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Manitowoc QD0452A User Manual

Manitowoc QD0452A
175 pages
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ICE MACHINES
Q
-Mode
l
Service Manual
Service Manual
Service Manual
C
2004 Manitowoc Ice, Inc.
80-1597-3
6/04

Table of Contents

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Manitowoc QD0452A Specifications

General IconGeneral
ModelQD0452A
Ice Production Capacity450 lbs
Ice TypeDice
Weight130 lbs
Daily Ice Production450 lbs
Condenser TypeAir-Cooled
Water Connection3/8" FPT
RefrigerantR404A
TypeUndercounter

Summary

Safety Notices

PERSONAL INJURY POTENTIAL

Warning about operating misused, abused, neglected, or altered equipment.

Warning

Alerts to potential personal injury situations. Read before proceeding.

Caution

Alerts to situations that could damage the ice machine. Read before proceeding.

Procedural Notices

Important

Provides useful information for performing procedures more efficiently.

Section 1 General Information

Model Numbers

Details on model identification, series, and air/water-cooled configurations.

How to Read a Model Number

Explains the format and meaning of model numbers for ice machines.

Ice Cube Sizes

Illustrates and describes the dimensions of regular, dice, and half-dice ice cubes.

Model/Serial Number Location

Warranty Coverage

GENERAL

Provides a general overview of warranty terms and contact information.

PARTS

Details warranty coverage for machine parts, including evaporator and compressor.

LABOR

Outlines warranty coverage for labor costs related to repairs.

EXCLUSIONS

Lists items and conditions not covered by the warranty.

AUTHORIZED WARRANTY SERVICE

Specifies requirements for authorized service providers for warranty repairs.

Section 2 Installation Instructions

General

Refers to a separate installation manual for detailed guidelines.

Ice Machine Dimensions

Provides physical dimensions for specific ice machine models.

Q200 – Q1000 ICE MACHINES

Q1300/Q1600/Q1800 ICE MACHINES

Q1300/Q1600/Q1800 ICE MACHINES (CONT.)

Ice Storage Bin Dimensions

S170/S400/S570 ICE STORAGE BINS

Details dimensions for S170, S400, and S570 ice storage bins.

S320/S420 ICE STORAGE BINS

Provides dimensions for S320 and S420 ice storage bins.

S970 ICE STORAGE BINS

Remote Condenser Dimensions

JC0495/JC0895/JC1095/JC1395

Details dimensions for JC0495, JC0895, JC1095, JC1395 remote condensers.

JC1895

Provides dimensions for the JC1895 remote condenser.

Location of Ice Machine

Stacking Two Ice Machines on a Single Storage Bin

Instructions for safely stacking two ice machines.

Ice Machine Heat of Rejection

Provides BTU/hr data for sizing AC systems and cooling towers.

Leveling the Ice Storage Bin

Air-Cooled Baffle

Instructions for installing the air baffle to prevent condenser air recirculation.

Electrical Service

GENERAL

General wiring guidelines and warnings.

VOLTAGE

Specifies acceptable voltage variations during operation.

FUSE/CIRCUIT BREAKER

Details requirements for fuses or circuit breakers.

MINIMUM CIRCUIT AMPACITY

Explains the purpose and determination of minimum circuit ampacity.

Self-Contained Electrical Wiring Connections

For United Kingdom Only

Specific wiring instructions for UK plugs and connections.

Remote Electrical Wiring Connections

Water Supply and Drain Requirements

WATER SUPPLY

Discusses water quality and treatment needs.

WATER INLET LINES

Guidelines for installing water inlet lines correctly.

DRAIN CONNECTIONS

Provides instructions for proper drain line installation.

Cooling Tower Applications

Information on using cooling towers with water-cooled models.

WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS

Remote Condenser/Line Set Installation

REMOTE ICE MACHINES REFRIGERANT CHARGE

Details on refrigerant charge requirements for remote models.

Air Temperature Around the Condenser

Specifies acceptable ambient temperature ranges for remote condensers.

GENERAL

GUIDELINES FOR ROUTING LINE SETS

Best practices for routing refrigerant lines for performance and access.

CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES

Line Set Length

Maximum allowable length for refrigerant line sets.

Line Set Rise/Drop

Maximum allowable vertical rise and drop for line sets.

Calculated Line Set Distance

Formula and process for calculating total allowable line set distance.

LENGTHENING OR REDUCING LINE SET LENGTHS

REMOTE RECEIVER SERVICE VALVE

Instructions for opening the receiver service valve before starting.

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

WARRANTY

Details warranty implications when using non-Manitowoc condensers.

