Manitowoc I0320, I0500, I0320A, I0500A User Manual

Ice Machines With R290
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
Part Number STH038 5/12
Indigo™ Series
Refrigerant
Safety Notices
!
Warning
!
Caution
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:
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.
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
Important
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:
Text in an Important box provides you with information that may help you perform a procedure more efficiently. Disregarding this information will not cause damage or injury, but it may slow you down as you work.
NOTE: Text set off as a Note provides you with simple, but useful, extra information about the procedure you are performing.
Read These Before Proceeding:
!
Caution
!
Caution
Important
! Warning
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.
Proper installation, care and maintenance are essential for maximum performance and trouble­free operation of your equipment. Visit our website www.manitowocfsg.com for manual updates, translations, or contact information for service agents in your area.
Routine adjustments and maintenance procedures outlined in this handbook are not covered by the warranty.
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
!
Warning
!
Warning
! Warning
other than those supplied by Manitowoc for your ice machine model.
Two or more people or a lifting device are required to lift this appliance.
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.
Do not damage the refrigeration circuit when installing, maintaining or servicing the unit.
! Warning
Do not operate equipment that has been misused,
! Warning
!
Warning
! Warning
!
Warning
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.
All covers and access panels must be in place and properly secured, before operating this equipment.
Do not obstruct machine vents or openings.
Do not store gasoline or other flammable vapors or liquids in the vicinity of this or any other appliance.
Do not clean with water jet.
! Warning
It is the responsibility of the equipment owner to
! Warning
! Warning
perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.
Two or more people are required to move this equipment to prevent tipping.
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). An ignition source at a temperature higher than 470°C is needed for a combustion to occur. Refer to nameplate to identify the type of refrigerant in your equipment. Only trained and qualified personnel aware of the dangers are allowed to work on the equipment.
! 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.
Table of Contents
General Information
How to Read a Model Number . . . . . . . . . 13
Model/Serial Number Location . . . . . . . . 14
Ice Machine Warranty Informatio n . . . . . 14
Owner Warranty Registration Card . . . 14
Commercial Warranty Coverage . . . . . 15
Installation
Location of Ice Machine . . . . . . . . . . . . . . 20
Clearance Req uir ements . . . . . . . . . . . . . 21
Ice Machine Heat of Rejection . . . . . . . . . 21
Ice Deflector . . . . . . . . . . . . . . . . . . . . . . . 22
Installation on a Bin . . . . . . . . . . . . . . . 22
Installation on a Dispenser . . . . . . . . . 22
Electrical Requirements . . . . . . . . . . . . . . 23
Maintenance
Cleaning and Sanitizing . . . . . . . . . . . . . . 25
General . . . . . . . . . . . . . . . . . . . . . . . . 25
Cleaning/Sanitizing Procedure . . . . . . 27
Preventative Maintenance Cleaning Proce-
dure . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Exterior Cleaning . . . . . . . . . . . . . . . . . 27
Cleaning / Sanitizing Procedure . . . . . . . 28
Cleaning Procedure . . . . . . . . . . . . . . 28
Sanitizing Procedure . . . . . . . . . . . . . . 33
Removal from Service/Winterization . . . 36
Part Number STH038 5/12 9
Operation
Control Panel Features . . . . . . . . . . . . . . 37
Menu Navigation Overview . . . . . . . . . . . 39
Display Panel Navigation . . . . . . . . . . . . 40
Alerts and Messages . . . . . . . . . . . . . . . . 42
