Manitowoc SD0302A User manual

Technician’s
Handbook
This manual is updated as new information and models
are released. Visit our website for the latest manual.
www.manitowocice.com
America’s #1 Selling Ice Machine
S Model
Ice Machines
Part Number 80-1479-3 7/10
Manitowoc

Safety Notices
As you work on Manitowoc equipment, be sure to pay
close attention to the safety notices in this handbook.
Disregarding the notices may lead to serious injury
and/or damage to the equipment.
Throughout this handbook, you will see the following
types of safety notices:
Procedural Notices
As you work on Manitowoc equipment, be sure to read
the procedural notices in this handbook. These notices
supply helpful information which may assist you as
you work.
Throughout this handbook, you will see the following
types of procedural notices:
!Warning
Text in a Warning b ox alerts yo u to a p otential
personal injury si tuation. Be su re to read the
Warning statement before proceeding, a nd w ork
carefully.
!Caution
Text in a Caution box alerts you to a si tuation in
which you could damage the equipment. Be sure
to read the Caution statement before proceeding,
and work carefully.
Important
Text in an Impo rtant b ox provid es you wi th
information t hat ma y h elp yo u perform a
procedure more ef ficiently. Di sregarding thi s
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.
Read These Before Proceeding:
!Caution
Proper i nstallation, ca re and ma intenance are
essential for maximum performance and trouble-
free op eration of you r Manitowo c eq uipment. If
you en counter prob lems not covered by this
handbook, do no t procee d, contact Ma nitowoc
Foodservice. We wi ll b e happy to p rovide
assistance.
Important
Routine ad justments and main tenance
procedures outlin ed in thi s handbook are not
covered by the warranty.
!Warning
PERSONAL INJURY POTENTIAL
Do n ot ope rate eq uipment that has b een
misused, ab used, ne glected, d amaged, o r
altered/modified from that of origi nal
manufactured specifications.
We reserve the right to make product
improvements at any time. Specifications and
design are subject to change without notice.

Part Number 80-1479-3 7/10 5
Table of Contents
General Information
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
Location of Ice Machine . . . . . . . . . . . . . . 21
Ice Machine Clearance Requirements . . 22
Ice Machine Heat of Rejection . . . . . . . . . 23
Remote Condenser Line Set Installation
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Calculating Remote Condenser
Installation Distances . . . . . . . . . . . . . 25
Lengthening or Reducing Line Sets . . 27
Connecting A Line Set . . . . . . . . . . . . 28
Component Identification
S Model Single Evaporator Models . . . . . 29
S Model Quad Evaporator Models . . . . . 30
Maintenance
General . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Cleaning / Sanitizing Procedure . . . . . . . 32
Cleaning Procedure . . . . . . . . . . . . . . 32
Parts Removal for Cleaning/Sanitizing 34
Procedure to Clean Heavily Scaled
Ice Machines . . . . . . . . . . . . . . . . . . . . . . . 40
General . . . . . . . . . . . . . . . . . . . . . . . . 40
Cleaning Procedure . . . . . . . . . . . . . . 40
Parts Removal for Cleaning/Sanitizing 43

6 Part Number 80-1479-3 7/10
Removal from Service/Winterization . . . 57
Self-Contained Air-Cooled Ice Machines 57
Water-Cooled Ice Machines . . . . . . . . 58
Remote Ice Machines . . . . . . . . . . . . . 58
Sequence of Operation
Self Contained Air or Water Cooled . . . . 59
Single & Quad Evaporator Models . . . 59
Safety Timers . . . . . . . . . . . . . . . . . . . . . . 64
Safety Limits . . . . . . . . . . . . . . . . . . . . . . 65
Remotes . . . . . . . . . . . . . . . . . . . . . . . 72
Troubleshooting
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
Symptom #1 Ice Machine will not run . 90
Compressor Electrical Diagnostics . . . 92
Symptom #2 Low Productionand/or Long
Freeze Cycle . . . . . . . . . . . . . . . . . . . . 94
Symptom #2 - Freeze Cycle Refrigeration
System Operational Analysis Tables . 96
Freeze Cycle Refrigeration System Opera-
tional Analysis Table Procedures . . . . 105
Harvest Problems . . . . . . . . . . . . . . . . . . 126
Symptom #3 Ice Will Not Harvest, Cubes
Are Not Melted . . . . . . . . . . . . . . . . . . 127
Symptom #3 - Traditional Remotes Only
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Symptom #4 Will Not Harvest, Cubes Are
Melted . . . . . . . . . . . . . . . . . . . . . . . . . 131

