Manitowoc Ice Ice Maker S Model S1000M User Manual
S Model  
S1000M  
Ice Machines  
Service  
Manual  
Thank you for selecting a Manitowoc Ice Machine, the dependability leader in ice making equipment and related products.  
With proper installation, care and maintenance, your new Manitowoc Ice Machine will provide you with many years of  
reliable and economical performance.  
Part Number 80-1559-3  
5/2005  
Download from Www.Somanuals.com. All Manuals Search And Download.  
Table of Contents  
Section 1  
General Information  
Model Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
How to Read a Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-1  
1-1  
1-1  
1-2  
Bin Caster . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Bagger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Guardian Sachet Packets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Arctic Pure Water Filter System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Manitowoc Cleaner and Sanitizer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
AuCS® Automatic Cleaning System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Dispenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Model/Serial Number Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-2  
1-2  
1-2  
1-2  
1-2  
1-2  
1-2  
1-3  
Owner Warranty Registration Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-4  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Warranty Coverage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-4  
1-4  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Labor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Exclusions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Authorized Warranty Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
1-4  
1-4  
1-4  
1-4  
1-4  
Section 2  
Installation Instructions  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Machine Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-1  
2-1  
s1000M Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Location of Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-1  
2-2  
Ice Machine Heat of Rejection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrical Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-2  
2-3  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Fuse/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Minimum Circuit Ampacity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electrical Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Self-Contained Electrical Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . .  
2-3  
2-3  
2-3  
2-3  
2-3  
2-4  
Self Contained Ice Machine  
115/1/60 or 208-230/1/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Self Contained Ice Machine  
2-4  
2-4  
208-230/3/60 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Self Contained Ice Machine  
230/1/50 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
For United Kingdom Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-4  
2-4  
Water Supply and Drain Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-5  
Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Water Inlet Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Drain Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Cooling Tower Applications  
2-5  
2-5  
2-5  
(Water-Cooled Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-5  
Water Supply and Drain Line Sizing/Connections . . . . . . . . . . . . . . . . . . .  
Installation Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-6  
2-7  
Before Starting the Ice Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
2-8  
Part No. 80-1559-3  
1-1  
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Table of Contents (continued)  
Section 3  
Ice Machine Operation  
Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-1  
3-2  
Initial Start-Up or Start-Up After Automatic Shut-Off . . . . . . . . . . . . . . . . . .  
Freeze Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Harvest Sequence . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Automatic Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Timers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Warm Water Rinse Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Operational Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-2  
3-2  
3-3  
3-3  
3-3  
3-3  
3-4  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Water Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Harvest Sequence Water Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
3-4  
3-4  
3-4  
3-5  
Section 4  
Maintenance  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Machine Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Exterior Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Water-Cooled Condenser  
4-1  
4-1  
4-1  
and Water Regulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
AlphaSan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Guardian . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-1  
4-1  
4-2  
Guardian Sachet Replacement Frequency . . . . . . . . . . . . . . . . . . . . . . . . .  
Sachet Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Clean Up Procedure for Damaged Sachet Packet . . . . . . . . . . . . . . . . . . .  
Interior Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-2  
4-2  
4-2  
4-3  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Sanitizing Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Removal of Parts For Cleaning/Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . .  
Removing the Front Panels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-3  
4-3  
4-4  
4-5  
4-11  
Removal from Service/Winterization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-12  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Self-Contained Air-Cooled Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Water-Cooled Ice Machines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
AuCS“ Accessory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
4-12  
4-12  
4-12  
4-12  
Section 5  
Before Calling For Service  
Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Limit Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
5-1  
5-2  
1-2  
Part No. 80-1559-3  
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Table of Contents (continued)  
Section 6  
Electrical System  
Energized Parts Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-1  
Self-Contained Water-Cooled Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wiring Diagram Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-1  
6-2  
Self-Contained Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-2  
6-9  
Wiring Diagram Legend . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
S1000M - Self Contained - 1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
S1000M - Self Contained - 3 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Component Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-9  
6-10  
6-11  
6-12  
Main Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Bin Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Compressor Electrical Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
PTCR Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Diagnosing Start Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Harvest Assist Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
ICE/OFF/CLEAN Toggle Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Electronic Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Thickness Probe (Harvest Initiation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-12  
6-12  
6-14  
6-15  
6-18  
6-18  
6-19  
6-20  
6-22  
How The Probe Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Harvest Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Freeze Time Lock-In Feature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Maximum Freeze Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Thickness Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Diagnosing Ice Thickness Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . .  
Water Level Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
6-22  
6-22  
6-22  
6-22  
6-22  
6-23  
6-24  
Water Level Probe Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Water Inlet Valve Safety Shut-Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Freeze Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Harvest Cycle Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Diagnosing Water Level Control Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . .  
Diagnosing An Ice Machine That Will Not Run . . . . . . . . . . . . . . . . . . . . . . . .  
6-24  
6-24  
6-24  
6-24  
6-25  
6-27  
Section 7  
Refrigeration System  
Sequence of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
7-1  
Self-Contained Water -Cooled Models . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Operational Analysis (Diagnostics) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
7-1  
7-3  
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Before Beginning Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Production Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Installation/Visual Inspection Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Water System Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Ice Formation Pattern . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Safety Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Analyzing Discharge Pressure  
7-3  
7-4  
7-4  
7-5  
7-5  
7-6  
7-8  
During Freeze or Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Analyzing Suction Pressure  
7-11  
7-12  
During Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Single Expansion Valve Ice Machines -  
Comparing Evaporator Inlet and  
Outlet Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Harvest Valve Temperature Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
How to Use the Refrigeration System  
7-14  
7-15  
Operational Analysis Tables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Refrigeration System Operational Analysis Tables . . . . . . . . . . . . . . . . . . .  
Pressure Control Specifications and Diagnostics . . . . . . . . . . . . . . . . . . . . .  
7-16  
7-17  
7-18  
High Pressure Cut-Out (HPCO) Control . . . . . . . . . . . . . . . . . . . . . . . . . . .  
7-18  
Part No. 80-1559-3  
1-3  
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Table of Contents (continued)  
Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts . . . . . . . . .  
Refrigerant Recovery/Evacuation and Recharging . . . . . . . . . . . . . . . . . . . . .  
7-19  
7-20  
Normal Self-Contained Model Procedures . . . . . . . . . . . . . . . . . . . . . . . . .  
System Contamination Clean-Up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Replacing Pressure Controls Without  
Removing Refrigerant Charge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Total System Refrigerant Charges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Refrigerant Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
Refrigerant Re-Use Policy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  
HFC Refrigerant Questions and Answers . . . . . . . . . . . . . . . . . . . . . . . . . .  
7-20  
7-23  
7-25  
7-27  
7-27  
7-28  
7-29  
7-30  
1-4  
Part No. 80-1559-3  
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Section 1  
General Information  
Section 1  
General Information  
Model Numbers  
How to Read a Model Number  
This manual covers the following models:  
#
CUBE SIZE CONDENSER TYPE  
DICE WATER-COOLED  
Self-Contained  
Water-Cooled  
3
5
HALF-DICE WATER-COOLED  
SD1003WM  
SY1005WM  
MARlNE MODEL  
NOTE: Model numbers ending in 3 indicate a 3-phase  
unit. Example: SY1005M3  
S Y 1005 W M  
ICE MACHINE  
MODEL  
ICE MACHINE  
SERIES  
!
Warning  
PERSONAL INJURY POTENTIAL  
ICE CUBE SIZE  
CONDENSER TYPE  
D
Y
DICE  
HALF DICE  
Do not operate equipment that has been misused,  
abused, neglected, damaged, or altered/modified  
from that of original manufactured specifications.  
W SELF-CONTAINEDWATER-COOLED  
Ice Cube Sizes  
!
Warning  
PERSONAL INJURY POTENTIAL  
Remove all ice machine panels before lifting and  
installing.  
Dice  
Half Dice  
7/8" x 7/8" x 7/8"  
3/8" x 1-1/8" x 7/8"  
2.22 x 2.22 x 2.22 cm 0.95 x 2.86 x 2.22 cm  
Part Number 80-1559-3  
1-1  
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General Information  
Accessories  
Section 1  
MANITOWOC CLEANER AND SANITIZER  
Manitowoc Ice Machine Cleaner and Sanitizer are  
available in convenient 16 oz. (473 ml) bottles. These  
are the only cleaner and sanitizer approved for use with  
Manitowoc products.  
Contact your Manitowoc distributor for these optional  
accessories:  
BIN CASTER  
Replaces standard legs.  
ICE BAGGER  
Cleaner Part Number  
Sanitizer Part Number  
16 ounce Bottle - 94-0546-3 16 ounce Bottle - 94-0565-3  
AuCS®-SO - 94-0546-3  
AuCS®-SI - 40-1326-3  
AuCS®-SO - 94-0565-3  
AuCS®-SI - 40-1327-3  
Maximize profits from bagged ice sales with this  
convenient accessory. This sturdy unit rests on the bin  
door frame, and adapts for left or right side filling.  
AUCS® AUTOMATIC CLEANING SYSTEM  
GUARDIAN™ SACHET PACKETS  
This accessory reduces equipment cleaning expense.  
The AuCS® accessory monitors ice making cycles and  
initiates cleaning procedures automatically.  
Guardian sachet packets release chlorine dioxide on a  
controlled basis to inhibit the growth of bacteria and  
slime.  
DISPENSER  
Guardian sachet packets are available through your  
local Manitowoc Ice Machine dealer.  
A counter-top dispenser is ideal for cafeterias and many  
types of self-service facilities. Manitowoc auto-fill, floor-  
standing ice dispensers meet the strict sanitary  
requirements of the food service, lodging and health  
care industries.  
ARCTIC PURE™ WATER FILTER SYSTEM  
Engineered specifically for Manitowoc ice machines,  
This water filter is an efficient, dependable, and  
affordable method of inhibiting scale formation, filtering  
sediment, and removing chlorine taste and odor.  
1-2  
Part Number 80-1559-3  
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Section 1  
General Information  
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.  
SV13147  
MODEL/SERIAL PLATE  
LOCATION  
Model/Serial Number Location  
Part Number 80-1559-3  
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General Information  
Section 1  
Owner Warranty Registration Card  
GENERAL  
EXCLUSIONS  
The packet containing this manual also includes  
warranty information. Warranty coverage begins the day  
your new ice machine is installed.  
The following items are not included in the ice machine’s  
warranty coverage:  
1. Normal maintenance, adjustments and cleaning.  
Important  
2. Repairs due to unauthorized modifications to the ice  
machine or use of non-standard parts without prior  
written approval from Manitowoc Ice, Inc.  
Complete and mail the OWNER WARRANTY  
REGISTARATION CARD as soon as possible to  
validate the installation date.  
3. Damage caused by improper installation of the ice  
machine, electrical supply, water supply or drainage,  
or damage caused by floods, storms, or other acts of  
God.  
If you do not return your OWNER WARRANTY  
REGISTRATION CARD, Manitowoc will use the date of  
sale to the Manitowoc Distributor as the first day of  
warranty coverage for your new ice machine.  
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.  
Warranty Coverage  
GENERAL  
The following Warranty outline is provided for your  
convenience. For a detailed explanation, read the  
warranty bond shipped with each product.  
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.  
Contact your local Manitowoc Distributor, Manitowoc Ice,  
Inc. or visit our website at www.manitowocice.com if you  
need further warranty information.  
7. This product is intended exclusively for commercial  
application. No warranty is extended for personal,  
family, or household purposes.  
Important  
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.  
PARTS  
1. Manitowoc warrants the ice machine against defects  
in materials and workmanship, under normal use  
and service for three (3) years from the date of  
original installation.  
NOTE: If the dealer you purchased the ice machine from  
is not authorized to perform warranty service, contact  
your Manitowoc distributor or Manitowoc Ice, Inc. for the  
name of the nearest authorized service representative.  
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.  
Service Calls  
Normal maintenance, adjustments and cleaning as  
outlined in this manual are not covered by the warranty.  
If you have followed the procedures listed on page 5-1 of  
this manual, and the ice machine still does not perform  
properly, call your authorized service company.  
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.  
1-4  
Part Number 80-1559-3  
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Section 2  
General  
Installation Instructions  
Section 2  
Installation Instructions  
These instructions are provided to assist the qualified  
installer. Check your local Yellow Pages for the name of  
the nearest Manitowoc distributor, or call Manitowoc Ice,  
Inc. for information regarding start-up services.  
Important  
Failure to follow these installation guidelines may  
affect warranty coverage.  
Ice Machine Dimensions  
S1000M ICE MACHINES  
WATER COOLED  
ELECTRICAL  
2.20" (5.58cm)  
H
A
B
1.81"  
(4.59cm)  
1.06 (2.69cm)  
4.21" (10.69cm)  
CONDENSER WATER  
OUTLET 1/2"FPT  
2.61"  
(6.62cm)  
2.85" (7.30cm)  
5.06" (12.85cm)  
D
6.68" (16.96cm)  
8.49" (21.56cm)  
AUXILLARY BASE  
CONDENSER WATER  
DRAIN 1/2"CPVC  
INLET 3/8"FPT  
SOCKET  
25.52" (64.82cm)  
WATER INLET  
3/8"FPT  
W
DRAIN 1/2"NPTF  
SV3143B  
SV3143  
Ice Machine  
Dimension A  
Dimension B  
Dimension W  
30 in. (76.2 cm)  
Dimension D  
Dimension H  
S1000M  
23.82 in (60.5 cm) 22.32 in (65.69 cm)  
24.50 in. (62.2 cm)  
29.5 in (74.9 cm)  
Part Number 80-1559-3  
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Installation Instructions  
Location of Ice Machine  
Section 2  
Ice Machine Heat of Rejection  
The location selected for the ice machine must meet the  
following criteria. If any of these criteria are not met,  
select another location.  
Heat of Rejection  
Series  
Ice Machine  
Air Conditioning  
Peak  
S1000M  
16,000  
22,000  
•
•
•
•
The location must be free of airborne and other  
contaminants.  
B.T.U./Hour  
Because the heat of rejection varies during the ice making cycle,  
the figure shown is an average.  
The air temperature must be at least 35°F (1.6°C),  
but must not exceed 110°F (43.4°C).  
Ice machines, like other refrigeration equipment, reject  
heat through the condenser. It is helpful to know the  
amount of heat rejected by the ice machine when sizing  
air conditioning equipment where self-contained air-  
cooled ice machines are installed.  
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.  
This information is also necessary when evaluating the  
benefits of using water-cooled or remote condensers to  
reduce air conditioning loads. The amount of heat added  
to an air conditioned environment by an ice machine  
using a water-cooled or remote condenser is negligible.  
Self-Contained  
Air-Cooled  
Water-Cooled  
and Remote*  
S1000M  
Top/Sides  
Back  
8" (20.3 cm)  
5" (12.7 cm)  
5" (12.7 cm)  
5" (12.7 cm)  
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.  
*There is no minimum clearance required. This value is  
recommended for efficient operation and servicing only.  
Caution  
!
The ice machine must be protected if it will be  
subjected to temperatures below 32°F (0°C).  
Failure caused by exposure to freezing  
temperatures is not covered by the warranty. See  
“Removal from Service/Winterization”.  
2-2  
Part Number 80-1559-3  
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Section 2  
Installation Instructions  
FUSE/CIRCUIT BREAKER  
Electrical Service  
A separate fuse/circuit breaker must be provided for  
each ice machine. Circuit breakers must be H.A.C.R.  
rated (does not apply in Canada).  
GENERAL  
!
Warning  
MINIMUM CIRCUIT AMPACITY  
All wiring must conform to local, state and national  
codes.  
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.)  
VOLTAGE  
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.  
The maximum allowable voltage variation is ±10% of the  
rated voltage at ice machine start-up (when the electrical  
load is highest).  
ELECTRICAL REQUIREMENTS  
!
Warning  
Refer to Ice Machine Model/Serial Plate for voltage/  
amperage specifications.  
The ice machine must be grounded in accordance  
with national and local electrical codes.  
Important  
Observe correct polarity of incoming line voltage.  
S Series Ice Machines  
Air-Cooled  
Water Cooled  
Remote  
Maximum  
Voltage  
Phase  
Cycle  
Maximum  
Fuse/Circuit  
Breaker  
Maximum  
Fuse/Circuit  
Breaker  
Ice Machine  
S1000  
Minimum  
Minimum  
Minimum  
Fuse/Circuit  
Breaker  
Circuit Amps  
Circuit Amps  
Circuit Amps  
208-230/1/60  
208-230/3/60  
230/1/50  
20  
15  
20  
13.6  
9.9  
20  
15  
20  
12.6  
8.9  
20  
15  
20  
12.8  
9.9  
12.6  
11.2  
12.0  
Part Number 80-1559-3  
2-3  
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Installation Instructions  
Section 2  
Self-Contained Electrical Wiring Connections  
SELF CONTAINED ICE MACHINE  
208-230/3/60  
!
Warning  
These diagrams are not intended to show proper  
wire routing, wire sizing, disconnects, etc., only the  
correct wire connections.  
L
L
L
1
1
2
All electrical work, including wire routing and  
grounding, must conform to local, state and national  
electrical codes.  
L
L
2
Though wire nuts are shown in the drawings, the ice  
machine field wiring connections may use either  
wire nuts or screw terminals.  
L
3
3
SELF CONTAINED ICE MACHINE  
115/1/60 OR 208-230/1/60  
GROUND  
GROUND  
TO SEPARATE  
ICE MACHINE  
CONNECTIONS  
FUSE/BREAKER  
SV1190  
L
L
1
1
SELF CONTAINED ICE MACHINE  
230/1/50  
N=115V  
OR  
L2=208-230V  
GROUND  
L
1
L
GROUND  
1
ICE MACHINE  
CONNECTIONS  
TO SEPARATE  
FUSE/BREAKER  
SV1258  
N
N
GROUND  
GROUND  
TO SEPARATE  
FUSE/BREAKER.  
DISCONNECT ALL  
POLES.  
ICE MACHINE  
CONNECTIONS  
SV1191  
For United Kingdom Only  
As the colors of the wires in the mains lead of the appliance may not correspond with the colored markings  
identifying the terminals in your plug, proceed as follows:  
•
The wire which is colored green and yellow must be connected to the terminal in the plug which is marked with  
the letter E or by the earth ground symbol or colored green or green and yellow.  
•
•
The wire colored blue must be connected to the terminal which is marked with the letter N or colored black.  
The wire colored brown must be connected to the terminal which is marked with the letter L or colored red.  
2-4  
Part Number 80-1559-3  
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Section 2  
Installation Instructions  
DRAIN CONNECTIONS  
Water Supply and Drain Requirements  
Follow these guidelines when installing drain lines to  
prevent drain water from flowing back into the ice  
machine and storage bin:  
WATER SUPPLY  
Local water conditions may require treatment of the  
water to inhibit scale formation, filter sediment, and  
remove chlorine odor and taste.  
•
•
•
•
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.  
Important  
If you are installing a Manitowoc Arctic Pure™ water  
filter system, refer to the Installation Instructions  
supplied with the filter system for ice making water  
inlet connections.  
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.  
WATER INLET LINES  
Follow these guidelines to install water inlet lines:  
Cooling Tower Applications  
(Water-Cooled Models)  
•
Do not connect the ice machine to a hot water  
supply. Be sure all hot water restrictors installed for  
other equipment are working. (Check valves on sink  
faucets, dishwashers, etc.)  
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.  
•
If water pressure exceeds the maximum  
recommended pressure, obtain a water pressure  
regulator from your Manitowoc distributor.  
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.  
•
•
Install a water shut-off valve for both the ice making  
and condenser water lines.  
Insulate water inlet lines to prevent condensation.  
•
•
•
Water entering the condenser must not exceed 90°F  
(32.2°C).  
Caution  
!
Water flow through the condenser must not exceed 5  
gallons (19 liters) per minute.  
Do not apply heat to water valve inlet fitting. This will  
damage plastic valve body.  
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 Number 80-1559-3  
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Installation Instructions  
Section 2  
WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS  
Caution  
!
Plumbing must conform to state and local codes.  
Tubing Size Up to Ice  
Machine Fitting  
Location  
Water Temperature  
Water Pressure  
Ice Machine Fitting  
35°F (1.6°C) Min.  
20 psi (137.9 kPA) Min.  
80 psi (551.5 kPA) Max.  
3/8" (.95 cm) minimum  
inside diameter  
Ice Making  
Water Inlet  
3/8" Female Pipe  
Thread  
90°F (32.2°C) Max.  
Ice Making  
Water Drain  
1/2" Female  
Pipe Thread  
1/2" (1.27 cm) minimum  
inside diameter  
---  
---  
40°F (4.4°C) Min.  
20 psi (137.9 kPA) Min.  
Condenser  
Water Inlet  
3/8" Female Pipe Thread  
90°F (32.2°C) Max.  
150 psi (1034.2 kPA) Max.  
