Cornelius 2000, 700, 500 User Manual

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CONTINUOUS FLOW ICEMAKER

500, 700, 1000, 2000 - Series

Service Manual

Release Date: May 27, 2004

Publication Number: 630460174SER

Revision Date: February 1, 2005

Revision: C

Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

CONTINUOUS FLOW ICEMAKER

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.

Continuous Flow Icemaker Service Manual

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Recognize Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1

General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2

Bin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Gearmotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5

Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Icemaker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6

Semi-annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7

Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8

Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Refrigeration System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12

Condenser Modulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13

Condenser Modulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14

Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

To Replace Gearmotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15

Installation and Shaft Seal Replacement 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Auger and Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16

Installation and Shaft Seal Replacement 700 & 1000 . . . . . . . . . . . . . . . . . . . . . . . .17

Upper Nut and Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

To Replace Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18

Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21

Continuous Flow Icemaker Service Manual

SAFETY

SAFETY INSTRUCTIONS

Read and Follow all Safety Instructions

Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated

cards).

Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regula-

tions before operating the machine.

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the machine be alert to the potential of personal injury or damage to the machine.

Different Types of Alerts

There are 3 types of safety alerts:

DANGER — Indicates an immediate hazardous situation which if not avoided WILL result in seri-

ous injury, death, or equipment damage.

Continuous Flow Icemaker Service Manual

WARNING — Indicates a potentially hazardous situation which, if not avoided, COULD result in

serious injury, death, or equipment damage.

CAUTION — Indicates a potentially hazardous situation which, if not avoided, MAY result in

minor or moderate injury or equipment damage.

SAFETY TIPS

• Carefully read all safety messages in this manual and safety signs on the machine.

• Keep safety signs in good condition and replace missing or damaged safety signs.

• Learn how to operate the machine and how to use the controls properly.

• Do not let anyone operate the machine without proper training. This appliance is not intended for use

by very young children or infirm persons without supervision. Young children should be supervised to

ensure that they do not play with the appliance.

• Keep your machine in proper working condition and do not allow unauthorized modifications to the

machine.

QUALIFIED SERVICE PERSONNEL

CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should

service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES.

SHIPPING AND STORAGE

CAUTION — Before shipping, storing, or relocating the Unit, syrup systems must be sanitized

and all sanitizing solution must be purged from the syrup systems. All liquids, after sanitizing, must be purged from the unit. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the Unit to freeze resulting in damage to the internal components.

Continuous Flow Icemaker Service Manual

GENERAL DESCRIPTION

This section gives the Unit description, theory of operation, and design data for continuous flow icemaker series 500, 700, 1000, and 2000.

SPECIFICATION CHART

Models

Condensing

Unit

VAC HZ PH Wire

Comp.

