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Manitowoc QD1392N User Manual

Manitowoc QD1392N
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 QD1392N Specifications

General IconGeneral
TypeModular Ice Maker
Ice TypeHalf Cube
Weight210 lbs
Condenser TypeAir-Cooled
Depth24 inches
Height30 inches
Voltage115/208-230V
Phase1
Hertz60 Hz
Ice StorageNot included
Water Connection3/8" FPT
Ice Production1392 lbs/24 hours
RefrigerantR404A

Summary

Manitowoc ICE MACHINES Q-Model Service Manual

Safety and Procedural Notices

Safety Notices

General guidance on paying close attention to safety notices and types of safety notices.

Procedural Notices

Guidance on reading procedural notices for helpful information during work.

Section 1 General Information

Model Numbers

Details the models covered by the service manual, including numbering conventions.

How to Read a Model Number

Explains the structure and meaning of ice machine model numbers.

Ice Cube Sizes

Illustrates and describes the different ice cube sizes produced by the machines.

Model/Serial Number Location

Specifies where to find the model and serial number decals on the equipment.

Warranty Coverage

Outlines the warranty terms for parts, labor, and general coverage.

Exclusions

Lists items and conditions not covered by the ice machine warranty.

Authorized Warranty Service

Specifies requirements for performing warranty repairs.

Section 2 Installation Instructions

General Installation Guidelines

Refers to a separate manual for complete installation guidelines.

Ice Machine Dimensions

Provides dimensional data for various Q-Series ice machine models.

Ice Storage Bin Dimensions

Details dimensions for S170, S400, S570, S320, S420 ice storage bins.

Remote Condenser Dimensions

Provides dimensional data for JC0495, JC0895, JC1095, JC1395, and JC1895 condensers.

Location of Ice Machine

Criteria for selecting an appropriate location for the ice machine.

Stacking Two Ice Machines on a Single Storage Bin

Instructions for stacking two ice machines using a required kit.

Ice Machine Heat of Rejection

Provides BTU/hr heat rejection data for sizing AC equipment and cooling towers.

Leveling the Ice Storage Bin

Procedure for correctly leveling the ice storage bin using adjustable legs.

Air-Cooled Baffle Installation

Steps to install the air baffle to prevent condenser air recirculation.

Electrical Service

Guidelines for voltage, fuses, circuit breakers, and minimum circuit ampacity.

Self-Contained Electrical Wiring Connections

Wiring diagrams for self-contained ice machines, detailing connections.

Remote Electrical Wiring Connections

Wiring diagrams for remote ice machines and condensers.

Water Supply and Drain Requirements

Guidelines for water supply, inlet lines, and drain connections.

Cooling Tower Applications

Considerations for water-cooled models using cooling towers.

WATER SUPPLY AND DRAIN LINE SIZING/CONNECTIONS

Details on water supply, drain lines, fittings, and tubing sizes.

Remote Condenser/Line Set Installation

Guidance on installing remote condensers and line sets, including refrigerant charge.

GUIDELINES FOR ROUTING LINE SETS

Recommendations for routing refrigerant lines for proper performance and service.

CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES

Procedure to calculate total line set distance considering rise, drop, and horizontal runs.

LENGTHENING OR REDUCING LINE SET LENGTHS

Instructions on modifying line set lengths while maintaining system integrity.

CONNECTING A LINE SET

Steps for properly connecting refrigerant line sets using quick connect fittings.

REMOTE RECEIVER SERVICE VALVE

Procedure for opening the receiver service valve before starting the ice machine.

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

Warranty and technical considerations for using non-Manitowoc condensers.

NON-MANITOWOC MULTI-CIRCUIT CONDENSER SIZING CHART

Specifications for sizing multi-circuit condensers, including volume and pressure ratings.

Installation Check List

A checklist to verify all installation steps have been completed correctly.

Additional Checks for Remote Models

Specific checks required for remote ice machine installations.

Section 3 Maintenance

Component Identification

Diagrams identifying key components of the ice machine.

Operational Checks

Procedures for checking machine operation, water level, and ice thickness.

ICE THICKNESS CHECK

Procedure to check and adjust ice thickness probe for correct ice bridge thickness.

HARVEST SEQUENCE WATER PURGE

Adjustment for harvest sequence water purge, used with special water systems.

Cleaning the Condenser

Instructions for cleaning air-cooled and water-cooled condensers.

WATER-COOLED CONDENSER AND WATER REGULATING VALVE

Symptoms and cleaning procedures for water-cooled condensers and regulating valves.

