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SY0604A
Manitowoc SY0604A User Manual
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T
echnician
’
s
Handbook
This manual is
upd
ated
as n
ew information and models
are released.
Visit our websi
te for the late
st manual.
www
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manitowocice.com
America’s #
1 Selling Ice
Machine
S Model
Ic
e Machines
Part Number 80-1479-3
7/10
Manito
woc
2
Table of Contents
Default Chapter
3
Safety Notices
3
Procedural Notices
3
Table of Contents
5
General Information
9
Model Numbers
9
How to Read a Model Number
10
Ice Cube Sizes
10
Model/Serial Number Location
11
Energy Efficient Ice Machine Serial Breaks
12
Ice Machine Warranty Information
13
Owner Warranty Registration Card
13
Commercial Warranty Coverage
14
Residential Ice Machine Warranty
16
Installation
21
Location of Ice Machine
21
Ice Machine Clearance Requirements
22
Procedure to Clean Heavily Scaled
23
Ice Machine Heat of Rejection
23
S420/S450
23
Remote Condenser Line Set Installation
24
Air Temperature Around the Condenser
24
Line Set Length
25
Line Set Rise/Drop
25
Calculating Remote Condenser Installation Distances
25
Calculated Line Set Distance
26
Maximum Line Set Distance Formula
27
Lengthening or Reducing Line Set Lengths
27
Connecting a Line Set
28
Component Identification
29
S Model Single Evaporator Models
29
S Model Quad Evaporator Models
30
Maintenance
31
General
31
Cleaning/Sanitizing Procedure
31
Heavily Scaled Cleaning Procedure
31
Cleaning / Sanitizing Procedure
32
Cleaning Procedure
32
Parts Removal for Cleaning/Sanitizing
34
Single Evaporator Ice Machines
34
Remove the Water Curtain
34
Remove the Ice Thickness Probe
34
Quad Evaporator Ice Machines
35
Remove the Water Trough Shield
35
Remove Splash Shields
35
Remove Ice Thickness Probe
35
Procedure to Clean Heavily Scaled Ice Machines
40
General
40
Cleaning Procedure
40
Parts Removal for Cleaning/Sanitizing
43
Ice Thickness Probe & Water Level Probe
52
Water Inlet Valve
53
Water Dump Valve
54
Drain Line Check Valve
56
Removal from Service/Winterization
57
Self-Contained Air-Cooled Ice Machines
57
Water-Cooled Ice Machines
58
Remote Ice Machines
58
Sequence of Operation
59
Self Contained Air or Water Cooled
59
Energized Control Board Lights
59
Refrigeration System Start-Up
59
Single & Quad Evaporator Models
59
Freeze
60
Freeze Sequence
60
Prechill
60
Harvest Sequence
61
Water Purge
61
Automatic Shut-Off
63
Safety Timers
64
Safety Limits
65
Safety Limit Stand-By Mode
66
After the 200Th Harvest Cycle Ends
67
Warm Water Rinse Cycle
67
Self Contained Air & Water-Cooled
68
Single Evaporator Model Energized Parts Chart
68
Initial Start-Up or Start-Up after Automatic Shut-Off
72
Remotes
72
Single Evaporator Models
72
Troubleshooting
81
Safety Limits
81
Quad Evaporator Machines Only
82
Analyzing Why a Safety Limit Stopped the Ice Machine
84
Safety Limit #1
85
Safety Limit #2
86
Safety Limit #3
87
Control Board Testing
88
Control Board Test Cycle
88
Troubleshooting by Symptom
89
Ice Machine Stops Running
89
Ice Machine Has a Long Freeze Cycle
89
Ice Machine Stops Running or Has a History of Shutting down
90
Symptom #1 Ice Machine will Not Run
90
Compressor Electrical Diagnostics
92
Check Resistance (Ohm) Values
92
Single Phase Compressors
92
Three Phase Compressors
92
Check Motor Windings to Ground
93
Compressor Drawing Locked Rotor
93
Compressor Drawing High Amps
93
Low Production, Long Freeze
94
Freeze Cycle
94
Symptom #2 - Freeze Cycle Refrigeration System Operational Analysis Tables
96
S Models Single Expansion Valve
97
Before Beginning Service
105
Freeze Cycle Refrigeration System Operational Analysis Table Procedures
105
Ice Production Check
106
Installation/Visual Inspection Checklist
108
Inadequate Clearances
108
Ice Machine Is Not Level
108
Condenser Is Dirty
108
Water System Checklist
109
Water Area (Evaporator) Is Dirty
109
Ice Formation Pattern
110
Normal Ice Formation
110
Extremely Thin at Evaporator Outlet
111
Extremely Thin at Evaporator Inlet
111
No Ice Formation
111
Analyzing Discharge Pressure in the Freeze Cycle
112
