Service / Training Manual
Distributed By:
Commercial Refrigeration Service, Inc.
WWW.CorneliusParts.COM
WWW.IceCubes.NET
(866) 423-6253
(623) 869-8881
for model numbers
beginning with
XAC,XWC,orXRC
Revision Date: October 17, 2005
Release Date: November 26, 2001
Publication Number: TP00952
Revision: F
www.cornelius.com
TABLE OF CONTENTS
Product Preview 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preview Questions 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Key Things to Know / Do 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Model and Serial Location 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Xtreme Ice Machine 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Serial Number Explanation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Specifications 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freight Damage Claims Procedure 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Technical Specifications 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cube Size: 5/8”W X 7/8”H X 7/8”D 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ambient Temperature: 50_F/10_C – 100_F/38_C 5. . . . . . . . . . . . . . . . . . . . . . .
Water Temperature: 50_F/10_C – 90_F/32_C 5. . . . . . . . . . . . . . . . . . . . . . . . . .
Water Pressure: 20–80 psi 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Fuse Size: See Nameplate 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Circuit Amp.: See Nameplate 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Type: R–404a 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigerant Charge: See Nameplate 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Location of Equipment 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Equipment Set-Up 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dispenser Installation 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Plumbing Connections 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Check Points 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up and Check Out 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up Sequence 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Preventative Maintenance Sequence 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Procedures 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning Procedure if there is ice on the evaporator plate. 10. . . . . . . . . . . . . . .
Prep – Cleaning Procedure 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cleaning the Water System and Evaporator 11. . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sanitizing The Water System and The Evaporator 12. . . . . . . . . . . . . . . . . . . . . .
Operations 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Selection 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Normal Operations 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Up Sequence (Primary) 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Secondary Start Up 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Dump Cycle 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Fill Cycle 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PreChill Cycle (300’s, 500’s, 600’s, 800’s, 1000’s, and 1200’s) 14. . . . . . . . . . . .
PreChill Cycle (1400’s and 1800’s) 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Freeze Cycle 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
i
Harvest Cycle 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Fan control 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjusting Bridge Thickness 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Total Ice Capacity 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Ice Production Check 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED Indicators 18. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harvest Button 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Manual Harvest 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Unit Check 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Clean Cycle 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety (Old Software) 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Features 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flashing code for self Diagnostics
(300’s, 500’s, 600’s, 800’s, 1000’s, and 1200’s) 21. . . . . . . . . . . . . . . . . . . . .
Flashing code for self Diagnostics (1400’s and 1800’s) 21. . . . . . . . . . . . . . . . . .
Water Fill Time Out 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Maximum Freeze Time Out 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Harvest Time Out 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bin Full Delay 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Condenser Temperature Delay 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Condenser Temperature 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open Condenser Thermistor 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failed Water Temperature 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open Water Thermistor 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety (New Software) 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Features 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flashing code for self Diagnostics
(300’s, 500’s, 600’s, 800’s, 1000’s, and 1200’s) 25. . . . . . . . . . . . . . . . . . . . .
Flashing code for self Diagnostics (1400’s and 1800’s) 25. . . . . . . . . . . . . . . . . .
Failed Freeze Time Out Shutdown 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failed Harvest Shutdown 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bin Full Delay 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Low Condenser Temperature Warning 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
High Condenser Temperature Warning and Shutdown 27. . . . . . . . . . . . . . . . . . .
Possible Causes 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open Condenser Thermistor Shutdown 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Inlet Warning 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ii
Possible Causes 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failed Water System Shutdown 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Failed Water Temperature Shutdown 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Open Water Temperature Thermistor 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Possible Causes 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Component Function (Circuit Board, Etc.) 29. . . . . . . . . . . . . . . . . .
Sensors 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Reset Operation 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Switches 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Voltage Checks 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Evaporator Proximity Switch Pins and Condenser Thermistor Pins 29. . . . . . . .
Stacking Cable 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Sensor [Thermistor] Diagnosis 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Condenser Fan Cycling Control 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Thermostatic Expansion Valves 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Starving TXV - Product Symptoms 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Flooding TXV - Product Symptoms 30. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Water Regulating Valve 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Service Stem Valves 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Moisture Contamination 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Contactor 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor & Starting Component Check-Out Procedure 33. . . . . . . . . . . . . . .
Relay 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Potential – 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Current – 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitors 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Leak Detection 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
System Evacuation & Recharging 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Self-Contained Products 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
REFRIGERANT DEFINITIONS (ASHRAE 3-1990) 36. . . . . . . . . . . . . . . . . . . . . .
