Cornelius WM600, CM600 Service Manual

ICE MAKER - WM600 AND CM600

Service Manual

Release Date: March 11, 2004

Publication Number: 630460082SER

Revision Date: March 18, 2014

Revision: C

Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

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 possi
ble 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.

This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is sub­ject to all of the restrictions and limitations contained in the Commercial Warranty.

Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
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 per
sons 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.

Contact Information:

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

www.cornelius-usa.com

800-238-3600

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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.

CORNELIUS INC

101 Regency Drive

Glendale Heights, IL

Tel: + 1 800-238-3600

Printed in U.S.A.

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 Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Remove Ice Maker From Carton: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

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

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

Water Inlet Hook–up: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

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

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

Initial start up, checks and adjustment instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Guide to Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Ice maker cleaning and sanitizing procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

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

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

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

Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

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

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

Purpose of Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

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

To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ice Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Refrigeration Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Refrigeration system adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Temperature / Pressure Chart* . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condenser Modulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condenser Modulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Troubleshooting Gear Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

The Gearmotor Will Not Run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

The Gearmotor Starts but Trips Repeatedly On The Overload Protector . . . . . . . . . . . . . . . . . 13

The Motor Runs but Output Shaft Does not Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Overload Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Motor Check: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Installation and Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Auger & Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

To Replace Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Guide to Good Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Ice Maker Service Manual

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DANGER:

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WARNING:

CAUTION:

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WARNING:

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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.

Publication Number: 630460082SER - 1 - © 2004-2014, Cornelius Inc.

Ice Maker Service Manual

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WARNING:

CAUTION:

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CAUTION:

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CAUTION:

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CAUTION:

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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.

Very high discharges pressure is present in system. Quick disconnects on your gages will minimize danger and loss
of refrigerant.

Unit requires separate electrical line. See instruction manual for proper fuse size.

There must be adequate clearance around ice maker. Allow minimum 6” air intake and 4” air exhaust for air
exhaust and panel removal.

NOTE: Unit must be installed per local plumbing and electrical codes. See Installation manual for
unit requirements. Failure to do so may cause damage to unit, which would void unit warranty.

NOTE: Using any parts other than genuine factory manufactured parts relieves the manufacturer
of all liability.

NOTE: Manufacturer reserves the right to change specifications at any time.

© 2004-2014, Cornelius Inc. - 2 - Publication Number: 630460082SER

Ice Maker Service Manual

GENERAL INFORMATION

SPECIFICATIONS

Model WM (Wall Model) 600 and CM (Counter Model) 600

Compressor 3/4 H.P. (R404 Refrigerant)

Voltage 115 VAC, 60 Hz, Single Phase

Current Draw 16 Amps

Circuit Breaker or Fuse Size 20 Amp Maximum Time Delay

DESCRIPTION

Models WM600 and CM600 Ice Makers are self-contained wall mount and counter style Units which automatically
make hard compressed-style ice and store it in a sealed hopper for sanitary dispensing.

INSTALLATION INSTRUCTIONS

IMPORTANT: An Ever pure Model 9320 – 42 Systems IV Model DB900 ice maker quality water
treatment unit MUST BE INSTALLED in the water supply line to the Ice Maker. Failure to do so may
result in poor quality ice, low production output, and may cause premature failure of the Ice Maker
evaporator and void the extended evaporator warranty.

This Ice Maker is provided with a stainless–steel evaporator designed to last the life of the product. But,
some of the chemicals in treated and untreated water, specifically chlorine and sulphur (sulphide), have the
ability to attack stainless–steel and cause premature failure. An initial investment in proper water treatment
will pay for itself in increased production, quality, and long life of the product.

REMOVE ICE MAKER FROM CARTON:

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

2. Locate the Startup Card either on the outside of the container or on the plastic liner. Fill in the proper informa­tion and send one copy to the factory and the other copy to the Distributor. The postage is prepaid.

CABINET REMOVAL

1. Unscrew and remove the front panels for electrical and start–up access.

2. Remove shipping tape from the storage hopper cover and the agitator in storage hopper.

PREPARATION OF INSTALLATION SITE

1. For maximum efficiency and ice output, select a location for your ice maker where it will not be exposed to sun­light, excessive heat or reflected radiation (preferably in a room with a temperature of 70° F to 80° F). The ice­maker normally will not function properly in temperatures below 65° F. The area surrounding the ice maker
should be well ventilated. (Consult ???? for proper airflow clearance). WM600 – Two (2) mounting brackets are
supplied for securing the Unit to a wall.