Condenser  
Water Drain  
1/2" Female  
Pipe Thread  
1/2" (1.27 cm) minimum  
inside diameter  
---  
---  
---  
---  
3/4" Female  
Pipe Thread  
3/4" (1.91 cm) minimum  
inside diameter  
Bin Drain  
3/8” FPT ICE MAKING WATER INLET FITTING,  
PLASTIC FITTING ON OPPOSITE SIDE DO NOT  
APPLY HEAT  
ELECTRICAL ENTRANCE  
18” (46 CM) VENT TUBE  
3/8” FPT CONDENSER WATER INLET  
(WATER COOLED UNITS ONLY  
1/2” DRAIN CONNECTION  
PLASTIC FITTING ON OPPOSITE  
SIDE DO NOT APPLY HEAT  
1/2” FPT CONDENSER WATER DRAIN  
(WATER COOLED UNITS ONLY)  
1/2” (1.3 CM) MIN  
DRAIN ID  
1/2” CPVC SOCKET AUXILLARY BASE  
DRAIN  
AIR GAP  
DO NOT TRAP DRAIN LINE,  
LEAVE AIR GAP BETWEEN  
DRAIN TUBE AND DRAIN  
OPEN, TRAPPED AND  
VENTED DRAIN  
SV3142  
Typical Water Supply Drain Installation  
2-6  
Part Number 80-1559-3  
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Section 2  
Installation Instructions  
Are the ice machine and bin drains vented?  
Installation Check List  
Is the Ice Machine level?  
Are all electrical leads free from contact with  
refrigeration lines and moving equipment?  
Has all of the internal packing been removed?  
Has the owner/operator been instructed  
regarding maintenance and the use of  
Manitowoc Cleaner and Sanitizer?  
Have all of the electrical and water connections  
been made?  
Has the supply voltage been tested and checked  
against the rating on the nameplate?  
Has the owner/operator completed the warranty  
registration card?  
Is there proper clearance around the ice machine  
for air circulation?  
Has the ice machine and bin been sanitized?  
Is the toggle switch set to ice? (The toggle switch  
is located directly behind the front panel).  
Has the ice machine been installed where  
ambient temperatures will remain in the range of  
35° - 110°F (1.6° - 43.3°C)?  
Is the ice thickness control set correctly? (Refer  
to Operational Checks to check/set the correct  
ice bridge thickness).  
Has the ice machine been installed where the  
incoming water temperature will remain in the  
range of 35° - 90°F (1.6° - 32.2°C)?  
Is there a separate drain for the water-cooled  
condenser?  
Part Number 80-1559-3  
2-7  
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Installation Instructions  
Section 2  
Before Starting the Ice Machine  
All Manitowoc ice machines are factory-operated and  
adjusted before shipment. Normally, new installations do  
not require any adjustment.  
To ensure proper operation, follow the Operational  
Checks in Section 3 of this manual. Starting the ice  
machine and completing the Operational Checks are the  
responsibilities of the owner/operator.  
Adjustments and maintenance procedures outlined in  
this manual are not covered by the warranty.  
!
Warning  
Potential Personal Injury Situation  
Do not operate equipment that has been misused.  
abused, neglected, damaged, or altered/modified  
from that of original manufactured specifications.  
2-8  
Part Number 80-1559-3  
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Section 3  
Ice Machine Operation  
Section 3  
Ice Machine Operation  
Component Identification  
Water Distribution Tube  
Toggle Switch  
Water Curtain  
Dump Valve  
Check Valve  
sv3149  
Ice Thickness Probe  
Curtain Retainer  
Water Level Probe  
Water Inlet Location  
Water Inlet Valve  
Water Pump  
(Located in Refrigeration Compartment)  
sv3150  
Part Number 80-1559-3  
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Ice Machine Operation  
Sequence Of Operation  
Section 3  
NOTE: The toggle switch must be in the ice position and  
the water curtain must be in place on the evaporator  
before the ice machine will start.  
FREEZE SEQUENCE  
3. Prechill  
The compressor is on for 30 seconds (60 seconds initial  
cycle) prior to water flow, to prechill the evaporator. The  
water fill valve remains on until the water level probe is  
satisfied.  
INITIAL START-UP OR START-UP AFTER  
AUTOMATIC SHUT-OFF  
1. Water Purge  
Before the compressor starts, the water pump and water  
dump solenoid are energized for 45 seconds, to  
completely purge the ice machine of old water. This  
feature ensures that the ice making cycle starts with  
fresh water.  
4. Freeze  
The water pump restarts after the prechill. An even flow  
of water is directed across the evaporator and into each  
cube cell, where it freezes. The water fill valve will cycle  
on and then off one more time to refill the water trough.  
The harvest valve(s) is also energized during water  
purge, although it stays on for an additional 5 seconds  
(50 seconds total on time) during the initial refrigeration  
system start-up.  
When sufficient ice has formed, the water flow (not the  
ice) contacts the ice thickness probe. After  
approximately 10 seconds of continual water contact,  
the harvest sequence is initiated. The ice machine  
cannot initiate a harvest sequence until a 6 minute  
freeze lock has been surpassed.  
The air compressor energizes for the last 10 seconds of  
the cycle.  
2. Refrigeration System Start-Up  
The compressor starts after the 45 second water purge,  
and it remains on throughout the entire Freeze and  
Harvest Sequences. The water fill valve is energized at  
the same time as the compressor. The harvest valve(s)  
remains on for 5 seconds during initial compressor start-  
up and then shuts off.  
At the same time the compressor starts, the condenser  
fan motor (air-cooled models) is supplied with power  
throughout the entire Freeze and Harvest Sequences.  
The fan motor is wired through a fan cycle pressure  
control, therefore it may cycle on and off. (The  
compressor and condenser fan motor are wired through  
the contactor. As a result, anytime the contactor coil is  
energized, the compressor and fan motor are supplied  
with power.)  
3-2  
Part Number 80-1559-3  
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Section 3  
Ice Machine Operation  
HARVEST SEQUENCE  
5. Water Purge  
AUTOMATIC SHUT-OFF  
7. Automatic Shut-Off  
The harvest valve(s) opens at the beginning of the water  
purge to divert hot refrigerant gas into the evaporator.  
When the storage bin is full at the end of a harvest  
sequence, the sheet of cubes fails to clear the water  
curtain and will hold it open. After the water curtain is  
held open for 30 seconds, the ice machine shuts off. The  
ice machine remains off for 3 minutes before it can  
automatically restart.  
The water pump continues to run, and the water dump  
valve energizes for 45 seconds to purge the water in the  
sump trough. The water fill valve energizes (turns on)  
and de-energizes (turns off) strictly by time. The water fill  
valve energizes for the last 15 seconds of the 45-second  
water purge.  
The ice machine remains off until enough ice has been  
removed from the storage bin to allow the ice to fall clear  
of the water curtain. As the water curtain swings back to  
the operating position, the bin switch re-closes and the  
ice machine restarts (steps 1 - 2), provided the 3 minute  
delay period is complete.  
After the 45 second water purge, the water fill valve,  
water pump and dump valve de-energize. (Refer to  
“Water Purge Adjustment” for details.)  
6. Harvest  
SAFETY TIMERS  
The harvest valve(s) remains open and the refrigerant  
gas warms the evaporator causing the cubes to slide, as  
a sheet, off the evaporator and into the storage bin. The  
sliding sheet of cubes swings the water curtain out,  
opening the bin switch.  
The control board has the following non-adjustable  
safety timers:  
•
The ice machine is locked into the freeze cycle for 6  
minutes before a harvest cycle can be initiated.  
The momentary opening and re-closing of the bin switch  
terminates the harvest sequence and returns the ice  
machine to the freeze sequence (Step 3 - 4.)  
•
The maximum freeze time is 60 minutes at which  
time the control board automatically initiates a  
harvest sequence (steps 5 & 6).  
The air compressor energizes after 35 seconds and  
remains energized throughout the entire harvest cycle.  
The air compressor will automatically energize for 60  
seconds when the harvest cycle time exceeded 75  
seconds in the previous cycle.  
•
The maximum harvest time is 3.5 minutes at which  
time the control board automatically initiates a freeze  
sequence (steps 3 & 4).  
WARM WATER RINSE CYCLE  
Closing the back of the evaporator allows ice to build up  
on the rear of the evaporator and the plastic evaporator  
frame parts. After 200 freeze/harvest cycles have been  
complete the control board will initiate a warm water  
rinse.  
After the 200th harvest cycle ends:  
•
The Clean and Harvest LED’s energize to indicate  
the ice machine is in a warm water rinse.  
•
The compressor and harvest valve remain  
energized.  
•
•
The water pump energizes.  
The water inlet valve energizes until water contacts  
the water level probe.  
•
•
The compressor and harvest valve warm the water  
for 5 minutes, then de-energize.  
The water pump remains energized for an additional  
5 minutes (10 minute total on time) then de-  
energizes.  
NOTE: The warm water rinse cycle can be terminated by  
moving the toggle switch to the OFF position, then back to ICE.  
Part Number 80-1559-3  
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Ice Machine Operation  
Section 3  
ICE THICKNESS CHECK  
Operational Checks  
The ice thickness probe is factory-set to maintain the ice  
bridge thickness at 1/8" (.32 cm).  
GENERAL  
Manitowoc ice machines are factory-operated and  
adjusted before shipment. Normally, new installations do  
not require any adjustment.  
NOTE: Make sure the water curtain is in place when  
performing this check. It prevents water from splashing  
out of the water trough.  
To ensure proper operation, always follow the  
Operational Checks:  
1. Inspect the bridge connecting the cubes. It should  
be about 1/8" (.32 cm) thick.  
•
•
•
when starting the ice machine for the first time  
after a prolonged out of service period  
after cleaning and sanitizing  
2. If adjustment is necessary, turn the ice thickness  
probe adjustment screw clockwise to increase  
bridge thickness, counterclockwise to decrease  
bridge thickness.  
NOTE: Routine adjustments and maintenance  
procedures are not covered by the warranty.  
WATER LEVEL  
ADJUSTING SCREW  
The water level sensor is set to maintain the proper  
water level above the water pump housing. The water  
level is not adjustable. If the water level is incorrect,  
check the water level probe for damage (probe bent,  
etc.). Repair or replace the probe as necessary.  
1/8” ICE BRIDGE THICKNESS  
SV3132  
Ice Thickness Check  
3. Make sure the ice thickness probe wire and the  
bracket do not restrict movement of the probe.  
Water Level Probe Location  
3-4  
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Section 3  
Ice Machine Operation  
HARVEST SEQUENCE WATER PURGE  
•
During the harvest sequence water purge, the water  
fill valve energizes and de-energizes by time. The  
water purge must be at the factory setting of 45  
seconds for the water fill valve to energize during the  
last 15 seconds of the water purge. If it is set to less  
than 45 seconds, the water fill valve will not energize  
during the water purge.  
The harvest sequence water purge adjustment may be  
used when the ice machine is hooked up to special  
water systems, such as a de-ionized water treatment  
system.  
!
Warning  
Disconnect electric power to the ice machine at the  
electrical disconnect before proceeding.  
Important  
45 second  
setting  
The harvest sequence water purge is factory-set at  
45 seconds. A shorter purge setting (with standard  
water supplies such as city water) is not  
recommended. This can increase water system  
cleaning and sanitizing requirements.  
0 second  
setting  
•
The harvest sequence water purge is factory set for  
45 seconds. Repositioning the jumper will set the  
harvest water purge to 0 seconds. This setting does  
not affect the SeCs or AuCs (cleaning) sequences.  
SV3139  
SV3140  
Water Purge Adjustment  
For your safety and to eliminate errors, we recommend  
that a qualified service technician make the harvest  
water purge adjustment.  
Part Number 80-1559-3  
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Ice Machine Operation  
Section 3  
THIS PAGE INTENTIONALLY LEFT BLANK  
3-6  
Part Number 80-1559-3  
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Section 4  
General  
Maintenance  
Section 4  
Maintenance  
Water-Cooled Condenser  
and Water Regulating Valve  
You are responsible for maintaining the ice machine in  
accordance with the instructions in this manual.  
Maintenance procedures are not covered by the  
warranty.  
Symptoms of restrictions in the condenser water circuit  
include:  
•
•
•
•
Low ice production  
!
Warning  
High water consumption  
High operating temperatures  
High operating pressures  
If you do not understand the procedures or the  
safety precautions that must be followed, call your  
local Manitowoc service representative to perform  
the maintenance procedures for you.  
If the ice machine is experiencing any of these symptoms,  
the water-cooled condenser and water regulating valve  
may require cleaning due to scale build-up.  
We recommend that you perform the following  
maintenance procedures a minimum of once every six  
months to ensure reliable, trouble-free operation and  
maximum ice production.  
Because the cleaning procedures require special pumps  
and cleaning solutions, qualified maintenance or service  
personnel must perform them.  
Ice Machine Inspection  
®
AlphaSan  
®
The goal of AlphaSan is to keep the plastic surfaces of  
!
Warning  
an ice machine cleaner, by reducing or delaying the  
formation of bio-film. The active ingredient in  
AlphaSan is the element silver in the form of silver ions  
(Ag+). AlphaSan slowly releases silver ions via an ion  
exchange mechanism. When AlphaSan is  
compounded directly into a plastic part, a controlled  
release of silver ions from the surface is regulated to  
maintain an effective concentration at or near the  
Disconnect electric power to the ice machine and  
the remote condensing unit at the electric service  
switch before cleaning the condenser.  
®
®
®
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.) on the sides or back of  
the ice machine. There must be adequate airflow  
through and around the ice machine to maximize ice  
production and ensure long component life.  
surface of the plastic ice machine part. AlphaSan’s  
unique ability to effectively control the release of silver  
not only protects against undesired discoloration of the  
plastic, but also will last the life of the plastic part.  
Although AlphaSan helps prevent bio-film build up it  
does not eliminate the need for periodic cleaning and  
®
Exterior Cleaning  
®
Clean the area around the ice machine as often as  
necessary to maintain cleanliness and efficient  
operation.  
maintenance. AlphaSan has no adverse effect on the  
taste of the ice or beverage.  
Sponge any dust and dirt off the outside of the ice  
machine with mild soap and water. Wipe dry with a  
clean, soft cloth.  
Heavy stains should be removed with stainless steel  
wool. Never use plain steel wool or abrasive pads. They  
will scratch the panels.  
Part Number 80-1559-3  
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Maintenance  
Section 4  
Guardian™  
Slime is a leading cause of ice machine breakdowns and  
biological growth is a health concern. The Guardian™  
system releases chlorine dioxide on a controlled basis to  
inhibit the growth of bacteria and fungi that form slime  
and cause malodors in the food zone of ice machines.  
SACHET INSTALLATION/REPLACEMENT  
PROCEDURE  
1. Remove the 2 front panel screws and remove panel.  
The Guardian™ will not control mineral or other water  
borne buildup. Your water quality will determine the  
length of time before mineral buildup affects ice machine  
performance. Mineral buildup must be removed as often  
as necessary to ensure trouble-free operation of the ice  
machine.  
The Guardian™ sachet holder is included with the  
sachet packets. Refer to installation/replacement  
procedure to install/change sachet holder/packet.  
Inside Left  
Front Door  
Remove  
Screws  
Screw Location  
Guardian  
2. Inside the front panel there are two thumbscrew  
holes covered by stickers, pierce the sticker with a  
screwdriver.  
3. Attach the sachet holder to the front panel by  
inserting the thumbscrews through the holes in the  
sachet holder and tighten the thumbscrews.  
4. Remove the new sachet packet from foil package  
and install into holder. Removing the foil package  
allows moisture in the air to activate the sachet  
contents.  
Guardian™ Location  
GUARDIAN™ SACHET REPLACEMENT  
FREQUENCY  
5. Close the left front door and tighten the screw.  
6. Discard the use sachet packet in the trash.  
Sachet packet(s) require replacement every thirty (30)  
days or whenever they come in direct contact with water.  
Refer to chart below for requirements.  
CLEAN UP PROCEDURE FOR DAMAGED SACHET  
PACKET  
1. Remove all ice from bin/dispenser and discard.  
Ice Machine  
Sachet Use  
S1000M  
1 or 2*  
2. Initiate a cleaning and sanitizing sequence on the  
ice machine (see next pages).  
*Although one sachet is recommended, extreme conditions may  
necessitate using two sachet packets.  
3. Clean the bin/dispenser. Flush the drain thoroughly  
to prevent future drain blockage.  
Guardian™ sachet packets are available through your  
local Manitowoc ice machine dealer.  
4. Sanitize the bin/dispenser.  
5. Install a replacement sachet packet and reinstall all  
panels.  
4-2  
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Section 4  
Maintenance  
Interior Cleaning and Sanitizing  
Caution  
!
GENERAL  
Never use anything to force ice from the evaporator.  
Damage may result.  
Clean and sanitize the ice machine every six months for  
efficient operation. If the ice machine requires more  
frequent cleaning and sanitizing, consult a qualified  
service company to test the water quality and  
recommend appropriate water treatment. An extremely  
dirty ice machine must be taken apart for cleaning and  
sanitizing.  
Step 3 Remove all ice from the bin.  
Step 4 To start cleaning, place the toggle switch in the  
CLEAN position. The water will flow through the water  
dump valve and down the drain. The Clean light will turn  
on to indicate the ice machine is in the Cleaning mode.  
Step 5 Wait about two minutes or until water starts to  
flow over the evaporator.  
Caution  
!
Use only Manitowoc approved Ice Machine Cleaner  
(part number 94-0546-3) and Sanitizer (part number  
94-0565-3). It is a violation of Federal law to use  
these solutions in a manner inconsistent with their  
labeling. Read and understand all labels printed on  
bottles before use.  
Step 6 Add the proper amount of Manitowoc Ice  
Machine Cleaner to the water trough by pouring  
between the water curtain and evaporator.  
Model  
Amount of Cleaner  
S1000M  
5 ounces (148 ml)  
CLEANING PROCEDURE  
Step 7 The ice machine will automatically time out a  
ten minute cleaning cycle, followed by six rinse cycles,  
and stop. The Clean light will turn off to indicate the  
Cleaning cycle is completed. This entire cycle lasts  
approximately 30 minutes.  
Caution  
!
Do not mix Cleaner and Sanitizer solutions together.  
It is a violation of Federal law to use these solutions  
in a manner inconsistent with their labeling.  
Step 8 When the cleaning process stops, move the  
toggle switch to OFF position. Refer to “Sanitizing  
Procedure” on the next page.  
!
Warning  
Wear rubber gloves and safety goggles (and/or face  
shield) when handling ice machine Cleaner or  
Sanitizer.  
Step 9  
A. The ice machine may be set to start and finish a  
self-cleaning procedure then automatically start  
ice making again.  
Ice machine cleaner is used to remove lime scale or  
other mineral deposits. It is not used to remove algae or  
slime. Refer to the section on Sanitizing for removal of  
algae and slime.  
B. You must wait about one minute into the  
cleaning cycle (until water starts to flow over the  
evaporator) then move the switch from CLEAN  
to ICE position.  
Step 1 Remove top cover. This will allow easiest  
access for pouring cleaner.  
C. When the self-cleaning cycle is completed, an  
ice making sequence will start automatically.  
Step 2 Set the toggle switch to the OFF position after  
ice falls from the evaporator at the end of a Harvest  
cycle. Or, set the switch to the OFF position and allow  
the ice to melt off the evaporator.  
Important  
After the toggle switch is moved to the ICE position,  
opening the curtain switch will interrupt the cleaning  
sequence. The sequence will resume from the point  
of interruption when the curtain switch closes.  
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Maintenance  
Section 4  
SANITIZING PROCEDURE  
Use sanitizer to remove algae or slime. Do not use it to  
remove lime scale or other mineral deposits.  
Step 5 Use the sanitizing solution and a sponge or  
cloth to sanitize (wipe) all parts and interior surfaces of  
the ice machine. Sanitize the following areas:  
Step 1 Set the toggle switch to the OFF position after  
ice falls from the evaporator at the end of a Harvest  
cycle. Or, set the switch to the OFF position and allow  
the ice to melt off the evaporator.  
A. Side walls  
B. Base (area above water trough)  
C. Evaporator plastic parts  
D. Bin or dispenser  
Caution  
!
Never use anything to force ice from the evaporator.  
Damage may result.  
Step 6 Rinse all sanitized areas with clear water.  
Step 7 Install the removed parts, restore power and  
place toggle switch in the ice position.  
Step 8 T o start a sanitizing cycle, move the toggle  
switch to the CLEAN position. The water will flow  
through the water dump valve and down the drain. The  
Clean light will turn on to indicate the ice machine is in  
the sanitizing mode.  
!
Warning  
Disconnect electric power to the ice machine (and  
dispenser if applicable) at the electric switch box  
before proceeding.  
Step 9 Wait about two minutes or untill water starts to  
flow over the evaporator.  
Step 2 Remove all ice from the bin.  