High Pressure Safety Switch 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Run-On 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Troubleshooting 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Xtreme Ice – Kits 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bin Stat Kit, P/N 630000408 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions 43. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Condensers 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation Instructions 47. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Condenser Location 49. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Head Pressure Control [Headmaster] 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote System Evacuation/Re-charge 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
iii
Xtreme Ice Training Manual
PRODUCT PREVIEW
PREVIEW QUESTIONS
Check your current knowledge by taking a few minutes to answer the following questions:
1. Does the ice machine need to be level?
_____ Yes _____ No?
2. What is the recommended clearance for a air cooled machine?
________________________________________________________________________________
____________________________
3. What kind of cleaner should be used when cleaning this ice machine?
________________________________________________________________________________
_______________________
4. Water filters are required in most installations?
_____ Yes _____ No?
5. Water regulators are required in most installations?
_____ Yes _____ No?
6. What initiates the harvest cycle? ____________________________________________
________________________________________________________________________________
_________
KEY THINGS TO KNOW / DO
S This is a batch harvest system.
S The sealant should be added before the unit is placed on the dispenser or bin. Always seal the ice
maker to the bin (with a gasket or food grade sealant). Sealing prevents melted ice from running out
of the joint between the ice machines!
S Choose the proper condenser for the application:
Air – with sufficient clean air circulation.
Water – high ambient temperature or dusty environment, restricted air flow, or where extra BTUs are
un–wanted.
Remote – when heat or noise are a problem!
S Always refer to serial plate for electrical power requirements and refrigeration charge and type of
refrigerant!
NOTE: Note serial plate locations. Lower left–hand corner of cabinet, inside the unit on the bulkhead between the evaporator and the compressor.
S Always use proper size and type of water conditioning equipment (filter, chlorine, etc.)!
S Do NOT use softened or reverse osmosis water!
S There is a manual reset high pressure cut out on the 500 series units.
S Installation of a bin thermostat control is required in some installations, such as ice drink dispensers
or ice drink unit!
S Bin stat is available to lower ice level! Part No. 630000408.
NOTE: If there is a very large slab of ice on the evaporator you will need to push the manual harvest button to remove it.
October 17, 2005 1
TP00952
MODEL AND SERIAL LOCATION
XTREME ICE MACHINE
Model/Serial
Number Location
Condenser Discharge Air
Deflector (as required)*
Bin Adapter (as required)*
Xtreme Ice Training Manual
FIGURE 1
*Bin adapters and condenser discharge air deflector may be equipped depending on your location or the
size of the storage bin.
Record the model number and the serial number of your ice equipment. These numbers are required
when requesting information from your local dealer/distributor/service company.
Model Number – Date Installed –
Serial Number – Purchased From -
SERIAL NUMBER EXPLANATION
63 A 01 01 BC 101
Sequential Number
Product Code (PC) – Ice Maker
Week of Manufacture – First week of the year
Year of Manufacture – 2001
Control Code (Revision Level)
Manufacturing Location – Mason City
SPECIFICATIONS
The following table contains equipment specification information for the Ice Machines.
