Manitowoc Neo Technician's Handbook
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Manitowoc Neo Technician's Handbook

Undercounter ice machines
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See also: Installation, Operation & Maintenance Manual
Manitowoc
Undercounter
Ice Machines
Technician's
Handbook
This manual is updated as new information and models are
released. Visit our website for the latest manual.
www.manitowocice.com
America's #1 Selling Ice Machine
Part Number STH042 3/14

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Summary of Contents for Manitowoc Neo

  • Page 1 Manitowoc Undercounter Ice Machines Technician’s Handbook This manual is updated as new information and models are released. Visit our website for the latest manual. www.manitowocice.com America’s #1 Selling Ice Machine Part Number STH042 3/14...

  • Page 3: Safety Notices

    Safety Notices As you work on Manitowoc equipment, be sure to pay close attention to the safety notices in this handbook. Disregarding the notices may lead to serious injury and/or damage to the equipment. Throughout this handbook, you will see the following...
  • Page 4 Procedural Notices As you work on Manitowoc equipment, be sure to read the procedural notices in this handbook. These notices supply helpful information which may assist you as you work. Throughout this handbook, you will see the following types of procedural notices:...
  • Page 5 Warning Do not use electrical appliances or accessories other than those supplied by Manitowoc for your ice machine model. Warning Two or more people or a lifting device are required to lift this appliance.
  • Page 6 Warning This equipment contains high voltage electricity and refrigerant charge. Installation and repairs are to be performed by properly trained technicians aware of the dangers of dealing with high voltage electricity and refrigerant under pressure.The technician must also be certified in proper refrigerant handling and servicing procedures.
  • Page 7 Warning Do not obstruct machine vents or openings. Warning Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance. Warning Do not clean with water jet. Warning It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.
  • Page 8 Warning When using electric appliances, basic precautions must always be followed, including the following: a. Read all the instructions before using the appliance. b. To reduce the risk of injury, close supervision is necessary when an appliance is used near children. c.

  • Page 9: Table Of Contents

    Table of Contents GENERAL INFORMATION Model Numbers ..... 13 How to Read a Model Number ..14 Ice Machine Warranty Information .
  • Page 10 OPERATION Touch Pad Features ....47 On/Off ......47 Delay .
  • Page 11 COMPONENT CHECK PROCEDURES Main Fuse ......95 Bin Switch ......96 Touch Pad .
  • Page 12 CHARTS Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts ..121 U0140 Self-contained Air-cooled ..122 U0140 Self-contained Water-cooled . . 123 U0190 Self-contained Air-cooled ..124 U0240 Self-contained Air-cooled .

  • Page 13: General Information

    General Information Model Numbers This manual covers the following models: Self-contained Self-contained Air-cooled Water-cooled UD0140A UD0140W UD0140AE UD0140WE UY0140A UY0140W UY0140AE UY0140WE UR0140A UR0140AE UD0190A UD0190AE UY0190A UY0190AE UR0190A UR0190AE UD0240A UD0240W UD0240AE UD0240WE UY0240A UY0240W UY0240AE UY0240WE UR0240A UR0240AE UD0310A UD0310W UD0310AE...

  • Page 14: How To Read A Model Number

    How to Read a Model Number Cube Size Capacity Condenser Series Type U D 0140 A E E - WRAS 50Hz R - Regular A - Air-cooled D - Dice W - Water-cooled Y - Half-dice Warning An ice machine contains high voltage electricity and refrigerant charge.

  • Page 15: Ice Machine Warranty Information

    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.
  • Page 16 Authorized Warranty Service To comply with the provisions of the warranty, a refrigeration service company qualified and authorized by your Manitowoc distributor, or a Factory Authorized Servicer must perform the warranty repair. Service Calls Normal maintenance, adjustments and cleaning as outlined in this manual are not covered by the warranty.

  • Page 17: Residential Warranty Coverage

    Subject to the exclusions and limitations below, Manitowoc Ice (“Manitowoc”) warrants to the original consumer that any new ice machine manufactured by Manitowoc (the “Product”) shall be free of defects in material or workmanship for the warranty period outlined below under normal use and maintenance,...
  • Page 18 IN NO EVENT SHALL MANITOWOC OR ANY OF ITS AFFILIATES BE LIABLE TO THE CONSUMER OR ANY OTHER PERSON FOR ANY INCIDENTAL,...
  • Page 19 To secure prompt and continuing warranty service, this warranty registration card must be completed and sent to Manitowoc within thirty (30) days from the sale date. Complete the following registration card and send it to Manitowoc at the address shown above. Retain a copy for your records.
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  • Page 21: Installation

    Installation Location of Ice Machine The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location. • The location must be indoors. • The location must be free of airborne and other contaminants.

