Manitowoc J250 Manuel utilisateur

J Model

Service

Manual

1997 Manitowoc Ice, Inc.

Part No. 83-5631-9

Rev A 8/97

Ice Machines

Safety Notices

As you work on a J-Series Ice Machine, be sure to

pay close attention to the safety notices in this

manual. Disregarding the notices may lead to serious

injury and/or damage to the ice machine.

Throughout this manual, you will see the following

types of safety notices:

WARNING

Text in a Warning box alerts you to a potential

personal injury situation. Be sure to read the

Warning statement before proceeding, and work

carefully.

CAUTION

Text in a Caution box alerts you to a situation in

which you could damage the ice machine. Be sure

to read the Caution statement before proceeding,

and work carefully.

Procedural Notices

As you work on a J-Series Ice Machine, be sure to

read the procedural notices in this manual. These

notices supply helpful information which may assist

you as you work.

Throughout this manual, you will see the following

types of procedural notices:

Important

Text in an Important box provides you with

information that may help you perform a procedure

more efficiently. Disregarding this information will

not cause damage or injury, but it may slow you

down as you work.

NOTE: Text set off as a Note provides you with

simple, but useful, extra information about the

procedure you are performing.

We reserve the right to make product improvements at any time.

Specifications and design are subject to change without notice.

Table of Contents

Section 1 - Warranty

Coverage..............................................................................................................................................................1-1

Section 2 - Installation References

(Refer to Installation Manual for complete Installation Guidelines)

Dimensions

Ice Machines...................................................................................................................................................2-1

Ice Storage Bins..............................................................................................................................................2-3

Remote Condensers........................................................................................................................................2-4

Location of Ice Machine ....................................................................................................................................2-5

Heat of Rejection................................................................................................................................................2-5

Electrical Fuse Size/Circuit Ampacity..............................................................................................................2-6

Electrical Wiring Connections

Self-Contained Electrical Connections ..........................................................................................................2-8

Remote Electrical Connections......................................................................................................................2-9

Water Connections and Drains.......................................................................................................................2-10

Cooling Tower Applications (Water-Cooled Models)...................................................................................2-11

Remote Condenser/Line Set Installation

Remote Ice Machines Refrigerant Charge....................................................................................................2-12

Routing Line Sets.........................................................................................................................................2-13

Calculating Remote Condenser Installation Distances ................................................................................2-14

Usage with Non-Manitowoc Multi-Circuit Condensers

Warranty.......................................................................................................................................................2-16

Line Set Routing and Sizing.........................................................................................................................2-16

Head Pressure Control Valve.......................................................................................................................2-16

Fan Motor.....................................................................................................................................................2-16

Internal Condenser Volume..........................................................................................................................2-17

Condenser ∆T...............................................................................................................................................2-17

Refrigerant Charge .......................................................................................................................................2-17

Quick-Connect Fittings................................................................................................................................2-17

Table of Contents (cont.)

Section 3 - Maintenance

Component Identification..................................................................................................................................3-1

Operational Checks

Water Level Check.........................................................................................................................................3-2

Ice Thickness Check.......................................................................................................................................3-2

Cleaning the Condenser

Air-Cooled Condenser (Self-Contained and Remote Models).......................................................................3-3

Water-Cooled Condenser and Water Regulating Valve.................................................................................3-4

Interior Cleaning and Sanitizing

General ...........................................................................................................................................................3-5

Cleaning Procedure ........................................................................................................................................3-5

Sanitizing Procedure ......................................................................................................................................3-6

Procedure to Cancel a Self-Cleaning or Sanitizing Cycle After It Has Started..............................................3-6

AuCSäAccessory .........................................................................................................................................3-7

Removal of Parts for Cleaning/Sanitizing......................................................................................................3-8

Water Treatment/Filtration ............................................................................................................................3-14

Removal from Service/Winterization

General .........................................................................................................................................................3-15

Self-Contained Air-Cooled Ice Machines....................................................................................................3-15

Water-Cooled Ice Machines.........................................................................................................................3-15

Remote Ice Machines...................................................................................................................................3-15

AuCSäAccessory .......................................................................................................................................3-15

Section 4 - Ice Machine Sequence of Operation

Self-Contained Air- and Water-Cooled............................................................................................................4-1

Remote.................................................................................................................................................................4-3

Section 5 - Water System Ice Making Sequence of Operation

Initial Start-Up or Start-Up After Automatic Shut-Off.................................................................................5-1

Freeze Cycle........................................................................................................................................................5-1

Harvest Cycle......................................................................................................................................................5-2

Automatic Shut-Off............................................................................................................................................5-2

iii

Table of Contents (cont.)