TP00952
2
October 17, 2005
Xtreme Ice Training Manual
Model
UNIT
Volts
Phase
Hertz
No. Wires
MIN. CIRCUIT
Amps
MAX. FUSE
SIZE. Amps
REFRIGERANT
Type
Weight (oz)
Weight (g)
COMPRESSOR
LRA
RLA
CONDENSER
FAN MOTOR
Amps
Watts
WATER PUMP
Amps
Watts
Model
UNIT
Volts
Phase
Hertz
No. Wires
MIN. CIRCUIT
Amps
MAX. FUSE
SIZE Amps
REFRIGERANT
Type
Weight (oz)
Weight (g)
COMPRESSOR
LRA
RLA
CONDENSER
FAN MOTOR
Amps
Watts
WATER PUMP
Amps
Watts
XAC
322/330
R404a
19
539
1.7
50
XWC
830
R404a
33
936
NA
NA
XWC
322/330
R404a
15
426
58.8
9.2
NA
NA
XRC
830
R404a
170
4,820
60
8.9
NANA1.2 (2)
XAC
522/530
115
1
60
2+Ground
XWC
522/530
XRC
522/530
XAC
630
XWC
630
230
1
60
2+Ground
XRC
630
20 15 20
20 15 20
R404a
25
709
1.7
50
R404a
23
652
68
11.9
NA
NA
R404a
135
3,827
NA
NA
R404
1,134
1.1
a
40
75
R404
a
35
992
40.6
6.9
NA
NA
R404
a
170
4,820
NA
NA
0.7
20
XAC
1030
XWC
1030
XRC
1030
XAC
1230
XWC
1230
XRC
1230
230
1
60
2+Ground
20
20
R404a
42
1,191
R404a
33
936
90
12
R404a
170
4,820
R404
1,191
13.5
a
49
96
R404
a
45
1,276
R404
a
210
5,954
84
12.2
1.2
60 (2)
NA
NA
NA
NA
(2)
60 (2)
NA
NA
NA
NA
0.7
20
XAC
830
R404
a
42
1,191
60
8.9
1.1
75
XWC
1230
E50
XAC
1444
E50
220
1
50
2+Ground
30
30
R404
R404
a
45
1,276
67
1,900
76
13.09621.5
0.6
NA
1/15h
NA
a
p
October 17, 2005 3
TP00952
Model
UNIT
Volts
Phase
Hertz
No. Wires
MIN. CIRCUIT
Amps
MAX. FUSE
SIZE Amps
XAC
1444
XWC
1444
30
30
XRC
1444
XAC
1844
230
1
60
2+Ground
XWC
1844
30
40
XRC
1844
XAC
322
E50
Xtreme Ice Training Manual
XAC 330
E50
10 15
10 15
XAC 522
E50
220
1
50
2+Ground
XAC 530
E50
REFRIGERANT
Type
Weight (oz)
Weight (g)
COMPRESSOR
LRA
RLA
CONDENSER
FAN MOTOR
Amps
Watts
WATER PUMP
Amps
Watts
Model
UNIT
Volts
Phase
Hertz
No. Wires
MIN. CIRCUIT
Amps
MAX. FUSE
SIZE Amps
R404
1900
XAC
R404
a
67
1021
0.6
1/15
HP
XAC
630
E50
15 20
15 20 20 15 15
R404
a
36
7088
108
17
NANANA
XAC
830
1030
E50
220
1
50
2+Ground
R404aR404aR404
a
250
2.7
1/3H
NA
E50
P
XAC
1230
E50
179
28
NANANA
XAC
1844
3PH
XWC
1844
3PH
3+Ground
R404
a
NA
230
3
60
20 15 15
a
19
539
1.75
50
0.7
20
XRC
1844
3PH
R404a
19
539
26.3
3.9
1.75
50
XWC
522/530
E60
230
60
2
+Ground
R404a
25
709
1.75
50
XWC
522
E50
220
1
1
50
2
+Ground
31
5.6
522/530
2
R404a
+Ground
25
709
1.75
50
XAC
E60
230
1
60
REFRIGERANT
Type
Weight (oz)
Weight (g)
COMPRESSOR
LRA
RLA
CONDENSER
FAN MOTOR
Amps
Watts
WATER PUMP
R404
1134
R404
a
40
34
5.5548.18311.37613
1.1
75
a
42
1191
1.1
75
Amps
Watts
NA= Not applicable
Important: All product supply voltage specifications are –5%/+10% for proper
component operation.
TP00952
R404
a
42
1191
1.2
(2)
60(2)
R404
a
49
1389
1.2
(2)
60(2)
R404aR404
a
135
17
2.7
1/3H
NA
P
NA
4
0.7
20
R404
a
NA
NA
34
6.8
NA
NA
R404a
23
652
31
5.6
NA
NA
October 17, 2005
R404a
26
737
34
6.8
1.2
60
Xtreme Ice Training Manual
GENERAL
FREIGHT DAMAGE CLAIMS PROCEDURE
The deliverer of your equipment (freight company, distributor or dealer) is responsible for loss or damage
of your shipment. All claims must be filed with the deliverer of your equipment. Please follow the steps
below to determine if your shipment is satisfactory or if a claim must be filed:
1. Check the number of products delivered against the number of products listed on the delivery receipt. Should the totals not match, have the driver note all errors on both copies and both you and
the driver sign and date said notation.
2. Inspect all cartons for visible damage. Open and inspect as required before the driver leaves and
have him or her note any damage on the receipts. All damaged claims must be inspected within 15
days of delivery. Notify your carrier immediately if concealed damage is found after delivery.
3. Should concealed damage be found when product is unpacked, retain the packing material and the
product and request an inspection from the deliverer.
4. All claims for loss or damage should be filed at once. Delays in filing will reduce the chance of
achieving a satisfactory resolution to the claim.
