Cornelius IMD 600-30, IMD 300-15, IMD 300-30, IMD 302-30, IMD 601-90 Training Manual

...

CORNELIUS ICE MAKERS

Training Manual

Release Date: March 14, 2003 Publication Number: TP00967 Revision Date: June 18, 2003 Revision: B Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

IMD 600-90 Front End Assembly

CORNELIUS ICE MAKERS

TRAINING 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:

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.

IMI Cornelius Inc.

Corporate Headquarters

One Cornelius Place

Anoka, MN 55303-6234

U.S.A.

Internet:

www.cornelius.com

Email:

tech.service@cornelius.com

In the U.S.A.:

phone:763-421-6120

800-238-3600

FAX:800-535-4231

Outside the U.S.A.:

phone:763-421-6120

FAX:763-422-3297

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Preview Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Key Things To Know / Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Popular Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Principles of Extruded Ice Making . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Flake vs Chunklet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Product Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Dimensions and Capacities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Key Points — IMD / WCC / WCF Ice Makers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Superheat & Suction Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Evaporator Squealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Do Not Agitate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Evaporator Efficiency . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Water and Air Temperature . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

IMD Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Ice Bin, Agitator, & Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

IMD Major Component Detail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

WCC / WCF Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Extruder & Evaporator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

System Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Water and Filtration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mechanical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Refrigeration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Refrigeration System Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Remote Units . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

WCC/WCF Controls and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

IMD Controls and Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Illuminated Merchandiser (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Key Switch (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Drink Front (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Auger Delay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Dispense Timer (Solid State Timer) P/N TE1-24X-31796 . . . . . . . . . . . . . . . . . 16

Stand-by Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Timing Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Run Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Full Bin Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Appendix A — Installation Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Bin / Dispenser Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Site Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Appendix B — Evolution of the Chunklet / Flaker Design . . . . . . . . . . . . . . . . . . . . 19

The Spline Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

The Pin Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Current Generation “D” Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Appendix C — Evaporator Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Procedure for WCC / WCF Ice Makers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Gear Motor Overload Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Cornelius Ice Makers Training Manual

INTRODUCTION

PREVIEW QUESTIONS

Check your current knowledge by taking a few minutes to answer the following questions:

1. How many thrust bearings are in each IMD/WCC/WCF unit?

__________________________________________________________________ __________________________________________________________________

2. How many manual reset overloads are in each IMD/WCC/WCF unit(s)?

__________________________________________________________________ __________________________________________________________________

3. What type of water filters should be used on a Wilshire Ice Maker?

__________________________________________________________________ __________________________________________________________________

4. What is the difference between Cubed and Extruded Ice Makers?

__________________________________________________________________ __________________________________________________________________

KEY THINGS TO KNOW / DO

• Rotational Freeze is the primary cause of evaporator squealing noises in units.

• What is the proper water level setting.

• How do you adjust low water safety switch.

• How do you adjust ice level switch on IMD Series.

• Why are there vertical groves (sanding) on the interior wall of the evaporator.

• Water quality is very important!

• Understanding control and safety switches!

• Refrigeration gauges used only when absolutely necessary!

• On the larger IMD units it is important to understand the function of the dispense timer.

Cornelius Ice Makers Training Manual

POPULAR APPLICATIONS

Because of their unique form of ice and their extremely compact size, the Cornelius/Wilshire ice maker has a wide range of popular applications. The IMD model line has found wide acceptance in the convenience store market, where it provides a compact package with no need for the counter person to refill the ice bin. The U.S. Navy has found the IMD to be an excellent choice for its on board food service requirements and other applications including hospitals, cafeterias, and nursing stations.

The WCC/WCF series is also being used in restaurants and the meat packing industry. The WCF series has met with success because of the particularly high quality of the flake ice it produces.

Because of the chewable nature of the Chunklet ice produced by the IMD and WCC ice makers, the ice has been very popular with consumers wherever it is available.

