Manitowoc Ice I1406P Manuel de service

Indigo™ Series

Air/Water/Remote Condenser Ice Machines

Technician’s Handbook

Part Number 000014794 5/17

Safety Notices

Read these precautions to prevent personal injury:

• 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.

• Routine adjustments and maintenance procedures outlined in this manual are not covered by the warranty.

• Proper installation, care and maintenance are essential for maximum performance and trouble-free operation of your equipment.

• Visit our website www.manitowocice.com for manual updates, translations, or contact information for service agents in your area.

• 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.

• This equipment is intended for indoor use only. Do not install or operate this equipment in outdoor areas.

• As you work on this 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.

Warning

Follow these electrical requirements during installation of this equipment.

• All field wiring must conform to all applicable codes of the authority having jurisdiction. It is the responsibility of the end user to provide the disconnect means to satisfy local codes. Refer to rating plate for proper voltage.

• This appliance must be grounded.

• This equipment must be positioned so that the plug is accessible unless other means for disconnection from the power supply (e.g., circuit breaker or disconnect switch) is provided.

• Check all wiring connections, including factory terminals, before operation. Connections can become loose during shipment and installation.

Warning

Follow these precautions to prevent personal injury during installation of this equipment:

• Installation must comply with all applicable equipment fire and health codes with the authority having jurisdiction.

• To avoid instability the installation area must be capable of supporting the combined weight of the equipment and product. Additionally the equipment must be level side to side and front to back.

• Remove all removable panels before lifting and installing and use appropriate safety equipment during installation and servicing. Two or more people are required to lift or move this appliance to prevent tipping and/or injury.

• Do not damage the refrigeration circuit when installing, maintaining or servicing the unit.

• Connect to a potable water supply only.

• This equipment contains refrigerant charge.

Warning

Follow these precautions to prevent personal injury while operating or maintaining this equipment.

• 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.

• 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.

• Crush/Pinch Hazard. Keep hands clear of moving components. Components can move without warning unless power is disconnected and all potential energy is removed.

• Moisture collecting on the floor will create a slippery surface. Clean up any water on the floor immediately to prevent a slip hazard.

Warning

Follow these precautions to prevent personal injury while operating or maintaining this equipment.

• Objects placed or dropped in the bin can affect human health and safety. Locate and remove any objects immediately.

• Never use sharp objects or tools to remove ice or frost.

• Do not use mechanical devices or other means to accelerate the defrosting process.

• When using cleaning fluids or chemicals, rubber gloves and eye protection (and/or face shield) must be worn.

DANGER

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, clean or maintain this appliance without proper supervision.

Warning

Follow these precautions to prevent personal injury during use and maintenance of this equipment:

• It is the responsibility of the equipment owner to perform a Personal Protective Equipment Hazard Assessment to ensure adequate protection during maintenance procedures.

• Do Not Store Or Use Gasoline Or Other Flammable Vapors Or Liquids In The Vicinity Of This Or Any Other Appliance. Never use flammable oil soaked cloths or combustible cleaning solutions for cleaning.

• All covers and access panels must be in place and properly secured when operating this equipment.

• Risk of fire/shock. All minimum clearances must be maintained. Do not obstruct vents or openings.

• Failure to disconnect power at the main power supply disconnect could result in serious injury or death. The power switch DOES NOT disconnect all incoming power.

• All utility connections and fixtures must be maintained in accordance with the authority having jurisdiction.

• Turn off and lockout all utilities (gas, electric, water) according to approved practices during maintenance or servicing.

