Cornelius IMD302-15A, IMD301-30A, IMD300-30A, IMD300-30W, IMD302-30A Installation Manual
...
COUNTERTOP ICE MAKER
IMD Series - Installation Manual
Release Date: March 12, 2004
Publication Number: 638085277INS
Revision Date: February 10, 2015
Revision: F
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
-
-
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
Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Remove Ice maker from Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Cabinet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Preparation of Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Water Inlet Hook-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Initial Start Up, Checks & Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Guide To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Ice maker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Purpose of Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Ice Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigeration System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Shaft Seal Installation and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Auger & Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Installation and Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Upper Nut and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
To Replace Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Troubleshooting Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Troubleshooting Gear Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
The Gear motor will not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
The Gear motor Starts but Trips Repeatedly on the Overload Protector . . . . . . . . . . . . . . . . . .16
The Motor Runs but Output Shaft does not Rotate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Guide To Good Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .20
Countertop Icemaker IMD Series Installation 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.
© 2004-2015, Cornelius Inc. - 1 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
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WARNING:
CAUTION:
!
CAUTION:
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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.
Publication Number: 638085277INS - 2 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
SHIPPINGWT.189LBS.(APPROX.)
GENERAL INFORMATION
SPECIFICATION CHART
Models
IMD300-15A Air Cooled 115 60 1 6 0.82 2 12 R134a 15
IMD302-15A Air Cooled 220/240 50 1 3 .5 1.6 12 R134a 15
IMD300-30A Air Cooled 115 60 1 10.5 1 2 25 R404A 20
IMD300-30W Water Cooled 115 60 1 10.1 N/A 2 13 R404A 20
IMD301-30A Air Cooled 208/230 60 1 5.7 1 1.6 28 R404A 20
IMD301-30W Water Cooled 208/230 60 1 5.7 N/A 1.6 13 R404A 20
IMD302-30A Air Cooled 220/240 50 1 5.3 0.5 1.6 28 R404A 20
IMD302-30W Water Cooled 220/240 50 1 5.3 N/A 1.6 13 R404A 20
IMD600-30A Air Cooled 115 60 1 14.6 1 2 25 R404A 20
IMD600-30W Water Cooled 115 60 1 12 N/A 2 14 R404A 20
IMD601-30A Air Cooled 208/230 60 1 7.7 1 1.6 28 R404A 20
IMD601-30W Water Cooled 208/230 60 1 7.7 N/A 1.6 14 R404A 20
IMD602-30W Water Cooled 220/240 50 1 8.2 N/A 1.6 14 R404A 20
IMD600-90A Air Cooled 115 60 1 14.6 1 2 20 R404A 25
IMD600-90W Water Cooled 115 60 1 12 N/A 2 14 R404A 20
IMD601-90A Air Cooled 208/230 60 1 7.7 1 1.6 24 R404A 20
IMD601-90W Water Cooled 208/230 60 1 7.7 N/A 1.6 14 R404A 20
IMD602-90A Air Cooled 220/240 50 1 8.2 0.5 1.6 24 R404A 20
IMD602-90W Water Cooled 220/240 50 1 8.2 N/A 1.6 14 R404A 20
Condensing
it
Un
VAC Hz Ph
Comp
RLA
Fan Amps
Grmtr
ps
Am
Refrigerant
Oz. Type
Circuit
Fuse
NOTE: For Units Not Listed in Above Chart, Refer to Nameplate or contact Factory Service.
© 2004-2015, Cornelius Inc. - 3 - Publication Number: 638085277INS
Figure 1. Dimension Drawing (15 lb.) IMD 300-15
Countertop Icemaker IMD Series Installation Manual
4.98”
0.37”
Figure 2
. Dimension Drawings (30 lbs.) IMD 300-30 and IMD 600-30
Figure 3. Dimension Drawings (90 lbs.) IMD 600-90
Publication Number: 638085277INS - 4 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
INSTALLATION INSTRUCTIONS
REMOVE ICE MAKER FROM CARTON
1. 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.
2. Locate Startup Card either on outside of container or on plastic liner. Fill in proper information and send one
copy to factory, and other copy to Distributor. Postage is prepaid.
