Course ID #ICE2121. Script Notes: MKC ICE, Training Development. 1/10/2017wy

Transcription

1 Course ID #ICE2121 Script Notes: MKC ICE, Training Development 1/10/2017wy

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3 Table of Contents Lesson 1 Introduction Welcome 4 Navigation 4 Sample Spot Check 5 Equipment Overview 5 Parts ID 5 Lesson 2: Installation Check List Installation Check 5 Head Section 6 Electrical 6 Plumbing 7 Review 7 Lesson 3: Document Download Document Download 7 Lesson 4: Safety Safety 7 Electrical Safety Condensing Section 7 Electrical Safety Head Section 8 Refrigerant Safety 8 Review 8 Lesson 5: Operation Operation 8 Sequence of Operation Start up 9 Sequence of Operation Pre Chill Cycle 9 Sequence of Operation Freeze Cycle 9 Sequence of Operation Harvest 10 How the Harvest System Works 10 Cleaning the Exterior 11 Cleaning and Sanitizing 11 Interior Cleaning Process 11 Page 2 of 19

4 Interior Sanitizing 12 Cleaning the Condenser 12 Operational Check 12 Review 13 Lesson 6: Troubleshooting Troubleshooting 13 Troubleshooting Flow Chart 13 Using the Service Menu 14 Control Board Self Test 14 Display Diagnostics 14 Alerts 14 Energize Relays 15 Ice Thickness Probe Diagnostics 1 15 Ice Thickness Probe Diagnostics 2 15 Water Level Diagnostics 16 Bin Switch 16 Interactive Exercise I 16 Symptom #2 Low Production 16 Low Production 17 Interactive Exercise II 17 Symptom #3 Ice will not harvest 17 Symptom #4 Ice will not harvest II 18 Review 18 Lesson 7: Final Exam Conclusion 19 Final Exam Instructions 19 Page 3 of 19

5 Lesson 1: Introduction Welcome: Welcome to the Interactive Training Module on the Manitowoc Ice Beverage Series Model IB1094YC Ice Machine and icvd1195 Condensing Unit. In these lessons we ll cover how to inspect the equipment to see if has been properly installed. We ll go over how to safely service the equipment. You ll see the sequence of operation and how the units work together to make ice. We ll go over the routine Cleaning and Maintenance requirements. And finally we ll cover some equipment issues and how to troubleshoot them properly Before we go any farther, you ll need to know how to navigate these lessons. Click on the NEXT Arrow, shown here, to precede to the navigation instructions. Navigation: Let s talk briefly on how to navigate this module. These are self guided lessons. You will have control over how fast and where you want to go. There are three symbols across the bottom of the screen. Each is a navigational link that will move you from screen to screen. For example, when you re ready to proceed to the next screen, you ll click on the arrow pointing to the right, shown here. If you want to go back to the previous screen, simply click on the arrow pointing to the left, located here. And, if you want to start all over again, from the beginning of the module, you ll click on the home symbol, which is located here. There are also buttons that allow you to control the action happening on the screen. They are rewind, pause/play, and fast forward. A course is broken up into separate lessons and these are further broken down into more detailed segments. This structure is the navigation menu. It is the top panel located here. To open the navigation menu, click on the button in the bottom bar. When open, the navigation menu will tell you what lesson and main subject point you are currently viewing. You can use this menu to navigate through the content of the lesson. Some bars in the menu will be headers that contain grouped subject matter; these expand and contract when clicked on to show or hide the underlying content. Others will link directly to the specific course material, when clicked on. Notice the icons next to the topics; these are indicators of the topics status. These icons are five stage images that display whether; the topic is not loaded, the topic is loading, the topic is loaded, the topic has been viewed, and that the topic has been fully viewed. When you click on a topic, it will begin loading immediately. Depending on the course, your menu may have its own navigation. The icon, shown here, will collapse the main menu and show you the only main lesson titles. The other icons, shown here, allow you to move from lesson to lesson. You can click on either one and will be directed to the beginning of the next lesson in order. For you convenience we have added audio controls. The slider will increase or decrease the volume level from 100 percent to zero percent. By clicking on the audio icon you can instantly mute or unmute the volume level. For those who are hearing impaired or are in a situation where they cannot hear the audio; we have a narration panel. This panel is located behind the navigation menu and is a direct script of the audio for the current material. To view the narration, click on the Closed Caption icon located in the bottom bar. Long scripts will have a scroll bar allowing the user to scroll through the text. To close the narration panel, click on the menu you would like to view and the panels will swap. During interactive exercises you may be asked to use a tool found in the toolbox. The toolbox is a panel that lists and describes all available tools in a course. The toolbox is located underneath the navigation menu. To view the toolbox, click on the button in the bottom bar, and it will swap with whichever panel is currently open. The toolbox displays a thumbnail image and a short description of reach tool in the toolbox. When instructed to do so, you will be able to select the correct tool and use it to complete interactive exercise. Once a tool is selected, some tools will prompt you to select the proper attachment for the tool before the tool will appear on the screen. After a tool has been selected, you can use the tool to complete the task at hand. Tools like the multimeter will need to be set to the correct setting before they can be used to complete the exercise. Most tools become the cursor when they are active. To use the Page 4 of 19