  • Page 22: Ice Machine Clearance Requirements

    Ice Machine Clearance Requirements Self-contained Self-contained Air-cooled Water-cooled Top/Sides 5" (127 mm)* 5" (127 mm)* Back 5" (127 mm)* 5" (127 mm)* *NOTE: The ice machine may be built into a cabinet. There is no minimum clearance requirement for the top or left and right sides of the ice machine.

  • Page 23: Leveling The Ice Machine

    Leveling the Ice Machine 1. Screw the leveling legs onto the bottom of the ice machine. 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.

  • Page 24: Electrical Requirements

    Electrical Requirements Voltage The maximum allowable voltage variation is ±10% of the rated voltage on the ice machine model/serial number plate at start-up (when the electrical load is highest). Fuse/Circuit Breaker A separate fuse/circuit breaker must be provided for each ice machine. Total Circuit Ampacity The total circuit ampacity is used to help select the wire size of the electrical supply.

  • Page 25: Electrical Specifications

    Electrical Specifications Air-cooled Ice Machine Max. Fuse/ Voltage Total Ice Machine Circuit Phase Cycle Amps Breaker 115/1/60 U140 208-230/1/60 230/1/50 115/1/60 U190 208-230/1/60 230/1/50 115/1/60 U240 208-230/1/60 230/1/50 115/1/60 10.0 U310 208-230/1/60 230/1/50 NOTE: * Indicates preliminary data Part Number STH042 3/14...
  • Page 26 Water-cooled Ice Machine Max. Fuse/ Voltage Total Ice Machine Circuit Phase Cycle Amps Breaker 115/1/60 U140 208-230/1/60 230/1/50 115/1/60 U240 208-230/1/60 230/1/50 115/1/60 10.0 U310 208-230/1/60 230/1/50 NOTE: * Indicates preliminary data Warning All wiring must conform to local, state and national codes.

  • Page 27: Water Service/Drains

    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.

  • Page 28: Drain Connections

    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. •...
  • Page 29 WATER SUPPLY AND DRAIN LINE SIZING/ CONNECTIONS Part Number STH042 3/14...
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  • Page 31: Maintenance

    The ice machine must be taken apart for cleaning and sanitizing. ! Caution Use only Manitowoc approved Ice Machine Cleaner (part number 94-0546-3) Sanitizer (part number 94-0565-3). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.

  • Page 32: Touch Pad Operation

    TOUCH PAD OPERATION Pressing and holding the clean button for 3 seconds starts the clean cycle. The Clean & On/Off lights energize indicating the clean cycle has started and ice making will automatically start when the Clean cycle is complete. •...
  • Page 33 ! Caution Do not mix Ice Machine Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Step 3 To start a cleaning cycle, press the Clean button.
  • Page 34 Step 5 Mix a solution of cleaner and warm water. Depending on the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly clean all parts. Solution Type Water Mixed with...
  • Page 35 Step 7 Mix a solution of sanitizer and warm water. Solution Type Water Mixed With Sanitizer 3 gal. (12 l) 2 oz (60 ml) sanitizer Use half of the sanitizer/water solution to sanitize all removed components. Use a spray bottle to liberally apply the solution to all surfaces of the removed parts or soak the removed parts in the sanitizer/water solution.

  • Page 36: Remove Parts For Cleaning

    REMOVE PARTS FOR CLEANING Warning Disconnect electric power to the ice machine at the electric switch box before proceeding. A. Remove the Harvest Float Switch and Ice Thickness Float Switch • Pull forward on the bottom of the bracket until clear of the tab, then slide bracket upward to remove the bracket and float as an assembly.
  • Page 37 WIRE CONNECTORS ARE LOCATED BEHIND BULKHEAD PULL THROUGH GROMMET TO DISCONNECT ICE THICKNESS FLOAT HARVEST FLOAT SWITCH & BRACKET SWITCH & BRACKET DISCONNECT WIRES FOR COMPLETE REMOVAL Part Number STH042 3/14...
  • Page 38 B. Remove the Water Trough • Remove the upper thumbscrew. • While supporting the water trough remove the thumbscrew from beneath the water trough. • Remove the water trough from the bin area. UPPER THUMBSCREW LOWER THUMBSCREW Part Number STH042 3/14...
  • Page 39 C. Remove the Ice Damper • Remove thumbscrew from bin switch cover. • Support ice damper and then pull bin switch cover and ice damper forward to remove. 1. REMOVE THUMBSCREW 2. SUPPORT ICE DAMPER THEN SLIDE RIGHT SIDE FORWARD TO REMOVE Part Number STH042 3/14...
  • Page 40 D. Remove the Water Distribution Tube • Distribution tube thumbscrews are retained to prevent loss. Loosen thumbscrews but do not pull thumbscrews out of distribution tube. • Loosen the two outer screws and pull forward on the distribution tube to release. NOTE: For ease of assembly when reinstalling the water distribution tube, install the top edge first.