PRINCIPLES OF EXTRUDED ICE MAKING

The Wilshire ice maker creates ice in a process called extrusion. The ice is frozen to an evaporator wall until it grows thick enough to harvest. At that point the ice is shaved from the wall by an auger and carried upward toward the extruding head. The extruding head is a finned device that forms or compresses the ice into its familiar chunklet shape. As the ice is compressed by the head, whatever remaining water there is on the surface of the ice will be squeezed away leaving a uniformly shaped chunk of ice. The ice made in this process is soft and edible, yet resists bridging in ice bins. Automatic agitation circuits in cold plate units or other dispensers should be disabled to prevent the breakdown of the ice.

FLAKE VS CHUNKLET

The WCC and WCF ice makers are virtually the same machine except for the extruding head and bin control bracket. The primary difference is the amount of compression exerted by the extruding head on the ice. This is comparable to going outside on a snowy day and scooping up a handful of snow. If the snow is tossed into the air without compacting it, it will break apart quickly. If the snow is packed into a ball, it will retain its shape even after striking the ground. The chunklet extruding head in the WCC has a sharp bend at the top of the channel where the ice is formed. As the ice comes to the top of the head it must make a sharp turn outward from the head. This bend causes just enough resistance to the upward flow of the ice to be compacted into a chunklet of ice.

The WCF head bend is very gradual and very little ice compacting occurs. Just enough pressure is applied for any excess water to be extracted to create a fluffy dry form of true flake ice.

Users of the Cornelius Wilshire bin top ice maker are pleased to know that any WCC can be converted into a WCF, or the reverse, in just a few minutes. Simply turn off the ice maker and its water supply, remove the top panel and the top of the auger assembly dispense tray. Pull the auger from the evaporator and disassemble it. Replace the head with the opposite head and restore the parts, power and water supply and manufacture the preferred type of ice.

NOTE: The IMD Ice Maker/Dispenser cannot be equipped with a flake head. Flake ice will not work in any dispenser.

Cornelius Ice Makers Training Manual

OVERVIEW

FIGURE 1

Product Description

Wilshire Ice Makers are available as ice making dispensers, modular chunklet, and modular flaked ice makers.

Wilshire Continuous Chunklet (WCC) and Wilshire Continuous Flake (WCF) ice makers come in three sizes determined by their evaporators inside diameter, (ID). The evaporator’s diameter is used as the defining measurement, although the height also increases with an increase in diameter.

Designation

• 500 series 2”

• 700 series 2 ½”

• 1000 series 3 ½” The designation approximates the maximum possible output of the ice maker in a 24-hour period. The WCF series of ice makers also includes a dual 3 ½” evaporator model called the WCF 2200. The ice maker dispenser series (IMD) use the numeric description of maximum ice per day and the bin

capacity. For example, the IMD 300-30 makes 300 pounds per day and stores 30 pounds of ice in its bin. Illuminated merchandisers are optional.

Ice Dispensing Lever

Ice Storage Bin

Ice Chute

Cornelius Ice Makers Training Manual

Dimensions and Capacities

IMD Units available with A/C or W/C condensers, Lever or Push button dispense.

NOTE: Health care IMD Units have the same capacity with different dimensions.

(W. D. H) Inches Bin Storage Capacity lbs./24 hrs.

70/50 90/70

IMD 300-15, 15 x 24 x 35 13 lbs. 246 202 IMD 300-30, 18.625 x 27.5 x 35.75 30 lbs. 360 301 IMD 302-30, 18.625 x 27.5 x 35.75 30 lbs. 300 250 IMD 600-30, 18.625 x 27.5 x 35.75 30 lbs. 618 493

IMD 600-30, 24 x 29 x 41 90 lbs. 618 493

IMD 601-90, 24 x 29 x 41 90 lbs. 618 493

(W. D. H) Inches Bin Storage Capacity lbs./24 hrs.