TECHNICAL SPECIFICATIONS
Cube Size: 5/8”W X 7/8”H X 7/8”D
Ambient Temperature: 50_F/10_C – 100_F/38_C
Water Temperature: 50_F/10_C – 90_F/32_C
Water Pressure: 20–80 psi
Maximum Fuse Size: See Nameplate
Circuit Amp.: See Nameplate
Refrigerant Type: R–404a
Refrigerant Charge: See Nameplate
October 17, 2005 5
TP00952
Xtreme Ice Training Manual
INSTALLATION INSTRUCTIONS
Installation and start up of the equipment should be performed by the distributor or the dealer’s professional staff.
LOCATION OF EQUIPMENT
For maximum performance the location should be away from heat sources such as ovens, direct sunlight,
hot air discharge, etc.
To reduce cost of maintenance and loss of efficiency, avoid placing air-cooled equipment in areas where
grease, flour and other airborne contaminants are present. Allow a minimum of 6I (15.24 cm.) clearance
at the rear and right side for proper air circulation. Restricted air circulation will affect the efficiency and
required maintenance of the product.
IMPORTANT: Never operate your equipment in room temperature below 50_F (10_) or above
100_F (38_C). Should the location of your product ever be exposed to freezing temperatures, it
must be shut down and winterized.
EQUIPMENT SET-UP
The following steps refer to the set-up of the ice bin and the cuber:
1. Remove the bin from its carton, place it on its back and install the legs and drain flange (if applicable) into the bottom of the bin. Bins must be installed on legs or sealed to the floor with RTV-732
sealant.
2. Set the bin up on its legs. Place the bin in its final location and level it with the adjustable feet in the
legs. (See Figure 2).
NOTE: It is critical that the unit be level to ensure adequate ice production.
3. Unpack the cuber from its carton, and set in place on the bin and adjust as required. Leave all panels on the cuber until it is set in place on the dispenser or bin.
4. Remove all internal packing from the cuber. Remove tape from evaporator curtain.
FIGURE 2
NOTE: Bin adapter and condenser air baffles may be required in certain installations.
TP00952
THREAD LEVELING
LEG INTO BASE
6
October 17, 2005
Xtreme Ice Training Manual
DISPENSER INSTALLATION
1. Order the proper cuber/dispenser adaptor kit. This package include gasket material, a hold-down
bracket, and bin stat kit (contact service provider for more information).
2. RTV applications (See Figure 3). If the ice bin is full, new ice will not be able to drop. Instead it
blocks the evaporator curtain open and no additional ice is made. This new ice may start to melt and
the resulting liquid can leak out of the joint between the ice maker and bin. To prevent this problem,
seal the joint with food grade silicon sealant.
FIGURE 3
3. Install Bin stat, Part No. 631500074 (See Bin Stat Kit Instructions).
Figure 4 is an example of a typical electrical and plumbing connection.
Electrical Service Line
Manual Disconnect
Switch
Shut-Off Valve
Water Filter
STRAIN RELIEF
MUST BE USED
Dump
Valve
Drain
Tube
*Air Gap 4”
“minimum”
Bin Drain
Tube
AIR-COOLED MODELS
Floor Drain
Bin Drain
Tube
WATER-COOLED MODELS
Electrical Service Line
Manual Disconnect Switch
Shut-Off Valve
Water Filter
Shut-Off Valve
Condenser Water Inlet
Strain Relief
must be used
Dump Valve
Drain Tube
Condenser Water
Drain Tube
*Air Gap 4”
“minimum”
Floor Drain
FIGURE 4
* An air gap of at least twice the diameter of the water supply inlet plus a minimum of 1” (25 mm) must
exist between the floor drain and drain tube.
NOTE: Leave all panels on the cuber until it is in place on the bin.
October 17, 2005 7
TP00952
Xtreme Ice Training Manual
PLUMBING CONNECTIONS
1. All plumbing lines and connections must conform to local and national plumbing codes.
2. Line shut-off valves must be located in supply water lines for cuber and condenser if product is water-cooled. Water supply to water-cooled condenser must include a stand-pipe to prevent “water
hammer”.
3. Should your local water supply quality require the installation of a water filter system, consult your
local distributor or dealer for proper size required.
4. Water supply pressure must not be lower than 20 PSI (1.37 BAR), nor should it exceed 80 PSI (5.52
BAR).
NOTE: Water filters larger than 5 microns do not give proper protection.
NOTE: Bin and cuber drain lines must never be connected together and must be vented.