RLA

Fan

Amps

GRMT

Amps

Refrigerant

Oz. Type

Circuit

Fuse

WCC500-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20 WCC500-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20 WCC502-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20 WCC502-W Water Cooled 220/240 50 1 2 5.3 N/A 1.6 11 R404A 20 WCF510-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20 WCF510-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20 WCF512-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20 WCF512-W Water Cooled 220/240 50 1 2 5.3 N/A 1.6 11 R404A 20 WCC700-A Air Cooled 115 60 1 2 12 1.6 2 24 R404A 20 WCC700-W Water Cooled 115 60 1 2 12 N/A 2 13 R404A 20 WCC701-A Air Cooled 208/230 60 1 2 7.7 1.6 2 24 R404A 20 WCC701-W Water Cooled 208/230 60 1 2 7.7 N/A 2 13 R404A 20 WCC702-A Air Cooled 220/240 50 1 2 8.2 0.5 1.6 24 R404A 20 WCC702-W Water Cooled 220/240 50 1 2 8.2 N/A 1.6 13 R404A 20 WCF710-A Air Cooled 115 60 1 2 12 1.6 2 24 R404A 20 WCF710-W Water Cooled 115 60 1 2 12 N/A 2 13 R404A 20 WCC711-A Air Cooled 208/230 60 1 2 7.7 1.6 2 24 R404A 20 WCC711-W Water Cooled 208/230 60 1 2 7.7 N/A 2 13 R404A 20 WCF712-A Air Cooled 220/240 50 1 2 8.2 0.5 1.6 24 R404A 20 WCF712-W Water Cooled 220/240 50 1 2 8.2 N/A 1.6 13 R404A 20 WCC1001-A Air Cooled 208/230 60 1 2 7.5 0.85 2 26 R404A 20 WCC1001-W Water Cooled 208/230 60 1 2 7.5 N/A 2 17 R404A 20 WCC1002-A Air Cooled 220/240 50 1 2 8.9 0.85 2 26 R404A 20 WCF1101-A Air Cooled 208/230 60 1 2 7.5 0.85 2 26 R404A 20 WCF1101-W Water Cooled 208/230 60 1 2 7.5 N/A 2 17 R404A 20 WCF1102-A Air Cooled 220/240 50 1 2 8.9 0.85 2 26 R404A 20 WCC1001-R Remote 220/240 60 1 2 7.5 N/A 2 120 R404A 15 WCF1101-R Remote 208/230 60 1 2 7.5 N/A 2 120 R404A 15 WCC2001–AAir–Cooled 208/230 60 1 2 12.9 .85 (2) 2 46 R404A 25 WCC2001–R Remote 208/230 60 1 2 12.9 1.7 (2) 2 220 R404A 25 WCC2001–W Water Cooled 208/230 60 1 2 12.9 N/A (2) 2 28 R404A 25 WCC2002–A Air Cooled 220/240 50 1 2 11.4 .85 (2) 2 46 R404A 25 WCF2201–AAir–Cooled 208/230 60 1 2 12.9 .85 (2) 2 46 R404A 25 WCF2201–W Water Cooled 208/230 60 1 2 12.9 N/A (2) 2 28 R404A 25 WCF2202–A Air Cooled 220/240 50 1 2 11.4 .85 (2) 2 46 R404A 25

NOTE: For units not listed in above chart, refer to nameplate or contact factory service.

WCC500

400

380 360

340 320 300 280

Capacity Lbs./24 hr.

260 240

90 80

70 60

Water Temperature Deg. F

–50 –70 –90 –100

Air Temperature Deg. F

90 80 70 60 50

WCC700

Water Temperature Deg. F

–50 –70 –90 –100

Air Temperature Deg. F

650

600

550

500

450

400

350

Capacity Lbs./24 hr.

90 80 70 60 50

WCC1000

Water Temperature Deg. F

–50 –70 –90 –100

Air Temperature Deg. F

1100

1000

900

800

700

600

Capacity Lbs./24 hr.

Continuous Flow Icemaker Service Manual

24.50

14.50

FRONT

3.50

FRONT

25.00 1.38

10.15 WATER IN 1/4 FLARE

1.50

1.81

SIDE

1.19

AIR OR WATER COOLED

ICE DISCHARGE

1.75

INLET 3/8 FLARED WATER COOLED ONLY

OUTLET 3/8 FLRE WATER COOLED ONLY

DRAIN 3/8 ID TYGON TUBE

ELECTRIC 7/8 DIA

2.12

2.50

BACK VIEW

27.00

FIGURE 1. SERIES 500 & 700 DIMENSION DRAWING (SHIPPING WT. 160 LBS. APPROX).

22.00

FRONT

9.04

(VIEWED FROM BOTTOM OF MACHINE)

24.00

SIDE

ICE DISCHARGE

2.06

BOTTOM VIEW

5.87

2.25

0.94 13.94

W/C INLET 3/8” FPT

POWER INLET 7/8” DIA.

4.50

1.88

AIR EXHAUST

2.19

9.00

BACK VIEW

(AIR COOLED)

ELECTRICAL 7/8” DIA.

10.44

WATER UB 1/4” MALE FLARE

DRAIN 3/8” ID TYGON TUBE

2.25

(REMOTE) DISCHARGE LINE 1/2 PUNCTURE FITTING

W/C OUTLET 3/8” FPT OR REMOTE COND. LIQ. LINE 3/8 PUCTURE FITTING

DRAIN 3/8” ID TUBE

WATER INLET 1/4” MALE FLARE

2.50

1.00

FIGURE 2. SERIES 1000 DIMENSION DRAWING (SHIPPING WT. 210 LBS. APPROX).

Continuous Flow Icemaker Service Manual

28.06

9.50

30.00

AIR INLET

FRONT

23.50

2.25

ICE DISCHARGE

18.13

WATER IN

ELECTRICAL 7/8 DIA.