Part Number 80-1479-3 7/10 7
Component Check Procedures
Electrical Components . . . . . . . . . . . . . . . 135
Main Fuse . . . . . . . . . . . . . . . . . . . . . . 135
ICE/OFF/CLEAN Toggle Switch . . . . . 136
Bin Switch . . . . . . . . . . . . . . . . . . . . . . 137
Cleaning the Ice Thickness or Water Level
Probe . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Water Level Control Circuitry . . . . . . . 141
Ice Thickness Probe (Harvest Initiation)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Harvest Assist Air Pump . . . . . . . . . . . 151
Compressor Electrical Diagnostics . . . . 152
Diagnosing Start Components . . . . . . 154
Refrigeration Components . . . . . . . . . . . 158
High Pressure Cutout (HPCO) Control 158
Fan Cycle Control . . . . . . . . . . . . . . . . 159
Water Regulating Valve . . . . . . . . . . . 160
Harvest Pressure Regulating (HPR) System
Remotes Only . . . . . . . . . . . . . . . . . . . 161
Head Pressure Control Valve . . . . . . . 164
Low Pressure Cutout (LPCO) Control . 167
Harvest Pressure Solenoid Valve . . . . 168
Refrigerant Recovery/Evacuation . . . . . . 169
Normal Self-Contained Model Procedures
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Normal Remote Model Procedures . . . 173
System Contamination Clean-Up . . . . . . 178
Determining Severity Of Contamination 178
Cleanup Procedure . . . . . . . . . . . . . . . 180
Replacing Pressure Controls Without Re-
moving Refrigerant Charge . . . . . . . . . 183
Specifications
Main Fuse . . . . . . . . . . . . . . . . . . . . . . 185
Fan Cycle Control . . . . . . . . . . . . . . . . 185
High Pressure Cutout (HPCO) Control 185
Filter-Driers . . . . . . . . . . . . . . . . . . . . . 186
Total System Refrigerant Charge . . . . 187

8 Part Number 80-1479-3 7/10
Charts
Cycle Times/24-Hour Ice Production/
Refrigerant Pressure Charts . . . . . . . . . . 191
S300 Series . . . . . . . . . . . . . . . . . . . . 192
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 Series . . . . . . . . . . . . . . . . . . . 242
S1600 Series . . . . . . . . . . . . . . . . . . . 253
S1800 Series . . . . . . . . . . . . . . . . . . . 256
S3300 Series . . . . . . . . . . . . . . . . . . . 265
Diagrams
Wiring Diagrams . . . . . . . . . . . . . . . . . . . 267
Wiring Diagram Legend . . . . . . . . . . . 267
Wiring Diagrams Before Energy Efficient &
EnergyStar Machines . . . . . . . . . . . . . 268
Wiring Diagrams for Energy Efficient & En-
ergyStar Machines . . . . . . . . . . . . . . . 279
Electronic Control Board . . . . . . . . . . . . 290
Single and Twin Evaporator . . . . . . . . 290
Single and Twin Evaporator With Test But-
ton . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Quad Evaporator Ice Machines . . . . . 292
Refrigeration Tubing Schematics . . . . . 293
Self-Contained Air- or
Water -Cooled Models . . . . . . . . . . . . 293
Remote Models . . . . . . . . . . . . . . . . . 295

