Cornelius 200, 525, 725 Service Manual

Page 1

SELF-CONTAINTED

FLAKED ICE MAKER

Model: Series 200, 525, 725 (R404A Refrigerant)

Service Manual

Series 200 Release Date: May 13, 2004 Publication Number: 166240010SER Revision Date: NA Revision: A Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

Page 2

SELF-CONTAINED FLAKED ICE MAKER

SERVICE MANUAL

The products, technical information, and instructions contained in this manual are subject to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation, operation or maintenance of this equipment. This manual assumes that the person(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and construction requirements are being met, in addition to the information contained in this manual.

To inquire about current revisions of this and other documentation or for assistance with any Cornelius product contact:

www.cornelius.com

800-238-3600

Trademarks and copyrights: Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus,

and Vista are registered trademarks of IMI Cornelius Inc. Optifill trademark is pending.

This document contains proprietary information and it may not be

reproduced in any way without permission from Cornelius.

Printed in U.S.A.

Page 3

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specifications 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ice Production Capacity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications 525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Ice Production Capacity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

525 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Specifications 725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ice Production Capacity (Approximate) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

725 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Electrical Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Circuit Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

On-Off Switch/Circuit Breaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Bin Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

High Pressure Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Gearmotor Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Power Relay/Contactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Fan Cycling Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Delay Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Compressor Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Potential Relays . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Capacitors - General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Sanitizing and Cleaning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Water Treatment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Winter Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Cleaning the Condenser (Air Cooled) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Page 4

Page 5

Self-Contained Flaked Ice Maker Service Manual

INTRODUCTION

We have strived to produce a quality product. The design has been kept simple thus insuring trouble-free operation.

This manual has been prepared to assist servicemen and users with information concerning installation, construction and maintenance of the ice making equipment. The problems of the serviceman and user have been given special attention in the development and engineering of our ice makers.

If you encounter a problem which is not covered in this manual, please feel free to write or call. We will be happy to assist you in any way we can.

When writing, please state the model

and serial number of the machine.

Page 6

Self-Contained Flaked Ice Maker Service Manual

SPECIFICATIONS 200

40-IN.

102-C M

34-IN.

86-C M

6-IN.

15-C M

26-IN.

66-C M

AIR

FLOW

26 1/2-IN.

67-C M

24 7/8-IN.

25-IN.

64-C M

A- 1/4 W ATE R INLE T S (S . A.E . MALE FLAR E ) B- 5/8 O.D. TUBE (DRAIN) C- 1/2 O.D. TUBE (DRAIN)

13 1/2-IN.

34-C M

7-IN.

18-C M

ON-OFF SWITCH

5-IN.

13-C M

19-IN.

48-C M

63-C M

FIGURE 1. 200 SERIES SPECIFICATIONS

ICE PRODUCTION CAPACITY (APPROXIMATE)

3/4-IN.

2-C M

7-IN.

18-C M

4-IN.

10-C M

REAR VIEW

OF CABINET

ELECTRICAL

BOX AREA

AIR

TEMPERATURE

50°F/10°C 70

°F/21°C °F/27°C

AIR

TEMPERATURE

°F/10°C

°F/21°C °F/27°C

AF–200–P(S)–SCR PRODUCTION CHART

WATER TEMPERATURE

°F/10°C70°F/21°C80°F/27°C

219 lbs/99 kgs 188 lbs/85 kgs 175 lbs/79 kgs 208 lbs/95 kgs 174 lbs/79 kgs 166 lbs/75 kgs 161 lbs/35 kgs 130 lbs/59 kgs 117 lbs/53 kgs

AF–200–P–SC50R PRODUCTION CHART

WATER TEMPERATURE

°F/10°C70°F/21°C80°F/27°C

234 lbs/106 kgs 206 lbs/94 kgs 197 lbs/90 kgs 213 lbs/97 kgs 190 lbs/86 kgs 180 lbs/82 kgs 183 lbs/83 kgs 164 lbs/75 kgs 156 lbs/71 kgs

Page 7

200

Self-Contained Flaked Ice Maker Service Manual

Compressor Model Copeland JS25CIE–IAA–203 (115V 60HZ)

Copeland AS13CIE–1AZ–908 (220V 50HZ)