Table of Contents

General Information

How to Read a Model Number ................ 15

Head Sections.............................15

Ice Cube Sizes ................................. 16

Model/Serial Number Location ............... 16

Model Numbers...............................17

Air-Water-Remote Condenser Models ..... 17

Ice Machine Warranty Information............ 18

LuminIce® II ...................................19

Installation

Ice Deflector .............................. 21

Location of Ice Machine.......................22

Clearance Requirements......................23

Air, Water, Remote Condenser Models......23

Ice Machine Heat of Rejection ................ 24

Installation on a Bin........................... 25

Ice Machine on a Dispenser Installation ...... 25

Lineset Applications .......................... 26

Remote Condenser ........................ 27

Remote Ice Machine Usage with

Non-Manitowoc Multi-Circuit Condensers.... 32

Maintenance

Cleaning and Sanitizing ...................... 37

General ................................... 37

Cleaning/Sanitizing Procedure............. 39

Preventative Maintenance Cleaning

Procedure................................. 39

Exterior Cleaning ..........................39

Cleaning / Sanitizing Procedure ..............40

Cleaning Procedure .......................40

Sanitizing Procedure ......................43

Parts Removal for Cleaning/Sanitizing...... 46

Preventative Maintenance Cleaning

Procedure..................................... 51

Removal from Service/Winterization .........53

Air-Cooled Ice Machines ...................53

Water-Cooled Ice Machines................54

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Operation

Control Panel Features........................ 55

Buttons ................................... 55

Display Panel.............................. 56

Menu Navigation Overview...................57

Display Panel Navigation .....................58

Alerts and Messages .......................... 60

Main Menu....................................61

Machine Info Menu ........................... 62

Password Entry ...............................63

Reset Password To Factory Defaults ........ 65

Set-Up Menu ..................................66

Language .................................67

Time & Date...............................67

Time Configuration........................ 69

Units......................................69

Ice Clarity ................................. 70

LCD Brightness............................ 70

Password On . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Edit Password .............................71

Clean Minder.............................. 71

IAuCS Runtime ............................ 72

Air Filter................................... 72

Water Filter................................ 73

LuminIce® Reminder....................... 74

Ice Bin Level Sensor .......................75

USB Setup................................. 75

Factory Defaults...........................75

Energy Saver Menu ...........................76

Ice Program ...............................77

Water Miser ...............................78

Statistics .................................. 78

Service Menu ................................. 79

Data History............................... 81

Real Time Data ............................ 82

Diagnostics ............................... 84

Manual Harvest ........................... 85

Replace Control Board.....................85

USB Setup................................. 85

Event Log Menu...........................86

Event Log .................................87

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USB Flash Drive Specifications and

Formatting................................ 92

Upgrading Firmware with a Flash Drive .... 94

Exporting Data to a Flash Drive ............ 96

Operational Checks ...........................98

General ................................... 98

Ice Thickness Check ....................... 99

Sequence of Operation ......................101

Self Contained Air or Water Cooled........101

Energized Parts Chart Self Contained

Models...................................105

Remote Condenser .......................107

Energized Parts Chart Remote Models.....111

Troubleshooting

Safety Limits .................................113

Safe Operation Mode.....................114

Water Assist Harvest......................114

Water Thaw Cycle ........................115

Analyzing Why a Safety Limit Stopped

the Ice Machine ..........................116

Safety Limit #1 ...........................116

Safety Limit #2 ...........................118

Troubleshooting By Symptom ...............119

Reset To Factory Defaults .................120

Symptom #1 Ice Machine Will Not Run ....121

Symptom #2 - Freeze Cycle Refrigeration

System Operational Analysis Tables .......126

Symptom #3 & #4 Harvest Problems Self-contained Air, Water & Remote

Condenser Models .......................155

Symptom #3 Self-Contained Air or

Water-cooled.............................156

Symptom #3 - Remote Condenser ........158

Symptom #4 Self-Contained Air,

Water-Cooled Or Remote .................160

Component Check Procedures

Electrical Components .......................163

Control Board, Display Board and Touch

Pad ......................................163

Control Board Relay Test ..................166

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Programming A Replacement Control

Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Main Fuse ................................169

Bin Switch................................170

Water Level Control Circuitry..............173

Ice Thickness Probe (Initiates Harvest).....179

High Pressure Cutout (HPCO) Control .....184

Fan Cycle Control.........................187

Thermistors ..............................188

Harvest Assist Air Pump ..................191

Compressor Electrical Diagnostics ........192

Diagnosing Start Components ............194

Refrigeration Components ..................197

Head Pressure Control Valve ..............197

Harvest Pressure Regulating (HPR)

System Remote Condenser Only ..........201

Water Regulating Valve ...................204

Refrigerant Recovery/Evacuation............205

Self-Contained Model Procedure..........205

Remote Condenser Model Procedure .....209

System Contamination Clean-Up ............215

Determining Severity Of Contamination ..215

Cleanup Procedure .......................217

Replacing Pressure Controls Without

Removing Refrigerant Charge.............220

Liquid Line Filter-Driers...................221

Total System Refrigerant Charge ..........222

Charts

Cycle Times/24-Hour Ice Production/ Refrigerant

Pressure Charts ..............................225

I0300 Series ..............................226

I0320 Series ..............................228

I0450 Series ..............................230

I0500 Series ..............................232

I0520 Series ..............................235

I0600 Series ..............................237

I0850 Series ..............................243

I0906 Series ..............................246

I1000 Series ..............................249

I1106 Series ..............................252

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I1200 Series ..............................255