  • Page 41: Preventative Maintenance Cleaning

    Preventative Maintenance Cleaning This cleaning procedure can be performed between the bi-annual cleaning and sanitizing cycles. This procedure does not require removing the ice from the bin. Step 1 Press the On/Off button after ice falls from the evaporator at the end of a Harvest cycle. Or, press the On/Off button and allow the ice to melt off the evaporator.

  • Page 42: Ice Machine Inspection

    Ice Machine Inspection Check all water fittings and lines for leaks. Also, make sure the refrigeration tubing is not rubbing or vibrating against other tubing, panels, etc. Do not put anything (boxes, etc.) in front of the ice machine. There must be adequate airflow through and around the ice machine to maximize ice production and ensure long component life.

  • Page 43: Cleaning The Condenser

    Cleaning the Condenser General Warning Disconnect electric power to the ice machine head section and the remote condensing unit at the electric service switches before cleaning the condenser. A dirty condenser restricts airflow, resulting in excessively high operating temperatures. This reduces ice production and shortens component life.

  • Page 44: Removal From Service/Winterization

    Removal from Service/Winterization 1. Clean and sanitize the ice machine. 2. Press the On/Off button to turn off the ice machine. 3. Turn off the water supply, disconnect and drain the incoming ice-making water line at the rear of the ice machine and drain the water trough. 4.

  • Page 45: Bin Removal

    Bin Removal 1. Disconnect power. 1. Remove all ice from bin. 2. Loosen screws and slide clips to release. 3. Disconnect clamp and remove bin drain. 4. Disconnect touch pad communication cable. 5. Slide bin forward to remove. NOTE: When reinstalling the bin, insure the bin seal is in place and is not pinched/folded as it mates to the cabinet.
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  • Page 47: Touch Pad Features

    Operation Touch Pad Features The touch pad offers a series of pressure sensitive buttons to control ice machine operation and provide operational status. On/Off - Blue = Machine On Off = Machine Is Off Delay - Blue = Delay Mode On Off = Delay Mode Is Off Clean - Yellow = Clean Cycle On Off = Cleaning is Off...

  • Page 48: Delay

    DELAY Pressing the Delay button will start a delay period. The ice machine will finish the freeze and harvest cycle and then start the delay period. • Pressing the button once will start a 4 hour delay period. • Pressing the button twice will start a 12 hour delay period.

  • Page 49: Bin Full

    BIN FULL The Bin Full light energizes when the bin is full or is de-energized if the bin is not full. SERVICE The service light indicates the machine needs attention. • Refer to safety limits if this light is energized. Part Number STH042 3/14...

  • Page 50: Ice Making Sequence Of Operation

    Ice Making Sequence of Operation NOTE: The On/Off button must be depressed and the ice damper must be closed before the ice machine will start. Water Purge Cycle The ice machine purges any remaining water from the water trough down the drain. Freeze Cycle Prechill - The refrigeration system chills the evaporator before water flow over the evaporator starts.

  • Page 51: Control Board Timers

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

  • Page 52: Safety Limits

    SAFETY LIMITS Safety limits are stored and indicated by the control board. The number of cycles required to stop the ice machine varies for each safety limit. Safety limits can be reset by pressing the On/Off button and starting a new ice making cycle. A safety limit is indicated by a flashing Service Light on the touch pad.
  • Page 53 Safety Limit 3 If the freeze time reaches 4 minutes and water is not sensed (float remains down for 10 continuous seconds) the ice machine stops. • Safety Limit 3 is bypassed on the initial cycle (manual start or after a full bin/safety limit condition).

  • Page 54: Energized Parts Chart

    Part Number STH042 3/14...
  • Page 55 Part Number STH042 3/14...

  • Page 56: Operational Checks

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

  • Page 57: Troubleshooting

    Troubleshooting Control Board Test Mode NOTE: The ice damper/bin switch can be open or closed and does not effect the operation of the test mode. To enter the test mode press and hold the test button on the control board for 3 seconds. The control board test mode performs the following functions for a 2 minute time period: •...

