Manitowoc Ice S1800 service manual Section Refrigeration System

Page 91

Section 7

Refrigeration System

 

 

10.Follow the normal evacuation procedure, except replace the evacuation step with the following:

Important

Dry nitrogen is recommended for this procedure. This will prevent CFC release.

A.Pull vacuum to 1000 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi (35 kPa .35 bar).

B.Change the vacuum pump oil.

C.Pull vacuum to 500 microns. Break the vacuum with dry nitrogen and sweep the system. Pressurize to a minimum of 5 psi (35 kPa .35 bar).

D.Change the vacuum pump oil.

E.Pull vacuum to 500 microns. Run the vacuum pump for 1/2 hour on self-contained models, 1 hour on remotes.

NOTE: You may perform a standing vacuum test to make a preliminary leak check. You should use an electronic leak detector after system charging to be sure there is no leak.

11.Charge the system with the proper refrigerant to the nameplate charge.

12.Operate the ice machine for one hour. Then, check the pressure drop across the suction line filter-drier.

A.If the pressure drop is less than 1 psi (7 kPa,

.7 bar), the filter-drier should be adequate for complete cleanup.

B.If the pressure drop exceeds 1 psi (7 kPa, .7 bar), change the suction line filter-drier and the liquid line drier. Repeat until the pressure drop is acceptable.

13.Operate the ice machine for 48-72 hours. Then, remove the suction line drier and change the liquid line drier.

14.Follow normal evacuation procedures.

REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE

This procedure reduces repair time and cost. Use it when any of the following components require replacement, and the refrigeration system is operational and leak-free.

•Water regulating valve

•High pressure cut-out control

•High side service valve

•Low side service valve

Important

This is a required in-warranty repair procedure.

1.Disconnect power to the ice machine.

2.Follow all manufacturer’s instructions supplied with the pinch-off tool. Position the pinch-off tool around the tubing as far from the pressure control as feasible. (See the figure on next page.) Clamp down on the tubing until the pinch-off is complete.

!Warning

Do not unsolder a defective component. Cut it out of the system. Do not remove the pinch-off tool until the new component is securely in place.

3.Cut the tubing of the defective component with a small tubing cutter.

4.Solder the replacement component in place. Allow the solder joint to cool.

5.Remove the pinch-off tool.

6.Re-round the tubing. Position the flattened tubing in the proper hole in the pinch off tool. Tighten the wingnuts until the block is tight and the tubing is rounded. (See the drawing on next page.)

NOTE: The pressure controls will operate normally once the tubing is re-rounded. Tubing may not re-round 100%.