CABINET REMOVAL
1. Locate and remove the (2) screws from under the front cover. Lift cover forward and up to remove.
2. Lift up front edge of top cover. Slide back about 1/2 inch and remove.
3. Remove (6) screws from the front of the machine.
4. Remove side panels by sliding the front edge out and then back slightly to disengage.
5. Remove the front splash panel by lifting slightly to disengage the front, then tilt forward and remove.
6. Remove bin top and remove shipping insert.
PREPARATION OF INSTALLATION SITE
The refrigeration system on air cooled units requires airflow, so a well ventilated area should be chosen.
1. In general a minimum of 6 inches must be maintained, free of any obstruction, for air intake. A minimum of 4
inches clearance is required for air exhaust.
2. For IMD600-30A, a minimum of 6 inches must be maintained, free of any obstruction, for air intake. A minimum
of 4 inches clearance is required at sides and 12 inches on top for air exhaust.
3. For IMD300-30A, a minimum of 6 inches must be maintained, free of any obstruction, for air intake. A minimum
of 4 inches clearance is required at sides and top for air exhaust.
4. With template provided make the necessary provisions in the counter for water, drain and the electrical hookup. Provisions are available for rear and bottom connections of water and electrical. Use hole plugs provided to
plug unused holes.
WATER INLET HOOK-UP
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” or
larger copper or flexible tubing.
2. Water Pressure - Unless otherwise specified, the unit is designed to operate on water pressures between 10
P.S.I. and 90 P.S.I. (NOTE: for pressures above 90 P.S.I. a regulator must be installed).
3. Water Cooled Condensers
A. Inlet to modulating valve uses 3/8” FPT. Use separate 3/8” or larger water line.
B. Outlet is 3/8” FPT.
4. Filter - Filter Conditioner is recommended on supply lines to ice makers. 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 ice maker causing premature component damage. Separate water supplies are recommended.
NOTE: Unit must be installed per local plumbing code.
© 2004-2015, Cornelius Inc. - 5 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
ELECTRICAL SUPPLY
1. Power Access - Is provided by way of a 7/8” dia. hole in both the base and the rear panel. Route incoming
power in conduit to ice maker electrical control box. Make connections to wires provided in control box and
ground lug/screw. Plug unused hole.
For IMD600-30A and IMD300-30A units, 8 feet, 2 inch long power cord with 3 prong plug attached to the unit.
2. Fused Line - Should be a dedicated circuit checked and sized according to electrical rating shown on unit
nameplate.
NOTE: Unit must be installed per local electrical code.
DRAIN CONNECTION
1. Install splash panel on machine and hold in place with (2) screws. Do not tighten at this time.
2. Remove drain tray mounting bracket from shipping carton.
3. Clip the drain try mounting bracket onto the bottom of the splash panel on the brackets provided.
4. Hook the drain tray into the splash panel and onto the mounting bracket.
5. Push the drain elbow securely onto the drain tray. Do not glue in place.
6. Complete drain hookup according to the instructions provided with unit.
NOTE: Steps 7 and 8 to be completed only after all start up checks and adjustments are performed.
7. Replace side panels tightening all (6) screws (including splash panel screws left loose).
8. Replace top panel and front cover and secure with (2) screws.
NOTE: In those cases where the unit is bse mounted and not on legs it should be sealed all around the
base with NSF listed sealant (P/N 04815-B).
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Countertop Icemaker IMD Series Installation Manual
AUGER ENGAGEMENT
Be certain that auger is fully engaged to lower drive and that extruding head is fully engaged to evaporator.
INITIAL START UP, CHECKS & ADJUSTMENT INSTRUCTIONS
NOTE: Do not start unit before completing above Installation Instructions.
Turn on water supply and main power switch (located on top o
are equipped with a 45 second delay timer. This means that the refrigeration system will not start until 45 seconds
of dispense are accumulated in the timer. Start the refrigeration system by depressing the ice dispense button for
45 seconds. Make the following system checks:
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 must
a
shut down. Adjustment is made by moving magnet up or down.
f electric box). All IMD 30 lb. and 90 lb. series units
Water Level unit stops running. Release float and unit will restart. Keep water in reservoir at level line while unit is in operation.
