Cornelius AC322 Installation Manual
SERIES 322
ICE CUBE MACHINE
Service/Installation
Guide
Part No. 166240008
March 17, 1995
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
IMI CORNELIUS INC; 1995Ó
PRINTED IN U.S.A
TABLE OF CONTENTS
Page
SAFETY INFORMATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 3.....................................................
PLUMBING CONNECTIONS 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNPACKING 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEVELING 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT LOCATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
UNIT SET--UP 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MAKE ELECTRICAL POWER SUPPLY CONNECTION 5. . . . . . . . . . . . . . . . . . . . .
MAKE PLUMBING CONNECTIONS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FOR WATER COOLED UNITS 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRAIN 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DRAIN CONNECTION INSTALLATION INSTRUCTIONS. 6. . . . . . . . . . . . . . . . . . .
WATER LEVEL RESERVOIR 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARTING THE UNIT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS FOR MOUNTING ON DRINK DISPENSERS 8
CHECKOUT PROCEDURE FOR HARVEST BIN SWITCHES 8. . . . . . . . . . .
ADJUSTMENT PROCEDURE FOR HARVEST BIN SWITCHES. 8. . . . . . . .
SANITIZING AND CLEANING PROCEDURE 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TREATMENT 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINTER STORAGE 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE AIR COOLED CONDENSER COIL 10. . . . . . . . . . . . . . . . . . . . . . . .
OPERATING CHARACTERISTICS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REFRIGERATION AND WATER SYSTEM MODEL AC322 12. . . . . . . . . . . . . . . . . .
REFRIGERATION AND WATER SYSTEM MODEL WC322 13. . . . . . . . . . . . . . . . .
DUMP CYCLE 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING BRIDGE THICKNESS 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOTAL ICE CAPACITY 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE PRODUCTION CHECK 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED INDICATORS 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BOARD DIAGNOSIS 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT FUNCTION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TEST PLUG 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET OPERATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATOR SWITCHES 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARVEST SAFETY TERMINATION 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLTAGE CHECKS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATOR PROXIMITY SWITCH 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLTAGE SELECTOR SWITCH 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR [THERMISTOR] DIAGNOSIS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTATIC EXPANSION VALVES 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARVING TXV - PRODUCT SYMPTOMS 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
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TABLE OF CONTENTS (cont’d)
FLOODING TXV - PRODUCT SYMPTOMS 21. . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER REGULATING VALVE 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE STEM VALVES 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOISTURE CONTAMINATION 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR CONTACTOR 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR & STARTING COMPONENT CHECK-OUT PROCEDURE 23. . . .
RELAY 23...........................................................
CAPACITORS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAK DETECTION 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM EVACUATION & RECHARGING 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF-CONTAINED PRODUCTS 25.........................................
CONDENSER FAN CYCLING CONTROL 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH PRESSURE SAFETY SWITCH 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SAFETY INFORMATION
Recognize Safety Information
This is the safety-alert symbol. When you see this
symbol on our machine or in this manual, be alert to
the potentially of personal injury .
Follow recommended precautions and safe operating
practices.
Understand Signal Words
A signal word - DANGER, WARNING, OR CAUTION
is used with the safety-alert symbol. DANGER identifies the most serious hazards.
DANGER
Safety signs with signal word DANGER or WARNING
are typically near specific hazards.
General precautions are listed on CAUTION safety
signs. CAUTION also calls attention to safety messages in this manual.
WARNING
CAUTION
Follow Safety Instructions
Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in
good condition. 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 instructions. Keep your machine in
proper working condition. Unauthorized modifications to the machine may impair function and/or safety and
affect the machine life.
CO2(Carbon Dioxide) Warning
CO2Displaces Oxygen. Strict Attention must be observed in the prevention of CO2(carbon dioxide)
gas leaks in the entire CO2and soft drink system. If a CO2gas leak is suspected, particularly in a
small area, immediately ventilate the contaminated area before attempting to repair the leak. Personnel exposed to high concentration of CO2gas will experience tremors which are followed rapidly by
loss of consciousness and suffocation.