DRAIN 3/8 I.D. TUBE

BACK

2.06

24.00

2.06

20.13

3.81

BOTTOM

VIEWED FROM BOTTOM OF MACHINE

2.06

FRONT

FIGURE 3. SERIES WCC2001-A AND WCF2201-A DIMENSION DRAWINGS

SIDE

BIN CONTROL

The type of bin control used on all WCC & WCF Models is an electronic control. The control is supplied with power to terminals X1 and X2. Terminals X3 and X4 are a normally closed switch which open when the thermostat sensor bulb senses ice.

The sensing element is located in a 5/16” stainless steel tube which hangs from the dispense tray cover down through the center of the drop tube.

To test switch, start the icemaker and block the outlet tube. When the ice fills the drop tube about 1/2 full the icemaker should shut off. When tube is cleared the ice maker should restart within 5 min.

The Bin control is in electrical series with coil on antifreeze relay along with the low water safety. If unit is water cooled, the condenser high pressure cut out is also in series.

The Control Switch is held in place inside electrical box by 2 screws. The Control bulb is in the drop tube. It can be removed by pulling the cable located on the top of the dispense tray cover. When replacing the sensor make sure the bulb is inserted to the bottom of the thermostat well.

Continuous Flow Icemaker Service Manual

BIN CONTROL SWITCH TERMINALS

FIGURE 4. BIN CONTROL SWITCH

GEARMOTOR

The gearmotor is equipped with a start relay and a manual reset overload.

When current is applied, the relay energizes and completes the circuit to the start winding. The motor reaches a predetermined speed and the relay drops out, disconnecting the start winding. The run winding remains in the circuit as long as current is applied.

The purpose of the overload is to automatically shut off the motor in the event of a mechanical bind of the transmission, an overload condition within the evaporator or an electrical malfunction. It does this by sensing amperage draw. If the motor stalls the start relay would energize and stay energized. The amperage would surge 5 to 6 times greater than the normal draw. In this event the overload would shut off the transmission in 4 to 8 seconds.

If the motor is subjected to an abnormal load, but does not reach a stall condition, the overload will react, but over a greater period of time. The reaction time depends upon the amperage to which it is subjected.

The overload, through the safety circuit, also shuts off the compressor.

Continuous Flow Icemaker Service Manual

CLEANING AND SANITIZING

ICEMAKER CLEANING AND SANITIZING PROCEDURES

Do not use any of the ice made during cleaning operations.

Clean and sanitize ice storage area when cleaning icemaker.

1. Turn machine off.

2. Shut off water supply.

3. Remove ice from storage bin.

4. Mix approved cleaner (2 gallons as directed). Recommended cleaner: Calgon Nickel-Safe, ice machine cleaner. Mixture: 3 ounces per gallon of water.

5. Clean auger/diverter assembly and ice transition/drop tube in a sink using cleaner mixture and reinstall in icemaker. Using cleaner, wipe down the dispense tray.

6. Turn machine on and add cleaner solution to water level control until 2 gallons have been used.

7. Turn on water supply and run machine for 15 minutes.

8. Turn off machine and remove all ice. Turn off water and drain water.

9. Sanitize using household liquid bleach (200 ppm chlorine). Mixture: 1/2 fluid ounce per gallon room temperature water. 2 minute exposure time.

10. Sanitize auger/diverter assembly and ice transition/drop tube in a sink using sanitizing solution and reinstall in icemaker. Using sanitizer, wipe down the dispense tray.

11. Fill icemaker with sanitizer by slowly pouring solution into water feed reservoir until full. Solution will drain through overflow tube. Turn on water. Run the ice machine for 15 minutes. Turn off ice machine and remove all ice.

12. If icemaker is used in conjunction with ice dispenser or storage bin, follow manufacturer’s recommended cleaning instructions at this time.

MAINTENANCE

Preventive maintenance can increase the trouble free life of your icemaker. Many authorized service agencies offer service contracts for your icemaker. Contact your local distributor for further information.

MONTHLY

1. Clean the condenser. Use a brush, vacuum cleaner or blow from inside with air or CO2 gas.

2. Inspect water feed reservoir at lease once a month until a definite pattern for cleaning and sanitizing has been established.

QUARTERLY

This is the maximum period of time between cleaning and sanitizing the icemaker. In addition to recommended monthly procedure, and if a more frequent cleaning and sanitizing pattern has not been established, unit must be cleaned and sanitized.

SEMI-ANNUALLY

Semi–Annually in addition to all previously established service procedures perform the following:

1. Check for water leaks in tube connections, water fittings and lower icemaker water seal.

2. Check drain tubes for clogs and aged tubes. Replace if tubes are stained or brittle.

3. Check for signs of condensation. Clean where necessary and replace insulation properly.

4. Check safety circuits for proper operation.

5. Check refrigeration system.

6. Check unit for abnormal noise. Tighten machine and cabinet screws, if necessary.

7. Check white upper bearings on auger assembly. If bearings are less than 1/16” thick, replace.

Continuous Flow Icemaker Service Manual

REPLACE

1/16

REPLACE

FIGURE 5. UPPER NUT AND BEARING ASSEMBLY

1/16

Continuous Flow Icemaker Service Manual

WATER LEVEL CONTROL

HOW WATER LEVEL CONTROL WORKS

When water is introduced through the inlet fitting the float rises. the float pushes against a lever which in turn forces the poppet assembly against the inlet fitting valve seat which seals the water off. Before the water inlet is sealed the safety switch is operated. In the event of a water failure the float would drop down and operate the safety switch to shut off the machine.

If water level control will not shut off and seal at level as indicated, be sure inlet pressure does not exceed recommended factory operating range.

Under ordinary circumstances adjustment should not be necessary providing it was properly adjusted when unit was installed or relocated. If, however, the control becomes inoperative, repair or replace. See Start–Up Adjustment in the Installation Manual.

PURPOSE

1. To automatically maintain proper water level in the evaporator when unit is running and making ice.

2. A safety switch is operated in the event of an interruption in water supply. The switch shuts off the electrical power to the icemaker and its refrigeration system. Switch will reset as soon as cause of water failure has been corrected and proper water level in icemaker has again been reached.

3. The transparent bowl not only provides a visible check of water level, but also is a good guide to the internal conditions which exist within the icemaker assembly itself. (See Cleaning Procedure.)

TO REPLACE WATER LEVEL CONTROL

1. Shut off the water supply. Shut off the main power switch or unplug the ice dispenser from electrical outlet.

2. Remove the flexible tubing from bottom of water level control and drain water from water level control and evaporator.

3. Remove flexible tubing at bottom of water level bowl connected to the overflow.

4. Hold water inlet fitting with proper tool to prevent it from rotating when disconnecting the water inlet.

5. Remove wing nut holding water control to its mounting bracket. Control can be removed by lifting straight up.

TO REPLACE WATER LEVEL SAFETY SWITCH

1. Shut off main power switch or unplug the ice dispenser from electrical outlet.

2. Unplug molex connector connecting switch to electrical box.

3. Remove the 2 screws anchoring the water level safety switch to the bottom of the water level control mounting bracket.

ELECTRICAL

Continuous Flow Icemaker Service Manual

FIGURE 6. SCHEMATIC AND WIRING DIAGRAM WCC2001-A AND WCF2201-A

FIGURE 7. SCHEMATIC AND WIRING DIAGRAM WCC500-A, WCC500-W, WCC700-A, WCC700-W, WCF510-A,

WCF510-W, WCF710-A, & WCF710-W

Continuous Flow Icemaker Service Manual

FIGURE 8. SCHEMATIC AND WIRING DIAGRAM WCC701-A, WCC701-W, WCC1001-A, WCC1001-W, WCF711-A,

WCF711-W, WCF1101-A, & WCF1101-W

FIGURE 9. SCHEMATIC AND WIRING DIAGRAM WCF1101R, WCC1001R, WCF1102R, & WCC1102R

Continuous Flow Icemaker Service Manual

FIGURE 10. SCHEMATIC AND WIRING DIAGRAM WCC502, WCC702, WCC1002, WCF512, WCF712, & WCF1102

FIGURE 11. SCHEMATIC AND WIRING DIAGRAM WCC2001-R AND WCF2201-R

Continuous Flow Icemaker Service Manual

REFRIGERATION SYSTEM

Thermostatic Expansion Valve NO Adjustment.