Condenser Air Cooled Refrigerant Charge 8 oz. R–404a (115V 60HZ)

7 oz. R–404a (220V 50HZ) Refrigerant Control (115V 60HZ) Automatic Expansion Valve (28–PSI) Refrigerant Control (220V 50HZ) Automatic Expansion Valve (31–PSI) Inlet Water Supply 1/4” SAE male flare Voltage 115V 60HZ or 220V 50HZ Gearmotor Electrical Rating 1/8 hp Gearmotor Amp. Rating 2 amps (115V 60 HZ)

1 amp (220V 50HZ) Total Amp. Draw 11.0 Amps (115V 60HZ)

4.0 Amps (220V 50HZ)

Maximum Fuse Size 15 Amp (115V 60HZ)

15 Amp (220V 50HZ)

Page 8

Self-Contained Flaked Ice Maker Service Manual

SPECIFICATIONS 525

34-IN.

86-C M

40-IN.

102-C M

MIN.

15-C M

26-IN.

66-C M

AIR IN

38 3/4-IN.

97-C M

6-IN.

MIN.

A- 3/8 W ATE R INL E T (S . A.E . MALE F LAR E ) B- 1/2 O.D. TUBE (CONDENSATE DRAIN) C- 3/4 N.P.T. BIN DR AIN D- CONDENSER WATER IN (W/C ONLY) E- CONDENSER WATER OUT (W/C ONLY)

26 1/2-IN.

67-C M

24 3/4-IN.

63-C M

14-IN.

36-C M

13 1/2-IN.

2-IN.

5-C M

21/2-IN.

6-C M

ON-OFF SWITCH

34-C M

ELECTRICAL

BOX AREA

55/8-IN.

19 1/2-IN.

50-C M

45/8-IN.

31/2-IN.

9-C M

14-C M

12-C M

33/8-IN.

9-C M

FIGURE 2. 525 SERIES SPECIFICATIONS

31/2-IN.

9-C M

REAR VIEW

OF CABINET

35/8-IN.

9-C M

5/8-IN.

2-C M

33/4-IN.

10-C M

26 3/8-IN.

67-C M

ICE PRODUCTION CAPACITY (APPROXIMATE)

AF–525–P(S)–SCR PRODUCTION CHART

AIR

TEMPERATURE

°F/10°C

70°F/21°C

°F/27°C

AIR

TEMPERATURE

°F/10°C °F/21°C

70 90

°F/27°C

°F/10°C70°F/21°C80°F/27°C

654 lbs/297 kgs 588 lbs/267 kgs 552 lbs/251 kgs 639 lbs/290 kgs 563 lbs/256 kgs 521 lbs/237 kgs 562 lbs/255 kgs 479 lbs/218 kgs 448 lbs/204 kgs

AF–525–P–SC50R PRODUCTION CHART

°F/10°C70°F/21°C80°F/27°C

629 lbs/286 kgs 528 lbs/240 kgs 494 lbs/225 kgs 621 lbs/282 kgs 525 lbs/239 kgs 489 lbs/222 kgs 493 lbs/224 kgs 414 lbs/188 kgs 387 lbs/176 kgs

WATER TEMPERATURE

Page 9

525

Self-Contained Flaked Ice Maker Service Manual

Compressor Model Copeland RS43CIE–IAA–214 (115V 60HZ)

Copeland RS43CIE–IAZ–214 (220V 50HZ)

Condenser Air Cooled Refrigerant Charge 17 oz. R-404a Refrigerant Control Automatic Expansion Valve (34–PSI) Inlet Water Supply 3/8” SAE Male Flare Voltage 115V 60HZ or 220V 50HZ Total Amp Draw 15.5 Amps (115V 60HZ)

6.0 Amps (220V 50HZ)

Gearmotor Amp Draw 2 Amps (115V 60HZ)

1 Amp (220V 50HZ) Gearmotor Electrical Rating 1/8 hp Maximum Fuse Size 20 Amp (115V 60HZ)

15 Amp (220V 50HZ)

Page 10

Self-Contained Flaked Ice Maker Service Manual

SPECIFICATIONS 725

86-C M

40-IN.