See Figure 4.
Low Water Safety Control - Adjust magnet by bending magnet arm as shown in Figure 4 to shut down unit if the
water level drops below the line on the side of the reservoir.
Bin Control until unit shuts down. Release plate and unit will restart (on IMD300-30, IMD600-30, and IMD600-90 the dispense
button must be depressed for 45 seconds before unit will start). Replace screws.
If necessary, adjust float by bending float arm up or down as needed. Push float assembly down until
Figure 4. Float Assembly
Remove four screws from top of bin cover and lift cover so bin control plate can be manually lifted
Dispense Switch and Mechanism
storage bin will open, and chain, sprockets, and agitator will rotate counterclockwise.
NOTE: If any of these checks or adjustments cannot be achieved, refer to Troubleshooting Section of
his manual or call our Technical Support Center for assistance at 1-800-238-3600.
t
© 2004-2015, Cornelius Inc. - 7 - Publication Number: 638085277INS
- By depressing the dispense switch, the dispense mechanism door on the
Countertop Icemaker IMD Series Installation Manual
!
WARNING:
GUIDE TO SERVICE
ICE MAKER CLEANING AND SANITIZING PROCEDURES
Do not use any of the ice made during cleaning operations.
Clean and sanitize ice storage area when cleaning ice maker.
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Shut off water supply.
2. Remove ice from storage bin.
3. Mix approved cleaner (2 gallons as directed). Recommended cleaner: Calgon Corp. of Virginia Chemicals,
ice machine cleaner. Mixture: 3-1/3 ounces per gallon of water. Do not use nickel safe cleaners.
4. Turn machine on and add cleaner solution to water level control (float reservoir) until 2 gallons have been used.
5. Turn on water supply and run machine for 15 minutes.
6. Turn off machine and remove and discard all ice.
7. Sanitize using household liquid bleach (50 ppm chlorine). Mixture: 1 fluid ounce per gallon room temperature
water. 2 minute exposure time.
8. Sanitize pre-cleaned inside areas of storage bin liner, door frame, door, as well as exposed surfaces of the
evaporator assembly and bin shutoff assembly with sanitizing solution and allow to air dry.
MAINTENANCE
Preventive maintenance can increase the trouble free life of your ice maker. Many authorized service agencies offer
service contracts for your ice maker. Contact your local distributor for further information.
Monthly
1. Clean the condenser. Use a brush, vacuum cleaner or blow from inside with air or CO2 gas. If unit is provided
with an air filter, clean or replace.
2. Inspect water feed reservoir at least once a month until a definite pattern for cleaning and sanitizing has been
established.
Quarterly
This is the maximum period of time between cleaning and sanitizing the ice maker. In addition to recommended
monthly procedure, and if a more frequent cleaning and sanitizing pattern has not been established, unit must be
cleaned and sanitized.
Publication Number: 638085277INS - 8 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
Semi-Annually
Semi-Annually in addition to all previously established service procedures perform the following:
1. Check for water leaks in tube connections, water fittings, and lower ice maker water seal.
2. Check drain tubes for clogs and “aged” tubes. Replace if tubes are stained or brittle.
3. Check for signs of condensation. Clean where necessary and replace insulation properly.
4. Check safety circuits for proper operation.
5. Check refrigeration system.
6. Check unit for abnormal noise. Tighten machine and cabinet screws, if necessary.
7. Check white upper bearings on auger assembly. If bearings are less than 1/16” thick, replace. See Figure 5.
Figure 5. Upper Bearing and Auger Assembly
NOTE: Preventive maintenance can increase the trouble-free life of your ice maker. Failure to perform
preventive maintenance could void your equipment warranty.
© 2004-2015, Cornelius Inc. - 9 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
!
WARNING:
!