I1400 Series ..............................257

I1406 Series ..............................260

I1800 Series ..............................263

Diagrams

Wiring Diagrams .............................267

Wiring Diagram Legend ..................267

I0300/I0450/I0500/I0520 - 1ph air/water ..268

I0320 - 1ph air/water .....................269

I0500 - 1ph Remote.......................270

I0600/I0606/I0850/I0906/I1000/I1106/I1200 -

1ph air/water.............................271

I0600/I606/I0850/I906/I1000/I1106/I1200 -

3ph air/water.............................272

I0600/I0606/I0850/I0906/I1000/I1106 - 1ph

Remote ..................................273

I0600/I0606/I0850/I0906/I1000/I1106 - 3ph

Remote ..................................274

I1400/I1406/I1800 - 1ph air/water.........275

I1400/I1406/I1800 - 3ph air/water.........276

I1400/II1406/I1800 1ph Remote...........277

I1400/I1406/I1800 - 3ph Remote ..........278

I1400 ECM Fan Motor - 1PH air ............279

I1400 ECM Fan Motor - 3PH air ............280

Electrical Noise Filter .....................281

Electronic Control Board.....................282

Refrigeration Tubing Schematics ............283

Self-Contained Air or Water-Cooled .......283

Remote Condenser Models ...............285

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14 Part Number 000014794 5/17

463 -460/60/3

Full Model Number

General Information

How to Read a Model Number

HEAD SECTIONS

P -Correctional Model

M -Marine Model

6 -60HZ

# HERTZ

5 -50HZ

J - Japan

X -LuminIce

K -Korea

Regulating Valve

HP -High Pressure Wate

251 -230/50/1

263 -208-230 /60/3

161 -115/60/1

261 -208-230 /60/1

VOLTAGE

A -Self-Contained Air-Cooled

CONDENSER TYPE

W -Self-Contained Water-Cooled

N -Remote Air-Cooled

C -CVD Air-Cooled

DC -IB Dice Model

YC -IB Half Dice

I Y 1000 W3 –263PHPX

Base Model Number

-Half-Dice

D -Dice

R -Regular

ICE CUBE SIZE

Not Used On IB Models

Part Number 000014794 5/17 15

-Ice Beverage

E MACHINE MODEL

-Indigo Model

3 -Three Phase

E -WRAS 50 Cycle Only

No Indicator -1 Phase

Ice Machine Series

Ice Cube Sizes

Regular

1-1/8" x 1-1/8" x 7/8"

2.86 x 2.86 x 2.22 cm

All Manitowoc ice machines require the ice storage system (bin, dispenser, etc.) to incorporate an ice deflector.

Prior to using a non-Manitowoc ice storage system with other Manitowoc ice machines, contact the manufacturer to assure their ice deflector is compatible with Manitowoc ice machines.

Dice

7/8" x 7/8" x 7/8"

2.22 x 2.22 x2.22 cm

Warning

Half Dice

3/8" x 1-1/8" x 7/8"

0.95 x 2.86 x 2.22 cm

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.

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Model Numbers

AIRWATERREMOTE CONDENSER MODELS

Self-Contained

Air-Cooled

ID0302A IY0304A ID0322A IY0324A ID0452A IY0454A IR0500A ID0502A IY0504A IR0520A ID0522A IY0524A ID0602A IY0604A ID0606A IY0606A IR0850A ID0852A IY0854A IR0906A ID0906A IY0906A ID1002A IY1004A ID1106A IY1106A ID1202A IY1204A ID1402A IY1404A ID1406A IY1406A IR1800A ID1802A IY1804A

NOTE: Marine and Prison models have a M or P suffix - Example ID0853WM Suffix at the end of the model number: 3 = 3 phase unit - Example IY1004A3

Self-Contained

Water-Cooled

ID0303W IY0305W ID0323W IY0325W

D0453W IY0455W IR0501W ID0503W IY0505W IR0521W ID0523W IY0525W ID0603W IY0605W ID0606W IY0606W IR0851W ID0853W IY0855W IR0906W ID0906W IY0906W ID1003W IY1005W ID1106W IY1106W ID1203W IY1205W ID1403W IY1405W ID1406W IY1406W IR1801W ID1803W IY1805W