NOTE: Always flush inlet water lines 1–2 minutes before connecting to Ice Maker.
ELECTRICAL
1. All wiring and connections must conform to national and local electrical codes.
2. Wire size and circuit protection must conform to specifications and cuber must be on a separate
electrical circuit.
3. Strain relief connectors must be used at the junction box of the control box and the cuber.
4. Cuber must be grounded by the control box ground screw or other method for intentional safety
grounding that meets code requirements.
5. A manual disconnect in a convenient location to the cuber must be installed.
NOTE: See Remote Condensers, Install Instructions.
NOTE: All HP-62 (R404A) ice machines have a voltage range of –5%, +10% from the serial plate
rating.
INSTALLATION CHECK POINTS
1. Has bin and cuber been leveled and sanitized?
2. Does electrical and plumbing meet code requirements?
3.
4. Are drain lines separate and vented?
5. Is there a 6I clearance on the right and back side for proper air circulation?
6.
7.
NOTE: A 6” top clearance will improve service accessibility.
If water-cooled, are inlet and drain connections to condenser correct?
Does the water curtain move freely? Does the inlet solenoid valve shut off incoming water to
the water pan?
Has the unit been properly sealed to the bin or dispenser?
START UP AND CHECK OUT
Start Up Sequence
1. Check all connections.
2. Turn on the main power switch. The red LED will flash 6 times then remain on for 4 seconds.
3.
4.
The unit will go through a 45 second hot gas defrost to remove any ice that might be on the
evaporator.
There will be approximately a (45) second evaporator pre–chill, then the water pump will start,
and the freeze cycle begins.
TP00952
8
October 17, 2005
Xtreme Ice Training Manual
Preventative Maintenance Sequence
The installation is not complete until you are sure the owner-operator understands the cuber operation
and his or her responsibility of preventative maintenance.
Does the owner-operator know:
1.
2. How to start and/or shut down the product, clean and sanitize it?
3.
4.
5. Whom to call for product information and/or service?
NOTE: CONDENSER SENSOR USED ONLY ON A/C UNITS. 1.8K ohm RESISTER USED ONLY ON
W/C & R/C UNITS.
Location of electrical disconnect switch and water shut-off valves?
Bin full operation and reset operation of high pressure cutout (water-cooled and remote
products and 500 series (Air Cooled)?
How to clean the condenser and fan blade?
October 17, 2005 9
TP00952
Xtreme Ice Training Manual
CLEANING PROCEDURES
Approved ice machine cleaners by brand names:
S Calgon Nickel Safe (green color only)
NOTE: Failure to use approved products will void the warranty.
CAUTION: Ice machine cleaners are acidic-based chemicals. Before beginning any
cleaning of the cuber, the ice in the storage bin or dispenser must be removed.
WARNING: When using any chemical, rubber gloves and eye protection should be worn.
Cleaning Procedure if there is ice on the evaporator plate.
1. Turn the power switch on.
2. Press and hold the Harvest button to start a 4 minute defrost cycle. (Button is located on the control
board see Figure 5).
BIN
SWITCHES
STOCKING
CABLE PLUG
HARVEST
UNIT
SELECTION
SWITCH
S3–2
RH EVAP
SWITCH
LH EVAP
SWITCH
ERROR
OFF
3 2 1
ON
OFF
S3–1
ON
CLEAN
DELAY
BRIDGE
THICKNESS
POT
MICRO
PROCESSOR
(MANUFACTURING DATE)
3643001
(WHITE LEAD)
CONDENSER SENSOR SEE NOTE
(BLACK LEAD)
WATER TEMP SENSOR
WATER PRESSURE LINE
FILL VALVE
#7
#6
#5
#4
#3
#2
#1
TRANSFORMER
DUPM VALVE
FAN MOTOR (AIR COOLED)
COMPRESSOR
WATER PUMP
HOT GAS
NEUTRAL
POWER
NOTE: CONDENSER SENSOR USED ONLY ON A/C UNITS.
1.8K ohm RESISTER USED ONLY ON W/C AND R/C UNITS.
FIGURE 5
NOTE: Condenser sensor used only on A/C units. 1.8k resistor used only in W/C and R/C units.
Single evaporator units must have the proximity connected in the top connection.
TP00952
10
October 17, 2005
Xtreme Ice Training Manual
PREP – CLEANING PROCEDURE
Use ice machine cleaner on a coarse-surface cloth material (such as terry cloth) and wipe down the inside wall of the evaporator area, the water pan, the water curtain and the plastic water deflector. If the
water distributor tube has heavy scale build-up, remove and soak it in full-strength nickel safe ice machine cleaner (or exchange the tube and clean the scaled tube at a later date) (See Figure 6).