  • Page 58: Diagnosing An Ice Machine That Will Not Run

    Diagnosing an Ice Machine that Will Not Run Warning High (line) voltage is applied to the control board at all times. Removing the control board fuse or pressing the power button will not remove the power supplied to the control board. 1.

  • Page 59: Ice Machine Does Not Cycle Into Harvest When Water Loses Contact With The Harvest Float Switch

    Ice Machine Does Not Cycle Into Harvest when Water Loses Contact with the Harvest Float Switch NOTE: The ice machine will make a thick or double slab when a new freeze cycle is started with ice already present on the evaporator. Two of the most common scenarios are: •...
  • Page 60 Step 3 Disconnect the harvest float switch wire from the control board and place a jumper on the control board harvest float switch terminals. Bypass the freeze time lock-in feature by pressing the power button to cycle the ice machine off/on. Wait until water flows over the evaporator, then refer to chart.

  • Page 61: Ice Machine Cycles Into Harvest Before Water

    Ice Machine Cycles Into Harvest Before Water loses Contact with the Harvest Float Switch Step 1 Disconnect power to the ice machine, remove the electrical panel to allow viewing of the control board lights and pull the wire connector for the harvest float switch through the bulkhead and disconnect.
  • Page 62 Step 2 Reapply power and press the power button to cycle the ice machine off/on and bypass the freeze time lock-in feature. Wait until water flows over the evaporator, then refer to chart. Result Correction The harvest light does not Refer to Float Switch come on and the ice Diagnostics...

  • Page 63: Ice Production Check

    If they match closely, determine if: Another larger ice machine is required. Relocating the existing equipment to lower the load conditions is required. Contact the local Manitowoc distributor for information on available options and accessories. Part Number STH042 3/14...

  • Page 64: Installation/Visual Inspection Checklist

    Installation/Visual Inspection Checklist Ice machine is not level • Level the ice machine Condenser is dirty • Clean the condenser Water filtration is plugged (if used) • Install a new water filter Water drains are not run separately and/or are not vented •...

  • Page 65: Water System Checklist

    Water System Checklist A water-related problem often causes the same symptoms as a refrigeration system component malfunction. Example: A water dump valve leaking during the freeze cycle, a system low on charge, and a starving TXV have similar symptoms. Water system problems must be identified and eliminated prior to replacing refrigeration components.

  • Page 66: Ice Formation Pattern

    Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction. However, when this analysis is used along with Manitowoc’s Refrigeration System Operational Analysis Table, it can help diagnose an ice machine malfunction. OUTLET...
  • Page 67 Extremely Thin at Evaporator Outlet There is no ice, or a considerable lack of ice formation on the outlet of the evaporator. Examples: No ice at all at the outlet of the evaporator, but ice forms at the inlet half of the evaporator. Or, the ice at the outlet of the evaporator reaches the correct thickness, but the outlet of the evaporator already has 1/2"...

  • Page 68: Safety Limit Feature

    Safety Limit Feature In addition to the standard safety controls, your Manitowoc ice machine features built-in safety limits that will stop the ice machine if conditions arise which could cause a major component failure. Service Light: The service light energizes whenever a safety limit has been exceeded.
  • Page 69 Safety Limit 3 If the freeze time reaches 4 minutes and water is not sensed (float remains down for 10 continuous seconds) the ice machine stops. • Safety Limit 3 is bypassed on the initial cycle (manual start or after a full bin/safety limit condition).
  • Page 70 Determining Which Safety Limit Stopped the Ice Machine: When a safety limit condition causes the ice machine to stop, the safety limit light on the control board continually flashes on and off. CONTROL BOARD SAFETY LIMIT LIGHT OPERATION, BEFORE THE POWER BUTTON HAS BEEN CYCLED ON/OFF: Watch the safety limit lights on the control board: •...

  • Page 71: Electrical System

    Safety Limit Checklist The following checklists are designed to assist the service technician in analysis. However, because there are many possible external problems, do not limit your diagnosis to only the items listed. Safety Limit #1 Freeze time exceeds 60 minutes for 3 consecutive freeze cycles.