Freeze Cycle Discharge Pressure High Checklist
113
Improper Installation
113
Water Condenser
113
Freeze Cycle Discharge Pressurelow Checklist
114
Analyzing Suction Pressure
115
Suction Pressure High Checklist
116
Suction Pressure Low Checklist
117
Harvest Valve Analysis
120
Discharge Line Temperature Analysis
122
Procedure
122
Water Regulating Valve
123
Final Analysis
124
Harvest Valve Leaking
124
Low Charge/Txv Starving
124
Txv Flooding
125
Compressor
125
Harvest Problems
126
Normal Ice Cube
126
Melted out Ice Cube
126
Symptom #3 Ice will Not Harvest, Cubes Are Not Melted
127
Symptom #3 - Traditional Remotes Only
129
Will Not Harvest, Melted Cubes
131
Harvest Problems
90
Component Check Procedures
135
Electrical Components
135
Main Fuse
135
Ice/Off/Clean Toggle Switch
136
Bin Switch
137
Bin Switch Fails Open
138
Bin Switch Fails Closed
138
Continuity Test
138
Water Curtain/Ice Damper Removal Notes
139
Cleaning the Ice Thickness or Water Level Probe
140
Water Level Control Circuitry
141
Freeze Cycle Water Level Setting
141
Water Inlet Valve Safety Shut-Off
141
Freeze Cycle Circuitry
141
Diagnosing Water Level Control Circuitry
142
Water Trough Overfilling Continued
143
Ice Thickness Probe (Harvest Initiation)
146
Ice Probe Light
146
Freeze Time Lock-In Feature
146
Maximum Freeze Time
147
Ice Thickness Check
147
Ice Thickness Adjustment
147
Diagnosing Ice Thickness Control Circuitry
148
Ice Probe Light on
148
Ice Probe Light off
148
Harvest Cycle Circuitry
150
Harvest Assist Air Pump
151
Compressor Electrical Diagnostics
152
Diagnosing Start Components
154
Relay Operation Check
155
Ptcr
156
PTCR Operation Check
157
Refrigeration Components
158
High Pressure Cutout (Hpco) Control
158
Check Procedure
158
Fan Cycle Control
159
Problem (Freeze Cycle)
160
Valve Not Maintaining Discharge Pressure
160
Water Regulating Valve
160
Harvest Pressure Regulating (HPR) System
161
Remotes Only
161
Head Pressure Control Valve
164
Low Pressure Cutout (LPCO) Control
167
Specifications
167
Harvest Pressure Solenoid Valve
168
Refrigerant Recovery/Evacuation
169
Connections
169
Normal Self-Contained Model Procedures
169
Self-Contained Recovery/Evacuation
170
Self-Contained Charging Procedures
171
Charging Connections
171
Normal Remote Model Procedures
173
Remote Recovery/Evacuation
174
Remote Charging Procedures
176
System Contamination Clean-Up
178
Determining Severity of Contamination
178
Contamination Cleanup Chart
179
Cleanup Procedure
180
Mild System Contamination
180
Severe System Contamination
181
Replacing Pressure Controls Without Removing Refrigerant Charge
183
Using Pinch-Off Tool
184
Specifications
185
Main Fuse
185
Fan Cycle Control
185
High Pressure Cutout (HPCO) Control
185
Cut-In (Close) Cut-Out (Open)
185
(1723 Kpa ±.34) (1517 Kpa
185
(17.23 Bar ±.34) (15.17 Bar
185
275 Psig ±5
185
(1896 Kpa ±34) (1551 Kpa ±34)
185
(18.96 Bar±.34) (15.51 Bar
185
Filter-Driers
186
Total System Refrigerant Charge
187
Cycle Times/24-Hour Ice Production/Refrigerant Pressure Charts
191
24 Hour Ice Production
192
Cycle Times
192
Operating Pressures
192
S300 Series
192
Operating Pressures
193
S320 Series
196
S420 Series
198
S450 Series
202
S500 Series
206
S600 Series
215
S850 Series
218
S1000 Series
227
S1200 Series
236
S1400 Self-Contained Air-Cooled
242
S1400 Series
242
All Self-Contained Air-Cooled
253
S1600 Series
253
S1800 Series
256
S3300 Series
265
Wiring Diagrams
267
Wiring Diagram Legend
267
Self Contained - 1 Phase
268
Wiring Diagrams before Energy Efficient
268
Energystar Machines
268
Self Contained - 3 Phase
271
Remote - 1 Phase
272
Wiring Diagrams for Energy Efficient & Energystar Machines
279
Electronic Control Board
290
Single and Twin Evaporator
290
Single and Twin Evaporator with Test Button
291
Quad Evaporator Ice Machines
292
Refrigeration Tubing Schematics
293
Self-Contained Air- or
293
Water -Cooled Models
293
Remote Models
295
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Manitowoc SY0604A Specifications
General
Model
SY0604A
Weight
245 lbs
Ice Type
Cube
Condenser
Air Cooled
Voltage
115V
Dimensions (H x W x D)
24.5 in
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