6 tool, place the situation end over the test area and click the left mouse button. When the tool is used correctly the course material should continue playing. The course will then remove the tool from view. Sample Spot Check: At the end of each lesson there will be quizzes called spot checks. Here is an example to shows you how to navigate the spot check interface. In the title bar, you will see information and buttons that pertain to the quiz. The first block of information is the type of quiz that you are currently taking. The next block of information will tell you which question you are on as well as the total number of questions. The final block of information will display pertinent information about the question you are answering. This information can range from: Select the best answer, to whether you got the question correct. The end displays the relative button that pertains to the question. Some questions will have an interactive element that will assist you in answering the question. The question will be displayed on the screen. In this case: What is the boiling point of water at sea level? With your curser, select 212 F, then confirm your answer with the submit button. When you get it right you will see That is Correct in the title bar. If you get the answer wrong you ll see That is Incorrect. During the spot check, you will not be able to view the next question until you have answered the current one correctly. Click on the arrow in the lower right corner of your screen to advance to the next screen. Equipment Overview: The model IB1094YC Head Section is mounted on top of an Ice and beverage dispensing system to supply ice for beverages. The model icvd1195 Condensing Unit for this system is mounted remotely, typically on the roof and refrigerant lines with communication wiring are run between the 2 sections. This system uses R 404a refrigerant. The Standard Head Section is powered by 115 volts and should be connected to a 15 amp circuit. The Standard CVD Condensing Unit is powered by either a 208 or 230 Volt single phase dedicated power supply. A 3 phase version is also available. The Model IB1094YC can produce up to 1,070 pounds, or 485 kilograms, of ice in a 24 hour period and because the condensing section is remote, the unit runs quietly inside the restaurant. A self diagnostic system provides information to assist in preventive maintenance and troubleshooting. Information is provided by an easy to read LCD display. A lift off door and hinged interface provides easy access for cleaning and service. Click next to learn more about the parts in each unit. Parts ID: Before we begin, let s familiarize ourselves with the ice machine and condensing unit. Choose any part on the left to view its location in the unit. Click anywhere to close the part window and select another. Lesson 2: Installation Check Installation Check: This is lesson 2 Installation Check. In this lesson we ll go over the points to inspect to see if an installation has been done properly or needs to be corrected. This system has a remote, air cooled condensing section and the Page 5 of 19

7 placement and connection with the head section are critical. A typical installation has the Condensing Unit on the roof. However, it can, in some cases, be placed on a concrete pad at ground level. For roof installations, there should be no more than a 35 foot rise, about 10.7 meters. For any Rise s greater than 20 feet, or about 6 meters, an S Trap must be placed at the halfway point of the vertical rise. This is for oil return to the Compressor which is located in the condensing unit. For ground level installations, there can be no more than a 15 foot drop, about 4.5 meters. The size of the lines is also critical. They must be the recommended diameter with no restrictions. Both Liquid Line and Suction lines must be properly insulated in order for the unit to function correctly. The Condensing Unit must not be placed where it s subjected to heat and grease from an exhaust fan. Ambient air must be able to flow freely through the condenser. The operating temperature range for this section is negative 20 to 120 degrees Fahrenheit which is negative 29 to 49 degrees Celsius. Head Section: For the Ice Making Head section, the location must be free of airborne and other contaminants. The air temperature must be between 35 degrees Fahrenheit or 1.6 degrees Celsius, but must not exceed 110 degrees Fahrenheit or 43 degrees Celsius. Ice Making Water Inlet must provide Water Pressure at least 20 psi or 1.38 bar, but must not exceed 80 psi or 5.52 bar. Do not place the ice machine near heat generating equipment or in direct sunlight. It must be protected from weather and also if it will be subjected to temperatures below 32 F or 0 C. Failure caused by exposer to freezing temperatures is not covered by the warranty. See the section on removal from service and winterization in the owner s manual. Ice Beverage Machines require that a proper ice level be maintained when installed on a dispenser. Ice Beverage machines ship with an ice level management sensor preinstalled. The ice machine head is installed with the electrical inlet, water supply inlet, refrigeration tubing and water drain entering from the back of the ice machine. The ice machine head section contains a service loop that must remain installed between the ice machine head section and line set. Sufficient tubing length must be available to allow 180 degrees rotation of the ice machine. Maintain a 3 inch space, about 7.6 centimeters, between the back of the ice machine and the back of the dispenser to allow room for the refrigeration line set service loop. The water inlet and electrical connection must contain a service loop to allow future service and maintenance access. The drain line must contain a union or other suitable means of disconnection at the ice machine head section. The location selected for the ice machine head section is very important and must meet all of these criteria. If any of these criteria are not met, select another location. Electrical: The condensing section must be connected to the correct voltage and phase. These units can be supplied with 208 or 230 volts in either single or 3 phase. icvd transformers leave the factory wired for a 230 Volt supply voltage. When connecting to a 208 Volt supply voltage, the transformer must be rewired to maintain a 24 volt secondary voltage. Failure to correctly wire the transformer can result in premature transformer failure. Check the Install use and care manual for proper breaker/fuse sizing. Check the data plate to confirm the voltage and phase. By Code, the Condensing section must have a shut off or disconnect within 6 feet or 1.8 meters, of its location. Inside the restaurant, the Head Section is supplied with 115 volts on a 15 amp circuit. A cord set with a NEMA 5 15 plug is typical. It should be positioned so that the unit can be unplugged for servicing, Page 6 of 19