Section 6 - Electrical System

Energized Parts Charts

Self-Contained Air- and Water-Cooled Models.............................................................................................6-1

Remote Models ..............................................................................................................................................6-2

Wiring Diagram Sequence of Operation

Self-Contained Models...................................................................................................................................6-3

Remote Models ............................................................................................................................................6-10

Wiring Diagrams

Wiring Diagram Legend...............................................................................................................................6-17

Old Style Self-Contained - J200/J250/J320 - 1 Phase..................................................................................6-18

Old Style Self-Contained - J420/J450/J600/J800/J1000 - 1 Phase..............................................................6-19

Old Style Self-Contained - J800/J1000 - 3 Phase........................................................................................6-20

Old Style Self-Contained - J1300/J1800 - 1 Phase......................................................................................6-21

Old Style Self-Contained - J1300/J1800 - 3 Phase......................................................................................6-22

Old Style Remote - J450/J600/J800/J1000 - 1 Phase...................................................................................6-23

Old Style Remote - J800/J1000 - 3 Phase....................................................................................................6-24

Old Style Remote - J1300/J1800 - 1 Phase..................................................................................................6-25

Old Style Remote - J1300/J1800 - 3 Phase..................................................................................................6-26

New Style Self-Contained - J200/J250/J320 - 1 Phase................................................................................6-27

New Style Self-Contained - J420/J450/J600/J800/J1000 - 1 Phase.............................................................6-28

New Style Self-Contained - J800/J1000 - 3 Phase.......................................................................................6-29

New Style Self-Contained - J1300/J1800 - 1 Phase.....................................................................................6-30

New Style Self-Contained - J1300/J1800 - 3 Phase.....................................................................................6-31

New Style Remote - J450/J600/J800/J1000 - 1 Phase.................................................................................6-32

New Style Remote - J800/J1000 - 3 Phase ..................................................................................................6-33

New Style Remote - J1300/J1800 - 1 Phase ................................................................................................6-34

New Style Remote - J1300/J1800 - 3 Phase ................................................................................................6-35

Table of Contents (cont.)

Section 6 - Electrical System (cont.)

Component Specifications and Diagnostics

Fuses.............................................................................................................................................................6-36

Bin Switch....................................................................................................................................................6-36

Compressor Electrical Diagnostics ..............................................................................................................6-38

PTCR Diagnostics........................................................................................................................................6-39

Discharge Line Thermistor...........................................................................................................................6-43

Ice/Off/Clean Toggle Switch........................................................................................................................6-44

Control Board Relays...................................................................................................................................6-45

Electronic Control Board (Old Style)...........................................................................................................6-46

Electronic Control Board (New Style).........................................................................................................6-47

Ice Thickness Probe (Harvest Initiation)

General .........................................................................................................................................................6-50

How the Probe Works..................................................................................................................................6-50

Freeze Time Lock-In Feature.......................................................................................................................6-50

Maximum Freeze Time................................................................................................................................6-50

Installation of New Probe on Old Style Control Board................................................................................6-50

Diagnosing Probe Control Circuitry

Ice Machine Cycles Into Harvest Before Water Contact with Probe.....................................................6-51

Ice Machine Does Not Cycle Into Harvest When Water Contacts Probe ..............................................6-52

Diagnosing Ice Machine That Will Not Run..................................................................................................6-53

Table of Contents (cont.)

Section 7 - Refrigeration System

Sequence of Operation

Self-Contained Air- or Water-Cooled Models...............................................................................................7-1

Remote Models ..............................................................................................................................................7-3

J1300/J1800 Refrigeration Tubing Schematics..............................................................................................7-6

Operational Analysis (Diagnostics)

General ...........................................................................................................................................................7-8

Before Beginning Service...............................................................................................................................7-9

Ice Production Check .....................................................................................................................................7-9

Installation/Visual Inspection Checklist.......................................................................................................7-10

Water System Checklist ...............................................................................................................................7-10

Ice Formation Pattern...................................................................................................................................7-11

Safety Limits ................................................................................................................................................7-13

Hot Gas Valve Temperature Check..............................................................................................................7-17

Single Expansion Valve Ice Machines - Comparing Evaporator Inlet and Outlet Temperatures................7-18