Step 3 Refer to Removal of Parts For Cleaning/  
Sanitizing and remove ice machine parts.  
Step 10 Add the proper amount of Manitowoc Ice  
Machine Sanitizer to the water trough by pouring  
between the water curtain and evaporator.  
Step 4 Mix a solution of water and sanitizer.  
Model  
Amount of Sanitizer  
Solution Type  
Water  
Mixed With  
S1000M  
5 ounces (148 ml)  
Sanitizer  
4 gal. (15 l)  
3 oz (90 ml) sanitizer  
Step 11 The ice machine will automatically time out a  
ten minute sanitizing cycle, followed by six rinse cycles,  
and stop. The Clean light will turn off to indicate the  
sanitizing cycle is completed. This entire cycle lasts  
approximately 30 minutes.  
Step 12 When the sanitizing process stops, move the  
toggle switch to ICE position.  
4-4  
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Section 4  
Maintenance  
REMOVAL OF PARTS FOR CLEANING/SANITIZING  
5. Use a soft-bristle brush or sponge (NOT a wire  
brush) to carefully clean the parts.  
1. Turn off the electrical and water supply to the ice  
machine (and dispenser when applicable).  
Caution  
!
Do not mix Cleaner and Sanitizer solutions together.  
It is a violation of Federal law to use these solutions  
in a manner inconsistent with their labeling.  
!
Warning  
Disconnect electric power to the ice machine (and  
dispenser if applicable) at the electric switch box  
before proceeding.  
Caution  
!
2. Remove all ice from the bin.  
Do not immerse the water pump motor in the  
cleaning or sanitizing solution.  
3. Remove the water curtain and the components you  
want to clean or sanitize. See the following pages for  
removal procedures for these parts.  
6. Use the sanitizing solution and a sponge or cloth to  
sanitize (wipe) the interior of the ice machine and  
the entire inside of the bin/dispenser.  
!
Warning  
Wear rubber gloves and safety goggles (and/or face  
shield) when handling Ice Machine Cleaner or  
Sanitizer.  
7. Thoroughly rinse all of the parts and surfaces with  
clear water.  
8. Install the removed parts.  
4. Soak the removed part(s) in a properly mixed  
solution.  
NOTE: Incomplete rinsing of the ice thickness probe or  
water level probe may leave a residue. This could cause  
the ice machine to malfunction. For best results, brush or  
wipe the probes off while rinsing it. Thoroughly dry the  
probes before installing them.  
Solution Type  
Cleaner  
Water  
Mixed With  
1 gal. (4 l)  
4 gal. (15 l)  
16 oz (500 ml) cleaner  
1 oz (30 ml) sanitizer  
9. Turn on the water and electrical supply.  
Sanitizer  
Part Number 80-1559-3  
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Maintenance  
Section 4  
1. Water Curtain  
2. Ice Thickness Probe  
A. Gently flex the curtain in the center and remove  
it from the right side.  
A. Compress the hinge pin on the top of the ice  
thickness probe.  
B. Slide the left pin out.  
STEP 1  
STEP 2  
COMPRESS  
HINGE PIN TO  
REMOVE  
SV3153  
SV3135  
Water Curtain Removal  
Ice Thickness Probe Removal  
B. Pivot the ice thickness probe to disengage one  
pin then the other. The ice thickness probe can  
be cleaned at this point without complete  
removal. Follow Step C for complete removal.  
!
Warning  
Disconnect the electric power to the ice machine at  
the electric service switch box.  
C. Disconnect the ice thickness control wiring from  
the control board.  
4-6  
Part Number 80-1559-3  
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Section 4  
Maintenance  
3. Water Distribution Tube  
4. Water Trough  
A. Depress tabs on right and left side of the water  
trough.  
!
Warning  
Removing the distribution tube while the water  
pump is running will allow water to spray from ice  
machine. Disconnect the electrical power to the ice  
machine and dispenser at the electric service switch  
box and turn off the water supply.  
B. Allow front of water trough to drop as you pull  
forward to disengage the rear pins.  
NOTE: Distribution tube thumbscrews are retained by o-  
rings to prevent loss. Loosen thumbscrews but do not  
pull thumbscrews out of distribution tube.  
A
B
DEPRESS TABS  
Water Distribution Tube Removal  
A. Remove outer half of distribution tube by  
loosening the four (4) thumbscrews (o-rings  
retain thumbscrews to distribution tube).  
B. Pull inner half of water distribution tube forward  
to release slip joint from water pump tubing  
connection.  
Part Number 80-1559-3  
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Maintenance  
Section 4  
Water Level Probe  
Water Pump  
1. Remove the water trough.  
!
Warning  
Disconnect the electric power to the ice machine at  
the electric service switch box and turn off the water  
supply before proceeding.  
!
Warning  
Disconnect the electrical power to the ice machine  
at the electrical disconnect before proceeding.  
1. Empty the water trough.  
2. The water level probe normally does not require  
removal for cleaning. The probe can be wiped and  
cleaned in place or proceed to step 3.  
A. Move the toggle switch from OFF to ICE.  
B. Wait 45 seconds.  
3. Pull the water level probe straight down to  
disengage.  
C. Place toggle switch in OFF position.  
4. Lower the water level probe until the wiring  
connector is visible. Disconnect the wire lead from  
the water level probe.  
5. Remove the water level probe from the ice machine.  
WATER  
PUMP  
SV3091  
Water Pump Removal  
WATER LEVEL PROBE  
SV3141  
2. Remove the water trough.  
3. Grasp pump and pull straight down on pump  
assembly until water pump disengages and  
electrical connector is visible.  
4. Disconnect the electrical connector.  
5. Remove the water pump assembly from ice  
machine.  
4-8  
Part Number 80-1559-3  
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Section 4  
Maintenance  
Water Dump Valve  
Important  
The water dump valve normally does not require  
removal for cleaning. To determine if removal is  
necessary:  
The plunger and the inside of the enclosing tube  
must be completely dry before assembly.  
1. Locate the water dump valve.  
2. Set the toggle switch to ICE.  
NOTE: During cleaning, do not stretch, damage or  
remove the spring from the plunger. If it is removed, slide  
the spring’s flared end into the plunger’s slotted top  
opening until the spring contacts the plunger spring stop.  
3. While the ice machine is in the freeze mode, check  
the dump valve’s clear plastic outlet drain hose for  
leakage.  
5. Remove the valve body.  
A. If the dump valve is leaking, remove,  
disassemble and clean it.  
6. Remove the tubing from the dump valve by twisting  
the clamps off.  
B. If the dump valve is not leaking, do not remove  
it. Instead, follow the “Cleaning Procedure”.  
7. Remove the two screws securing the dump valve  
and the mounting bracket.  
Follow the procedure below to remove the dump valve.  
PLUNGER  
SPRING STOP  
CAP  
!
Warning  
Disconnect the electric power to the ice machine at  
the electric service switch box and turn off the water  
supply before proceeding.  
COIL  
SPRING  
1. If so equipped, remove the water dump valve shield  
from its mounting bracket.  
PLUNGER  
2. Lift and slide the coil retainer cap from the top of the  
coil.  
DIAPHRAM  
ENCLOSING  
TUBE  
3. Note the position of the coil assembly on the valve  
for assembly later. Leaving the wires attached, lift  
the coil assembly off the valve body and the  
enclosing tube.  
4. Press down on the plastic nut on the enclosing tube  
and rotate it 1/4 turn. Remove the enclosing tube,  
plunger, and plastic gasket from the valve body.  
VALVE BODY  
Dump Valve Disassembly  
NOTE: At this point, the water dump valve can easily be  
cleaned. If complete removal is desired, continue with  
step 5.  
Part Number 80-1559-3  
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Maintenance  
Section 4  
Evaporator Tray Removal  
Drain Line Check Valve  
1. Remove the water trough.  
The drain line check valve normally does not require  
removal for cleaning. Water loss from the sump trough  
will indicate removal and cleaning are required.  
2. Remove thumbscrew on left side of tray.  
3. Allow left side of tray to drop as you pull the tray to  
the left side. Continue until the outlet tube  
disengages from the right side.  
sv3154  
1. Remove check valve and tube assembly.  
A. Tip assembly to right until tubing disengages.  
B. Lift up on assembly to remove.  
2. Remove insulation from check valve assembly.  
3. Remove vinyl tubing from top of check valve.  
4. Soak in cleaner solution 10 minutes, and then flush  
with water to remove debris.  
4-10  
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Section 4  
Maintenance  
Water Inlet Valve  
Removing the Front Panel  
The water inlet valve normally does not require removal  
for cleaning. Refer to Section 5 for a list of causes for  
“No Water Entering Water Trough” or “Water Overflows  
Water Trough.  
1. Disconnect power to ice machine.  
2. Loosen thumbscrews. Do not remove they are  
retained by o-rings to prevent loss.  
1. When the ice machine is off, the water inlet valve  
must completely stop water flow into the machine.  
2. When the ice machine is on, the water inlet valve  
must allow the proper water flow through it. Set the  
toggle switch to ON. Watch for water flow into the ice  
machine. If the water flow is slow or only trickles into  
the ice machine, refer to Section 5.  
Follow the procedure below to remove the water inlet  
valve.  
Thumb  
Screws  
!
Warning  
Disconnect the electric power to the ice machine  
and dispenser at the electric service switch box and  
turn off the water supply before proceeding.  
1. Remove the 1/4” hex head screws.  
2. Remove, clean, and install the filter screen.  
Panel Removal  
FILTER  
ACCESS  
SCREWS  
WATER  
INLET  
VALVE  
SV1622  
Part Number 80-1559-3  
4-11  
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Maintenance  
Section 4  
WATER-COOLED ICE MACHINES  
Removal from Service/Winterization  
1. Perform steps 1-6 under “Self-Contained Air-Cooled  
Ice Machines.”  
GENERAL  
Special precautions must be taken if the ice machine is  
to be removed from service for an extended period of  
time or exposed to ambient temperatures of 32°F (0°C)  
or below.  
2. Disconnect the incoming water and drain lines from  
the water-cooled condenser.  
3. Insert a large screwdriver between the bottom spring  
coils of the water regulating valve. Pry upward to  
open the valve.  
Caution  
!
If water is allowed to remain in the ice machine in  
freezing temperatures, severe damage to some  
components could result. Damage of this nature is  
not covered by the warranty.  
Follow the applicable procedure below.  
SELF-CONTAINED AIR-COOLED ICE MACHINES  
1. Disconnect the electric power at the circuit breaker  
or the electric service switch.  
2. Turn off the water supply.  
3. Remove the water from the water trough.  
4. Disconnect and drain the incoming ice-making water  
line at the rear of the ice machine.  
5. Blow compressed air in both the incoming water and  
the drain openings in the rear of the ice machine  
until no more water comes out of the inlet water lines  
or the drain.  
6. Make sure water is not trapped in any of the water  
lines, drain lines, distribution tubes, etc.  
SV1624  
Pry Open the Water Regulating Valve  
4. Hold the valve open and blow compressed air  
through the condenser until no water remains.  
®
AUCS Accessory  
®
Refer to the AuCS Accessory manual for winterization  
®
of the AuCS Accessory.  
4-12  
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Section 5  
Checklist  
Before Calling For Service  
Section 5  
Before Calling For Service  
If a problem arises during operation of your ice machine, follow the checklist below before calling service. Routine  
adjustments and maintenance procedures are not covered by the warranty.  
Problem  
Possible Cause  
To Correct  
Ice machine does not operate.  
No electrical power to the ice machine  
and/or condensing unit.  
Replace the fuse/reset the breaker/turn  
on the main switch.  
ICE/OFF/CLEAN toggle switch set  
improperly.  
Move the toggle switch to the ICE  
position.  
Water curtain stuck open.  
Water curtain must be installed and  
swinging freely. (See Section 4)  
Ice machine stops, and can be restarted Safety limit feature stopping the ice  
Refer to “Safety Limit Feature” on the  
next page.  
by moving the toggle switch to OFF and  
back to ICE.  
machine.  
Ice machine does not release ice or is  
slow to harvest.  
Ice machine is dirty.  
Ice machine is not level.  
Clean and sanitize the ice machine.  
(See Section 4)  
Level the ice machine. (See Section 2)  
Low air temperature around ice machine Air temperature must be at least 35°F  
head section.  
(1.6°C).  
Ice machine does not cycle into harvest  
mode.  
The six-minute freeze time lock-in has  
not expired yet.  
Wait for the freeze lock-in to expire.  
Ice thickness probe is dirty.  
Clean and sanitize the ice machine.  
(See Section 4)  
Ice thickness probe is disconnected.  
Connect the wire.  
Ice thickness probe is out of adjustment. Adjust the ice thickness probe.  
(See Section 3)  
Uneven ice fill (thin at the top of  
evaporator).  
Verify sufficient water level in sump  
trough. Contact a qualified service  
company to check refrigeration system.  
Ice quality is poor (soft or not clear).  
Poor incoming water quality.  
Contact a qualified service company to  
test the quality of the incoming water and  
make appropriate filter  
recommendations.  
Water filtration is poor.  
Ice machine is dirty.  
Replace the filter.  
Clean and sanitize the ice machine.  
(See Section 4)  
Water dump valve is not working.  
Disassemble and clean the water dump  
valve. (See Section 4)  
Water softener is working improperly (if  
applicable).  
Repair the water softener.  
Part Number 80-1559-3  
5-1  
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Before Calling For Service  
Section 5  
Problem  
Possible Cause  
To Correct  
Ice machine produces shallow or  
incomplete cubes, or the ice fill pattern on  
the evaporator is incomplete.  
Ice thickness probe is out of adjustment. Adjust the ice thickness probe.  
(See Section 4)  
Water trough level is too low.  
Check the water level probe for damage.  
(See Section 3)  
Water inlet valve filter screen is dirty.  
Remove the water inlet valve and clean  
the filter screen. (See Section 4)  
Water filtration is poor.  
Hot incoming water.  
Replace the filter.  
Connect the ice machine to a cold water  
supply. (See Section 2)  
Water inlet valve is not working.  
Incorrect incoming water pressure.  
Replace the water inlet valve.  
Water pressure must be 20-80 psi  
(138 - 551 kPA)  
Ice machine is not level.  
Level the ice machine.  
(See Section 2)  
Low ice capacity.  
Water inlet valve filter screen is dirty.  
Remove the water inlet valve and clean  
the filter screen. (See Section 4)  
Incoming water supply is shut off.  
Open the water service valve.  
Water inlet valve stuck open or leaking.  
Place toggle switch in OFF position, if  
water continues to enter water trough  
replace the water inlet valve.  
The harvest assist air compressor is not Call for service.  
functioning.  
1. Move the ICE/OFF/CLEAN switch to OFF and then  
Safety Limit Feature  
back to ICE.  
In addition to the standard safety controls, such as the  
high pressure cutout, your Manitowoc ice machine  
features built-in safety limits which will stop the ice  
machine if conditions arise which could cause a major  
component failure.  
A. If the safety limit feature has stopped the ice  
machine, it will restart after a short delay.  
Proceed to step 2.  
B. If the ice machine does not restart, see “Ice  
machine does not operate” on the previous  
page.  
Before calling for service, re-start the ice machine using  
the following procedure:  
2. Allow the ice machine to run to determine if the  
condition is recurring.  
A. If the ice machine stops again, the condition has  
recurred. Call for service.  
B. If the ice machine continues to run, the condition  
has corrected itself. Allow the ice machine to  
continue running.  
5-2  
Part Number 80-1559-3  
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Section 6  
Electrical System  
Section 6  
Electrical System  
Energized Parts Charts  
SELF-CONTAINED WATER-COOLED MODELS  
Control Board Relays  
Contactor  
Ice Making  
Sequence Of  
Operation  
1
2
3
4
5
6
7
7A  
7B  
Length  
Of Time  
Harvest  
Valve  
(Left)  
Harvest  
Valve  
(Right)*  
Water  
Inlet  
Valve  
Cond.  
Fan  
Motor  
Water  
Pump  
Air  
Comp.*  
Dump  
Valve  
Contactor  
Coil  
Comp.  
35 sec.  
Off  
On  
(when  
used)  
START-UP 1  
1. Water Purge  
On  
On  
Off  
On  
On  
Off  
Off  
Off  
Off  
45 Seconds  
10 sec.  
On  
2. Refrigeration  
System Start-Up  
Off  
Off  
On  
Off  
Off  
Off  
Off  
Off  
Off  
On  
On  
On  
On  
5 Seconds  
May  
Cycle  
On/Off  
during  
the first  
45 sec.  
Initial Start-Up  
FREEZE  
SEQUENCE  
3. Pre-Chill  
May Cycle is 60 Seconds  
Off  
On/Off  
30 Seconds  
thereafter  
Until 10 sec.  
water contact  
with ice  
thickness  
probe  
Cycles  
Off, then  
On one  
more  
MayCycle  
On/Off  
4. Freeze  
On  
Off  
Off  
Off  
Off  
On  
On  
time  
30 sec.  
Off,  
15 sec.  
On  
HARVEST  
SEQUENCE  
5. Water Purge  
On; after  
35 sec.  
MayCycle Factory-set at  
On  
Off  
Off  
On  
On  
Off  
On  
On  
Off  
On  
Off  
Off  
On  
On  
Off  
On  
On  
Off  
On/Off  
45 Seconds  
MayCycle  
On/Off  
Bin switch  
activation  
6. Harvest  
On  
Off  
Off  
Until bin  
switch  
re-closes &  
3 min. delay  
7. AUTOMATIC  
SHUT-OFF  
Off  
Off  
1. Initial Start-Up or Start-Up After Automatic Shut-Off  
* Not Used on all Models  
Condenser Fan Motor  
Safety Timers  
The fan motor is wired through a fan cycle pressure control,  
therefore, it may cycle on and off.  
The control board has the following non-adjustable safety  
timers:  
Harvest Water Purge  
•
The ice machine is locked into the freeze cycle for 6  
minutes, before a harvest sequence can be initiated.  
The circuit board has an adjustable water purge in the harvest  
cycle. This permits a 0 or 45 second purge cycle.  
•
The maximum freeze time is 60 minutes, at which time the  
control board automatically initiates a harvest sequence  
(steps 5-6).  
Auto Shut-Off  
The ice machine remains off for 3 minutes before it can  
automatically restart. The ice machine restarts (steps 1-2)  
immediately after the delay period, if the bin switch re-closes  
prior to 3 minutes.  
•
The maximum harvest time is 3-1/2 minutes, at which time  
the control board automatically terminates the harvest  
sequence. If the bin switch is open, the ice machine will go  
to automatic shut-off (step 7). If the bin switch is closed, the  
ice machine will go to the freeze sequence (steps 3-4).  
Part Number 80-1559-3  
6-1  
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Electrical System  
Section 6  
Wiring Diagram Sequence of  
Operation  
L2 or N  
L1  
Ground  
(89)  
Water Valve  
(21)  
(20)  
(99)  
(55)  
SELF-CONTAINED MODELS  
(61)  
(22)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
(5)  
(1)  
(7)  
(4)  
Harvest Valve  
(77)  
Initial Start-Up or Start-Up After  
Automatic Shut-Off  
(88)  
(60)  
(80)  
Dump Valve  
(75)  
1. WATER PURGE  
(76)  
(81)  
Water Pump  
Before the compressor starts, the  
water pump and water dump  
solenoid are energized for 45  
seconds to purge old water from the  
ice machine. This ensures that the  
ice-making cycle starts with fresh  
water.  
(57)  
(98)  
(42)  
Trans.  
(58)  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
Ice Thickness  
The harvest valve(s) is also  
(74)  
(9)  
Probe  
(8)  
Bin Switch  
energized during the water purge. In  
the case of an initial refrigeration  
start-up, it stays on for an additional  
5 seconds (50 seconds total).  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
Clean  
OFF  
ICE  
(2)  
(Red)  
The air compressor energizes for the  
last 10 seconds of the cycle.  
Compressor  
(Yellow)  
Run Capacitor  
(45)  
(46)  
Contactor  
Contacts  
(Black)  
L1  
Overload  
(85)  
(50)  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-2  
Self-Contained — Water Purge  
Table 6-1. Self-Contained Models  
1. Water Purge (45 Seconds)  
Toggle Switch  
Bin Switch  
ICE  
Closed  
Control Board Relays  
#1  
Water Pump  
ON  
ON  
#2  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
Water Inlet Valve  
Water Dump Valve  
Contactor Coil  
#3  
ON (When Used)  
#4  
35 sec. OFF / 10 sec. ON  
#5  
OFF  
#6  
ON  
#7  
Open / OFF  
OFF  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
OFF  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
6-2  
Part Number 80-1559-3  
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Section 6  
Electrical System  
2. REFRIGERATION SYSTEM  
START-UP  
L2 or N  
L1  
Ground  
(89)  
Water Valve  
(99)  
(21)  
(20)  
(55)  
The compressor starts after the 45-  
second water purge, and it remains  
on throughout the Freeze and  
Harvest cycles.  