8 Plumbing Review: The water supply should be treated to eliminate contaminates and hardness. This will reduce scale build up and reduce maintenance. The unit must be supplied with a 20 to 80 PSI water pressure, about 1.4 to 5.5 bar at the 3/8 inch inlet. If the water pressure is above 80psi, a water regulating valve is recommended to be added to the water supply line and set to maintain 50 psi. The supply water temperature should be between 35 and 90 degrees Fahrenheit or 1.7 to 32 degrees Celsius. The drain is a nominal ½ inch and must slope to a building drain. Review: In this lesson we went over the critical points to check to see if an installation has been done correctly. Equipment that hasn t been properly installed may not work correctly or may be subject to premature failure. By assuring that the installation is correct, you can eliminate it as a possible cause when you re troubleshooting a problem. So let s go to the Spot Checks Lesson 3: Document Download Document Download: Here are links for all applicable documents for the model series IB1094YC ice cube ice machine with icvd remote condensing unit. Such as the: Service Manual, Owner s Manual, and Parts list. By clicking on a link, that document can be viewed or saved for later reference. The control board setting for RO / DI water document shows how to set up the unit if Reverse Osmosis or Deionized water is being used. Lesson 4: Safety Safety: This is lesson 4 Safety. In this lesson we ll go over the safety instructions you ll need in order to safely service the Manitowoc Model IB1094YC Ice Cube Machine and the icvd1195 Condensing unit. Keep in mind that the unit must only be serviced by properly trained and authorized technicians and that certain procedures require that the technician performing them to be EPA Certified. We will also examine both electrical and refrigerant safety concerns. For a complete set of warnings and cautions, please refer to the Service Manual. Let s start with electrical safety. Electrical Safety Condensing Unit: This equipment contains high voltage so care must be taken to prevent shocks. Servicing this equipment must only be performed by properly trained and qualified technicians who are experienced in and have the tools for dealing with high voltage circuits. Prior to starting the servicing of the Condensing Section, you must perform a Lockout Tag out Procedure. As you saw in a previous lesson, by code, there must be a Service Disconnect within 6 feet or Page 7 of 19

9 about 1.8 meters, of the unit. Before removing any panels, turn this to the off position and lock it with your own padlock. Next, fill out and attach a safety tag. You cannot proceed until this step is complete. If you must perform a test with the unit turned on, you can restore the power as needed. This unit must be properly grounded in accordance with all applicable codes. Electrical Safety Head Section: When servicing the Head Section, first unplug it and perform a Lockout Tag out Procedure. The power switch button does not disconnect all incoming power. Once that s done, you can proceed. If you need the unit turned on for testing, you can then plug it back in. Always inspect the plug and cord for damage. If damage is found, replace the cord set. This section must be connected to a properly grounded outlet. Refrigerant Safety: Let s move onto refrigerant safety. Keep in mind that the refrigerant in the system is under high pressure. Therefore you should never puncture or otherwise damage any of the lines or components containing the refrigerant. Always use refrigerant recovery equipment when opening the system and never vent refrigerant into the atmosphere. Do not breathe refrigerant vapors. This can cause serious or fatal injury. These vapors also reduce oxygen levels in confined areas. Don t allow liquid refrigerant to come in contact with your skin. This can cause frostbite. Never touch the refrigerant lines with your bare hands. Use caution when working around these lines. Some are hot enough to cause burns. Review In this lesson we went over some of the safety instructions you ll need to follow when servicing the Manitowoc Ice/Beverage Series IB1094YC Remote Ice Cube Machine and icvd1195 Condensing Unit. For a complete list of safety instructions, refer to the Service Manual. Lesson 5: Operation Operation: This is lesson 5 Operation. In this lesson we ll go over how the Model IB1094YC Ice Machine with remote icvd 1195 Condensing Unit works. We ll cover the all the steps in the freeze and harvest cycle, the cleaning process and other Maintenance procedures. Inside the Head section is a Control Board, the Brains of the ice machine that has two primary functions: It does what it s programed to do by the factory And it does what the input devices tell it to do throughout the sequence of operation. During the Sequence of Operation, the Control board will close and open contacts on a series of relays that send voltage to output devices, such as the Contactor Coil, Water inlet valve, water pump, and others. We ll identify not Page 8 of 19

10 only what s energized and when but why the output devices are energized. So let s look at the Sequence of Operation. Sequence of operation Start up: With both the Head Section and the Condensing Unit connected to their separate power supplies, press the ON Off button to turn the unit on. This is located on the Display interface on the head section and gives input to the control board to tell it to start the sequence of operation. However, before starting, the control board looks for input from the Damper Door Switch and the Ice Bin Level Sensor. Both of these input devices must also tell the control board that it s safe to start the first step of the ice making sequence of operation. The first step of the sequence is called the Water Purge. This is where the Control board energizes both the water pump and dump valve for 45 seconds. The purpose of the purge is to drain any water remaining in the system so that the cycle starts with fresh water. After 45 seconds has elapsed, the Control Board completes the water purge, de energizes the water pump and the dump valve. At this point we enter the refrigeration system start up. The Harvest Valve and Air Pump are energized for 5 seconds. By energizing the Harvest Valve, it allows the pressures to equalize in the system and eases the start up of the compressor. The Air Pump is wired in parallel with the Harvest Valve and is being energized at this time. Its main job is during Harvest to push air between the ice slab and the evaporator, but at this time it clears any condensation from the air line before we start the freeze cycle to prevent condensation from freezing and clogging up the air line. In the next 5 seconds, the harvest valve and air pump remain activated and the control board energizes and opens the Liquid Line Solenoid. The Control board closes the contacts on the CVD relay which sends the 24 volts back to the contactor coil and energizes, closes the contacts which energize the Compressor and Condenser Fan Motor. The 24 volts originate at the Transformer in the Condensing Unit and are connected to the Control Board via the communication cable. The Condenser Fan motor is wired through a fan cycling pressure switch, so it will cycle on and off as the refrigerant pressure increases and decreases. The Control board also energizes and opens the Water Inlet Valve. This fills the water trough. Sequence of operation Pre Chill Cycle: At this point the Harvest valve is de energized and closes which directs the refrigerant through the Thermal Expansion Valves or TXVs. The Liquid Line Solenoid, Contactor, Compressor and Condenser Fan will run for a 2 minute Pre Chill cycle. During this time the Water Inlet Valve may cycle On and Off because it s now being controlled by input from the Water Level Probe. The purpose of this cycle is to get the evaporator temperature below the incoming water temperature which prevents slushing. The Start up pre chill cycle time is longer due to the evaporator temperature being warmer than if the ice machine just harvested ice. Sequence of operation Freeze cycle: Once the time for the Pre Chill has elapsed, the unit will begin a freeze cycle. The Compressor and Condenser fan continue to run to provide refrigeration to chill the Evaporator. The Control board energizes and activates the Water Pump which pumps water from the trough and provides it to the Water Distribution Tube which evenly distributes water across the top of the Evaporator. The Water Inlet Valve will cycle as controlled by the Water Level Probe to replenish the water trough for up to two times in the Freeze cycle. This is a batch system which means that one batch of water in the water trough should be enough for one batch of ice on the evaporator. The second Page 9 of 19

11 water fill is primarily to prevent slushing. There s a 6 minute minimum for each freeze cycle. Once the 6 minutes has elapsed the cycle will continue until Ice forming on the Evaporator touches the Ice Thickness Probe. There s also a factory set Maximum freeze cycle time of 60 minutes. Sequence of operation Harvest: So, after the first 6 minutes have elapsed in the freeze cycle and when the ice contacts the Thickness Probe OR after the maximum 60 minutes, the Control Board will enter into a Harvest Sequence. The Water Pump and Dump Valve are activated for 45 seconds to purge the left over mineral laden water from the trough. During this time the Harvest Valve opens and allows refrigerant gas to travel to the Evaporator. When the refrigerant pressure is low enough to open the fan cycling pressure switch the Condenser Fan Motor stops and the Head Pressure Regulating Valve is forced into a 100% bypass. The discharge gas is re routed to the Receiver which boosts its temperature and pressure. This forces more vapor to the Evaporator for harvesting the Ice Sheet. The Air Pump is wired in parallel with the Harvest Valve so it too is activated and it begins to push air between the ice slab and the surface of the evaporator. This is to break the vacuum that forms between the ice and Evaporator as the ice melts. The Liquid Line Solenoid remains open and the Compressor and Condenser Fan continue to operate by way of the 24 volt contactor. After the 45 seconds the Water Pump and Dump Valve are de energized. The Harvest Valve and Liquid Line Solenoid remain open and the Compressor continues to run for a maximum of 3½ minutes. The Condenser Fan has the potential to run; however, the head pressure should be low enough to cycle the Fan Motor off. When the ice sheet releases from the Evaporator, it falls and trips the counterweighted Damper Door that triggers a magnetic proximity switch. This switch signals the Control Board. If the door swings back up within 30 seconds, the Control Board knows that the ice sheet has cleared the damper door and it can begin another pre chill cycle. This time, since the unit has been running, the pre chill time is only 30 seconds long instead of the Start up pre chill time of 2 minutes. However, if the damper door doesn t swing back up and close within 30 seconds, the Control Board will assume that the bin is full and goes into a 10 minute shut off period. In addition to the damper door, the Indigo IB Ice Machine utilizes a Bin Level Sensor that s a thermistor connected directly to the Control Board. This probe should be positioned at time of installation to a vertical position. Its main purpose is to keep the level of ice in the dispenser from overfilling and pushing up on the water trough. If it senses a temperature below freezing, the Control Board will know that it s contacting ice and assume the bin is full. After the ice falls during harvest cycle the Control Board will then turn the Ice Machine off and de energize all output devices, with the exception of the 24 volt CVD relay. The icvd condensing unit will pump the refrigerant down into the receiver and once the Low Pressure Cut Out Switch opens the Control Board de energizes the contactor. The Control Board will not stop in mid cycle when the ice level sensor senses ice; it completes the harvest cycle and then shuts off. During Auto shut off, the control board initiates another timer called a 10 minute auto delay from restart. After the following 10 minute shut off period, with the Damper door in the upright position and the Bin level sensor is not sensing ice, the unit will begin another Start up with a 2 minute pre chill. How the Harvest system Works: The method used in harvesting the ice sheet is different in this system because of the separation between the Compressor and the Evaporator. Because the liquid line can be up to 100 feet or 30.5 meters, a great deal of heat loss would occur even with insulated lines and increase size of the Liquid Line. Instead, vapor from the top of the Receiver is routed to the evaporator where it changes to a liquid state and gives off its latent heat of condensation. Page 10 of 19

12 This heats the evaporator surface and the ice sheet is released. Liquid refrigerant from the evaporator collects in the accumulator during harvest and the J tube with in the suction line accumulator allows only vapor back to the compressor. Some liquid will be sucked through the oil return orifice during harvest but flashes to a vapor as it passes through the hole. The liquid level in the accumulator will increase during the harvest cycle and then decrease to normal levels during the freeze cycle. Cleaning the Exterior: The model IB1094YC Ice Making Head Section should be thoroughly cleaned every 6 months or more often if required. Let s start with cleaning the exterior. Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation. Wipe surfaces with a damp cloth rinsed in water to remove dust and dirt from the outside of the ice machine. If a greasy residue persists, use a damp cloth rinsed in a mild dish soap and water solution. Wipe dry with a clean, soft cloth. The exterior panels have a clear coating that is stain resistant and easy to clean. Products containing abrasives will damage the coating and scratch the panels. Never use steel wool or abrasive pads for cleaning. Never use chlorinated, citrus based or abrasive cleaners on exterior panels and plastic trim pieces. Cleaning and Sanitizing: The cleaning process removes scale and mineral deposits from the areas in the machine that are in direct contact with water. Sanitization will disinfect and remove any algae and slime. Only use Manitowoc approved Cleaner and Sanitizer in this procedure. Read, understand and use these chemicals according to the instructions on their labels. Never mix Cleaner and Sanitizer solutions together. And when handling them, wear safety goggles or a face shield and chemical resistant rubber gloves. Open the front door and remove the Water Shield. There should be no ice on the Evaporator during cleaning and sanitizing, so immediately after a harvest, press the ON OFF button to turn the machine OFF. Or, turn the Ice Machine off and allow any ice to melt and remove all ice from the storage bin and discard it. Never try to force ice from the Evaporator. You could damage it. Although not required and depending on your installation, removing the ice machine top cover may allow easier access. Now you re ready to start the cleaning process. Interior Cleaning Process: The Ice Machine has a programmed routine that will guide you through the cleaning process. The display will show time remaining and when to add chemicals. To start, press the Clean Button. The display will show Purging Water and the Water Inlet and Dump Valves will open. Water will flow through the trough and down the drain for about 1 minute. The display then shows, Water Fill and the dump valve will close. When the trough fills up the display will show Washing Add Chemical. Add 5 ounces, or 150 milliliters of Manitowoc approved Cleaner to the water trough. The display will show Washing and the timer will continue to countdown. When the unit has timed out and turned off, unplug it from the power supply. Remove the Splash Shield, Ice Thickness Probe, Water Trough, Water Level Probe and Distribution Tube. Mix up a solution of Cleaner and lukewarm water. Use 1 gallon of water and 16 ounces of cleaner which is 4 liters of water to 500 milliliters of Cleaner. You may need to mix more solution if the unit has heavy mineral deposits. Take half the solution and apply it to all the parts that were removed. The solution will foam when it contacts the mineral deposits. After the foaming stops, use a soft Page 11 of 19

13 bristle nylon brush, sponge or cloth to clean the parts. Never use a wire brush for this. All the parts, with the exception of the Ice Thickness Probe, can be immersed and soaked in the solution. Once clean, rinse all parts with clean water. Take the other half of the solution and wipe down the side walls, base, Plastic Evaporator parts, and the dispenser. Then rinse with clean water. Interior Sanitizing: The next step is to Sanitize the unit. Mix a solution of Manitowoc approved Sanitizer. Use 3 gallons of lukewarm water and 2 ounces of Sanitizer. This is roughly 12 liters of water and 60 milliliters of Sanitizer. Use half the solution to sanitize the parts and reserve the other half for the machine. Fill a spray bottle with the solution and liberally spray the solution on all the surfaces of the parts. You can also soak the parts, except the Ice Thickness Probe, in the solution. Don t rinse these parts! Using the other half of the solution, fill your spray bottle and liberally spray down the interior surfaces you ve cleaned. Again, don t rinse these areas. Reinstall the parts and allow the unit to sit undisturbed for 20 minutes. This gives the sanitizer time to work. When the 20 minutes are up, press the Clean Button. The display will show Purging Water and the Water Inlet Valve will open and fill the Water Trough. This will take about a minute. The display will show Washing Add Chemical. Pour 3 ounces of Sanitizer into the Water Trough. Press the Check Mark when the Auto Ice On Bracket appears, this puts a check mark into the Auto Ice On bracket and allows the ice machine to automatically start an Ice Making Cycle once the cleaning sequence of operation is complete. Close and secure the front door and the unit will automatically complete the Sanitizing cycle. This takes about 30 minutes. The unit will then begin making ice. Cleaning the Condenser: Air must flow freely through the condenser in order for the unit to operate properly. A dirty condenser will restrict the air flow and result in excessive operating temperatures. This will reduce ice production and can cause premature component failure. The Condenser should be cleaned at least every 6 months. To see if a Condenser needs cleaning, shine a flashlight through the coil and look for dirt or debris between the fins. Also inspect the Condenser Fan Blades. Dirty fan blades cut down on air movement and may unbalance the blade putting excess strain on the motor bearings. If cleaning is needed, first shut off the power supply and perform a Lockout Tag out Procedure. If the dirt appears to be dust or lint, blow compressed air from the inside out. This is opposite to the normal air flow. Be careful not to damage or bend any fins. Use a fin comb to remove stubborn debris and straighten any bent fins. Gently wipe the fan with a cloth, taking care not to bend the blades. If the dirt appears to be grease or grease and dirt, spray the coils and fan blade with a degreasing agent and rinse with warm water making sure not to spray any electrical components. If the dirt still remains, repeat the process until it s clean. Operational Check: Once the unit is back in service, check the ice bridge thickness. The ice bridge thickness is factory set to 1/8 inch or 3 millimeters. This thickness is maintained by the Ice Thickness Probe. This system uses Acoustical Ice Sensing Technology to detect the surface of the ice that s building on the evaporator. Immediately after a harvest access the storage bin and inspect the ice. If an adjustment is needed there s an adjustment screw on the Ice Thickness Probe. Turn the screw clockwise to increase the thickness and counter clockwise to decrease. Turning the screw 120 degrees, or 1/3 revolution, is about 1/16 inch, or 1.5 millimeters, of adjustment. A gap of 9/32 of an inch, Page 12 of 19