102-C M

MIN.

34-IN.

6-IN.

15-C M

26-IN. 66-C M

48-IN.

122-C M

AIR IN

30-IN.

76-C M

A- 3/8 WATER INLET (S.A.E.MALE FLARE) B- 1/2 O.D. TUB E (CO NDE NS ATE DR AIN) C- 3/4 N.P.T. BIN DR AIN D- CONDENSER WATER IN (W/C ONLY) E- CONDENSER WATER OUT (W/C ONLY)

SWITCH

28 3/8-IN.

72-C M

16 3/8-IN.

42-C M

17 1/8-IN.

43-C M

2-IN.

5-C M

21/2-IN.

6-C M

ON-OFF

ELECTRICAL

BOX AREA

19 1/2-IN.

50-C M

FIGURE 3. 725 SERIES SPECIFICATIONS

23/4-IN.

7-C M

55/8-IN.

14-C M

41/2-IN.

11- C M

31/4-IN.

8-C M

23/8-IN.

6-C M

5/8-IN.

2-C M

5 1/32-IN.

13-C M

32 1/16-IN.

81-C M

REAR VIEW

OF CABINET

4-IN.

10-C M

ICE PRODUCTION CAPACITY (APPROXIMATE)

AF–725–P–SCR PRODUCTION CHART

725

AIR

TEMPERATURE

°F/10°C70°F/21°C80°F/27°C

°F/10°C

70°F/21°C

°F/27°C

654 lbs/297 kgs 588 lbs/267 kgs 552 lbs/251 kgs 639 lbs/290 kgs 563 lbs/256 kgs 521 lbs/237 kgs 562 lbs/255 kgs 479 lbs/218 kgs 448 lbs/204 kgs

Compressor Model Copeland RS43CIE-IAA-214 Condenser Air Cooled Refrigerant Charge 17 oz. R-404a Refrigerant Control Automatic Expansion Valve (34–PSI) Inlet Water Supply 3/8” SAE Male Flare Voltage 115V 60HZ Total Amp Draw 15.5 Amps Gearmotor Amp Draw 2 Amps Gearmotor Electrical Rating 1/8 hp

WATER TEMPERATURE

Maximum Fuse Size 20 Amp

Page 11

ELECTRICAL CIRCUIT

CIRCUIT DESCRIPTION

As the manual on-off circuit breaker switch is pushed to ”on”, an electrical circuit is completed to the gearmotor via the circuit breaker gearmotor overload, power relay/contactor, gearmotor delay thermostat and the bin thermostat. After the previous circuit has been completed the condenser fan motor will start as will the compressor (via the high pressure control, the compressor starting relay and low ambient control).

On-Off Switch/Circuit Breaker

This switch interrupts power to the entire unit. The switch has a circuit breaker incorporated into its’ design. This circuit breaker will trip out in the event the gearmotor draws to high of amps. In such an event the power is interrupted to the unit. To reset the circuit breaker and reestablish power to the unit, push the switch to the “off” position and then back to the “on” position.

Bin Thermostat

This is electrically in ”series” with the ice making system. When the bin is full, the contact opens, terminating power to the machine.

High Pressure Control

Switch contact will open at 450 PSI for R404a breaking the circuit to the compressor. This control is manually re-settable.

Self-Contained Flaked Ice Maker Service Manual

Gearmotor Start Relay

This is a current type relay which means as the gearmotor run winding comes ”on” the line, the current draw initially is relatively heavy through the relay coil (coil is in series with run winding). It then acts like a normal relay and the N.O. start contact ”makes”, completing a circuit through the start capacitor to the start winding. As the gearmotor picks up speed, the amp draw through the relay coil drops off allowing the armature to return to its normal position (start contact ”opens”). This action removes the start winding from the circuit.

Power Relay/Contactor

This relay controls the compressor power only.

Fan Cycling Switch

The function of this switch is to maintain condensing pressures at a satisfactory level during-low ambient conditions. The switch breaks the circuit to the condenser fan motor at 205 PSI and makes the circuit at 275 PSI.

Delay Thermostat

This thermostat keeps the gearmotor running until the suction line temperature reaches 45° after the full bin switch terminates power to the power relay.