(61)  
(22)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
(5)  
(1)  
(7)  
(4)  
Harvest Valve  
(77)  
(88)  
(60)  
(80)  
Dump Valve  
(75)  
(76)  
(98)  
(81)  
The water fill valve is energized at  
the same time as the compressor.  
Water Pump  
(57)  
(42)  
Trans.  
(58)  
The harvest valve(s) remains on for  
the first 5 seconds of the initial  
compressor start-up and then shuts  
off.  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
At the same time the compressor  
starts, the condenser fan motor (air-  
cooled models) is supplied with  
power throughout the entire freeze  
and harvest sequences.  
Ice Thickness  
(74)  
(9)  
Probe  
(8)  
Bin Switch  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
Clean  
OFF  
ICE  
The fan motor is wired through a fan  
cycle pressure control, and may  
cycle on and off. (The compressor  
and the condenser fan motor are  
wired through the contactor. Any time  
the contactor coil is energized, the  
compressor and fan motor are  
supplied with power.)  
(2)  
(Red)  
Compressor  
(Yellow)  
Run Capacitor  
(45)  
(46)  
Contactor  
Overload  
(85)  
(50)  
Contacts  
(Black)  
L1  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-4  
Self-Contained — Refrigeration System Start-Up  
Table 6-2. Self-Contained Models  
2. Refrigeration System Start Up (5 Seconds)  
Toggle Switch  
Bin Switch  
ICE  
Closed  
Control Board Relays  
#1  
Water Pump  
OFF  
ON  
#2  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
Water Inlet Valve  
Water Dump Valve  
Contactor Coil  
#3  
ON (When Used)  
#4  
OFF  
#5  
OFF  
#6  
OFF  
#7  
Closed / ON  
ON  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
OFF  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
Part Number 80-1559-3  
6-3  
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Electrical System  
Section 6  
Freeze Sequence  
L2 or N  
(99)  
L1  
Ground  
(89)  
3. PRE-CHILL  
Water Valve  
(21)  
(20)  
(55)  
To pre-chill the evaporator, the  
compressor runs for 30 seconds (60  
seconds initial cycle) prior to water  
flow.  
(22)  
(61)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
(5)  
(1)  
(7)  
(4)  
Harvest Valve  
(77)  
(88)  
(60)  
(80)  
Dump Valve  
(75)  
(76)  
(98)  
(81)  
The water fill valve remains on until  
the water level probe is satisfied.  
Water Pump  
(57)  
(42)  
Trans.  
(58)  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
Ice Thickness  
(74)  
(9)  
Probe  
(8)  
Bin Switch  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
(2)  
Clean  
OFF  
ICE  
(Red)  
Compressor  
(Yellow)  
Run Capacitor  
(46)  
Contactor  
Contacts  
(Black)  
L1  
Overload  
(85)  
(50)  
(45)  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-3  
Self-Contained — Pre-Chill  
Table 6-3. Self-Contained Models  
3. Pre-Chill (60 Seconds Initial Cycle - 30 Seconds thereafter)  
Toggle Switch  
Bin Switch  
ICE  
Closed  
Control Board Relays  
#1  
Water Pump  
OFF  
OFF  
#2  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
Water Inlet Valve  
Water Dump Valve  
Contactor Coil  
#3  
OFF (When Used)  
#4  
OFF  
#5  
On  
#6  
OFF  
#7  
Closed / ON  
ON  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
May Cycle ON / OFF  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
6-4  
Part Number 80-1559-3  
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Section 6  
Electrical System  
4. FREEZE  
L2 or N  
L1  
Ground  
(89)  
Water Valve  
(99)  
The water pump starts after the pre-  
chill. An even flow of water is directed  
across the evaporator and into each  
cube cell, where it freezes.  
(21)  
(20)  
(55)  
(22)  
(61)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
Harvest Valve  
(77)  
(88)  
(60)  
(80)  
(5)  
(1)  
(7)  
(4)  
Dump Valve  
The water fill valve will cycle off then  
on one more time to refill the water  
trough.  
(75)  
(76)  
(98)  
(81)  
Water Pump  
(57)  
(42)  
Trans.  
(58)  
When sufficient ice has formed, the  
water flow (not the ice) contacts the  
ice thickness probes. After  
approximately 10 seconds of  
continual contact, a harvest cycle is  
initiated.  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
Ice Thickness  
(74)  
(9)  
Probe  
(8)  
NOTE: The ice machine cannot  
initiate a harvest cycle until a 6-  
minute freeze lock has expired.  
Bin Switch  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
(2)  
Clean  
OFF  
ICE  
(Red)  
Compressor  
(Yellow)  
Run Capacitor  
(46)  
Contactor  
Contacts  
(Black)  
L1  
Overload  
(85)  
(50)  
(45)  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-5  
Self-Contained — Freeze  
Table 6-4. Self-Contained Models  
4. Freeze (Until 10 Seconds of Water Contact with Ice Thickness Probe)  
Toggle Switch  
Bin Switch  
ICE  
Closed  
Control Board Relays  
#1  
#2  
#3  
#4  
Water Pump  
ON  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
OFF  
OFF (When Used)  
OFF  
Cycles OFF, then ON  
one more time  
#5  
Water Inlet Valve  
#6  
Water Dump Valve  
Contactor Coil  
OFF  
#7  
Closed / ON  
ON  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
May Cycle ON / OFF  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
Part Number 80-1559-3  
6-5  
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Electrical System  
Section 6  
Harvest Sequence  
L2 or N  
(99)  
L1  
Ground  
(89)  
5. WATER PURGE  
Water Valve  
(21)  
(20)  
(55)  
(22)  
The harvest valve(s) opens at the  
beginning of the water purge to divert  
hot refrigerant gas into the  
evaporator.  
(61)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
(5)  
(1)  
(7)  
(4)  
Harvest Valve  
(77)  
(88)  
(60)  
(80)  
Dump Valve  
(75)  
(76)  
(98)  
(81)  
Water Pump  
The water pump continues to run,  
and the water dump valve energizes  
for 45 seconds to purge the water in  
the sump trough. The water fill valve  
energizes and de-energizes strictly  
by time. The water fill valve energizes  
for the last 15 seconds of the 45-  
second water purge.  
(57)  
(42)  
Trans.  
(58)  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
Ice Thickness  
(74)  
(9)  
Probe  
(8)  
After the 45 second water purge, the  
water fill valve, water pump and  
dump valve de-energize. (Refer to  
“Water Purge Adjustment” for  
details.)  
Bin Switch  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
(2)  
Clean  
OFF  
ICE  
(Red)  
Compressor  
(Yellow)  
The air compressor (when used) will  
energize after 35 seconds.  
Run Capacitor  
(46)  
Contactor  
Contacts  
(Black)  
L1  
Overload  
(85)  
(50)  
(45)  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-6  
Self-Contained — Water Purge  
Table 6-5. Self-Contained Models  
5. Water Purge (45 Seconds)  
Toggle Switch  
Bin Switch  
ICE  
Closed  
Control Board Relays  
#1  
#2  
#3  
#4  
Water Pump  
ON  
ON  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
ON (When Used)  
ON; after 35 seconds  
30 seconds OFF,  
15 seconds ON  
#5  
Water Inlet Valve  
#6  
Water Dump Valve  
Contactor Coil  
ON  
#7  
Closed / ON  
ON  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
OFF; May Cycle ON  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
6-6  
Part Number 80-1559-3  
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Section 6  
Electrical System  
6. HARVEST  
L2 or N  
L1  
Ground  
(89)  
Water Valve  
(99)  
The harvest valve(s) remains open  
and the refrigerant gas warms the  
evaporator. This causes the cubes to  
slide, as a sheet, off the evaporator  
and into the storage bin.  
(21)  
(20)  
(55)  
(22)  
(61)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
(5)  
(1)  
(7)  
(4)  
Harvest Valve  
(77)  
(88)  
(60)  
(80)  
Dump Valve  
(75)  
(76)  
(98)  
(81)  
Water Pump  
The sliding sheet of cubes swings the  
water curtain out, opening the bin  
switch. This momentary opening and  
closing of the bin switch terminates  
the Harvest Cycle and returns the ice  
machine to the Freeze Cycle (steps  
3-4).  
(57)  
(42)  
Trans.  
(58)  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
The air compressor (when used)  
remains energized throughout the  
entire harvest cycle. The air  
compressor will automatically  
energize after 60 seconds when the  
harvest cycle time exceeded 75  
seconds in the previous cycle.  
Ice Thickness  
(74)  
(9)  
Probe  
(8)  
Bin Switch  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
(2)  
Clean  
OFF  
ICE  
(Red)  
Compressor  
(Yellow)  
Run Capacitor  
(46)  
Contactor  
Contacts  
(Black)  
L1  
Overload  
(85)  
(50)  
(45)  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-7  
Table 6-6. Self-Contained Models  
6. Harvest (Until Bin Switch Activation)  
Toggle Switch  
Bin Switch  
ICE  
Closed  
Control Board Relays  
#1  
Water Pump  
OFF  
ON  
#2  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
Water Inlet Valve  
Water Dump Valve  
Contactor Coil  
#3  
ON (When Used)  
#4  
ON  
#5  
OFF  
#6  
OFF  
#7  
Closed / ON  
ON  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
OFF; May Cycle ON  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
Part Number 80-1559-3  
6-7  
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Electrical System  
Section 6  
Automatic Shut-Off  
7. AUTOMATIC SHUT-OFF  
L2 or N  
(99)  
L1  
Ground  
(89)  
Water Valve  
(21)  
When the storage bin is full at the  
end of a harvest cycle, the sheet of  
cubes fails to clear the water curtain  
and holds it open. After the water  
curtain is held open for 30 seconds,  
the ice machine shuts off.  
(20)  
(55)  
(22)  
(61)  
High  
Pressure  
Cutout  
Control Board  
(2)  
(6)  
(5)  
(1)  
(7)  
(4)  
Harvest Valve  
(77)  
(88)  
(60)  
(80)  
Dump Valve  
(75)  
(76)  
(98)  
(81)  
Water Pump  
(57)  
The ice machine remains off until  
enough ice is removed from the  
storage bin to allow the sheet of  
cubes to drop clear of the water  
curtain. As the water curtain swings  
back to the operating position, the bin  
switch closes and the ice machine  
restarts (steps 1-2), provided the 3  
minute delay period is complete.  
(42)  
Trans.  
(58)  
Fuse (7a)  
Terminates at  
Pin Connection  
(59)  
L2  
Contactor Coil  
(25)  
(56)  
Air Compressor  
(26)  
Ice Thickness  
(74)  
(9)  
Probe  
(8)  
Bin Switch  
Water Level Probe  
Low DC  
Voltage  
Plug  
(6)  
(1)  
(2)  
NOTE: The ice machine must remain  
off for 3 minutes before it can  
automatically restart.  
Clean  
OFF  
ICE  
(Red)  
Compressor  
(Yellow)  
(46)  
Run Capacitor  
Contactor  
Contacts  
(Black)  
L1  
Overload  
(85)  
(50)  
(45)  
PTCR  
Fan Motor  
(86)  
(51)  
Fan Cycle  
Control  
Run Capacitor  
SV3137-1  
Self-Contained — Automatic Shut-Off  
Table 6-7. Self-Contained Models  
7. Automatic Shut-Off (Until Bin Switch Closes)  
Toggle Switch  
Bin Switch  
ICE  
Open  
Control Board Relays  
#1  
Water Pump  
OFF  
OFF  
#2  
Harvest Valve (Left)  
Harvest Valve (Right)  
Air Compressor  
Water Inlet Valve  
Water Dump Valve  
Contactor Coil  
#3  
OFF (When Used)  
#4  
OFF  
#5  
OFF  
#6  
OFF  
#7  
Open / OFF  
OFF  
#7A  
#7B  
Compressor  
Condenser Fan Motor  
OFF  
Safety Controls (Which could stop ice machine operation)  
High Pressure Cut-Out  
Closed  
Closed  
Main Fuse (On Control Board)  
6-8  
Part Number 80-1559-3  
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Section 6  
Electrical System  
Wiring Diagrams  
The following pages contain electrical wiring diagrams. Be sure you are referring to the correct diagram for the ice  
machine which 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 overloads)  
**  
Fan Motor Run Capacitor  
(Some models do not incorporate fan motor run capacitor)  
TB  
Terminal Board Connection  
(Terminal board numbers are printed on the actual terminal board)  
( )  
Wire Number Designation  
(The number is marked at each end of the wire)  
—>>—  
Multi-Pin Connection  
(Electrical Box Side) —>>— (Compressor Compartment Side)  
Part Number 80-1559-3  
6-9  
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Electrical System  
Section 6  
S1000M - SELF CONTAINED - 1 PHASE  
L1  
L2 or N  
Ground  
(99)  
Water Valve  
(20)  
(21)  
(77)  
(89)  
(55)  
(22)  
(61)  
Control  
Board  
(2)  
Harvest Valve  
High Pressure  
Cutout  
(88)  
(60)  
(6)  
(5)  
(80)  
Dump Valve  
(76)  
(75)  
(1)  
(7)  
(81)  
Water Pump  
(4)  
(98)  
(59)  
(57)  
(99)  
Trans.  
Fuse (7a)  
(58)  
Terminates at  
Pin Connection  
L2  
(42)  
Contactor  
Coil  
(56)  
(26)  
Air Compressor  
(25)  
(74)  
Ice Thickness  
Probe  
(9)  
Bin Switch  
(8)  
(6)  
Water Level Probe  
Low DC  
Voltage  
Plug  
Clean  
OFF  
(1)  
ICE  
(2)  
(Red)  
Compressor  
(Yellow)  
Run  
Capacitor  
Contactor  
Contacts  
Overload  
(50)  
(46)  
(Black)  
L1  
(45)  
(51)  
(85)  
(86)  
PTCR  
Fan Motor  
Fan Cycle  
Control  
Run Capacitor  
SV3130  
6-10  
Part Number 80-1559-3  
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Section 6  
Electrical System  
S1000M - SELF CONTAINED - 3 PHASE  
(99)  
Water Valve  
L2 L1  
L3  
Ground  
(89)  
(20)  
(21)  
(61)  
(22)  
Control  
Board  
(55)  
Harvest Valve  
Dump Valve  
(3)  
(77)  
High Pressure  
Cutout  
(80)  
(81)  
(60)  
(4)  
(2)  
(88)  
(76)  
(1)  
(5)  
(6)  
Water Pump  
(57)  
(98)  
(99)  
Trans.  
(58)  
Fuse (7a)  
Terminates at  
Pin Connection  
(75)  
(59)  
L2  
Contactor  
Coil  
(42)  
(56)  
(26)  
Air Compressor  
(25)  
(74)  
Ice Thickness  
Probe  
(9)  
(8)  
Bin Switch  
Clean  
(6)  
Low DC  
Voltage  
Plug  
Water Level Probe  
(1)  
OFF  
ICE  
(2)  
(75)  
Contactor  
Contacts  
L3 L2 L1  
Fan Motor  
(51)  
(85)  
(86)  
Fan Cycle  
Control  
T2  
Run Capacitor  
T1  
T3  
Compressor  
SV3131  
Part Number 80-1559-3  
6-11  
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Electrical System  
Section 6  
Component Specifications and Diagnostics  
MAIN FUSE  
Function  
BIN SWITCH  
Function  
The control board fuse stops ice machine operation if  
electrical components fail causing high amp draw.  
Movement of the water curtain controls bin switch  
operation. The bin switch has two main functions:  
Specifications  
1. Terminating the harvest cycle and returning the ice  
machine to the freeze cycle.  
The main fuse is 250 Volt, 7 amp.  
Check Procedure  
This occurs when the bin switch is opened and  
closed again within 30 seconds during the harvest  
cycle.  
!
Warning  
2. Automatic ice machine shut-off.  
High (line) voltage is applied to the control board  
(terminals #55 and #56) at all times. Removing the  
control board fuse or moving the toggle switch to  
OFF will not remove the power supplied to the  
control board.  
If the storage bin is full at the end of a harvest cycle,  
the sheet of cubes fails to clear the water curtain and  
holds it open. After the water curtain is held open for  
30 seconds, the ice machine shuts off. The ice  
machine remains off until enough ice is removed  
from the storage bin to allow the sheet of cubes to  
drop clear of the water curtain. As the water curtain  
swings back to the operating position, the bin switch  
closes and the ice machine restarts, provide the  
three-minute delay has expired.  
1. If the bin switch light is on with the water curtain  
closed, the fuse is good.  
!
Warning  
Disconnect electrical power to the entire ice  
machine before proceeding.  
Important  
The water curtain must be ON (bin switch(s) closed)  
to start ice making.  
2. Remove the fuse. Check the resistance across the  
fuse with an ohm meter.  
Specifications  
Reading  
Open (OL)  
Closed (O)  
Result  
The bin switch is a magnetically operated reed switch.  
The magnet is attached to the lower right corner of the  
water curtain. The switch is attached to the right  
bulkhead wall.  
Replace fuse  
Fuse is good  
The bin switch is connected to a varying D.C. voltage  
circuit. (Voltage does not remain constant.)  
NOTE: Because of a wide variation in D.C. voltage, it is  
not recommended that a voltmeter be used to check bin  
switch operation.  
6-12  
Part Number 80-1559-3  
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Section 6  
Electrical System  
Symptoms  
Water Curtain Removal Notes  
Bin Switch Fails Open  
The water curtain must be on (bin switch closed) to start  
ice making. While a freeze cycle is in progress, the water  
curtain can be removed and installed at any time without  
interfering with the electrical control sequence.  
•
The ice machine will not start with the toggle switch  
in the ice position, but runs normally with the toggle  
switch in the clean position.  
If the ice machine goes into harvest sequence while the  
water curtain is removed, one of the following will  
happen:  
Bin Switch Fails Closed  
•
Safety limit 2 is recorded in the control board  
memory and the harvest cycle continues after the ice  
opens and closes the water curtain (harvest cycle is  
3.5 minutes long).  
•
Water curtain remains off:  
When the harvest cycle time reaches 3.5 minutes  
and the bin switch is not closed, the ice machine  
stops as though the bin were full.  
Diagnostic Aids:  
•
Always use the water curtain magnet to cycle the  
switch (a larger or smaller magnet will affect switch  
operation).  
•
Water curtain is put back on:  
If the bin switch closes prior to reaching the 3.5-  
minute point, the ice machine immediately returns to  
another freeze sequence prechill.  
•
Readings are affected by your test lead connection  
and VOM battery strength. Verify you have solid  
connections and a correctly functioning VOM before  
testing bin switch.  
•
•
Open the curtain for 3 seconds, then close the  
curtain for 3 seconds. This will allow your VOM  
display to settle.  
With the bin switch closed your meter reading should  
be 0 (0 to 10 is acceptable). With the curtain open the  
reading must be infinity (OL).  
Continuity 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 25 times by  
opening and closing the water curtain. Watch for  
consistent readings each time the bin switch is  
cycled open and closed (bin switch failure could be  
erratic).  
Part Number 80-1559-3  
6-13  
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Electrical System  
Section 6  
COMPRESSOR ELECTRICAL DIAGNOSTICS  
Determine if the Compressor is Seized  
The compressor will not start or will trip repeatedly on  
overload.  
Check the amp draw while the compressor is trying to  
start.  
Check Resistance (Ohm) Values  
COMPRESSOR DRAWING LOCKED ROTOR  
The two likely causes of this are:  
NOTE: Compressor windings can have very low ohm  
values. Use a properly calibrated meter.  
•
•
Defective starting component  
Perform the resistance test after the compressor cools.  
The compressor dome should be cool enough to touch  
(below 120°F/49°C) to assure that the overload is closed  
and the resistance readings will be accurate.  
Mechanically seized compressor  
To determine which you have:  
1. Install high and low side gauges.  
2. Try to start the compressor.  
3. Watch the pressures closely.  
SINGLE PHASE COMPRESSORS  
1. Disconnect power from the cuber and remove the  
wires from the compressor terminals.  
A. If the pressures do not move, the compressor is  
seized. Replace the compressor.  
2. The resistance values between C and S and  
between C and R, when added together, should  
equal the resistance value between S and R.  
B. If the pressures move, the compressor is turning  
slowly and is not seized. Check the capacitors  
and start relay.  
3. If the overload is open, there will be a resistance  
reading between S and R, and open readings  
between C and S and between C and R. Allow the  
compressor to cool, then check the readings again.  
COMPRESSOR DRAWING HIGH AMPS  
The continuous amperage draw on start-up should not  
be near the maximum fuse size indicated on the serial  
tag.  
THREE PHASE COMPRESSORS  
1. Disconnect power from the cuber and remove the  
wires from the compressor terminals.  
Diagnosing Capacitors  
•
If the compressor attempts to start, or hums and trips  
the overload protector, check the starting  
components before replacing the compressor.  
2. The resistance values between L1 and L2, between  
L2 and L3, and between L3 and L1 should all be  
equal.  
•
Visual evidence of capacitor failure can include a  
bulged terminal end or a ruptured membrane. Do not  
assume a capacitor is good if no visual evidence is  
present.  
3. If the overload is open, there will be open readings  
between L1 and L2, between L2 and L3, and  
between L3 and L1. Allow the compressor to cool,  
then check the readings again.  
•
•
A good test is to install a known good substitute  
capacitor.  
Check Motor Windings to Ground  
Check continuity between all three terminals and the  
compressor shell or copper refrigeration line. Scrape  
metal surface to get good contact. If continuity is  
present, the compressor windings are grounded and the  
compressor should be replaced.  
Use a capacitor tester when checking a suspect  
capacitor. Clip the bleed resistor off the capacitor  
terminals before testing.  
6-14  
Part Number 80-1559-3  
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Section 6  
Electrical System  
PTCR DIAGNOSTICS  
What is a PTCR?  
Compressor Start Sequence  
PTCR’s provide additional starting torque by increasing  
the current in the auxiliary (start) winding during starting.  
The PTCR is wired across the run capacitor (in series  
with the start winding).  
A PTCR (or Positive Temperature Coefficient Resistor) is  
made from high-purity, semi-conducting ceramics.  
A PTCR is useful because of its resistance versus  
temperature characteristic. The PTCR has a low  
resistance over a wide (low) temperature range, but  
upon reaching a certain higher temperature, its  
resistance greatly increases, virtually stopping current  
flow. When the source of heat is removed, the PTCR  
returns to its initial base resistance.  
1. It is important for the refrigerant discharge and  
suction pressures to be somewhat equalized prior to  
the compressor starting. To assure equalization of  
pressures the harvest valve (and HPR valve on  
remotes) will energize for 45 seconds prior to  
compressor starting. The harvest valve (and HPR  
valve on remotes) remains on for an additional 5  
seconds while the compressor is starting.  
In severe duty cycles, it can be used to repeatedly  
switch (virtually stop) large currents at line voltages.  
2. When starting the compressor, the contactor closes  
and the PTCR, which is at a low resistance value,  
allows high starting current to flow in the start  
winding.  
PTCR’s have been used for many years in millions of  
HVAC applications. In place of using the conventional  
start relay/start capacitor, a simple PTCR provides the  
starting torque assistance to PSC (Permanent Split  
Capacitor) single-phase compressors, which can  
equalize pressures before starting.  
3. The current passing through the PTCR causes it to  
rapidly heat up, and after approximately .25-1  
second it abruptly “switches” to a very high  
resistance, virtually stopping current flow through it.  
4. At this point the motor is up to speed and all current  
going through the start winding will now pass  
through the run capacitor.  
5. The PTCR remains hot and at a high resistance as  
long as voltage remains on the circuit.  
6. It is important to provide time between compressor  
restarts to allow the PTCR to cool down to near its  
initial temperature (low resistance). When the  
contactor opens to stop the compressor, the PTCR  
cools down to its initial low resistance and is again  
ready to provide starting torque assistance. To  
assure the PTCR has cooled down, during an  
automatic shut-off, the S model ice machines have a  
built-in 3-minute off time before it can restart.  
Part Number 80-1559-3  
6-15  
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Electrical System  
Section 6  
S-Model Automatic Shut-Off and Restart  
Troubleshooting PTCR’s  
When the storage bin is full at the end of a harvest cycle,  
the sheet of cubes fails to clear the water curtain and will  
hold it open. After the water curtain is held open for 7  
seconds, the ice machine shuts off. To assure the PTCR  
has cooled, the ice machine remains off for 3 minutes  
before it can automatically restart.  
WHY A GOOD PTCR MAY FAIL  
TO START THE COMPRESSOR  
The PTCR must be cooled before attempting to start the  
compressor, otherwise the high starting torque may not  
last long enough.  
For example, if the PTCR is properly cooled, say 60°F  
(15.6°C) when the compressor starts, it will take .25 to  
1.0 seconds before its temperature reaches 260°F  
(126.6°C), and current flow is stopped.  
The ice machine remains off until enough ice has been  
removed from the storage bin to allow the ice to fall clear  
of the water curtain. As the water curtain swings back to  
operating position, the bin switch closes and the ice  
machine restarts, provided the three-minute delay period  
is complete.  
If the PTCR is still warm, say 160°F (71.1°C) when the  
compressor starts, it will take only .125 to .50 seconds  
before its temperature reaches 260°F (126.6°C), and  
current flow is stopped. This decreased time may be  
insufficient to start the compressor.  
L1  
L2  
A good PTCR may be too hot to operate properly at  
start-up because:  
CONTACTOR  
RUN CAPACITOR  
CONTACTS  
R
C
R
R
•
The ice machine’s 3-minute delay has been  
overridden. Opening and closing the service  
disconnect or cycling the toggle switch from OFF to  
ICE will override the delay period.  
S
COMPRESSOR  
SV1506  
•
The control box temperature is too high. Though  
rare, very high air temperatures (intense sunlight,  
etc.) can greatly increase the temperature of the  
control box and its contents. This may require a  
longer off time to allow the PTCR to cool.  
PTCR  
During Start-Up (First .25 - 1.0 Seconds)  
L2  
L1  
•
The compressor has short-cycled, or the compressor  
overload has opened. Move the toggle switch to OFF  
and allow the compressor and PTCR to cool.  
CONTACTOR  
CONTACTS  
RUN CAPACITOR  
R
C
Continued on next page …  
R
R
S
COMPRESSOR  
SV1507  
PTCR  
After Start-Up  
(Current Flows Through Run Capacitor)  
6-16  
Part Number 80-1559-3  
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Section 6  
Electrical System  
There are other problems that may cause compressor  
start-up failure with a good PTCR in a new, properly  
wired ice machine.  
Room  
Temperature  
Resistance  
Manitowoc  
Part Number Part Number  
Cera-Mite  
Model  
S1000M  
8504993  
305C19  
18-40 Ohms  
•
The voltage at the compressor during start-up is too  
low.  
Manitowoc ice machines are rated at ±10% of  
nameplate voltage at compressor start-up. (Ex: An  
ice machine rated at 208-230 should have a  
compressor start-up voltage between 187 and 253  
volts.)  
•
The compressor discharge and suction pressures  
are not matched closely enough or equalized.  
These two pressures must be somewhat equalized  
before attempting to start the compressor. The  
harvest valve (and HPR valve on remotes) energizes  
for 45 seconds before the compressor starts, and  
remains on 5 seconds after the compressor starts.  
Make sure this is occurring and the harvest valve  
(and HPR solenoid) coil is functional before  
assuming that the PTCR is bad.  
SV1540  
Manitowoc PTCR’s 8504993  
CHECKING THE PTCR  
!
Warning  
Disconnect electrical power to the entire ice  
machine at the building electrical disconnect box  
before proceeding.  
1. Visually inspect the PTCR. Check for signs of  
physical damage.  
NOTE: The PTCR case temperature may reach 210°F  
(100°C) while the compressor is running. This is normal.  
Do not change a PTCR just because it is hot.  
2. Wait at least 10 minutes for the PTCR to cool to  
room temperature.  
3. Remove the PTCR from the ice machine.  
4. Measure the resistance of the PTCR as shown  
below. If the resistance falls outside of the  
acceptable range, replace it.  
Part Number 80-1559-3  
6-17  
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Electrical System  
Section 6  
DIAGNOSING START COMPONENTS  
HARVEST ASSIST AIR COMPRESSOR  
Function  
If the compressor attempts to start, or hums and trips the  
overload protector, check the start components before  
replacing the compressor.  
The air compressor breaks the vacuum between the  
sheet of ice and the evaporator which results in shorter  
harvest cycles.  
Capacitor  
Visual evidence of capacitor failure can include a bulged  
terminal end or a ruptured membrane. Do not assume a  
capacitor is good if no visual evidence is present. A good  
test is to install a known good substitute capacitor. Use a  
capacitor tester when checking a suspect capacitor. Clip  
the bleed resistor off the capacitor terminals before  
testing.  
Specifications  
115 Volt or 230 Volt - matches the ice machine voltage.  
Check Procedure  
1. Verify when the air compressor should be running in  
the sequence of operation.  
2. If the compressor is not running when it should be  
check voltage at the control board.  
Relay  
The relay has a set of contacts that connect and  
disconnect the start capacitor from the compressor start  
winding. The contacts on the relay are normally closed  
(start capacitor in series with the start winding). The  
relay senses the voltage generated by the start winding  
and opens the contacts as the compressor motor starts.  
The contacts remain open until the compressor is de-  
energized.  
3. If there is no voltage present at the control board,  
replace the control board.  
4. If there is voltage present at the control board check  
for voltage at the air compressor connector.  
5. If there is no voltage present at the air compressor  
connector replace wire.  
6. If there is voltage at the air compressor connector,  
use a volt ohm meter to verify there is no continuity  
through the motor windings then replace motor.  
Relay Operation Check  
1. Disconnect wires from relay terminals.  
2. Verify the contacts are closed.  
Measure the resistance between terminals 1 and 2.  
No continuity indicates open contacts. Replace the  
relay.  
3. Check the relay coil.  
Measure the resistance between terminals 2 and 5.  
No resistance indicates an open coil. Replace the  
relay.  
6-18  
Part Number 80-1559-3  
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Section 6  
Electrical System  
ICE/OFF/CLEAN TOGGLE SWITCH  
Function  
The switch is used to place the ice machine in ICE, OFF  
or CLEAN mode of operation.  
Specifications  
Single-pole, single-throw switch. The switch is  
connected into a varying low D.C. voltage circuit.  
Check Procedure  
NOTE: Because of a wide variation in D.C. voltage, it is  
not recommended that a volt meter be used to check  
toggle switch operation.  
1. Inspect the toggle switch for correct wiring.  
2. Isolate the toggle switch by disconnecting the Molex  
connector.  
3. Check continuity across the toggle switch terminals.  
Note where the wire numbers are connected to the  
switch terminals, or refer to the wiring diagram to  
take proper readings.  
Switch Setting  
Terminals  
1-6  
Ohm Reading  
Open  
ICE  
1-2  
Closed  
Open  
2-6  
1-6  
Closed  
Open  
CLEAN  
OFF  
1-2  
2-6  
Open  
1-6  
Open  
1-2  
Open  
2-6  
Open  
4. Replace the toggle switch if ohm readings do not  
match all three switch settings.  
Part Number 80-1559-3  
6-19  
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Electrical System  
Section 6  
ELECTRONIC CONTROL BOARD  
N 115V  
L2 208-230V  
PRIMARY POWER SUPPLY  
AC LINE VOLTAGE  
ELECTRICAL  
PLUG (NUMBERS  
MARKED ON  
WIRES)  
MAIN FUSE (7A)  
AIR COMPRESSOR  
(NOT USED ON  
ALL MODELS)  
WATER PURGE  
ADJUSTMENT  
CLEAN LIGHT (YELLOW)  
LEFT BIN LIGHT (GREEN)  
RIGHT BIN LIGHT (GREEN)  
REMOTE BIN LIGHT (GREEN)  
WATER LEVEL LIGHT (GREEN)  
ICE LEVEL LIGHT (GREEN)  
HARVEST LIGHT (RED)  
SAFETY LIMIT 1 LIGHT (RED)  
SAFETY LIMIT 2 LIGHT (RED)  
DC LOW VOLTAGE  
ELECTRICAL PLUG  
(NUMBERS MARKED ON  
WIRES)  
AUTOMATIC CLEANING  
SYSTEM (AuCS) PLUG  
ICE THICKNESS  
PROBE (3/16''  
CONNECTION)  
WATER LEVEL PROBE  
REMOTE BIN  
SV3129  
Control Board  
6-20  
Part Number 80-1559-3  
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Section 6  
Electrical System  
General  
Inputs  
S-Model control boards use a dual voltage transformer.  
This means only one control board is needed for both  
115V and 208-230V use.  
The control board, along with inputs, controls all  
electrical components, including the ice machine  
sequence of operation. Prior to diagnosing, you must  
understand how the inputs affect the control board  
operation.  
Safety Limits  
In addition to standard safety controls, such as the high  
pressure cut-out, the control board has built-in safety  
limits.  
Refer to specific component specifications (inputs),  
wiring diagrams and ice machine sequence of operation  
sections for details.  
These safety limits protect the ice machine from major  
component failures. For more information, see “Safety  
Limits” in Section 7.  
As an example, refer to “Ice Thickness Probe” on the  
next page for information relating to how the probe and  
control board function together.  
This section will include items such as:  
•
•
•
•
•
How a harvest cycle is initiated  
How the harvest light functions with the probe  
Freeze time lock-in feature  
Maximum freeze time  
Diagnosing ice thickness control circuitry  
Part Number 80-1559-3  
6-21  
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Electrical System  
Section 6  
MAXIMUM FREEZE TIME  
Ice Thickness Probe (Harvest Initiation)  
The control system includes a built-in safety which will  
automatically cycle the ice machine into harvest after 60  
minutes in the freeze cycle.  
HOW THE PROBE WORKS  
Manitowoc’s electronic sensing circuit does not rely on  
refrigerant pressure, evaporator temperature, water  
levels or timers to produce consistent ice formation.  
ICE THICKNESS CHECK  
The ice thickness probe is factory-set to maintain the ice  
bridge thickness at 1/8" (.32 cm).  
As ice forms on the evaporator, water (not ice) contacts  
the ice thickness probe. After the water completes this  
circuit across the probe continuously for 6-10 seconds, a  
harvest cycle is initiated.  
NOTE: Make sure the water curtain is in place when  
performing this check. It prevents water from splashing  
out of the water trough.  
1. Inspect the bridge connecting the cubes. It should  
be about 1/8" (.32 cm) thick.  
2. If adjustment is necessary, turn the ice thickness  
probe adjustment screw clockwise to increase  
bridge thickness, or counterclockwise to decrease  
bridge thickness.  
NOTE: The starting point before final adjustment is  
approximately a 3/16 inch gap.  
SV3135  
ADJUSTING SCREW  
Ice Thickness Probe  
HARVEST LIGHT  
1/8” ICE BRIDGE THICKNESS  
This light’s function is to be on as water contacts the ice  
thickness probe during the freeze cycle, and remain on  
throughout the entire harvest cycle. The light will flicker  
as water splashes on the probes.  
SV3132  
Ice Thickness Check  
FREEZE TIME LOCK-IN FEATURE  
Make sure the ice thickness probe wire and the bracket  
do not restrict movement of the probe.  
The ice machine control system incorporates a freeze  
time lock-in feature. This prevents the ice machine from  
short cycling in and out of harvest.  
Ice Thickness Probe Cleaning  
The control board locks the ice machine in the freeze  
cycle for six minutes. If water contacts the ice thickness  
probe during these six minutes, the harvest light will  
come on (to indicate that water is in contact with the  
probe), but the ice machine will stay in the freeze cycle.  
After the six minutes are up, a harvest cycle is initiated.  
This is important to remember when performing  
diagnostic procedures on the ice thickness control  
circuitry.  
1. Mix a solution of Manitowoc ice machine cleaner  
and water (2 ounces of cleaner to 16 ounces of  
water) in a container.  
2. Soak ice thickness probe in container of cleaner/  
water solution while disassembling and cleaning  
water circuit components (soak ice thickness probe  
for 10 minutes or longer).  
3. Clean all ice thickness probe surfaces including all  
plastic parts (do not use abrasives). Verify the ice  
thickness probe cavity is clean. Thoroughly rinse ice  
thickness probe (including cavity) with clean water,  
then dry completely. Incomplete rinsing and  
drying of the ice thickness probe can cause  
premature harvest.  
To allow the service technician to initiate a harvest cycle  
without delay, this feature is not used on the first cycle  
after moving the toggle switch OFF and back to ICE.  
4. Reinstall ice thickness probe, then sanitize all ice  
machine and bin/dispenser interior surfaces.  
6-22  
Part Number 80-1559-3  
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Section 6  
Electrical System  
DIAGNOSING ICE THICKNESS CONTROL CIRCUITRY  
Ice Machine Does Not Cycle Into Harvest When Water Contacts The Ice Thickness Control Probe  
Step 1 Bypass the freeze time lock-in feature by moving the ICE/OFF/CLEAN switch to OFF and back to ICE.  
Step 2 Wait until the water starts to flow over the evaporator (freeze cycle).  
Step 3 Disconnect the ice thickness control from the control board, then connect a jumper wire from the control  
board to any cabinet ground and monitor the harvest light.  
Monitoring of Harvest Light  
Correction  
The harvest light comes on, and 10 seconds later, ice machine The ice thickness probe is causing the malfunction.  
cycles from freeze to harvest.  
The harvest light comes on but the ice machine stays in the  
freeze sequence.  
The control circuitry is functioning properly. The ice machine is  
in a six-minute freeze time lock-in (verify step 1 of this  
procedure was followed correctly).  
The harvest light does not come on.  
The control board is causing the malfunction.  
HARVEST LIGHT  
ICE THICKNESS  
PROBE CONNECTION  
Ice Machine Cycles Into Harvest Before Water Contact With The Ice Thickness Probe  
Step 1 Disconnect the ice thickness probe from the control board.  
Step 2 Wait until water starts to flow over the evaporator, then monitor the harvest light:  
Monitoring of Harvest Light  
Correction  
The harvest light stays off and the ice machine remains in the  
freeze sequence.  
The ice thickness probe is causing the malfunction.  
Verify that the Ice Thickness probe is adjusted correctly.  
The control board is causing the malfunction.  
The harvest light comes on, and 10 seconds later, the ice  
machine cycles from freeze to harvest.  
Part Number 80-1559-3  
6-23  
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Electrical System  
Section 6  
FREEZE CYCLE CIRCUITRY  
Water Level Control Circuitry  
Manitowoc’s electronic sensing circuit does not rely on  
float switches or timers to maintain consistent water  
level control. During the freeze cycle, the water inlet  
valve energizes (turns on) and de-energizes (turns off) in  
conjunction with the water level probe located in the  
water trough.  
WATER LEVEL PROBE LIGHT  
The water level probe circuit can be monitored by  
watching the water level light. The water level light is on  
when water contacts the probe, and off when no water is  
in contact with the probe. The water level light functions  
any time power is applied to the ice machine, regardless  
of toggle switch position.  
During the first 45 seconds of the Freeze Cycle:  
•
•
•
The water inlet valve is on when there is no water in  
contact with the water level probe.  
During the freeze cycle, the water level probe is set to  
maintain the proper water level above the water pump  
housing. The water level is not adjustable. If the water  
level is incorrect, check the water level probe position.  
Reposition or replace the probe as necessary.  
The water inlet valve turns off after water contacts  
the water level probe for 3 continuous seconds.  
The water inlet valve will cycle on and off as many  
times as needed to fill the water trough.  
WATER INLET VALVE SAFETY SHUT-OFF  
In the event of a water level probe failure, this feature  
limits the water inlet valve to a 12-minute on time.  
Regardless of the water level probe input, the control  
board automatically shuts off the water inlet valve if it  
remains on for 12 continuous minutes.  
After 45 seconds into the Freeze Cycle:  
The water inlet valve will cycle on, and then off one more  
time to refill the water trough. The water inlet valve is  
now off for the duration of the freeze sequence.  
HARVEST CYCLE CIRCUITRY  
The water level probe does not control the water inlet  
valve during the harvest cycle. During the harvest cycle  
water purge, the water inlet valve energizes and de-  
energizes strictly by time. The harvest water purge  
jumper may be set at 45 seconds (top and center  
terminals) or 0 seconds (center and bottom terminals).  
Set the harvest water purge to 0 seconds when reverse  
osmosis or deionized water is used. Use the factory  
setting of 45 seconds for all other types of water.  
HARVEST WATER PURGE ADJUSTMENT  
45 SECOND  
JUMPER  
POSITION  
0 SECOND  
JUMPER  
POSITION  
SV3139  
SV3140  
6-24  
Part Number 80-1559-3  
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Section 6  
Electrical System  
DIAGNOSING WATER LEVEL CONTROL CIRCUITRY  
Problem: Water Trough Overfilling During The  
Freeze Cycle  
Step 2 Wait until the freeze cycle starts  
(the freeze cycle starts when the water pump energizes).  
Step 1 Start a new freeze sequence by moving the ICE/  
OFF/CLEAN toggle switch to OFF, then back to ICE. (if  
water flows with the switch off, check the water inlet  
valve).  
Step 3 Disconnect water level probe wire from control  
board and connect a jumper from the control board  
terminal and any cabinet ground, then refer to chart.  
Important  
Important  
For the test to work properly you must wait until the  
freeze cycle starts, prior to connecting the jumper  
wire. If you restart the test you must disconnect the  
jumper wire, restart the ice machine, (step 1) and  
then reinstall the jumper wire after the compressor  
starts.  