WARNING:
WATER LEVEL CONTROL
HOW WATER LEVEL CONTROL WORKS
When water is introduced through the inlet fitting the float rises. The float pushes against a lever which in turn
forces the poppet assembly against the inlet fitting valve seat which seals the water off, (see
water inlet is sealed the safety switch is operated. In the event of a water failure the float would drop down and
operate the safety switch to shut off the machine.
If water level control will not shut off and seal at level as indicated, be sure inlet pressure does not exceed recommended factory operating range.
Under ordinary circumstances adjustment should not be necessary providing it was properly adjusted when unit
was installed or relocated. If, however, the control becomes inoperative, repair or replace. See Start-Up Adjust
ment.
PURPOSE OF WATER LEVEL CONTROL
1. To automatically maintain proper water level in the evaporator when unit is running and making ice.
2. A safety switch is operated in the event of an interruption in water supply. The switch shuts off the electrical
power to the ice maker and its refrigeration system. Switch will reset as soon as cause of water failure has
been corrected and proper water level in ice maker has again been reached.
3. The transparent bowl not only provides a visible check of water level, but also is a good guide to the internal
conditions which exist within the ice maker assembly itself. (See Cleaning Procedure).
Figure 4). Before the
-
TO REPLACE WATER LEVEL CONTROL
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Shut off the water supply.
2. Remove the flexible tubing from bottom of water level control and drain water from water level control and evaporator.
3. Remove flexible tubing at bottom of water level bowl connected to the overflow.
4. Hold water inlet fitting with proper tool to prevent it from rotating when disconnecting the water inlet.
5. Remove wing nut holding water control to its mounting bracket. Control can be removed by lifting straight up.
TO REPLACE WATER LEVEL SAFETY SWITCH
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Unplug Molex connector connecting switch to electrical box.
2. Remove the 2 screws anchoring the water level safety switch to the bottom of the water level control mounting
bracket.
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Countertop Icemaker IMD Series Installation Manual
CAUTION:
!
ICE LEVEL CONTROL
The ice level control assembly is secured to the top of the ice storage container cover. The cover is secured to the
storage container with four screws. The level control switch is operated by a plate assembly located beneath the
diaphragm. When the plate assembly is down due to lack of ice in storage container, electrical impulse is sent to
compressor, starting the ice making cycle. As ice level increases in storage container, the plate assembly is pushed
up. When storage container is full, it de-actuates the switch, stopping the compressor and ice making cycle.
The operating positions of the switch are fixed, no adjustments are necessary. If switch replacement becomes necessary, simply disconnect cable at connector, remove wires from switch.
REFRIGERATION SYSTEM ADJUSTMENTS
A complete understanding of the ice maker and hermetic refrigeration system is necessary before any adjustments
are made. The refrigeration technician must use high and low side pressure readings, water, and air temperatures,
plus general conditions of cleanliness to assess the refrigeration system status when making any adjustments.
All ice maker products are tested and adjusted at the factory prior to shipment where the ambient temperature
ranges from 65°F to 90°F, depending on the season of the year.
Whenever a new ice maker is initially installed and started-up, it is imperative that the start-up operator make the
following checks and readjustments for local conditions.
Expansion Valve
You will find a thermal expansion valve on ice makers, which is used to control the amount of refrigerant flowing
through the evaporator. Improperly installed or defective expansion valves may cause low production, soft ice,
squeaking from evaporator and excessive load inside evaporator.
By using general refrigeration troubleshooting along with the pressure charts (refer pressure chart on page 15),
you can easily determine whether or not the expansion valve is working properly.
ADJUSTMENT AND TROUBLESHOOTING
When troubleshooting the expansion valve, you must:
1. Be sure you have adequate water flowing into the evaporator, a clean and properly ventilated condenser, and
the system is properly charged and free of any restrictions. Also be sure compressor is operating properly.
2. Take reservoir water temperature and air temperature from condenser inlet and determine at what pressure
unit should be running. On machines equipped with thermostatic valve there is NO adjustment. If correct pres
sure cannot be obtained, be sure system has time to stabilize, 10-15 minutes.
3. Be sure sensing bulb is located at outlet side of evaporator about 3-4 inches away from evaporator and be sure
to insulate well and clamp tightly to tubing. If system pressures are still not adequate, take a second water and
air temperature reading and go over other parts of the system for possible problems. If proper charge is ques
tionable evacuate and recharge to nameplate and leak check. If valve still malfunctions replace valve.
Use general refrigeration system practices when replacing and recharging unit. After new valve is in place, go
through previous monitored adjustments and troubleshooting to be sure valve is functioning properly.
NOTE: On water cooled units adjust condenser modulating valve before troubleshooting expansion
valve.
-
-
Very high discharge pressure is present in system. Quick disconnects on your gages will minimize Danger and loss of
refrigerant. Comply with federal regulations for reclaiming refrigerant.Condenser Modulating Valve
© 2004-2015, Cornelius Inc. - 11 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
!
WARNING:
CONDENSER MODULATING VALVE REMOVAL
The reason for using a water modulating valve is to supply the correct amount of water to the condenser to maintain the proper operating pressure in the refrigeration system high side. The flow of water through the valve is
creased as the high side pressure rises and decreases as high side pressure lowers.
in
To calibrate the amount of water flow with the refrigeration system high side pressure, turn adjustment screw
cated on end of valve opposite of bellows (see Figure 6). Turn screw counterclockwise to raise opening point.
lo
Opening point of valve should be set to maintain proper operating pressure in refrigeration system high side, refer
o pressure chart on page 15. Closing point of valve should be set low enough to close valve during compressor
t
stand by periods.
NOTE: Cold water will absorb more h
ically increase as inlet temperature increase.
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
eat faster than warm water. The water flow will therefore automat-
Figure 6. Adjustment Screw
Failure to comply could result in serious injury, death or damage to the equipment.
1. Shut off water supply to condenser and reclaim refrigerant from system.
2. Remove inlet water line from Condenser Modulating Valve. Also remove tube from refrigerant high side line.
3. Remove Condenser Modulating Valve and bracket.
4. Remove valve from bracket.
5. Replace Condenser Modulating Valve by reversing Steps 2 thru 4.
6. Recharge unit with refrigerant per nameplate.
7. Turn power and water ON to unit.
8. With unit running adjust modulating valve to proper setting.
9. Go through a complete system check.
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Countertop Icemaker IMD Series Installation Manual
GEAR MOTOR
The gear motor is equipped with a start relay and a manual reset overload. When current is applied, the relay energizes and completes the circuit to the start winding. The motor reaches a predetermined speed and the relay drops
ut, disconnecting the start winding. The run winding remains in the circuit as long as current is applied.
o
The purpose of the overload is to automatically shut off the motor in the event of a mechanical bind of the transmission, an overload condition within the evaporator or an ele
draw. If the motor stalls the start relay would energize and stay energized. The amperage would surge to 5 to 6
times greater than normal draw. In this event the overload would shut off the transmission in 4 to 8 seconds.
If the motor is subjected to an abnormal load,
greater period of time. The reaction time depends upon the amperage to which it is subjected.
The overload, through the safety circuit, also shuts off the compressor.
Refer to Troubleshooting Guide.
but does not reach stall condition, the overload will react, but over a
ctrical malfunction. It does this by sensing amperage
Figure 7. IMD 300 Shaft Seal Figure 8. Auger and Extruding Head Removal
SHAFT SEAL INSTALLATION AND REPLACEMENT
1. Place shaft seal locator seat over gear motor output shaft, embossed side down, and push down until shaft
seal seat rests flush on top of gear motor.
2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and push down until seal rests
n top of the shaft seal seat. (Lubricate rubber on ceramic seal with [#06195] rubber lubricant.)
o
3. Place shaft seal with carbon face down (spring up) over
rests on carbon face of output shaft seal.
4. Push down on the washer compressing the spring on the output shaft seal. While holding the seals (down) in
lace slide the E-Ring into the groove on the output shaft.
p
output shaft and push (gently) downward until seal
© 2004-2015, Cornelius Inc. - 13 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
!
WARNING:
AUGER & EXTRUDING HEAD REMOVAL
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Remove storage container cover and put aside.
