Manitowoc Indigo Series 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
Indigo™ Series
Air/Water/Remote Condenser
Ice Machines
Part Number STH025 02/12
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 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 equipment. Be sure
to read the Caution statement before proceeding,
and work carefully.
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 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 installation, care and maintenance are
essential for maximum performance and trouble-
free operation of your Manitowoc equipment. If
you encounter problems not covered by this
handbook, do not proceed, contact Manitowoc
Foodservice. We will be happy to provide
assistance.
Important
Routine adjustments and maintenance
procedures outlined in this handbook 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.
We reserve the right to make product
improvements at any time. Specifications and
design are subject to change without notice.

Part Number STH025 02/12 5
Table of Contents
General Information
How to Read a Model Number . . . . . . . . . 11
Head Sections . . . . . . . . . . . . . . . . . . . 11
Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . 12
Model/Serial Number Location . . . . . . . . 13
Model Numbers . . . . . . . . . . . . . . . . . . . . . 14
Air-Water-Remote Condenser Models 14
Ice Machine Warranty Information . . . . . 15
Owner Warranty Registration Card . . . 15
Commercial Warranty Coverage . . . . . 16
Residential Ice Machine Limited Warranty
18
Installation
Ice Deflector . . . . . . . . . . . . . . . . . . . . 23
Location of Ice Machine . . . . . . . . . . . . . . 24
Clearance Requirements . . . . . . . . . . . . . 25
Air, Water, Remote Condenser Models 25
Ice Machine Heat of Rejection . . . . . . . . . 26
Installation on a Bin . . . . . . . . . . . . . . . . . 27
Ice Machine on a Dispenser Installation 27
Lineset Applications . . . . . . . . . . . . . . . . 28
Remote Condenser . . . . . . . . . . . . . . . 29
Additional Refrigerant Charge For
51’ to 100’ Line Sets . . . . . . . . . . . . . . 30
Calculating Allowable Lineset Distance 31
Component Identification
I Model Single Evaporator Models . . . . . 35

6 Part Number STH025 02/12
Maintenance
Cleaning and Sanitizing . . . . . . . . . . . . . 37
General . . . . . . . . . . . . . . . . . . . . . . . . 37
Cleaning/Sanitizing Procedure . . . . . . 39
Preventative Maintenance Cleaning Proce-
dure . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Exterior Cleaning . . . . . . . . . . . . . . . . 39
Cleaning / Sanitizing Procedure . . . . . . . 40
Cleaning Procedure . . . . . . . . . . . . . . 40
Sanitizing Procedure . . . . . . . . . . . . . 43
Parts Removal for Cleaning/Sanitizing. 46
Removal from Service/Winterization . . . 52
Air-Cooled Ice Machines . . . . . . . . . . 52
Water-Cooled Ice Machines . . . . . . . . 53
Operation
Control Panel Features . . . . . . . . . . . . . . 57
Buttons . . . . . . . . . . . . . . . . . . . . . . . . 57
Display Panel . . . . . . . . . . . . . . . . . . . 58
Menu Navigation Overview . . . . . . . . . . . 59
Display Panel Navigation . . . . . . . . . . . . 60
Alerts and Messages . . . . . . . . . . . . . . . . 62
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . 63
Machine Info Menu . . . . . . . . . . . . . . . . . 64
Password Entry . . . . . . . . . . . . . . . . . . . . 65
Reset Password To Factory Defaults . 67

