Cornelius COR12VM Service Manual

®

VISUAL MERCHANDISERS

COR7VM, COR12VM, COR17VM, COR23VM,

COR35VMSD, COR45VMSD, COR49VMD, COR67VMST

Service Manual

Release Date: May 24, 2005

Publication Number: 630460243SER

Revision Date: NA

Revision: A

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

for all your Literature needs.

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.

Copyright © 2005, All Rights Reserved, IMI Cornelius, Inc.

Visual Merchandiser Service Manual

TABLE OF CONTENTS

Features of the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Cleaning and Preventive Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Fluorescent Lamp and Ballast Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Ballast Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Required tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To remove the ballast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

To replace the fluorescent lamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Temperature Control Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Required tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

To remove the temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Evaporator Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

To disconnect the evaporator fan motor electrical terminals . . . . . . . . . . . . . . . 10

To remove the evaporator fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condensing Unit Fan Motor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To pull out the condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

To replace the condensing unit fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Starting Relay, Overload Protector, and Start Capacitor Replacement . . . . . . . . . 17

Required tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

To pull out the condensing unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

To remove the electrical box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

To replace the relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

To replace the overload protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

To replace the starting capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

To install the electrical box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Door and Spring Hinge System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

To remove the motor cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

To remove the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

To install the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

To assemble spring hinge components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Glass Door Pane Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To remove the motor cover and door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Required tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To remove the glass door pane . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

To install the door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Starter relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

© 2005, IMI Cornelius Inc. - i - Publication Number: 630460243SER

Visual Merchandiser Service Manual

Thermal protector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condenser . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

Condenser fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Evaporator fan motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Capillary tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Drier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Accumulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Temperature control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Cooling cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

The Refrigeration Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Wiring Diagram 115 V/60 Hz/1 Phase . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Possible causes and solutions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Publication Number: 630460243SER - ii - © 2005, IMI Cornelius Inc.

FEATURES OF THE UNIT

Fluorescent interior light

Visual Merchandiser Service Manual

Heavy duty hinges

Strong body with 1 3/4”

thick walls, injected with

CFC-free polyurethane

foam

Forced-air evaporator
for quick temperature

pull down

NSF compliant

interior cabinet

Heavy duty R-134a

condensing unit with zero

maintenance condenser

Double-pane low-e glass
door for high ambient
conditions

Durable PVC frame

Exterior cabinet made of
galvanized, pre-painted
steel, with baked polyester
paint

Reinforced heavy-duty
shelves

Reinforced, 16-gauge,
galvanized steel base

FIGURE 1

CLEANING AND PREVENTIVE MAINTENANCE

Weekly or sooner, as required:

1. Disconnect the power source before cleaning. Remove all products and place in a proper cooler.

2. Clean the interior and exterior with a mild soap or detergent solution and then rinse with a warm

baking soda solution (one cup of baking soda to one gallon of warm water). Dry the interior

completely before replacing products.

3. Clean the condenser unit periodically by vacuuming the unit compartment, especially the

condenser unit coil (it looks like a small auto radiator). If the condenser coil has accumulated dirt
and grease (possible in heavy traffic areas or a kitchen), use a strong cleaning solution. If you find
any oil in the condensing unit compartment, call a qualified service person immediately.

4. Empty out and clean the drain pan located next to the condensing unit as required. Check regularly

for excessive water accumulation.

5. Plug in the cabinet and wait until the proper temperature is achieved before reloading the cabinet

with product.

© 2005, IMI Cornelius Inc. - 1 - Publication Number: 630460243SER

Visual Merchandiser Service Manual

FLUORESCENT LAMP AND BALLAST REPLACEMENT

CAUTION - Make sure the power supply is

turned off before making any electrical
repairs.

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source
of trouble and making the necessary repairs.

To remove the motor cover

1. Open the door.

2. Use a #2 Phillips screwdriver to remove the flat-head screw
holding condensing the unit motor cover.

3. Remove the condensing unit motor cover by pulling it up and out.

FIGURE 2

FIGURE 3

FIGURE 4

Publication Number: 630460243SER - 2 - © 2005, IMI Cornelius Inc.

BALLAST REPLACEMENT

Required tool

• one #2 Phillips screwdriver with a 4” long blade

To remove the ballast

1. Push down with your fingers on the plastic tabs that hold the male and female connectors in
position. Then pull out the male connector (connected to the ballast).

Visual Merchandiser Service Manual

FIGURE 5

2. Use a Phillips screwdriver to remove the single screw holding the ballast to the metal bracket. The
ballast sits on a metal bracket to make replacement easier.

