Manitowoc UG080A User manual

Manitowoc
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
UG Models
Manitowoc Ice P/N 040004390 11/14

Safety Notices
When using or servicing these Ice Machines, 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 ice machine.
Throughout this handbook, you will see the following
types of safety notices:
! Warning
Text in a Warning box alerts you to a potential
personal injury situation. Be sure to read the
Warning statement before proceeding, and work
carefully.
!
Caution
Text in a Caution box alerts you to a situation in
which you could damage the ice machine. Be sure
to read the Caution statement before proceeding,
and work carefully.

Procedural Notices
When using or servicing these Ice Machines, be sure
to read the procedural notices in this handbook. These
notices supply helpful information that may assist you
as you work.
Throughout this handbook, you will see the following
types of procedural notices:
NOTE: Text set off as a Note provides you with
simple, but useful extra information about the
procedure you are performing.
Important
Text in an Important box provides you with
information that may help you perform a procedure
more efficiently. Disregarding this information will not
cause damage or injury, but may slow you down as
you work.

Read These Before Proceeding:
We reserve the right to make product improvements at
any time. Specifications and design are subject to
change without notice.
!
Caution
Proper installation, care and maintenance are
essential for maximum ice production and trouble
free operation of your Manitowoc Ice Machine. If you
encounter problems not covered by this manual, do
not proceed, contact Manitowoc Ice, Inc. We will be
happy to provide assistance.
Important
Routine adjustments and maintenance procedures
outlined in this manual are not covered by the
warranty.
! Warning
PERSONAL INJURY POTENTIAL
Do not operate equipment that has been misused,
abused, neglected, damaged, or altered/modified
from that of original manufactured specifications.
! Warning
POTENTIAL PERSONAL INJURY SITUATION
This ice machine contains refrigerant charge.
Installation and Servicing must be performed by a
properly trained refrigeration technician aware of the
Dangers of dealing with refrigerant charged
equipment.

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Table of Contents
Table of Contents . . . . . . . . . . . . . . . . . . . . . . . . . . 1
General Information 1
Model Numbers. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Installation 3
Location of Ice Machine . . . . . . . . . . . . . . . . . . . . . 3
Water Service/Drains . . . . . . . . . . . . . . . . . . . . . . 4
Electrical Requirements . . . . . . . . . . . . . . . . . . . . 5
Electrical Specifications . . . . . . . . . . . . . . . . . . . . 6
Power Consumption - kwh per 24 hours . . . . . . . 7
Ice Machine Heat of Rejection . . . . . . . . . . . . . . . 8
Component Identification 9
Component Removal . . . . . . . . . . . . . . . . . . . . . 11
Spray Bar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Maintenance 17
Cleaning & Sanitizing Procedure . . . . . . . . . . . . 18
Operation 23
Sequence Of Operation . . . . . . . . . . . . . . . . . . . . 23
Cube Shape . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Troubleshooting 29
All Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Ice Machine Will Not Run. . . . . . . . . . . . . . . . . . 29
Compressor Won’t Run . . . . . . . . . . . . . . . . . . . 30
Compressor Electrical Diagnostics. . . . . . . . . . . 31
Diagnosing Start Components . . . . . . . . . . . . . . 33
Water Pump Won’t Run . . . . . . . . . . . . . . . . . . . 34
Hot Gas Valve Won’t Energize. . . . . . . . . . . . . . 34
Water Inlet Valve Won’t Energize. . . . . . . . . . . . 34
Ice Machine Prematurely Harvests . . . . . . . . . . 35
ce Machine Will Not Harvest . . . . . . . . . . . . . . . 36
Evaporator Thermostat. . . . . . . . . . . . . . . . . . . . 37
Water System Checklist . . . . . . . . . . . . . . . . . . . . 44
Ice Production Check . . . . . . . . . . . . . . . . . . . . . . 45
Analyzing Discharge Pressure . . . . . . . . . . . . . . 46
Discharge Pressure High Checklist . . . . . . . . . . 47
Freeze Cycle Discharge Pressure Low Checklist 48
Analyzing Suction Pressure. . . . . . . . . . . . . . . . . 49
Suction Pressure High Checklist . . . . . . . . . . . . 51