  • Page 72: Refrigeration System

    Refrigeration System • Non-Manitowoc components • Improper refrigerant charge • Defective compressor • TXV starving or flooding (check bulb mounting) • Non-condensable in refrigeration system • Plugged or restricted high side refrigerant lines or component • Defective harvest valve Part Number STH042 3/14...
  • Page 73 Electrical system • Water inlet valve defective • Bin switch defective • Premature harvest Refrigeration system • Non-Manitowoc components • Improper refrigerant charge • Defective harvest valve • TXV flooding (check bulb mounting) • Defective fan cycling control Part Number STH042 3/14...
  • Page 74 Safety Limit 3 Freeze time reaches 4 minutes and water is not sensed. Possible Cause Checklist Improper installation • Refer to “Installation/Visual Inspection Checklist” on page 64. Water System • Dirty/defective water dump valve • Low water float valve dirty or defective •...

  • Page 75: Analyzing Discharge Pressure

    Analyzing Discharge Pressure 1. Determine the ice machine operating conditions: Air temp. entering condenser ______ Air temp. around ice machine ______ Water temp. entering sump trough ______ 2. Refer to “Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts” on page 121 for ice machine being checked.
  • Page 76 • Overcharged • Non-condensable in system • Wrong type of refrigerant Other • Non-Manitowoc components in system • High side refrigerant lines/component restricted (before mid-condenser) Freeze Cycle Discharge Pressure Low Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” on page 64.

  • Page 77: Analyzing Suction Pressure

    Analyzing Suction Pressure The suction pressure gradually drops throughout the freeze cycle. The actual suction pressure (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times. To analyze and identify the proper suction pressure drop throughout the freeze cycle, compare the published suction pressure to the published freeze cycle time.
  • Page 78 Procedure Step 1. Determine the ice machine operating conditions. Example: Air temp. entering condenser: 90°F/32.2°C Air temp. around ice machine: 80°F/26.7°C Water temp. entering water fill valve: 70°F/21.1°C 2A. Refer to “Cycle Time” and “Operating Pressure” charts for ice machine model being checked. Using operating conditions from Step 1, determine published freeze cycle time and published freeze cycle suction pressure.
  • Page 79 High Checklist” on page 76. Improper Refrigerant Charge • Overcharged • Wrong type of refrigerant • Non-condensable in system Other • Non-Manitowoc components in system • Harvest valve leaking • TXV flooding (check bulb mounting) • Defective compressor Part Number STH042 3/14...

  • Page 80: Suction Pressure Low Checklist

    Improper Refrigerant Charge • Undercharged • Wrong type of refrigerant Other • Non-Manitowoc components in system • Improper water supply over evaporator refer to “Water System Checklist” on page 65. • Loss of heat transfer from tubing on back side of evaporator •...

  • Page 81: Harvest Valve

    Harvest Valve General The harvest valve is an electrically operated valve that opens when energized, and closes when de- energized. Normal Operation The valve is de-energized (closed) during the freeze cycle and energized (open) during the harvest cycle. The valve is positioned between the receiver and the evaporator and performs two functions: 1.
  • Page 82 As the amount of leakage increases the length of the freeze cycle increases and the amount of ice at the outlet of the evaporator decreases. Refer to the Parts Manual for proper valve application. If replacement is necessary, use only “original” Manitowoc replacement parts. Part Number STH042 3/14...
  • Page 83 Use the following procedure and table to help determine if a harvest valve is remaining partially open during the freeze cycle. 1. Wait five minutes into the freeze cycle. 2. Feel the inlet of the harvest valve(s). Important Feeling the harvest valve outlet or across the harvest valve itself will not work for this comparison.
  • Page 84 Findings Comments The inlet of the harvest This is normal as the valve is cool enough to discharge line should touch and the compressor always be too hot to touch discharge line is hot. and the harvest valve inlet, although too hot to touch Cool &...

  • Page 85: Comparing Evaporator Inlet/Outlet

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

  • Page 86: Discharge Line Temperature Analysis

    Discharge Line Temperature Analysis GENERAL Knowing if the discharge line temperature is increasing, decreasing or remaining constant can be an important diagnostic tool. Maximum compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle. Comparing the temperatures over several cycles will result in a consistent maximum discharge line temperature.
  • Page 87 Discharge Line Temperature Above 150°F (66°C) at End of Freeze Cycle: Ice machines that are operating normally will have consistent maximum discharge line temperatures above 150°F (66°C). Verify the expansion valve sensing bulb is positioned and secured correctly. Discharge Line Temperature Below 150°F (66°C) at End of Freeze Cycle Ice machines that have a flooding expansion valve will have a maximum discharge line temperature that...