Part Number 80-1479-3 7/10 9
General Information
Model Numbers
This manual covers the following models:
NOTE: Model numbers ending in 3 indicate a 3
phase unit. Example: SY1004A3.
Self-Contained
Air-Cooled Self-Contained Water-Cooled Remote
SD0302A
SY0304A
SD0303W
SY0305W
---
---
SD0322A
SY0324A
SD0323W
SY0325W
---
---
SR0420A
SD0422A
SY0424A
SR0421W
SD0423W
SY0425W
---
---
SD0452A
SY0454A
SD0453W
SY0455W
---
---
SR0500A
SD0502A
SY0504A
SR0501W
SD0503W
SY0505W
SD0592N
SY0594N
SD0602A
SY0604A
SD0603W
SY0605W
SD0692N
SY0694N
SR0850A
SD0852A
SY0854A
SR0851W
SD0853W
SY0855W
SR0890N
SD0892N
SY0894N
SR1000A
SD1002A
SY1004A
SR1001W
SD1003W
SY1005W
SR1090N
SD1092N
SY1094N
SD1202A
SY1204A
SD1203W
SY1205W
---
---
SD1402A
SY1404A
SD1403W
SY1405W
SD1492N
SY1494N
SR1600A
SD1602A
SY1604A
SR1601W
SD1603W
SY1605W
SR1690N
SD1692N
SY1694N
SR1800A
SD1802A
SY1804A
SR1801W
SD1803W
SY1805W
SR1890N
SD1892N
SY1894N
---
---
---
---
SD3303W
SD3303WHP
SY3305W
SY3305WHP
---
---
---
---

10 Part Number 80-1479-3 7/10
HOW TO READ A MODEL NUMBER
Ice Cube Sizes
Regular
1-1/8" x 1-1/8" x 7/8"
2.86 x 2.86 x 2.22 cm
Dice
7/8" x 7/8" x 7/8"
2.22 x 2.22 x2.22 cm
Half Dice
3/8" x 1-1/8" x 7/8"
0.95 x 2.86 x 2.22 cm
!Warning
Personal Injury Potential
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
S Y 1094 N SI
ICE MACHINE
MODEL
ICE CUBE SIZE
R REGULAR
D DICE
Y HALF DICE
# CUBE SIZE
0 REGULAR
1 REGULAR
2 DICE
3 DICE
4 HALF-DICE
5 HALF-DICE
CONDENSER TYPE
AIR-COOLED
WATER-COOLED
AIR-COOLED
WATER-COOLED
AIR-COOLED
WATER-COOLED
A SELF-CONTAINED AIR-COOLED
W SELF-CONTAINED WATER-COOLED
N REMOTE AIR-COOLED
9 REMOTE
AIR-COOLED
CONDENSER TYPE
ICE MACHINE
SERIES
ADDITIONAL SPECS
3 PHASE
M MARINE UNIT
HP HIGH PRESSURE
WATER VALVE
SI AUCS-SI INCLUDED

Part Number 80-1479-3 7/10 11
Model/Serial Number Location
These numbers are required when requesting
information from your local Manitowoc Distributor,
service representative, or Manitowoc Ice, Inc. The
model and serial number are listed on the OWNER
WARRANTY REGISTRATION CARD. They are also
listed on the MODEL/SERIAL NUMBER DECAL
affixed to the ice machine.
!Warning
All Man itowoc ice ma chines re quire th e ice
storage system (bin, dispenser, etc.) to
incorporate an ice deflector.
48” w ide S Model ice mach ines re quire add ing
Manitowoc Ice Deflector Kit K00 349 w hen
installing wi th non-Manitowoc ice sto rage
systems.
30” w ide S Model ice mach ines re quire add ing
Manitowoc Ice Deflector Kit K00 347 w hen
installing wi th non-Manitowoc ice sto rage
systems.
Prior to using a non -Manitowoc ice sto rage
system with other Manitowoc ice machin es,
contact th e manufacturer to assu re th eir ice
deflector is comp atible wi th Mani towoc ice
machines.

12 Part Number 80-1479-3 7/10
Energy Efficient Ice Machine
Serial Breaks
Some specifications have changed with our release of
more Energy Efficient machines. The following
machines have a serial break to indicate when they
became more Energy Efficient.
Series Ice
Machine Serial Break/Manufacture Date for Energy Efficient Machines
S300 110704351
S420 110667970
S450 110670157
S500 110684316
S850 110683282
S1000 110697023
S1200 110707329
S1400W Manufacture Date After 0711
(November 2007)
S1400W
Manufacture Date Between
0711 & 0905
(November 2007 & May 2009)
S1400A
S1400W
S1400N
Manufacture Date After 0905
(May 2009)
S1800A
S1800W
S1800N
Manufacture Date After 0910
(October 2009)

Part Number 80-1479-3 7/10 13
Ice Machine Warranty Information
OWNER WARRANTY REGISTRATION CARD
Warranty coverage begins the day the ice machine is
installed.
If the OWNER WARRANTY REGISTRATION CARD is
not returned, Manitowoc will use the date of sale to the
Manitowoc Distributor as the first day of warranty
coverage for your new ice machine.
Important
Complete and mail the OW NER WARRANTY
REGISTRATION C ARD as soon as p ossible to
validate the installation date.