Remote

----

---IR0590N ID0592N IY0594N

----

---ID0692N IY0694N ID0696N IY0696N IR0890N ID0892N IY0894N IR0996N ID0996N IY0996N ID1092N IY1094N ID1196N IY1196N

----

---ID1492N IY1494N ID1496N IY1496N IR1890N ID1892N IY1894N

Part Number 000014794 5/17 17

K = Korean model. J = Japan model HP = High Pressure Water Regulating Valve - I0450/I0500 Water Cooled Condenser models

Ice Machine Warranty Information

For warranty information visit:

http://www.manitowocice.com/Service/Warranty

• Warranty Verification

• Warranty Registration

• View and download a copy of the warranty Owner Warranty Registration Card

Warranty coverage begins the day the ice machine is installed.

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LuminIce® II

The LuminIce® growth inhibitor recirculates the air in the ice machine foodzone over a UV bulb. This process will inhibit the growth of common micro-organisms on all exposed foodzone surfaces.

• LuminIce® bulbs require replacement on a yearly basis.

• The control board can be set to automatically display a reminder after 12 months.

• A remote light is available for reminder indication.

NOTE: LuminIce® and LuminIce® II bulbs are not interchangeable; verify your model before ordering a replacement bulb.

Cleanup Procedure for Accidental Bulb Breakage

The cleanup procedure is identical to the procedure used to clean up compact fluorescent (CFL) or fluorescent tube lights. These lights contain a small amount of mercury sealed within a glass tube. Breaking these types of lights will release mercury and mercury vapor. The broken bulb can continue to release mercury vapor until it is cleaned up and removed.

The latest EPA procedures can be viewed on their website at www.epa.gov/cfl/cflcleanup.html.

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Installation

Warning

PERSONAL INJURY POTENTIAL

Remove all ice machine panels before lifting.

Caution

The ice machine head section must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/Winterization” on page 53.

ICE DEFLECTOR

An ice deflector is required for all ice machines installed on a bin.

Part Number 000014794 5/17 21

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.

• Self contained air and water cooled - The air temperature must be at least 35°F (1.6°C), but must not exceed 110°F (43.4°C).

• Remote air cooled - The air temperature must be at least -20°F (-29°C), but must not exceed 120°F (49°C)

• Ice Making Water Inlet - Water Pressure must be at least 20 psi (1.38 bar), but must not exceed 80 psi (5.52 bar).

• Condenser Water Inlet - Water Pressure must be at least 20 psi (1.38 bar), but must not exceed 150 psi (10.34 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 below for clearance requirements.

• The ice machine must be protected if it will be subjected to temperatures below 32°F (0°C). Failure caused by exposure to freezing temperatures is not covered by the warranty. See “Removal from Service/ Winterization”

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Clearance Requirements

AIR, WATER, REMOTE CONDENSER MODELS

I0300

Top/Sides 16" (40.6 cm) 8" (20.3 cm)

Back 5" (12.7 cm) 5" (12.7 cm)

I0450 - I0500

I0600 -I0606 I0850 - I0906 I1000 - I1106

Top/Sides 8" (20.3 cm) 8" (20.3 cm)

Back 5" (12.7 cm) 5" (12.7 cm)

I0320 - I0520

Top/Sides 12" (30.5 cm) 8" (20.3 cm)

Back 5" (12.7 cm) 5" (12.7 cm)

I0500 Tropical Rating 230/50/1 Air-Cooled Only

Top 24” (61 cm) N/A

Sides/back 12” (30.5 cm) N/A

I1200

Top 8" (20.3 cm) 8" (20.3 cm)

Sides 12" (30.5 cm) 8" (20.3 cm)

Back 5" (12.7 cm) 5" (12.7 cm)

I1400 - I1406

I1800

Top/Sides 24" (61.0 cm) 8" (20.3 cm)

Back 12" (30.5 cm) 5" (12.7 cm)

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Self-Contained

Air-Cooled

Self-Contained

Water-Cooled

Water-Cooled and

Remote

Water-Cooled and

Remote

Water-Cooled

and Remote

Water-Cooled

and Remote

Part Number 000014794 5/17 23

Ice Machine Heat of Rejection

Series Ice

Machine

I0300 4600 5450 I0320 3300 4500 I0450 5400 6300 I0500 6100 6900 I0520 5400 6300

I0600/I0606 9000 13900

I0850 13000 16000 I0906 12700 14800

I1000/I1106 16250 18600

I1200 20700 24500

I1400/I1406 23500 27000

I1800 30000 35000

*BTU/Hour Because the heat of rejection varies during the ice making cycle, the figure shown is an average.