Compressor Start Relay

This is a current type relay and contains a N.O. contact which is connected in series with the start winding of the compressor. The relay coil is electrically in series with the run winding. When power is applied, the compressor draws high current which sets up a magnetic field in the magnet coil which causes the relay to operate, closing the relay contact. As the compressor approaches operating speed, the current flowing through the coil decreases, permitting the relay contact to open, thereby opening the starting circuit.

Page 12

Self-Contained Flaked Ice Maker Service Manual

Potential Relays

The potential relay is used as a compressor starting relay, The contact in the potential relay is N.C. The magnet coil is connected across (parallel) the start winding and is affected by induced voltage, generated by the start winding. As the compressor comes up to design speed, the voltage across the relay coil increases and at running speed is sometimes as much as 2 1/2 times the supply voltage. This voltage sets up a magnetic field which causes the relay to operate. The starting relay is calibrated to remove the start capacitor (open the starting circuit) at approximately 85% of the motor design speed.

NOTE: BOTH TYPES OF RELAYS ARE DESIGNED TO OPERATE WITHIN VERY NARROW LIMITS OF VOLTAGE AND CURRENT DICTATED BY MOTOR DESIGN, THEREFORE, WHEN MAKING A REPLACEMENT OF A RELAY ALWAYS PROVIDE AN EXACT REPLACEMENT, RECOMMENDED BY THE COMPRESSOR MANUFACTURER.

Capacitors - General

An electrical capacitor is a device which stores up electrical energy. Capacitors are used with single phase motors to provide starting torque and improve running characteristics; by feeding this energy to the start winding in step with the run winding.

Any capacitor has three (3) essential parts, two (2) of which are usually foil plates separated and insulated by the third part called the dielectric.

Two general types of capacitors are used with electric motors. The electrolytic starting capacitor usually uses a very thin film of oxide on the metallic plate as the dielectric. The running capacitor usually is of the liquid filled type.

Page 13

Self-Contained Flaked Ice Maker Service Manual

MAINTENANCE

IMPORTANT: THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED AT LEAST EVERY SIX MONTHS ON FLAKED ICE MACHINES.

1. Check power supply with machine running for proper voltage.

2. Check water level in the float tank reservoir. Water level should be maintained at the top of the

evaporator. Adjust if necessary. (See illustration and adjustment procedure)

3. Clean the air-cooled condenser coil with a stiff brush or vacuum cleaner (See procedure).

CAUTION: Condenser cooling fins are sharp, use care when cleaning.

4. Clean the ice storage bin and flush the bin drain at least once a month.

5. If a water conditioner is installed in the inlet water line, change, replace, or clean the filter, strainer

or cartridge as required.

6. If heavy mineral deposits on the auger and evaporator shell are encountered due to bad local water

conditions, follow sanitizing and cleaning procedure.

7. Loosen hold-down cam locks and remove gearmotor assembly.

8. Check thrust washer; replace if noticeably worn.

9. Lift out auger and examine for wear. The corkscrew auger guide bushing pressed into the drive

block should be checked for wear. Replace if loose or if worn flat with auger drive block. If the Helix auger on the corkscrew auger round bar becomes flat on the inside more than 1/8 of an inch over a length of two inches or more it should be replaced.

NOTE: HELIX AUGERS DO HAVE MACHINED FLAT RELIEF SURFACES. DON’T CONFUSE THEM WITH WORN FLAT AREAS.

Check the insert in the bottom ring of the Helix auger and replace if excessively worn.

10. Check shell vertical strips for wear. Replace the shell if excessive wear is shown.

11. Check O-Ring, replace if worn or cut.

12. Re-assemble, steps 7 through 11.

CAUTION: In re-assembling the auger gearmotor, the hold down clamps must be tight and secure. In re-installing the evaporator shell, be absolutely sure that the “o” ring is not pinched off as this would cause a water leak around the base of the evaporator. Lubricate the “o” ring with food grade lubricant before re-assembling shell.

13. Check for alignment of ice chute. Make sure chute gasket is not blocking path of ice flow.

14. Check bin thermostat operation. In the mid-range position the bin thermostat will open at 42° and

has a 6° differential.