This restart must be done prior to performing  
diagnostic procedures. This assures the ice  
machine is not in a freeze cycle water inlet valve  
safety shut off mode. You must complete the entire  
diagnostic procedure within 6 minutes of starting.  
GREEN WATER LEVEL LIGHT  
WATER LEVEL PROBE CONNECTION  
SV3135  
Step 3  
Step 3 Jumper wire connected from control board terminal to ground  
Is water flowing into  
the water trough?  
The Water Level  
Light is:  
The Water Inlet Valve  
Solenoid Coil is:  
Cause  
The water level probe is causing the problem.  
Clean or replace the water level probe.  
NO  
ON  
De-Energized  
YES  
YES  
ON  
Energized  
The control board is causing the problem.  
The water fill valve is causing the problem.  
OFF  
De-Energized  
Part Number 80-1559-3  
6-25  
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Electrical System  
Section 6  
Problem: Water Will Not Run Into The Sump Trough  
During The Freeze Cycle  
Step 2 Wait until the freeze cycle starts (approximately  
45 seconds, the freeze cycle starts when the  
compressor energizes).  
Step 1 Verify water is supplied to the ice machine, and  
then start a new freeze sequence by moving the ICE/  
OFF/CLEAN toggle switch to OFF then back to ICE.  
Step 3 Disconnect the water level probe from the water  
level probe terminal on the control board.  
Important  
Important  
For the test to work properly you must wait until the  
freeze cycle starts, prior to disconnecting the water  
level probe. If you restart the test you must  
reconnect the water level probe, restart the ice  
machine, (step 1) and then disconnect the water  
level probe after the compressor starts.  
This restart must be done prior to performing  
diagnostic procedures. This assures the ice machine  
is not in a freeze cycle water inlet valve safety shut-  
off mode. You must complete the entire diagnostic  
procedure within 6 minutes of starting.  
GREEN WATER LEVEL LIGHT  
DISCONNECT WATER  
LEVEL PROBE FROM  
CONTROL BOARD  
TERMINAL  
SV3135  
Step 3  
Step 3 Disconnect water level probe from control board terminal  
Is water flowing into  
the water trough?  
The Water Level  
Light is:  
The Water Inlet Valve  
Solenoid Coil is:  
Cause  
YES  
OFF  
Energized  
The water level probe is causing the problem.  
Clean or replace the water level probe.  
NO  
NO  
OFF  
Energized  
The water inlet valve is causing the problem.  
The control board is causing the problem.  
ON OR OFF  
De-Energized  
6-26  
Part Number 80-1559-3  
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Section 6  
Electrical System  
Diagnosing An Ice Machine That Will Not Run  
!
Warning  
High (line) voltage is applied to the control board  
(terminals #55 and #56) at all times. Removing  
control board fuse or moving the toggle switch to  
OFF will not remove the power supplied to the  
control board.  
Step  
Check  
Notes  
1
Verify primary voltage supply to ice  
machine.  
Verify that the fuse or circuit breaker is closed.  
2
Verify the high-pressure cutout is closed. The H.P.C.O. is closed if primary power voltage is present at terminals  
#55 and #56 on the control board.  
3
4
5
Verify control board fuse is OK.  
If the bin switch light functions, the fuse is OK.  
Verify the bin switch functions properly.  
A defective bin switch can falsely indicate a full bin of ice.  
A defective toggle switch may keep the ice machine in the OFF mode.  
Verify ICE/OFF/CLEAN toggle switch  
functions properly.  
6
7
Verify low DC voltage is properly  
grounded.  
Loose DC wire connections may intermittently stop the ice machine.  
Replace the control board.  
Be sure Steps 1-6 were followed thoroughly. Intermittent problems are  
not usually related to the control board.  
Part Number 80-1559-3  
6-27  
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Electrical System  
Section 6  
S1000M - SELF CONTAINED -  
1 PHASE WITH TERMINAL BOARD  
1
2
3
4
6
5
SV2071  
6-28  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
Section 7  
Refrigeration System  
Sequence of Operation  
SELF-CONTAINED WATER -COOLED MODELS  
EVAPORATOR  
HEAT  
EXCHANGER  
EXPANSION VALVE  
HOT GAS SOLENOID VALVE  
X
COMPRESSOR  
AIR OR WATER  
CONDENSER  
STRAINER  
DRIER  
RECEIVER  
(WATER COOLED ONLY)  
HIGH PRESSURE VAPOR  
HIGH PRESSURE LIQUID  
LOW PRESSURE LIQUID  
LOW PRESSURE VAPOR  
SV1569  
Figure 7-1. Self-Contained Prechill and Freeze Cycle  
Prechill Refrigeration Sequence  
Freeze Cycle Refrigeration Sequence  
No water flows over the evaporator during the prechill.  
The refrigerant absorbs heat (picked up during the  
harvest cycle) from the evaporator. The suction pressure  
decreases during the prechill.  
The refrigerant absorbs heat from water running over the  
evaporator surface. The suction pressure gradually  
drops as ice forms.  
Part Number 80-1559-3  
7-1  
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Refrigeration System  
Section 7  
EVAPORATOR  
HEAT  
EXCHANGER  
EXPANSION VALVE  
HOT GAS SOLENOID VALVE  
COMPRESSOR  
AIR OR WATER  
CONDENSER  
STRAINER  
DRIER  
RECEIVER  
(WATER COOLED ONLY)  
HIGH PRESSURE VAPOR  
HIGH PRESSURE LIQUID  
LOW PRESSURE LIQUID  
LOW PRESSURE VAPOR  
SV1570  
Figure 7-2. Self-Contained Harvest Cycle  
Harvest Cycle Refrigeration Sequence  
Hot gas flows through the energized harvest valve,  
heating the evaporator. The harvest valve is sized to  
allow the proper amount of refrigerant into the  
evaporator. This specific sizing (along with the proper  
system refrigerant charge) assures proper heat transfer,  
without the refrigerant condensing and slugging the  
compressor.  
7-2  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
2. An ice machine that is low on charge may cause a  
good expansion valve to starve. If a service  
technician fails to verify the system charge, he may  
replace the expansion valve in error.  
Operational Analysis (Diagnostics)  
GENERAL  
When analyzing the refrigeration system, it is important  
to understand that different refrigeration component  
malfunctions may cause very similar symptoms.  
During the replacement procedure, recovery,  
evacuation and recharging are performed correctly.  
The ice machine now functions normally. The  
technician erroneously thinks that the problem was  
properly diagnosed and corrected by replacing the  
expansion valve.  
Also, many external factors can make good refrigeration  
components appear bad. These factors can include  
improper installation, or water system malfunctions such  
as hot incoming water supply or water loss.  
The following two examples illustrate how similar  
symptoms can result in a misdiagnosis.  
The service technician’s failure to check the ice  
machine for a low charge condition resulted in a  
misdiagnosis and the needless replacement of a  
good expansion valve.  
1. An expansion valve bulb that is not securely  
fastened to the suction line and/or not insulated will  
cause a good expansion valve to flood. If a service  
technician fails to check for proper expansion valve  
bulb mounting, he may replace the expansion valve  
in error.  
When analyzing the refrigeration system, use the  
Refrigeration System Operational Analysis Table. This  
table, along with detailed checklists and references, will  
help prevent replacing good refrigeration components  
due to external problems.  
The ice machine now functions normally. The  
technician erroneously thinks that the problem was  
properly diagnosed and corrected by replacing the  
expansion valve. Actually, the problem (loose bulb)  
was corrected when the technician properly  
mounted the bulb of the replacement expansion  
valve.  
The service technician’s failure to check the  
expansion valve bulb for proper mounting (an  
external check) resulted in a misdiagnosis and the  
needless replacement of a good expansion valve.  
Part Number 80-1559-3  
7-3  
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Refrigeration System  
Section 7  
BEFORE BEGINNING SERVICE  
2. Refer to the appropriate 24 Hour Ice Production  
Chart. Use the operating conditions determined in  
Step 1 to find published 24 hour ice production.  
Ice machines may experience operational problems only  
during certain times of the day or night. A machine may  
function properly while it is being serviced, but  
malfunctions later. Information provided by the user can  
help the technician start in the right direction, and may  
be a determining factor in the final diagnosis.  
3. Perform an actual ice production check. Use the  
formula below.  
__________  
Freeze Time  
+
÷
__________  
Harvest Time  
=
=
__________  
Total Cycle Time  
1.  
2.  
Ask these questions before beginning service:  
__________  
Total Cycle Time  
__________  
Cycles Per Day  
1440  
Minutes in 24  
Hours  
•
•
•
When does the ice machine malfunction? (night, day,  
all the time, only during the freeze cycle, etc.)  
__________  
Weight of One  
Harvest  
x
__________  
Cycles Per Day  
=
__________  
Actual 24 Hour Ice  
Production  
When do you notice low ice production? (one day a  
week, every day, on weekends, etc.)  
3.  
Can you describe exactly what the ice machine  
seems to be doing?  
Important  
Times are in minutes.  
Example: 1 min., 15 sec. converts to 1.25 min.  
(15 seconds ÷ 60 seconds = .25 minutes)  
•
•
Has anyone been working on the ice machine?  
During “store shutdown,” is the circuit breaker, water  
supply or air temperature altered?  
•
Is there any reason why incoming water pressure  
might rise or drop substantially?  
Weights are in pounds.  
Example: 2 lb., 6 oz. converts to 2.375 lb.  
(6 oz. ÷ 16 oz. = .375 lb.)  
ICE PRODUCTION CHECK  
The amount of ice a machine produces directly relates to  
the operating water and air temperatures. This means  
an ice machine in a 70°F (21.1°C) room with 50°F  
(10.0°C) water produces more ice than the same model  
condensing unit with a 90°F (32.2°C) outdoor ambient  
temperature and 70°F (21.1°C) water.  
Weighing the ice is the only 100% accurate  
check. However, if the ice pattern is normal and the  
1/8" thickness is maintained, the ice slab weights  
listed with the 24 Hour Ice Production Charts may  
be used.  
1. Determine the ice machine operating conditions:  
4. Compare the results of step 3 with step 2. Ice  
production checks that are within 10% of the chart  
are considered normal. If they match closely,  
determine if:  
Air temp. entering condenser:  
Air temp. around ice machine:  
_______ °  
_______ °  
Water temp. entering sump trough: _______ °  
•
•
•
another ice machine is required.  
more storage capacity 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.  
7-4  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
INSTALLATION/VISUAL INSPECTION CHECKLIST  
WATER SYSTEM CHECKLIST  
A water-related problem often causes the same  
symptoms as a refrigeration system component  
malfunction.  
Possible Problem  
Corrective Action  
Ice machine is not level  
Level the ice machine  
Water filtration is plugged (if Install a new water filter  
used)  
Water system problems must be identified and  
eliminated prior to replacing refrigeration components.  
Water drains are not run  
separately and/or are not  
vented  
Run and vent drains  
according to the Installation  
Manual  
Possible Problem  
Corrective Action  
Clean as needed  
Water area (evaporator) is  
dirty  
Water inlet pressure not  
between 20 and 80 psi  
(1-5 Bar, 138- 552 kPa)  
Install a water regulator valve  
or increase the water  
pressure  
Incoming water temperature If too hot, check the hot water  
is not between 35°F (1.6°C)  
and 90°F (32.2°C).  
line check valves in other  
store equipment  
Water filtration is plugged (if Install a new water filter  
used)  
Water dump valve leaking  
during the freeze cycle  
Clean/replace dump valve as  
needed  
Vent tube is not installed on  
water outlet drain  
See Installation Instructions  
Hoses, fittings, etc., are  
leaking water  
Repair/replace as needed  
Water fill valve is stuck open Clean/replace as needed  
Water is spraying out of the  
sump trough area  
Stop the water spray  
Uneven water flow across the Clean the ice machine  
evaporator  
Water is freezing behind the Correct the water flow  
evaporator  
Plastic extrusions and  
gaskets are not secured to  
the evaporator  
Remount/replace as needed  
Part Number 80-1559-3  
7-5  
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Refrigeration System  
Section 7  
ICE FORMATION PATTERN  
2. Extremely Thin at Evaporator Outlet  
Evaporator ice formation pattern analysis is helpful in ice  
machine diagnostics.  
There is no ice, or a considerable lack of ice formation at  
the outlet of the evaporator.  
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.  
Examples: No ice at all at the outlet half of the  
evaporator, but ice forms at the inlet half of the  
evaporator. Or, the ice at the outlet of the evaporator  
reaches 1/8" to initiate a harvest, but the inlet of the  
evaporator already has 1/2" to 1" of ice formation.  
Improper ice formation can be caused by any number of  
problems.  
Possible cause: Water loss, low on refrigerant, starving  
TXV, faulty water fill valve etc.  
Important  
Keep the water curtain in place while checking the  
ice formation pattern to ensure no water is lost.  
NO ICE or THIN ICE  
1. Normal Ice Formation  
Ice forms across the entire evaporator surface.  
OUTLET  
At the beginning of the freeze cycle, it may appear that  
more ice is forming at the inlet of the evaporator than at  
the outlet. At the end of the freeze cycle, ice formation at  
the outlet will be close to, or just a bit thinner than, ice  
formation at the inlet. The dimples in the cubes at the  
outlet of the evaporator may be more pronounced than  
those at the inlet. This is normal.  
ICE  
The ice thickness probe must be set to maintain the ice  
bridge thickness at approximately 1/8". If ice forms  
uniformly across the evaporator surface, but does not  
reach 1/8" in the proper amount of time, this is still  
considered normal.  
INLET  
Figure 7-3. Extremely Thin Ice Formation at  
Evaporator Outlet  
7-6  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
3. Extremely Thin at Evaporator Inlet  
5. No Ice Formation  
There is no ice, or a considerable lack of ice formation at  
the inlet of the evaporator. Examples: The ice at the  
outlet of the evaporator reaches 1/8" to initiate a harvest,  
but there is no ice formation at all at the inlet of the  
evaporator.  
The ice machine operates for an extended period, but  
there is no ice formation at all on the evaporator.  
Possible causes: Water inlet valve, water pump, starving  
expansion valve, low refrigerant charge, compressor,  
etc.  
Possible causes: Insufficient water flow, flooding TXV,  
etc.  
OUTLET  
OUTLET  
ICE  
INLET  
INLET  
Figure 7-6. No Ice Formation  
Figure 7-4. Extremely Thin Ice Formation at  
Evaporator Inlet  
4. Spotty Ice Formation  
There are small sections on the evaporator where there  
is no ice formation. This could be a single corner, or a  
single spot in the middle of the evaporator. This is  
generally caused by loss of heat transfer from the tubing  
on the back side of the evaporator.  
OUTLET  
ICE  
INLET  
Figure 7-5. Spotty Ice Formation  
Part Number 80-1559-3  
7-7  
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Refrigeration System  
Section 7  
SAFETY LIMITS  
General  
Analyzing Why Safety Limits May Stop the Ice  
Machine  
According to the refrigeration industry, a high percentage  
of compressors fail as a result of external causes. These  
can include: flooding or starving expansion valves, dirty  
condensers, water loss to the ice machine, etc. The  
safety limits protect the ice machine (primarily the  
compressor) from external failures by stopping ice  
machine operation before major component damage  
occurs.  
In addition to standard safety controls, such as high  
pressure cut-out, the control board has two built in safety  
limit controls which protect the ice machine from major  
component failures.  
Safety Limit #1: If the freeze time reaches 60 minutes,  
the control board automatically initiates a harvest cycle.  
If 6 consecutive 60-minute freeze cycles occur, the ice  
machine stops.  
The safety limit system is similar to a high pressure cut-  
out control. It stops the ice machine, but does not tell  
what is wrong. The service technician must analyze the  
system to determine what caused the high pressure cut-  
out, or a particular safety limit, to stop the ice machine.  
Safety Limit #2: If the harvest time reaches 3.5 minutes,  
the control board automatically returns the ice machine  
to the freeze cycle.  
If 500 consecutive 3.5 minute harvest cycles occur, the  
ice machine stops.  
The safety limits are designed to stop the ice machine  
prior to major component failures, most often a minor  
problem or something external to the ice machine. This  
may be difficult to diagnose, as many external problems  
occur intermittently.  
Safety Limit Indication  
When a safety limit condition is exceeded:  
•
Six consecutive cycles for safety limit 1 - the  
control board enters the limit into memory.  
Example: An ice machine stops intermittently on safety  
limit #1 (long freeze times). The problem could be a low  
ambient temperature at night, a water pressure drop, the  
water is turned off one night a week, etc.  
•
Three consecutive cycles for safety limit 2 - the  
control board enters the limit into memory and  
the ice machine continues to run.  
Use the following procedures to determine if the control  
board contains a safety limit indication.  
Refrigeration and electrical component failures may also  
trip a safety limit. Eliminate all electrical components and  
external causes first. If it appears that the refrigeration  
system is causing the problem, use Manitowoc’s  
Refrigeration System Operational Analysis Table, along  
with detailed charts, checklists, and other references to  
determine the cause.  
1. Move the toggle switch to OFF.  
2. Move the toggle switch back to ICE.  
3. Watch the safety limit lights (SL-1 and SL-2). If a  
safety limit has been recorded, either the SL-1 light  
will flash once or the SL-2 light will flash twice,  
corresponding to safety limit 1 or 2 to indicate which  
safety limit stopped the ice machine.  
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.  
7-8  
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Section 7  
Refrigeration System  
Safety Limit #1  
Refer to previous page for safety limit operation.  
Freeze time exceeds 60 minutes for 6 consecutive freeze cycles.  
Possible Cause  
Check/Correct  
Improper installation  
Water system  
See “Installation/Visual Inspection Checklist”  
Low water pressure [20 psi (138 kPa) min.]  
High water pressure [80 psi (552 kPa) max.]  
High water temperature (90°F/32.2°C max.)  
Clogged water distribution tube  
Dirty/defective water fill valve  
Dirty/defective water dump valve  
Defective water pump  
Loss of water from sump area  
Electrical system  
Low incoming voltage  
Ice thickness probe out of adjustment  
Harvest cycle not initiated electrically  
Contactor not energizing  
Compressor electrically non-operational  
Defective fan cycling control  
Defective fan motor  
Miscellaneous  
Restricted condenser airflow  
High inlet air temperature (Self-Contained -110°F/43.3°C max.)  
Restricted condenser water flow  
Low water pressure [20 psi (138 kPa) min.]  
High water temperature (90°F/32.2°C max.)  
Dirty/defective water regulating valve  
Water regulating valve out of adjustment  
Improper refrigerant charge  
Refrigeration system  
Non-Manitowoc components  
Defective head pressure control (remotes)  
Defective harvest valve  
Defective compressor  
TXV starving or flooding (check bulb mounting)  
Non-condensables in refrigeration system  
Plugged or restricted high side refrigerant lines or component  
SAFETY LIMIT NOTES  
•
If the toggle switch is moved to the OFF position and  
then back to the ICE position prior to reaching the  
100-harvest point, the last safety limit exceeded will  
be indicated.  
•
Because there are many possible external problems,  
do not limit your diagnosis to only the items listed in  
this chart.  
•
If a Safety Limit light did not flash prior to the ice  
machine restarting, then the ice machine did not stop  
because it exceeded a safety limit.  
•
•
A continuous run of 100 harvests automatically  
erases the safety limit code.  
The control board will store and indicate only one  
safety limit – the last one exceeded.  
Part Number 80-1559-3  
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Refrigeration System  
Section 7  
Safety Limit #2  
Refer to page 7-8 for safety limit operation.  
Harvest time exceeds 3.5 minutes for 500 consecutive harvest cycles.  
Possible Cause  
Check/Correct  
Improper installation  
Water system  
See “Installation/Visual Inspection Checklist”  
Water area (evaporator) dirty  
Dirty/defective water dump valve  
Vent tube not installed on water outlet drain  
Water freezing behind evaporator  
Plastic extrusions and gaskets not securely mounted to the  
evaporator  
Low water pressure [20 psi (138 kPa) min.]  
Loss of water from sump area  
Clogged water distribution tube  
Dirty/defective water fill valve  
Defective water pump  
Electrical system  
Ice thickness probe out of adjustment  
Ice thickness probe dirty  
Bin switch defective  
Premature harvest  
Refrigeration system  
Non-Manitowoc components  
Water regulating valve dirty/defective  
Improper refrigerant charge  
Defective head pressure control valve (remotes)  
Defective harvest pressure control (HPR) valve (remotes)  
Defective harvest valve  
TXV flooding (check bulb mounting)  
Defective fan cycling control  
SAFETY LIMIT NOTES  
•
•
If the toggle switch is moved to the OFF position and  
then back to the ICE position prior to reaching the  
100-harvest point, the last safety limit exceeded will  
be indicated.  
•
Because there are many possible external problems,  
do not limit your diagnosis to only the items listed in  
this chart.  
