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Manitowoc QY0284A User Manual

Manitowoc QY0284A
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 QY0284A Specifications

General IconGeneral
Ice TypeCube
Condenser TypeAir-Cooled
TypeUndercounter
Water Connection3/8" FPT
Power Supply115V/60Hz/1Ph

Summary

Safety Notices

Procedural Notices

General Information

Model Numbers

Covers the various models of Manitowoc ice machines discussed in the manual.

How to Read a Model Number

Provides a guide to understanding the components of a Manitowoc ice machine model number.

Ice Cube Sizes

Details the different sizes of ice cubes produced by the machines.

Installation Instructions

General

General guidance for installation, referring to a separate manual.

Ice Machine Dimensions

Provides dimensional data for specific ice machine models.

Remote Electrical Wiring Connections

Wiring diagrams for remote ice machine configurations.

Water Supply and Drain Requirements

Guidelines for water supply and drain connections.

CALCULATING REMOTE CONDENSER INSTALLATION DISTANCES

Procedure for calculating maximum line set distances based on rise, drop, and runs.

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

Specific considerations for using non-Manitowoc condensers with remote ice machines.

Installation Check List

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

Maintenance

Component Identification

Identifies key components of the ice machine using diagrams.

Operational Checks

Routine checks to ensure proper operation and identify potential issues.

ICE THICKNESS CHECK

Procedure for checking and adjusting ice thickness.

Cleaning the Condenser

Step-by-step instructions for cleaning the condenser.

Interior Cleaning and Sanitizing

Procedures for cleaning and sanitizing the inside of the ice machine.

CLEANING PROCEDURE

Step-by-step guide for cleaning the ice machine.

SANITIZING PROCEDURE

Step-by-step instructions for sanitizing the ice machine.

AUTOMATIC CLEANING SYSTEM (AuCS)

Information about the AuCS accessory for automated cleaning.

REMOVAL OF PARTS FOR CLEANING/SANITIZING

Instructions for safely removing components for cleaning.

Water Dump Valve

Instructions for removing and cleaning the water dump valve.

Ice Thickness Probe

Procedure for removing and cleaning the ice thickness probe.

Water Level Probe

Instructions for removing and cleaning the water level probe.

Water Inlet Valve

Procedure for cleaning the water inlet valve.

Water Distribution Tube

Instructions for removing and cleaning the water distribution tube.

Water Curtain

Instructions for removing and cleaning the water curtain.

Water Treatment/Filtration

Information on water treatment systems and filtration.

FILTER REPLACEMENT PROCEDURE

Step-by-step guide for replacing filter cartridges.

Removal from Service/Winterization

Instructions for preparing the ice machine for extended periods of non-use or cold temperatures.

Ice Machine Sequence of Operation

Self-Contained Air- and Water-Cooled

Details the operational steps for self-contained models.

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

Steps for initial start-up or restart after automatic shutdown.

FREEZE SEQUENCE

Explains the freeze cycle steps: Prechill and Freeze.

HARVEST SEQUENCE

Details the harvest sequence steps: Water Purge and Harvest.

AUTOMATIC SHUT-OFF

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

Remote

Operational steps for remote ice machine models.

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

Steps for initial start-up or restart after automatic shutdown for remote models.

FREEZE SEQUENCE

Explains the freeze cycle steps: Prechill and Freeze for remote models.

HARVEST SEQUENCE

Details the harvest sequence steps for remote models.

AUTOMATIC SHUT-OFF

Explains the automatic shut-off condition for remote models.

Water System Ice Making Sequence of Operation

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

Water system operations during initial start-up or after automatic shutdown.

FREEZE CYCLE

Describes water flow and fill valve actions during the freeze cycle.

WATER INLET VALVE SAFETY SHUT-OFF

The safety feature limiting water inlet valve operation.

HARVEST CYCLE

Water system actions during the harvest cycle.

AUTOMATIC SHUT-OFF

Water system behavior during automatic shut-off.