+/- 10 lbs. Discharge Pressure

Water Temperature

WCC 500 WCC 700 WCC 1000 WCC 2200

40° 65° 90° 50° 65° 90° 50° 65° 90° 50° 65° 90° 50° 162 166 168 60° 177 180 60° 171 172 60° 201 203 60° 188 ‘92 194 70° 205 208 70° 199 200 70° 219 220 70° 214 218 220 80° 233 236 80° 227 228 80° 253 254 80° 245 249 251 90° 269 272 90° 263 264 90° 298 300 90° 275 279 281 100° 304 307 100° 298 299 100° 330 332

100° 309 313 315 328 334 340 324 328 332 362 364 366

Air Temperature

REFRIGERATION SYSTEM ADJUSTMENTS

A complete understanding of the icemaker and hermetic refrigeration system is necessary before any adjustments are made. The refrigeration technician must use high and low side pressure readings, water and air temperatures, plus general conditions of cleanliness to assess the refrigeration system status when making any adjustments.

All icemaker products are tested and adjusted at the factory prior to shipment where the ambient temperature ranges from 65° to 90°F, depending on the season of the year.

Whenever a new icemaker product is initially installed and started–up, it is imperative that the start–up operation make the following checks and/or readjustments for local conditions.

EXPANSION VALVE

You will find a thermostatic expansion valve on icemakers, which is used to control the amount of refrigerant flowing through the evaporator. Improperly installed or defective expansion valves may cause low production, soft ice, squeaking from evaporator and excessive load inside evaporator.

By using general refrigeration system troubleshooting along with the pressure charts you can easily determine whether or not the expansion valve is working properly.

ADJUSTMENT AND TROUBLESHOOTING

When troubleshooting the expansion valve you must first be sure you have adequate water flowing into evaporator, a clean condenser, unit is properly ventilated, and system is properly charged and free from any restrictions. Also be sure compressor is operating properly.

Second, take reservoir water temperature and air temperature from condenser inlet and determine at what pressure unit should be running. Machines are equipped with thermostatic valves, there is NO adjustment. If correct pressure cannot be obtained, first be sure system has time to stabilize 10–15 minutes. Second, be sure sensing bulb is located at 12:00 position on outlet side of evaporator about 3–4 inches away from evaporator and be sure to insulate well and clamp tightly to tubing. If system pressures are still not adequate, take a second water and air temperature reading and go over other parts of system for possible problems. If proper charge is questionable evacuate and recharge to nameplate and leak check. If valve still malfunctions replace valve.

When replacing valve be sure to bleed refrigerant gas from low side port so as not to lose refrigerant oil. Use general refrigerant system practices when replacing and recharging unit. After new valve is in place, go through previous monitored adjustments and troubleshooting to be sure valve is functioning properly.

NOTE: Units with thermostatic expansion valve—valve is located on bottom refrigerant line. Sensing bulb is located on top refrigerant line. On water cooled units adjust condenser modulating valve before troubleshooting expansion valve.

CAUTION: Very High discharge pressure is present in system. Quick disconnects on you gauges will minimize danger and loss of refrigerant. Comply with federal regulations for reclaiming refrigerant.

CONDENSER MODULATING VALVE

The reason for using a water modulating valve is to supply the correct amount of water to the condenser. and to maintain a proper operating pressure to refrigeration system high side.

The flow of water through the valve is increased as the high side pressure rises and is decreased as high side pressure lowers.

To calibrate the amount of water flow with the refrigeration system high side pressure, turn adjustment screw located on end of valve opposite of bellows. Turn screw counterclockwise to raise opening point or clockwise to lower opening point. Opening point of valve should be set to maintain proper operating pressure in refrigeration system high side. Refer to Pressure Chart on. Closing point of valve should be set low enough to close valve during compressor stand–by periods.

NOTE: Cold water will absorb heat faster than warm water. The water flow will therefore automatically increase as inlet temperature increases.

