Cornelius CCM0322 Service Manual
IMI CORNELIUS INC.
www.cornelius.com
Model CCM and CCU Series
Nordic Ice Maker
Service and Maintenance Manual
Publication Number: 631806061
Revision Date: May 1, 2008
Revision: B
Visit the IMI Cornelius web site at www.cornelius.com
CCM and CCU Series Service and Maintenance Manual Manual Number 631806061
for all your Literature needs.
*
Table Of Contents
Table of Contents
Table of Contents Page A1
General Information
How To Use This Manual Page A2
Model And Serial Number Format Page A3
Electrical And Mechanical Specifications Page A4-A5
Installation Guidelines Page A6
Electrical And Plumbing Requirements Page A7-A12
Remote Condenser Installation Page A13-A14
How The Machine Works Page A15
Undercounter Model Bin Removal Page A16-A17
Scheduled Maintenance
Maintenance Procedure Page B1
Cleaning and Sanitizing Instructions Page B1-B2
Winterizing Procedure Page B3
Cabinet Care Page B4
Troubleshooting Trees
How to Use The Troubleshooting Trees Page C1
Troubleshooting Trees Table Of Contents Page C2
Troubleshooting Trees Page C3-C18
Water System
Water Distribution And Components Page D1-D5
Refrigeration System
Refrigeration Cycle And Components Page E1
Harvest Cycle Page E5
Remote System Page E5-E6
Pump Down System Page E7
Refrigerant Specifications Page E8-E20
Electrical System
Control Circuit Page F1
Compressor And Start Components Page F1-F2
Untimed Freeze Cycle Page F3
Timed Freeze Cycle Page F4
Harvest Cycle Page F5-F9
Pump Down System Page F9
Bin Control Page F-9
Wiring Diagrams Page G1
Page A1
General Information
How To Use This Manual
Cornelius provides this manual as an aid to the service technician in installation, operation, and
maintenance of the CCM/CCU Series (electro-mechanical) cube ice machines. If used properly
this manual can also assist the service technician to troubleshoot and diagnose most of the
problems that may occur with the machine.
The first two sections of this manual provide general information and maintenance information.
The remainder of the manual beginning with Section C provides troubleshooting and service
information. Section C contains flow charts called troubleshooting trees. Page C-1 provides
instructions on using the troubleshooting trees. Each troubleshooting tree is named to describe
a particular problem with the operation of the machine.
When following the troubleshooting trees, the service technician will be led through questions
and checks and end up with a probable solution. When using the troubleshooting trees, it is
important that the service technician understand the operation and adjustments of the
components being checked and the component suspected of malfunctioning. A detailed
description of the operation and adjustments of the components as well as other service
information is available in the pages that follow Section C.
Sections D, E, and F focus on a particular system in the ice machine: water distribution system,
refrigeration system, and it is important that these sections be used together with the
Troubleshooting Trees in Section C.
Most aspects of the CCM/CCU Series machines are covered in this manual, however, should
you encounter any conditions not addressed herein, please contact the Cornelius Technical
Service Department for assistance. You may also e-mail the Cornelius Technical Service
Department:
E-Mail: tech.service@Cornelius.com
Website : www.cornelius.com
Telephone Number
800-238-3600 All Departments
Any Service communication must include:
• Model Number
• Serial number
• A detailed explanation of the problem
Note the warning symbol where it appears in this manual.
It is an alert for important safety information on a hazard
that might cause serious injury.
Keep this manual for future reference.
The CCM/CCU Series Service Parts Manuals are available separately.
Cornelius products are not designed for outdoor installation.
Page A2
General Information
Model and Serial Number Format
Sample Data Plate
Note: The date code will change monthly and yearly to reflect the date of manufacture.
The serial number format and machine specifics are
detailed on the data plate.
Model Number
CCM 06 30 A H 1 2
Condenser Type: A=Air, W=Water, R=Remote
Cabinet Width (in inches)
Approximate Production X 10 in 24 hours 70°F Air / 50°F Water
Series: Cornelius Cuber Modular (U=Undercounter)
Large data plate will be placed on the back of the unit.
Serial Number
A 0708 GC 004
87
Sequencial Serial Number
Product Line
GC=Cuber
GB=Remote Condenser
GA= Dispenser
Date Code, Year Month format. (2007
Revision Level (Internal)
Manufacturing Facility
Small data plate will be placed by the service valves
Engineering Rev Level
Voltage:1=115V, 2=230V, 3=230V 3ph 5=50Hz.
Cube Size: H=Half Cube, F=Full Cube
August 08)
.
Page A3
General Information
Electrical and Mechanical Specifications, “CCM/CCU” Series
Cycle Time
Back
Model
CCU0150A1 R-404a 12 60 - 47 205-400 47 24 - 38 3 115-60-1
CCU0150W1 R-404a 9 60 - 47 250 47 22 - 28 3 115-60-1
CCU0220A1 R-404a 12 60 - 42 218-400 42 17 - 24 3 115-60-1
CCU0220W1 R-404a 9 60 - 41 250 41 17 - 20 3 115-60-1
CCU0220A2 R-404a 12 60 - 41 218-400 41 18 - 28 3 230-60-1
CCU0220W2 R-404a 9 60 - 41 250 41 19 - 23 3 230-60-1
CCU0300A1 R-404a 16 51 - 30 218-400 33 15 - 20 3 115-60-1
CCU0300W1 R-404a 13 60 - 27 250 33 12 - 15 3 115-60-1
CCM0330A1 R-404a 25 60 - 35 200 - 400 36 13 - 17 3 115-60-1
CCM0330W1 R-404a 13 60 - 35 250 35 13 - 16 3 115-60-1
CCM0322A1 R-404a 18 60 - 36 200 - 400 36 14 - 25 3 115-60-1
CCM0322W1 R-404a 11 60 - 36 250 36 12 - 17 3 115-60-1
CCM0430A1 R-404a 30 54 - 39 200-400 44 14 - 20 5.5 115-60-1
CCM0430W1 R-404a 14 60 - 38 250 43 14 - 18 5.5 115-60-1
CCM0430A2 R-404a 30 58 - 34 210 - 400 43 14 -19 5.5 208/230-60-1
CCM0430W2 R-404a 14 57 - 37 250 43 14 - 17 5.5 208/230-60-1
CCM0530A1 R-404a 25 55 - 31 217 - 400 37 13 - 16 5.5 115-60-1
CCM0530W1 R-404a 15 48 - 31 250 38 13 - 15 5.5 115-60-1
CCM0530R1 R-404a 132 50 - 32 240 - 400 39 13 - 16 5.5 115-60-1
CCM0522A1 R-404a 21 56 - 39 212 - 400 46 14 - 20 5.5 115-60-1
CCM0522W1 R-404a 12 54 - 39 250 44 14 - 17 5.5 115-60-1
CCM0630A2 R-404a 24 60 - 46 200-400 35 11 - 15 5.5 208/230-60-1
CCM0630W2 R-404a
CCM0630R2 R-404a
CCM0830A2 R-404a 27 60 - 35 175 - 400 35 11 - 18 7 208/230-60-1
CCM0830W2 R-404a 24 60 - 35 250 35 10 - 15 7 208/230-60-1
CCM0830R2 R-404a 176 60 - 35 240 - 400 35 9 - 16 7 208/230-60-1
CCM1030A2 R-404a 34 60 - 37 175 - 400 37 9 - 15 7 208/230-60-1
CCM1030W2 R-404a 24 60 - 37 250 37 9 - 13 7 208/230-60-1
CCM1030R2 R-404a 176 60 - 36 240 - 400 36 9 - 14 7 208/230-60-1
CCM1448A2 R-404a 104 60 - 35 175 - 400 35 11 - 17 11 208/230-60-1
CCM1448W2 R-404a 25 60 - 35 250 35 11 - 16 11 208/230-60-1
CCM1448R2 R-404a 240 60 - 35 192 - 400 35 11 - 17 11 208/230-60-1
CCM1448A2 1 R-404a 60 60 - 35 200 - 400 37 11 - 15 11.6 208/230-60-1
CCM1448W2 1 R-404a 30 60 - 35 250 32 11 - 14 11.6 208/230-60-1
CCM1448R2 1 R-404a 240 60 - 35 240 - 400 38 11 - 15 11.6 208/230-60-1
CCM1448A3 R-404a 104 60 - 35 175 - 400 35 12 - 20 11 208/230-60-3
CCM1448W3 R-404a 25 60 - 35 250 35 12 - 18 11 208/230-60-3
CCM1448R3 R-404a 240 60 - 35 240 - 400 35 12 - 20 11 208/230-60-3
CCM1448A3 1 R-404a 60 60 - 35 200 - 400 37 11 - 15 11.6 208/230-60-3
CCM1448W3 1 R-404a 30 60 - 35 250 34 11 - 13 11.6 208/230-60-3
CCM1448R3 1 R-404a 240 60 - 35 240 - 400 38 12 - 14 11.6 208/230-60-3
CCM1530R2 R-404a 240 60 - 35 240 - 400 35 11 - 16 11 208/230-60-1
CCM1530R2 1 R-404a 240 60 - 35 240 - 400 38 11 - 14 11.6 208/230-60-1
CCM1848W2 R-404a 35 60 - 34 250 34 11 - 17 14 208/230-60-1
CCM1848R2 R-404a 400 60 - 37 240 - 400 37 10 - 17 14 208/230-60-1
CCM1848W2 1 R-404a 37 60 - 53 250 38 11 - 13 14 208/230-60-1
CCM1848R2 1 R-404a 272 72 - 61 240 - 400 38 12 - 15 14 208/230-60-1
CCM1848W3 R-404a 35 60 - 35 250 35 10 - 16 14 208/230-60-3
CCM1848R3 R-404a 400 60 - 35 240 - 400 35 10 - 17 14 208/230-60-3
CCM1848W3 1 R-404a 37 60 - 53 250 38 11 - 13 14 208/230-60-3
CCM1848R3 1 R-404a 272 71 - 63 240 - 400 38 13 - 15 14 208/230-60-3
CCM2148W2 R-404a 37 60 - 35 250 35 9 - 14 14 208/230-60-1
CCM2148R2 R-404a 400 60 - 37 240 - 400 37 9 - 14 14 208/230-60-1
Ref.