14 Part Number 80-1479-3 7/10
COMMERCIAL WARRANTY COVERAGE
Manitowoc Ice, (hereinafter referred to as the
"COMPANY") warrants for a period of thirty-six months
from the installation date (except as limited below) that
new ice machines manufactured by the COMPANY
shall be free of defects in material or workmanship
under normal and proper use and maintenance as
specified by the COMPANY and upon proper
installation and start-up in accordance with the
instruction manual supplied with the ice machine.
The COMPANY'S warranty hereunder with respect to
the compressor shall apply for an additional twenty-
four months, excluding all labor charges, and with
respect to the evaporator for an additional twenty-four
months, including labor charges.
The obligation of the COMPANY under this warranty is
limited to the repair or replacement of parts,
components, or assemblies that in the opinion of the
COMPANY are defective. This warranty is further
limited to the cost of parts, components or assemblies
and standard straight time labor charges at the
servicing location. Time and hourly rate schedules, as
published from time to time by the COMPANY, apply to
all service procedures.
Additional expenses including without limitation, travel
time, overtime premium, material cost, accessing or
removal of the ice machine, or shipping are the
responsibility of the owner, along with all maintenance,
adjustments, cleaning, and ice purchases.
Labor covered under this warranty must be performed
by a COMPANY Contracted Service Representative or
a refrigeration service agency as qualified and
authorized by the COMPANY'S local Distributor.
The COMPANY'S liability under this warranty shall in
no event be greater than the actual purchase price
paid by customer for the ice machine.

Part Number 80-1479-3 7/10 15
The foregoing warranty shall not apply to (1) any part
or assembly that has been altered, modified, or
changed; (2) any part or assembly that has been
subjected to misuse, abuse, neglect, or accidents; (3)
any ice machine that has been installed and/or
maintained inconsistent with the technical instructions
provided by the COMPANY; or (4) any ice machine
initially installed more than five years from the serial
number production date. This warranty shall not apply
if the Ice Machine's refrigeration system is modified
with a condenser, heat reclaim device, or parts and
assemblies other than those manufactured by the
COMPANY, unless the COMPANY approves these
modifications for specific locations in writing.
THIS WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES OR GUARANTEES OF ANY
KIND, EXPRESSED OR IMPLIED, INCLUDING ANY
IMPLIED WARRANTY OF MERCHANTABILITY
OR FITNESS FOR A PARTICULAR PURPOSE.
In no event shall the COMPANY be liable for any
special, indirect, incidental or consequential damages.
Upon the expiration of the warranty period, the
COMPANY'S liability under this warranty shall
terminate. The foregoing warranty shall constitute the
sole liability of the COMPANY and the exclusive
remedy of the customer or user.
To secure prompt and continuing warranty service, the
warranty registration card must be completed and sent
to the COMPANY within five (5) days from the
installation date.
To obtain warranty service or information regarding
your Product, please contact us at:
MANITOWOC ICE
2110 So. 26th St. P.O. Box 1720,
Manitowoc, WI 54221-1720
Telephone: [phone] Fax: [phone]
www.manitowocice.com

16 Part Number 80-1479-3 7/10
RESIDENTIAL ICE MACHINE LIMITED WARRANTY
WHAT DOES THIS LIMITED WARRANTY COVER?
Subject to the exclusions and limitations below,
Manitowoc Ice, Inc. (“Manitowoc”) warrants to the
original consumer that any new ice machine
manufactured by Manitowoc (the “Product”) shall be
free of defects in material or workmanship for the
warranty period outlined below under normal use and
maintenance, and upon proper installation and start-
up in accordance with the instruction manual supplied
with the Product.
HOW LONG DOES THIS LIMITED WARRANTY
LAST?
WHO IS COVERED BY THIS LIMITED WARRANTY?
This limited warranty only applies to the original
consumer of the Product and is not transferable.
Product Covered Warranty Period
Ice Machine Twelve months from the
sale date