14 about 7 millimeters, is the suggested starting point to adjust the distance between the Evaporator grid and the flat part of the Probe. Use a 9/32 or 7 millimeter drill bit to set the initial gap and make adjustment from there if needed. The Ice Thickness Probe should swing freely. Make sure the wire isn t restricting its movement. Review: In this lesson we went over the sequence of operation of the Model IB1094YC Ice Machine with CVD Remote Condensing Unit. We also covered the Cleaning and Sanitizing Procedure, as well as other important steps to maintain the equipment. So, let s go to the Spot Checks. Lesson 6: Troubleshooting Troubleshooting: This is lesson 6 Troubleshooting. Troubleshooting is an exercise in the logic of cause and effect. It s a step by step process that starts with the observation of symptoms, goes through the testing of components and systems, and ends with a diagnosis. While an Ice Machine can seem like a complex piece of equipment, like anything, if you break it down by symptoms, it becomes easier to understand. We ll also go over some of the diagnostics you can use for troubleshooting. And we ll look at some examples. A complete Troubleshooting Guide can be found in the Service Manual. Problems with IB1094YC Ice Cube Machine with the remote icvd1195 Condensing Unit will manifest themselves in one of four symptoms: 1. The Ice Machine Stops Running or has a History of Shutting Down 2. The Freeze Cycle is too Long or Slow Ice Production 3. The Ice Machine Won t Harvest When the Freeze Cycle is Normal and Ice isn t Melted after the Attempted Harvest 4. The Ice Machine Won t Harvest When the Freeze Cycle is Normal and Ice IS Melted after the Attempted Harvest There are several causes for each symptom, so instead of looking at individual problems, we ll show how to use the tools provided in the Service Manual to troubleshoot and diagnose issues. So let s look at the first symptom the ice machine stops running or has a history of shutting down. Troubleshooting Flow Chart: The flow chart steps you through the troubleshooting process by asking yes or no questions. Through observation and testing you can answer the questions. Each symptom has its own flow chart. For example, you have a unit that s not running and look at the display and it s not lit. That s the first symptom. Open the door and look at the Control Board and there are no LEDs lit or flashing. You test the incoming power supply at the board and find line voltage. The next step is to test the Fuse. The Fuse tests good. Following the flow chart you see it takes you to the Display and Control Board Diagnostics. We ll look at that later in this lesson. Following those diagnostic tests you find you have a non responsive Control Board. You replace it and retest the unit and it operates correctly. By Page 13 of 19

15 following the flow chart you were able to repair the machine without any guessing or unneeded effort. There are several paths in the Flow Chart. By answering the questions, you may follow a different path. Don t guess. Use your tools and instruments to answer the questions correctly. An incorrect answer will send you down the wrong path. Some paths end in a reference to diagnostics for a certain component or system. We ll go over some of these later in this lesson. Using the Service Menu: One feature of the Indigo Control System is a Service Menu with features such as: Data History, Real Time Data, Diagnostics, And so on. To access the Service Menu, press the Menu button and then use the Down button to scroll to Service. Press the Right Arrow again to access all the Service features. Scroll up or down through the list then press the Right Arrow to access each feature. These may help you understand what has been going on with the machine before you arrived. Control board Self Test: The control board has a built in self test to help with diagnosing problems with the Board or Keypad and display. Click the buttons as shown. Press the Menu button and then use the Down button to scroll to Service. Press the Right Arrow, and then use the Down arrow to scroll down to Diagnostics. Press the Right Arrow again and the display will read Control Board. Press the Right Arrow one more time and the display will read Self Check. Press the Right Arrow to start the test. The display will show 5 check marks one at a time during the test. When the test is done the display will show Status Passed indicating that the Controller is functioning properly. You can then run a diagnostic test on the Touch Pad. From the Status Passed Screen press the Right arrow and the display will show Passed Yes. Press the Right Arrow again and the display will read, Key Pad Test. Press the Right Arrow to start the test. The screen will look like this: Press each button and the corresponding symbol will highlight. It s a good idea to test the ON Off button last since it will turn off the ice machine. Press the Right Arrow 5 times rapidly to exit. Display Diagnostics: The Control Board, Display Board and Touch Pad provide user input and control the Ice Machine s sequence of operation. Anytime power is supplied to wires 55 and 56 on the control board, the Display and Micro lights should flash like a heartbeat. These can be used for diagnostics. If the Micro light flashes and Display light is off. Disconnect and reconnect both ends of the communication cable running between the control board and the back of the display module. Reboot the circuit board by disconnecting power supply and wait a minimum of 15 seconds, then re apply power and check for normal blinking lights. If Display light flashes, Test run the ice machine. If Display light remains off, replace communication cable first as a test, then replace Display Touchpad Assembly if required. Alerts: The Control board will display and log Alerts. When the Alert Symbol occurs on the display, it means there is a problem that needs to be addressed. To view the Alert, press the Left Arrow, then scroll up to see the details. Page 14 of 19