SIGHT GLASS

Continuous Flow Icemaker Service Manual

THERMOSTATIC EXPANSION VALVE

FIGURE 12. EXPANSION VALVE FIGURE 13. ADJUSTMENT SCREW

Continuous Flow Icemaker Service Manual

CONDENSER MODULATING VALVE REMOVAL

1. Disconnect power to unit, then shut off water supply to condenser and evacuate refrigerant from system.

2. Remove inlet water line from Condenser Modulating Valve. Also remove tube from high side refrigerant line.

3. Remove Condenser Modulating Valve and bracket from unit.

4. Remove valve from bracket.

5. Replace Condenser Modulating Valve by reversing Steps 2 through 4. Then pull system into vacuum.

6. Charge unit with proper amount of refrigeration.

7. Turn power and water on to unit.

8. With unit running, adjust modulating valve to proper setting.

9. Go through a complete system check.

GEARMOTOR

OVERLOAD TRIPPED

Check water level control

and evaporator water tube

for line build-up restrictions.

IMPORTANT

Icemaker runs when

reset but problem has

not been found. Continue checking for overload as follows to

guard against future

problems.

Icemaker

runs.

Short run. Trips

again in 2

minutes. Check

gearmotor circuits.

OVERLOAD GUIDE ELECTRICAL:

High or low voltage. Weak power lines can cause overloads on icemakers restarts. High running current (2.4amps or above). Check motor circuits and start relay. Auger delay failed.

ICEMAKER

Mechanical parts worn. Scored evaporator or auger. Worn thrust bearing. Icemaker not turning off. Failed ice level control. Over compression. Low water inlet temperature. Restrictions in water line from reservoir.

REFRIGERANT

Contaminated charge or bad compressor. Low charge or gas leak. Low suction pressure. Improper expansion valve. Sensing bulb location or insulation

and/or defective expansion valve.

CAUTION

Clear ice from

evaporator and

auger before

resetting overload.

Reset overload.

Resets but

motor does

not run.

Resets but motor does

not run.

Check

gearmotor

circuits.

Will not

Reset.

Overload

hot try again.

Will not

reset.

Replace

overload.

YES

CLEAN

See Instructions.

MOTOR CHECK

The resistance readings on the winding will be between 5 to 25 ohms. A meter capable of these low readings must be used. The start relay cover must be removed.

If no continuity on start or run winding test, replace gearmotor. If continuity on grounded motor test, replace gearmotor.

START RELAY

1. Check between “2” and “4” on relay (with relay unplugged). If there is continuity replace the relay, as the relay contacts should be open.

2. Check between “3” and “4” on relay, if no continuity replace the relay.

Continuous Flow Icemaker Service Manual

FIGURE 14. GEARMOTOR ASSEMBLY

TO REPLACE GEARMOTOR ASSEMBLY

1. Disconnect the icemaker from the electrical power source.

2. Disconnect the transmission cable from the electrical box.

3. Remove the 4 hex head bolts securing the evaporator to the top of the transmission.

4. Remove the 4 bolt’s holding the transmission and bracket to frame base, while supporting the weight of the evaporator. Remove the transmission from the unit.

5. When replacing the transmission, it may be necessary to rotate the auger back and forth to align the motor shaft and auger.

AUGER NUT

BEARING DELRIN

ANTI–ROTATION RIB – 3 PLACES

BEARING NYLON

GROOVE

EXTRUDING HEAD

AUGER

“D” DRIVE

FIGURE 15. AUGER AND EXTRUDING HEAD REMOVAL

Continuous Flow Icemaker Service Manual

INSTALLATION AND SHAFT SEAL REPLACEMENT 500

1. Place shaft seal locator seat over gear motor output shaft, embossed side down, and push down until shaft seal seat rests flush on top of gear motor.

2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and push down until seal rests on top of the shaft seal seat. (Lubricate rubber on ceramic seal with rubber lubricant.)

3. Place shaft seal with carbon face down (spring up) over output shaft and push (gently) downward until seal rests on ceramic face of the output shaft seal.

4. Place flat washer over output shaft and let rest on the output shaft seal. Push down on the washer compressing the spring on the output shaft seal. While holding the seals (down) in place slide the E–ring into the groove on the output shaft.

FIGURE 16. SHAFT SEAL 500

E–RING

WASHER, PLAIN FLAT

SHAFT SEAL

LOCATOR SEAL

GEARMOTOR

UGER AND EXTRUDING HEAD REMOVAL

1. Disconnect unit from power supply.

2. Remove storage container cover and put aside.

3. Turn off water supply to icemaker.

4. After ice has melted from head take hold of the auger nut and lift straight up to disengage from icemaker.

5. When replacing the auger assembly, make certain that both the auger engages the output shaft drive and the extruding head ribs engage the evaporator tube.