SANITIZING AND CLEANING PROCEDURE

1. Turn unit off at switch in upper rear right side panel.

2. Turn water off and remove water hose from bottom of float chamber inside of ice bin and allow to

drain from the evaporator via the hose end; or

3. Remove float chamber cover and while holding float up to prevent more water from entering the

float chamber, remove water hose from float chamber and proceed to drain the float chamber and evaporator.

4. With water still off, restore water hose to float chamber and add 1/2 oz. of ”sanitizer” (see note

below). Turn water on.

5. Remove the bin door, float chamber cover, ice chute trim cover, two thumb screws and chute trim

gasket.

6. Using soap, hot water, and a non-metallic bristle brush or plastic scouring pad, scrub the parts

removed in step 4 as well as the interior of the ice bin, ice chute, thermowell, door tracks, ice bin top, and around bin opening.

Page 14

Self-Contained Flaked Ice Maker Service Manual

NOTE: Use care when cleaning around thermowell sensing tube; the small capillary is easily broken. Rinse all parts in clean water.

7. In a 5 gallon bucket, mix a sanitizing solution of 1/2 oz. of sanitizer to 1 gallon of warm water (100° to 120° F).

8. Place all small, loose parts into the sanitizing solution and allow them to soak for 10 minutes.

9. Using a clean cloth and the sanitizing solution, wipe down the interior of the ice chute, thermowell door tracks, ice bin top, and around bin opening. Allow to air dry.

10. Reassemble the float chamber cover, ice chute gasket and cover, and bin door.

11. Turn unit switch on and allow machine to make ice for at least 1/2 hour then discard all of the ice.

DO NOT ALLOW ICE WITH SANITIZER IN IT TO BE USED.

NOTE: APPROVED SANITIZER: Household bleach such as Hi-Lex or Clorox.

WATER TREATMENT

During the freezing process, the impurities in the water have a tendency to be rejected. However, the more dissolved solids in the water, the more troublesome the freezing operation will be.

Bicarbonates in the water are the most troublesome of the impurities. These impurities will cause scaling on the evaporator, clogging of the float valve mechanism and other parts in the water system. If the concentration of impurities is high, wet mushy ice may be the result.

Parts of the ice maker, that are in contact with the water or ice, may corrode if the water is high in acidity. In some areas, water may have to be treated in order to overcome some of the problems that arise because of the mineral content.

IMI Cornelius has water filter/treatment systems available to control impurities found in your water supply. Contact your local dealer for more information.

WINTER STORAGE

If the unit is to be stored in an area where the temperature will drop below freezing, it is most important that all water lines be drained to prevent them from freezing and possible rupture.

To blow out the water line, disconnect the water supply at the cabinet inlet and use air pressure to force the water into the water reservoir pan. This can then be removed from the water pan.

WATER COOLED CONDENSER compressed air hose. Start machine. As head pressure reaches the appropriate level opening the water regulating valve, the compressed air will force the water out. Do not let the machine operate longer than necessary.

- To remove water from condenser unhook water supply and attach

CLEANING THE CONDENSER (AIR COOLED)

In order to produce at full capacity, the refrigeration condenser must be kept clean. The frequency of cleaning will be determined by surrounding condition. A good maintenance plan calls for an inspection at least every two months.

Remove the unit compartment grill at the front. With a vacuum cleaner, remove all accumulated dust and lint that has adhered to the finned condenser.

CAUTION: Condenser cooling fins are sharp. Use care when cleaning.

