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 8/12
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:
!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.

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:
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 it
may slow you down as you work.

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
manual, do not proceed, contact Manitowoc
Foodservice. We will be happy to provide
assistance.
!Caution
Proper installation, care and maintenance are
essential for maximum performance and trouble-
free operation of your equipment. Visit our
website www.manitowocfsg.com for manual
updates, translations, or contact information for
service agents in your area.
Important
Routine adjustments and maintenance
procedures outlined in this handbook are not
covered by the warranty.
!Warning
Read this manual thoroughly before operating,
installing or performing maintenance on the
equipment. Failure to follow instructions in this
manual can cause property damage, injury or
death.

!Warning
Do not use electrical appliances or accessories
other than those supplied by Manitowoc for your ice
machine model.
!Warning
Two or more people or a lifting device are
required to lift this appliance.
!Warning
This equipment contains high voltage electricity
and refrigerant charge. Installation and repairs are
to be performed by properly trained technicians
aware of the dangers of dealing with high voltage
electricity and refrigerant under pressure.The
technician must also be certified in proper
refrigerant handling and servicing procedures. All
lockout and tag out procedures must be followed
when working on this equipment.
!Warning
Do not damage the refrigeration circuit when
installing, maintaining or servicing the unit.

!Warning
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. Do not allow
children to play with this appliance.
!Warning
All covers and access panels must be in place
and properly secured, before operating this
equipment.
!Warning
Do not obstruct machine vents or openings.
!Warning
Do not store gasoline or other flammable vapors
or liquids in the vicinity of this or any other
appliance.
!Warning
Do not clean with water jet.

!Warning
It is the responsibility of the equipment owner to
perform a Personal Protective Equipment Hazard
Assessment to ensure adequate protection
during maintenance procedures.
!Warning
Two or more people are required to move this
equipment to prevent tipping.

!Warning
When using electric appliances, basic
precautions must always be followed, including
the following:
a. Read all the instructions before using
the appliance.
b. To reduce the risk of injury, close
supervision is necessary when an
appliance is used near children.
c. Do not contact moving parts.
d. Only use attachments recommended or
sold by the manufacturer.
e. Do not use outdoors.
f. For a cord-connected appliance, the
following must be included:
• Do not unplug by pulling on cord. To
unplug, grasp the plug, not the cord.
• Unplug from outlet when not in use
and before servicing or cleaning.
• Do not operate any appliance with a
damaged cord or plug, or after the
appliance malfunctions or is dropped
or damaged in any manner. Contact
the nearest authorized service facility
for examination, repair, or electrical
or mechanical adjustment.
g. Follow applicable lock out tag out
procedures before working on
equipment.
h. Connect to a properly grounded outlet
only.

We reserve the right to make product
improvements at any time. Specifications and
design are subject to change without notice.

Part Number STH025 8/12 11
Table of Contents
General Information
How to Read a Model Number . . . . . . . . . 17
Head Sections . . . . . . . . . . . . . . . . . . . 17
Ice Cube Sizes . . . . . . . . . . . . . . . . . . . . . 18
Model/Serial Number Location . . . . . . . . 18
Model Numbers . . . . . . . . . . . . . . . . . . . . . 19
Air-Water-Remote Condenser Models 19
Ice Machine Warranty Information . . . . . 21
Owner Warranty Registration Card . . . 21
Commercial Warranty Coverage . . . . . 22
Residential Ice Machine Limited Warranty
24
Installation
Ice Deflector . . . . . . . . . . . . . . . . . . . . 29
Location of Ice Machine . . . . . . . . . . . . . . 30
Clearance Requirements . . . . . . . . . . . . . 31
Air, Water, Remote Condenser Models 31
Ice Machine Heat of Rejection . . . . . . . . . 32
Installation on a Bin . . . . . . . . . . . . . . . . . 33
Ice Machine on a Dispenser Installation 33
Lineset Applications . . . . . . . . . . . . . . . . 34
Remote Condenser . . . . . . . . . . . . . . . 35
Additional Refrigerant Charge For 
51’ to 100’ Line Sets . . . . . . . . . . . . . . 36
Calculating Allowable Lineset Distance 37

12 Part Number STH025 8/12
Maintenance
Cleaning and Sanitizing . . . . . . . . . . . . . 39
General . . . . . . . . . . . . . . . . . . . . . . . . 39
Cleaning/Sanitizing Procedure . . . . . . 41
Preventative Maintenance Cleaning Proce-
dure . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Exterior Cleaning . . . . . . . . . . . . . . . . 41
Cleaning / Sanitizing Procedure . . . . . . . 42
Cleaning Procedure . . . . . . . . . . . . . . 42
Sanitizing Procedure . . . . . . . . . . . . . 45
Parts Removal for Cleaning/Sanitizing. 48
Preventative Maintenance Cleaning Proce-
dure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Removal from Service/Winterization . . . 56
Air-Cooled Ice Machines . . . . . . . . . . 56
Water-Cooled Ice Machines . . . . . . . . 57
Operation
Control Panel Features . . . . . . . . . . . . . . 59
Buttons . . . . . . . . . . . . . . . . . . . . . . . . 59
Display Panel . . . . . . . . . . . . . . . . . . . 60
Menu Navigation Overview . . . . . . . . . . . 61
Display Panel Navigation . . . . . . . . . . . . 62
Alerts and Messages . . . . . . . . . . . . . . . . 64
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . 65
Machine Info Menu . . . . . . . . . . . . . . . . . 66
Reset Password To Factory Defaults . 66
Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . 67
Language . . . . . . . . . . . . . . . . . . . . . . 68
Time & Date . . . . . . . . . . . . . . . . . . . . 68
Time Configuration . . . . . . . . . . . . . . . 70
Units . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Ice Clarity . . . . . . . . . . . . . . . . . . . . . . 71
LCD Brightness . . . . . . . . . . . . . . . . . 71

Part Number STH025 8/12 13
Password Entry . . . . . . . . . . . . . . . . . . . . 72
Clean Minder . . . . . . . . . . . . . . . . . . . . 73
IAuCS Runtime . . . . . . . . . . . . . . . . . . 74
Air Filter . . . . . . . . . . . . . . . . . . . . . . . . 74
Water Filter . . . . . . . . . . . . . . . . . . . . . 75
LuminIce™ reminder . . . . . . . . . . . . . . 76
Ice Bin Level Sensor . . . . . . . . . . . . . . 77
USB Setup . . . . . . . . . . . . . . . . . . . . . 77
Energy Saver Menu . . . . . . . . . . . . . . . . . 78
Ice Program . . . . . . . . . . . . . . . . . . . . . 79
Water Miser . . . . . . . . . . . . . . . . . . . . . 80
Statistics . . . . . . . . . . . . . . . . . . . . . . . 80
Factory Defaults . . . . . . . . . . . . . . . . . 81
Service Menu . . . . . . . . . . . . . . . . . . . . . . 82
Data History . . . . . . . . . . . . . . . . . . . . 84
Real Time Data . . . . . . . . . . . . . . . . . . 85
Diagnostics . . . . . . . . . . . . . . . . . . . . . 87
Manual Harvest . . . . . . . . . . . . . . . . . . 88
Replace Control Board . . . . . . . . . . . . 88
USB Setup . . . . . . . . . . . . . . . . . . . . . 88
Event Log Menu . . . . . . . . . . . . . . . . . 89
Event Log . . . . . . . . . . . . . . . . . . . . . . 90
USB Flash Drive Specifications and Format-
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Upgrading Firmware with a Flash Drive 96
Exporting Data to a Flash Drive . . . . . 98
Operational Checks . . . . . . . . . . . . . . . . . 100
General . . . . . . . . . . . . . . . . . . . . . . . . 100
Ice Thickness Check . . . . . . . . . . . . . . 101
Sequence of Operation . . . . . . . . . . . . . . 102
Self Contained Air or Water Cooled . . 102
Energized Parts Chart Self Contained Mod-
els . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Remote Condenser . . . . . . . . . . . . . . . 108
Energized Parts Chart Remote Models 111

14 Part Number STH025 8/12
Troubleshooting
Safety Limits . . . . . . . . . . . . . . . . . . . . . . 113
Safe Operation Mode . . . . . . . . . . . . . 113
Analyzing Why a Safety Limit Stopped the
Ice Machine . . . . . . . . . . . . . . . . . . . . 114
Safety Limit #1 . . . . . . . . . . . . . . . . . . 115
Safety Limit #2 . . . . . . . . . . . . . . . . . . 116
Troubleshooting By Symptom . . . . . . . . 117
Reset To Factory Defaults . . . . . . . . . 118
Symptom #1 Ice Machine Will Not Run 119
Symptom #2 - Low Production, Long Freeze
Cycle . . . . . . . . . . . . . . . . . . . . . . . . . 122
Symptom #2 - Freeze Cycle Refrigeration
System Operational Analysis Tables . 125
Symptom #3 & #4 Harvest Problems 
Self-contained Air, Water & Remote Con-
denser Models . . . . . . . . . . . . . . . . . . 154
Symptom #3 Self-Contained Air or Water-
cooled . . . . . . . . . . . . . . . . . . . . . . . . . 155
Symptom #3 - Remote Condenser . . . 157
Symptom #4 Self-Contained Air, Water-
cooled or Remote . . . . . . . . . . . . . . . . 159

Part Number STH025 8/12 15
Component Check Procedures
Electrical Components . . . . . . . . . . . . . . . 161
Control Board, Display board and Touch
Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Control Board Relay Test . . . . . . . . . . 164
Programming A Replacement Control Board
165
Main Fuse . . . . . . . . . . . . . . . . . . . . . . 167
Bin Switch . . . . . . . . . . . . . . . . . . . . . . 168
Water Level Control Circuitry . . . . . . . 171
Ice Thickness Probe (Harvest Initiation)
177
High Pressure Cutout (HPCO) Control 182
Fan Cycle Control . . . . . . . . . . . . . . . . 185
Thermistors . . . . . . . . . . . . . . . . . . . . . 186
Harvest Assist Air Pump . . . . . . . . . . . 189
Compressor Electrical Diagnostics . . . 190
Diagnosing Start Components . . . . . . 192
Refrigeration Components . . . . . . . . . . . 195
Head Pressure Control Valve . . . . . . . 195
Harvest Pressure Regulating (HPR) System
Remote Condenser Only . . . . . . . . . . . 199
Water Regulating Valve . . . . . . . . . . . 202
Refrigerant Recovery/Evacuation . . . . . . 203
Self-Contained Model Procedure . . . . 203
Remote Condenser Model Procedure . 207
System Contamination Clean-Up . . . . . . 213
Determining Severity Of Contamination 213
Cleanup Procedure . . . . . . . . . . . . . . . 215
Replacing Pressure Controls Without Re-
moving Refrigerant Charge . . . . . . . . . 218
Liquid Line Filter-Driers . . . . . . . . . . . . 219
Total System Refrigerant Charge . . . . 220

16 Part Number STH025 8/12
Charts
Cycle Times/24-Hour Ice Production/
Refrigerant Pressure Charts . . . . . . . . . . 221
I0300 Series . . . . . . . . . . . . . . . . . . . . 222
I0320 Series . . . . . . . . . . . . . . . . . . . . 224
I0450 Series . . . . . . . . . . . . . . . . . . . . 226
I0500 Series . . . . . . . . . . . . . . . . . . . . 228
I0520 Series . . . . . . . . . . . . . . . . . . . . 231
I0600 Series . . . . . . . . . . . . . . . . . . . . 233
I0850 Series . . . . . . . . . . . . . . . . . . . . 236
I1000 Series . . . . . . . . . . . . . . . . . . . . 239
I1200 Series . . . . . . . . . . . . . . . . . . . . 242
I1400 Series . . . . . . . . . . . . . . . . . . . . 244
I1800 Series . . . . . . . . . . . . . . . . . . . . 247
Diagrams
Wiring Diagrams . . . . . . . . . . . . . . . . . . . 251
Wiring Diagram Legend . . . . . . . . . . . 251
I0300/I0450/I0500/I0520 . . . . . . . . . . 252
I0320 . . . . . . . . . . . . . . . . . . . . . . . . . 253
I0500 . . . . . . . . . . . . . . . . . . . . . . . . . 254
I0600/I0850/I1000/I1200 . . . . . . . . . . 255
I0600/I0850/I1000 . . . . . . . . . . . . . . . 256
I1400/I1800 . . . . . . . . . . . . . . . . . . . . 257
I1400/I1800 . . . . . . . . . . . . . . . . . . . . 258
Electronic Control Board . . . . . . . . . . . . 259
Refrigeration Tubing Schematics . . . . . 260
Self-Contained Air or Water -Cooled . 260
Remote Condenser Models . . . . . . . . 261

Part Number STH025 8/12 17
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
6 - Energy Plus Model

18 Part Number STH025 8/12
Ice Cube Sizes
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.
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
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 8/12 19
Model Numbers
AIR-WATER-REMOTE CONDENSER MODELS
Self-Contained
Air-Cooled Self-Contained Water-Cooled Remote
ID0302A
IY0304A
ID0306A
IY0306A
ID0303W
IY0305W
ID0306W
IY0306W
----
ID0322A
IY0324A
ID0323W
IY0325W
----
IR0520A
ID0522A
IY0524A
IR0421W
ID0423W
IY0425W
----
----
ID0452A
IY0454A
ID0456A
IY0456A
ID0453W
IY0455W
ID0456W
IY0456W
----
IR0500A
ID0502A
IY0504A
IR0501W
ID0503W
IY0505W
IR0590N
ID0592N
IY0594N
ID0602A
IY0604A
ID0606A
IY0606A
ID0603W
IY0605W
ID0606W
IY0606W
ID0692N
IY0694N
ID0696N
IY0696N
IR0850A
ID0852A
IY0854A
IR0856A
ID0856A
IY0856A
IR0851W
ID0853W
IY0855W
IR0856W
ID0856W
IY0856W
IR0890N
ID0892N
IY0894N
IR0896N
ID0896N
IY0896N
ID1002A
IY1004A
ID1006A
IY1006A
ID1003W
IY1005W
ID1006W
IY1006W
ID1092N
IY1094N
ID1096N
IY1096N
ID1202A
IY1204A
ID1206A
IY1206A
ID1203W
IY1205W
ID1206W
IY1206W
---

20 Part Number STH025 8/12
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
ID1402A
IY1404A
ID1406A
IY1406A
ID1403W
IY1405W
ID1406W
IY1406W
ID1492N
IY1494N
ID1496N
IY1496N
IR1800A
ID1802A
IY1804A
IR1801W
ID1803W
IY1805W
IR1890N
ID1892N
IY1894N
Self-Contained
Air-Cooled Self-Contained Water-Cooled Remote