WCC 500A, 14.5 x 25 x 24.5 n/a 369 285

WCC 500W, 14.5 x 25 x 24.5 n/a 369 285

WCC 501A, 14.5 x 25 x 24.5 n/a 369 285 WCC 700A, 14.5 x 25 x 24.5 n/a 616 513

WCC 700W, 14.5 x 25 x 24.5 n/a 369 513

WCC 701A, 14.5 x 25 x 24.5 n/a 616 513

WCC 701W, 14.5 x 25 x 24.5 n/a 369 513

WCC 700R, 14.5 x 25 x 24.5 n/a 616 513 WCC1001A, W, R, 22 x 24 x 27 n/a 940 748 WCC2001A, W, R, 30 x 24 x 28 n/a 1735 1262

(W. D. H) Inches Bin Storage Capacity lbs./24 hrs.

WCF 510A, W, 14.5 x 25 x 24.5 n/a 442 367

WCF 710A, W, R, 14.5 x 25 x 24.5 n/a 892 702

WCF 711A, W, R, 14.5 x 25 x 24.5 n/a 892 702

WCF1101A, W, R, 22 x 24 x 27 n/a 1426 1134

WCC2001A, W, R, 30 x 25 x 28 n/a 2280 1711

Cornelius Ice Makers Training Manual

KEY POINTS — IMD / WCC / WCF ICE MAKERS

SUPERHEAT & SUCTION TEMPERATURE

Cornelius/Wilshire IMD/WCC/WCF ice makers run at only 4° F superheat. For this reason they are equipped with non-adjustable expansion valves.

Suction temperature should be in the 5 to 8 degree below zero temperature range, regardless of refrigerant type.

EVAPORATOR SQUEALING

Squealing noises coming from the evaporator always are accompanied by low production. These noises are caused by a “rotational freeze”. A rotational freeze is usually caused by mineral buildup on the evaporator wall. These deposits are not always visible, especially when the evaporator is wet. The production of ice depends on the ice freezing to the wall of the evaporator and being shaved off by the auger.

The evaporator wall is belt sanded to create scratches from top to bottom. These scratches give the ice something to hold onto, preventing it from rotating with the auger. If the grooves become filled with mineral deposits, the ice will not have any grip on the evaporator and begin to rotate, instead of being shaved and pushed upward. The squealing noises are caused by the ice continuing to expand as it rotates.

Ice sticking together in the bin is almost always the result of water chemistry. High concentrates of minerals in the water, chlorine, and salinity are usually found to be the cause. Filters that are specially designed for ice makers usually contain chemicals called phosphates. These phosphates will prevent minerals from freezing into the ice in cubers by keeping the particle in suspension and returning it to the wastewater sump. In the WCC/WCF/IMD ice makers, there is no wastewater; therefore the chemical has nowhere to go except into the ice bin with the ice. Once there, it behaves like salt, causing the ice to breakdown and stick together. This can result in damaged agitator blades or a 200-LB block of ice may be formed in a commercial bin. This effect is less pronounced in the WCF than it is in the WCC or IMD models. There for phosphate feeders and scale inhibitors should not be used with WCC/WCF or

IMD ice makers.

DO NOT AGITATE

Due to the slightly irregular shape of chunklet ice, it does not require timed agitation to remain loose. It is an accepted practice to check with the manufacturer of a dispenser before using extruded ice. In some cases, special agitator blades or bin liners may be required. Automatic agitation circuits must be turned off or disabled on any dispenser serving extruded ice. If the agitation circuit is enabled it will cause the ice to breakdown and not dispense properly. Eventually, the agitator blades may be damaged.

+ 21 hidden pages

Cornelius IMD 600-30, IMD 300-15, IMD 300-30, IMD 302-30, IMD 601-90 Training Manual

Specifications and Main Features

Frequently Asked Questions

User Manual