Interior Cleaning and Sanitizing

General procedures for cleaning and sanitizing the ice machine interior.

MANITOWOC’S PATENTED CLEANING OR SANITIZING TECHNOLOGY

Information on the machine's built-in cleaning and sanitizing cycle technology.

ALPHASAN

Explanation of AlphaSan's role in keeping plastic surfaces cleaner.

CLEANING PROCEDURE

Step-by-step guide for using ice machine cleaner to remove mineral deposits.

SANITIZING PROCEDURE

Step-by-step guide for using sanitizer to remove algae and slime.

AUTOMATIC CLEANING SYSTEM (AuCS®)

Details on the AuCS accessory for automatic cleaning and sanitizing cycles.

Manual Start Operation

Instructions for manually starting the automatic cleaning system.

REMOVAL OF PARTS FOR CLEANING/SANITIZING

Procedure for removing parts for thorough cleaning and sanitizing.

Water Dump Valve

Procedure for removing and cleaning the water dump valve.

Water Pump

Procedure for removing the water pump for cleaning or replacement.

Ice Thickness Probe

Procedure for removing and cleaning the ice thickness probe.

Water Level Probe

Procedure for removing and cleaning the water level probe.

Water Inlet Valve

Procedure for removing and cleaning the water inlet valve.

Water Distribution Tube

Procedure for removing and disassembling the water distribution tube for cleaning.

Water Curtain

Procedure for removing the water curtain.

Water Treatment/Filtration

Information on water treatment systems and filter replacement procedures.

Removal from Service/Winterization

Precautions and procedures for removing the ice machine from service or for winterization.

Section 4 Ice Machine Sequence of Operation

Self-Contained Air- and Water-Cooled

Details the operational sequence for self-contained air and water-cooled models.

Remote

Details the operational sequence for remote ice machine models.

Section 5 Water System Ice Making Sequence of Operation

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

Sequence for initial startup or restart after automatic shut-off.

FREEZE CYCLE

Describes the freeze cycle operation, including pre-chill and water flow.

WATER INLET VALVE SAFETY SHUT-OFF

Explains the safety feature limiting water inlet valve operation time.

HARVEST CYCLE

Describes the harvest cycle operation, including water purge and ice release.

AUTOMATIC SHUT-OFF

Explains the automatic shut-off condition when the storage bin is full.

Section 6 Electrical System

Energized Parts Charts

Charts showing energized parts during different ice making sequences.

Self-Contained Air- and Water-Cooled Models

Energized parts and sequence charts for self-contained models.

Remote Models

Energized parts and sequence charts for remote models.

Wiring Diagram Sequence of Operation

Explains the sequence of operation using wiring diagrams.

Self-Contained Models

Detailed wiring diagrams and sequences for self-contained models.

Refrigeration System Start-Up

Details the refrigeration system startup sequence for self-contained units.

Freeze Sequence

Describes the freeze sequence, including pre-chill for self-contained units.

Harvest Sequence

Details the harvest sequence, including water purge for self-contained units.

Automatic Shut-Off

Explains the automatic shut-off function for self-contained units.

Remote Models

Wiring diagrams and sequences for remote ice machine models.

Refrigeration System Start-Up

Details the refrigeration system startup sequence for remote units.

Freeze Sequence

Describes the freeze sequence, including pre-chill for remote units.

Harvest Sequence

Details the harvest sequence, including water purge for remote units.

Automatic Shut-Off

Explains the automatic shut-off function for remote units.

Wiring Diagrams

General introduction to wiring diagrams and their symbols.

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

Wiring diagram for specific self-contained models with terminal boards.

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

Wiring diagram for specific self-contained models without terminal boards.

Q320 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD

Wiring diagram for specific self-contained models without terminal boards.

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

Wiring diagram for specific self-contained models with terminal boards.

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

Wiring diagram for specific self-contained models without terminal boards.

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

Wiring diagram for specific self-contained 3-phase models with terminal boards.

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

Wiring diagram for specific self-contained 3-phase models without terminal boards.

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

Wiring diagram for specific self-contained models with terminal boards.

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

Wiring diagram for specific self-contained models without terminal boards.

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

Wiring diagram for specific self-contained 3-phase models with terminal boards.

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

Wiring diagram for specific self-contained 3-phase models without terminal boards.

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

Wiring diagram for specific remote models with terminal boards.

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

Wiring diagram for specific remote models without terminal boards.

Q800/Q1000 -REMOTE - 3 PHASE WITH TERMINAL BOARD

Wiring diagram for specific remote 3-phase models with terminal boards.