Part Number 80-1634-3

7-25

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Page 90 Page 92
Contents Service Manual Personal Injury Potential Read These Before ProceedingTable of Contents Section Maintenance Table of Contents Section Ice Machine OperationSection Before Calling For Service Section Refrigeration System Table of Contents Section Electrical SystemTable of Contents Self-Contained Water-Cooled How to Read a Model NumberModel Numbers Ice Cube SizesGeneral Information Section Accessories Model/Serial Number Location Section General Information Model/Serial Number LocationWarranty Coverage General Ice Machine DimensionsWidth, Depth, and Height Dimensions Electrical and AuCS DimensionsSeries Heat of Rejection Ice Machine Air Conditioning Installation Instructions Section Location of Ice MachineIce Machine Heat of Rejection S1800M Water-CooledElectrical Requirements Section Installation Instructions Electrical ServiceVoltage Minimum Circuit AmpacitySelf Contained ICE Machine 230/1/50 For United Kingdom OnlySelf Contained ICE Machine 115/1/60 or 208-230/1/60 Self Contained ICE Machine 208-230/3/60Drain Connections Cooling Tower ApplicationsWater Supply Water Inlet LinesCondenser Installation Instructions SectionTypical Water Supply Drain Installation Water Supply and Drain Line SIZING/CONNECTIONSSection Installation Instructions Installation Check List Potential Personal Injury Situation AuCS Automatic Cleaning SystemComponent Identification Section Ice Machine OperationInitial START-UP or START-UP After Automatic SHUT-OFF Ice Machine Operation Section Sequence Of OperationAutomatic SHUT-OFF 7. Automatic Shut-Off Safety TimersHarvest Sequence 5. Water Purge HarvestIce Thickness Check Ice Machine Operation Section Operational ChecksWater Level ICE Thickness CheckHarvest Sequence Water Purge Water Purge AdjustmentThis page Intentionally Left Blank Ice Machine Operation SectionAlphaSan→ Exterior CleaningIce Machine Inspection Water-Cooled Condenser Water Regulating ValveSachet Replacement Procedure Maintenance Section GuardianInstallation Sachet Replacement FrequencyStep Section Maintenance Interior Cleaning and SanitizingCleaning Procedure Model Amount of CleanerSanitizing Procedure Maintenance SectionSolution Type Water Mixed With Sanitizer Solution Type Water Mixed With Removal of Parts for CLEANING/SANITIZINGWater Curtain Removal Ice Thickness Probe Water CurtainIce Thickness Probe Removal Water Trough Water Distribution TubeWater Distribution Tube Removal Water Pump Water Level ProbeWater Pump Removal Water Dump Valve Dump Valve DisassemblyDrain Line Check Valve Evaporator Tray RemovalWater Inlet Valve Pry Open the Water Regulating Valve AUCS→ Accessory Maintenance Section Removal from Service/WinterizationSELF-CONTAINED WATER-COOLED ICE Machines Problem Possible Cause To Correct ChecklistSafety Limit Feature Before Calling For Service SectionSection Electrical System Energized Parts ChartsSELF-CONTAINED WATER-COOLED Models Self-Contained Water Purge SELF-CONTAINED ModelsInitial Start-Up or Start-Up After Automatic Shut-Off Water PurgeRefrigeration System START-UP Refrigeration System Start Up 5 Seconds Toggle SwitchSelf-Contained Refrigeration System Start-Up Self-Contained Pre-Chill Self-Contained Models Electrical System SectionFreeze Sequence PRE-CHILLFreeze Toggle Switch Bin Switch Control Board RelaysSelf-Contained Freeze Self-Contained Models Harvest Sequence Harvest Automatic SHUT-OFF Automatic Shut-OffSelf-Contained Automatic Shut-Off Wiring Diagram Legend Section Electrical System Wiring DiagramsControl Board S1800 SELF-CONTAINED 1 PhaseS1800 SELF-CONTAINED 3 Phase Main Fuse SpecificationsCheck Procedure BIN SwitchWater Curtain Removal Notes SymptomsDiagnostic Aids Continuity TestDetermine if the Compressor is Seized Compressor Electrical DiagnosticsCheck Resistance Ohm Values Check Motor Windings to GroundWhat is a PTCR? Ptcr DiagnosticsCompressor Start Sequence During Start-Up First .25 1.0 Seconds Troubleshooting PTCR’sWHY a Good Ptcr MAY Fail To Start the Compressor Model Automatic Shut-Off and RestartPart Number Checking the PtcrManitowoc Ptcr Model Manitowoc Cera-Mite RoomRelay Operation Check Diagnosing Start ComponentsCapacitor RelaySwitch Setting Terminals Ohm Reading ICE/OFF/CLEAN Toggle SwitchControl Board Electronic Control BoardInputs Safety LimitsHarvest Light Freeze Time LOCK-IN FeatureIce Thickness Probe Cleaning HOW the Probe WorksMonitoring of Harvest Light Correction Diagnosing ICE Thickness Control CircuitryFreeze Cycle Circuitry Water Inlet Valve Safety SHUT-OFFElectrical System Section Water Level Control Circuitry Water Level Probe LightDiagnosing Water Level Control Circuitry Problem Water Trough Overfilling During Freeze CycleWait until the freeze cycle starts On or OFF Step Check Self Contained 1 Phase with Terminal Board Freeze Cycle Refrigeration Sequence SELF-CONTAINED Water -COOLED ModelsRefrigeration System Section S1800 SELF-CONTAINED Tubing Schematic General Times are in minutes Before Beginning ServiceWeights are in pounds ICE Production CheckWater System Checklist INSTALLATION/VISUAL Inspection ChecklistPossible Problem Corrective Action Extremely Thin at Evaporator Outlet ICE Formation PatternNormal Ice Formation No Ice Formation Extremely Thin at Evaporator InletSafety Limit Indication Safety LimitsAnalyzing Why Safety Limits May Stop the Ice Machine Possible Cause Check/Correct Safety Limit NotesSection Refrigeration System Analyzing Discharge Pressure During Freeze or Harvest Cycle ProcedureFreeze Cycle Discharge Pressure High Checklist Freeze Cycle Discharge Pressure Low ChecklistAnalyzing Suction Pressure During Freeze Cycle Step Example Using SY1004A Model Ice MachineFreeze Cycle Suction Pressure Low Checklist Freeze Cycle Suction Pressure High ChecklistHarvest Valve Analysis Harvest Valve Temperature Check GeneralFindings Comments Discharge Line Temperature Analysis General Column 3 TXV Flooding Final AnalysisColumn 1 Harvest Valve Leaking Column 2 LOW CHARGE/TXV StarvingModels Dual Expansion Valve Ice Machine Model Number Refrigeration System Operational Analysis TablesHigh Pressure CUT-OUT Hpco Control Operating Pressures S1800 SeriesSelf-Contained Water-Cooled Cycle Times Hour Ice ProductionConnections SELF-CONTAINED RECOVERY/EVACUATIONCharging Connections Self-Contained Charging ProceduresDetermining Severity Of Contamination System Contamination CLEAN-UPSevere System Contamination Cleanup Procedure Mild System Contamination Cleanup ProcedureSection Refrigeration System 10. Using Pinch-Off Tool Drier End Part Model Connection Size Number FILTER-DRIERSSeries Version Charge S1800M Total System Refrigerant Charges48 oz Recycle RecoverNew Product Specifications Refrigerant DefinitionsReclaimed Refrigerant Recovered or Recycled RefrigerantRefrigerant RE-USE Policy New RefrigerantHFC Refrigerant Questions and Answers This page Intentionally Left Blank Page Attend a Manitowoc Factory Service School
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