Page 15

Self-Contained Flaked Ice Maker Service Manual

BIN

THERMOSTAT

MANUAL RESET

HIGH PR ESS CNTRL

C.O. 450 PSIG

CONTACTOR

BK WH

ON--OFF SWITCH

CIRCUIT BREAKER

RATED 2.0 AMPS

GEAR MOTOR START RELAY

COMPRESSOR

OVERLOAD

C.O. 205 C .I. 275

GEAR MOTOR

START CAPACITOR

64-- 77 MFD 165 VAC

FAN SW IT C H

COMPRESSOR

GEAR

MOTOR

FAN MOTOR

RD YL

COMPRESSOR START RELAY

COMPRESSOR START CAPACITOR

145-- 174 MFD 220 VAC

115 V O LTS 60 H z

AF--200--P-- SC --R

Part No. 161909061 Artwork 50922

FIGURE 4. WIRING DIAGRAM AF- 200-P–SC–R 115 VOLTS 60 HZ

Page 16

Self-Contained Flaked Ice Maker Service Manual

GN/Y

HIGH PRESS CNTRL

CONTACTOR

BIN

THERMOSTAT

MANUAL RESET

C.O. 450 PSIG

RD BK

ON--OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

GEAR MOTOR START RELAY

COMPRESSOR

OVERLOAD

GEAR MOTOR

START CAPACITOR

220/250 VAC

FAN SW IT C H

C.O. 205 C.I. 275

21-- 25 MFD

COMPRESSOR

GN/Y

GEAR

MOTOR

GN/Y

FAN MO TO R

COMPRESSOR START RELAY

GN/Y

COMPRESSOR START CAPACITOR

50-- 60 MFD 330 VAC

AF--200--P--SC--50--R

220 VOLTS 50 Hz

Part No. 161909064 Artwork 50929

FIGURE 5. WIRING DIAGRAM AF–200–P–SC–50–R 220 VOLTS 50 HZ

Page 17

Self-Contained Flaked Ice Maker Service Manual

BLBL

BIN

THERMOSTAT

CONTROL HIGH PR ESSURE

C.O. 450 PSI

CONTACTOR

BK WH

DELAY

THERMOSTAT

ON--OFF SWITCH

CIRCUIT BREAKER

RATED 2.0 AMPS

GEAR MOTOR START RELAY

C.I. 275 C.O.205

COMPRESSOR

OVERLOAD

POTENTIAL START RELAY

FAN SW IT C H

GEAR MOTOR

START

CAPACITOR

WIRE N UT

COMPRESSOR

MOTOR

GEAR

CONDENSOR FAN

COMPRESSOR

START CAPACITOR 243-- 292 MFD 115 VA C

A F 5 2 5 -- S C -- R

A F 7 2 5 -- S C -- R

115 V O LTS 60 H z

Part No. 161909062 Artwork 50923 Rev. B

FIGURE 6. WIRING DIAGRAM AF525-SC–R AND AF725–SC–R 115 VOLTS 60 HZ

Page 18

Self-Contained Flaked Ice Maker Service Manual

ON--OFF SWITCH

BIN

THERMOSTAT

CIRCUIT BREAKER RATED 1.5 AMPS

DELAY

THERMOSTAT

GEAR MOTOR START RELAY

GEAR MOTOR

START

CAPACITOR

GEAR

MOTOR

AF/WF --525PSC--50--R

Part No. 161909063 Artwork 50925

Rev. A

CONTROL HIGH PRESSURE

CONTACTOR

FAN SW IT C H

COMPRESSOR

OVERLOAD

FAN MOTOR

WIRE N UT

COMPRESSOR

COMPRESSOR START RELAY

COMPRESSOR

START CAPACITOR

43-- 52 MFD 330 V

220 VOLTS 50 Hz

FIGURE 7. WIRING DIAGRAM AF/WF–525PSC–50–R 220 VOLTS 50 HZ

Page 19

Self-Contained Flaked Ice Maker Service Manual

TROUBLESHOOTING

Trouble Probable Cause Remedy

Unit will not run A. On-off switch in ”off” position. A. Turn switch to ”on”.

B. Defective on-off switch. B. Check and replace.

Compressor cycles intermittently.

C. Blown fuse. C. Replace fuse and check for

D. Thermostat set too warm for ambient.

E. Power relay contacts corroded. E. Check and clean.

F. Defective thermostat. F. Check and replace.

G. Loose electrical connection. G. Check wiring.

H. Gearmotor overload protector has cut off machine.

A. Low voltage A. Check line voltage

B. Dirty condenser B. Clean condenser

C. Air circulation restricted C. Remove restriction

D. Defective condenser fan motor D. Check and replace

E. Defective relay, overload protector or starting capacitor.

F. Loose electrical connection F. Check wiring

cause of blown fuse.

