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Manitowoc NEO User Manual

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

Table of Contents

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Manitowoc NEO Specifications

General IconGeneral
BrandManitowoc
ModelNEO
CategoryIce Maker
LanguageEnglish

Summary

Safety Notices

Warning and Caution Definitions

Explains the meaning of Warning and Caution boxes used in the manual.

Procedural Guidance

Important and Note Explanations

Describes the purpose of 'Important' and 'Note' text for procedural information.

Key Safety Precautions

General Warnings Before Proceeding

Provides essential safety warnings including caution, warranty, and lifting advice.

Electrical and Operational Safety

Covers high voltage, refrigerant hazards, circuit protection, and safe equipment operation.

Equipment Usage Safety

Details safety regarding vents, flammable vapors, water jets, PPE, and moving the unit.

Electric Appliance Usage Precautions

Outlines general safety rules for using electric appliances, including cord safety.

General Information

Model Number Identification

Lists the various ice machine models covered by this manual.

Understanding Model Numbers

Model Number Structure Explained

Breaks down the components of an ice machine model number for interpretation.

Ice Machine Warranty Information

Warranty Registration Importance

Stresses the need to complete and mail the warranty registration card promptly.

Commercial Warranty Coverage Details

Outlines warranty coverage for parts and labor under commercial use.

Warranty Exclusions and Service

Lists items not covered by warranty and requirements for authorized service.

Residential Warranty Coverage

Limited Warranty Terms

Details what the residential limited warranty covers, its duration, and consumer rights.

What the Limited Warranty Does Not Cover

Specifies exclusions from the limited warranty, including maintenance and misuse.

Obtaining Warranty Service

Contact Information for Service

Provides contact details and website for obtaining warranty service and information.

Installation Guidelines

Ice Machine Location Requirements

Specifies the criteria for selecting an appropriate location for the ice machine.

Installation Clearances and Heat Load

Clearance Requirements Table

Recommended clearances for different sides of the ice machine for efficient operation.

Leveling the Ice Machine

Leveling Legs Installation

Instructions on how to install and adjust the leveling legs for proper machine placement.

Electrical Requirements

Voltage, Fuse, and Ampacity Details

Covers voltage variation, fuse/breaker needs, and total circuit ampacity.

Air-Cooled Electrical Specifications

Air-Cooled Model Electrical Data

Table detailing electrical specs like voltage, fuse, and amps for air-cooled models.

Water-Cooled Electrical Specifications

Water-Cooled Model Electrical Data

Table detailing electrical specs like voltage, fuse, and amps for water-cooled models.

Water Service and Inlet Lines

Water Supply Considerations

Advice on water treatment and connecting to a potable water source.

Drain Connections and Cooling Tower Use

Drain Line Installation Guidelines

Rules for installing drain lines to prevent backflow and ensure proper drainage.

Maintenance Section

Interior Cleaning and Sanitizing

General procedure for cleaning and sanitizing the ice machine interior.

Touch Pad Operation for Cleaning

Cleaning Cycle Control Steps

Steps for initiating, pausing, and stopping the cleaning cycle via the touch pad.

Cleaning Cycle Steps 3 and 4

Cleaner Amounts Per Model

Details cleaner amounts required for different models during the cleaning cycle.

Mixing and Using Cleaning Solution

Cleaning Solution Mixing and Component Cleaning

Instructions for mixing cleaning solution and cleaning internal components.

Mixing and Using Sanitizer Solution

Sanitizer Solution Mixing and Surface Sanitization

Instructions for mixing sanitizer solution and sanitizing internal surfaces.

Component Removal for Cleaning

Float Switch Removal Procedure

Steps for removing float switches, including safety precautions.

Water Trough Removal Steps

Removing the Water Trough

Instructions for removing the water trough by unscrewing.

Ice Damper and Bin Switch Cover Removal

Removing Ice Damper and Bin Switch Cover

Steps for removing the ice damper and bin switch cover.

Water Distribution Tube Removal

Removing the Water Distribution Tube

Instructions on how to loosen and remove the water distribution tube.

Preventative Maintenance Cleaning

Preventative Cleaning Steps

Procedure for performing preventative maintenance cleaning, including cleaner amounts.

Ice Machine Inspection and Exterior Cleaning

Inspection Points and Airflow

Key inspection points like leaks, tubing, and airflow requirements.

Condenser Cleaning Procedures

Condenser Cleaning Importance and Safety

Explains why condenser cleaning is vital and outlines safety measures.

Ice Machine Removal and Winterization

Winterization Procedure Steps

Detailed steps for preparing the ice machine for removal or winter storage.

Bin Removal Procedure

Bin Reinstallation Seal Note

Important note regarding the bin seal during reinstallation.

Ice Machine Operation

Touch Pad Features Overview

Describes the functions of each touch pad button and indicator lights.

Delay Mode Operation and Control

Clean Cycle Operation and Control

Details how to start, pause, abort, and stop the cleaning cycle.

Bin Full and Service Indicators

Indicator Light Functions

Explains the function of the bin full and service indicator lights.