If a Safety Limit light did not flash prior to the ice  
machine restarting, then the ice machine did not stop  
because it exceeded a safety limit.  
•
•
A continuous run of 100 harvests automatically  
erases the safety limit code.  
The control board will store and indicate only one  
safety limit – the last one exceeded.  
7-10  
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Section 7  
Refrigeration System  
ANALYZING DISCHARGE PRESSURE  
DURING FREEZE OR HARVEST CYCLE  
3. Perform an actual discharge pressure check.  
Freeze Cycle  
PSIG (kPa)  
Harvest Cycle  
PSIG (kPa)  
Procedure  
1. Determine the ice machine operating conditions:  
Beginning of Cycle  
Middle of Cycle  
End of Cycle  
__________  
__________  
__________  
__________  
__________  
__________  
Air temp. entering condenser  
Air temp. around ice machine  
Water temp. entering sump trough  
______  
______  
______  
4. Compare the actual discharge pressure (step 3) with  
the published discharge pressure (step 2).  
2. Refer to Operating Pressure Chart for ice machine  
being checked.  
The discharge pressure is normal when the actual  
pressure falls within the published pressure range for the  
ice machine’s operating conditions.  
Use the operating conditions determined in step 1 to  
find the published normal discharge pressures.  
Freeze Cycle _______  
Harvest Cycle_______  
Freeze Cycle Discharge Pressure High Checklist  
Possible Cause  
Check/Correct  
See “Installation/Visual Inspection Checklist”  
Low water pressure [20 psi (138 kPa) min.]  
High inlet water temperature (90°F/32.2°C max.)  
Dirty condenser  
Improper installation  
Restricted condenser water flow (water-cooled  
models)  
Dirty/defective water regulating valve  
Water regulating valve out of adjustment  
Overcharged  
Improper refrigerant charge  
Other  
Non-condensables in system  
Wrong type of refrigerant  
Non-Manitowoc components in system  
High side refrigerant lines/component restricted (before mid-condenser)  
Defective head pressure control valve (remote models)  
Freeze Cycle Discharge Pressure Low Checklist  
Possible Cause  
Improper installation  
Check/Correct  
See “Installation/Visual Inspection Checklist”  
Undercharged  
Improper refrigerant charge  
Wrong type of refrigerant  
Water regulating valve (water-cooled condensers)  
Other  
Out of adjustment  
Defective  
Non-Manitowoc components in system  
Defective head pressure control valve (remote models)  
Defective fan cycle control  
NOTE: Do not limit your diagnosis to only the items listed in the checklists.  
Part Number 80-1559-3  
7-11  
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Refrigeration System  
Section 7  
ANALYZING SUCTION PRESSURE  
DURING FREEZE CYCLE  
NOTE: Analyze discharge pressure before analyzing  
suction pressure. High or low discharge pressure may  
be causing high or low suction pressure.  
The suction pressure gradually drops throughout the  
freeze cycle. The actual suction pressure (and drop rate)  
changes as the air and water temperatures entering the  
ice machine change. This affects 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.  
“Operating Pressure” and “Freeze Cycle Time” charts  
can be found later in this section.  
Procedure  
Step  
Example Using SY1004WM Model Ice Machine  
Water temp. entering condenser:  
Water temp. entering water fill valve:  
90°F/32.2°C  
70°F/21.1°C  
1. Determine the ice machine operating  
conditions.  
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.  
Published freeze cycle time:  
7.6 - 8.8 minutes  
Published freeze cycle suction pressure:  
48-28 PSIG  
Published Freeze Cycle Time (minutes)  
4
1
2
6
8
2B. Compare the published freeze cycle time  
and published freeze cycle suction pressure.  
Develop a chart.  
43  
48 43  
33  
28  
Published Freeze Cycle Suction Pressure (psig)  
3. Perform an actual suction pressure check at  
the beginning, middle and end of the freeze  
cycle. Note the times at which the readings are  
taken.  
Beginning of freeze cycle:  
70 PSIG at 1 minute  
57 PSIG at 4 minutes  
40 PSIG at 8 minutes  
Middle of freeze cycle:  
End of freeze cycle:  
Time Into  
Freeze Cycle  
Published  
Actual  
4. Compare the actual freeze cycle suction  
pressure (Step 3) to the published freeze cycle  
time and pressure comparison (Step 2B).  
Determine if the suction pressure is high, low  
or acceptable.  
Result  
Pressure  
48 PSIG  
38 PSIG  
28 PSIG  
Pressure  
70 PSIG  
57 PSIG  
40 PSIG  
1 minutes  
4 minutes  
8 minutes  
High  
High  
High  
7-12  
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Section 7  
Refrigeration System  
Freeze Cycle Suction Pressure High Checklist  
Possible Cause  
Check/Correct  
Improper installation  
Discharge pressure  
See “Installation/Visual Inspection Checklist”  
Discharge pressure is too high, and is affecting low side  
(See “Freeze Cycle Discharge Pressure High Checklist” )  
Improper refrigerant charge  
Other  
Overcharged  
Wrong type of refrigerant  
Non-Manitowoc components in system  
H.P.R. solenoid leaking  
Harvest valve stuck open  
TXV flooding (check bulb mounting)  
Defective compressor  
Freeze Cycle Suction Pressure Low Checklist  
Possible Cause  
Check/Correct  
Improper installation  
Discharge pressure  
See “Installation/Visual Inspection Checklist”  
Discharge pressure is too low, and is affecting low side  
(See “Freeze Cycle Discharge Pressure Low Checklist”)  
Improper refrigerant charge  
Other  
Undercharged  
Wrong type of refrigerant  
Non-Manitowoc components in system  
Improper water supply over evaporator (See “Water System Checklist” )  
Loss of heat transfer from tubing on back side of evaporator  
Restricted/plugged liquid line drier  
Restricted/plugged tubing in suction side of refrigeration system  
TXV starving  
NOTE: Do not limit your diagnosis to only the items listed in the checklists.  
Part Number 80-1559-3  
7-13  
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Refrigeration System  
Section 7  
SINGLE EXPANSION VALVE ICE MACHINES -  
COMPARING EVAPORATOR INLET AND  
OUTLET TEMPERATURES  
Use this procedure to document freeze cycle inlet and  
outlet temperatures.  
1. Use a quality temperature meter, capable of taking  
temperature readings on curved copper lines.  
NOTE: This procedure will not work on the dual  
expansion valve ice machines.  
2. Attach the temperature meter sensing device to the  
copper lines entering and leaving the evaporator.  
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.  
Important  
Do not simply insert the sensing device under the  
insulation. It must be attached to and reading the  
actual temperature of the copper line.  
The actual temperatures entering and leaving the  
evaporator vary by model, and change throughout the  
freeze cycle. This makes documenting the “normal” inlet  
and outlet temperature readings difficult. The key to the  
diagnosis lies in the difference between the two  
temperatures five minutes into the freeze cycle. These  
temperatures must be within 7° of each other.  
3. Wait five minutes into the freeze cycle.  
4. Record the temperatures below and determine the  
difference between them.  
5. Use this with other information gathered on the  
Refrigeration System Operational Analysis Table to  
determine the ice machine malfunction.  
______________  
Inlet Temperature  
______________  
Outlet Temperature  
_______________  
Difference  
Must be within 7° at 5  
minutes into freeze cycle  
7-14  
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Section 7  
Refrigeration System  
HARVEST VALVE TEMPERATURE CHECK  
General  
3. Feel the compressor discharge line.  
!
Warning  
A harvest valve requires a critical orifice size. This  
meters the amount of hot gas flowing into the evaporator  
during the harvest cycle. If the orifice is even slightly too  
large or too small, long harvest cycles will result.  
The inlet of the harvest valve and the compressor  
discharge line could be hot enough to burn your  
hand. Just touch them momentarily.  
A too-large orifice causes refrigerant to condense to  
liquid in the evaporator during the harvest cycle. This  
liquid will cause compressor damage. A too-small orifice  
does not allow enough hot gas into the evaporator. This  
causes low suction pressure, and insufficient heat for a  
harvest cycle.  
4. Compare the temperature of the inlet of the harvest  
valves to the temperature of the compressor  
discharge line.  
Findings  
Comments  
The inlet of the  
This is normal as the discharge line  
Refer to the Parts Manual for proper valve application. If  
replacement is necessary, Use only “original” Manitowoc  
replacement parts.  
harvest valve is cool should always be too hot to touch and  
enough to touch and the harvest valve inlet, although too  
the compressor  
hot to touch during harvest, should be  
discharge line is hot. cool enough to touch after 5 minutes  
into the freeze cycle.  
Harvest Valve Analysis  
Symptoms of a harvest valve remaining partially open  
during the freeze cycle can be similar to symptoms of  
either an expansion valve or compressor problem. The  
best way to diagnose a harvest valve is by using  
Manitowoc’s Ice Machine Refrigeration System  
Operational Analysis Table.  
The inlet of the  
This is an indication something is  
harvest valve is hot wrong, as the harvest valve inlet did  
and approaches the not cool down during the freeze cycle.  
temperature of a hot If the compressor dome is also entirely  
compressor  
discharge line.  
hot, the problem is not a harvest valve  
leaking, but rather something causing  
the compressor (and the entire ice  
machine) to get hot.  
Use the following procedure and table to help determine  
if a harvest valve is remaining partially open during the  
freeze cycle.  
Both the inlet of the This is an indication something is  
harvest valve and  
the compressor  
discharge line are  
cool enough to  
touch.  
wrong, causing the compressor  
discharge line to be cool to the touch.  
This is not caused by a harvest valve  
leaking.  
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.  
The harvest valve outlet is on the suction side (cool  
refrigerant). It may be cool enough to touch even if  
the valve is leaking.  
Part Number 80-1559-3  
7-15  
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Refrigeration System  
Section 7  
HOW TO USE THE REFRIGERATION SYSTEM  
OPERATIONAL ANALYSIS TABLES  
Final Analysis  
The column with the highest number of check marks  
identifies the refrigeration problem.  
General  
These tables must be used with charts, checklists and  
other references to eliminate refrigeration components  
not listed on the tables and external items and problems  
which can cause good refrigeration components to  
appear defective.  
COLUMN 1 - HARVEST VALVE LEAKING  
A leaking harvest valve must be replaced.  
COLUMN 2 - LOW CHARGE/TXV STARVING  
Normally, a starving expansion valve only affects the  
freeze cycle pressures, not the harvest cycle pressures.  
A low refrigerant charge normally affects both pressures.  
Verify the ice machine is not low on charge before  
replacing an expansion valve.  
The tables list five different defects that may affect the  
ice machine’s operation.  
NOTE: A low-on-charge ice machine and a starving  
expansion valve have very similar characteristics and  
are listed under the same column.  
1. Add refrigerant charge in 2 to 4 oz. increments as a  
diagnostic procedure to verify a low charge. If the  
problem is corrected, the ice machine is low on  
charge. Find the refrigerant leak.  
NOTE: Before starting, see “Before Beginning Service”  
for a few questions to ask when talking to the ice  
machine owner.  
The ice machine must operate with the nameplate  
charge. If the leak cannot be found, proper  
refrigerant procedures must still be followed Change  
the liquid line drier. Then, evacuate and weigh in the  
proper charge.  
Procedure  
Step 1 Complete the “Operation Analysis” column.  
Read down the left “Operational Analysis” column.  
Perform all procedures and check all information listed.  
Each item in this column has supporting reference  
material to help analyze each step.  
2. If the problem is not corrected by adding charge, the  
expansion valve is faulty.  
While analyzing each item separately, you may find an  
“external problem” causing a good refrigerant  
component to appear bad. Correct problems as they are  
found. If the operational problem is found, it is not  
necessary to complete the remaining procedures.  
COLUMN 3 - TXV FLOODING  
A loose or improperly mounted expansion valve bulb  
causes the expansion valve to flood. Check bulb  
mounting, insulation, etc., before changing the valve. On  
dual expansion valve machines, the service technician  
should be able to tell which TXV is flooding by analyzing  
ice formation patterns. Change only the flooding  
expansion valve.  
Step 2 Enter check marks (√) in the small 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.  
COLUMN 4 - COMPRESSOR  
Example: Freeze cycle suction pressure is determined  
to be low. Enter a check mark in the “low” box.  
Replace the compressor and start components. To  
receive warranty credit, the compressor ports must be  
properly sealed by crimping and soldering them closed.  
Old start components must be returned with the faulty  
compressor.  
Step 3 Add the check marks listed under each of the  
four columns. Note the column number with the highest  
total and proceed to “Final Analysis.”  
NOTE: If two columns have matching high numbers, a  
procedure was not performed properly and/or supporting  
material was not analyzed correctly.  
7-16  
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Section 7  
Refrigeration System  
REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES  
S Models Single Expansion Valve  
This table must be used with charts, checklists and other references to eliminate  
refrigeration components not listed on the table and external items and problems, which  
can cause good refrigeration components to appear defective.  
Operational Analysis  
Ice Production  
1
2
3
4
Air-Temperature Entering Condenser_____________  
Water Temperature Entering Ice Machine_________  
Published 24 hour ice production________________  
Calculated (actual) ice production_______________  
NOTE: The ice machine is operating properly if the ice fill patterns is normal and ice production is within 10% of charted  
capacity.  
All installation and water related problems must be corrected before proceeding with chart.  
Installation and Water  
System  
Ice formation is extremely  
thin on outlet of evaporator  
-or-  
No ice formation on the  
entire evaporator  
Ice formation is extremely  
thin on outlet of evaporator  
-or-  
No ice formation on entire  
evaporator  
Ice formation normal  
-or-  
Ice formation is extremely  
thin on inlet of evaporator  
-or-  
Ice formation normal  
-or-  
No ice formation on entire  
evaporator  
Ice Formation Pattern  
No ice formation on entire  
evaporator  
Safety Limits  
Refer to “Analyzing Safety  
Limits” to eliminate all non-  
refrigeration problems.  
Stops on safety limit:  
Stops on safety limit:  
Stops on safety limit:  
Stops on safety limit:  
1
1
1 or 2  
1
Freeze Cycle  
Discharge Pressure  
If discharge pressure is High or Low refer to freeze cycle high or low discharge pressure problem checklist to eliminate  
problems and/or components not listed on this table before proceeding.  
_____  
______  
______  
End  
1 minute Middle  
into cycle  
If suction pressure is High or Low refer to freeze cycle high or low suction pressure problem checklist to eliminate problems  
and/or components not listed on this table before proceeding.  
Freeze Cycle  
Suction Pressure  
Suction pressure is High  
Suction pressure is Low or  
Suction pressure is High  
Suction pressure is High  
_____  
______  
______  
End  
Normal  
1 minute Middle  
Inlet and outlet  
within 7°  
of each other  
Inlet and outlet  
not within 7°  
of each other  
Inlet and outlet  
within 7°  
of each other  
-or-  
Inlet and outlet  
not within 7°  
of each other  
-and-  
Inlet and outlet  
within 7°  
of each other  
Wait 5 minutes into the freeze  
cycle.  
Compare temperatures of  
evaporator inlet and  
evaporator outlet.  
-and-  
Inlet is colder than outlet  
Inlet  
Outlet  
____ ° F (° C)  
____ ° F (° C)  
Inlet is warmer than outlet  
Difference ____ ° F (° C)  
The harvest valve inlet is  
Hot  
The harvest valve inlet is  
Cool enough to hold hand  
on  
The harvest valve inlet is  
Cool enough to hold hand  
on  
The harvest valve inlet is  
Cool enough to hold hand  
on  
Wait 5 minutes into the freeze  
cycle.  
-and-  
Compare temperatures of  
compressor discharge line  
and harvest valve inlet.  
approaches the temperature  
of a Hot compressor  
discharge line.  
-and-  
-and-  
-and-  
the compressor discharge  
line is Hot.  
the compressor discharge  
line is Cool  
enough to hold hand on.  
the compressor discharge  
line is Hot.  
Final Analysis  
Enter total number of boxes  
checked in each column.  
Low On Charge  
-Or-  
TXV Starving  
Harvest Valve Leaking  
TXV Flooding  
Compressor  
Part Number 80-1559-3  
7-17  
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Refrigeration System  
Section 7  
Pressure Control Specifications and  
Diagnostics  
HIGH PRESSURE CUT-OUT (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  
Cut-out:  
Cut-in:  
450 psig ±10 (3103 kPa ±69, 31 Bar ±.69)  
Manual or automatic reset  
Must be below 300 psig (2068 kPa, 20.68  
Bar ±.69) to reset  
Check Procedure  
1. Set ICE/OFF/CLEAN switch to OFF.  
2. Connect manifold gauges.  
3. Hook voltmeter in parallel across the HPCO, leaving  
wires attached.  
4. On water-cooled models, close the water service  
valve to the water condenser inlet. On self-contained  
air-cooled and remote models, disconnect the fan  
motor.  
5. Set ICE/OFF/CLEAN switch to ICE.  
6. No water or air flowing through the condenser will  
cause the HPCO control to open because of  
excessive pressure. Watch the pressure gauge and  
record the cut-out pressure.  
!
Warning  
If discharge pressure exceeds 460 psig (2068 kPa,  
20.68 Bar ) and the HPCO control does not cut out,  
set ICE/OFF/CLEAN switch to OFF to stop ice  
machine operation.  
Replace the HPCO control if it:  
•
•
Will not reset [below 300 psig (2068 kPa, 20.68 Bar )]  
Does not open at the specified cut-out point  
7-18  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
S1000 SERIES  
Cycle Time/24 Hour Ice Production/  
Refrigerant Pressure Charts  
Self-Contained Water-Cooled  
These charts are used as guidelines to verify correct ice  
machine operation.  
NOTE: These characteristics may vary depending on  
operating conditions.  
Accurate collection of data is essential to obtain the  
correct diagnosis.  
Cycle Times  
Freeze Time + Harvest Time = Total Cycle Time  
•
Refer to “OPERATIONAL ANALYSIS TABLE” for the  
list of data that must be collected for refrigeration  
diagnostics. This list includes: before beginning  
service, ice production check, installation/visual  
inspection, water system checklist, ice formation  
pattern, safety limits, comparing evaporator inlet/  
outlet temperatures, discharge and suction pressure  
analysis.  
Air Temp.  
Around Ice  
Machine  
°F/°C  
Freeze Time  
Harvest  
Time  
Water Temperature °F/°C  
50/10.0  
70/21.1  
90/32.2  
70/21.1  
80/26.7  
6.8-7.9  
6.9-8.0  
6.9-8.1  
7.0-8.1  
7.4-8.6  
7.5-8.7  
7.6-8.8  
7.7-8.9  
8.5-9.8  
8.6-9.9  
.75-2.00  
90/32.2  
8.7-10.1  
8.9-10.2  
•
Ice production checks that are within 10% of the  
chart are considered normal. This is due to variances  
in water and air temperature. Actual temperatures  
will seldom match the chart exactly.  
100/37.8  
Times in minutes  
24 Hour Ice Production  
•
•
Zero out manifold gauge set before obtaining  
pressure readings to avoid misdiagnosis.  
Air Temp.  
Around Ice  
Machine  
°F/°C  
Water Temperature °F/°C  
50/10.0  
70/21.1  
90/32.2  
Discharge and suction pressure are highest at the  
beginning of the cycle. Suction pressure will drop  
throughout the cycle. Verify the pressures are within  
the range indicated.  
70/21.1  
80/26.7  
90/32.2  
100/37.8  
1000  
990  
980  
970  
930  
920  
910  
900  
830  
820  
810  
800  
•
•
Record beginning of freeze cycle suction pressure  
one minute after water pump energizes.  
Based on average ice slab weight of 5.75- 6.50lb  
50Hz production derate is 7%  
90/32.2 Air Temperature  
Around Ice Machine  
Condenser  
Water  
Consumption  
Water Temperature °F/°C  
50/10.0  
70/21.1  
90/32.2  
Gal/24 hours  
710  
1500  
5100  
Water regulating valve set to maintain 240 PSIG discharge pressure  
Operating Pressures  
Freeze Cycle  
Harvest Cycle  
Air Temp.  
AroundIce  
Machine  
°F/°C  
Discharge Suction Discharge Suction  
Pressure Pressure Pressure Pressure  
PSIG  
PSIG  
40-24  
40-25  
42-26  
48-28  
52-28  
54-28  
PSIG  
PSIG  
75-90  
75-90  
80-95  
85-105  
90-110  
95-115  
50/10.0  
70/21.1  
80/26.7  
90/32.2  
100/37.8  
110/43.3  
235-245  
235-245  
235-250  
240-270  
250-280  
250-285  
160-175  
160-175  
170-185  
175-205  
180-210  
185-215  
Suction pressure drops gradually throughout the freeze cycle  
Part Number 80-1559-3  
7-19  
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Refrigeration System  
Section 7  
Refrigerant Recovery/Evacuation and Recharging  
NORMAL SELF-CONTAINED MODEL PROCEDURES  
Refrigerant Recovery/Evacuation  
SELF-CONTAINED RECOVERY/EVACUATION  
1. Place the toggle switch in the OFF position.  
Do not purge refrigerant to the atmosphere. Capture  
refrigerant using recovery equipment. Follow the  
manufacturer’s recommendations.  
2. Install manifold gauges, scale, and recovery unit or  
two-stage vacuum pump.  
MANIFOLD SET  
Important  
OPEN  
OPEN  
Manitowoc Ice, Inc. assumes no responsibility for  
the use of contaminated refrigerant. Damage  
resulting from the use of contaminated refrigerant is  
the sole responsibility of the servicing company.  
BACKSEATED  
BACKSEATED  
LOW SIDE  
SERVICE  
VALVE  
HIGH SIDE  
SERVICE  
VALVE  
Important  
Replace the liquid line drier before evacuating and  
recharging. Use only a Manitowoc (O.E.M.) liquid  
line filter drier to prevent voiding the warranty.  
CONNECTIONS  
Manifold gauge sets must utilize low loss fittings to  
comply with U.S. Government rules and regulations.  
Make these connections:  
VACUUM PUMP/  
RECOVERY UNIT  
OPEN  
CLOSED  
1. Suction side of the compressor through the suction  
service valve.  
SV1404A  
2. Discharge side of the compressor through the  
discharge service valve.  
Figure 7-7. Recovery/Evacuation Connections  
3. Open (backseat) the high and low side ice machine  
service valves, and open high and low side on  
manifold gauges.  
4. Perform recovery or evacuation:  
A. Recovery: Operate the recovery unit as directed  
by the manufacturer’s instructions.  
B. Evacuation prior to recharging: Pull the system  
down to 500 microns. Then, allow the pump to  
run for an additional half hour. Turn off the pump  
and perform a standing vacuum leak check.  
5. Follow the Charging Procedures.  
7-20  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
Self-Contained 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.  
2. Close the vacuum pump valve, the low side service  
valve, and the low side manifold gauge valve.  
3. Open the high side manifold gauge valve, and  
backseat the high side service valve.  
4. Open the charging cylinder and add the proper  
refrigerant charge (shown on nameplate) through  
the discharge service valve.  
1. Be sure the toggle switch is in the OFF position.  
5. Let the system “settle” for 2 to 3 minutes.  
6. Place the toggle switch in the ICE position.  
MANIFOLD SET  
7. Close the high side on the manifold gauge set. Add  
any remaining vapor charge through the suction  
service valve (if necessary).  
CLOSED  
OPEN  
NOTE: Manifold gauges must be removed properly to  
ensure that no refrigerant contamination or loss occurs.  
FRONTSEATED  
BACKSEATED  
LOW SIDE  
SERVICE  
VALVE  
HIGH SIDE  
SERVICE  
VALVE  
8. Make sure that all of the vapor in the charging hoses  
is drawn into the ice machine before disconnecting  
the charging hoses.  
A. Run the ice machine in freeze cycle.  
B. Close the high side service valve at the ice  
machine.  
C. Open the low side service valve at the ice  
machine.  
CHARGING  
CYLINDER  
VACUUM PUMP/  
RECOVERY UNIT  
D. Open the high and low side valves on the  
manifold gauge set. Any refrigerant in the lines  
will be pulled into the low side of the system.  
CLOSED  
OPEN  
SV1404B  
E. Allow the pressures to equalize while the ice  
machine is in the freeze cycle.  
Figure 7-8. Charging Connections  
F. Close the low side service valve at the ice  
machine.  
G. Remove the hoses from the ice machine and  
install the caps.  
Part Number 80-1559-3  
7-21  
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Refrigeration System  
Section 7  
EVAPORATOR  
HEAT EXCHANGER  
EXPANSION  
VALVE  
HOT GAS  
SOLENOID  
VALVES  
x
LOW SIDE  
SERVICE VALVE  
(BACKSEATED)  
COMPRESSOR  
STRAINER  
HARVEST  
PRESSURE  
SOLENOID  
VALVE  
HARVEST  
PRESSURE  
REGULATING  
VALVE  
CHECK  
VALVE  
x
HIGH SIDE  
SERVICE VALVE  
(BACKSEATED)  
LIQUID  
LINE  
SOLENOID  
DISCHARGELINE  
QUICK CONNECT  
SCHRAEDER FITTING  
DRIER  
REMOTE CONDENSER  
RECEIVER  
SERVICE VALVE  
1/2 OPEN  
B
CHECK VALVE  
R
C
HEAD PRESSURE  
CONTROL VALVE  
MANIFOLD SET  
TEE  
OPEN  
OPEN  
OPEN  
VACUUM PUMP/  
RECOVERY UNIT  
SCALE  
SV1461  
CLOSED  
Figure 7-9. Recovery/Evacuation Connections  
7-22  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
SYSTEM CONTAMINATION CLEAN-UP  
General  
If either condition is found, or if contamination is  
suspected, use a Total Test Kit from Totaline or a similar  
diagnostic tool. These devices sample refrigerant,  
eliminating the need to take an oil sample. Follow the  
manufacturer’s directions.  
This section describes the basic requirements for  
restoring contaminated systems to reliable service.  
If a refrigerant test kit indicates harmful levels of  
contamination, or if a test kit is not available, inspect the  
compressor oil.  
Important  
Manitowoc Ice, Inc. assumes no responsibility for  
the use of contaminated refrigerant. Damage  
resulting from the use of contaminated refrigerant is  
the sole responsibility of the servicing company.  
1. Remove the refrigerant charge from the ice  
machine.  
2. Remove the compressor from the system.  
3. Check the odor and appearance of the oil.  
Determining Severity Of Contamination  
System contamination is generally caused by either  
moisture or residue from compressor burnout entering  
the refrigeration system.  
4. Inspect open suction and discharge lines at the  
compressor for burnout deposits.  
5. If no signs of contamination are present, perform an  
acid oil test.  
Inspection of the refrigerant usually provides the first  
indication of system contamination. Obvious moisture or  
an acrid odor in the refrigerant indicates contamination.  
Check the chart below to determine the type of cleanup  
required.  
Contamination/Cleanup Chart  
Symptoms/Findings  
Required Cleanup Procedure  
No symptoms or suspicion of contamination  
Moisture/Air Contamination symptoms  
Normal evacuation/recharging procedure  
Refrigeration system open to atmosphere for longer than 15  
minutes  
Mild contamination cleanup procedure  
Refrigeration test kit and/or acid oil test shows contamination  
Leak in water-cooled condenser  
No burnout deposits in open compressor lines  
Mild Compressor Burnout symptoms  
Oil appears clean but smells acrid  
Mild contamination cleanup procedure  
Severe contamination cleanup procedure  
Refrigeration test kit or acid oil test shows harmful acid content  
No burnout deposits in open compressor lines  
Severe Compressor Burnout symptoms  
Oil is discolored, acidic, and smells acrid  
Burnout deposits found in the compressor and lines, and in  
other components  
Part Number 80-1559-3  
7-23  
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Refrigeration System  
Section 7  
Mild System Contamination Cleanup Procedure  
1. Replace any failed components.  
Severe System Contamination Cleanup Procedure  
1. Remove the refrigerant charge.  
2. If the compressor is good, change the oil.  
3. Replace the liquid line drier.  
2. Remove the compressor.  
3. Disassemble the harvest solenoid valve. If burnout  
deposits are found inside the valve, install a new  
harvest valve, and replace manifold strainer, TXV  
and harvest pressure regulating valve.  
NOTE: If the contamination is from moisture, use heat  
lamps during evacuation. Position them at the  
compressor, condenser and evaporator prior to  
evacuation. Do not position heat lamps too close to  
plastic components, or they may melt or warp.  
4. Wipe away any burnout deposits from suction and  
discharge lines at compressor.  
5. Sweep through the open system with dry nitrogen.  
Important  
Dry nitrogen is recommended for this procedure.  
This will prevent CFC release.  
Important  
Refrigerant sweeps are not recommended, as they  
release CFC’s into the atmosphere.  
4. Follow the normal evacuation procedure, except  
replace the evacuation step with the following:  
6. Install a new compressor and new start components.  
A. Pull vacuum to 1000 microns. Break the vacuum  
with dry nitrogen and sweep the system.  
7. Install a suction line filter-drier with acid and  
moisture removal capability (P/N 89-3028-3). Place  
the filter drier as close to the compressor as  
possible.  
Pressurize to a minimum of 5 psi (35 kPa).  
B. Pull vacuum to 500 microns. Break the vacuum  
with dry nitrogen and sweep the system.  
Pressurize to a minimum of 5 psi (35 kPa).  
8. Install an access valve at the inlet of the suction line  
drier.  
C. Change the vacuum pump oil.  
9. Install a new liquid line drier.  
D. Pull vacuum to 500 microns. Run the vacuum  
pump for 1/2 hour on self-contained models, 1  
hour on remotes.  
Continued on next page …  
NOTE: You may perform a standing vacuum test to  
make a preliminary leak check. You should use an  
electronic leak detector after system charging to be sure  
there is no leak.  
5. Charge the system with the proper refrigerant to the  
nameplate charge.  
6. Operate the ice machine.  
7-24  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
10. Follow the normal evacuation procedure, except  
replace the evacuation step with the following:  
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.  
Important  
Dry nitrogen is recommended for this procedure.  
This will prevent CFC release.  
•
•
•
•
Water regulating valve (water-cooled only)  
High pressure cut-out control  
High side service valve  
A. Pull vacuum to 1000 microns. Break the vacuum  
with dry nitrogen and sweep the system.  
Pressurize to a minimum of 5 psi (35 kPa .35 bar).  
Low side service valve  
B. Change the vacuum pump oil.  
C. Pull vacuum to 500 microns. Break the vacuum  
with dry nitrogen and sweep the system.  
Important  
Pressurize to a minimum of 5 psi (35 kPa .35 bar).  
This is a required in-warranty repair procedure.  
D. Change the vacuum pump oil.  
1. Disconnect power to the ice machine.  
E. Pull vacuum to 500 microns. Run the vacuum  
pump for 1/2 hour on self-contained models, 1  
hour on remotes.  
2. Follow all manufacturer’s instructions supplied with  
the pinch-off tool. Position the pinch-off tool around  
the tubing as far from the pressure control as  
feasible. (See the figure on next page.) Clamp down  
on the tubing until the pinch-off is complete.  
NOTE: You may perform a standing vacuum test to  
make a preliminary leak check. You should use an  
electronic leak detector after system charging to be sure  
there is no leak.  
!
Warning  
11. Charge the system with the proper refrigerant to the  
nameplate charge.  
Do not unsolder a defective component. Cut it out of  
the system. Do not remove the pinch-off tool until  
the new component is securely in place.  
12. Operate the ice machine for one hour. Then, check  
the pressure drop across the suction line filter-drier.  
3. Cut the tubing of the defective component with a  
small tubing cutter.  
A. If the pressure drop is less than 1 psi (7 kPa,  
.7 bar), the filter-drier should be adequate for  
complete cleanup.  
4. Solder the replacement component in place. Allow  
the solder joint to cool.  
B. If the pressure drop exceeds 1 psi (7 kPa, .7 bar),  
change the suction line filter-drier and the liquid  
line drier. Repeat until the pressure drop is  
acceptable.  
5. Remove the pinch-off tool.  
6. Re-round the tubing. Position the flattened tubing in  
the proper hole in the pinch off tool. Tighten the  
wingnuts until the block is tight and the tubing is  
rounded. (See the drawing on next page.)  
13. Operate the ice machine for 48-72 hours. Then,  
remove the suction line drier and change the liquid  
line drier.  
NOTE: The pressure controls will operate normally once  
the tubing is re-rounded. Tubing may not re-round  
100%.  
14. Follow normal evacuation procedures.  
Part Number 80-1559-3  
7-25  
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Refrigeration System  
Section 7  
SV1406  
Figure 7-10. Using Pinch-Off Tool  
7-26  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
FILTER-DRIERS  
TOTAL SYSTEM REFRIGERANT CHARGES  
The filter-driers used on Manitowoc ice machines are  
manufactured to Manitowoc specifications.  
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.  
The difference between Manitowoc driers and off-the-  
shelf driers is in filtration. Manitowoc driers have dirt-  
retaining filtration, with fiberglass filters on both the inlet  
and outlet ends. This is very important because ice  
machines have a back-flushing action which takes place  
during every harvest cycle.  
Series  
Version  
Charge  
These filter-driers have a very high moisture removal  
capability and a good acid removal capability.  
S1000M  
Water-Cooled  
38 oz.  
The size of the filter-drier is important. The refrigerant  
charge is critical. Using an improperly sized filter-drier  
will cause the ice machine to be improperly charged with  
refrigerant.  
NOTE: All ice machines on this list are charged using  
R-404A refrigerant.  
Listed below are the recommended O.E.M. field  
replacement driers:  
Additional Refrigerant Charges  
For line sets between 50’ - 100’.  
End  
Connection  
Size  
Drier  
Size  
Part  
Number  
Refrigerant  
Maximum  
Model  
Nameplate to be added  
Charge  
Series  
System Charge  
Never Exceed  
for 50’ - 100’  
line sets  
Self-Contained  
Water Cooled  
UK-032S  
UK-165S  
1/4"  
89-3025-9  
89-3028-3  
8.5 lb.  
2 lb.  
10.5 lb.  
S1000M  
Suction Filter  
5/8"  
(136 oz.)  
(32 oz.)  
(168 oz.)  
Suction Filter used when cleaning up severely contaminated systems  
Important  
Driers are covered as a warranty part. The drier  
must be replaced any time the system is opened for  
repairs.  
Part Number 80-1559-3  
7-27  
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Refrigeration System  
Section 7  
REFRIGERANT DEFINITIONS  
Recover  
Reclaim  
To reprocess refrigerant to new product specifications  
(see below) by means which may include distillation. A  
chemical analysis of the refrigerant is required after  
processing to be sure that product specifications are  
met. This term usually implies the use of processes and  
procedures available only at a reprocessing or  
manufacturing facility.  
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. This term usually applies  
to procedures implemented at the field job site or at a  
local service shop.  
Chemical analysis is the key requirement in this  
definition. Regardless of the purity levels reached by a  
reprocessing method, refrigerant is not considered  
“reclaimed” unless it has been chemically analyzed and  
meets ARI Standard 700 (latest edition).  
New Product Specifications  
This means ARI Standard 700 (latest edition). Chemical  
analysis is required to assure that this standard is met.  
7-28  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
REFRIGERANT RE-USE POLICY  
3. Recovered or Recycled Refrigerant  
Manitowoc recognizes and supports the need for proper  
handling, re-use, and disposal of, CFC and HCFC  
refrigerants. Manitowoc service procedures require  
recapturing refrigerants, not venting them to the  
atmosphere.  
•
Must be recovered or recycled in accordance  
with current local, state and federal laws.  
•
Must be recovered from and re-used in the same  
Manitowoc product. Re-use of recovered or  
recycled refrigerant from other products is not  
approved.  
It is not necessary, in or out of warranty, to reduce or  
compromise the quality and reliability of your customers’  
products to achieve this.  
•
•
Recycling equipment must be certified to ARI  
Standard 740 (latest edition) and be maintained  
to consistently meet this standard.  
Important  
Recovered refrigerant must come from a  
“contaminant-free” system. To decide whether  
the system is contaminant free, consider:  
Manitowoc Ice, Inc. assumes no responsibility for  
use of contaminated refrigerant. Damage resulting  
from the use of contaminated, recovered, or  
recycled refrigerant is the sole responsibility of the  
servicing company.  
– Type(s) of previous failure(s)  
– Whether the system was cleaned, evacuated  
and recharged properly following failure(s)  
Manitowoc approves the use of:  
– Whether the system has been contaminated  
by this failure  
1. New Refrigerant  
– Compressor motor burnouts and improper  
past service prevent refrigerant re-use.  
•
Must be of original nameplate type.  
2. Reclaimed Refrigerant  
– Refer to “System Contamination Cleanup” to  
test for contamination.  
•
•
Must be of original nameplate type.  
Must meet ARI Standard 700 (latest edition)  
specifications.  
4. “Substitute” or “Alternative” Refrigerant  
•
Must use only Manitowoc-approved alternative  
refrigerants.  
•
Must follow Manitowoc-published conversion  
procedures.  
Part Number 80-1559-3  
7-29  
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Refrigeration System  
Section 7  
HFC REFRIGERANT QUESTIONS AND ANSWERS  
Manitowoc uses R-404A and R-134A HFC refrigerants with ozone depletion potential (ODP) factors of zero (0.0). R-  
404A is used in ice machines and reach-in freezers and R-134A is used in reach-in refrigerators.  
1. What compressor oil does Manitowoc require for  
use with HFC refrigerants?  
5. How do I leak-check a system containing HFC  
refrigerant?  
Manitowoc products use Polyol Ester (POE) type  
compressor oil. It is the lubricant of choice among  
compressor manufacturers.  
Use equipment designed for HFC detection. Do not  
use equipment designed for CFC detection. Consult  
leak detection equipment manufacturers for their  
recommendations. Also, standard soap bubbles will  
work with HFC refrigerants.  
2. What are some of the characteristics of POE oils?  
They are hygroscopic, which means they have the  
ability to absorb moisture. POE oils are 100 times  
more hygroscopic than mineral oils. Once moisture  
is absorbed into the oil, it is difficult to remove, even  
with heat and vacuum. POE oils are also excellent  
solvents, and tend to “solvent clean” everything  
inside the system, depositing material where it is not  
wanted.  
6. Does Manitowoc use a special liquid line filter-drier  
with HFC refrigerants?  
Yes. Manitowoc uses an ALCO “UK” series filter-  
drier for increased filtration and moisture removal.  
During a repair, Manitowoc recommends installing  
the drier just before hooking up a vacuum pump.  
7. Is other special equipment required to service HFC  
refrigerants?  
3. What do these POE oil characteristics mean to me?  
You must be more exacting in your procedures. Take  
utmost care to prevent moisture from entering the  
refrigeration system. Refrigeration systems and  
compressors should not be left open to the  
atmosphere for more than 15 minutes. Keep oil  
containers and compressors capped at all times to  
minimize moisture entry. Before removing the  
system charge to replace a faulty component, be  
sure you have all of the needed components at the  
site. Remove new system component plugs and  
caps just prior to brazing. Be prepared to connect a  
vacuum pump immediately after brazing.  
No. Standard refrigeration equipment such as  
gauges, hoses, recovery systems, vacuum pumps,  
etc., are generally compatible with HFC refrigerants.  
Consult your equipment manufacturer for specific  
recommendations for converting existing equipment  
to HFC usage. Once designated (and calibrated, if  
needed) for HFC use, this equipment should be  
used specifically with HFC refrigerants only.  
8. Do I have to recover HFC refrigerants?  
Yes. Like other refrigerants, government regulations  
require recovering HFC refrigerants.  
9. Will R-404A or R-134A separate if there is a leak in  
the system?  
4. Are there any special procedures required if a POE  
system is diagnosed with a refrigerant leak?  
No. Like R-502, the degree of separation is too small  
to detect.  
For systems found with positive refrigerant system  
pressure, no special procedures are required.  
10. How do I charge a system with HFC refrigerant?  
For systems found without any positive refrigerant  
pressure, assume that moisture has entered the  
POE oil. After the leak is found and repaired, the  
compressor oil must be changed. The compressor  
must be removed and at least 95% of the oil drained  
from the suction port of the compressor. Use a  
“measuring cup” to replace the old oil with exactly  
the same amount of new POE oil, such as Mobil  
EAL22A.  
The same as R-502. Manitowoc recommends  
charging only liquid refrigerant into the high side of  
the system.  
Remember, care must be taken to prevent moisture  
from getting into the refrigeration system during  
refrigeration repairs.  
7-30  
Part Number 80-1559-3  
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Section 7  
Refrigeration System  
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Part Number 80-1559-3  
7-31  
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Refrigeration System  
Section 7  
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7-32  
Part Number 80-1559-3  
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Attend A Manitowoc Factory Service School  
• Improve Your Service Techniques  
• Network with Your Peers  
• 4 1/2 Days of Intensive Training on Manitowoc Ice Machines  
• Extensive “Hands On” Training on a Variety of Equipment  
• Breakfast, Lunch and Hotel Room Included with Tuition  
• Contact Your Distributor or Manitowoc Ice, Inc. for Details  
OR  
• Visit Our Website at www.manitowocice.com for School Dates  
MANITOWOC ICE, INC.  
2110 South 26th Street P.O. Box 1720  
Manitowoc, WI 54221-1720  
Phone: (920) 682-0161  
Service Fax: (920) 683-7585  
Web Site - www.manitowocice.com  
© 2005 Manitowoc Ice, Inc.  
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