Electrical System

Energized Parts Charts

Charts showing which parts are energized during different operational sequences.

SELF-CONTAINED AIR- AND WATER-COOLED MODELS

Energized parts information specific to self-contained models.

REMOTE MODELS

Energized parts information specific to remote models.

Wiring Diagram Sequence of Operation

Explains wiring diagrams in relation to the operational sequence.

SELF-CONTAINED MODELS

Wiring diagrams and sequence for self-contained models.

1. WATER PURGE

Details the water purge phase of the start-up sequence.

2. REFRIGERATION SYSTEM START-UP

Describes the refrigeration system start-up sequence.

3. PRE-CHILL

Details the pre-chill phase of the freeze cycle.

4. FREEZE

Explains the freeze phase of the ice making cycle.

HARVEST SEQUENCE

Describes the water purge phase of the harvest cycle for self-contained models.

5. WATER PURGE

Details the water purge phase within the harvest sequence for self-contained models.

6. HARVEST

Explains the harvest phase of the ice making cycle.

7. AUTOMATIC SHUT-OFF

Describes the automatic shut-off sequence.

REMOTE MODELS

Wiring diagrams and sequences for remote models.

1. WATER PURGE

Details the water purge phase for remote models.

2. REFRIGERATION SYSTEM START-UP

Describes the refrigeration system start-up for remote models.

3. PRE-CHILL

Details the pre-chill phase for remote models.

4. FREEZE

Explains the freeze phase for remote models.

5. WATER PURGE

Details the water purge phase within the harvest sequence for remote models.

6. HARVEST

Explains the harvest phase for remote models.

7. AUTOMATIC SHUT-OFF

Describes the automatic shut-off sequence for remote models.

Wiring Diagrams

Introduces the wiring diagrams section and their importance.

WIRING DIAGRAM LEGEND

Explains the symbols and notations used in the wiring diagrams.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

Q320 - SELF CONTAINED - 1 PHASE WITHOUT TERMINAL BOARD

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific self-contained models.

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

Wiring diagram for specific remote models.

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

Wiring diagram for specific remote models.

Q800/Q1000 -REMOTE - 3 PHASE WITH TERMINAL BOARD

Wiring diagram for specific remote models.

Q800/Q1000 -REMOTE - 3 PHASE WITHOUT TERMINAL BOARD

Wiring diagram for specific remote models.

Q1300/Q1800 - REMOTE - 1 PHASE WITH TERMINAL BOARD

Wiring diagram for specific remote models.

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

Wiring diagram for specific remote models.

Q1300/Q1800 - REMOTE - 3 PHASE WITH TERMINAL BOARD

Wiring diagram for specific remote models.

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

Wiring diagram for specific remote models.

Component Specifications and Diagnostics

Details specifications and diagnostic procedures for components.

MAIN FUSE

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

BIN SWITCH

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

Check Procedure

Steps to check the bin switch operation.

OHM Test

Procedure for testing the bin switch using an ohmmeter.

COMPRESSOR ELECTRICAL DIAGNOSTICS

Troubleshooting steps for compressor electrical issues.

Check Resistance (Ohm) Values

Procedures for checking 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 compressor windings for ground faults.

Determine if the Compressor is Seized

Steps to diagnose a seized compressor.

COMPRESSOR DRAWING HIGH AMPS

Troubleshooting for compressors drawing excessive start-up current.

Diagnosing Capacitors

Guidance on diagnosing potential capacitor failures.

PTCR DIAGNOSTICS

Explanation of PTCRs and their diagnostic procedures.

Compressor Start Sequence

Details the sequence of events during compressor start-up.

Q-Model Automatic Shut-Off and Restart

How automatic shut-off and restart procedures relate to PTCR cooling.

Troubleshooting PTCR’s

Common reasons why PTCRs 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 testing of the toggle switch.

CONTROL BOARD RELAYS

Details on the control board relays and their functions.

ELECTRONIC CONTROL BOARD

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

General

General information about the Q-Model control boards.