Type
Charge
Ounces
17 45 - 40
132 44 - 42 240 - 400 38
Press.
Approx.
Head
Press.
Approx.
250
Timer
Initiate
Setting
34
Approx.
Minutes
70/50-90/70
11 - 13 5.5 208/230-60-1
12 - 15 5.5 208/230-60-1
Batch
Weight
Pounds
Volt. Cycle
Phase
Page A4
General Information
Electrical and Mechanical Specifications, “CCM/CCU” Series
Cycle Time
Back
Model
CCM2148W2 1 R-404a 44 48 - 46 250 34 11 - 12 14 208/230-60-1
CCM2148R2 1 R-404a 272 62 - 56 240 - 400 37 12 - 13 14 208/230-60-1
CCM2148W3 R-404a 37 60 - 35 250 35 9 - 13 14 208/230-60-3
CCM2148R3 R-404a 400 60 - 35 240 - 400 35 9 - 14 14 208/230-60-3
CCM2148W3 1 R-404a 44 49 - 47 250 34 12 - 13 14 208/230-60-3
CCM2148R3 1 R-404a 272 64 - 58 240 - 400 37 12 - 14 14 208/230-60-3
Ref.
Type
Charge
Ounces
Press.
Approx.
Head
Press.
Approx.
Timer
Initiate
Setting
Approx.
Minutes
70/50-90/70
Cycle Time
Back
Model
CCU0220A5 R-404a 12 60 - 35 175 - 400 45 22 - 32 3 220-240/50/1
CCU0220W5 R-404a 9 60 - 35 250 46 21 - 25 3 220-240/50/1
CCU0330A5 R-404a 14 51 - 30 218 - 400 33 15 - 20 3 220-240/50/1
CCU0330W5 R-404a 13 60 - 27 250 33 13 - 18 3 220-240/50/1
CCM0330A5 R-404a 23 60 - 53 200 - 400 32 12 - 16 3 220-240/50/1
CCM0330W5 R-404a 12 48 - 47 250 31 12 - 15 3 220-240/50/1
CCM0322A5 R-404a 22 60 - 35 175 - 400 35 13 - 20 3 220-240/50/1
CCM0430A5 R-404a 23 56 - 31 207-400 38 16 - 22 5.5 220-240/50/1
CCM0430W5 R-404a 13 57 - 34 250 41 14 - 17 5.5 220-240/50/1
CCM0522A5 R-404a 21 55 - 38 200 - 400 46 13 - 18 5.5 220-240/50/1
CCM0630A5 R-404a 22 50 - 40 200 - 400 35 13 - 18 5.5 220-240/50/1
CCM0630W5 R-404a 14 47 - 45 250 32 14 - 16 5.5 220-240/50/1
CCM0630R5 R-404a 132 45 - 43 240 - 400 35 15 - 18 5.5 220-240/50/1
CCM0830A5 R-404a 24 60 - 35 250 35 10 - 14 7 220-240/50/1
CCM0830W5 R-404a 240 60 - 35 240 - 400 35 10 - 17 7 220-240/50/1
CCM0830R5 R-404a 176 60 - 35 240 - 400 35 10 - 17 7 220-240/50/1
CCM1030A5 R-404a 33 60 - 35 175 - 400 35 10 - 17 7 220-240/50/1
CCM1030W5 R-404a 24 60 - 36 250 36 9 - 14 7 220-240/50/1
CCM1030R5 R-404a 176 60 - 35 240 - 400 35 9 - 15 7 220-240/50/1
CCM1448A5 R-404a 104 60 - 35 175 - 400 35 13 - 21 11 220-240/50/1
CCM1448W5 R-404a 25 60 - 35 250 35 12 - 18 11 220-240/50/1
CCM1448R5 R-404a 240 60 - 35 192 - 400 35 14 - 19 11 220-240/50/1
CCM1448A5 1 R-404a 60 60 - 35 200- 400 36 12 - 16 11.6 220-240/50/1
CCM1448W5 1 R-404a 25 60 - 35 250 36 12 - 14 11.6 220-240/50/1
CCM1448R5 1 R-404a 240 60 - 35 240 - 400 39 12 - 15 11.6 220-240/50/1
Ref.
Type
Charge
Ounces
Press.
Approx.
Head
Press.
Approx.
Timer
Initiate
Setting
Approx.
Minutes
70/50-90/80
Batch
Weight
Pounds
Batch
Weight
Pounds
Volt. Cycle
Phase
Volt. Phase
Cycle
Page A5
General Information
Installation Guidelines
Note: Installation should be performed by a Cornelius trained Service Technician.
For proper operation of the Cornelius ice machine, the following installation guidelines must be
followed. Failure to do so may result in loss of production capacity, premature part failures, and
may void all warranties.
Ambient Operating Temperatures
Minimum Operating Temperature: 50°F (10°C)
Maximum Operating Temperature 100°F (38°C), 110°F (43°C) on 50 Hz. Models.
Note: Cornelius products are not designed for outdoor installation.
Incoming Water Supply (See Plumbing Diagram for line sizing Page A7-A12)
Minimum incoming water temperature: 40°F (4.5°C)
Maximum incoming water temperature: 100°F (38°C)
Minimum incoming water pressure: 20 psi (1.4 bar)
Maximum incoming water pressure: 60 psi (4.1 bar)
Note: If water pressure exceeds 60 psi (4.1 bar), a water pressure regulator must be
installed.
Drains: All drain lines must be installed per local codes. Flexible tubing is not recommended.
Route bin drain, purge drain and water condenser drain individually to a floor drain. The use of
condensate pumps for draining water is not recommended by Cornelius. Cornelius assumes no
responsibility for improperly installed equipment.
Water Filtration: A water filter system should be installed with the ice machine.
Clearance Requirements: Self contained air cooled ice machines must have a minimum of 6
inches (15cm) of clearance at the rear, top, and sides of the ice machine for proper air circulation.
Stacking: If the ice machines are to be stacked, refer to the instructions in the stacking kit.
Cornelius does not endorse stacking air-cooled ice machines.
Dispenser Application: A thermostatic bin control kit must be installed if the CCM series ice
machine is placed on a dispenser. A bin top may or may not be required. (Exception is the
CHD22/CHD30 Dispenser)
Electrical Specifications: Refer to the serial plate at the rear of the ice machine or the charts on
page A4 and A5.
Adjustments
Level the machine within 1/8 inch in all directions.
Check the bin control for proper adjustment, Page F9
Check the water in the water trough for proper level, Page D1
Check the ice bridge for proper thickness, Page F4
Check the cam switch adjustment. Page F8
Check the water regulating valve adjustment if water cooled, Page E2
Page A6
General Information
Electrical and Plumbing Requirements: CCU0150 and CCU0220
Note: The CCU0150 and CCU0220 do
not have a splash curtain.
These models utilize a thermostatic
bin control in place of a mechanical
bin switch.
Page A7
General Information
Electrical and Plumbing Requirements: CCU0300 00
Note: The CCU0300 does not have a
splash curtain.
This model utilize a thermostatic bin
control in place of a mechanical bin
switch.
Page A8
General Information
Electrical and Plumbing Requirements: CCM0330, CCM0430, CCM0530, CCM0630, CCM0830
and CCM1030 (30 Inch Wide Cubers)
Page A9
General Information
Electrical and Plumbing Requirements: CCM1448**1, CCM1848**1, CCM2148**1
(48 Inch Wide Cubers)
Page A10
General Information
Electrical and Plumbing Requirements: CCM0322 and CCM0522 (22 Inch Wide Cubers)
Page A11
General Information
Electrical and Plumbing Requirements: CCM1530 Remote
Page A12
General Information
Remote Condenser Installation
For proper operation of the Cornelius ice machine, the following installation guidelines must be followed. Failure to do
so may result in loss of production capacity, premature part failure, and may void all warranties.
Use the following for planning the placement of the remote condenser relative to the ice machine.
Location Limits: Remote condenser location must not exceed ANY of the following:
● Maximum rise from the ice machine to the remote condenser is 35 physical feet.
● Maximum drop from the ice machine to the remote condenser is 15 physical fe et.
● Physical line set maximum length is 75 feet.
● Calculated
● Ambient operating temperatures: -20°F (-28.9°C) to 120°F (48.9°C)
Calculation Formula
● Drop = dd x 6.6 (dd = distance in feet)
● Rise = rd x 1.7 (rd = distance in feet)
● Horizontal Run = hd x 1 (hd = distance in feet)
● Calculation: Drop(s) + Rise(s) + Horizontal Run = dd+rd+hd=Cal culated Line Length
Configurations that do NOT meet these requirements must receive written authorization from
Cornelius. This includes multipass or rack system remote condensers.
Do NOT:
● Route a line set that rises, then falls, then rises.
● Route a line set that falls, then rises, then falls.
Remote Condenser Location:
Limited to a 25, 40, 45, 60 or a 75 foot length of precharged refrigerant tubing connecting the ice machine to the
remote condenser. The remote condenser must be above or level with the ice machine. Select the best available
location, protecting the remote condenser from extremes of dirt, dust and sun. Meet all applicable building codes.
Usually the services of a licensed electrician are required.
Roof Attachment:
1. Install and attach the remote condenser to the roof of the building, using the methods and practices of construction
that conform to the local building codes, including having a roofing contractor secure the remote condenser to the
roof.
2. Have an electrician connect the remote condenser fan motor wires to the ice machine, using the junction box at the
back of the ice machine.
Precharged Line Set Routing
CAUTION: Do not connect the precharged tubing until all routing and forming of the tubing is complete. See
the coupling instructions for connecting information.
1. Each set of precharged tubing refrigerant lines consists of a 3/8 diameter liquid line and a 1/2 inch diameter
discharge line. Both ends of each line have quick connect couplings, one end has a Schrader valve conne ction
which goes to the condenser.
Note: The openings in the building ceiling or wall, listed in the next step, are the minimum sizes recommended for
passing the refrigerant lines through.
2. Have the roofing contractor cut a minimum hole for the refrigerant lines of 2.50 inch. Check local codes, a separate
hole may be required for the electrical power to the condenser.
CAUTION: DO NOT KINK OR CRIMP REFRIGERANT TUBING WHEN INSTALLING IT.
3. Route the refrigerant lines through the roof opening. Follow straight line routing whenever possible. Any excess
tubing MUST remain within the building.
4. Spiral the excess length of precharged tubing inside the building. Use a horizontal spiral to avoid any traps in the
lines.
5. Have the roofing contractor seal the holes in the roof per local codes.
CAUTION: The couplings on the sets of precharged lines are self sealing when installed properly. Carefully
line set length maximum is 100 feet.
follow the instructions in the RC manual.
Page A13
General Information
The following remote ice makers incorporate the mixing valve in the condenser. This configuration allows
up to a 100 foot calculated remote line set run. Reference the diagram below to calculate the maximum 100
foot line set run.
Ice Machine Model Number Remote Condenser Model Number
CCM2148R*1 RC21002C
CCM1848R*1 RC21002C
CCM1448R*1 RC14002C
CCM1530R*1 RC14002C
CCM1030R RC08002
CCM0830R RC08002
CCM0630R RC06002
CCM0530R RC05001
Limitations for remote machines that have the mixing valve mounted in the condenser.
Maximum Rise is 35 feet.
Maximum Drop is 15 feet.
Maximum equivalent run is 100 feet.
Formula for figuring maximum equivalent run is as follows:
Rise x 1.7 + Drop x 6.6 + horizontal run = equivalent run.
Examples: 35 ft. rise x 1.7 + 40 ft. horizontal = 99.5 equivalent feet line run
35 ft. rise
40 ft. horizontal
34 ft. horizontal
10 ft. drop x 6.6 + 34 ft horizontal = 100
equivalent feet line run
Page A14
10 ft. drop
General Information
How the CCM/CCU ice machine works
A general description of how the CMM/CCU series cubers work is given below. The remainder of
the manual provides more detail about the components and systems.
With the ICE/OFF/WASH switch in the ICE position, the compressor, water pump and condenser
fan motor (when applicable) will energize starting the freeze cycle.
During the freeze cycle, water is circulated over the evaporator(s) where the ice cubes are formed.
When the suction pressure has pulled down to the proper cut-in pressure of the timer initiate
(pressure control), the contacts will close and energize the time delay module (timer). See Page
A4-A5 for proper cut-in pressures. At this time the cubes will close to completion.
The remaining portion of the freeze cycle is determined by the timer setting. The timer is pre-set at
the factory to achieve the proper ice bridge thickness but may need to be adjusted upon initial
start-up, see Page F4 for initial timer settings.
Once the amount of time on the timer has passed, the control relay will be energized and the
machine will enter harvest. Power is now supplied to the water purge valve, hot gas valve, and the
harvest motor. The water purge valve opens, and allows the water pump to purge the water
remaining in the water, removing impurities and sediment. This allows the machine to produce
clear ice cubes and keep mineral build up at a minimum. The hot gas solenoid opens allowing hot
gas to go directly to the evaporator, heating the evaporator and breaking the bond between the
evaporator and the ice slab.
The harvest assist motor, which is also energized during harvest, turns a slip clutch, which pushes
a probe against the back of the ice slab. Once the evaporator has reached approximately 40°F
(4.5°F) in temperature, the slip clutch overcomes the bonding of the ice to the evaporator and
pushes the slab of ice off of the evaporator and into the storage bin. The clutch also actuates a
switch that rides on the outer edge of the clutch. When the clutch completes one revolution, the
switch is tripped and the machine enters the next freeze cycle.
When ice drops into a full bin during harvest, the splash curtain is held open which activates a bin
switch shutting the machine off. When ice is removed from the bin, the splash curtain will close
and the machine will come back on.
Page A15
General Information
Undercounter Bin Removal-CCU0300 Series
The storage bin can be removed by:
1 Remove the lower grill.
2. Remove two screws securing bin to cabinet base.
3. Remove the thumbscrews from the back wall of the bin. 3. Remove the thumbscrews from the back wall of the bin.
4. Disconnect bin drain. 4. Disconnect bin drain.
5. Lift front of bin slightly and pull bin forward to remove. 5. Lift front of bin slightly and pull bin forward to remove.
3
2
Page A16
General Information
Undercounter Bin Removal-CCU0150/0220 Series
The storage bin can be removed by:
1. Remove the two screws at the rear of the top panel.
2. Remove the two screws from the front panel.
3. Remove two screws securing bin to cabinet base.
4. Disconnect bin drain.
5. Lift front of bin slightly and pull bin forward to remove.
1
2
4
5
3
Page A17
Scheduled Maintenance
Maintenance
Note: Maintenance should be performed by a Cornelius trained Service Technician.
Electrical shock and/or injury from moving parts inside this
machine can cause serious injury. Disconnect electrical
supply to machine prior to performing any adjustments or
repairs.
Failure to perform the required maintenance at the frequency specified will void warranty coverage
in the event of a related failure. To insure economical, trouble free operation of the machine, the
following maintenance is required every 6 months.
Maintenance Procedure
1. Clean the ice-making section per the instructions below. Cleaning should be performed a
minimum of every 6 months. Local water conditions may require that cleaning be performed more
often.
2. Check ice bridge thickness. See page F4 for proper thickness and adjustment procedure.
3. Check water level in trough. See page D1 for proper water level and adjustment.
4. Clean the condenser (air-cooled machines) to insure unobstructed air flow.
5. Check for leaks of any kind: Water, Refrigerant, Oil, Etc.
6. Check the bin switch for proper adjustment. See page F9 for bin switch adjustment.
7. Check the cam switch adjustment. See page F8 for cam switch adjustment.
8. Check the water valve (water-cooled machines) for proper adjustment. See page E2.
9. Check all electrical connection.
10. Oil the fan motor if the motor has an oil fitting. (Self contained air-cooled models only)
Cleaning and Sanitizing
1. Harvest problems may occur if the following procedures are not performed every 6 months.
2. Remove the ice machine front panel.
3. Make sure that all the ice is off of the evaporator. If ice is being made, wait for cycle
completion, then turn the machine “OFF” at the ICE/OFF/WASH selector switch.
4. Remove or melt all ice in the storage bin.
Page B1
Scheduled Maintenance
Cleaning and Sanitizing (continued)
5. Add recommended amount of approved Nickel Safe ice machine cleaner to the water trough
according to label instructions on the container.
6. Initiate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “WASH”
position. Allow the cleaner to circulate for approximately 15 minutes to remove mineral
deposits.
7. Depress the purge switch and hold until the ice machine cleaner has been flushed down the
drain and diluted by fresh incoming water.
8. Terminate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “OFF”
position. Remove the splash curtain and inspect the evaporator and water spillway to assure all
mineral residue has been removed.
9. If necessary, wipe the evaporator, spillway and other water transport surfaces with a clean soft
cloth to remove any remaining residue. If necessary, remove the water distribution tube,
disassemble and clean with a bottlebrush, see page D2. Reassemble all components and
repeat steps 4 through 7 as required to remove residue.
10. Turn OFF ice machine water supply and clean the water trough thoroughly to remove all scale
or slime build-up. If necessary, remove the water trough to reach all splash areas and float.
11. Prepare 1½ to 2 gallons (5.7 to 7.5 liters) of approved (EPA/FDA) sodium hypochloride food
equipment sanitizer to form a solution with 100 to 200 ppm free chlorine yield.