Suction Pressure Low Checklist . . . . . . . . . . . . . 52
Discharge Line Temperature Analysis. . . . . . . . .53
Component Check Procedures 55
On/Off/Wash-Fill Toggle Switch . . . . . . . . . . . . . 55
Bin thermistor (T3). . . . . . . . . . . . . . . . . . . . . . . . 56
SUMP WATER THERMiSTOR (T1)& LIQUID LINE
THERMiSToR(T2). . . . . . . . . . . . . . . . . . . . . . . 58
high Pressure Cutout (HPCO) Control . . . . . . . . 65
Hot Gas Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Refrigerant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .71
Recover/Evacuation/Charging. . . . . . . . . . . . . . . 71
System Contamination Cleanup . . . . . . . . . . . . . 74
Mild System Contamination Cleanup . . . . . . . . . 76
Severe System Contamination Cleanup Procedure
77
Filter-Driers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Total System Refrigeration Charge . . . . . . . . . . 80
Cycle Times/24 Hour Ice Production and
Refrigerant Pressure Charts 81
ug18A Self-Contained Air-Cooled — Standard
Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
ug18A Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . . . 83
ug18A Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . . . 84
UG020A
Self-Contained Air-Cooled — Standard
Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
UG020A
Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . . . 86
UG020A
Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . . . 87
UG030A-251 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
UG030A-251 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
UG030A-251 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . . . 90
UG030A-261 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
UG030A-261 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
UG030A-261 Self-Contained Air-Cooled — Stan-

dard Cube (Continued) . . . . . . . . . . . . . . . . . . 93
UG030A-161 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
UG030A-161 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
UG030A-161 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . . 96
UG030W
Self-Contained WATER--Cooled —
Standard Cube. . . . . . . . . . . . . . . . . . . . . . . . . 97
UG030W
Self-Contained WATER--Cooled —
Standard Cube. . . . . . . . . . . . . . . . . . . . . . . . . 98
UG030W
Self-Contained WATER--Cooled —
Standard Cube (Continued). . . . . . . . . . . . . . . 99
UG040A-251 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
UG040A-251 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . 101
UG040A-251 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . 102
UG040A-261 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
UG040A-261 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . 104
UG040A-261 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . 105
UG050A-251 Self-Contained Air-Cooled — Stan-
dard Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
UG050A-251 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . 107
UG050A-251 Self-Contained Air-Cooled — Stan-
dard Cube (Continued) . . . . . . . . . . . . . . . . . 108
UG050W Self-Contained water-Cooled . . . . . . 109
UG050W Self-Contained water-Cooled . . . . . . 110
UG050W Self-Contained water-Cooled . . . . . . 111
UG065AG-251G Self-Contained Air-Cooled —
Standard Cube. . . . . . . . . . . . . . . . . . . . . . . . 112
UG065 Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . 113
UG065 Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . 114
UG080A Self-Contained Air-Cooled — Standard
Cube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115
UG080A Self-Contained Air-Cooled — Standard
Cube (Continued) . . . . . . . . . . . . . . . . . . . . . 116
UG080A Self-Contained Air-Cooled — Standard

Cube (Continued) . . . . . . . . . . . . . . . . . . . . . . 117
Diagrams 119
Wiring Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . .119
UG18/UG20 air-cooled . . . . . . . . . . . . . . . . . . . 119
UG30/UG50/UG65 air-cooled . . . . . . . . . . . . . . 120
UG30/UG50 water-cooled . . . . . . . . . . . . . . . . 122
Tubing Schematics . . . . . . . . . . . . . . . . . . . . . . .123
ug18/UG20/UG30/UG40/UG65 Tubing Schematic .
123
UG50/UG80 Tubing Schematic. . . . . . . . . . . . . 124

–1–
General Information
Model Numbers
This manual covers the following models:
Self-Contained
Air-Cooled Water-Cooled
UG018A N/A
UG020A N/A
UG030A UG030W
UG040A N/A
UG050A UG050W
UG065A N/A
UG080A N/A