Part Number 80-1479-3 7/10 17
WHAT ARE MANITOWOC ICE’S OBLIGATIONS
UNDER THIS LIMITED WARRANTY?
If a defect arises and Manitowoc receives a valid
warranty claim prior to the expiration of the warranty
period, Manitowoc shall, at its option: (1) repair the
Product at Manitowoc’s cost, including standard
straight time labor charges, (2) replace the Product
with one that is new or at least as functionally
equivalent as the original, or (3) refund the purchase
price for the Product. Replacement parts are
warranted for 90 days or the balance of the original
warranty period, whichever is longer. The foregoing
constitutes Manitowoc’s sole obligation and the
consumer’s exclusive remedy for any breach of this
limited warranty. Manitowoc’s liability under this limited
warranty is limited to the purchase price of Product.
Additional expenses including, without limitation,
service travel time, overtime or premium labor
charges, accessing or removing the Product, or
shipping are the responsibility of the consumer.
HOW TO OBTAIN WARRANTY SERVICE
To obtain warranty service or information regarding
your Product, please contact us at:
MANITOWOC ICE
2110 So. 26th St.
P.O. Box 1720,
Manitowoc, WI 54221-1720
Telephone: [phone] Fax: [phone]
www.manitowocice.com

18 Part Number 80-1479-3 7/10
WHAT IS NOT COVERED?
This limited warranty does not cover, and you are
solely responsible for the costs of: (1) periodic or
routine maintenance, (2) repair or replacement of the
Product or parts due to normal wear and tear, (3)
defects or damage to the Product or parts resulting
from misuse, abuse, neglect, or accidents, (4) defects
or damage to the Product or parts resulting from
improper or unauthorized alterations, modifications, or
changes; and (5) defects or damage to any Product
that has not been installed and/or maintained in
accordance with the instruction manual or technical
instructions provided by Manitowoc. To the extent that
warranty exclusions are not permitted under some
state laws, these exclusions may not apply to you.
EXCEPT AS STATED IN THE FOLLOWING SENTENCE, THIS
LIMITED WARRANTY IS THE SOLE AND EXCLUSIVE
WARRANTY OF MANITOWOC WITH REGARD TO THE
PRODUCT. ALL IMPLIED WARRANTIES ARE STRICTLY
LIMITED TO THE DURATION OF THE LIMITED WARRANTY
APPLICABLE TO THE PRODUCTS AS STATED ABOVE,
INCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF
MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR
PURPOSE.
Some states do not allow limitations on how long an
implied warranty lasts, so the above limitation may not
apply to you.

Part Number 80-1479-3 7/10 19
IN NO EVENT SHALL MANITOWOC OR ANY OF ITS
AFFILIATES BE LIABLE TO THE CONSUMER OR ANY
OTHER PERSON FOR ANY INCIDENTAL, CONSEQUENTIAL
OR SPECIAL DAMAGES OF ANY KIND (INCLUDING,
WITHOUT LIMITATION, LOSS OF PROFITS, REVENUE OR
BUSINESS) ARISING FROM OR IN ANY MANNER
CONNECTED WITH THE PRODUCT, ANY BREACH OF THIS
LIMITED WARRANTY, OR ANY OTHER CAUSE
WHATSOEVER, WHETHER BASED ON CONTRACT, TORT
OR ANY OTHER THEORY OF LIABILITY.
Some states do not allow the exclusion or limitation of
incidental or consequential damages, so the above
limitation or exclusion may not apply to you.
HOW STATE LAW APPLIES
This limited warranty gives you specific legal rights,
and you may also have rights that vary from state to
state or from one jurisdiction to another.
REGISTRATION CARD
To secure prompt and continuing warranty service, this
warranty registration card must be completed and sent
to Manitowoc within thirty (30) days from the sale date.
Complete the registration card and send it to
Manitowoc.

20 Part Number 80-1479-3 7/10
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