Manitowoc Indigo Series Technician's Handbook

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

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