Continuous Flow Icemaker Service Manual

INSTALLATION AND SHAFT SEAL REPLACEMENT 700 & 1000

1. Place shaft seal locator seat and shaft seal mount over gearmotor output shaft and push down until shaft seal seat and shaft seal mount rest flush on top of gearmotor.

2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and push down until seal nest in recess of shaft seal mount. (lubricate rubber on ceramic seal with rubber lubricant).

3. Place shaft seal with carbon face down (spring up) over output shaft and push (gently) downward until seal rests on carbon face of the output shaft seal.

FIGURE 17. SHAFT SEAL 700 AND 1000

E–RING

WASHER, PLAIN FLAT

SHAFT SEAL

MOUNT, SHAFT SEAL

SEAT, SHAFT SEAL

GEARMOTOR

PPER NUT AND BEARING ASSEMBLY

The upper white bearing located on top of the auger is used to absorb the force between the auger and extruding head.

NOTE: The bearings are 3/32 thick. When they wear below 1/16 they should be replaced. Bearings to be inspected for wear during quarterly maintenance.

To Replace Bearing

1. Disconnect unit from electric power.

2. Remove top panels.

3. Remove Dispense Tray Cover.

4. Use an open end wrench on auger nut connected to bearing and turn counterclockwise to remove assembly.

5. Remove worn bearings. Replace with new bearings and then reinstall assembly.

NOTE: If auger turns with nut, remove cover on top of gearmotor stator and hold motor while loosening nut.

ELECTRICAL CHECKOUT

1. Be sure the unit is disconnected from the power source. Remove the compressor electrical box cover. Check for obvious damage and loose wires.

2. Disconnect the fan motor leads. Since capacitors store energy, short the capacitor with a screwdriver. This will prevent shocks.

3. Disconnect the compressor terminal wires.

Continuous Flow Icemaker Service Manual

OVERLOAD CHECK

Using a volt–ohmmeter check the continuity across the overload, contact #1 and #3. If none, wait for unit to cool down and try again. If still no continuity, the overload protector is defective and should be replaced.

COMPRESSOR CHECK

The resistance readings on the windings will be between 0.25 to 10.00 ohms, a meter capable of these low readings must be used.

1. Check between “C” and “R.” Replace the compressor if there is no continuity as the run windings are open.

2. Check between “C” and “S.” Replace the compressor if there is no continuity as the start windings are open.

3. Check between “C” and “R” or “S” and the shell of the compressor. If there is continuity, replace the compressor as the motor is grounded.

4. Check between screw terminal on the overload and “C” on the compressor. Check and repair the lead or connections if there is no continuity.

FIGURE 18. OVERLOAD CHECK

FIGURE 19. COMPRESSOR CHECK

CAPACITOR CHECK

1. Check or replace start capacitor, disconnect bleed resistor before checking for shorted capacitor.

2. Check or replace run capacitor (if supplied) check for shorted capacitor or either terminal grounded to case.

GEAR MOTOR OVERLAY

FIGURE 20. GEAR MOTOR OVERLOAD

SAFETY CONTROLS

Your icemaker unit has several safety and control devices incorporated into its design.

WARNING: None of the below described devices should ever be “bypassed” to allow the unit to function.

The safety and control system shut–off devices are:

1. Low water shut off reed switch located in icemaker float assembly. (Automatic reset type.)

2. Gearmotor thermal overload, manual reset type (red button on motor).

3. Compressor thermal overload, automatic reset type.

4. Anti–freeze relay and associated circuit. See wiring diagrams.

5. Main service switch located on top of the control box.

6. Bin Control.

7. High pressure cut out (water cooled only).

Continuous Flow Icemaker Service Manual

CUSTOMER COMMENTS

GUIDE T O GOOD ICE

CHECK ICEMAKER LOCATION CONDITIONS FIRST

CHECK ICE MAKER

“It runs but the ice is too soft.”

“The icemaker is not producing enough ice.”

“The ice is too wet.”

“It makes too much noise.” (With this comment the ice is usually extremely hard and larger than normal.)

Over Compression

Proper air flow for condensing system.

Location too close to high units such as coffee urns, deep fryers, grills, etc.

Supply water conditions

Water too warm (above 90 F).

Water artificially softened above 262 ppm sodium chloride.

Normal water supply too high in total dissolved solids (above 500 PPM).

Check to see if noise objection is normal fan and air flow noise.

Supply water conditions.

Water too cold (below

50 F). (Possibly running from pre-cooler.)

Use gauges for checking suction and head pressures. See manual for correct reading and conditions. Check frost line and sight glass.

Check water level for proper adjustment and restrictions. See Manual.

Check evaporator assembly for worn parts, bearings, scored evaporator and auger, bad expansion valve. etc.

Check for loose parts and screws rattling.

Check evaporator assembly for worn parts, bearings, scored evaporator and auger, bad expansion valve, etc.

Obstructions partially blocking ice exit from top of evaporator.

Check fan and fan shroud.

TROUBLESHOOTING CHART - ICEMAKER NOT OPERATING

NO POWER

Check electrical wiring in con trol box for loose connec tions. Check for failed service switch or relay. Check power to machine.

High pressure switch open or cycling on and off.

Discharge king valve partially closed.

Open valve

Non-condensible in system.

Evacuate and recharge system. Clean condenser.

Low pressure switch open or cycling on and off.

Low on refrigerant.

Remote condenser units only

Remote condenser not running.

Check electrical wiring in control box for loose connections.

To o mu ch refrigerant in system.

Remote condenser units only

Check power to condenser.

Condenser fan not running.

Check electrical circuit to fan motor. Check fan motor.

Plugged liquid line dryer.

ICEMAKER RUNS BUT DOES NOT MAKE ICE

Condenser fan running but compressor not running

Check line voltage. Check compressor winding & components.

Evaporator water tube may have an air bubble. Clear air bubble from tube.

Head Pressure high.

Condenser dirty or restricted.

Restricted liquid line.

Val ve stuck open.

Replace valve.

Plugged or faulty TXV.

LOW WATER SAFETY SWITCH OPEN

Check that water is turned on. Check for restriction in water line. Check incoming water pressure (minimum 10 lbs.). Check water safety switch.

High suction pressure (30 lbs. or above).

TXV not operating properly.

Bulb loose.

Clean and tighten.

Icemaker froze up.

Suction line not insulated.

Bulb uninsulated.

Clean and insulate.

Low suction pressure (20 lbs. or below).

TXV bulb lost charge.

Replace valve evacuate and recharge.

ICEMAKER OPERATING BUT SOFT ICE

Check bin switch

Ye s

Clean all related drain lines.

IMPORTANT Icemaker runs when reset but problem has not been found. Continue checking for overload as follows to guard against future problems

Refer to guide to Good Ice in service manual.

Icemaker runs

Short run trips again in 2 min utes. Check gear motor circuit.

GEARMOTOR OVERLOAD TRIPPED

Check water level control and evaporator water tube for lime build up restriction.

CAUTION Clear ice from evaporator and auger before re setting over load.

Reset overload.

Reset but motor does not run.

Check gearmotor circuit.

Will not reset.

Overload hot try again.

Will not reset replace overload

Ye s

CLEAN see instructions.

TROUBLESHOOTING

Continuous Flow Icemaker Service Manual

Check for leaks.

LAC not operating properly (minimum discharge pressure 180 lbs.).

Replace LAC valve, evacuate and recharge system.

Replace dryer. Evacuate and recharge system.

Check for kinks or damage to liquid line.

Check drive on gearmotor.

Replace valve. Evacuate and recharge system.

Check if auger is turning.

Check gears in gearbox.

Check if extruding head is down in evaporator tube.

OVERLOAD GUIDE ELECTRICAL High or low voltage weak power lines can cause overloads on icemaker restarts High running current. Check motor circuits and start relay - Auger delay failed. ICEMAKER Mechanical parts worn. Scored evaporator or auger. Worn thrust bearing. Ice maker not turning off. Failed ice level control. Over compression. Low water inlet temperature. Restriction in water line from reservoir. REFRIGERANT Contaminated charge or bad compressor. Low charge or gas leak. Low suction pressure. Improper expansion valve sensing bulb. Location or insulation and/or defective expansion valve

IMI Cornelius Inc.

www.cornelius.com

Cornelius 2000, 700, 500 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual