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Manitowoc Indigo Series User Manual

Manitowoc Indigo Series
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Technicians
Handbook
This manual is updated as new information and models
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www.manitowocice.com
America’s #1 Selling Ice Machine
Indigo™ Series
Ice Machines
Preliminary Manual
Part Number Preliminary 6/11
Manitowoc

Table of Contents

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Manitowoc Indigo Series Specifications

General IconGeneral
ModelIndigo Series
Ice TypeNugget
Cooling SystemAir-cooled, Water-cooled
Power SupplyVaries by model
MaterialStainless steel exterior
Water Connection1/2" NPT water inlet

Summary

Safety Notices

Procedural Notices

General Information

How to Read a Model Number

HEAD SECTIONS

Details on the components and structure of the head sections.

Model/Serial Number Location

Ice Machine Warranty Information

COMMERCIAL WARRANTY COVERAGE

RESIDENTIAL ICE MACHINE LIMITED WARRANTY

Installation

STACKING TWO ICE MACHINES ON A SINGLE STORAGE BIN

Instructions for stacking ice machines on a single bin.

ICE DEFLECTOR

Requirement for an ice deflector when installed on a bin.

Location of Ice Machine

ICE BEVERAGE MODELS

Location of ICVD Condensing Units

Clearance Requirements

Ice Machine Heat of Rejection

I1470C/I1870C/I2170C

Installation on a Manitowoc Bin

Details for installing these models on Manitowoc bins.

Ice Machine on a Dispenser Installation

Lineset Applications

Remote Condenser

QUIETQUBE® REMOTE CONDENSING UNIT

Additional Refrigerant Charge For 51’ to 100’ Line Sets

CALCULATING ALLOWABLE LINESET DISTANCE

Component Identification

I Model Single Evaporator Models

Visual identification of components for single evaporator models.

Ice Beverage Models

I Model Dual Evaporator

I Model Quad Evaporator Models

ICVD0695/ICVD0895/ICVD1095/ICVD1195/ICVD1295/ICVD1495

ICVD1895/ICVD2195

Maintenance

Cleaning and Sanitizing

Steps for cleaning and sanitizing the ice machine components.

Preventative Maintenance Cleaning Procedure

Exterior Cleaning

Cleaning / Sanitizing Procedure

CLEANING PROCEDURE

Step-by-step guide for cleaning the ice machine.

SANITIZING PROCEDURE

PARTS REMOVAL FOR CLEANING/SANITIZING

Single Evaporator Ice Machines

Part removal instructions specific to single evaporator models.

Ice Beverage Ice Machines

Dual Evaporator Ice Machines

Quad Evaporator Ice Machines

Ice Thickness Probe & Water Level Probe

Water Inlet Valve

Water Dump Valve

Removal from Service/Winterization

AIR-COOLED ICE MACHINES

Winterization steps for air-cooled ice machines.

WATER-COOLED ICE MACHINES

Operation

Control Panel Features

Overview of the control panel buttons and display.

BUTTONS

DISPLAY PANEL

Menu Navigation Overview

Display Panel Navigation

Alerts and Messages

Main Menu

Machine Info Menu

Set-Up Menu

LANGUAGE

Procedure to select the display language.

TIME & DATE

Steps to set the correct time and date for the machine's location.

Password Entry

RESET PASSWORD TO FACTORY DEFAULTS

TIME CONFIGURATION

UNITS

ICE CLARITY

LCD BRIGHTNESS

PASSWORD ON

EDIT PASSWORD

CLEAN MINDER

IAUCS RUNTIME

AIR FILTER

WATER FILTER

LUMINICE™ REMINDER

USB SETUP

FACTORY DEFAULTS

Energy Saver Menu

WATER MISER

Feature to reduce water usage by eliminating flush cycles.

ICE PROGRAM

STATISTICS

Service Menu

Data History

Accessing historical operational data and event logs.

Real Time Data

Viewing live operational data for temperature, inputs, and outputs.

Diagnostics

Running diagnostic tests on control board, sensors, and switches.

Manual Harvest

Initiating a manual harvest cycle.

Replace Control Board

Procedure for programming a replacement control board.

USB Setup

USB setup options for firmware and data transfer.

Event Log Menu

Accessing and clearing the event log.

EVENT LOG

UPGRADING FIRMWARE WITH A FLASH DRIVE OR TRANSFERRING SETUP DATA TO MULTIPLE MACHINES

Control Board

EXPORTING DATA TO A FLASH DRIVE

SAFE OPERATION MODE

Operational Checks

ICE THICKNESS CHECK

Sequence of Operation

SELF CONTAINED AIR OR WATER COOLED

Describes the operation sequence for self-contained air/water cooled models.

Single & Quad Evaporator Models

Operation sequence specific to single and quad evaporator models.

Prechill

Freeze

Water Purge

Harvest

Automatic Shut-Off

Control Board Timers

Single Evaporator Self Contained Air & Water-Cooled Models Energized Parts Chart

REMOTE CONDENSER

Single Evaporator Models

Operation sequence for single evaporator remote condenser models.

Prechill

Freeze

Water Purge

Harvest

Automatic Shut-Off

Single Evaporator Remote Air-Cooled Condenser Models Energized Parts Chart

QUIETQUBE® MODELS

INITIAL START-UP OR START-UP AFTER AUTOMATIC SHUT-OFF

Startup procedures for QuietQube® models.

Pre chill

Freeze

Water Purge

Harvest

AUTOMATIC SHUT-OFF

RESTART AFTER AUTOMATIC SHUT-OFF

Single & Twin Evaporator QuietQube® Models Energized Parts Chart

SAFETY TIMERS

WATER ASSIST HARVEST FEATURE

Troubleshooting

Safety Limits

Explanation of built-in safety limit controls protecting against component failure.

ANALYZING WHY A SAFETY LIMIT STOPPED THE ICE MACHINE

SAFETY LIMIT #1

SAFETY LIMIT #2

Troubleshooting By Symptom

SYMPTOM #1

Troubleshooting steps for ice machine stops running or history of shutdown.

SYMPTOM #2

Troubleshooting steps for long freeze cycles, thick ice, or low production.

SYMPTOM #3

Troubleshooting steps for harvest problems with normal freeze cycle.

Symptom #4

Troubleshooting steps for harvest problems with melted ice cubes.

Reset To Factory Defaults

SYMPTOM #1 ICE MACHINE WILL NOT RUN

Diagnosing an Ice Machine That Will Not Run

DIAGNOSING A CONDENSING UNIT THAT WILL NOT RUN

COMPRESSOR ELECTRICAL DIAGNOSTICS

CHECK MOTOR WINDINGS TO GROUND

COMPRESSOR DRAWING LOCKED ROTOR

COMPRESSOR DRAWING HIGH AMPS

SYMPTOM #2 - SELF-CONTAINED AIR, WATER & REMOTE CONDENSER MODELS

How to Use the Freeze Cycle Refrigeration System Operational Analysis Table

Guidance on using the operational analysis tables for diagnosis.

PROCEDURE

SYMPTOM #2 - FREEZE CYCLE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES

SINGLE EXPANSION VALVE SELF CONTAINED AIR, WATER & REMOTE CONDENSER

Analysis tables specific to single expansion valve models.

DUAL EXPANSION VALVE SELF CONTAINED AIR, WATER & REMOTE CONDENSER

FOUR EXPANSION VALVE SELF CONTAINED WATER-COOLED S

Ice Production Check

Installation/Visual Inspection Checklist

Water System Checklist

Ice Formation Pattern

Normal Ice Formation

Description and characteristics of normal ice formation.

Extremely Thin at Evaporator Outlet

Extremely Thin at Evaporator Inlet

No Ice Formation

Evaporator Tubing Routing

Analyzing Discharge Pressure in the Freeze Cycle

FREEZE CYCLE DISCHARGE PRESSURE HIGH CHECKLIST

FREEZE CYCLE DISCHARGE PRESSURE LOW CHECKLIST

Analyzing Suction Pressure

Suction Pressure High Checklist

SUCTION PRESSURE LOW CHECKLIST

Self-contained & Remote Condenser Single Expansion Valve Machines - Comparing Evaporator Inlet and Outlet Temperatures

Self-contained Multiple Expansion Valve Ice Machines - Comparing Evaporator Outlet Temperatures

Harvest Valve Analysis

SELF-CONTAINED OR REMOTE CONDENSER MODELS HARVEST VALVE ANALYSIS

Analysis steps for harvest valves on self-contained/remote models.

Discharge Line Temperature Analysis

Water Regulating Valve

Final Analysis - Self-contained Air, Water & Remote Condenser Models

COLUMN 3 - TXV FLOODING OR REFRIGERANT OVERCHARGE

COLUMN 4 - COMPRESSOR

COLUMN 5 - HARVEST PRESSURE VALVE LEAKING (4 EVAPORATOR MODELS ONLY)

SYMPTOM #3 HARVEST PROBLEMS

SELF-CONTAINED AIR, WATER & REMOTE CONDENSER MODELS

Harvest problem diagnosis for specific models.

SYMPTOM #3 SELF-CONTAINED AIR OR WATER-COOLED

SYMPTOM #3 - REMOTE CONDENSER

SYMPTOM #4 SELF-CONTAINED AIR, WATER-COOLED OR REMOTE

Symptom #2 - QuietQube® Remote Condensing Unit Models

SYMPTOM #2 LOW PRODUCTION, LONG FREEZE

Specific issues related to low production and long freeze cycles.

How to Use the Freeze Cycle Refrigeration System Operational Analysis Table

Guidance on using the operational analysis tables for diagnosis.

PROCEDURE

QUIETQUBE® MODELS- Freeze Cycle Refrigeration System Operational Analysis Tables

I Model QuietQube® Single Expansion Valve

Specific analysis tables for I Model QuietQube® single expansion valve.

QUIETQUBE® MODELS- Freeze Cycle Refrigeration System Operational Analysis Tables

Twin Expansion Valve – I1470C/I1870C/I2170C Models

Specific analysis tables for these QuietQube® twin expansion valve models.

QUIETQUBE® MODELS- Freeze Cycle Refrigeration System Operational Analysis Tables

Quad Expansion Valve – I3070C

Specific analysis tables for the I3070C quad expansion valve model.

QUIETQUBE® MODELS - FREEZE CYCLE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLE PROCEDURES

Before Beginning Service

Questions to ask the owner before servicing QuietQube® models.

QuietQube® Models - Ice Production Check

QuietQube® Models - Installation/Visual Inspection Checklist

QuietQube® Models - Water System Checklist

QuietQube® Models - Ice Formation Pattern

Normal Ice Formation

Description and characteristics of normal ice formation.

Extremely Thin at Evaporator Outlet

Extremely Thin at Evaporator Inlet

No Ice Formation

Evaporator Tubing Routing

QuietQube® Models - Analyzing Discharge Pressure in the Freeze Cycle

QUIETQUBE® MODELS - FREEZE CYCLE DISCHARGE PRESSURE HIGH CHECKLIST

QUIETQUBE® MODELS - FREEZE CYCLE DISCHARGE PRESSURE LOW CHECKLIST

QuietQube® Models - Analyzing Suction Pressure

QuietQube® Models - Suction Pressure High Checklist

QUIETQUBE® MODELS - SUCTION PRESSURE LOW CHECKLIST

QuietQube® Models - Harvest Valve Analysis

QUIETQUBE® REMOTE CONDENSING UNIT MODELS

Harvest problem diagnosis for QuietQube® remote models.

QuietQube® Models - Analyzing Freeze Cycle Suction Line Temperature

QuietQube® Model Final Analysis

SYMPTOM #3 HARVEST PROBLEMS

QUIETQUBE® REMOTE CONDENSING UNIT MODELS

Harvest problem diagnosis for QuietQube® remote models.

SYMPTOM #3 QUIETQUBE® MODELS WITH ICVD CONDENSING UNITS

SYMPTOM #4 QUIETQUBE® MODELS WITH ICVD CONDENSING UNITS

Component Check Procedures

Electrical Components

Focus on electrical components like control board, display, touch pad.

CONTROL BOARD, DISPLAY BOARD AND TOUCH PAD

Functional overview of the control board assembly.

Display Diagnostics

Steps to diagnose issues with the display module.

Control Board Diagnostics

Touch Pad Diagnostics

CONTROL BOARD RELAY TEST

UPGRADING FIRMWARE WITH A FLASH DRIVE OR TRANSFERRING SETUP DATA TO MULTIPLE MACHINES

Control Board

EXPORTING DATA TO A FLASH DRIVE

MAIN FUSE

BIN SWITCH

Diagnostics

SYMPTOMS

Common symptoms of bin switch failures.

Bin Switch Fails Open

Symptoms and behavior when the bin switch fails open.

Bin Switch Fails Closed

Symptoms and behavior when the bin switch fails closed.

DIAGNOSTICS

Steps to diagnose bin switch operation.

WATER LEVEL CONTROL CIRCUITRY

Diagnostics

SYMPTOMS

Symptoms related to water trough fill issues.

WATER TROUGH OVERFILLING DURING THE FREEZE CYCLE

Steps to diagnose and resolve water trough overfilling.

ICE THICKNESS PROBE (HARVEST INITIATION)

Ice Thickness Check

Diagnostics

Premature harvest

Symptoms indicating premature harvest cycles.

Will not harvest

Symptoms indicating the machine will not harvest.

ICE MACHINE CYCLES INTO HARVEST BEFORE ICE CONTACTS THE ICE THICKNESS PROBE

Troubleshooting steps when harvest occurs before ice contacts the probe.

ICE MACHINE DOES NOT CYCLE INTO HARVEST

HIGH PRESSURE CUTOUT (HPCO) CONTROL

CHECK PROCEDURE

Symptom #2 Machine is running and the display indicates “HPC Fault” and an alert triangle

LOW PRESSURE CUTOUT (LPCO) CONTROL

FAN CYCLE CONTROL

THERMISTORS

T1 - Air or Water cooled Models

Location and function of T1 thermistor for air/water cooled models.

SYMPTOM

CHECK PROCEDURE

Steps to check thermistor readings and control board.

Thermistor Test

Procedure to test thermistor resistance against temperature charts.

Control Board Test

Procedures to test the control board using thermistor pins.

HARVEST ASSIST AIR PUMP

COMPRESSOR ELECTRICAL DIAGNOSTICS

CHECK MOTOR WINDINGS TO GROUND

COMPRESSOR DRAWING LOCKED ROTOR

COMPRESSOR DRAWING HIGH AMPS

DIAGNOSING START COMPONENTS

Relay

PTCR

PTCR Operation Check

Refrigeration Components

HEAD PRESSURE CONTROL VALVE

Information on Manitowoc head pressure control valves.

Refrigerant Charge Verification

Process for verifying the correct refrigerant charge.

Freeze Cycle Operation All Models

Harvest Cycle Operation

Remote Condenser Models

Harvest cycle operation of the head pressure control valve for remote models.

Harvest Cycle Operation QuietQube® Models

Diagnostics

FREEZE CYCLE - REMOTE CONDENSER & QUIETQUBE® REMOTE CONDENSING UNIT

Diagnostic steps for freeze cycle issues on these specific models.

Harvest Cycle

Undercharge Symptoms

Symptoms indicating a refrigerant undercharge.

Overcharge Symptoms

Symptoms indicating a refrigerant overcharge.

HARVEST CYCLE DIAGNOSTICS QUIETQUBE ® REMOTE CONDENSING UNIT

HARVEST PRESSURE REGULATING (HPR) SYSTEM REMOTE CONDENSER ONLY

FREEZE CYCLE

HARVEST CYCLE

HPR DIAGNOSTICS

WATER REGULATING VALVE

HARVEST PRESSURE SOLENOID VALVE (I3300W Only)

SUCTION ACCUMULATOR OPERATION QUIETQUBE® REMOTE CONDENSING UNIT

Refrigerant Recovery/Evacuation

SELF-CONTAINED MODEL PROCEDURE

Refrigerant recovery/evacuation steps for self-contained models.

Self-Contained Recovery/Evacuation

Self-Contained Charging Procedures

REMOTE CONDENSER MODEL PROCEDURE

CONNECTIONS

Ice Machine Head Section - All Models

Connections for the ice machine head section.

REMOTE CONDENSER RECOVERY/EVACUATION

REMOTE RECOVERY/EVACUATION CONNECTIONS

Remote Charging Procedures

REMOTE CHARGING CONNECTIONS

QUIETQUBE® MODELS

CONNECTIONS

Required connections for QuietQube® remote system recovery/evacuation.

Refrigerant Recovery Connections ICVD Condensing Unit

RECOVERY/EVACUATION PROCEDURES

CHARGING PROCEDURES

System Contamination Clean-Up

DETERMINING SEVERITY OF CONTAMINATION

Methods to determine the level of system contamination.

Contamination Cleanup Chart

CLEANUP PROCEDURE

Mild System Contamination

Detailed procedure for mild system contamination cleanup.

Severe System Contamination

REPLACING PRESSURE CONTROLS WITHOUT REMOVING REFRIGERANT CHARGE

LIQUID LINE FILTER-DRIERS

SUCTION FILTER

TOTAL SYSTEM REFRIGERANT CHARGE

QuietQube® ICVD Models

Charts

Cycle Times/24-Hour Ice Production/ Refrigerant Pressure Charts

Guidelines for verifying correct operation using charts.

I0300 SERIES

I0300W

I0320 SERIES

I0320W

I0450 SERIES

I0450W

I0500 SERIES

I0500W

I0600 SERIES

I0520 SERIES

I0520W

I0600 SERIES

I0600W

I0600N

I0680C/ICVD0695

IB0690C/ICVD695

I0850 SERIES

I0850W

I0850N

I0870C

I1000 SERIES

I1000W

I1000N

I1070C/ICVD1095

IB1090C/ICVD1195

I1200 SERIES

S1200W

Diagrams

Wiring Diagrams

Electrical wiring diagrams for different machine configurations.

WIRING DIAGRAM LEGEND

Explanation of symbols used in wiring diagrams.

I0300/I0320/I0450/I0500/I0520

I0500

I0600/I0850/I1000/I1200

I0600/I0850/I1000

I0670C/I0870C/I1070C/I1270C

IB0690C/IB0890C/IB1090C

I1400/I1800

I1400/I1800

Electronic Control Board

Refrigeration Tubing Schematics

SELF-CONTAINED AIR OR WATER -COOLED

Tubing schematics for self-contained air/water-cooled models.

REMOTE CONDENSER MODELS

REMOTE CONDENSING UNIT MODELS

IB MODELS

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