Shipping, Storing, Or Relocating Unit
CAUTION: Before shipping, storing, or relocating this Unit, the syrup systems must be sanitized and
all sanitizing solution must be purged from the syrup systems. All water must also be purged from
the plain and carbonated water systems. A freezing ambient temperature will cause residual water
remaining inside the Unit to freeze resulting in damage to internal components of the Unit.
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SPECIFICATIONS
322 SERIES
15.00
7.00
16.38
11.25
5.00
23.50
A WATER INLET
B PUMP OUT DRAIN
C ELECTRICAL CONNECTION
D CONDENSATE DRAIN
E CONDENSER (WATER OUT)(W/C ONLY)
F CONDENSER (WATER IN)(W/C ONL Y)
AIR IN
F
E
D
2.75
2.25
22.00
C
A
6 FT ELECTRICAL
CORD
14.75
.75
B
NOTE: MUST USE 20 AMP RECEPTACLE
Net Weight . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . 122 lbs.
2.00
23.50
22.00
5.00
1.00
FRONT
21.00
OPENING
ill 140
Shipping Weight . .. . . .. . . .. . . .. . . .. . . .. . . .. 138 lbs.
Compressor Copeland .. . . .. . . .. . . .. . . .. . . .. 5,300/BTU
Refrigerant . . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . . R--22
Electrical
Freeze Cycle Amps Draw . . .. . . .. . . .. . . .. . . . 8.0
Time Delay Fuse Retains (amps) ... . . .. . . .. . . 20.0
Minimum Circuit Ampacity (amps) . . .. . . .. . . .. 20.0
Power Supply (Single Phase) . .. . . .. . . .. . . .. . 115V/60 Hz
Plumbing Connections
Inlet Water Supply . . . .. . . .. . . .. . . .. . . .. . . .. . Max. pressure 50 PSI 3/8” SAE MFL Ftg
Bin Drain . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . .. . . Through Bin
Waster Water (from water cooled models) . .. . . Two 3/8 in. SAE MFL Fittings
Pump Out Drain Connection . .. . . .. . . .. . . .. . . 1/2 in. ID Tubing
UNPACKING
1. Uncrate machine and/or bin by removing the staples from around the bottom of cardboard crate and lift off.
2. Remove bolts fastening the crate skid to the bottom of the unit. If auxiliary legs have been purchased for
the bin, they should be installed at this time.
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LEVELING
1. 1. If legs are used, adjust the leveling legs of the storage bin until the unit is level and all four(4) legs are
in sold contact with the floor. Leveling is very important to obtain proper draining and to maintain the proper
level in the water pump pan of the ice cuber.
Note: If the bin is to be installed flush to the floor, the bin must be sealed to floor with an approved
mastic such as Dow R.T.V. #732, 734, or G.E. #102, 108. This is an N.S.F. requirement and is the responsibility of the installer.
UNIT LOCATION
1. Allow at least a minimum of six inches at the rear and side of the ice machine for proper air RHP circulation.
2. This unit has been designed to be installed in an indoor location which is clean and which can be adequately ventilated. The air and water temperatures should never exceed 100 F or fall below 50 F. (Temperatures
above 100 F will cut the ice making capacity below an economical level. Temperatures below 50 F will
cause a malfunction of thermostatic sensors).
3. The unit should be located where air circulation is not restricted. The unit should not be located near a
kitchen grill. Air which contains grease vapors will deposit grease on the condenser. The condenser should
always be kept clean.
UNIT SET--UP
1. Take off front panel of machine and remove hardware bag and service manual envelope.
2. Mount the ice maker to the top of the ice storage bin or adapter in the proper position over the ice drop
opening. The ice maker must then be sealed both on the outside and the inside bottom edges with an approved N.S.F. mastic such as Dow R.T.V. #732, 734, or G.E. R.T.V. #102, 108 (Diagram 2). This is an
N.S.F. requirement and the responsibility of the installer.
3. Remove shipping tape from evaporator curtains.
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MAKE ELECTRICAL POWER SUPPLY CONNECTION
Requirements: 115V/60 Hz 1 ph., 230V/60 Hz. 1 ph., or 220V/50 Hz. 1 ph when used.