16 You ll see the Date and Time stamp of the Alert, Cycle Count, and possible causes. The Alerts are also logged into memory and a total of the 99 alerts can be stored. To view the recorded alerts, press the menu key and scroll to the Event Log. You can then scroll though the alerts to view the history of the unit. Energize Relays: Using the Key Pad you can energizes all the relays on the Controller. This can be an excellent tool for troubleshooting. With the unit turned OFF, access the Service Menu and scroll to Control Board, then to Enable Relays. At this point the Relays on the board will engage for 3 ½ minutes. Each relay on the board will have the LED lit. The Components controlled by the relays will be energized and you can check them individually to see if they are getting voltage. If the component is getting voltage but isn t functioning, it needs to be replaced. However, if there s no voltage at a particular component, go the 9 pin connector on the board and check for output voltage there. If you find voltage here, you have a wiring problem. However, no output voltage means you have a relay on the Control Board that s not closing and you ll need to replace the Control Board. Ice Thickness Probe Diagnostics 1: The Ice Thickness Probe must be functioning and correctly adjusted in order for the Unit to work properly. As you saw in a previous lesson, there should be a 9/32 inch gap, about 7 millimeters, between the flat portion on the face of the probe and the empty Evaporator grid in order to maintain a 1/8 inch, or 3 millimeter ice bridge. However if the Probe or circuit should fail, the unit wouldn t harvest until the maximum time of 60 minutes. Since the probe plugs directly into the Controller there are 2 components to check. To test the Ice Thickness Probe, first make sure there s no ice on the Evaporator. You can initiate a Manual Harvest by accessing the Service Menu. Once the Evaporator has cleared, you can turn the unit off and inspect the probe for physical damage. There should be no bulging, cracks or deformations. The Probe should pivot freely with no restrictions from the pivots or probe wire. If there is no evidence of damage, you can perform the Ice Thickness Probe Tap Test. Access the service menu and scroll to Real Time Data. Press the Right Arrow and scroll down until 100 and 120 Hertz are displayed. The numbers to the right should slow increase or decrease. This is data from the probe microphone. Swing the probe up and lightly tap on the nipple. If the numbers increase into the tens of thousands, the probe passes. If the number remain the same or do not increase into the thousands, you ll need to test the resistance of the probe. Disconnect the Probe from the board. Select the multimeter with probes from the toolbox. Set the meter to the Ohm Scale. Move the Red probe to the Red Wire and the black probe to the black wire. A good probe will give you a reading of 1.4 to 2.5 Kilo Ohms. Now reverse the probes. You should see a reading of 1.2 to 1.5 Kilo Ohms. If your readings are within these ranges the probe is good. If not the probe should be replaced. Ice Thickness Probe Diagnostics 2; If the probe tests good: you need to test the voltage output from the Controller. Set the Multimeter to DC Volts and test across the 2 pins. You should see a reading between 3.25 and 3.35 volts DC. If the voltage is normal, the board is good. If not, replace the Controller. If both the Probe and the Controller Test Good and you still suspect this system, inspect the connector on the probe. A loose pin can result in an open connection. Tighten or replace any loose pins. Page 15 of 19

17 Water Level Probe Diagnostics: The Water Level Probe hangs from the base into the Water Trough. Its job is to regulate the water level. The Probe assembly has 3 individual probes. One grounds the water in the trough. One measures the conductivity of the water. And the last is used to control the water level. Check the continuity of each probe through its wire to the connector. You can also view the input from the Water Level Probe to the control board through the interface by scrolling to Service, then Diagnostics, then Inputs and press the Down Arrow until WTR Low and WTR High are displayed. No is displayed on both WTR Low and WTR High if no water is touching the water level probes. If Yes is displayed, the control board is receiving a sensing water level signal. Bin Switch: The Bin Switch is a Magnetic Proximity Switch that s triggered by a magnet on the Damper door. When the door is in the up position, the magnet on the damper is in close proximity to the switch and closes the contacts in the switch. When the Ice sheet falls from the Evaporator during a harvest cycle, the damper door opens and the magnet moves away from the Bin Switch which opens its contacts. The Control Board sends a variable DC voltage signal through this switch, so it s best to test it either in the Service Menu by scrolling to Service, then Diagnostics, then Inputs and press the right arrow to display curtain switch readings. This unit only uses Curtain Switch 1. Curtain Switch 2 will show Open in the display. Or you can test the switch with a continuity check while opening and closing the damper. Remember, a closed Damper means a Closed Switch, and an open Damper means an open Switch. Interactive Exercise 1: Now it s your turn. Use the Flow Chart to troubleshoot and diagnose the problem. Go to the toolbox and select the tools or instruments you ll need. To select a component to check, just click in the highlighted area. To remove wires, just click on them. We ll plot your progress on the Flow Chart. You ve found a blown fuse; that means there s a problem somewhere else. Normally it s due to a short circuit in one of the output devices. Here are the possibilities: Water Inlet Valve Air Pump Harvest Valve Dump Valve Water Pump Contactor Coil Transformer Check each one to determine the problem. OK, you ve found a shorted Dump Valve. Replace it and the fuse and you ve solved the problem. Symptom #2: Low Production, Long Freeze Cycle/Operational Analysis Chart Manitowoc has come up with a column style chart to help diagnose when coming across a Symptom where the Freeze Cycle is too long or experiencing slow ice production. To complete the chart read down the left column and Page 16 of 19