Q800/Q1000 -REMOTE - 3 PHASE WITHOUT TERMINAL BOARD

Wiring diagram for specific remote 3-phase models without terminal boards.

Q1300/Q1800 - REMOTE - 1 PHASE WITH TERMINAL BOARD

Wiring diagram for specific remote models with terminal boards.

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

Wiring diagram for specific remote models without terminal boards.

Q1300/Q1800 - REMOTE - 3 PHASE WITH TERMINAL BOARD

Wiring diagram for specific remote 3-phase models with terminal boards.

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

Wiring diagram for specific remote 3-phase models without terminal boards.

Component Specifications and Diagnostics

Specifications and diagnostic procedures for main fuse and bin switch.

MAIN FUSE

Function, specifications, and check procedure for the main fuse.

BIN SWITCH

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

Check Procedure

Procedure to check the bin switch operation and readings.

Water Curtain Removal Notes

Notes on water curtain removal and its effect on the control sequence.

COMPRESSOR ELECTRICAL DIAGNOSTICS

Procedures for diagnosing compressor electrical issues.

Check Resistance (Ohm) Values

Guide for checking compressor winding resistance values.

SINGLE PHASE COMPRESSORS

Procedure for checking resistance on single-phase compressors.

THREE PHASE COMPRESSORS

Procedure for checking resistance on three-phase compressors.

Check Motor Windings to Ground

Procedure to check compressor windings for ground faults.

Determine if the Compressor is Seized

Steps to diagnose a seized compressor.

COMPRESSOR DRAWING LOCKED ROTOR

Troubleshooting causes for a compressor drawing a locked rotor amperage.

COMPRESSOR DRAWING HIGH AMPS

Troubleshooting causes for a compressor drawing high amperage on start-up.

Diagnosing Capacitors

Guidance on diagnosing and testing compressor capacitors.

PTCR DIAGNOSTICS

Explanation of PTCR function and diagnostic procedures.

Compressor Start Sequence

Details the role of PTCRs in the compressor start sequence.

Q-Model Automatic Shut-Off and Restart

Explains the auto shut-off and restart mechanism related to PTCRs.

Troubleshooting PTCR’s

Common reasons why a PTCR might fail to start the compressor.

CHECKING THE PTCR

Procedure for visually inspecting and measuring PTCR resistance.

ICE/OFF/CLEAN TOGGLE SWITCH

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

CONTROL BOARD RELAYS

Details on control board relays and their functions.

ELECTRONIC CONTROL BOARD

Diagram and description of the electronic control board.

General Control Board Information

Overview of control board features, safety limits, and inputs.

Ice Thickness Probe (Harvest Initiation)

Explanation of how the ice thickness probe initiates harvest.

HOW THE PROBE WORKS

Details on the electronic sensing circuit and probe function.

HARVEST/SAFETY LIMIT LIGHT

Function of the harvest and safety limit indicator lights.

FREEZE TIME LOCK-IN FEATURE

Explanation of the freeze time lock-in feature to prevent short cycling.

MAXIMUM FREEZE TIME

Details the built-in safety limit for maximum freeze cycle time.

ICE THICKNESS CHECK

Procedure to check and adjust ice thickness for proper bridge formation.

Ice Thickness Probe Cleaning

Instructions for cleaning the ice thickness probe.

DIAGNOSING ICE THICKNESS CONTROL CIRCUITRY

Troubleshooting steps for ice thickness control circuit malfunctions.

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

Troubleshooting for premature harvest cycles before water contact.

Water Level Control Circuitry

Explanation of water level control circuitry and related components.

WATER LEVEL PROBE LIGHT

Monitoring the water level probe via the water level light.

FREEZE CYCLE CIRCUITRY

Details the water level control during the freeze cycle.

HARVEST CYCLE CIRCUITRY

Explains water level control during the harvest cycle water purge.

DIAGNOSING FREEZE CYCLE POTABLE WATER LEVEL CONTROL CIRCUITRY

Troubleshooting steps for water trough overfilling during freeze cycle.

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

Troubleshooting steps for no water flow into the sump trough during freeze cycle.

Diagnosing An Ice Machine That Will Not Run

Checklist to diagnose why an ice machine will not start.

Q0420/Q0450/Q0600/Q800/Q1000 - SELF CONTAINED - 1 PHASE WITH TERMINAL BOARD

Wiring diagram for specific self-contained models with terminal boards.

Section 7 Refrigeration System

Sequence of Operation

Overview of the ice making process for self-contained models.

SELF-CONTAINED AIR OR WATER -COOLED MODELS

Details the pre-chill and freeze cycle for self-contained models.