12. Add enough sanitizing solution to fill the water trough to overflowing and place the
ICE/OFF/WASH switch to the “WASH” position and allow circulation to occur for 10 minutes
and inspect all disassembled fittings for leaks. During this time, wipe down all other ice
machine splash areas, plus the interior surfaces of the bin, deflector and door with the
remaining sanitizing solution. Inspect to insure that all functional parts, fasteners, thermostat
bulbs (if used), etc. are in place.
13. Depress the purge switch and hold until sanitizer has been flushed down the drain. Turn ON
the ice machine water supply and continue to purge to the diluted sanitizing solution for another
1 to 2 minutes.
14. Place the ICE/OFF/WASH switch to the “ICE” position and replace the front panel.
15. Discard the first two ice harvests.
Page B2
Winterizing Procedures
Winterizing Procedures
Important!
Whenever the ice machine is taken out of operation during the winter months, the procedure below
must be performed. Failure to do so may cause serious damage.
1. Turn off water to machine.
2. Make sure all ice is off of the evaporator(s). If ice is being made, initiate harvest or wait for
cycle completion.
3. Place the ICE/OFF/WASH switch to the “OFF” position.
4. Disconnect the tubing between the water pump discharge and water distribution tube.
5. Drain the water system completely.
6. On water cooled machines, hold the water regulating valve
open by prying upward on the water valve spring with a
screwdriver while using compressed air to blow all the water out
of the condenser.
7. Remove all of the ice in the storage bin and discard.
Page B3
Cabinet Care
Cleaning stainless steel
Commercial grades of stainless steel are susceptible to rusting. It is important that you properly
care for the stainless steel surfaces of your ice machine and bin to avoid the possibility of rust or
corrosion. Use the following recommended guidelines for keeping your stainless steel looking like
new:
1. Clean the stainless steel thoroughly once a week. Clean frequently to avoid build-up of
hard, stubborn stains. Also, hard water stains left to sit can weaken the steel's corrosion
resistance and lead to rust. Use a nonabrasive cloth or sponge, working with, not across, the
grain.
2. Don't use abrasive tools to clean the steel surface. Do not use steel wool, abrasive sponge
pads, wire brushes or scrapers to clean the steel. Such tools can break through the "passivation"
layer - the thin layer on the surface of stainless steel that protects it from corrosion.
3. Don't use cleaners that use chlorine or chlorides. Don't use chlorine bleach or products like
Comet to clean the steel. Chlorides break down the passivation layer and can cause rusting.
4. Rinse with clean water. If chlorinated cleansers are used, you must thoroughly rinse the
surface with clean water and wipe dry immediately.
5. Use the right cleaning agent. The table below lists the recommended cleaning agents for
common stainless steel cleaning problems:
Cleaning Activity Cleaning Agent Method of Application
Routine cleaning Soap, Ammonia, Windex, or Apply with a clean cloth
detergent with water. or sponge. Rinse with
Fantastik, 409 Spic’nSpan clean water and wipe dry.
Liquid are also approve for
Stainless Steel.
Removing grease or Easy-Off or similar oven Apply generously, allow
fatty acids cleaners. to stand for 15-20 minutes.
Rinse with clean water.
Repeat as required.
Removing hard water spots Vinegar Swab or wipe with clean cloth.
and scale. Rinse with clean water and
dry.
Page B4
Troubleshooting Trees
How To Use The Troubleshooting Trees
The troubleshooting trees were developed to be used in conjunction with the service information in
the sections that follow. If used together as intended, these two parts of the manual will allow the
ice machine service technician to quickly diagnose many of the problems encountered with the ice
machines. When used as designed, the troubleshooting trees can lead you from a general
symptom to the most likely component to suspect as the cause of the problem. The trees are not
designed to be “parts changer guides”: please do not use them as such.
Components returned to the factory for warranty are tested by the factory and will not be covered
under the warranty policy if they are not defective.
The troubleshooting trees are made of three types of boxes:
QUESTION boxes (Circle) ask a yes/no question and the answer will lead to either another
question box, a check box or a solution box.
CHECK boxes (Rectangle) will suggest a point to check for proper operation, and will often refer
you to a page in the service information sections of this manual. The result of the check may lead
to another box, or a solution box.
SOLUTION boxes (Hexagon) suggest the most likely component to cause the malfunction
described in the heading of the tree. When reaching a solution box, DO NOT immediately assume
the component is defective. The final step is to verify that the component is indeed defective, by
using the service information in the sections that follow.
To use the troubleshooting trees, first find the page with the heading describing the type of
problem occurring. Begin at the top of the page and follow the tree, step-by-step. When a check
box is reached, it may be necessary to refer to another section in the manual.