–2–
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3
Installation
Location of Ice Machine
The location selected for the ice machine must meet
the following criteria. If any of these criteria are not
met, select another location.
•The location must be indoors.
•The location must be free of airborne and other
contaminants.
•The air temperature must be at least 10ºC but must
not exceed 43.4ºC.
•The location must not be near heat-generating
equipment or in direct sunlight.
•The location must be capable of supporting the
weight of the ice machine and a full bin of ice.
•The location must allow enough clearance for water,
drain, and electrical connections in the rear of the
ice machine.
•The location must not obstruct airflow through or
around the ice machine (condenser airflow is in and
out the front). Refer to the chart below f or clearance
requirements.
*NOTE: The ice machine may be built into a cabinet.
There is no minimum clearance requirement for the
top or left and right sides of the ice machine. The listed
values are recommended for efficient operation and
servicing only.
Self-Contained
Air-Cooled Self-Contained Water-Cooled
Top/Sides 203 mm (8")* 127 mm (5")*
Back 127 mm (5")* 127 mm (5")*

4
WATER SERVICE/DRAINS
Water Supply
Local water conditions may require treatment of the
water to inhibit scale formation, filter sediment, and
remove chlorine odor and taste.
Water Inlet Lines
•Do not connect the ice machine to a hot water
supply. Be sure all hot water restrictors installed for
other equipment are working. (Check valves on sink
faucets, dishwashers, etc.)
•If water pressure exceeds the maximum
recommended pressure, 5 bar (500 kPA), install a
water pressure regulator.
•Install a water shut-off valve.
Drain Connections
•Drain lines must have a 2.5 cm per meter drop, and
must not create traps.
•The floor drain must be large enough to
accommodate drainage from all drains.
!
Caution
The ice machine must be protected if it will be
subjected to temperatures below 0°C. Failure
caused by exposure to freezing temperatures is not
covered by the warranty.

5
ELECTRICAL REQUIREMENTS
Voltage
The maximum allowable voltage variation is ±6% of
the rated voltage on the ice machine model/serial
number plate at start-up (when the electrical load is
highest).
All ice machines are factory pre-wired with a power
cord only, no plug is supplied.
Fuse/Circuit Breaker
A separate fuse/circuit breaker must be provided for
each ice machine. An electrical disconnect switch
must be provided if the ice machine is hard wired
(wired without a plug).
Total Circuit Ampacity
The total circuit ampacity is used to help select the
wire size of the electrical supply.
The wire size (or gauge) is also dependent upon
location, materials used, length of run, etc., so a
qualified electrician must make the determination.

6
ELECTRICAL SPECIFICATIONS
Ice Machine Voltage/Phase/
Cycle
Air-Cooled Water-Cooled
Maximum Fuse/
Circuit Breaker Total Amps
Maximum
Fuse/Circuit
Breaker
Total Amps
UG018 230/1/50 10 2.0 N/A N/A
UG020
230/1/50 10 2.3 N/A N/A
230/1/60 10 2.3 N/A N/A
UG030
230/1/50 15 2.8 15 2.5
230/1/60 15 2.8 N/A N/A
115/1/60 15 5.5 N/A N/A
UG040
230/1/50 15 3.0 N/A N/A
230/1/60 15 3.0 N/A N/A

7
UG050
230/1/50 15 4.0 15 2.8
230/1/60 15 4.0 N/A N/A
115/1/60 15 6.8 N/A N/A
UG065
230/1/50 15 4.5 N/A N/A
230/1/60 15 4.5 N/A N/A
UG080
230/1/50 15 5.5 N/A N/A
230/1/60 15 5.5 N/A N/A

8
ICE MACHINE HEAT OF REJECTION
Series Ice
Machine
Heat of Rejection
Air Conditioning Peak
UG18 1,150 2,300
UG20 1,400 2,600
UG30 1,900 3,300
UG40 2,100 4,100
UG50 2,600 5,000
UG65 2,900 5,000
UG80 4,300 7,400
BTU/Hour
Because the heat of rejection varies during the ice
making cycle, the figure shown is an average.

9
Component Identification
Water
Curtains
Water
Trough
Control
board
On/Off/Wash-Fill
To g g le S w i t c h
Air Cooled
Condenser

10
Evaporator
Spray
Nozzles
Toggle Switch
Spray Bar
Ice Chute