Part Number STH025 02/12 7
Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . 68
Language . . . . . . . . . . . . . . . . . . . . . . 68
Time & Date . . . . . . . . . . . . . . . . . . . . 68
Time Configuration . . . . . . . . . . . . . . . 70
Units . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Ice Clarity . . . . . . . . . . . . . . . . . . . . . . 71
LCD Brightness . . . . . . . . . . . . . . . . . . 71
Password On . . . . . . . . . . . . . . . . . . . . 72
Edit password . . . . . . . . . . . . . . . . . . . 72
Clean Minder . . . . . . . . . . . . . . . . . . . . 72
IAuCS Runtime . . . . . . . . . . . . . . . . . . 73
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . 73
Water Filter . . . . . . . . . . . . . . . . . . . . . 74
LuminIce™ reminder . . . . . . . . . . . . . . 74
USB Setup . . . . . . . . . . . . . . . . . . . . . 75
Factory Defaults . . . . . . . . . . . . . . . . . 75
Energy Saver Menu . . . . . . . . . . . . . . . . . 76
Ice Program . . . . . . . . . . . . . . . . . . . . . 77
Water Miser . . . . . . . . . . . . . . . . . . . . . 78
Statistics . . . . . . . . . . . . . . . . . . . . . . . 78
Service Menu . . . . . . . . . . . . . . . . . . . . . . 79
Data History . . . . . . . . . . . . . . . . . . . . 81
Real Time Data . . . . . . . . . . . . . . . . . . 82
Diagnostics . . . . . . . . . . . . . . . . . . . . . 84
Manual Harvest . . . . . . . . . . . . . . . . . . 85
Replace Control Board . . . . . . . . . . . . 85
USB Setup . . . . . . . . . . . . . . . . . . . . . 85
Event Log Menu . . . . . . . . . . . . . . . . . 86
Event Log . . . . . . . . . . . . . . . . . . . . . . 87
USB Flash Drive Specifications and Format-
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Upgrading Firmware with a Flash Drive or
Transferring Setup Data To Multiple Ma-
chines . . . . . . . . . . . . . . . . . . . . . . . . . 93
Exporting Data to a Flash Drive . . . . . 95
Safe Operation Mode . . . . . . . . . . . . . 96

8 Part Number STH025 02/12
Operational Checks . . . . . . . . . . . . . . . . . 97
General . . . . . . . . . . . . . . . . . . . . . . . . 97
Ice Thickness Check . . . . . . . . . . . . . 98
Sequence of Operation . . . . . . . . . . . . . . 99
Self Contained Air or Water Cooled . . 99
Remote Condenser . . . . . . . . . . . . . . 104
Troubleshooting
Safety Limits . . . . . . . . . . . . . . . . . . . . . . 109
Analyzing Why a Safety Limit Stopped the
Ice Machine . . . . . . . . . . . . . . . . . . . . 110
Safety Limit #1 . . . . . . . . . . . . . . . . . . 111
Safety Limit #2 . . . . . . . . . . . . . . . . . . 112
Troubleshooting By Symptom . . . . . . . . 115
Symptom #1 Ice Machine will not run . 117
Symptom #2 - Self-contained Air, Water &
Remote Condenser Models . . . . . . . . 123
Symptom #2 - Freeze Cycle Refrigeration
System Operational Analysis Tables . 125
Symptom #3 Harvest Problems
Self-contained Air, Water & Remote Con-
denser Models . . . . . . . . . . . . . . . . . . 148
Symptom #3 Self-Contained Air or Water-
cooled . . . . . . . . . . . . . . . . . . . . . . . . . 149
Symptom #3 - Remote Condenser . . . 151
Symptom #4 Self-Contained Air, Water-
cooled or Remote . . . . . . . . . . . . . . . . 153

Part Number STH025 02/12 9
Component Check Procedures
Electrical Components . . . . . . . . . . . . . . . 157
Control Board, Display board and Touch
Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Control Board Relay Test . . . . . . . . . . 160
USB Flash Drive Specifications and Format-
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Upgrading Firmware with a Flash Drive or
Transferring Setup Data To Multiple Ma-
chines . . . . . . . . . . . . . . . . . . . . . . . . . 164
Exporting Data to a Flash Drive . . . . . 166
Programming A Replacement Control Board
168
Main Fuse . . . . . . . . . . . . . . . . . . . . . . 170
Bin Switch . . . . . . . . . . . . . . . . . . . . . . 171
Water Level Control Circuitry . . . . . . . 174
Ice Thickness Probe (Harvest Initiation)
178
High Pressure Cutout (HPCO) Control 182
Fan Cycle Control . . . . . . . . . . . . . . . . 185
Thermistors . . . . . . . . . . . . . . . . . . . . . 186
Harvest Assist Air Pump . . . . . . . . . . . 190
Compressor Electrical Diagnostics . . . 191
Diagnosing Start Components . . . . . . 193
Refrigeration Components . . . . . . . . . . . 198
Head Pressure Control Valve . . . . . . . 198
Harvest Pressure Regulating (HPR) System
Remote Condenser Only . . . . . . . . . . . 202
Water Regulating Valve . . . . . . . . . . . 205
Refrigerant Recovery/Evacuation . . . . . . 206
Self-Contained Model Procedure . . . . 206
Remote Condenser Model Procedure . 210

10 Part Number STH025 02/12
System Contamination Clean-Up . . . . . . 216
Determining Severity Of Contamination 216
Cleanup Procedure . . . . . . . . . . . . . . 218
Replacing Pressure Controls Without Re-
moving Refrigerant Charge . . . . . . . . 221
Liquid Line Filter-Driers . . . . . . . . . . . 223
Total System Refrigerant Charge . . . . 224
Charts
Cycle Times/24-Hour Ice Production/
Refrigerant Pressure Charts . . . . . . . . . . 225
I0300 Series . . . . . . . . . . . . . . . . . . . . 226
I0320 Series . . . . . . . . . . . . . . . . . . . . 228
I0450 Series . . . . . . . . . . . . . . . . . . . . 230
I0500 Series . . . . . . . . . . . . . . . . . . . . 232
I0520 Series . . . . . . . . . . . . . . . . . . . . 235
I0600 Series . . . . . . . . . . . . . . . . . . . . 237
I0850 Series . . . . . . . . . . . . . . . . . . . . 240
I1000 Series . . . . . . . . . . . . . . . . . . . . 243
I1200 Series . . . . . . . . . . . . . . . . . . . . 246
I1400 Series . . . . . . . . . . . . . . . . . . . . 248
I1800 Series . . . . . . . . . . . . . . . . . . . . 251
Diagrams
Wiring Diagrams . . . . . . . . . . . . . . . . . . . 255
Wiring Diagram Legend . . . . . . . . . . . 255
I0300/I0450/I0500/I0520 . . . . . . . . . . 256
I0320 . . . . . . . . . . . . . . . . . . . . . . . . . 257
I0500 . . . . . . . . . . . . . . . . . . . . . . . . . 258
I0600/I0850/I1000/I1200 . . . . . . . . . . 259
I0600/I0850/I1000 . . . . . . . . . . . . . . . 260
I1400/I1800 . . . . . . . . . . . . . . . . . . . . 261
I1400/I1800 . . . . . . . . . . . . . . . . . . . . 262
Electronic Control Board . . . . . . . . . . . . 263
Refrigeration Tubing Schematics . . . . . 264
Self-Contained Air or Water -Cooled . 264
Remote Condenser Models . . . . . . . . 265

Part Number STH025 02/12 11
General Information
How to Read a Model Number
HEAD SECTIONS
I Y 0855 W3 – 263PHPX
ICE MACHINE MODEL I - Indigo Model IB - Ice Beverage # CUBE SIZE CONDENSER TYPE 0 - Regular Air-Cooled 1 - Regular Water-Cooled 2 - Dice Air-Cooled 3 - Dice Water-Cooled 4 - Half-Dice Air-Cooled 5 - Half-Dice Water-Cooled
0 to 6 & 8 - Self-Contained Unit 7 & 8 - CVD Remote Condensing Unit 9 - Remote Air-Cooled Condenser
OR
9 - Ice Beverage Remote Condensing Unit
ICE CUBE SIZE R - Regular D - Dice Y - Half-Dice Not Used On IB Models
Ice Machine Series
CONDENSER TYPE
A - Self-Contained Air -Cooled W - Self-Contained Water -Cooled N - Remote Air-Cooled C - CVD Air-Cooled DC - IB Dice Model YC - IB Half Dice 3 - Three Phase
E - WRAS 50 Cycle Only NO INDICATOR- 1 Phase
VOLTAGE
161 - 115/60/1 261 - 208-230 /60/1 251 - 230/50/1 263 - 208-230 /60/3 463 - 460/60/3
# HERTZ
5 - 50HZ 6 - 60HZ
HP - High Pressure Water
Regulating Valve
P - Correctional Model M - Marine Model
X - LuminIce

12 Part Number STH025 02/12
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. This appliance is not
intended for use by persons (including children) with
reduced physical, sensory or mental capabilities, or
lack of experience and knowledge, unless they have
been given supervision concerning use of the
appliance by a person responsible for their safety.
!Warning
All Manitowoc ice machines require the ice
storage system (bin, dispenser, etc.) to
incorporate an ice deflector.
Prior to using a non-Manitowoc ice storage
system with other Manitowoc ice machines,
contact the manufacturer to assure their ice
deflector is compatible with Manitowoc ice
machines.

Part Number STH025 02/12 13
Model/Serial Number Location
These numbers are required when requesting
information from your local Manitowoc Distributor,
service representative, or Manitowoc Ice. 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 front and rear of the ice machine.

14 Part Number STH025 02/12
Model Numbers
AIR-WATER-REMOTE CONDENSER MODELS
NOTE: Marine and Prison models have a M or P suffix -
Example ID0853WM
3 suffix at the end of the model number indicates a 3 phase
unit - Example IY1004A3
Self-Contained
Air-Cooled Self-Contained Water-Cooled Remote
ID0302A
IY0304A
ID0303W
IY0305W
----
ID0322A
IY0324A
ID0323W
IY0325W
----
IR0520A
ID0522A
IY0524A
IR0421W
ID0423W
IY0425W
----
----
ID0452A
IY0454A
ID0453W
IY0455W
----
IR0500A
ID0502A
IY0504A
IR0501W
ID0503W
IY0505W
IR0590N
ID0592N
IY0594N
ID0602A
IY0604A
ID0603W
IY0605W
ID0692N
IY0694N
IR0850A
ID0852A
IY0854A
IR0851W
ID0853W
IY0855W
IR0890N
ID0892N
IY0894N
ID1002A
IY1004A
ID1003W
IY1005W
ID1092N
IY1094N
ID1202A
IY1204A
ID1203W
IY1205W
---
ID1402A
IY1404A
ID1403W
IY1405W
ID1492N
IY1494N
IR1800A
ID1802A
IY1804A
IR1801W
ID1803W
IY1805W
IR1890N
ID1892N
IY1894N

Part Number STH025 02/12 15
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 born on date
recorded in the control board or 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 OWNER WARRANTY
REGISTRATION CARD as soon as possible to
validate the installation date.

16 Part Number STH025 02/12
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 STH025 02/12 17
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

18 Part Number STH025 02/12
RESIDENTIAL ICE MACHINE LIMITED WARRANTY
WHAT DOES THIS LIMITED WARRANTY COVER?
Subject to the exclusions and limitations below,
Manitowoc Ice (“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 STH025 02/12 19
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

20 Part Number STH025 02/12
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 ASSTATED INTHE FOLLOWING SENTENCE, THIS
LIMITED WARRANTY ISTHE SOLE AND EXCLUSIVE
WARRANTY OFMANITOWOC WITH REGARD TOTHE
PRODUCT. ALL IMPLIED WARRANTIES ARE STRICTLY
LIMITED TOTHE DURATION OFTHE LIMITED WARRANTY
APPLICABLE TOTHE PRODUCTS ASSTATED ABOVE,
INCLUDING BUT NOT LIMITED TO, ANY WARRANTY OF
MERCHANTABILITY OROFFITNESS 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.