (-11.1 to -8.3°C) during the last 75% of the freeze cycle (average load conditions).

REFRIGERANT CHARGE

Remote ice machines have the serial plate refrigerant charge (total system charge) located in the ice maker section. (Remote condensers and line sets are supplied with only a vapor charge.)

Caution

Never add more than nameplate charge to ice machine for any application.

Caution

Do not use a fan cycling control to try to maintain discharge pressure. Compressor failure will result.

Part No. 80-1100-3 2-17

QUICK CONNECT FITTINGS

The ice machine and line sets come with quick connect fittings. It is recommended th at matching q uic k connects (availab le through Manitow oc Distributors) be installed in the multi-circuit condenser, and that a vapor “holding” charge (5 oz.) of proper refrigerant be added to the condenser prior to connection of the ice machine or line set to the condenser.

Installation Instructions Section 2

NON-MANITOWOC MULTI-CIRCUIT CONDENSER SIZING CHART

Internal

Ice

Machine

Model

Refrigerant Heat of Rejection

Type Charge

Average

Btu/hr

Peak

Condenser

Volu m e ( c u ft)

Design

Pressure

Min Max Discharge Liquid

Q450 R-404A 6 lbs. 7,000 9,600 0.020 0.035 500 psig Q600 R-404A 8 lbs. 9,000 13,900 0.045 0.060

safe working

pressure

Quick Connect Stubs-

Male Ends

coupling

P/N

83-6035-3

coupling

P/N

83-6034-3

Head

Pressure

Control

Valve

Manitowoc

P/N

83-6809-3

Q800 R-404A 8 lbs. 12,400 19,500 0.045 0.060 Q1000 R-404A 9.5 lbs. 16,000 24,700 0.065 0.085 Q1300 R-404A 14 lbs.124,000 35,500 0.085 0.105 Q1600 R-404A 17 lbs.136,000 50,000 0.130 0.170 Q1800 R-404A 17 lbs.

Amount reflects additional R-404A refrigerant added to nameplate charge for 50' to 100' line sets, to ensure proper operation at all ambient

conditions. Q1300 has 1.5 lbs. additional R-404A. Q1600 and Q1800 has 2.0 lbs. additional R-404A

SINGLE CIRCUIT REMOTE CONDENSER

36,000 50,000 0.130 0.170

DISCHARGE LINE

2,500 psig

burst

pressure

mounting flange P/N 83-6006-3

ELECTRICAL DISCONNECT

mounting flange P/N 83-6005-3

substitutes

LIQUID LINE

ELECTRICAL DISCONNECT

ICE MACHINE

ELECTRICAL SUPPLY

DISCHARGE REFRIGERANT LINE

BIN

36.00" (91.44 cm) DROP

LIQUID REFRIGERANT LINE

Figure 2-10. Typical Single Circuit Remote Condenser Installation

SV1615

2-18

Part No. 80-1100-3

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