HEAD PRESSURE CONTROL VALVE

Requirement for a specific head pressure control valve.

FAN MOTOR

Guidance on controlling the condenser fan motor.

INTERNAL CONDENSER VOLUME

Limits on internal condenser volume to prevent compressor failure.

CONDENSER ∆T

Explains condenser temperature difference (∆T) parameters.

REFRIGERANT CHARGE

Information on system refrigerant charge for remote models.

QUICK CONNECT FITTINGS

Notes on using quick connect fittings and initial charge.

NON-MANITOWOC MULTI-CIRCUIT CONDENSER SIZING CHART

Installation Check List

Additional Checks for Remote Models

Specific checks required for remote ice machine installations.

Section 3 Maintenance

Component Identification

Identifies key components of the ice machine with diagrams.

Operational Checks

GENERAL

General guidelines for performing operational checks.

WATER LEVEL

How to check and troubleshoot water level issues.

ICE THICKNESS CHECK

Procedure for checking and adjusting ice thickness.

HARVEST SEQUENCE WATER PURGE

Cleaning the Condenser

Instructions for cleaning the condenser to maintain performance.

AIR-COOLED CONDENSER

Specific steps for cleaning air-cooled condensers.

WATER-COOLED CONDENSER AND WATER REGULATING VALVE

Interior Cleaning and Sanitizing

GENERAL

General recommendations for cleaning and sanitizing.

MANITOWOC’S PATENTED CLEANING OR SANITIZING TECHNOLOGY

Details the automatic cleaning system features.

ALPHASAN®

Explains the AlphaSan® antimicrobial technology.

CLEANING PROCEDURE

SANITIZING PROCEDURE

AUTOMATIC CLEANING SYSTEM (AuCS®)

Automatic Operation

Describes how the AuCS operates automatically.

Manual Start Operation

Steps for manually starting the AuCS cleaning cycle.

REMOVAL OF PARTS FOR CLEANING/SANITIZING

Water Dump Valve

Water Pump

Ice Thickness Probe

Details on removing and cleaning the ice thickness probe.

Water Level Probe

Water Inlet Valve

Instructions for checking and cleaning the water inlet valve.

Water Distribution Tube

Water Curtain

Procedure for removing and cleaning the water curtain.

Water Treatment/Filtration

FILTER REPLACEMENT PROCEDURE

Step-by-step guide for replacing filter cartridges.

Removal from Service/Winterization

SELF-CONTAINED AIR-COOLED ICE MACHINES

Winterization steps for self-contained air-cooled models.

WATER-COOLED ICE MACHINES

Winterization steps for water-cooled models.

REMOTE ICE MACHINES

Winterization steps for remote ice machines.

AUCS® Accessory

Refers to accessory manual for AuCS winterization.

Section 4 Ice Machine Sequence of Operation

INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF

Describes the initial startup and restart process.

FREEZE SEQUENCE

Explains the steps involved in the freeze cycle.

HARVEST SEQUENCE

AUTOMATIC SHUT-OFF

Describes how the machine shuts off when the bin is full.

Remote Q450/Q600/Q800/Q1000/Q1300/Q1600/Q1800

INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF

Details startup process for remote models.

FREEZE SEQUENCE

Explains the freeze cycle for remote models.

HARVEST SEQUENCE

AUTOMATIC SHUT-OFF

Explains automatic shut-off for remote models.

Section 5 Water System Ice Making Sequence of Operation

Self-Contained and Remote Models

Notes that the sequence is the same for both model types.

INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF

Describes startup sequence involving water system components.

FREEZE CYCLE

Details water flow during the freeze cycle.

WATER INLET VALVE SAFETY SHUT-OFF

Explains the safety feature limiting water inlet valve operation time.

HARVEST CYCLE

Section 6 Electrical System

Energized Parts Charts

Tables showing energized components during different operational sequences.

SELF-CONTAINED AIR- AND WATER-COOLED MODELS

Energized parts for self-contained models.

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

Details energized parts during startup.

REMOTE MODELS

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

Energized parts during startup for remote models.

Wiring Diagram Sequence of Operation

SELF-CONTAINED MODELS

Wiring diagrams for self-contained models.

1. WATER PURGE

Describes wiring during the water purge phase.

2. REFRIGERATION SYSTEM START-UP

Freeze Sequence

3. PRE-CHILL

Electrical components active during the pre-chill phase.

4. FREEZE

Harvest Sequence

5. WATER PURGE

Details electrical states during water purge.

6. HARVEST

7. AUTOMATIC SHUT-OFF

REMOTE MODELS

Initial Start-Up Or Start-Up After Automatic Shut-Off

Startup sequence wiring for remote models.

1. WATER PURGE

Wiring during remote water purge.

2. REFRIGERATION SYSTEM START-UP

Freeze Sequence

3. PRE-CHILL

Electrical states during remote pre-chill.

4. FREEZE

Harvest Sequence

5. WATER PURGE

Electrical states during remote water purge.

6. HARVEST

7. AUTOMATIC SHUT-OFF

Wiring Diagrams

WIRING DIAGRAM LEGEND

Explains the symbols and conventions used in wiring diagrams.

Q200/Q280/Q320 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD

Q280/Q370 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD

Q320 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD

Q420/Q450/Q600/Q800/Q1000 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD

Q420/Q450/Q600/Q800/Q1000 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD

Q800/Q1000 - SELF CONTAINED - 3 PHASE WITH TERMINAL BOARD

Q800/Q1000 - SELF CONTAINED - 3 PHASE WITHOUT TERMINAL BOARD

Q1300/Q1800 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD

Q1300/Q1600/Q1800 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD

Q1300/Q1800 - SELF CONTAINED - 3 PHASE WITH TERMINAL BOARD

Q1300/Q1600/Q1800 - SELF CONTAINED - 3 PHASE WITHOUT TERMINAL BOARD

Q450/Q600/Q800/Q1000 - REMOTE - 1 PHASE WITH TERMINAL BOARD

Q450/Q600/Q800/Q1000 - REMOTE - 1 PHASE WITHOUT TERMINAL BOARD

Q800/Q1000 - REMOTE - 3 PHASE WITH TERMINAL BOARD

Q800/Q1000 - REMOTE - 3 PHASE WITHOUT TERMINAL BOARD

Q1300/Q1800 - REMOTE - 1 PHASE WITH TERMINAL BOARD

Q1300/Q1600/Q1800 - REMOTE - 1 PHASE WITHOUT TERMINAL BOARD

Q1300/Q1800 - REMOTE - 3 PHASE WITH TERMINAL BOARD

Q1300/Q1600/Q1800 - REMOTE - 3 PHASE WITHOUT TERMINAL BOARD

Component Specifications and Diagnostics

MAIN FUSE

Specifications and diagnostics for the main fuse.

BIN SWITCH

Function, specifications, and check procedure for the bin switch.

Check Procedure

OHM Test

Procedure for testing the bin switch with an ohmmeter.

Water Curtain Removal Notes

Notes on water curtain removal and its effect on operation.

COMPRESSOR ELECTRICAL DIAGNOSTICS

Check Resistance (Ohm) Values

Procedure to check compressor winding resistance.

SINGLE PHASE COMPRESSORS

Resistance checks specific to single-phase compressors.

THREE PHASE COMPRESSORS

Resistance checks specific to three-phase compressors.

Check Motor Windings to Ground

Procedure to check for grounded motor windings.

Determine if the Compressor is Seized

Steps to diagnose a seized compressor.

COMPRESSOR DRAWING HIGH AMPS

Troubleshooting high amperage draw on startup.

Diagnosing Capacitors

Guidance on diagnosing and testing start capacitors.

PTCR DIAGNOSTICS

What is a PTCR?

Explanation of a Positive Temperature Coefficient Resistor.

Compressor Start Sequence

How PTCRs contribute to the compressor start sequence.

Q-Model Automatic Shut-Off and Restart

Troubleshooting PTCR’s

Common issues and troubleshooting steps for PTCRs.

WHY A GOOD PTCR MAY FAIL TO START THE COMPRESSOR

Reasons why a PTCR might fail to start the compressor.

CHECKING THE PTCR

ICE/OFF/CLEAN TOGGLE SWITCH

CONTROL BOARD RELAYS

Lists the relays on the control board and their functions.

ELECTRONIC CONTROL BOARD

General

Safety Limits

Built-in safety features of the control board.

Inputs

Explains how inputs affect control board operation.

Ice Thickness Probe (Harvest Initiation)

HOW THE PROBE WORKS

Explains the operational principle of the ice thickness probe.

HARVEST/SAFETY LIMIT LIGHT

Function of the harvest/safety limit indicator light.

FREEZE TIME LOCK-IN FEATURE

How the system prevents short cycling.

MAXIMUM FREEZE TIME

Safety feature limiting freeze cycle duration.

ICE THICKNESS CHECK

Procedure for checking and adjusting ice thickness.

Ice Thickness Probe Cleaning

Steps for cleaning the ice thickness probe.

DIAGNOSING ICE THICKNESS CONTROL CIRCUITRY

Step 2 Jumper wire connected from probe to ground

Diagnostic step involving grounding the probe.

Step 3 Jumper wire connected from control board terminal 1C to ground

Diagnostic step involving grounding control board terminal 1C.

Ice Machine Cycles Into Harvest Before Water Contact With The Ice Thickness Probe

Step 2 Disconnect probe from control board terminal 1C

Diagnostic step to isolate the probe connection.

Water Level Control Circuitry

WATER LEVEL PROBE LIGHT

Monitoring water level via the indicator light.

FREEZE CYCLE CIRCUITRY

Electrical path for water level control during freeze.

HARVEST CYCLE CIRCUITRY

Water level control during harvest cycle.

DIAGNOSING FREEZE CYCLE POTABLE WATER LEVEL CONTROL CIRCUITRY

Step 2 Jumper wire connected from probe to ground

Diagnostic step for water level control.

Problem: Water Trough Overfilling During The Freeze Cycle (continued)

Problem: Water Will Not Run Into The Sump Trough During The Freeze Cycle

Step 2 Checking for normal operation

Diagnostic step to check normal operation.

Step 3 Disconnect water level probe from control board terminal 1F

Diagnostic step to isolate water level probe.

Diagnosing An Ice Machine That Will Not Run

Q0420/Q0450/Q0600/Q0800/Q1000 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD

Section 7 Refrigeration System

Sequence of Operation

Overview of how the refrigeration system operates.

SELF-CONTAINED AIR OR WATER -COOLED MODELS

Refrigeration sequence for self-contained models.

Prechill Refrigeration Sequence

Refrigerant flow during prechill.

Freeze Cycle Refrigeration Sequence

Refrigerant flow during freeze cycle.

Harvest Cycle Refrigeration Sequence

REMOTE MODELS

Prechill Refrigeration Sequence

Refrigerant flow during prechill for remote models.

Freeze Cycle Refrigeration Sequence

Refrigerant flow during freeze cycle for remote models.

Harvest Cycle Refrigeration Sequence

Automatic Shut-Off

Q1300/Q1600/Q1800 REFRIGERATION TUBING SCHEMATICS

Q1300/Q1600/Q1800 Remote Models

Operational Analysis (Diagnostics)

GENERAL

General advice on analyzing the refrigeration system.

BEFORE BEGINNING SERVICE

ICE PRODUCTION CHECK

Procedure to check ice production rates and compare to specifications.

INSTALLATION/VISUAL INSPECTION CHECKLIST

WATER SYSTEM CHECKLIST

Checklist for identifying and resolving water system issues.

ICE FORMATION PATTERN

1. Normal Ice Formation

Description of normal ice formation on the evaporator.

2. Extremely Thin at Evaporator Outlet

Identifies and describes thin ice formation at the evaporator outlet.

3. Extremely Thin at Evaporator Inlet

4. Spotty Ice Formation

5. No Ice Formation

SAFETY LIMITS

Safety Limit #1

Describes the freeze time safety limit.

Safety Limit #2

Describes the harvest time safety limit.

Safety Limit Indication

How to interpret safety limit indicators on the control board.

Analyzing Why Safety Limits May Stop the Ice Machine

Safety Limit #1

SAFETY LIMIT NOTES

General notes and tips for understanding safety limits.

Safety Limit #2

SAFETY LIMIT NOTES

General notes and tips for understanding safety limits.

ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE

Freeze Cycle Discharge Pressure High Checklist

Checklist for diagnosing high discharge pressure.

Freeze Cycle Discharge Pressure Low Checklist

Checklist for diagnosing low discharge pressure.

ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE

Freeze Cycle Suction Pressure High Checklist

Freeze Cycle Suction Pressure Low Checklist

Checklist for diagnosing low suction pressure.

SINGLE EXPANSION VALVE ICE MACHINES - COMPARING EVAPORATOR INLET AND OUTLET TEMPERATURES

HARVEST VALVE TEMPERATURE CHECK

General

General information about harvest valve function.

Harvest Valve Analysis

Procedure to diagnose harvest valve problems.

DISCHARGE LINE TEMPERATURE ANALYSIS

HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

General

General advice on using the analysis tables.

Procedure

Step-by-step guide for performing the analysis.

Final Analysis

Interpreting the analysis results to identify problems.

REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

Q and J Model Dual Expansion Valve

HARVEST PRESSURE REGULATING (H.P.R.) SYSTEM

Remotes Only

Notes that the HPR system is for remote models.

