Manitowoc Indigo™ Series Ice Machines With R290 Refrigerant Technician’s Handbook This manual is updated as new information and models are released. Visit our website for the latest manual. www.manitowocice.
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.
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: 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 troublefree operation of your Manitowoc equipment. If you encounter problems not covered by this manual, do not proceed, contact Manitowoc Foodservice Group. We will be happy to provide assistance. ! Caution Proper installation, care and maintenance are essential for maximum performance and troublefree operation of your equipment. Visit our website www.manitowocfsg.
! 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.
! 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 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 Some 50 hz models may contain up to 150 grams of R290 (propane) refrigerant. R290 (propane) is flammable in concentrations of air between approximately 2.1% and 9.5% by volume (LEL lower explosion limit and UEL upper explosion limit).
! 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.
Table of Contents General Information How to Read a Model Number . . . . . . . . . 13 Model/Serial Number Location . . . . . . . . 14 Ice Machine Warranty Information . . . . . 14 Owner Warranty Registration Card . . . 14 Commercial Warranty Coverage . . . . . 15 Installation Location of Ice Machine . . . . . . . . . . . . . . 20 Clearance Requirements . . . . . . . . . . . . . 21 Ice Machine Heat of Rejection . . . . . . . . . 21 Ice Deflector . . . . . . . . . . . . . . . . . . . . . . .
Operation Control Panel Features . . . . . . . . . . . . . . Buttons . . . . . . . . . . . . . . . . . . . . . . . . Display Panel . . . . . . . . . . . . . . . . . . . Menu Navigation Overview . . . . . . . . . . . Display Panel Navigation . . . . . . . . . . . . Alerts and Messages . . . . . . . . . . . . . . . . Main Menu . . . . . . . . . . . . . . . . . . . . . . . . Machine Info Menu . . . . . . . . . . . . . . . . . Password Entry . . . . . . . . . . . . . . . . . . . .
Energy Saver Menu . . . . . . . . . . . . . . . . . 56 Ice Program . . . . . . . . . . . . . . . . . . . . . 57 Water Miser . . . . . . . . . . . . . . . . . . . . . 58 Statistics . . . . . . . . . . . . . . . . . . . . . . . 58 Service Menu . . . . . . . . . . . . . . . . . . . . . . 59 Data History . . . . . . . . . . . . . . . . . . . . 61 Real Time Data . . . . . . . . . . . . . . . . . . 62 Diagnostics . . . . . . . . . . . . . . . . . . . . . 64 Manual Harvest . . . . . . . . . . . . . . . . . .
Troubleshooting Safety Limits . . . . . . . . . . . . . . . . . . . . . . 85 Safety Limit #1 . . . . . . . . . . . . . . . . . . 86 Safety Limit #2 . . . . . . . . . . . . . . . . . . 87 Troubleshooting By Symptom . . . . . . . . 88 Symptom #1 Ice Machine will not run . 90 Symptom #2 Low Production, Long Freeze . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94 Symptom #2 - Freeze Cycle Refrigeration System Operational Analysis Tables . 96 Symptom #3 Harvest Problems . . . . .
Component Check Procedures Electrical Components . . . . . . . . . . . . . . . 123 Control Board, Display board and Touch Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 123 Control Board Relay Test . . . . . . . . . . 126 USB Flash Drive Specifications and Formatting . . . . . . . . . . . . . . . . . . . . . . . . . . . 128 Upgrading Firmware with a Flash Drive or Transferring Setup Data To Multiple Machines . . . . . . . . . . . . . . . . . . . . . . . . . 131 Exporting Data to a Flash Drive . .
Charts Cycle Times/24-Hour Ice Production/Charts I0320A Air-Cooled Model . . . . . . . . . . 168 I0500A Air-Cooled Model . . . . . . . . . . 170 Diagrams Wiring Diagrams . . . . . . . . . . . . . . . . . . . Wiring Diagram Legend . . . . . . . . . . . I0320 . . . . . . . . . . . . . . . . . . . . . . . . . I0500 . . . . . . . . . . . . . . . . . . . . . . . . . Electronic Control Board . . . . . . . . . . . . Refrigeration Tubing Schematics . . . . .
Part Number STH038 5/12 Ice Machine Series P - R290 Refrigerant ICE MACHINE MODEL I - Indigo Model IB - Ice Beverage ICE CUBE SIZE R - Regular D - Dice Y - Half-Dice Not Used On IB Models # HERTZ 5 - 50HZ 6 - 60HZ CONDENSER TYPE A - Self-Contained Air -Cooled W - Self-Contained Water -Cooled N - Remote Air-Cooled C - CVD Air-Cooled DC - IB Dice Model 3 - Three Phase YC - IB Half Dice E - WRAS 50 Cycle Only NO INDICATOR - 1 Phase 0 to 6 & 8 - Self-Contained Unit 7 & 8 - CVD Remote Condensing Unit 9 - Re
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. Ice Machine Warranty Information OWNER WARRANTY REGISTRATION CARD Warranty coverage begins the day the ice machine is installed.
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.
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.
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.
This Page Intentionally Left Blank 18 Part Number STH038 5/12
Installation ! Caution The ice machine head section must be protected if it will be subjected to temperatures below 0°C (32°F). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization” page 36. ! Warning An ice machine contains high voltage electricity and refrigerant charge.
Location of Ice Machine The location selected for the ice machine must meet the following criteria. If any of these criteria are not met, select another location. • The location must be free of airborne and other contaminants. • Air temperature - Minimum 1.6°C maximum 43°C. • Ice Making Water Inlet - Water Pressure must be at least 1.38 bar, but must not exceed 5.52 bar. • The location must not be near heat-generating equipment or in direct sunlight and protected from weather.
Clearance Requirements I0320 Self-Contained Air-Cooled Top/Sides 305 mm Back 127 mm I0500 Self-Contained Air-Cooled Top/Sides 203 mm Back 127 mm Ice Machine Heat of Rejection Series Ice Machine Heat of Rejection Air Conditioning* Peak I0320 3800 6000 I0500 6100 6900 *BTU/Hour Because the heat of rejection varies during the ice making cycle, the figure shown is an average.
ICE DEFLECTOR INSTALLATION ON A BIN An ice deflector is required for all bin installations and is included with all Manitowoc bins. Order the appropriate deflector kit for any bin without a deflector. Align sides and back of ice machine with sides and back of bin, when placing ice machine on bin.. ! Warning Do not operate any ice machine with the deflector removed.
Electrical Requirements Voltage The maximum allowable voltage variation is +10/-0% of the rated voltage on the ice machine model/serial number plate at start-up (when the electrical load is highest). Fuse/Breaker A separate fuse/circuit breaker must be provided for each ice machine. Total Circuit Ampacity The total circuit ampacity is used to help select the wire size of the electrical supply. The wire size (or gauge) is also dependent upon location, materials used, length of run, etc.
This Page Intentionally Left Blank 24 Part Number STH038 5/12
Maintenance Cleaning and Sanitizing GENERAL You are responsible for maintaining the ice machine in accordance with the instructions in this manual. Maintenance procedures are not covered by the warranty. Clean and sanitize the ice machine every six months for efficient operation. If the ice machine requires more frequent cleaning and sanitizing, consult a qualified service company to test the water quality and recommend appropriate water treatment.
! Caution Use only Manitowoc approved Ice Machine Cleaner and Sanitizer for this application (Manitowoc Cleaner part number 94-0546-3 and Manitowoc Sanitizer part number 94-0565-3). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Read and understand all labels printed on bottles before use. ! Caution Do not mix Cleaner and Sanitizer solutions together. Do not use these solutions in a manner inconsistent with their labeling.
CLEANING/SANITIZING PROCEDURE This procedure must be performed a minimum of once every six months. • The ice machine and bin must be disassembled cleaned and sanitized. • All ice produced during the cleaning and sanitizing procedures must be discarded. • Removes mineral deposits from areas or surfaces that are in direct contact with water.
Cleaning / Sanitizing Procedure ! Caution Use only Manitowoc approved Ice Machine Cleaner and Sanitizer for this application (Manitowoc Cleaner part number 94-0546-3 and Manitowoc Sanitizer part number 94-0565-3). It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling. Read and understand all labels printed on bottles before use. CLEANING PROCEDURE ! Caution Do not mix Cleaner and Sanitizer solutions together.
