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