Once a solution box is reached, refer to the appropriate section to verify that the component in the
solution box is, indeed, the problem. Adjust, repair or replace the component as necessary.
?
9
!
Page C1
Troubleshooting Trees
Troubleshooting Trees Table Of Contents
Machine Does Not Run C3
Machine Runs, Does Not Make Ice C4 – C5
Slow Production (Cube Formation Good) C6
Low Suction Pressure C7
High Suction Pressure C8
Cubes Are Hollow C9
Uneven Bridge Thickness C10
Ice Bridge Thickness Varies Cycle To Cycle C11
Machine Produces Cloudy Ice C12
Poor Water Distribution Over Evaporator C13
Machine Does Not Enter Harvest C14
Machine Enters Harvest, Then Returns To Freeze Prematurely C15
Length Of Harvest Excessive C16
Ice Does Not Release From Evaporator C17
Hot Evaporator, Low Suction Pressure (Remote Only) C18
Page C2
Troubleshooting Trees
K
K
Machine Does Not Run
Is the selector
switch set to
ICE?
NO
Set selector
Switch to the
ICE position
YES NOT OK
Check for correct
power supply to the
Pressure Safety
Temperature Safety
machine
Check High
Control
Check High
Control
OK
TRIPPED
OK
OPEN
Correct field
wiring deficiency
Reset and
identify reason
for high head
pressure
Replace or
identify reason
for being open.
OK
Check Bin Control
for proper
adjustment, see
page F9
GOOD
Is this a Remote
unit?
OK
Is the Liquid line
Solenoid energized
and open?
BAD
NO
O
NOT O
Adjust as
required or
replace if
defective
Selector Switch
could be
defective, see
page F1
Find reason for
non-activity or
replace if
defective
Page C3
Troubleshooting Trees
Machine Runs, Does Not Make Ice
Is water
running over
the
evaporator?
NO
Go to the
Troubleshooting
Tree on page
C12
Check High
Pressure reset if
necessary
YES GO TO PAGE C5
Check for power to
the compressor
YES
Is the
compressor
running?
NO
GOOD
bad contactor or coil.
contactor coil
OK
Does the unit
have a remote
condenser?
Check contactor for
Replace if defective
Compressor or
Start
Components
could be
defective, see
page F2
OK
Continue if the
machine has a
remote
condenser
OK
Check the suction
pressure, is it low or
high?
LOW
Check refrigerant
charge
HIGH
OK
OK
NO
Check Selector
Switch,
Replace if defective
Pumpdown
Control possibly
bad
Liquid Line
Solenoid not
opening
Page C4
Troubleshooting Trees
Machine Runs, Does Not Make Ice (continued)
Is water
leaking out of
the Purge
Drain or Water
Trough?
YES
Repair water
leakage defect
NO
Check refrigerant
pressures, see page
E1
LOW SUCTION OK
Recover and weigh
in refrigerant charge
OK
Low side
restriction or
defective TXV
HIGH OR NORMAL
SUCTION
If head pressure is
also high, make sure
Condenser is clean
and machine has
good air flow
Check Hot Gas
Valve for leakage
during freeze, see
page E5
OK
Check for inefficient
Compressor
Page C5
Troubleshooting Trees
K
Slow Production (Cube Formation Good)
Does
installation
meet
guidelines?
Correct any
installation
defects
NO
YES
Check for excessive
head pressure
TOO HIGH
Is this unit air
cooled or
water cooled?
AIR
Condenser
OK
Is the Air
clean?
Check refrigeration
system, Section E
YES
Check refrigeration
system, Section E
NO
WATER
Check Water
Regulating Valve,
See page E2
O
See Condenser
service information
page E2
NOT OK
Clean
Condenser and
Condenser Fan
Blade
Adjust or
replace Water
Regulating
Valve
Page C6
Troubleshooting Trees
Low Suction Pressure
Does
installation
meet
guidelines?
YES
Is the water
flow over the
Evaporator
correct?
YES
Check for correct
head pressure, see
page E10
NOT OK
NO
NO
Is the
machine a
remote unit?
YES
NO
Correct
deficiency in
installation
Go to
Troubleshooting
Tree on page
C12
Low charge,
locate and
repair leak,
evacuate and
recharge
system
OK
Check TXV for
moisture based
restriction
WET SYSTEM
Replace drier,
evacuate and
recharge
system
See
Troubleshooting
Tree page C18
DRY SYSTEM NOT OK
Check for refrigerant
tubing restriction,
Check Evaporator
coil separation, see
crimps, etc.
OK
NOT OK
page E4
OK
TXV possibly
defective, see
page E3 and
page E4
Correct
restricted tubing
Replace
defective
Evaporator
Page C7
Loading...