Main Menu . . . . . . . . . . . . . . . . . . . . . . . . 43
Machine Info Menu . . . . . . . . . . . . . . . . . 44
Password Entry . . . . . . . . . . . . . . . . . . . . 45
Set-Up Menu . . . . . . . . . . . . . . . . . . . . . . . 48
Buttons . . . . . . . . . . . . . . . . . . . . . . . . 37
Display Panel . . . . . . . . . . . . . . . . . . . 38
Reset Password To Factory Defaults . 47
Language . . . . . . . . . . . . . . . . . . . . . . 48
Time & Date . . . . . . . . . . . . . . . . . . . . 48
Time Configuration . . . . . . . . . . . . . . . 50
Units . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Ice Clarity . . . . . . . . . . . . . . . . . . . . . . 51
LCD Brightness . . . . . . . . . . . . . . . . . 51
Password On . . . . . . . . . . . . . . . . . . . 52
Edit password . . . . . . . . . . . . . . . . . . . 52
Clean Minder . . . . . . . . . . . . . . . . . . . 52
IAuCS Runtime . . . . . . . . . . . . . . . . . . 53
Air Filter . . . . . . . . . . . . . . . . . . . . . . . 53
Water Filter . . . . . . . . . . . . . . . . . . . . . 54
LuminIce™ reminder . . . . . . . . . . . . . 54
USB Setup . . . . . . . . . . . . . . . . . . . . . 55
Factory Defaults . . . . . . . . . . . . . . . . . 55
10 Part Number STH038 5/12
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 . . . . . . . . . . . . . . . . . . 65
Replace Control Board . . . . . . . . . . . . 65
USB Setup . . . . . . . . . . . . . . . . . . . . . 65
Event Log Menu . . . . . . . . . . . . . . . . . 66
Event Log . . . . . . . . . . . . . . . . . . . . . . 67
USB Flash Drive Specifications and Format-
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Upgrading Firmware with a Flash Drive or Transferring Setup Data To Multiple Ma-
chines . . . . . . . . . . . . . . . . . . . . . . . . . 73
Exporting Data to a Flash Drive . . . . . 75
Safe Operation Mode . . . . . . . . . . . . . 76
Operational Checks . . . . . . . . . . . . . . . . . 77
General . . . . . . . . . . . . . . . . . . . . . . . . 77
Ice Thickness Check . . . . . . . . . . . . . . 78
Sequence of Operation . . . . . . . . . . . . . . 79
Self Contained Air or Water Cooled . . 79
Part Number STH038 5/12 11
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 . . . . . 118
Symptom #3 Will Not Harvest, Cubes Not
Melted . . . . . . . . . . . . . . . . . . . . . . . . . 119
Symptom #4 Will Not Harvest, Cubes Melt-
ed . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
12 Part Number STH038 5/12
Component Check Procedures
Electrical Components . . . . . . . . . . . . . . . 123
Control Board, Display board and Touch
Pad . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Control Board Relay Test . . . . . . . . . . 126
USB Flash Drive Specifications and Format-
ting . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Upgrading Firmware with a Flash Drive or Transferring Setup Data To Multiple Ma-
chines . . . . . . . . . . . . . . . . . . . . . . . . . 131
Exporting Data to a Flash Drive . . . . . 133
Programming A Replacement Control Board
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Main Fuse . . . . . . . . . . . . . . . . . . . . . . 137
Bin Switch . . . . . . . . . . . . . . . . . . . . . . 138
Water Level Control Circuitry . . . . . . . 141
Ice Thickness Probe (Harvest Initiation)
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
High Pressure Cutout (HPCO) Control 151
Fan Cycle Control . . . . . . . . . . . . . . . . 154
Thermistors . . . . . . . . . . . . . . . . . . . . . 155
Harvest Assist Air Pump . . . . . . . . . . . 159
Compressor Electrical Diagnostics . . . 160
Diagnosing Start Components . . . . . . 162
Refrigerant Recovery/Evacuation/Charging
procedures . . . . . . . . . . . . . . . . . . . . . 166
Liquid Line Filter-Driers . . . . . . . . . . . . 166
Total System Refrigerant Charge . . . . 166
Part Number STH038 5/12 13
Charts
Cycle Times/24-Hour Ice Production/Charts
Diagrams
Wiring Diagrams . . . . . . . . . . . . . . . . . . . 173
Electronic Control Board . . . . . . . . . . . . 176
Refrigeration Tubing Sche matics . . . . . 177
I0320A Air-Cooled Model . . . . . . . . . . 168