CM600 – Consult Figure 1B and 1C for dimensions for mounting the Unit to the counter. Note that the Unit must be

level for proper operation.

2. The Unit must be sealed to the counter. Locate the desired position for the Unit, then mark the outline dimen­sions on the counter.

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Ice Maker Service Manual

3. Apply a continuous bead of NSF listed silastic sealant (Dow 732 or equal) approximately 1/4–inch inside of the
Unit outline dimensions. Then, position the Unit on the counter within the outline dimensions. All excess seal­ant must be wiped away immediately.

IMPORTANT: The WM600 with a full ice storage hopper weighs 450 pounds. Make sure that the
mounting surface is adequately reinforced to support this weight.

The mounting hole dimensions for the brackets are shown in Figure 1 Use these dimensions to locate the Unit at the
desired height on the wall.

IMPORTANT: Provide support for the Unit until all eight (8)–mounting bolts are installed. Do not hang
the Unit from the top mounting angle bracket only while installing the lower angle.

WATER INLET HOOK–UP:

1. Water Inlet – The fitting is a 1/4”–in. compression fitting located at the bottom of the Unit. Connect water sup­ply with a 1/4–inch or larger copper or flexible tubing.

2. Water Pressure – Unless otherwise specified, the Unit is designed to operate on a water pressures between
10 P.S.I. and 90 P.S.I. (NOTE: for pressures above 90 P.S.I; a water pressure regulator must be installed).

3. Water Cooled Condensers – The inlet uses a 3/8–inch compression fitting. Use a separate 3/8–inch or larger
water line.

4. Filters – Filter Conditioners are recommended on supply lines to the Ice Makers. Never run the water supply to
the water cooled condenser through a Filter/Conditioner. It uses up the cartridge unnecessarily and a saturated
cartridge can starve the Ice Maker causing premature component damage. Separate water supplies are rec­ommended.

WM600 – Connect a 1–1/4 inch IPS (or equal) drain line to the 1–1/4 inch diameter P–trap at the lower bottom of
the Unit. The line must pitch downward to an open drain and must contain no traps or improper drainage will
result.

CM600 – Connect two (2) 3/4–inch IPS (or equal) drain lines to the 3/4–inch threaded drain connections at the
lower rear of the Unit. These lines must pitch downward to an open drain and must contain no traps or improper
drainage will result. For water–cooled Units, a third 3/4–inch FPT drain fitting is provided for the condenser drain
(see Figure 1B).

NOTE: The Unit must be installed per local plumbing codes.

ELECTRICAL SUPPLY

1. Power Access – Is provided by way of a 7/8–inch diameter hole located on the lower left side of the Unit.
Route incoming power in conduit, to the Ice Maker electrical control box. Make connections to wires provided in
the control box and the ground lug/screw.

2. Fused Line – Should be a dedicated circuit checked and sized according to the electrical rating shown on the
Unit nameplate.

NOTE: The Unit must be installed per local electrical codes.

AUGER ENGAGEMENT

Be certain that the auger is fully engaged to the lower drive and that the extruding head is fully engaged to the
evaporator.

© 2004-2014, Cornelius Inc. - 4 - Publication Number: 630460082SER

Ice Maker Service Manual

INITIAL START UP, CHECKS AND ADJUSTMENT INSTRUCTIONS

NOTE: Do not start the Unit before completing the previous Installation steps.

Turn on the water supply and main power switch (located on top of the electrical box).

NOTE: If the Unit will not start, be sure the water reservoir is full. The low water safety control must
be properly adjusted to start and shut down the Unit. If the water level drops below the bottom of
the reservoir, the Unit must shut down. Adjustment is made by moving the magnet up or down.

Figure 1. Float Adjustment

Water Level Control Adjustment – If necessary, adjust the float by bending the float arm up or down as

needed. Push the float assembly down until the Unit stops running. Release the float and the Unit will

restart. Keep water in the reservoir at the level line while the Unit is in operation (See Figure 1).

Low Water Safety Control – Adjust the magnet by bending the magnet arm as shown in Figure 1 to shut down the

Unit if the water level drops below the line on the side of the reservoir.

Bin Control – Remove four clips from top of the bin cover and lift cover so the bin control switch can be manually lifted
until the Unit shuts down. Release the plate and unit will restart

Dispense Switch and Mechanism – By depressing the dispense switch, the dispense mechanism door on the
storage bin will open, and the agitator will rotate counterclockwise.

NOTE: If any of these checks or adjustments cannot be achieved, refer to Troubleshooting Section
of this manual or call our Technical Support Center for assistance.

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