Step 1 Open the front door to access the evaporator compartment. Ice must not be on the evaporator during the clean/sanitize cycle. Follow one of the methods below: • Press the power switch at the end of a harvest cycle after ice falls from the evaporator(s). • Press the power switch and allow the ice to melt . ! Caution Never use anything to force ice from the evaporator. Damage may result. Step 2 Remove all ice from the bin/dispenser. Step 3 Press the clean switch.
Step 4 Wait until the clean cycle is complete (approximately 24 minutes). Then disconnect power to the ice machine (and dispenser when used). ! Warning Disconnect the electric power to the ice machine at the electric service switch box. Step 5 Remove parts for cleaning.. E D A C B Off On / Off Mode [ ! ] A. Remove the water curtain • • Gently flex the curtain in the center and remove it from the right side. Slide the left pin out. B.
C. Remove the water level probe • • • • Pull the water level probe straight down to disengage. Lower the water level probe until the wiring connector is visible. Disconnect the wire lead from the water level probe. Remove the water level probe from the ice machine. D. Remove the ice thickness probe • • Compress the hinge pin on the top of the ice thickness probe. Pivot the ice thickness probe to disengage one pin then the other.
Step 6 Disassemble distribution tube by loosening the two (2) middle thumbscrews and dividing. Mix a solution of cleaner and lukewarm water. Depending upon the amount of mineral buildup, a larger quantity of solution may be required. Use the ratio in the table below to mix enough solution to thoroughly clean all parts. Solution Type Cleaner Water Mixed With 4 L (1 gal) 500 ml (16 oz) cleaner Step 7 Use 1/2 of the cleaner/water mixture to clean all components.
Step 8 While components are soaking, use 1/2 of the cleaner/water solution to clean all food zone surfaces of the ice machine and bin (or dispenser). Use a nylon brush or cloth to thoroughly clean the following ice machine areas: • Side walls • Base (area above water trough) • Evaporator plastic parts - including top, bottom, and sides • Bin or dispenser Rinse all areas thoroughly with clean water. SANITIZING PROCEDURE Step 9 Mix a solution of sanitizer and lukewarm water.
Step 11 Use 1/2 of the sanitizer/water solution to sanitize all food zone surfaces of the ice machine and bin (or dispenser). Use a spray bottle to liberally apply the solution. When sanitizing, pay particular attention to the following areas: • Side walls • Base (area above water trough) • Evaporator plastic parts - including top, bottom and sides • Bin or dispenser Do not rinse the sanitized areas. Step 12 Replace all removed components. Step 13 Wait 20 minutes.
Ice Thickness Probe & Water Level Probe Clean the probes using the following procedure. 1. Mix a solution of Manitowoc ice machine cleaner and water 60 ml (2 oz) of cleaner to 500 ml (16 oz) of water in a container. 2. Soak probes in container of cleaner/water solution while disassembling and cleaning water circuit components (soak probes for 10 minutes or longer). 3. Clean all probe surfaces including all plastic parts (do not use abrasives). Verify all surfaces are clean.
Removal from Service/Winterization General Special precautions must be taken if the ice machine is to be removed from service for an extended period of time or exposed to ambient temperatures of 0°C (32°F) or below. ! Caution If water is allowed to remain in the ice machine in freezing temperatures, severe damage to some components could result. Damage of this nature is not covered by the warranty. 1. Press the power button. 2.
Power Button Cleaning Button Manitowoc LCD Display Navigation Arrows Menu Button Checkmark Operation Control Panel Features The control panel offers a series of pressure sensitive buttons and a four-line interactive display panel. BUTTONS Power Button: Powers the ice machine when in the On/Off Mode. The ice machine can also be programmed to automatically power on and off in two Energy Saver modes. Cleaning Button: Initiates a cleaning cycle. Refer to the Maintenance section for details.
Menu Button: Moves the display from the Home Screen, where ice machine status, alerts and messages are viewed, to the Main Menu, where machine information and its event log can be accessed, machine and Energy Saver settings can be adjusted, and service issues can be addressed. Left and Right Arrows: The Left arrow moves the display to the previous screen, allowing the user to “back out” of programming. Both the Left and Right arrows will move the cursor (underline) within a line of settings.
Menu Navigation Overview Menu Navigation Overview Clean Button AuCS Timer Initiated Clean Function AuCS Clean Function On/Off Button Press Left Arrow From Main Menu Home Screen When Alert Present When Message Present Alerts Menu Messages Menu Menu Button Main Menu Function (Optional) Password Entry Machine Info 90/70 cap Model # IMH Serial # Cond Serial # Warranty -Machine -Evaporator -Compressor Install Date Manuf Date Main SW Ver Disply SW Ver Set-Up Language Time & Date Time Config Units
Display Panel Navigation [Language Time & Date Time Config Units >]▼ > > > ▼ Highlights: Brackets indicate if a line on the screen is “highlighted” or actionable. Move the brackets from line to line using the Down or Up arrow. Move the brackets down from the fourth line to view more of the menu displayed. Arrows: Two kinds of arrows give cues to additional information. “>” symbols show that another screen is available by pressing Checkmark while a line is highlighted.
Cursor: A cursor (underline) is used within lines where actual settings can be adjusted. In these screens, use the Up and Down arrows to make changes to the value underlined. Move the cursor from digit to digit using the Right and Left arrows. Use the Checkmark to move the cursor down one line. Exit and re-enter the screen to start again at the top.
Alerts and Messages When messages and alerts exist, they will be highlighted and can be selected with the Left arrow. Alerts displayed will have priority over messages. Off On / Off Mode [ ! ] For example, if alerts are appearing in the fourth line of the display: 1. Press the Left arrow. A list of alerts will appear in the display. 2. Choose the alert you wish to address by moving the highlight brackets with the Down arrow. 3. Press Checkmark again.
Machine Info Set-Up Energy Saver Factory Defaults Service Exit Main Menu Main Menu From the Home screen, press the Menu button to enter the Main menu, where you can choose to see machine information, make setup changes, set the Energy Saver mode, or enter the Service Menu.
Machine Info Menu From the Main menu, ensure that Machine Info is highlighted and press the Checkmark to view a list including capacity, model number, IMH (Ice Machine Head) serial number, condenser serial number, warranty, installation date, date of manufacture and software version. Use the Down arrow to highlight an item and use the Checkmark to view the information. Press the Left arrow to return to previous screens.
Password Entry A password is not required, although a password can be turned on to prevent unauthorized control setting modification. You can use the Factory Default Password of "1234" or enter a four digit custom pin number of your choosing. To turn on the password feature use the following procedure. 1. Press the Menu button. 2. From the Main menu, use the Down arrow to highlight setup and press the Right arrow. 3. Use the Down arrow to highlight Password ON and press the Right arrow. 4.
To enter a four digit password of your choosing use the following procedure. 1. Press the Menu button. 2. From the Main menu, use the Down arrow to highlight setup and press the Right arrow. 3. Use the Down arrow to select Edit Password and press the Right arrow. 4. Using the Up & Down arrows, enter the first digit of the factory password in the flashing icon. 5. Press the right arrow to move to the next cell and use the Up & Down arrows to add the number 2. Repeat this process to add 3 & 4. 6.
RESET PASSWORD TO FACTORY DEFAULTS The password can be reset to the factory defaults when required. The default factory password is 1234. To reset the ice machine to factory defaults use the following procedure. 1. Press the Menu button. 2. From the Main menu, use the Down arrow to highlight Defaults 3. Press the Checkmark button two times to reset the ice machine. The display will return to the SetUp menu and the defaults listed below will be in effect. Refer to Setup to adjust settings.
Set-Up Menu From the Main menu, use the Down arrow to navigate to Set-Up and press the Checkmark. Select and customize machine settings on this menu. Press the Left arrow to return to previous screens. LANGUAGE 1. From the Set-Up menu, use the Down arrow to highlight Language. 2. Press the Checkmark. You can choose to view the display in a language other than English, by highlighting your choice and pressing the Checkmark. Selecting one language will deselect the others. 3.
4. Press the Checkmark. The date will appear on the first line of the display (Mo/Day/Yr) and the time will appear on the second line (24 Hour). The month will have a blinking cursor. 5. Using the Up or Down arrow, adjust the month, if necessary. 6. When the correct month appears, use the Right arrow to move the blinking cursor to day. 7. Using the Up or Down arrow, adjust the day, if necessary. 8. When the correct day appears, use the Right arrow to move the blinking cursor to year. 9.