18 gather the information or data listed. Each item has supporting reference material in the service manual to help you analyze that step. There may be external problems that could cause a good component to appear to be faulty or not working. Correct problems as they are found and if an operational problem is found and corrected, it s not necessary to complete the remaining procedures. So, let s use the chart to diagnose a Low Production problem. Low Production The Restaurant s complaint is that the Ice Machine isn t keeping up with demand. Since Ice Production is relative to the Water Temperature and the Ambient Air Temperature at the Condensing Unit, you have to look it up on the chart in the service manual. Based on our conditions air entering the condenser is at 80 degrees Fahrenheit and water entering the ice machine head section is at 50 degrees Fahrenheit we should be getting 930 pounds of ice per 24 hour period. That means the time required for 1 cycle is about 11 to 14 ½ minutes. If you time a complete cycle, anything under 15 minutes is, with a proper bridge thickness of ice, not low production. However, if your cycle time is 21 ½ minutes, like this example, you know you have a problem. If you do the calculations, that equates to 536 pounds of ice per 24 hour period. You ve inspected the installation and it s OK. Now look at the Ice formation on the Evaporator. In this case it s normal, so mark the chart accordingly. There are no safety limit alerts. Next set up your gauges on the discharge and suction lines and run a cycle. Note the pressures one minute into the freeze, halfway through and at the end of the freeze, just before harvest. Looks like the discharge pressure is normal but the suction pressure is high. Mark the chart. If the Discharge pressure was too high or too low, it should be repaired before any further diagnostics. Next listen to the Harvest Valve during the freeze cycle. Mark the columns according to what you find. Next attach a temperature probe to the suction line no more than 6 inches from the Shutoff Valve. Record the temperature at the end of the freeze cycle. Mark the chart with your findings. Now look at the columns and add up the number of check marks in each. The one with the highest number is where the problem is. In our example it s an inefficient Compressor. Interactive Exercise 2: Here is the chart again with different test results filled in. Mark the chart, based on this information, and answer the question when it appears. That s correct! Either the unit is overcharged or you have a flooding TXV. To find out which, recover the charge from the unit and weigh it. If it s within a pound or 2 of the data plate charge, you have an issue with one or both of the TXVs. Check to make sure the Bulbs are installed correctly and all the insulation is in place. If that s all good, replace the TXVs. Since this unit has 2 Expansion Valves piped in parallel, replace both of them. Sometimes one faulty TXV will cause the other one to over compensate. To insure the correct TXV gets replaced, replace them both. Symptom 3 Ice Will Not Harvest Ice on the Evaporator not melted after the ice machine has tried to harvest the ice: The third symptom is when ice freezes normally, but the unit won t harvest and the ice is not melted on the Evaporator during the harvest cycle. The sheet of cubes at the end of the harvest cycle appears normal and the ice is difficult to remove from the Evaporator by hand. (Note: Never use any tool to remove ice ) Once removed the back of the cubes are square and show no signs of melting. This indicates a refrigeration problem. The source of the problem could be in the freeze or harvest cycle. Use this Flow Chart to diagnose the problem. Check the Page 17 of 19

19 Harvest Valve to see if it s being energized. In this scenario, it s working correctly. You ve installed your gauges on the Liquid and Suction Lines and see that the pressures are off. You ve already checked the installation and it s OK. If you have High Head Pressure and Low Suction Pressure during Harvest: that points to a malfunctioning Harvest Valve. But you re seeing Low Head Pressure and Low Suction Pressure. This points to several other possibilities. So let s see if line and component temperatures can tell us something. Feel the Receiver 30 seconds into the Harvest Cycle. It should be warm, but this one s cold. Next feel the Liquid Line at the Condensing Unit. It should be Hot, but it s cold. Look to see if the Condenser Fan Motor runs below the Cut out set point pressure during Harvest. If it runs you have a problem with the Fan Cycling Control. This one is OK. Next feel the temperature of the Discharge Line 30 seconds into the Harvest Cycle. If it feels cool, then the Head Pressure Control Valve, or Headmaster, isn t in 100 % bypass. This is due to either an incorrect refrigerant charge or a Headmaster that s not bypassing 100%. Recover and weight the Charge. If it s within specs of the Data Plate charge, replace the Headmaster. Warning: Never de braze the Headmaster. (ON Screen Only) If the diaphragm has ruptured and refrigerant has replaced the Nitrogen in the valve dome; increased pressure from the heat of your torch could cause the Valve to rupture. Instead use a tubing cutter to remove it. A new Valve will have nitrogen in the dome and is safe to braze in place. Of course, this is only one path on this flow chart. There could be several other causes for this symptom. Follow the Flow chart, perform the tests and you ll be able to diagnose the problem correctly. Symptom 4 Ice Will Not Harvest Ice Melted out on the Evaporator after the ice machine attempted to harvest: Symptom 4 may look a lot like Symptom 3 at first glance in that the ice sheet remains on the Evaporator. The difference is that the ice won t be well defined and will look partially melted. Here is the flow chart to for this problem. First, make sure the unit is level. If the unit it leaning back the ice cannot slide off the Evaporator. Next look to see if the water trough is flowing over the Evaporator during the first 45 seconds of the Harvest Cycle. If it is, there s a problem with the Dump Valve. If that s OK, shut the ice machine off and allow the ice to melt and fall off of the Evaporator, dry it, and check to see if it needs cleaning. Drying the Evaporator and inspecting the Evaporator while dry is an important step in diagnosis. Often a wet Evaporator will give you the illusion of being clean when, in fact, it s not. This is also a good time to look for damage to the Evaporator plating, solder, gasket, and surrounding plastic. If everything looks good, you should use the flow chart for Symptom 2 to diagnose. Otherwise, the problem is friction on the Evaporator not allowing the ice to release properly. That means you should clean and sanitize the unit according to the procedures you saw in the previous lesson. Review: In this lesson we covered over how to troubleshoot the four basic symptoms that can occur with Manitowoc Model IB1094YC Ice Cube Machine with icvd1195 Remote Condensing unit. While we didn t cover every problem that can occur, we did go over the troubleshooting Charts that you will use to Observe, Test, and Diagnose problems. Remember the location of the Troubleshooting Charts, as well other charts and data are in the Service Manual. So let s go to the Spot Checks. Lesson 7: Final Exam Page 18 of 19