Ice Making Sequence of Operation

Ice Making Cycle Phases

Describes the water purge, freeze, harvest, and full bin cycles.

Control Board Timers

Timer Functions and Freeze Lock-ins

Explains freeze time lock-in, maximum cycle times, and water fill valve operation.

Safety Limit Functions Explained

Safety Limit 1 and 2 Conditions

Details conditions for Safety Limits 1 and 2 based on cycle times.

Safety Limit 3 Conditions

Details conditions for Safety Limit 3 related to freeze time and water sensing.

Energized Parts Chart

Ice Making Sequence Component States

Table showing energized components during the ice making sequence.

Operational Checks

Ice Thickness Check and Adjustment

How to check and adjust ice cube thickness settings.

Troubleshooting Overview

Control Board Test Mode Procedure

Procedure for using the control board test mode for diagnostics.

Operating Without Bin/Touch Pad

How to operate the machine for diagnostics when the bin and touch pad are removed.

Diagnosing Machine Startup Issues

Troubleshooting Guide for Non-Operation

Step-by-step guide to diagnose why the ice machine is not running.

Troubleshooting Harvest Cycle Entry

Failure to Cycle Into Harvest

Diagnosing issues when the machine fails to enter the harvest cycle due to float switch problems.

Troubleshooting Harvest Cycle Timing

Premature Harvest Cycle Entry

Diagnosing issues when the machine enters harvest cycle before ice is released.

Ice Production Check Procedure

Calculating Actual Ice Production

Method for checking actual ice production against published data.

Installation and Visual Inspection Checklist

Key Installation and Visual Checks

Checklist for critical installation and visual inspection points.

Water System Troubleshooting Checklist

Common Water System Issues

Checklist for diagnosing water-related problems affecting ice production.

Ice Formation Pattern Analysis

Normal Ice Formation Characteristics

Describes typical ice formation patterns on the evaporator surface.

Abnormal Ice Formation Patterns and Causes

Details abnormal patterns and their potential causes.

Safety Limit Functions Explained

Safety Limit 1 and 2 Indicators

Details conditions for Safety Limits 1 and 2 based on cycle times.

Determining Safety Limit Activation

Interpreting Safety Limit Lights on Control Board

How to identify which safety limit has been activated using control board lights.

Safety Limit #1 Troubleshooting Checklist

Causes for Safety Limit 1 Activation

Lists potential causes for Safety Limit 1, covering installation, water, electrical, and refrigeration systems.

Safety Limit #2 Troubleshooting Checklist

Causes for Safety Limit 2 Activation

Lists potential causes for Safety Limit 2, covering installation, water, electrical, and refrigeration systems.

Safety Limit #3 Troubleshooting Checklist

Causes for Safety Limit 3 Activation

Lists potential causes for Safety Limit 3, focusing on water system and electrical issues.

Analyzing Discharge Pressure

Discharge Pressure Measurement Procedure

Procedure for measuring and comparing discharge pressure to normal operating ranges.

Discharge Pressure Troubleshooting

High Discharge Pressure Causes Checklist

Lists potential causes for high discharge pressure, including installation and refrigerant issues.

Analyzing Suction Pressure

Suction Pressure Measurement Guide

Guide for analyzing suction pressure, emphasizing comparison with discharge pressure.

Suction Pressure Analysis Procedure

Suction Pressure Comparison Chart

Details how to compare actual suction pressure readings with published data.

Suction Pressure High Troubleshooting

Causes for High Suction Pressure Checklist

Lists potential causes for high suction pressure, including installation, discharge pressure, and refrigerant issues.

Suction Pressure Low Troubleshooting

Causes for Low Suction Pressure Checklist

Lists potential causes for low suction pressure, including installation, discharge pressure, and refrigerant issues.

Harvest Valve Functionality

Normal Harvest Valve Operation Explained

Explains the role and operation of the harvest valve during freeze and harvest cycles.

Harvest Valve Failure Analysis

Valve Failure Modes

Describes symptoms of harvest valve failing to open or remaining open.

Harvest Valve Temperature Test Procedure

Procedure for testing harvest valve operation using temperature comparison.

Evaporator Inlet/Outlet Temperature Comparison

Temperature Difference Analysis Method

How to measure and analyze evaporator inlet/outlet temperature differences for diagnostics.

Discharge Line Temperature Analysis

Discharge Line Temperature Monitoring Procedure

Procedure for measuring compressor discharge line temperature and its significance.

Interpreting Discharge Line Temperatures

Explains the meaning of high and low discharge line temperatures at the end of the freeze cycle.

Refrigeration Component Diagnostics Introduction

Diagnostic Procedure Overview

Introduction to diagnostic tables, emphasizing prior correction of electrical/water issues.

Refrigeration Diagnostic Procedure Steps

Step 1: Completing Operational Analysis

Instructions for completing the operational analysis column with check marks.

Step 2: Totaling Analysis and Finalizing

How to sum check marks and proceed to the final analysis.

Final Analysis of Refrigeration Problems

Column 1: Harvest Valve Leaking Diagnosis

Diagnosis and solution for a leaking harvest valve.