  • Page 88: Refrigeration Component Diagnostics

    Refrigeration Component Diagnostics All electrical and water related problems must be corrected before these charts will work properly. These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed and external items and problems that will cause good refrigeration components to appear defective.
  • Page 89 PROCEDURE Step 1 Complete each item individually in the “Operational Analysis” column. Enter check marks ( ) in the boxes. Each time the actual findings of an item in the “Operational Analysis” column matches the published findings on the table, enter a check mark. Example: Freeze cycle suction pressure is determined to be low.

  • Page 90: Final Analysis

    FINAL ANALYSIS The column with the highest number of check marks identifies the refrigeration problem. Column 1 – Harvest Valve Leaking A leaking harvest valve must be replaced. Column 2 – Low Charge/TXV Starving Normally, a starving expansion valve only affects the freeze cycle pressures, not the harvest cycle pressures.

  • Page 91: Refrigeration Component Diagnostic Chart

    Refrigeration Component Diagnostic Chart Part Number STH042 3/14...
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  • Page 95: Component Check Procedures

    Component Check Procedures Main Fuse Function The control board fuse stops ice machine operation if electrical components fail causing high amp draw. Specifications • The main fuse is 250 Volt, 10 amp. Warning High (line) voltage is applied to the control board at all times.

  • Page 96: Bin Switch

    Bin Switch Function Bin switch operation is controlled by the movement of the ice damper. The bin switch has two main functions: 1. Terminating the harvest cycle and returning the ice machine to the freeze cycle. This occurs when the bin switch is opened and closed again within 7 seconds of opening during the harvest cycle.
  • Page 97 Ohm Test 1. Disconnect the bin switch wires to isolate the bin switch from the control board. 2. Connect an ohmmeter to the disconnected bin switch wires. 3. Cycle the bin switch open and closed numerous times by opening and closing the water curtain. NOTE: To prevent misdiagnosis: •...

  • Page 98: Touch Pad

    Touch Pad Function User interface to select ice making, delay start or cleaning cycle and provides feedback on ice machine operation. Check For Normal Operation Action Normal Function Press and hold the control All Touch Pad lights turn on board test button for 3 seconds Press test button All Touch Pad lights turn off Press power button...
  • Page 99 Ohm Test Disconnect wire from control board and Ohm touch pad and interconnecting wire to verify correct operation. Pressing and depressing the touch pad must open and close the circuit. A switch that functions correctly will close as the button is pressed and open as the button is released.

  • Page 100: Float Switch

    Float Switch Function Open and close to indicate to the control board the level of water in the water trough. Specifications Normally closed, float operated magnetic reed switch. The float switch contacts are closed in the down position. When water raises the float to the up position the magnet in the float opens the contacts.
  • Page 101 FLOAT OPEN FLOAT CLOSED NOTE: Make adjustments with the ice machine in the off position. Making adjustments during the freeze cycle may produce an initial sheet of ice that is thicker than future cycles. Part Number STH042 3/14...

  • Page 102: Compressor Electrical Diagnostics

    Compressor Electrical Diagnostics The compressor does not start or will trip repeatedly on overload. Check Resistance (Ohm) Values NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter. Perform the resistance test after the compressor cools. The compressor dome should be cool enough to touch (below 120°F/49°C) to ensure that the overload is closed and the resistance readings will be accurate.

  • Page 103: Compressor Drawing Locked Rotor

    Compressor Drawing Locked Rotor The two likely causes of this are: • Defective starting component • Mechanically seized compressor To determine which you have: 1. Install high and low side gauge. 2. Try to start the compressor. 3. Watch the pressures closely. •...

  • Page 104: Fan Cycle Control

    Fan Cycle Control Function Cycles the fan motor on and off to maintain proper operating discharge pressure. The fan cycle control closes on an increase, and opens on a decrease in discharge pressure. Specifications Cut-In Cut-Out Model (Close) (Open) 250 psig ±5 200 psig ±5 U140 U190...

  • Page 105: High Pressure Cutout (Hpco) Control

    High Pressure Cutout (HPCO) Control Function Stops the ice machine if subjected to excessive high- side pressure. The HPCO control is normally closed, and opens on a rise in discharge pressure. Specifications 450 psig ±10 Cut-out: Cut-in: Automatic reset (Must be below 300 psig to reset). Check Procedure 1.

  • Page 106: Filter-Driers

    Liquid Line Filter Drier The filter-drier used on Manitowoc ice machines are manufactured to Manitowoc specifications. The difference between a Manitowoc drier and an off- the-shelf drier is in filtration. A Manitowoc drier has dirt-retaining filtration, with fiberglass filters on both the inlet and outlet ends.
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  • Page 108: Refrigerant Recovery/Evacuation

    Refrigerant Recovery/Evacuation DEFINITIONS Recover To remove refrigerant, in any condition, from a system and store it in an external container, without necessarily testing or processing it in any way. Recycle To clean refrigerant for re-use by oil separation and single or multiple passes through devices, such as replaceable core filter-driers, which reduce moisture, acidity and particulate matter.