FIGURE 6

© 2005, IMI Cornelius Inc. - 3 - Publication Number: 630460243SER

Visual Merchandiser Service Manual

3. To remove the ballast, lift the ballast wires over the metal bracket which holds the back end of the
ballast.

4. To reinstall a new ballast reverse steps 1 through 3.

FIGURE 7

To replace the fluorescent lamp

1. Pull one end of the lamp holder base half way out.

2. Pull the other end of the lamp holder base half way out.

FIGURE 8

FIGURE 9

Publication Number: 630460243SER - 4 - © 2005, IMI Cornelius Inc.

3. Once the two bases have been pulled half way out, use both
hands to pull out the entire lamp assembly

4. Remove the lamp holder bases from each end of the lamp.

Visual Merchandiser Service Manual

FIGURE 10

FIGURE 11

5. Remove the plastic cover from the lamp. Now you can
replace the lamp.

6. To install a new lamp, reverse steps 1 through 5.

FIGURE 12

© 2005, IMI Cornelius Inc. - 5 - Publication Number: 630460243SER

Visual Merchandiser Service Manual

TEMPERATURE CONTROL REPLACEMENT

CAUTION - Make sure the power supply is

turned off before making any electrical
repairs.

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source
of trouble and making the necessary repairs.

Required tool

• one #2 Phillips screwdriver with a 4” long blade

To remove the temperature control

1. Remove the two Phillips head screws that hold the
temperature control mounting plate (located on the baffle).

FIGURE 13

With the temperature control mounting plate removed from the baffle, you can see the thermostat,
light, and fan motor connectors.

Evaporator fan motor connections

Fluorescent lamp connections

Temperature control connections

FIGURE 14

Publication Number: 630460243SER - 6 - © 2005, IMI Cornelius Inc.

Visual Merchandiser Service Manual

2. Disconnect the electrical connections from the temperature
control.

FIGURE 15

3. Carefully pull the bulb sensor out of the temperature control well. There is a patch of permagum at
the opening of the well which seals the bulb sensor from humidity.

Temperature control sensing bulb

Temperature control well

FIGURE 16

© 2005, IMI Cornelius Inc. - 7 - Publication Number: 630460243SER

Visual Merchandiser Service Manual

The bulb sensor has a slight curve to make a tight fit inside
the temperature control well.

4. Remove the temperature control knob by pulling it outward.

FIGURE 17

5. Use a Phillips screwdriver to remove the two Phillips head
screws the hold the temperature control to its mounting
plate.

FIGURE 18

FIGURE 19

Publication Number: 630460243SER - 8 - © 2005, IMI Cornelius Inc.

6. With the two Phillips head screws removed, you can now
install a new temperature control by reversing steps 1
through 5.

Visual Merchandiser Service Manual

FIGURE 20

EVAPORATOR FAN MOTOR REPLACEMENT

CAUTION - Make sure the power supply is

turned off before making any electrical
repairs.

If any electrical problems arise, a wiring diagram is included with each cabinet to aid in tracing the source
of trouble and making the necessary repairs.

Required tools

To replace the evaporator fan motor, you need:

• one #2 Phillips screwdriver with 4” blade

• one side-cutting pliers

• one 1/4” socket screwdriver

© 2005, IMI Cornelius Inc. - 9 - Publication Number: 630460243SER

Visual Merchandiser Service Manual

To disconnect the evaporator fan motor electrical terminals

1. Remove the two Phillips head screws that hold the
temperature control mounting plate (located on the baffle).

With the temperature control mounting plate removed from the baffle, you can see the thermostat, light,
and fan motor connectors.

Evaporator fan motor connections

FIGURE 21

FIGURE 22

2. Disconnect the fan motor electrical connector.

Fluorescent lamp connections

Temperature control connections

FIGURE 23

Publication Number: 630460243SER - 10 - © 2005, IMI Cornelius Inc.

3. Remove the rubber grommet, located in the plastic bushing near at the right air diffuser.

To remove the evaporator fan motor

1. Use a Phillips screwdriver to remove the four screws holding
the evaporator fan grill at the baffle.

Visual Merchandiser Service Manual

FIGURE 24

2. Remove the fan blade. Use the side-cutting pliers to
unscrew the nut-type washer that holds the fan motor in
place.

FIGURE 25

FIGURE 26

© 2005, IMI Cornelius Inc. - 11 - Publication Number: 630460243SER

Visual Merchandiser Service Manual

3. Pass the electrical wire of the motor through the plastic bushing on the air diffuser.

4. Use a Phillips screwdriver to remove the four screws holding the base of the fan motor to the top of
the internal cabinet.

Plastic bushing on the air diffuser

FIGURE 27

Four Phillips head screws

FIGURE 28

5. Use a 1/4” socket screwdriver to remove the three socket head screws holding the fan motor to its
base.

Three socket head screws

FIGURE 29

6. Replace the fan motor with another of the same model. Reinstall the fan motor by reversing steps 1
through 5.

Publication Number: 630460243SER - 12 - © 2005, IMI Cornelius Inc.