2. Turn off water supply to ice maker.
3. After ice has melted from head take hold of the auger nut and lift straight up to disengage from ice maker.
4. When replacing the auger assembly, make certain that both the auger engages the output shaft drive and the
xtruding head ribs engage the evaporator tube collar. See Figure 8.
e
Figure 9. IMD 600 Shaft Seal
INSTALLATION AND SHAFT SEAL REPLACEMENT
1. Place shaft seal locator seat over gear motor output shaft, embossed side down, and push down until shaft
seal seat rests flush on top of gear motor.
2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and push down until seal rests
n top of the shaft seal seat. (Lubricate rubber on ceramic seal with [#06195] rubber lubricant.)
o
3. Place shaft seal with carbon face down (spring up) over
rests on carbon face of the output shaft seal.
4. Place flat washer over output shaft and let rest on the output shaft seal. Push down on the washer compressing
he spring on the output shaft seal. While holding the seals (down) in place slide the E-ring into the groove on
t
the output shaft.
output shaft and push (gently) downward until seal
UPPER NUT AND BEARINGS
The upper bearings located on top of the auger is used to absorb the force between the auger and extruding head.
The bearings are 3/32” thick. When they wear below 1/16” they should be replaced. Bearings to be
nspected for wear during quarterly maintenance. See Figure 8.
i
Publication Number: 638085277INS - 14 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
!
WARNING:
TO REPLACE BEARINGS
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Dispense all ice from unit.
2. Remove panels.
3. Unplug Dispense Motor and Ice Level Switch.
4. Remove four screws holding dispense cover in place.
5. Remove dispense cover assembly.
6. Use an open end wrench on auger nut connected to bea
7. Remove worn bearings. Replace with new bearings and then reinstall assembly.
NOTE: If auger turns with nut, remove cover on top of gear motor stator and hold rotor while loosening
t.
nu
8. Reconnect power to ice maker.
ring and turn counterclockwise to remove assembly.
TROUBLESHOOTING COMPRESSOR
Basically the compressor problems can be narrowed down to three areas of checkout.
1. THE COMPRESSOR WILL NOT RUN
• No voltage to the compressor ter
• Low voltage - below 90% of nameplate rated voltage.
• Problems in the compressor electrical circuit
2. THE COMPRESSOR STARTS BUT TRIPS REPEATEDLY ON THE OVERLOAD PROTECTOR
• Check for proper fan operation and clean condenser.
• Check the compressor suction and discharge pressures.
• Voltage - The voltage should be within 10% of the rated nameplate voltage.
• High compressor amperage draw, it should never exceed 120% of the rated nameplate amperage. See
rical Checkout Instructions.
Elect
3. THE COMPRESSOR RUNS BUT WILL NOT REFRIGERATE
• Check the compressor suction and discharge pressures.
70°F 50% RH 90°F 65% RH 104°F 65% RH 70°F 50% RH 90°F 65% RH 104°F 65% RH
Discharge Temperature (°F) 180 202 225 195 213 232
Suction Temperature (°F) 29 43 49 29 38 45
Discharge Pressure (psig) 220 280 338 236 306 365
Suction Pressure (psig) 23 26 30 25 28 33
Current (Amps) 7.5 8 8.5 11 12 13
minals - check circuit.
. See Electrical Checkout Instructions.
Table 1. Pressure temperature chart
IMD 300-30 IMD 600-30
ELECTRICAL CHECKOUT
1. Be sure the unit is disconnected from the power source. Remove the compressor electrical box cover. Check
for obvious damage and loose wires.
© 2004-2015, Cornelius Inc. - 15 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
2. Disconnect the fan motor leads. Since capacitors store energy, short the capacitor with a screwdriver. This will
prevent shocks.
3. Disconnect the compressor terminal wires.
Figure 10. Overload Check Figure 11. Compressor Check
OVERLOAD CHECK
Using a volt-ohm meter check the continuity across the overload, contacts #1 & #3. If none, wait for unit to cool
down and try again. If still no continuity, the overload protector is defective and should be replaced.
COMPRESSOR CHECK
The resistance readings on the windings will be between 0.25 and 10.00 ohms, a meter capable of these low readings must be used.