Air Conditioning* Peak

Heat of Rejection

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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 (30" or 48") for any bin without a deflector.

Warning

PERSONAL INJURY POTENTIAL

Do not operate any ice machine with the deflector removed.

Ice Machine on a Dispenser Installation

No deflector is needed for machines that match the size of the dispenser (30" head section on a 30" dispenser) unless required by the dispenser manufacturer. Adapters are required when a smaller ice machine is going on a larger dispenser (22" machine on a 30" dispenser).

Part Number 000014794 5/17 25

Lineset Applications

Warning

The 60-month compressor warranty (including the 36-month labor replacement warranty) will not apply if the Manitowoc Ice Machine, Condenser or QuietQube® Condensing Unit were not installed according to specifications. This warranty also will not apply if the refrigeration system is modified with a condenser, heat reclaim device, or other parts or assemblies not manufactured by Manitowoc Ice.

Caution

Recovery locations vary by model. Verify you are making the correct connections for your model to prevent accidental release of high pressure refrigerant.

Important

Manitowoc remote systems are only approved and warranted as a complete new package. Warranty on the refrigeration system will be void if new equipment is connected to pre-existing (used) tubing, remote condenser, remote condensing unit or ice machine head section.

26 Part Number 000014794 5/17

REMOTE CONDENSER

Ice Machine

I0590N JC0495

I0690N I0696N I0890N I0996N I1090N I1196N I1490N I1496N I1890N

*Line Set Discharge Line Liquid Line

RT 1/2" (1.27 cm) 5/16" (.79 cm) RL 1/2" (1.27 cm) 3/8" (.95 cm)

Air Temperature Around the Condenser

Minimum Maximum

-20°F (-29°C) 120°F (49°C)

Remote Single

Circuit Condenser

JC0895

JC0995

JC1395

Line Set*

RT-20-R404A RT-35-R404A RT-50-R404A RT-20-R404A RT-35-R404A RT-50-R404A RT-20-R404A RT-35-R404A RT-50-R404A RL-20-R404A RL-35-R404A RL-50-R404A

Part Number 000014794 5/17 27

Additional Refrigerant Charge For 51' to 100' Line Sets

Ice Machine Condenser Additional Amount of

Refrigerant To Be Added

To Nameplate Charge

I0590N JC0495 1.5 lbs - 680g I0690N JC0895 1.5 lbs - 680g I0696N JC0895 2 lbs - 907g I0890N JC0895 2 lbs - 907g I0996N JC0995 2 lbs - 907g I1090N JC0995 2 lbs - 907g I1196N JC0995 2 lbs - 907g I1490N JC1395 2 lbs - 907g I1496N JC1395 2 lbs - 907g I1890N JC1395 2 lbs - 907g

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Calculating Allowable Lineset Distance

Line Set Length

The maximum length is 100' (30.5 m).

Line Set Rise/Drop

The maximum rise is 35' (10.7 m).

The maximum drop is 15' (4.5 m).

35 FT. (10.7 M)

MAXIMUM DISTANCE

35 ft. (10.7 m) Rise: The maximum distance the

Condenser or Condensing Unit can be above the ice machine.

15 FT. (4.5 M)

MAXIMUM

DISTANCE

15 ft. (4.5 m) Drop: The maximum distance the

Condenser or Condensing Unit can be below the ice machine.

Part Number 000014794 5/17 29

Calculated Line Set Distance

The maximum calculated distance is 150' (45.7 m).

Line set rises, drops, horizontal runs (or combinations of these) in excess of the stated maximums will exceed compressor start-up and design limits. This will cause poor oil return to the compressor.

Make the following calculations to make sure the line set layout is within specifications.

1. Insert the measured rise into the formula below.

Multiply by 1.7 to get the calculated rise. (Example: A condenser located 10 feet above the ice machine has a calculated rise of 17 feet.)

2. Insert the measured drop into the formula below.

Multiply by 6.6 to get the calculated drop. (Example. A condenser located 10 feet below the ice machine has a calculated drop of 66 feet.)

3. Insert the measured horizontal distance into the

formula below. No calculation is necessary.

4. Add together the calculated rise, calculated drop, and horizontal distance to get the total calculated distance. If this total exceeds 150' (45.7 m), move the condenser to a new location and perform the calculations again.

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