  • Page 109: Refrigerant Re-Use Policy

    REFRIGERANT RE-USE POLICY Manitowoc recognizes and supports the need for proper handling, re-use, and disposal of refrigerants. Manitowoc service procedures require recapturing refrigerants, not venting them to the atmosphere. It is not necessary, in or out of warranty, to reduce or compromise the quality and reliability of your customers’...
  • Page 110 Compressor motor burnouts and improper past service prevent refrigerant re-use. • Refer to “System Contamination Cleanup” on page 114 to test for contamination. 5. “Substitute” or “Alternative” Refrigerant • Must use only Manitowoc-approved alternative refrigerants. • Must follow Manitowoc-published conversion procedures. Part Number STH042 3/14...

  • Page 111: Recovery And Recharging Procedures

    RECOVERY AND RECHARGING PROCEDURES Do not purge refrigerant to the atmosphere. Capture refrigerant using recovery equipment. Follow the manufacturer’s recommendations. Important Manitowoc Ice assumes no responsibility for the contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 112 Follow the Charging Procedures below. CHARGING PROCEDURES Important The charge is critical on all Manitowoc ice machines. Use a scale or a charging cylinder to ensure the proper charge is installed. 1. Be sure the power button is in the OFF position.
  • Page 113 7. Close the high side on the manifold gauge set. Add any remaining vapor charge through the suction service valve (if necessary). NOTE: Manifold gauge set must be removed properly to ensure that no refrigerant contamination or loss occurs. 8. Make sure that all of the vapor in the charging hoses is drawn into the ice machine before disconnecting the charging hoses.

  • Page 114: System Contamination Cleanup

    System Contamination Cleanup This section describes the basic requirements for restoring contaminated systems to reliable service. Important Manitowoc Ice assumes no responsibility for the contaminated refrigerant. Damage resulting from the use of contaminated refrigerant is the sole responsibility of the servicing company.
  • Page 115 Contamination/Cleanup Chart Required Symptoms/Findings Cleanup Procedure No symptoms or suspicion of Normal contamination evacuation/ recharging procedure Moisture/Air Contamination symptoms Mild Refrigeration system open to contamination atmosphere for longer than 15 minutes cleanup Refrigeration test kit and/or acid oil test procedure shows contamination No burnout deposits in open compressor lines...

  • Page 116: Mild System Contamination Cleanup Procedure

    MILD SYSTEM CONTAMINATION CLEANUP PROCEDURE 1. Replace any failed components. 2. If the compressor is good, change the oil. 3. Replace the liquid line drier. NOTE: If the contamination is from moisture, use heat lamps during evacuation. Position them at the compressor, condenser and evaporator prior to evacuation.

  • Page 117: Severe System Contamination Cleanup Procedure

    SEVERE SYSTEM CONTAMINATION CLEANUP PROCEDURE 1. Remove the refrigerant charge. 2. Remove the compressor. 3. Disassemble the harvest solenoid valve. If burnout deposits are found inside the valve, install a rebuild kit, and replace the TXV and head pressure control valve. 4.

  • Page 118: Replacing Pressure Controls Without Removing Refrigerant Charge

    REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE This procedure reduces repair time and cost. Use it when any of the following components require replacement, and the refrigeration system is operational and leak-free. • Fan cycle control • High pressure cut-out control •...
  • Page 119 FIG. A - “PINCHING OFF” TUBING FIG. B - RE-ROUNDING TUBING SV1406 Using Pinch Off Tool Part Number STH042 3/14...

  • Page 120: Total System Refrigerant Charge

    Total System Refrigerant Charge Important This information is for reference only. Refer to the ice machine serial number tag to verify the system charge. Serial plate information overrides information listed on this page. Air- Water- Refrigerant Model Cooled Cooled Type 10 oz 11 oz U140...

  • Page 121: Cycle Times, 24 Hr. Ice Production And Refrigerant Pressure Charts

    Charts Cycle Times, 24 Hr. Ice Production and Refrigerant Pressure Charts These charts are used as guidelines to verify correct ice machine operation. Accurate collection of data is essential to obtain the correct diagnosis. • Production and cycle times are for dice cube - Half dice cube cycle times can be 1-2 minutes faster depending on model and ambient temperature.