D. Adjust colder.

H. Turn switch to off then to on.

E. Check and replace

Making wet ice. A. Surrounding air temperature

*NOTE: Special care must be used with R404a (HP62) charged systems using (POE) Polyolester oil. The refrigeration system must not be open longer than 15 min., and the appropriate drier must be used due to the moisture absorption properties of the POE oil.

Unit runs but makes no ice.

too high

B. High water level in float reservoir

C. Dirty condenser C. Clean condenser

D. Faulty compressor D. Check and replace*

E. Refrigerant leak E. Check and repair

F. ”O” ring leaking at bottom of evaporator shell

A. Leak in refrigerant system A. Check and repair

B. Moisture in system B. Check, dehydrate and add

C. No water C. Check water supply

A. Correct or move unit

B. Lower water level

F. Check and replace

drier to system

Page 20

Self-Contained Flaked Ice Maker Service Manual

D. ”O” ring leaking at bottom of

D. Check and replace ”O” ring

evaporator shell

E. Compressor not running E. Check and replace ”O” ring

Water leaks. A. Worn or bad float valve A. Check and replace

B. Float and arm assembly stuck B. Check and replace

C. ”O” ring leaking at bottom of

C. Check and replace

evaporator shell

D. Storage bin drain and tubing D. Check and repair

Excessive noise or chattering.

A. Mineral or scale deposits on inside of evaporator shell

A. Remove and clean inside surfaces by immersing evaporator shell in ice machine cleaner

B. Intermittent water supply B. Check inlet water line

C. Water level in float tank too low C. Check and adjust water

level

D. Auger gearmotor end-play or

D. Repair or replace

worn bearings

E. Air lock in gravity water supply

E. Check and adjust warmer line from float tank to evaporator shell

Machine runs with full bin of ice.

A. Storage bin thermostat set too cold

B. Bin thermostat thermowell out

A. Check and adjust warmer

B. Adjust thermowell of path of ice

Unit off on reset. A. Ice jams up in evaporator shell A. Clean inside surface of

evaporator shell

B. Bin thermostat will not shut-off

B. Check and adjust or replace machine. Set too cold.

C. Auger motor has worn

C. Check and replace bearings

Unit goes off on reset. A. Ice chute out of alignment,

A. Re-align restricted ice flow out of evaporator section

B. Ice chute center separator bent

B. Replace ice chute restricting ice flow out of evaporator section

C. Incoming water temperature too cold

D. Bin thermostat does not shutoff when bin is full of ice

C. Maintain temperature above

50°F

D. Replace bin thermostat if

necessary

E. Mineral or scale deposits on

E. Inspect and clean inside of evaporator shell and evaporator

F. Strips loose or missing on inside of evaporator shell

F. Inspect and replace

evaporator shell if necessary

Page 21

Self-Contained Flaked Ice Maker Service Manual

Unit goes off on reset. (cont’d)

G. Low ambient temperature in room where unit is located

H. Gearmotor sticking which causes it to draw excessive amperage (over 2.0 amps)

I. Plugged expansion valve, causing low back pressure

G. Maintain temperature above 50°

H. Check amp draw of gearmotor with an amprobe (1.7 amps)

I. Check back pressure, replace valve, evacuate and recharge system, replace drierstrainer

J. Slight leak, causing low back pressure

J. Check back pressure, find gas leak, repair leak, evacuate system, add drier and recharge

K. Loose hold-down assy K. Check and tighten or

replace

L. Auger worn excessively on the

L. Replace auger inside surfaces causing thicker flaked ice to be made

M. Auger out of line causing excessive wear on the lower

M. Replace auger and

evaporator shell outside surface where it rubs against evaporator shell liner at the bottom

N. Broken auger N. Replace auger

O. Evaporator surfaces worn or gouged, causing thicker ice to be

O. Inspect and replace

evaporator if necessary made

P. Auger guide bushing worn down

P. Replace auger guide

bushing (corkscrew type

augers only)

Q. Loose gearmotor mounting

Q. Check and tighten plate

R. Low water level in float tank reservoir

R. Adjust float arm to maintain

correct water level

S. Worn thrust washer S. Replace

Page 22

IMI Cornelius Inc.

www.cornelius.com

Cornelius 200, 525, 725 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual