Cornelius 500 Series, 2000 Series, 700 Series, 1000 Series Installation Manual

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CONTINUOUS FLOW ICE MAKER

500, 700, 1000, 2000 - Series

Installation Manual

Release Date: July 1, 2008

Publication Number: 630460174INS

Revision Date: May 1, 2013

Revision: F

Visit the IMI Cornelius web site at

www.cornelius.com for all your Literature needs.

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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 son(s) working on the equipment have been trained and are skilled in w 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.

This Product is warranted only as provided in ject to all of the restrictions and limitations contained in the Commercial Warranty.

Cornelius’ Commercial Warrant applicable to this Product and is sub-

this equipment. This manual assumes that the per-

orking with electrical, plumbing, pneumatic,

Cornelius will not be responsible for any repair, replacement or from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident, (6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained persons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100% compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the product dispensed which are adversely impacted by changes in liquid scale or chemical composition.

other service required by or loss or damage resulting

Contact Information:

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

www.cornelius.com

-238-3600

800

Trademarks and Copyrights:

This document contains proprietary information and it may not be reproduced in any way without permission from Cornelius.

This document contains the original instructions for the unit described.

IMI CORNELIUS INC

101 Regency

Glendale Heights, IL

Tel: + 1 800-238-3600

Drive

Printed in U.S.A.

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TABLE OF CONTENTS

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

Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

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

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

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

Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Remove Icemaker from Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Cabinet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Preparation of Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Water Inlet Hook Up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Initial Start Up, Checks and Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

For WCC2001QT-R Only: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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Continuous Flow Icemaker Installation Manual

DANGER:

WARNING:

CAUTION:

WARNING:

SAFETY INSTRUCTIONS

READ AND FOLLOW ALL SAFETY INSTRUCTIONS

Safety Overview

• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or laminated cards).

• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before operating this unit.

Recognition

Recognize Safety Alerts

This is the safety alert symbol. When you see it in this manual or on the unit,

be alert to the potential of personal injury or damage to the unit.

DIFFERENT TYPES OF ALERTS

Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment damage.

Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment damage.

SAFETY TIPS

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

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

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

• Do not let anyone operate the unit 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 unit in proper working condition and do not allow unauthorized modifications to the unit.

QUALIFIED SERVICE PERSONNEL

Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.

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Continuous Flow Icemaker Installation Manual

WARNING:

CAUTION:

WARNING:

SAFETY PRECAUTIONS

This unit has been specifically designed to provide protection against personal injury. To ensure continued protection observe the following:

Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify all of the power is off to the unit before any work is performed.

Failure to disconnect the power could result in serious injury, death or equipment damage.

Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in injury or equipment damage.

SHIPPING AND STORAGE

Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the unit to freeze resulting in damage to internal components.

GENERAL SAFETY INSTRUCTIONS

1. Do not store explosive substances such as aerosol cans with a flammable propellant in this appliance.

2. This appliance is intended to be used in household and similar applications such as

• Staff kitchen areas in shops, offices and other working environments;

• Farm houses and by clients in hotels, motels and other residential type environments;

• Bed and breakfast type environments;

• Catering and similar non-retail applications.

NOTE: If the appliance is to be limited to less than the above, this has to be clearly stated in the

instructions.

Connect to potable water supply only.

To avoid a hazard due to instability of the appliance, it must be fixed in accordance with the instructions.

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Continuous Flow Icemaker Installation Manual

WARNING:

INSTALLATION INSTRUCTIONS

This manual covers unpacking and inspection, selecting location, installing unit, and preparing for operation.

REMOVE ICEMAKER FROM CARTON

Keep unit in the upright position, remove carton and pallet from unit and inspect unit for damage. Upon inspection of unit, if any damage is found, file a claim with carrier immediately.

CABINET REMOVAL

1. Front Panel—Remove 4 screws and pull forward.

2. Top Panel—Remove screws and lift upward. 4 screws 500/700, 6 screws 1000.

3. Side Panel—Remove 4 screws and pull forward.

4. Back Panel—Should not be removed.

PREPARATION OF INSTALLATION SITE

The refrigeration system on air cooled units requires airflow, so a well ventilated area should be chosen.

1. A minimum of 12 inches must be maintained, free of any obstructions, for air intake. A minimum of 4 inches rance is required for air exhaust.

clea

2. For WCC500A units, maintain minimum clearances of 18 inches on top and 6 inches on sides as well as in the

rear for sufficient air flow.

3. The unit can be installed either on an ice storage bin or ice dispenser using the proper adapter kits. (Refer to

sales literature for information.) The install is kit provided with each icemaker and adapter kits will supply everything to locate unit correctly. In all cases the icemaker should be sealed all around the base with an NSF listed sealant. (63804815B)

WATER INLET HOOK UP

IIt is the responsibility of the installer to ensure that the water supply to the dispensing equipment is provided with protection back flow by an air gap as defined in ANSI A 112.1.2-1979; or an approved vacuum breaker or other such method as proved effective by test and must comply with all federal, state and local codes.

Failure to comply could result in serious injury, death or damage to the equipment.

Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed and

maintained according to Federal, State and Local laws.

1. Water Inlet—fitting is a 1/4 SAE male flare located at the rear of the unit. Connect water supply with a 1/4 SAE

flare nut and 1/4” copper or flexible tubing or larger.

2. Water Pressure—Unless otherwise specified, the unit is designed to operate on water pressures between

137.9 kpa and 620.5kpa (NOTE: for pressures above 90 P.S.I. a regulator must be installed.)

3. Condenser Inlet Connections—Use a separate 3/8” copper line or larger water line. Connect to 3/8 FPT fit-

ting on water modulating valve.

4. Filter/Conditioners are recommended on supply lines to icemakers. Never run the water supply to water cooled

condenser through filter/conditioner, it uses up the cartridge unnecessarily and a saturated cartridge can starve the icemaker causing premature component damage. Separate water supplies are recommended.

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Continuous Flow Icemaker Installation Manual

CAUTION:

Auger/

Extruder

Head

DRAIN CONNECTION

1. Overflow Line—is a 3/8” I.D. flexible tube located at the rear of the unit. Extend this line to proper drain.

2. Condenser Outlet—is a 3/8” FPT located on the rear panel.

ELECTRICAL SUPPLY

1. Power Access—is provided with a 7/8” diameter. knockout hole in the rear panel. Route incoming power in

conduit, through rear panel to icemaker electrical control box. Make connections to wires provided in the control box and ground lug/screw.

For WCC700A, WCC702A units, 8 ft. 2 inch long (2.4 m) power cord with 3-prong plug attached to the unit.

Only trained and certified electrical technicians should replace the power cord or the unit should be returned to an Authorized Service Center for power cord replacement. The replacement cord must meet all requirements of the original equipment manufacturer.

Failure to comply could result in serious injury, death or damage to the equipment

2. Fused Line—should be checked and sized according to electrical rating shown on unit nameplate.

AUGER ENGAGEMENT

Be certain that auger is fully engaged to lower drive and extruder head is fully engaged into evaporator. Perform the following procedure to engage the auger properly.

1. Install the extruder head on top of the evaporator, as shown in Figure 1.

2. When the auger is lowered into the evaporator, rotate the auger to engage the motor drive shaft, see Figure 2.

Figure 1.

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Continuous Flow Icemaker Installation Manual

CAUTION:

Extruder

Evaporator

Head

All tabs &

slots engaged

Figure 2.

3. Carefully rotate the extruder head until the tabs on the extruder head drop into the slots on the evaporator

plate, as shown in Figure 3. When the auger/extruder head assembly is rotated to the proper position, it will drop about 1/4 inch to more fully engage the motor drive shaft.

NOTE: Not all the tabs are the same width. Therefore, you must rotate the auger until all the tabs

are properly aligned with the evaporator slots. This may require almost a complete rotation of the extruder head to complete.

Keep hands out of the way when rotating the extruder head. When the auger is aligned, it drops down quickly and a finger may be pinched due to the weight of the auger/extruder head assembly.

Failure to lock the extruder head tabs into the evaporator slots causes the auger to be out of proper alignment with the evaporator. This may cause excessive loads on the auger that can potentially result in excessive noise and tripping the drive motor overload.

Figure 3.

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Continuous Flow Icemaker Installation Manual

INITIAL START UP, CHECKS AND ADJUSTMENT INSTRUCTIONS

NOTE: Do not start unit before completing installation steps on the previous page.

Turn on water supply (if unit is water cooled turn water on to condenser also) turn on main power switch (located on

of electrical box), and make the following system checks:

top

NOTE: If unit will not start be sure water reservoir is full. Low water safety control must be properly

djusted to start and shut down unit. If water level drops below bottom of reservoir, unit

a must shut down. Adjustment is made by moving magnet up or down.

Water Level—I

unit stops running. Release float and unit will restart. Keep water in reservoir at level line while unit is in operation.

f necessary adjust float by bending float arm up or down as needed, push float assembly down until

Low Water Safety Control—Adjust drops below bottom of reservoir.

Bin Control—Place ice ar should start in two minutes.

Water modulating valve (water cooled units only)—Opening point of condenser water modulating valve should be set to maintain proper operating pressure in the refrigeration system high side. Closing point of valve should be set low enough to close valve during compressor stand by periods. To raise, turn counterclockwise, to lower turn clockwise.

ound probe, unit should shut down in one minute. Remove ice from around probe, unit

magnet by bending magnet arm as needed to shut unit down if water level

Figure 4. Icemaker Float Assembly

NOTE: If any of these checks or adjustments cannot be achieved, refer to Service Manual or call for

actory assistance at 1-800-238-3600.

For WCC2001QT-R Only:

1. The WCC2001QT-R is equipped with a compressor start delay. The auger motors will run before compressor start for approximately two minutes. This is to clear out the evaporators and is normal.

2. The WCC2001QT-R is equipped with an auger motor run delay. The auger motors will run after compressor shut down for approximately two minutes. This is to clear out the evaporators and is normal.

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IMI Cornelius Inc.

www.cornelius.com