I0500A Air-Cooled Model . . . . . . . . . . 170
Wiring Diagram Legend . . . . . . . . . . . 173
I0320 . . . . . . . . . . . . . . . . . . . . . . . . . 174
I0500 . . . . . . . . . . . . . . . . . . . . . . . . . 175
14 Part Number STH038 5/12
General Information
How to Read a Model Number
P - Correctional Model
M - Marine Model
5 - 50H Z
6 - 60H Z
# HER TZ
X - LuminIce
Regulating Valve
HP - High Pressure Water
161 - 115 /60/1
261 - 208 -230 /60/1
251 - 230 /50/1
263 - 208 -230 /60/3
VOLTAGE
463 - 460 /60/3
3 - Three Phase
E - WRAS 50 Cyc le Only
NO INDICATOR - 1 Phase
OR
A - Self-Contained Air -Cooled
W - Self-Contained Water -Cooled
N - Remote Air-Cooled
C - CVD Air-Cooled
DC - IB Dice Model
CONDENSER TYPE
YC - IB Half Dice
P I Y 0855 W3 – 263PHPX
0 to 6 & 8 - Self-Contained Unit
7 & 8 - CVD R emote C ondensing U nit
9 - Remote Air -Cooled C ondenser
9 - Ice Beverage Remote Condensing Unit
# CUBE SIZE CONDENSER TYPE
0 - Regular Air-Cooled
1 - Regular Water-Cooled
2 - Dice Air-Cooled
Part Number STH038 5/12 13
3 - Dice Water-Cooled
4 - Half-Dice Air-Cooled
5 - Half-Dice Water- Cooled
ICE MACHINE MODEL
I - Indigo Model
ICE CUBE SIZE
R - Regular
D - Dice
Y - Half-Dice
Not Used On IB Models
IB - Ice Beverage
Ice Machine Series
P - R290 Refrigerant
Model/Serial Number Location
Important
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.
Complete and mail the OWNER WARRANTY REGISTRATION CARD as soon as possible to validate the installation date.
If the OWNER WARRANTY REGISTRATION CARD is not returned, Manitowoc will use the born on date recorded in the control board or the date of sale to the Manitowoc Distributor as the first day of warranty coverage for your new ice machine.
14 Part Number STH038 5/12
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.
The COMPANY'S warranty hereunder with respect to the compressor shall apply for an additional twenty­four months, excluding all labor charges, and with respect to the evaporator for an additional twenty-four months, including labor charges.
The obligation of the COMPANY under this warranty is limited to the repair or replacement of parts, components, or assemblies that in the opinion of the COMPANY are defective. This warranty is further limited to the cost of parts, components or assemblies and standard straight time labor charges at the servicing location. Time and hourly rate schedules, as published from time to time by the COMPANY, apply to all service procedures.
Part Number STH038 5/12 15
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.
The COMPANY'S liability under this warranty shall in no event be greater than the actual purchase price paid by customer for the ice machine.
The foregoing warranty shall not apply to (1) any part or assembly that has been altered, modified, or changed; (2) any part or assembly that has been subjected to misuse, abuse, neglect, or accidents; (3) any ice machine that has been installed and/or maintained inconsistent with the technical instructions provided by the COMPANY; or (4) any ice machine initially installed more than five years from the serial number production date. This warranty shall not apply if the Ice Machine's refrigeration system is modified with a condenser, heat reclaim device, or parts and assemblies other than those manufactured by the COMPANY, unless the COMPANY approves these modifications for specific locations in writing.
16 Part Number STH038 5/12
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. The foregoing warranty shall constitute the sole liability of the COMPANY and the exclusive remedy of the customer or user.
To secure prompt and continuing warranty service, the warranty registration card must be completed and sent to the COMPANY within five (5) days from the installation date.
To obtain warranty service or information regarding your Product, please contact us at:
MANITOWOC ICE 2110 So. 26th St. P.O. Box 1720, Manitowoc, WI 54221-1720 Telephone: 920-682-0161 Fax: 920-683-7585 www.manitowocice.com
Part Number STH038 5/12 17
18 Part Number STH038 5/12
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Installation
!
Caution
!
Warning
!
Warning
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.
An ice machine contains high voltage electricity and refrigerant charge. Repairs are to be performed by properly trained refrigeration 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.
Some 50 hz models may contain up to 15 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). An ignition source at a temperature higher than 470°C is needed for a combustion to occur. Refer to nameplate to identify the type of refrigerant in your equipment. Only trained and qualified personnel aware of the dangers are allowed to work on the equipment.
Part Number STH038 5/12 19
Location of Ice Machine
!
Warning
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.
The location must not obstruct air flow through or around the ice machine. Refer to chart for clearance requirements.
The ice machine must be protected if it will be subjected to temperatures below 0°C. Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization”.
Do not obstruct machine vents or openings.
20 Part Number STH038 5/12
Clearance Requirements
I0320 Self-Contained Air-Cooled
Top/Sides 305 mm
Back 127 mm
I0500
Top/Sides 203 mm
Back 127 mm
Self-Contained Air-Cooled
Ice Machine Heat of Rejection
Heat of Rejection
Series Ice
Machine
Conditioning*
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.
Air
Peak
Part Number STH038 5/12 21
ICE DEFLECTOR
!
Warning
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..
Do not operate any ice machine with the deflector removed.
INSTALLATION ON A DISPENSER
No deflector is needed for machines that match the size of the dispenser unless required by the dispenser manufacturer. Adapters are required when a smaller ice machine is going on a larger dispenser. Align sides and back of ice machine with sides and back of dispenser/adapter, when placing ice machine on dispenser.
22 Part Number STH038 5/12
Electrical Requirements
!
Warning
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., so it must be determined by a qualified electrician.
All wiring must conform to local, state and national codes and the appliance must be grounded.
Part Number STH038 5/12 23
24 Part Number STH038 5/12
This Page Intentionally Left Blank
Maintenance
!
Warning
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. An extremely dirty ice machine must be taken apart for cleaning and sanitizing.
Manitowoc Ice Machine Cleaner and Sanitizer are the only products approved for use in Manitowoc ice machines.
Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer.
Part Number STH038 5/12 25
!
Caution
Use only Manitowoc approved Ice Machine
!
Caution
!
Warning
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.
Do not mix Cleaner and Sanitizer solutions together. Do not use these solutions in a manner inconsistent with their labeling.
Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer.
26 Part Number STH038 5/12
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.
PREVENTATIVE MAINTENANCE CLEANING PROCEDURE
This procedure cleans all components in the water flow path, and is used to clean the ice machine between the bi-yearly cleaning/sanitizing procedure.
EXTERIOR CLEANING
Clean the area around the ice machine as often as necessary to maintain cleanliness and efficient operation.
Wipe surfaces with a damp cloth rinsed in water to remove dust and dirt from the outside of the ice machine. If a greasy residue persists, use a damp cloth rinsed in a mild dish soap and water solution. Wipe dry with a clean, soft cloth.
The exterior panels have a clear coating that is stain resistant and easy to clean. Products containing abrasives will damage the coating and scratch the panels.
Never use steel wool or abrasive pads for cleaning.
Never use chlorinated, citrus based or abrasive cleaners on exterior panels and plastic trim pieces.
Part Number STH038 5/12 27
Cleaning / Sanitizing Procedure
!
Caution
!
Caution
!
Warning
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
Do not mix Cleaner and Sanitizer solutions together. It is a violation of Federal law to use these solutions in a manner inconsistent with their labeling.
Wear rubber gloves and safety goggles (and/or face shield) when handling Ice Machine Cleaner or Sanitizer.
Ice machine cleaner is used to remove lime scale and mineral deposits. Ice machine sanitizer disinfects and removes algae and slime.
NOTE: Although not required and dependant on your installation, removing the ice machine top cover may allow easier access.
28 Part Number STH038 5/12
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