Analyzing Discharge Pressure During Freeze or Harvest Cycle

Procedure................................................................................................................................................7-19

Freeze Cycle Discharge Pressure High Checklist ..................................................................................7-19

Freeze Cycle Discharge Pressure Low Checklist...................................................................................7-19

Analyzing Suction Pressure During Freeze Cycle

Procedure................................................................................................................................................7-20

Freeze Cycle Suction Pressure High Checklist......................................................................................7-21

Freeze Cycle Suction Pressure Low Checklist.......................................................................................7-21

How to Use the Refrigeration System Operational Analysis Tables............................................................7-22

Refrigeration System Operational Analysis Tables

Single TXV ............................................................................................................................................7-24

Dual TXV...............................................................................................................................................7-25

Remotes Only

Harvest Pressure Regulating (H.P.R.) System .......................................................................................7-26

Headmaster Control Valve.....................................................................................................................7-28

Table of Contents (cont.)

Section 7 - Refrigeration System (cont.)

Pressure Control Specifications and Diagnostics

Fan Cycle Control ........................................................................................................................................7-30

High Pressure Cutout (HPCO) Control........................................................................................................7-30

Cycle Time/24 Hour Ice Production/Refrigerant Pressure Charts

J200 ..............................................................................................................................................................7-31

J250 ..............................................................................................................................................................7-32

J320 ..............................................................................................................................................................7-33

J420/J450......................................................................................................................................................7-34

J600 ..............................................................................................................................................................7-35

J800 ..............................................................................................................................................................7-37

J1000 ............................................................................................................................................................7-38

J1300 ............................................................................................................................................................7-40

J1800 ............................................................................................................................................................7-41

Refrigerant Recovery/Evacuating and Recharging

Normal Self-Contained Model Procedures ..................................................................................................7-44

Normal Remote Model Procedures..............................................................................................................7-46

System Contamination Cleanup...................................................................................................................7-50

Replacing Pressure Controls Without Removing Refrigerant Charge.........................................................7-52

Filter-Driers..................................................................................................................................................7-54

Total System Refrigerant Charges................................................................................................................7-54

Refrigerant Definitions.................................................................................................................................7-55

Refrigerant Re-Use Policy............................................................................................................................7-56

HFC Refrigerant Questions and Answers....................................................................................................7-57

Section 1 Warranty

1-1

Section 1

Warranty

Coverage

GENERAL

The following Warranty outline is provided for your

convenience. For a detailed explanation, read the

warranty bond shipped with each product.

Contact your local Manitowoc representative or

Manitowoc Ice, Inc. if you need further warranty

information.

PARTS

1. Manitowoc warrants the ice machine against

defects in materials and workmanship, under

normal use and service for three (3) years from

the date of original installation.

2. The evaporator and compressor are covered by an

additional two (2) year (five years total) warranty

beginning on the date of the original installation.

LABOR

1. Labor required to repair or replace defective

components is covered for three (3) years from

the date of original installation.

2. The evaporator is covered by an additional two

(2) year (five years total) labor warranty

beginning on the date of the original installation.

EXCLUSIONS

The following items are not included in the ice

machine’s warranty coverage:

1. Normal maintenance, adjustments and cleaning as

outlined in the Owner/Operator Use and Care

Guide.

2. Repairs due to unauthorized modifications to the

ice machine or the use of non-standard parts

without prior written approval Manitowoc Ice,

Inc.

3. Damage caused by improper installation of the ice

machine, electrical supply, water supply or

drainage, or damage caused by floods, storms, or

other acts of God.

4. Premium labor rates due to holidays, overtime,

etc.; travel time; flat rate service call charges;

mileage and miscellaneous tools and material

charges not listed on the payment schedule.

Additional labor charges resulting from the

inaccessibility of the ice machine are also

excluded.

5. Parts or assemblies subjected to misuse, abuse,

neglect or accidents.

6. Damage or problems caused by installation,

cleaning and/or maintenance procedures

inconsistent with the technical instructions

provided in the Installation Manual and the

Owner/Operator Use and Care Guide.

AUTHORIZED WARRANTY SERVICE

To comply with the provisions of the warranty, a

refrigeration service company, qualified and

authorized by a Manitowoc distributor, or a

Contracted Service Representative must perform the

warranty repair.

Warranty Section 1

1-2

THIS PAGE INTENTIONALLY LEFT BLANK

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