Self-Contained Harvest Cycle

Describes the harvest cycle for self-contained models.

REMOTE MODELS

Overview of the refrigeration cycle for remote models.

Remote Automatic Shut-Off

Explains the automatic shut-off mechanism for remote models.

Q1300/Q1600/Q1800 REFRIGERATION TUBING SCHEMATICS

Refrigeration tubing diagrams for Q1300/Q1600/Q1800 self-contained models.

Q1300/Q1600/Q1800 Remote Models

Refrigeration diagrams for Q1300/Q1600/Q1800 remote models.

Operational Analysis (Diagnostics)

General guidance on analyzing refrigeration system malfunctions.

BEFORE BEGINNING SERVICE

Questions to ask before starting service to aid in diagnosis.

ICE PRODUCTION CHECK

Procedure for checking ice production based on operating conditions.

INSTALLATION/VISUAL INSPECTION CHECKLIST

Checklist for common installation and visual inspection issues.

WATER SYSTEM CHECKLIST

Checklist for common water system problems affecting operation.

ICE FORMATION PATTERN

Analysis of evaporator ice formation patterns for diagnostic purposes.

Normal Ice Formation

Description of normal ice formation across the evaporator surface.

Extremely Thin at Evaporator Outlet

Describes ice formation that is very thin at the evaporator outlet.

Extremely Thin at Evaporator Inlet

Describes ice formation that is very thin at the evaporator inlet.

Spotty Ice Formation

Describes ice formation with small sections missing on the evaporator.

No Ice Formation

Describes a machine operating with no ice formation on the evaporator.

SAFETY LIMITS

Explanation of safety limit controls protecting major components.

Control Board with Black Microprocessor

Safety limit operation for control boards with black microprocessors.

Control Board with Orange Label

Safety limit operation for control boards with orange label microprocessors.

Safety Limit Indication

Procedures to determine which safety limit has stopped the ice machine.

Analyzing Why Safety Limits May Stop the Ice Machine

Analysis of external causes that may trigger safety limits to stop the machine.

Safety Limit #1

Details Safety Limit #1 related to freeze time exceeding 60 minutes.

Safety Limit #2

Details Safety Limit #2 related to harvest time exceeding 3.5 minutes.

ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE

Procedure to analyze discharge pressure during freeze or harvest cycles.

ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE

Procedure to analyze suction pressure drop during the freeze cycle.

Freeze Cycle Suction Pressure High Checklist

Checklist for diagnosing high suction pressure during the freeze cycle.

Freeze Cycle Suction Pressure Low Checklist

Checklist for diagnosing low suction pressure during the freeze cycle.

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

Procedure to compare evaporator inlet and outlet temperatures for diagnosis.

HARVEST VALVE TEMPERATURE CHECK

Procedure to check harvest valve temperature for leaks or issues.

DISCHARGE LINE TEMPERATURE ANALYSIS

Analysis of discharge line temperature for diagnostic purposes.

HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

Guide on how to use operational analysis tables for diagnosing refrigeration issues.

REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

Tables to help diagnose refrigeration problems by comparing operating conditions.

Q and J Model Dual Expansion Valve

Operational analysis table for Q and J Model Dual Expansion Valve machines.

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

Explanation of the HPR system used in remote ice machines.

HPR DIAGNOSTICS

Diagnostic steps for the Harvest Pressure Regulating (HPR) system.

HEADMASTER CONTROL VALVE

Operation and diagnosis of the Headmaster control valve in remote systems.

LOW ON CHARGE VERIFICATION

Procedure to verify if the ice machine is low on refrigerant charge.

FAN CYCLE CONTROL VS. HEADMASTER

Comparison of fan cycle control and headmaster functionality.

Pressure Control Specifications and Diagnostics

Specifications and diagnostics for fan cycle and HPCO controls.

Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts

Charts for cycle times, ice production, and operating pressures for various models.

FILTER-DRIERS

Information on Manitowoc filter-driers and their importance.

TOTAL SYSTEM REFRIGERANT CHARGES

Table listing system refrigerant charges for various ice machine models.

REFRIGERANT DEFINITIONS

Definitions for refrigerant recovery, recycle, and reclaim.

REFRIGERANT RE-USE POLICY

Manitowoc's policy on the approved use of new, reclaimed, and recovered refrigerants.

HFC REFRIGERANT QUESTIONS AND ANSWERS

Answers to common questions regarding HFC refrigerants and compressor oil.

HFC REFRIGERANT QUESTIONS AND ANSWERS

Further Q&A on HFC refrigerant servicing and charging procedures.

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