  • Page 122: U0140 Self-Contained Air-Cooled

    U0140 SELF-CONTAINED AIR-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time Air Temp. Entering Harvest Water Temperature °F/°C Condenser Time °F/°C 50/10 70/21 90/32 70/21 10.2-11.7 12.4-14.1 13.0-14.8 80/27...

  • Page 123: U0140 Self-Contained Water-Cooled

    U0140 SELF-CONTAINED WATER-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time Air Temp. Around Ice Harvest Water Temperature °F/°C Machine Time °F/°C 50/10 70/21 90/32 70/21 9.8-11.2 11.2-12.8 13.0-14.8...

  • Page 124: U0190 Self-Contained Air-Cooled

    U0190 SELF-CONTAINED AIR-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time Air Temp. Entering Harvest Water Temperature °F/°C Condenser Time °F/°C 50/10 70/21 90/32 70/21 16.1-18.3 19.8-22.5 21.2-24.0 80/27...

  • Page 125: U0240 Self-Contained Air-Cooled

    U0240 SELF-CONTAINED AIR-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time Air Temp. Entering Harvest Water Temperature °F/°C Condenser Time °F/°C 50/10 70/21 90/32 70/21 14.1-16.1 17.0-19.3 18.6-21.1 80/27...

  • Page 126: U0240 Self-Contained Water-Cooled

    U0240 SELF-CONTAINED WATER-COOLED NOTE: These characteristics may vary depending on operating conditions. Cycle Times Freeze Time + Harvest Time = Cycle Time Freeze Time Air Temp. Harvest Around Ice Water Temperature °F/°C Time Machine °F/°C 50/10 70/21 90/32 70/21 16.1-18.3 17.0-19.3 18.0-20.5 80/27...

  • Page 127: U0310 Self-Contained Air-Cooled

    U0310 SELF-CONTAINED AIR-COOLED NOTE: These characteristics may vary depending on operating conditions. Data on this page is preliminary and subject to change. Cycle Times Freeze Time + Harvest Time = Total Cycle Time Freeze Time Air Temp. Entering Harvest Water Temperature °F/°C Condenser Time °F/°C...

  • Page 128: U0310 Self-Contained Water-Cooled

    U0310 SELF-CONTAINED WATER-COOLED NOTE: These characteristics may vary depending on operating conditions. Data on this page is preliminary and subject to change. Cycle Times Freeze Time + Harvest Time = Cycle Time Freeze Time Air Temp. Harvest Around Ice Water Temperature °F/°C Time Machine °F/°C 50/10...

  • Page 129: Wiring Diagrams

    Diagrams Wiring Diagrams The following pages contain electrical wiring diagrams Be sure you are referring to the correct diagram for the ice machine you are servicing. Warning Always disconnect power before working on electrical circuitry. Wiring Diagram Legend The following symbols are used on all of the wiring diagrams: Internal Compressor Overload (Some models have external compressor...

  • Page 130: Wiring Diagram - All Models

    WIRING DIAGRAM - ALL MODELS Part Number STH042 3/14...

  • Page 131: Electronic Control Board

    ELECTRONIC CONTROL BOARD WATER PUMP HIGH FLOAT MAIN COMP LOW FLOAT BIN SWITCH WATER DUMP HARVEST TEST SWITCH WATER FILL FUSE Part Number STH042 3/14...

  • Page 132: Tubing Schematic - U0140

    Tubing Schematic - U0140 EVAPORATOR HEAT EXPANSION EXCHANGER VALVE HARVEST SOLENOID STRAINER COMPRESSOR DRIER AIR OR WATER CONDENSER RECEIVER ( WATER COOLED ONLY) Part Number STH042 3/14...

  • Page 133: Tubing Schematic - U0190/U0240/U0310

    Tubing Schematic - U0190/U0240/U0310 EVAPORATOR HEAT EXCHANGER EXPANSION VALVE HARVEST SOLENOID VALVE STRAINER COMPRESSOR DRIER AIR OR WATER RECEIVER CONDENSER (WATER COOLED ONLY) Part Number STH042 3/14...
  • Page 134 This Page Intentionally Left Blank Part Number STH042 3/14...
  • Page 136 Manitowoc Ice 2110 South 26th Street, P.O. Box 1720 © 2013 Manitowoc Manitowoc, WI 54221-1720, USA Part Number STH042 3/14 Ph: 920-682-0161 Fax: 920-683-7589 Visit us online at: www.manitowocfoodservice.com...

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