Safety Limits

Details on built-in safety limits protecting major components.

Inputs

Explanation of how inputs affect control board operation.

Ice Thickness Probe (Harvest Initiation)

How the ice thickness probe functions and initiates harvest.

HOW THE PROBE WORKS

Explanation of the electronic sensing circuit of the ice thickness probe.

HARVEST/SAFETY LIMIT LIGHT

Function of the harvest/safety limit indicator light.

FREEZE TIME LOCK-IN FEATURE

Explanation of the freeze time lock-in feature.

MAXIMUM FREEZE TIME

Describes the built-in safety for maximum freeze time.

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

Troubleshooting steps when the ice machine doesn't cycle into harvest.

Water Level Control Circuitry

Details how the water level control system functions.

WATER LEVEL PROBE LIGHT

Monitoring the water level using the indicator light.

Freeze Cycle Water Level Setting

How the water level is maintained during the freeze cycle.

WATER INLET VALVE SAFETY SHUT-OFF

The safety feature limiting water inlet valve operation.

FREEZE CYCLE CIRCUITRY

Explanation of water flow and valve actions during the freeze cycle.

HARVEST CYCLE CIRCUITRY

Water inlet valve actions during the harvest cycle water purge.

DIAGNOSING FREEZE CYCLE POTABLE WATER LEVEL CONTROL CIRCUITRY

Troubleshooting steps for water trough overfilling.

Problem: Water Trough Overfilling During The Freeze Cycle

Identifies the problem of water trough overfilling.

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

Continues troubleshooting water trough overfilling.

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

Troubleshooting when the sump trough does not receive water.

Diagnosing An Ice Machine That Will Not Run

A step-by-step guide to troubleshoot machines that fail to start.

Refrigeration System

Sequence of Operation

Describes the operational steps of the refrigeration system.

SELF-CONTAINED AIR OR WATER -COOLED MODELS

Operational sequence for self-contained air and water-cooled models.

Prechill Refrigeration Sequence

Details the prechill phase of the refrigeration cycle.

Freeze Cycle Refrigeration Sequence

Explains the refrigeration process during the freeze cycle.

Harvest Cycle Refrigeration Sequence

Details the refrigeration process during the harvest cycle.

REMOTE MODELS

Operational sequence for remote ice machine refrigeration systems.

Prechill Refrigeration Sequence

Prechill phase of the refrigeration cycle for remote models.

Freeze Cycle Refrigeration Sequence

Freeze phase of the refrigeration cycle for remote models.

Automatic Shut-Off

The automatic shut-off process and refrigerant migration protection.

Q1300/Q1600/Q1800 REFRIGERATION TUBING SCHEMATICS

Diagrams showing the refrigerant tubing layout for specific models.

Figure 7-7. Q1300/Q1600/Q1800 Remote Models

Illustration of refrigerant tubing for remote models.

Operational Analysis (Diagnostics)

General guidance for analyzing refrigeration system malfunctions.

BEFORE BEGINNING SERVICE

Questions to ask and information to gather before starting service.

ICE PRODUCTION CHECK

How to check ice production and the factors affecting it.

INSTALLATION/VISUAL INSPECTION CHECKLIST

Checklist for verifying proper installation and visual inspection.

WATER SYSTEM CHECKLIST

Checklist to identify and resolve water system related problems.

ICE FORMATION PATTERN

Using ice formation patterns to diagnose machine malfunctions.

SAFETY LIMITS

Details built-in safety limits protecting the ice machine.

Safety Limit #1: If the freeze time reaches 60 minutes...

Describes Safety Limit #1 related to freeze time.

Safety Limit #2: If the harvest time reaches 3.5 minutes...

Describes Safety Limit #2 related to harvest time.

Safety Limit Indication

How safety limits are indicated via lights on the control board.

Analyzing Why Safety Limits May Stop the Ice Machine

Explains common external causes for safety limit trips.

Safety Limit #1

Possible causes and checks for safety limit #1 related to freeze time.

