Manitowoc Indigo Series User manual

Technician’s Handbook
This manual is updated as new information and models are released.
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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