Refer to serial plate for minimum circuit ampacity and maximum time delay fuse size.
All wiring must conform to national and local electrical codes.
MAKE PLUMBING CONNECTIONS
Water supply -- (install per local codes) (See diagram 3).
The water inlet connection to the unit is a 3/8” male flare connection located at the rear of the ice machine.
WARNING: If the water pressure exceeds 50 pounds, a water pressure regulator should be
installed in the water inlet line between the water shut--off valve and the strainer.
Install a reducer fitting on the shut --off valve to accommodate the water stainer, which is supplied with each ice
machine and MUST be used. This is very important for cleaning. Connect either 3/8” or 1/2” copper tubing between the water inlet fitting of the ice machine and the water strainer.
For water cooled units
Two water inlet connections are provided. One for the ice making (evaporator) section which is located on the
back of the machine and is a 3/8” flared connection. The other is for the water cooled condenser.
The reason for the separate water inlet connections is that some installations use a water tower for cooling the
water used in the water cooled condenser and some installations use treated water (filtered) for the ice making
inlet water connections. Be sure to install water line (incoming) to the 3/8” male flare connection on the back of
the unit that supplies water to the water regulating valve inside. The setting of the water regulating valve from
the factory should be 200 pounds for R--22 units. NOTE: Always flush out water lines before starting unit. Adjustments, if necessary, should be done at installation.
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166240008
NOTE: TAKE CARE NOT T O
KINK OR COLLAPSE VINYL
TUBING.
VENT
DRAIN WC
CONDENSER
DRAIN
CONDENSATION
POWER CORD
(322 UNIT ONL Y)
STRAINER WATER
(NON-DIRECTIONAL)
SERVICE VALVES
50 PSI MAX. WATER PRESSURE
WATER SUPPL YICE MAKING
WATER SUPPL YWC CONDENSER
DUMP VALVE
DRAIN
DRAIN
PIPE
VENT
BIN
DRAIN
OPEN TRAPPED OR VENTED
DRAIN
TYPICAL INSTALLATION: ALL ELECTRICAL & PLUMBING
MUST BE DONE PER LOCAL CODES.
DRAIN
Provide a suitable trapped open drain as close as possible to the area where the ice maker is going to be
installed. This may be an existing floor or a 1--1/4” trapped open drain. Two separate drain lines are required for
air cooled units, one for the storage bin and one for the dump valve drain hose.
An additional separate drain line will be required for water cooled units from the outlet of the condenser coil to
the drain. Run all gravity drain lines with a good fall to the open drain.
All Plumbing Must Be Installed In Accordance With Local Codes.
NOTE: In some cases it may be necessary to insulate the water supply line and drain line. Condensate
dripping to the floor can cause serious staining of carpets or hardwoods.
ill018
DRAIN CONNECTION INSTALLATION INSTRUCTIONS.
Taking care not to kink or collapse vinyl tubing at any point, route tubes to any open, trapped or vented floor
drain. Run tubing to drain separately. Do not tee any drain hoses together. Add drain tubing required to reach
floor drain.
WATER LEVEL RESERVOIR
The Float Valve is mounted in a fixed position thru it’s mounting bracket to maintain the proper water level in the
water reservoir. For the 300 & 322 series units the bracket is mounted thru the bottom hole of the bracket.
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SUPPORT WEB
ADJUST HERE
RESERVOIR
1/4”
WATER LEVEL
FLOAT ASSEMBLY
WARNING: Ice maker will not operate properly when water supply temperature is below
50_F. or above 100_F. Water supply flowing pressure must not exceed 50 PSI.
ILL023
STARTING THE UNIT
After the ice cuber has been unpacked and leveled and all plumbing and electrical connections have been
made, start the unit, and check for proper operation.
A cuber has three separate circuits: the water circuit, the refrigerant circuit and the electrical circuit.
1. Start checking the water circuit by making sure that there are not thread of flare joint leaks, either outside
the unit or in the compressor section. Next check the water flow over the evaporator and make sure that all
holes in the water distributor are open, (See Diagram 5) and that there is no undue splash or loss of water
into the ice bin.
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