TIME CONFIGURATION 1. From the Set-Up menu, use the Down arrow to highlight Time Config. 2. Press the Checkmark. On this screen, you can choose whether the date will be displayed as Mo/Day/Yr or Day/Mo/Yr by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. You can also choose whether the time will be displayed as 12 Hour or 24 Hour by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 4.
ICE CLARITY In areas with poor potable water quality, the ice machine makes cloudy ice. Setting Ice Clarity to ON will add additional water during the freeze cycle to dilute the water that contains a high content of dissolved solids in the water trough. This feature decreases production and increases water usage. A water filter is recommended to produce the highest quality ice while maintaining the least expensive mode of operation. 1. From the Set-Up menu, use the Down arrow to highlight Ice Clarity. 2.
PASSWORD ON A password can be added to prevent unauthorized changes to ice machine settings. 1. From the Set-Up menu, use the Down arrow to highlight Password On. 2. Enter the password and press the Checkmark. 3. Press the Left arrow to return to previous screens and to the Set-Up menu. EDIT PASSWORD The password can be changed on this screen 1. From the Set-Up menu, use the Down arrow to highlight Edit Password. 2. Press the Checkmark and confirm current password. 3.
IAUCS RUNTIME Automatic Cleaning System is an optional accessory and will perform a cleaning cycle at a set time interval. 1. From the Set-Up menu, use the Down arrow to highlight AuCS RunTime. 2. Press the Checkmark. On this screen, you can choose to turn the feature ON or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other. 3. You can also choose the time interval from this screen by highlighting Set Interval and pressing the Checkmark. 4.
WATER FILTER The ice machine has a feature that displays a replace water filter reminder at a set time interval. 1. From the Set-Up menu, use the Down arrow to highlight Water Filter. 2. Press the Checkmark. You can record the filter type on this screen by highlighting Filter Type and pressing the Checkmark. 3. After making your selection, press the Left arrow to return to the previous screen. 4.
USB SETUP Refer to “Upgrading Firmware with a Flash Drive” and “Exporting Data to a Flash Drive” for more information on this setting. Flash drives must be correctly sized and formatted - 2 gigabytes or smaller, Fat 32 file system, 512 allocation units - Refer to page 69 for full specification and formatting details. FACTORY DEFAULTS The entire setup can be reset to the factory defaults. 1. From the Set-Up menu, use the Down arrow to highlight Fact Deflts. 2.
Energy Saver Menu From the Main menu, use the Down arrow to navigate to Energy Saver and press the Checkmark. Set up an energy saving ice program, enable the Water Miser and view usage statistics from this menu. Press the Left arrow to return to previous screens.
ICE PROGRAM To save energy and water, the ice machine can be programmed to only power up during time periods that the ice will be used or when the bin level is being depleted by heavy use. Important Setting an ice program will take the ice machine out of the On/Off Mode and the Power button will be disabled. 1. In the Energy Saver menu, ensure that Ice Program is highlighted. 2. Press the Checkmark.
WATER MISER Water Miser is a feature that reduces water usage by eliminating flush cycles. Enabling this feature is only recommended for systems with de-ionized or reverse osmosis filtering. 1. From the Energy Saver menu, use the Down arrow to highlight Water Miser. 2. Press the Checkmark. On this screen, you can choose to turn the Water Miser ON or OFF by highlighting your choice and pressing the Checkmark. Selecting one will deselect the other.
Service Menu From the Main menu, use the Down arrow to navigate to Service and press the Checkmark. This menu is intended for the use of trained service personnel. Below is an overview of the service menu. The following pages list the navigation options available by drilling into the menus with the down arrow.
60 Part Number STH038 5/12 Current Day Current Day Current Day Current Day Current Day Current Day Lifetime Data History -1 -2 -3 -4 -5 Time & Temp Inputs Outputs Real Time Data Control Board Temp Sensors Input Diagnostics USB Stick Manual Setup USB Setup Harvest Started Download Firm Download Conf Export ALL Export Setup USB Setup Repl Cnt Bd Manual Harvest Service Clear View Event Log
DATA HISTORY Press the Checkmark with Data History highlighted to view a list of eight-digit dates (Current, Current + 1 ... Current + 5), along with Lifetime (be sure to use the Down arrow to reveal all the available information).
REAL TIME DATA Press the Checkmark with Real Time Data highlighted to get readings on Time & Temp, Inputs and Outputs (be sure to use the Down arrow to reveal all the available information).
Outputs • Status Off/On - Displays stage of cycle • Water Pump Off/On • Hot Gas Valve 1 Off/On • Hot Gas Valve 2 Off/On • Air Pump Off/On • Water Valve Off/On • Dump Valve Off/On • Compressor Control Off/On • AuCS Relay Off/On • LuminIce Off/On • Exit Part Number STH038 5/12 63
DIAGNOSTICS Press the Checkmark with Diagnostics highlighted to enter screens where you can run diagnostics on the control board, sensors and switches.
MANUAL HARVEST Press the Checkmark with Manual Harvest highlighted to initiate a manual harvest. Manual Harvest • Harvest Started • Exit REPLACE CONTROL BOARD Press the Checkmark with Replace Control Board highlighted to program the replacement control board. The data can copied from the defective control board (refer to exporting data to a flash drive page xx), or entered manually through the Indigo interface.
EVENT LOG MENU From the Service menu, use the Down arrow to navigate to Event Log and press the Checkmark. Ensure View ELog is highlighted and press the Checkmark to see the first event code, when it occurred and how many times. Use the Down arrow to view information on subsequent event codes. For more information on event codes, see “Service Menu”. Use the Left arrow to return to the Event Log menu.
EVENT LOG Refer to the following table for Event Code descriptions.
68 Event Log Detail Detail Event Log Service Definition Error Description Long Freeze Definition Long Harvest Long Harvest 3 consecutive - 3.5 Minute Harvests logs SL#2 in memory, but runs until 500 long harvest cycles occur.
Part Number STH038 5/12 Detail Event Log Service Definition E-Log Display Text Error Description Definition E11 Refig Fault Refrigeration System (Refrig Fault) The compressor discharge temperature did not increase by at least 10 F, and the evaporator temperature did not decreased by at least 10 F - Measured from Refrigeration Start up to Two Minutes into the Freeze cycle.
70 Detail Event Log Service Definition E-Log Display Text Error Description Definition Part Number STH038 5/12 E21 T1 Fault T1 Sensor E22 T2 Fault T2 Sensor E23 T3 Fault T3 Sensor E24 T4 Fault T4 Sensor E25 Bin Prb Fault Bin Low Sens E26 Bin Prb Fault Bin Med Sens E27 Bin Prb Fault Bin Hi Sens E28 AUCS AUCS (Aucs not Present) (Event Log only - No alarm) E29 USB COMM USB Comm (Event Log only - No Alarm) Engineering purposes Only E30 USB DNLD USB download error (dlnd) Event L
USB FLASH DRIVE SPECIFICATIONS AND FORMATTING Updating firmware on Indigo™ model ice machines requires a properly formatted 2 GB or smaller USB flash drive. All USB flash drives must be formatted before use to remove any software programs or files currently on the flash drive. USB Flash Drive Specifications: • USB 2 Version • 2 GB or less capacity • Fat32 File System • 512 MB File Allocation Unit USB Flash Drive Formatting: Procedure to format a USB flash drive varies with operating system software.
Windows XP Computers: 1. Insert USB flash drive; your computer may indicate: • “Found New Hardware” follow the prompts to install the USB flash drive • USB flash drive may auto launch - Close auto launch window. 2. To access Disk Management: • Left click on the Windows Start Button • Left click on “Run” • Type compmgmt.msc and left click on “OK” • Left click on “Disk Management”. 3. Verify USB flash drive capacity is 2 GB or less 4.
UPGRADING FIRMWARE WITH A FLASH DRIVE OR TRANSFERRING SETUP DATA TO MULTIPLE MACHINES Important The flash drive must be formatted before using, All files and software on the flash drive are removed during the formatting process. Refer to page 69 USB Flash Drive Specifications and Formatting. 1. Drag and drop the files from your email onto a flash drive or refer to Exporting data to a flash drive to transfer settings to multiple machines. 2. Ensure that the ice machine’s power is on. 3.
Bin Switches Bin Thermostat USB Display Light Micro Light Clean Light Harvest Light SL-1 Light SL-2 Light Thermistors T1 T2 Dump Valve T3 T4 USB Connector Left Bin Switch Light Transformer Right Bin Switch Light Water Level Probe Light Display Ice Thickness Probe Light RS485 RT Harvest Bin LED LuminIce Battery Compressor LT Harvest Water Level Probe Fuse Relay Lights Pump Control Board 10. Follow the on-screen instructions: A.
EXPORTING DATA TO A FLASH DRIVE Data can be copied from the control board memory to a flash drive and used to transfer setup and/or cycle data to a replacement control board or to transfer setup information to multiple ice machines. Data may also be requested by service department personnel for analysis or as an aid to troubleshooting. The data files are small and can be attached to an email.
Select only “Ice Machine Settings” file when multiple machines will be programmed with the same user specified settings. Select “Export All” if you are installing a replacement board. 8. Highlight Export ALL or Export Setup, depending on your requirements, and press the Checkmark. A display of instructions will appear. 9. Follow these on-screen instructions to: A. Insert Drive (Insert the flash drive into the USB port on the ice machine’s control board.) B. Press Check (Press the Checkmark.) C.
Operational Checks GENERAL Manitowoc ice machines are factory-operated and adjusted before shipment. Normally, new installations do not require any adjustment. To ensure proper operation, always follow the Operational Checks: • when starting the ice machine for the first time • after a prolonged out of service period • after cleaning and sanitizing NOTE: Routine adjustments and maintenance procedures are not covered by the warranty.
ICE THICKNESS CHECK After a harvest cycle, inspect the ice cubes in the ice storage bin. The ice thickness probe is factory-set to maintain the ice bridge thickness at 3 mm (1/8"). NOTE: Make sure the water curtain is in place when performing this check. It prevents water from splashing out of the water trough. 1. Inspect the bridge connecting the cubes. It should be about 3 mm (1/8") thick. 2.
Sequence of Operation SELF CONTAINED AIR OR WATER COOLED NOTE: The power button must be depressed and the water curtain/ice dampers must be in place on the evaporator before the ice machine will start. Initial Start-Up or Start-Up After Automatic Shut-Off 1. Water Purge Before the refrigerant compressor starts, the water pump and water dump solenoid energize to purge the ice machine of old water. This feature ensures that the ice making cycle starts with fresh water. 2.
Freeze Sequence 3. Prechill The compressor lowers the temperature of the evaporator(s) before the water pump is energized. The water fill valve will energize and remain on until water completes the water level probe circuit. 4. Freeze The water pump(s) energizes and water flows over the evaporator. After water contacts the water level probe the water fill valve de-energizes. The control board will automatically cycle the water fill valve within the 6 minute water fill time limit.
Automatic Shut-Off 7. Automatic Shut-Off When the storage bin is full at the end of a harvest sequence, the sheet of cubes fails to clear the water curtain/ice damper and will hold it open. After the water curtain/ice damper is held open for 30 seconds, the ice machine shuts off. The ice machine remains off for 3 minutes before it can automatically restart.
82 Single Evaporator Models Energized Parts Chart Ice Making Sequence of Operation Water Pump Harvest Valve(s) Air Pump(s)* Water Inlet Valve Water Dump Valve Contactor Coil Compressor Condenser Fan Motor Length of Time On Off Off Off On Off Off Off 45 Seconds Off On On Off Off Off Off Off 5 Seconds Off On On Off Off On On On 5 Seconds Off On On May Cycle Initial Start-Up is 120 Seconds Start-Up 1. Water Purge 2.
Part Number STH038 5/12 Single Evaporator Models Energized Parts Chart (Continued) Ice Making Sequence of Operation Water Pump Harvest Valve(s) Air Pump(s)* Water Inlet Valve Water Dump Valve Contactor Coil Compressor On On On Off On On On 6. Harvest Off On On Off Off On On 7. Automatic Shut-Off Off Off Off Off Off Off Off Harvest Sequence 5.
This Page Intentionally Left Blank 84 Part Number STH038 5/12
Troubleshooting Safety Limits In addition to standard safety controls, the control board has built in safety limit controls which protect the ice machine from major component failures. Safety limits are stored and indicated by the control board after three cycles. The number of cycles required to stop the ice machine varies for each safety limit. • Safety Limit 1 - If the freeze time reaches 60 minutes, the control board automatically initiates a harvest cycle.
SAFETY LIMIT #1 Freeze time exceeds 60 minutes for 6 consecutive freeze cycles. Possible cause list Water System • Loss of water from sump area • Low water pressure 1.37 bar min (20 psig) • High water pressure 5.
SAFETY LIMIT #2 Harvest time exceeds 3.5 minutes for 500 consecutive harvest cycles Possible Cause Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” page 102 Water System • Loss of water from sump area • Water area (evaporator) dirty • Dirty/defective water dump valve • Low water pressure 1.
Troubleshooting By Symptom The troubleshooting procedures follow flow charts. There are four symptoms, the symptom that you are experiencing will determine which flow chart to use. The flow chart asks yes and no questions to determine the problem. The flow chart will direct you to a procedure to correct the problem.
Reset To Factory Defaults Before starting troubleshooting procedures, reset the control board to factory defaults to prevent misdiagnosis. Before resetting to factory defaults do one of the following: A. Copy settings to a usb device and flash settings into the control board when diagnostics are complete. B. Write down any customer settings so they can be re-entered when diagnostics are complete. This procedure also resets the password to the factory default. The default factory password is 1234.
90 SYMPTOM #1 ICE MACHINE WILL NOT RUN START Is the display interface energized and functioning? Does the ice machine start when the Power button is pushed? Yes No Yes No Are there any lights on or flashing on the control board? Part Number STH038 5/12 Refer to display & control board diagnostics Yes Is there an Alert or Error Logged? Yes Refer to Alert/Error Log No Micro light flashing heartbeat? No Yes No Refer to display & control board diagnostics
Part Number STH038 5/12 Yes Yes Display light flashing heartbeat? Line voltage at wires 55 & 56 on 9 pin control board connector? No No Refer to display & control board diagnostics Yes Supply power to the ice machine Install the water curtain/damper.
92 Yes Yes No Press power button to start ice making, does safety limit light flash? Is magnet on the water curtain/damper Yes No Part Number STH038 5/12 Refer to display & control board diagnostics Ice machine starts? Yes Yes Which light flashes? Test run ice machine SL1 SL2 No Replace the water curtain/damper. Refer to bin switch diagnostics.
Diagnosing an Ice Machine That Will Not Run ! Warning High (line) voltage is applied to the control board (terminals #55 and #56) at all times. Removing control board fuse or pressing the power button will not remove the power supplied to the control board. 1. Verify primary voltage is supplied to ice machine and the fuse/circuit breaker is closed. 2. Verify the high pressure cutout is closed. 3. Verify control board fuse is okay.
SYMPTOM #2 LOW PRODUCTION, LONG FREEZE Ice Machine has a Long Freeze Cycle. Ice Formation is Thick or Thin on Top or Bottom of Evaporator or Low Production How to Use the Freeze Cycle Refrigeration System Operational Analysis Table GENERAL These tables must be used with charts, checklists and other references to eliminate refrigeration components not listed on the tables and external items and problems which can cause good refrigeration components to appear defective.
PROCEDURE Step 1 Complete the “Operation Analysis” column. Read down the left “Operational Analysis” column. Perform all procedures and check all information listed. Each item in this column has supporting reference material to help analyze each step. While analyzing each item separately, you may find an “external problem” causing a good refrigerant component to appear bad. Correct problems as they are found. If the operational problem is found, it is not necessary to complete the remaining procedures.
96 SYMPTOM #2 - FREEZE CYCLE REFRIGERATION SYSTEM OPERATIONAL ANALYSIS TABLES SINGLE EXPANSION VALVE SELF CONTAINED AIR and WATERCOOLED CONDENSER Operational Analysis Ice Production Installation and Water System Ice Formation Pattern Part Number STH038 5/12 Discharge Line Temperature 3 minutes into the freeze cycle 1 2 3 4 Air-Temperature Entering Condenser_____________ Water Temperature Entering Ice Machine_________ Published 24 hour ice production________________ Calculated (actual) ice production
Part Number STH038 5/12 SINGLE EXPANSION VALVE SELF CONTAINED AIR and WATERCOOLED CONDENSER Operational Analysis Suction Line Temperature 3 minutes into the freeze cycle 1 2 3 4 Normal or High Normal or High Low Normal or High If suction temperature is High or Low refer to freeze cycle high or low suction temperature problem Freeze Cycle checklist page 109 to eliminate problems and/or components not listed on this table before proceeding.
98 SINGLE EXPANSION VALVE SELF CONTAINED AIR and WATERCOOLED CONDENSER Part Number STH038 5/12 Operational Analysis 1 2 3 4 Wait 5 minutes into the freeze cycle. Compare temperatures of compressor discharge line and harvest valve inlet. The harvest valve inlet is Hot -andapproaches the temperature of a Hot compressor discharge line. The harvest valve inlet is Cool enough to hold hand on -andthe compressor discharge line is Hot.
Before Beginning Service Ice machines may experience operational problems only during certain times of the day or night. A machine may function properly while it is being serviced, but malfunctions later. Information provided by the user can help the technician start in the right direction, and may be a determining factor in the final diagnosis. Ask these questions before beginning service: • When does the ice machine malfunction? (night, day, all the time, only during the Freeze cycle, etc.
Ice Production Check The amount of ice a machine produces directly relates to the operating water and air temperatures. This means a condensing unit with a 21°C ambient temperature and 10°C water produces more ice than the same model condensing unit with a 32°C ambient temperature and 21°C water. 1. Determine the ice machine operating conditions: Air temp entering condenser:____° Air temp around ice machine:____° Water temp entering sump trough:____° 2.
Weighing the ice is the only 100% accurate check. However, if the ice pattern is normal and the 3 mm bridge thickness is maintained, the ice slab weights listed with the 24-Hour Ice Production Charts may be used. 3. Compare the results of step 3 with step 2. Ice production checks that are within 10% of the chart are considered normal. If they match closely, determine if: • Another ice machine is required. • More storage capacity is required.
Installation/Visual Inspection Checklist Inadequate Clearances • Check all clearances on sides, back and top.
Water System Checklist A water-related problem often causes the same symptoms as a refrigeration system component malfunction. Water system problems must be identified and eliminated prior to replacing refrigeration components. Water area (evaporator) is dirty • Clean as needed Water inlet pressure not between 1-5 Bar, 138-552 kPa.
Ice Formation Pattern Evaporator ice formation pattern analysis is helpful in ice machine diagnostics. Analyzing the ice formation pattern alone cannot diagnose an ice machine malfunction. However, when this analysis is used along with Manitowoc’s Freeze Cycle Refrigeration System Operational Analysis Tables, it can help diagnose an ice machine malfunction. Any number of problems can cause improper ice formation.
2. Extremely Thin at Evaporator Outlet There is no ice, or a considerable lack of ice formation, at the outlet of the evaporator. Examples: No ice at all on the outlet half of the evaporator, but ice forms on the inlet half of the evaporator. Or, the ice at the outlet of the evaporator reaches 3 mm. to initiate a harvest, but the inlet of the evaporator already has 12 mm to 24 mm of ice formation. 3.
Analyzing Discharge Temperature in the Freeze Cycle 1. Determine the ice machine operating conditions: Air temp. entering condenser______ Air temp. around ice machine______ Water temp. entering sump trough______ 2. Refer to Operating Temperature (starting on page 167) for ice machine being checked. Use the operating conditions determined in step 1 to find the published normal discharge temperatures. Freeze Cycle______ Harvest Cycle______ 3. Perform an actual discharge temperature check.
FREEZE CYCLE DISCHARGE TEMPERATURE HIGH CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” (page 102) Air Condenser • Dirty condenser filter • Dirty condenser fins • High inlet air temperature • Condenser discharge air recirculation • Defective fan cycling control (page 154) • Defective fan motor Other • Overcharged • Non-condensable (air) in system • Wrong type of refrigerant • Non-Manitowoc components in system • High side refrigerant lines/component restricted Part Num
FREEZE CYCLE DISCHARGE TEMPERATURE LOW CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” (page 102) Other • Undercharged • Wrong type of refrigerant • Non-Manitowoc components in system • Liquid line/component restricted 108 Part Number STH038 5/12
Analyzing Suction Temperature The suction temperature gradually drops throughout the freeze cycle. The actual suction temperature (and drop rate) changes as the air and water temperature entering the ice machine changes. These variables also determine the freeze cycle times. To analyze and identify the proper suction temperature drop throughout the freeze cycle, compare the published suction temperature to the published freeze cycle time.
Suction Temperature High Checklist Improper Installation • Refer to “Installation/Visual Inspection Checklist” page 102 Discharge Temperature • Discharge temperature is too high and is affecting suction temperature – refer to “Freeze Cycle Discharge Temperature High Checklist” (page 107) Improper Refrigerant Charge • Overcharged (also see “Freeze Cycle Discharge Temperature High Checklist” page 107) • Wrong type of refrigerant • Non condensable in system Components • Harvest valve leaking - continue the tab
SUCTION TEMPERATURE LOW CHECKLIST Improper Installation • Refer to “Installation/Visual Inspection Checklist” (page 102) Discharge Temperature • Discharge temperature is too low and is affecting low side – refer to “Freeze Cycle Discharge Temperature Low Checklist” (page 108) Improper Refrigerant Charge • Undercharged • Wrong type of refrigerant Other • Non-Manitowoc components in system • Improper water supply over evaporator – refer to “Water System Checklist” (page 103) • Restricted/plugged liquid line d
Comparing Evaporator Inlet and Outlet Temperatures The temperatures of the suction line entering and leaving the evaporator alone cannot diagnose an ice machine. However, comparing these temperatures during the freeze cycle, along with using Manitowoc’s Freeze Cycle Refrigeration System Operational Analysis Table, can help diagnose an ice machine malfunction. The actual temperatures entering and leaving the evaporator vary by model, and change throughout the freeze cycle.
Harvest Valve Analysis Symptoms of a harvest valve remaining partially open during the freeze cycle can be similar to symptoms of either an expansion valve or compressor problem. The best way to diagnose a harvest valve is by using Manitowoc’s Ice Machine Freeze Cycle Refrigeration System Operational Analysis Table. Use the following procedures to determine if a harvest valve is remaining partially open during the freeze cycle. 1. Wait five minutes into the freeze cycle. 2.
Findings Comments The inlet of the harvest valve is cool enough to touch and the compressor discharge line is hot. This is normal as the discharge line should always be too hot to touch and the harvest valve inlet, although too hot to touch during harvest, should be cool enough to touch after 5 minutes into the freeze cycle. Cool & Hot The inlet of the harvest valve is hot and approaches the temperature of a hot compressor discharge line.
Discharge Line Temperature Analysis GENERAL Knowing if the discharge line temperature is increasing, decreasing or remaining constant can be an important diagnostic tool. Compressor discharge line temperature on a normally operating ice machine steadily increases throughout the freeze cycle. Ambient air temperatures affect the discharge line temperature. Higher ambient air temperatures at the condenser and/or higher inlet water temperature = higher discharge line temperatures at the compressor.
Final Analysis The column with the highest number of Checkmarks identifies the refrigeration problem. COLUMN 1 - HARVEST VALVE LEAKING Replace the valve as required. COLUMN 2 - LOW CHARGE/TXV STARVING Normally, a starving expansion valve only affects the freeze cycle, not the harvest cycle. A low refrigerant charge normally affects both cycles. Verify the ice machine is not low on charge before replacing an expansion valve. 1. Add refrigerant charge to verify a low charge.
COLUMN 3 - TXV FLOODING OR REFRIGERANT OVERCHARGE A loose or improperly mounted expansion valve bulb causes the expansion valve to flood. Check bulb mounting, insulation, etc., before changing the valve. Verify refrigerant amount is correct by weighing recovered refrigerant before replacing a TXV. COLUMN 4 - COMPRESSOR Replace the compressor. To receive warranty credit, the compressor ports must be properly sealed.
SYMPTOM #3 HARVEST PROBLEMS Normal Ice Cube Melted Out Ice Cube Definition of a harvest problem; At the end of a 3.5 minute harvest cycle the slab of ice is still contacting the evaporator. The slab of ice may or may not be removable by hand. Harvest problems can be split into two categorizes. • • 118 Melted sheet of cubes at the end of the harvest cycle. Ice can be removed rather easily by hand. The back of the cubes are misshapen and melted.
Part Number STH038 5/12 SYMPTOM #3 WILL NOT HARVEST, CUBES NOT MELTED Ice Machine Will Not Harvest - Freeze Cycle is Normal and Ice Cubes are Not Melted After Harvest START Low production, Normal fill pattern, long harvest cycle, Possible SL #2, Back of cubes are not melted YES Discharge line temperature is normal at the end of the freeze cycle? NO Refer to Symptom #2 Freeze Cycle Operational Analysis Table YES Is harvest valve energized? Refer to Sequence of Operation & Wiring Diagrams NO YES NO
120 YES Self Contained Air-cooled Condenser? YES Fan cycling control operates correctly in freeze cycle? NO YES Replace Fan Cycling Control Fan cycling control opens below setpoint in harvest cycle? NO YES Are you sure Discharge line temperature is normal? Part Number STH038 5/12 Repeat this flowchart & verify all data
Part Number STH038 5/12 SYMPTOM #4 WILL NOT HARVEST, CUBES MELTED Ice Machine Will Not Harvest - Freeze Cycle is Normal and Ice Cubes are Melted After Harvest START Are back of the cubes melted at end of harvest cycle? NO YES NO Level Ice Machine YES NO Does ice remain frozen to the evaporator at the end of the harvest cycle? Is Ice Machine level? YES Refer to Symptom #2 Freeze Cycle Operational Analysis Table Is water flowing over the evaporator in the first 45 seconds of harvest? NO YES Refe
122 NO Is the evaporator dirty? (Dry evaporator first then check) YES NO Part Number STH038 5/12 Discharge line temperature is normal at the end of the freeze cycle? YES NO Refer to Heavily Scaled Cleaning Procedure Refer to Symptom #2 Freeze Cycle Operational Analysis Table Refer to Manual Cleaning Procedure
Component Check Procedures Electrical Components CONTROL BOARD, DISPLAY BOARD AND TOUCH PAD FUNCTION The control board, display board and touch pad provide user input and control the ice machine sequence of operation. NOTE: Anytime power is supplied to wires #55 & #56 on the control board, the “Display” and “Micro” lights will flash like a heartbeat. The two green lights are located on the top right corner of the control board. Display Diagnostics 1. Micro light flashes and display light is off. 2.
Control Board Diagnostics 1. Micro light is not flashing a heartbeat. 2. Disconnect line voltage power supply to the ice machine and wait a minimum of 15 seconds, then reapply power. A. Micro light flashes - continue with step 3. B. Micro light is off - Replace control board. 3. Perform the following keystrokes on the display.
Touch Pad Diagnostics Follow the control board diagnostics to the Status Passed display. Perform the following keystrokes on the display. • Display reads Status Passed, press the right arrow • Display reads Pass Yes, press the right arrow • Display reads Key Pad Test, press the right arrow 4. Test the functionality of all buttons on the touch pad. NOTE: Pushing the power button will start and stop the ice machine. Testing it last will allow the ice machine to continue running a freeze cycle.
CONTROL BOARD RELAY TEST The control board can be set to energize all relays for 3.5 minutes. This allows testing to verify control board relays are closed and line voltage is available for ice machine components - Water pump, dump valve, water inlet valve, harvest valve(s), air compressor, contactor/compressor/fan motor - The fan cycle control must close to energize the fan motor. 1. Press power button to turn off ice machine. 2. Perform the following keystrokes on the display.
4. Test for line voltage at the individual components. A. Line voltage is present and the component is non functional - Replace component B. Voltage is not present at the component Proceed to step 5 5. Refer to wiring diagram and determine wire location on the 9 pin molex connector for the component you are testing. 6. Check for line voltage at the control board 9 pin molex connector. A. Line voltage at 9 pin connector - Repair wiring to component B.
USB FLASH DRIVE SPECIFICATIONS AND FORMATTING Updating firmware on Indigo™ model ice machines requires a properly formatted 2 GB or smaller USB flash drive. All USB flash drives must be formatted before use to remove any software programs or files currently on the flash drive. USB Flash Drive Specifications: • USB 2 Version • 2 GB or less capacity • Fat32 File System • 512 Byte File Allocation Unit USB Flash Drive Formatting: Procedure to format a USB flash drive varies with operating system software.
Windows 7 or Windows Vista Computers: 1. Insert USB flash drive; your computer may indicate: • “Found New Hardware” follow the prompts to install the USB flash drive • USB flash drive may auto play - Close auto play window 2. Press Windows Key and E key simultaneously to access windows explorer. 3. Right click on your USB Flash Drive. 4. Left click on “Format”. 5.
Windows XP Computers: 1. Insert USB flash drive; your computer may indicate: • “Found New Hardware” follow the prompts to install the USB flash drive • USB flash drive may auto launch - Close auto launch window. 2. To access Disk Management: • Left click on the Windows Start Button • Left click on “Run” • Type compmgmt.msc and left click on “OK” • Left click on “Disk Management”. 3. Verify USB flash drive capacity is 2 GB or less 4.
UPGRADING FIRMWARE WITH A FLASH DRIVE OR TRANSFERRING SETUP DATA TO MULTIPLE MACHINES Important Do not use a flash drive with a built-in software program, such as Sandisk brand. 1. Refer to USB Flashdrive Specifications and Formatting page 128 and prepare the flash drive. 2. Drag and drop the firmware file onto a flash drive or refer to Exporting data to a flash drive to transfer settings to multiple machines. 3. Ensure that the ice machine’s power is on. 4. Press the Menu button. 5.
11. Follow these on-screen instructions to: A. Insert Drive (Insert the flash drive into the USB port on the ice machine’s control board.) B. Press Check (Press the Checkmark.) C. Wait For Comp (Wait approximately 5 to 10 minutes for the Firmware upgrade to complete. 12. Depending on software version either Complete, Success or the On/Off screen will appear. 13. Verify the new firmware version loaded by navigating to Menu/Machine information/Main Software Version and verify the firmware version number.
EXPORTING DATA TO A FLASH DRIVE Data can be copied from the control board memory to a flash drive and used to transfer setup and/or cycle data to a replacement control board or to transfer setup information to multiple ice machines. Data may also be requested by service department personnel for analysis or as an aid to troubleshooting. The data files are small and can be attached to an email. Important Do not use a flash drive with a built-in software program, such as Sandisk brand. 1. 2. 3. 4.
7. Press the Checkmark again. A submenu with Export ALL and Export Setup appears. NOTE: There are four files stored in ice machine memory: • Asset Data - ASDATAoo.CSV • Operating Data - OPDATAoo.CSV • Real Time Data - RTDATAoo.CSV • Ice Machine Settings - Settinoo.CSV Select only “Ice Machine Settings” file when multiple machines will be programmed with the same user specified settings. Select “Export All” if you are installing a replacement board. 8.
PROGRAMMING A REPLACEMENT CONTROL BOARD Indigo™ replacement control boards require the Model and Serial number to be entered to activate the appropriate look up tables for operation and diagnostic. This can be done two different ways, USB Setup or Manual Setup. USB Setup - Applicable when the control board is operational and has a mechanical issue such as a sticking relay. The asset data is transferred to the replacement control board from the faulty control board.
Manual Setup - Applicable when the control board is non-operational or data from the faulty board is suspect. Install replacement control board and reapply power. Dependant on firmware version the screen will either display “Manual Setup” directly or you will need to navigate to the screen. If you need to navigate to the control board screen: 1. Press the Menu button. 2. Press the Down arrow until Service is highlighted, then press the Checkmark. 3.
MAIN FUSE FUNCTION The control board fuse stops ice machine operation if electrical components fail, causing high amp draw. SPECIFICATIONS The main fuse is 250 Volt, 8 amp. ! Warning High (line) voltage is applied to the control board (terminals #55 and #56) at all times. Removing the control board fuse or pressing the On/Off button will not remove the power supplied to the control board. CHECK PROCEDURE 1. If the bin switch light is on with the water curtain/ ice dampers closed, the fuse is good.
BIN SWITCH FUNCTION Movement of the water curtain/ice dampers control bin switch operation. The bin switch has two main functions: 1. Terminating the Harvest cycle and returning the ice machine to the Freeze cycle. This occurs when the bin switch is opened and closed again within 30 seconds during the Harvest cycle. 2. Automatic ice machine shut-off. If the storage bin is full at the end of a Harvest cycle, the sheet of cubes fails to clear the water curtain/ice dampers and holds it open.
SPECIFICATIONS The bin switch is a magnetically operated reed switch. The magnet is attached to the lower right corner of the water curtain/ice dampers. The bin switch is connected to a varying D.C. voltage circuit. (Voltage does not remain constant.) NOTE: Because of a wide variation in D.C. voltage, it is not recommended that a voltmeter be used to check bin switch operation.
DIAGNOSTICS • • • • 1. Verify bin switch, damper and damper magnet are in place. Press the Menu button. Scroll down to Service and press right arrow. Scroll down to Diagnostics and press right arrow Scroll down to Inputs and press right arrow to display curtain switch readings (Curt SW1, Curt SW2, etc). 2. Open and close the ice damper(s) repeatedly while observing the display and control board lights. A.
WATER LEVEL CONTROL CIRCUITRY FUNCTION The water level probe controls the water level by sensing whether water is or is not contacting the water level probe. The water level probe has three sensing probes. Two probes are equal in length and are used to measures conductivity for diagnostics, ice clarity and water miser options. Factory default settings measure resistance from both long probes to the short probe.
Freeze Cycle Operation During the Freeze cycle, the water inlet valve energizes and de-energizes in conjunction with the water level probe located in the water trough. During the first 45 seconds of the Freeze cycle: • The water inlet valve is ON when there is no water in contact with the water level probes. • The water inlet valve turns OFF after water contacts the water level probes for 3 continuous seconds.
WATER TROUGH OVERFILLING DURING THE FREEZE CYCLE Step 1 Press the power button and turn off the ice machine. Step 2 If water continues to flow with the ice machine off, disconnect power. If water continues to flow verify water pressure is below 80 psig before replacing the water inlet valve. Step 3 Check water level probe mounting and verify secure wiring connections at the probe and control board. Step 4 Scroll to Service/Diagnostics/Inputs and press down arrow until Wtr Low and Wtr High are displayed.
Step 6. Water level probe wires #2 & #3 jumpered at the control board connector Is Water Flowing into the Water Trough? 144 The Water Level Light Is: The Water Inlet Valve Solenoid Coil Is: Cause No On De-energized The interconnecting wire or water level probe is causing the problem. Ohm, then clean or replace the water level probe or wire. Yes Off Energized The control board is causing the problem. Yes On De-energized The water fill valve is causing the problem.
WATER WILL NOT RUN INTO THE SUMP TROUGH DURING THE FREEZE CYCLE Step 1 Verify water is supplied to the ice machine. Step 2 Scroll to Service/Diagnostics/Inputs and press down arrow until Wtr Low and Wtr High are displayed. A. Yes is displayed - Control board is receiving a sensing water signal. Proceed to step 3. B. No is displayed - Control board is not receiving a sensing water signal. Proceed to Control Board Diagnostics page 124. Step 3 Disconnect water level probe, observe LCD display text. A.
ICE THICKNESS PROBE (HARVEST INITIATION) FUNCTION The ice thickness probe senses ice on the evaporator and signals the control board to start a harvest cycle. After ice forms on the evaporator, the ice will contact the ice thickness probe and a harvest cycle is initiated. SPECIFICATIONS Freeze Time Lock-In Feature The ice machine control system incorporates a freeze time lock-in feature. This prevents the ice machine from short cycling in and out of harvest.
Ice Thickness Check The ice thickness probe is factory-set to maintain the ice bridge thickness at 3 mm. NOTE: Make sure the water curtain/splash shields are in place when performing this check. It prevents water from splashing out of the water trough. 1. Inspect the bridge connecting the cubes. It should be about 3 mm thick. 2. If adjustment is necessary, turn the ice thickness probe adjustment screw clockwise to increase bridge thickness or counterclockwise to decrease bridge thickness.
Diagnostics SYMPTOMS Premature harvest • Display indicates ITP Failure • Low ice production • Thin ice in bin • Freeze cycles are faster than published cycle times Will not harvest • Display indicates ITP Failure • Low ice production • Thick ice in bin • Large sheet of ice on evaporator • Harvest cycle doesn’t start • Freeze cycles are slower than published cycle times 148 Part Number STH038 5/12
ICE MACHINE CYCLES INTO HARVEST BEFORE ICE CONTACTS THE ICE THICKNESS PROBE 1. Reboot the control board by disconnecting and reconnecting line voltage to the ice machine. 2. Verify ice thickness probe gap is approximately 7 mm. 3. Wait six minutes: • Ice Machine remains in freeze cycle - Allow ice machine to run. • Ice machine cycles into harvest - Replace ice thickness probe to determine if problem is resolved. If problem persists replace the control board.
ICE MACHINE DOES NOT CYCLE INTO HARVEST If ice is on the evaporator initiate a manual harvest cycle by performing the following keystrokes. • Press Menu • Scroll down to Service and press right arrow • Scroll down to Manual Harvest and press right arrow - A new freeze cycle will start after the manual harvest cycle is complete. 1. Reboot the control board by disconnecting and reconnecting line voltage to the ice machine. 2. Verify ice thickness probe gap is approximately 7 mm. 3.
HIGH PRESSURE CUTOUT (HPCO) CONTROL FUNCTION Stops the ice machine if subjected to excessive highside pressure. The HPCO control is normally closed, and opens on a rise in discharge pressure. SPECIFICATIONS. Specifications Cut-Out Cut-In 2413 kPa ±24.13 bar ±.69 Automatic Reset 350 psig ±10 Must be below 1723 kPa 17.23 bar (250 psig) to reset. SYMPTOM Opening the HPCO will cause the control board to initiate a 60 minute delay.
CHECK PROCEDURE Symptom #1 Machine is off and the display indicates “Delay xx min, HPCO Active”. 1. Leave all wiring connectors attached and perform testing within the 60 minute time delay period 2. Check for line voltage at P9 connector on control board (Two wire connector adjacent to 9 pin connector). A. Line voltage present - HPCO switch has reset and closed. B. No line voltage present - HPCO switch is open. 3. Depending on timing either wait for the delay period to end or start a new freeze cycle.
Symptom #2 Machine is running and the display indicates “HPC Fault” and an alert triangle 1. Navigate to the event log on the Service menu. Scroll down to HPC Fault #5. Open the event and view when and how often HPCO Fault has occurred. 2. If this is a one time event it may be intermittent and caused by conditions around the unit changing. For example: High ambient temperature, blocked vents, etc. 3. Run the system to see if the control trips.
FAN CYCLE CONTROL FUNCTION Cycles the fan motor on and off. The fan cycle control closes on an increase, and opens on a decrease in discharge pressure. SPECIFICATIONS Specifications Model Cut-In (Close) I0320 I0520 1723 kPa ±.34 (17.23 bar ±.34) Cut-Out (Open) 1517 kPa ±.34 (15.17 bar ±.34) CHECK PROCEDURE 1. Verify fan motor windings are not open or grounded, and fan spins freely. 2. Connect manifold gauges to ice machine. 3.
THERMISTORS FUNCTION Thermistor resistance values change with temperature. The value supplied to the control board is used to identify temperature at the thermistor location. SPECIFICATIONS : Temperature of Thermistor Resistance °C °F -30° - -20° -22° - -4° K Ohms (x 1000) 820.85 - 466.35 -20° - -10° -4° - 14° 466.35 - 269.05 -10° - 0° 14° - 32° 269.05 - 160.70 0° - 10° 32° - 50° 160.70 - 98.930 10° - 20° 50° - 68° 98.930 - 62.015 20° - 30° 68° - 86° 62.015 - 39.
Four thermistors are located on the ice machine. They are labeled T1, T2, T3, T4 T1 - Air or Water cooled Models • Liquid line temperature sensor located at the outlet of the condenser. T2 - Air or Water cooled Models • Discharge line temperature sensor located near the compressor. T3 -Single Expansion Valve Models • Suction line temperature sensor located at the inlet of the evaporator. T4 -Single Expansion Valve Models • Suction line temperature sensor located at the outlet of the evaporator.
Part Number STH038 5/12 C [2] [5] T4 T4 C [1] T3 T4 N [48 48] T4 T3 N [1] T4 T4 T3 W [1] T4 A& W [48 48] T3 Co n d e n s i n g O p t io n A [1] R404a Ent Evap [Evap In] [Left] R404a Lvg Evap [Evap Out] T3 T3 T3 [Right] R404a Lvg Evap [Evap Out] T2 T2 T2 T2 T2 Compressor or Discharge T1 T1 T1 R404a Lvg Condenser [Liquid Line] T1 T1 T1 T1 R404a Ent Receiver Temperature Sensing Universal Location T2 T2 R404a Lvg Receiver [DipTu Tube] Spl plit System Remote Condensing
SYMPTOM Alert icon on the display is flashing and the alert indicates a T1, T2, T3, or T4 Fault. CHECK PROCEDURE • • • • Press the Menu button. Scroll down to Service and press right arrow. Scroll down to Diagnostics and press right arrow Scroll down to Temp Sensors and press right arrow to display thermistor temperature readings. NOTE: An open thermistor will display -30°C and a shorted thermistor displays 246°C. Thermistor Test 1. Disconnect thermistor from control board and measure resistance. 2.
HARVEST ASSIST AIR PUMP FUNCTION The air pump breaks the vacuum between the sheet of ice and the evaporator which results in shorter harvest cycles. SPECIFICATIONS 230 Volt - matches the ice machine voltage. CHECK PROCEDURE 1. The air pump is wired in parallel with the harvest valve - Verify the ice machine is in the harvest cycle and the harvest valve is energized. 2.
COMPRESSOR ELECTRICAL DIAGNOSTICS The compressor does not start or will trip repeatedly on overload. Check Resistance (Ohm) Values NOTE: Compressor windings can have very low ohm values. Use a properly calibrated meter. Perform the resistance test after the compressor cools. The compressor dome should be cool enough to touch (below 120°F/49°C) to assure that the overload is closed and the resistance readings will be accurate. SINGLE PHASE COMPRESSORS 1.
CHECK MOTOR WINDINGS TO GROUND Check continuity between all three terminals and the compressor shell or copper refrigeration line. Scrape metal surface to get good contact. If continuity is present, the compressor windings are grounded and the compressor should be replaced. COMPRESSOR DRAWING LOCKED ROTOR To determine if the compressor is seized, check the amp draw while the compressor is trying to start. The two likely causes of this are a defective starting component and a mechanically seized compressor.
DIAGNOSING START COMPONENTS If the compressor attempts to start, or hums and trips the overload protector, check the start components before replacing the compressor. Capacitor Visual evidence of capacitor failure can include a bulged terminal end or a ruptured membrane. Do not assume a capacitor is good if no visual evidence is present. A good test is to install a known good substitute capacitor. Use a capacitor tester when checking a suspect capacitor.
Relay The relay has a set of contacts that connect and disconnect the start capacitor from the compressor start winding. The contacts on the relay are normally closed (start capacitor in series with the start winding). The relay senses the voltage generated by the start winding and opens the contacts as the compressor motor starts. The contacts remain open until the compressor is de-energized. RELAY OPERATION CHECK 1. Disconnect wires from relay terminals. 2. Verify the contacts are closed.
PTCR The PTCR allows current to flow through the start winding at compressor startup. Current flow heats the ceramic discs in the PTCR. The electrical resistance increases with temperature and stops all except a trickle of current flow through the start winding. The small flow of current keeps the PTCR hot 127°C and the start winding out of the circuit.
PTCR Operation Check 1. Visually inspect the PTCR. Check for signs of physical damage. NOTE: The PTCR case temperature may reach 100°C while the compressor is running. This is normal. Do not change a PTCR just because it is hot. 2. Wait at least 10 minutes for the PTCR to cool to room temperature. 3. Remove the PTCR from the ice machine. 4. Measure the resistance of the PTCR as shown.
REFRIGERANT RECOVERY/EVACUATION/ CHARGING PROCEDURES Requirements and procedures vary by location. Follow your local laws governing the recovery, evacuation and charging of equipment that contains propane refrigerant. LIQUID LINE FILTER-DRIERS The filter-driers used on Manitowoc ice machines are manufactured to Manitowoc specifications. The difference between a Manitowoc drier and an offthe-shelf drier is in filtration.
Charts Cycle Times/24-Hour Ice Production/ Charts These charts are used as guidelines to verify correct ice machine operation. Accurate collection of data is essential to obtain the correct diagnosis. • Ice production checks that are within 10% of the chart are considered normal. This is due to variances in water and air temperature. Actual temperatures will seldom match the chart exactly.
I0320A AIR-COOLED MODEL CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °C/°F Freeze Time Water Temperature °C/°F 10°C/50°F 21°C/70°F NO DATA Harvest Time1 32°C/90°F 21°C/70°F 27°C/80°F 1-2.5 32°C/90°F 38°C/100°F 1 Times in minutes 24 HOUR ICE PRODUCTION Air Temp.
21°C Water Temperature Air Temp Entering Condenser °F/°C Freeze Cycle Discharge Temp T2 Harvest Cycle Suction Temp1 T4 Discharge Temp T2 NO DATA Suction Temp T4 10°C 50°F 21°C 70°F 27°C 80°F 32°C 90°F 38°C 100°F 1 Suction temperature drops gradually throughout the freeze cycle 32°C Water Temperature Air Temp Entering Condenser °F/°C Freeze Cycle Discharge Temp T2 Harvest Cycle Suction Temp1 T4 Discharge Temp T2 NO DATA Suction Temp T4 10°C 50°F 21°C 70°F 27°C 80°F 32°C 90°F 38°C 100°F 1 Suc
I0500A AIR-COOLED MODEL CYCLE TIMES Freeze Time + Harvest Time = Total Cycle Time Air Temp. Entering Condenser °C/°F Freeze Time 10°C/50°F 21°C/70°F 32°C/90°F 21°C/70°F 13.4-15.3 14.5-16.5 15.7-17.9 27°C/80°F 14.5-16.5 15.5-17.7 16.6-19.0 32°C/90°F 15.7-17.9 16.9-19.3 18.9-21.5 38°C/100°F 17.2-19.6 18.9-21.5 21.0-23.9 Water Temperature °C/°F Harvest Time1 1-2.5 1 Times in minutes 24 HOUR ICE PRODUCTION Air Temp.
21°C Water Temperature Air Temp Entering Condenser °F/°C Freeze Cycle Harvest Cycle Discharge Temp T2 Suction Temp1 T4 Discharge Temp T2 Suction Temp T4 10°C 50°F 77 / 85 170 / 185 -6 / -11 21 / 11 46 / 52 115 / 125 2 / 13 35 / 55 21°C 70°F 23 / 88 175 / 190 -5 / -10 22 / 13 49 / 57 120 / 135 2 / 13 36 / 55 27°C 80°F 82 / 91 108 / 195 -4 / -9 24 / 15 52 / 63 15 / 145 3 / 13 37 / 55 32°C 90°F 88 / 93 190 / 200 -4 / -9 25 / 15 60 / 66 140 / 150 3 / 13 37 / 55 38°C 100°F 96 / 113 20
This Page Intentionally Left Blank 172 Part Number STH038 5/12
Diagrams Wiring Diagrams The following pages contain electrical wiring diagrams. Be sure you are referring to the correct diagram for the ice machine you are servicing. ! Warning Always disconnect power before working on electrical circuitry.
I0320 Self Contained - 1 Ph 174 Part Number STH038 5/12
I0500 Self Contained - 1 Ph Part Number STH038 5/12 175
Electronic Control Board Bin Switches Bin Thermostat USB Display Light Micro Light Clean Light Harvest Light SL-1 Light SL-2 Light Thermistors T1 T2 Dump Valve T3 T4 Transformer Left Bin Switch Light Right Bin Switch Light Water Level Probe Light Display Ice Thickness Probe Light RS485 RT Harvest Bin LED LuminIce Battery Compressor LT Harvest Water Level Probe Fuse Relay Lights Pump Water Pump AuCS Water Remote CVD V C LPC HPC1 HPC2 Ice Thickness Probe Compressor L1 Dump L2 Not Used
Refrigeration Tubing Schematics T4 Thermistor E VA P O R ATO R H E AT EXCHANGER EXPANSION VALVE T3 Thermistor H O T G A S S O L E N O I D VA LV E X COMPRESSOR STRAINER A I R O R WAT E R CONDENSER T2 Thermistor DRIER RECEIVER ( WAT E R C O O L E D O N LY ) T1 Thermistor Part Number STH038 5/12 177
178 Part Number STH038 5/12
Manitowoc Ice 2110 South 26th Street, P.O. Box 1720 Manitowoc, WI 54221-1720, USA Ph: 001-920-682-0161 Fax: 001-920-683-7589 Visit us online at: www.manitowocfsg.