GENERAL

General description of the HPR system.

FREEZE CYCLE

HARVEST CYCLE

HPR DIAGNOSTICS

HEADMASTER CONTROL VALVE

Operation

How the Headmaster valve functions.

Diagnosing

Steps to diagnose Headmaster valve issues.

LOW ON CHARGE VERIFICATION

FAN CYCLE CONTROL VS. HEADMASTER

Compares fan cycle control and Headmaster functions.

Pressure Control Specifications and Diagnostics

FAN CYCLE CONTROL

Specifications and diagnostics for the fan cycle control.

HIGH PRESSURE CUT-OUT (HPCO) CONTROL

Specifications and diagnostics for the HPCO safety control.

Cycle Time/24 Hour Ice Production/ Refrigerant Pressure Charts

Q200 SERIES Self-Contained Air-Cooled

Performance data for Q200 air-cooled models.

Q200 SERIES Self-Contained Water-Cooled

Performance data for Q200 water-cooled models.

Q280 SERIES Self-Contained Air-Cooled

Q280 SERIES Self-Contained Water-Cooled

Q320 SERIES Self-Contained Air-Cooled

Q320 SERIES Self-Contained Water-Cooled

Q370 SERIES Self-Contained Air-Cooled

Q370 SERIES Self-Contained Water-Cooled

Q420/450 SERIES Self-Contained Air-Cooled

Q420/450 SERIES Self-Contained Water-Cooled

Q450 SERIES Remote

Q600 SERIES Self-Contained Air-Cooled

Q600 SERIES Self-Contained Water-Cooled

Q600 SERIES Remote

Q800 SERIES Self-Contained Air-Cooled

Q800 SERIES Self-Contained Water-Cooled

Q1000 SERIES Self-Contained Air-Cooled

Q1000 SERIES Remote

Q1300 SERIES Self-Contained Air-Cooled

Q1300 SERIES Self-Contained Water-Cooled

Q1600 SERIES Self-Contained Air-Cooled

Q1600 SERIES Self-Contained Water-Cooled

Q1800 SERIES Self-Contained Air-Cooled

Q1800 SERIES Self-Contained Water-Cooled

Q1300 SERIES Remote

Q1600 SERIES Remote

Q1800 SERIES Remote

Refrigerant Recovery/Evacuation and Recharging

NORMAL SELF-CONTAINED MODEL PROCEDURES

Procedures for recovery/evacuation on self-contained models.

Refrigerant Recovery/Evacuation

General steps for refrigerant recovery and evacuation.

CONNECTIONS

Required connections for recovery/evacuation.

Self-Contained Charging Procedures

NORMAL REMOTE MODEL PROCEDURES

Refrigerant Recovery/Evacuation

Steps for refrigerant recovery/evacuation on remote models.

CONNECTIONS

Required connections for remote system evacuation.

Remote Charging Procedures

SYSTEM CONTAMINATION CLEAN-UP

General

Basic requirements for restoring contaminated systems.

Determining Severity Of Contamination

How to assess the level of system contamination.

Mild System Contamination Cleanup Procedure

Severe System Contamination Cleanup Procedure

REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE

FILTER-DRIERS

TOTAL SYSTEM REFRIGERANT CHARGES

Table listing refrigerant charge amounts for various models.

REFRIGERANT DEFINITIONS

Recover

Definition of refrigerant recovery.

Recycle

Definition of refrigerant recycling.

Reclaim

Definition of refrigerant reclamation.

New Product Specifications

Defines standards for new refrigerant products.

REFRIGERANT RE-USE POLICY

Manitowoc approves the use of:

Lists approved refrigerant types.

1. New Refrigerant

Conditions for using new refrigerant.

2. Reclaimed Refrigerant

Conditions for using reclaimed refrigerant.

3. Recovered or Recycled Refrigerant

Conditions for using recovered/recycled refrigerant.

4. “Substitute” or “Alternative” Refrigerant

Conditions for using substitute refrigerants.

HFC REFRIGERANT QUESTIONS AND ANSWERS

1. What compressor oil does Manitowoc require for use with HFC refrigerants?

Specifies required compressor oil for HFC refrigerants.

2. What are some of the characteristics of POE oils?

Details properties of Polyol Ester oils.

3. What do these POE oil characteristics mean to me?

Explains the implications of POE oil characteristics for service.

7. Is other special equipment required to service HFC refrigerants?

8. Do I have to recover HFC refrigerants?

9. Will R-404A or R-134A separate if there is a leak in the system?

10. How do I charge a system with HFC refrigerant?

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