1. Check between “C” & “R”. Replace compressor if there is no continuity as the run windings are open.
2. Check between “C” & “S”. Replace the compressor if ther
3. Check between “C” & “R”, or “S” and shell of the compressor. If there is continuity replace the compressor as
e motor is grounded.
th
4. Check between screw terminal on the overload and “C” on the compressor. Check and repair the lead or connections if there is no continuity.
e is no continuity as the start windings are open.
CAPACITOR CHECK
1. Check or replace start capacitor, disconnect bleed resistor before checking for shorted capacitor.
2. Check or replace run capacitor (if supplied), check for shorted capacitor or either terminal grounded to case.
TROUBLESHOOTING GEAR MOTORS
Basically, gear motor problems can be narrowed down to three areas of checkout.
The Gear motor will not run
1. No voltage to the transmission terminals - check external circuit.
2. Low voltage - check supply.
3. Problems in the gear motor electrical circuit. See Figure 12.
The Gear motor Starts but Trips Repeatedly on the Overload Protector
1. Voltage - high or low voltage can cause the overload to trip.
2. High gear motor amperage draw, see Specification Chart for ratings and Troubleshooting Guide.
Publication Number: 638085277INS - 16 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
CAUTION:
!
The Motor Runs but Output Shaft does not Rotate
Replace defective gear motor.
Be sure unit is disconnected from the power source. Disconnect the transmission cable.
OVERLOAD CHECK
1. Allow motor to cool and reset overload if necessary.
2. Remove motor end bell and stator, if necessary.
3. Check terminals 1 and 3 on overload. No continuity replace overload. Use a volt-ohm meter. See Figure 10 and
Figure 11.
NOTE: Gear motor and related components can be checked from Pin Connector. See Figure 12.
MOTOR CHECK
The resistance readings on the windings will be between 5 to 25 ohms. A meter capable of these low readings must
be used. The Start Relay cover must be removed.
If no continuity on start or run winding test, replace stator. If continuity on grounded motor test, replace stator.
© 2004-2015, Cornelius Inc. - 17 - Publication Number: 638085277INS
Figure 12. Pin Numbers.
Countertop Icemaker IMD Series Installation Manual
!
WARNING:
!
WARNING:
SAFETY CONTROLS
Your Ice maker unit has several safety and control devices incorporated into its design.
None of the below described devices should ever be “bypassed” to allow the unit to function.
The safety and control system shut-off devices are:
Figure 13. Gear Motor warning
1. Gear motor thermal overload, manual reset type (red button on motor). See Figure 13.
2. Main service switch located on top of the control box.
3. Low water shut off reed switch located in ice maker float assembly (Automatic reset type).
4. Compressor thermal overload, automatic reset type.
5. Hopper shut-off.
6. High pressure cut out (water cooled only).
Do not reset gear motor overload if ice is present in the evaporator.
Publication Number: 638085277INS - 18 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
GUIDE TO GOOD ICE
© 2004-2015, Cornelius Inc. - 19 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
SCHEMATICS
Figure 14. Component Interconnection Schematic
Publication Number: 638085277INS - 20 - © 2004-2015, Cornelius Inc.
Countertop Icemaker IMD Series Installation Manual
© 2004-2015, Cornelius Inc. - 21 - Publication Number: 638085277INS
Figure 15.Troubleshooting Chart
Countertop Icemaker IMD Series Installation Manual
Publication Number: 638085277INS - 22 - © 2004-2015, Cornelius Inc.
Figure 16. . Schematic IMD 300-15
Countertop Icemaker IMD Series Installation Manual
Figure 17. Schematic IMD 300-30, IMD 600-30, IMD 601-30, IMD 600-90 and IMD 601-90
© 2004-2015, Cornelius Inc. - 23 - Publication Number: 638085277INS
Countertop Icemaker IMD Series Installation Manual
Figure 18. Schematic IMD 302-30, IMD 602-30 and IMD 602-90
Publication Number: 638085277INS - 24 - © 2004-2015, Cornelius Inc.
Cornelius Inc.
www.cornelius.com
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