Column 2: Low Charge/TXV Starving Diagnosis

Diagnosis and solution for low charge or TXV starving issues.

Column 3: TXV Flooding Diagnosis

Diagnosis and solution for TXV flooding issues.

Column 4: Compressor Issues Diagnosis

Diagnosis and solution for compressor problems, including warranty credit procedures.

Refrigeration Component Diagnostic Charts

Chart 1: Ice Production and Pattern Analysis

Chart correlating ice production and formation patterns with diagnostic columns.

Chart 2: Pressure Readings Analysis

Chart correlating pressure readings with diagnostic columns.

Component Check Procedures

Main Fuse Check Procedure

Procedure for checking the main fuse using an ohmmeter and safety precautions.

Bin Switch Function and Testing

Bin Switch Operation and Control

Explains the functions of the bin switch and its control over ice making.

Bin Switch Ohm Test Procedure

Procedure for testing the bin switch continuity using an ohmmeter.

Touch Pad Operation and Testing

Touch Pad Functionality Checks

Steps to verify normal operation of the touch pad buttons.

Touch Pad Ohm Test Procedure

Procedure for testing touch pad circuits using an ohmmeter and connector pinout.

Float Switch Diagnostics

Float Switch Functions and Specifications

Explains the purpose and operation of the harvest and ice thickness float switches.

Float Switch Testing and Adjustment

Steps for checking float switch operation and making adjustments.

Compressor Electrical Diagnostics

Compressor Resistance and Overload Checks

Procedure for checking compressor winding resistance and overload status.

Compressor Locked Rotor and High Amps Diagnosis

Diagnosing causes of compressor locked rotor or high amperage draw.

Fan Cycle Control Testing

Fan Cycle Control Function and Specifications

Explains the fan cycle control's role in regulating discharge pressure and its specifications.

High Pressure Cutout (HPCO) Control Testing

HPCO Control Function and Specifications

Describes the HPCO control's function to stop the machine on high pressure and its specifications.

Filter-Drier Information

Liquid Line Filter Drier Importance and Replacement

Explains the function and importance of the liquid line filter drier, including replacement requirements.

Refrigerant Recovery and Evacuation

Refrigerant Handling Definitions

Defines terms like Recover, Recycle, Reclaim, and New Product Specifications for refrigerants.

Refrigerant Re-Use Policy

Approved Refrigerant Usage Guidelines

Outlines Manitowoc's policy on using new, reclaimed, and recovered refrigerants.

Refrigerant Recovery and Recharging Procedures

Important Notes for Recovery and Recharging

Emphasizes avoiding contamination and replacing the liquid line drier.

Self-Contained Refrigerant Handling

Recovery, Evacuation, and Charging Steps

Detailed steps for recovering, evacuating, and charging refrigerant.

System Contamination Cleanup

Determining Contamination Severity

Methods for identifying and assessing refrigerant system contamination.

Contamination and Cleanup Chart

Chart mapping symptoms to required cleanup procedures.

Mild System Contamination Cleanup Procedure

Steps for Mild Contamination Cleanup

Detailed procedure for cleaning systems with mild contamination.

Severe System Contamination Cleanup Procedure

Steps for Severe Contamination Cleanup

Detailed procedure for cleaning systems with severe contamination.

Component Replacement Without Refrigerant Removal

Pinch-Off Tool Procedure for Controls

Steps for replacing controls using a pinch-off tool while retaining refrigerant.

Total System Refrigerant Charge

Refrigerant Charge Specifications by Model

Table listing refrigerant charge amounts for different ice machine models.

Performance Charts Introduction

Cycle Times and Ice Production Charts Overview

Introduction to charts used for verifying ice machine operation and performance.

U0140 Air-Cooled Performance Data

U0140 Air-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0140 air-cooled models.

U0140 Water-Cooled Performance Data

U0140 Water-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0140 water-cooled models.

U0190 Air-Cooled Performance Data

U0190 Air-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0190 air-cooled models.

U0240 Air-Cooled Performance Data

U0240 Air-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0240 air-cooled models.

U0240 Water-Cooled Performance Data

U0240 Water-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0240 water-cooled models.

U0310 Air-Cooled Performance Data

U0310 Air-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0310 air-cooled models.

U0310 Water-Cooled Performance Data

U0310 Water-Cooled Cycle Times and Pressures

Data on cycle times and pressures for U0310 water-cooled models.

Diagrams and Schematics

Wiring Diagrams Overview

Introduction to the electrical wiring diagrams included in the manual.

Wiring Diagram Symbol Legend

Explains the symbols used in the wiring diagrams.

All Models Wiring Diagram

Provides the main electrical wiring diagram applicable to all models.

Electronic Control Board Layout

Diagram showing the layout and connectors of the electronic control board.

U0140 Tubing Schematic

Diagram illustrating the tubing layout for the U0140 model.

U0190/U0240/U0310 Tubing Schematic

Diagram illustrating the tubing layout for U0190, U0240, and U0310 models.

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