Safety Limit #2

Possible causes and checks for safety limit #2 related to harvest time.

ANALYZING DISCHARGE PRESSURE DURING FREEZE OR HARVEST CYCLE

Steps to measure and analyze discharge pressure.

Freeze Cycle Discharge Pressure High Checklist

Checklist for diagnosing high discharge pressure during freeze cycle.

Freeze Cycle Discharge Pressure Low Checklist

Checklist for diagnosing low discharge pressure during freeze cycle.

ANALYZING SUCTION PRESSURE DURING FREEZE CYCLE

Steps to measure and analyze suction pressure during freeze cycle.

Freeze Cycle Suction Pressure High Checklist

Checklist for diagnosing high suction pressure during freeze cycle.

Freeze Cycle Suction Pressure Low Checklist

Checklist for diagnosing low suction pressure during freeze cycle.

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

Procedure for comparing evaporator temperatures for diagnostics.

HARVEST VALVE TEMPERATURE CHECK

Procedure to check harvest valve temperature for diagnostics.

Harvest Valve Analysis

Methods to diagnose harvest valve issues.

DISCHARGE LINE TEMPERATURE ANALYSIS

Analyzing discharge line temperature for diagnostic purposes.

HOW TO USE THE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

Instructions for utilizing the operational analysis tables for diagnosis.

Final Analysis

How to interpret the results and identify the problem.

REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

Tables correlating operating conditions with potential problems.

Q and J Model Dual Expansion Valve

Analysis tables specific to dual expansion valve models.

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

Explanation of the H.P.R. system for remote ice machines.

HPR DIAGNOSTICS

Steps for diagnosing issues with the HPR system.

HEADMASTER CONTROL VALVE

Information on the headmaster control valve for remote systems.

Diagnosing

Steps to diagnose issues with the headmaster control valve.

LOW ON CHARGE VERIFICATION

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

FAN CYCLE CONTROL VS. HEADMASTER

Explains the difference and interaction between fan cycle controls and headmasters.

Pressure Control Specifications and Diagnostics

Specifications and diagnostic procedures for pressure controls.

FAN CYCLE CONTROL

Function, specifications, and testing of the fan cycle control.

HIGH PRESSURE CUT-OUT (HPCO) CONTROL

Function, specifications, and testing of the HPCO control.

Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts

Charts detailing cycle times, ice production, and pressures for Q200 series.

Q200 SERIES Self-Contained Air-Cooled

Characteristics for Q200 series self-contained air-cooled models.

Cycle Times

Data on freeze and harvest cycle times.

24 Hour Ice Production

Data on 24-hour ice production.

Operating Pressures

Refrigerant pressure data under various conditions.

Q200 SERIES Self-Contained Water-Cooled

Characteristics for Q200 series self-contained water-cooled models.

Q280 SERIES Self-Contained Air-Cooled

Characteristics for Q280 series self-contained air-cooled models.

Q280 SERIES Self-Contained Water-Cooled

Characteristics for Q280 series self-contained water-cooled models.

Q320 SERIES Self-Contained Air-Cooled

Characteristics for Q320 series self-contained air-cooled models.

Q320 SERIES Self-Contained Water-Cooled

Characteristics for Q320 series self-contained water-cooled models.

Q370 SERIES Self-Contained Air-Cooled

Characteristics for Q370 series self-contained air-cooled models.

Q370 SERIES Self-Contained Water-Cooled

Characteristics for Q370 series self-contained water-cooled models.

Q420/450 SERIES Self-Contained Air-Cooled

Characteristics for Q420/450 series self-contained air-cooled models.

Q420/450 SERIES Self-Contained Water-Cooled

Characteristics for Q420/450 series self-contained water-cooled models.

Q450 SERIES Remote

Characteristics for Q450 series remote models.

Q600 SERIES Self-Contained Air-Cooled

Characteristics for Q600 series self-contained air-cooled models.

Q600 SERIES Self-Contained Water-Cooled

Characteristics for Q600 series self-contained water-cooled models.

Q600 SERIES Remote

Characteristics for Q600 series remote models.

Q800 SERIES Self-Contained Air-Cooled

Characteristics for Q800 series self-contained air-cooled models.

Q800 SERIES Self-Contained Water-Cooled

Characteristics for Q800 series self-contained water-cooled models.

Q1000 SERIES Self-Contained Water-Cooled

Characteristics for Q1000 series self-contained water-cooled models.

Q1000 SERIES Remote

Characteristics for Q1000 series remote models.

Q1300 SERIES Remote

Characteristics for Q1300 series remote models.

Q1600 SERIES Self-Contained Water-Cooled

Characteristics for Q1600 series self-contained water-cooled models.

Q1600 SERIES Self-Contained Air-Cooled

Characteristics for Q1600 series self-contained air-cooled models.

Q1600 SERIES Self-Contained Water-Cooled

Characteristics for Q1600 series self-contained water-cooled models.

Q1800 SERIES Remote

Characteristics for Q1800 series remote models.

Q1300 SERIES Self-Contained Air-Cooled

Characteristics for Q1300 series self-contained air-cooled models.

Q1300 SERIES Self-Contained Water-Cooled

Characteristics for Q1300 series self-contained water-cooled models.

Q1600 SERIES Remote

Characteristics for Q1600 series remote models.

Q1800 SERIES Self-Contained Air-Cooled

Characteristics for Q1800 series self-contained air-cooled models.

Q1800 SERIES Remote

Characteristics for Q1800 series remote models.

Refrigerant Recovery/Evacuation

Steps for recovering and evacuating refrigerant safely.

SELF-CONTAINED MODEL PROCEDURES

Procedures specific to self-contained models.

CONNECTIONS

Required connections for recovery/evacuation.

SELF-CONTAINED RECOVERY/EVACUATION

Detailed steps for recovering and evacuating refrigerant from self-contained units.

Self-Contained Charging Procedures

Step-by-step guide for charging self-contained ice machines.

NORMAL REMOTE MODEL PROCEDURES

Procedures specific to remote models.

Refrigerant Recovery/Evacuation

Steps for recovering and evacuating refrigerant from remote units.

CONNECTIONS

Required connections for remote system evacuation.

REMOTE RECOVERY/EVACUATION

Detailed steps for recovering and evacuating refrigerant from remote units.

Remote Charging Procedures

Step-by-step guide for charging remote ice machines.

SYSTEM CONTAMINATION CLEAN-UP

Basic requirements for restoring contaminated refrigeration systems.

Determining Severity Of Contamination

How to determine the severity of system contamination.

Contamination/Cleanup Chart

Chart correlating symptoms with required cleanup procedures.

Mild System Contamination Cleanup Procedure

Steps for cleaning systems with mild contamination.

Severe System Contamination Cleanup Procedure

Steps for cleaning systems with severe contamination.

REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE

Procedure to replace components without discharging the system.

FILTER-DRIERS

Details on the types and importance of filter-driers.

TOTAL SYSTEM REFRIGERANT CHARGES

Table listing refrigerant charge amounts for various models.

REFRIGERANT DEFINITIONS

Definitions of terms related to refrigerant handling.

Recover

Definition of refrigerant recovery.

Recycle

Definition of refrigerant recycling.

Reclaim

Definition of refrigerant reclamation.

New Product Specifications

Specification standard for new refrigerants.

REFRIGERANT RE-USE POLICY

Manitowoc's policy on refrigerant handling and re-use.

Manitowoc approves the use of:

Approved types of refrigerants for use.

HFC REFRIGERANT QUESTIONS AND ANSWERS

Answers to common questions about HFC refrigerants.

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

Information on special equipment for servicing HFC refrigerants.

8. Do I have to recover HFC refrigerants?

Explanation of HFC refrigerant recovery requirements.

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

Information on refrigerant separation in case of leaks.

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

Procedure for charging HFC refrigerant into the system.

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