Water Restrictor
INNER WATER DISTRIBUTOR
”O” RING
WATER DIST. ASSEMBLY
SCALE 1:2
”O” RING
INNER WATER DISTRIBUTOR BARB
All single evaporator units use a water restrictor
to regulate the water flow pattern over the evaporator.
FIGURE 6
Cleaning the Water System and Evaporator
1. Turn the power switch to “OFF”.
2. Remove all ice from the storage bin.
3. Remove the water curtain(s), pour 1/2 oz. of ice machine cleaner down the top of the evaporator.
The cleaner will drain into the water pan.
4. Remove the water tube, clean with brush and “Calgon Nickel Safe” ice machine cleaner.
5. Return the water curtain(s) to their proper operating positions.
6. Add “Calgon Nickel Safe” ice machine cleaner directly into the water pan (green only):
S 5 oz. for the 300’s,
S 8 oz. for the 500’s, 600’s, and 800’s,
S 12 oz. for the Dual Evaporator, and
S 16 oz. for the Quad.
7. Turn the power switch to “ON” , allow the compressor to start, and depress the clean button two
times on the front of the electrical box.
8. The unit will run through a fifteen (15) minute cleaning cycle, which includes 3 rinse cycles.
9. Once the cleaning cycle finishes, the error LED will flash 8 times.
10. When the clean cycle is complete, turn the power switch to “OFF” for five (5) seconds, then to “ON”.
The unit will return to normal operating mode. Discard the first batch of ice produced.
NOTE: Ice machines should only be cleaned when needed, not by a timed schedule of every 60
days, etc. Should your ice machine require cleaning more than twice a year, consult your distributor or dealer about proper water treatment.
October 17, 2005 11
TP00952
Xtreme Ice Training Manual
SANITIZING THE WATER SYSTEM AND THE EVAPORATOR
NOTE: To be performed only after cleaning the ice machine:
1. Turn the power switch to “OFF”.
2. Add 1/4 ounce (7.08 g) sodium hypochlorite solution (common liquid laundry bleach) to the water
pan. You may also use a commercial sanitizer such as Calgon Ice Machine Sanitizer following the
directions on the product label.
3. Turn the Cuber power switch “ON” allowing the compressor to start. Depress the clean button two
times on the control board. The unit will run through a 15 minute sanitizing cycle.
4. Once the sanitizing cycle is complete, the error LED will flash 8 times. Turn the power switch to
“OFF” for 5 seconds and then turn to “ON”. Discard the first batch of ice produced.
5. To sanitize the bin and other surface areas, use 1 ounce of liquid bleach per gallon of water and wipe
all areas with the solution. Or use a commercial sanitizer.
6. Cleaning and sanitizing are now complete. Cuber may be returned to normal service.
TP00952
12
October 17, 2005
Xtreme Ice Training Manual
OPERATIONS
CAUTION: WHEN REPLACING THIS BOARD, BE SURE THE DIP SWITCH SETTINGS ARE IN THE
PROPER POSITION FOR YOUR UNIT.
UNIT SELECTION
1. The unit selection dip switches tell the microprocessor the correct water level difference for harvest
and the number of proximity switch circuits to monitor.
2. The unit selection dip switches are a series of 3 switches that can be placed in either the ON or OFF
position.
3. The following list shows the dip switch settings for each model:
NOTE: The unit selection switches are preset at the factory to the correct model. Use the chart
below if the control is replaced.
Model
Switch 1 Switch 2 Switch 3 Proximity Switch Circuits
300 OFF OFF OFF 1
500 ON OFF OFF 1
600/800/1000 OFF ON OFF 1
1200 ON ON OFF 2
1400/1800 OFF OFF ON 2
NORMAL OPERATIONS
1. Start up sequence.
2. Secondary start up.
3. Dump cycle.
4. Water fill cycle (See Figure 7).
PRESSURE
LINE
PRESSURE TRANSDUCER
START LEVEL (A)
WATER PAN
1. During fill, water level rises to (A).
2. During Ice Product cycle, water level
lowers to (B). Defrost cycle initiated.
FIGURE 7
5. Prechill cycle.
6. Freeze cycle.
7. Harvest cycle.
8. Continue with the dump cycle.
9. Fan cycles on condenser temperature (88–100_F).
10. The safety features are monitored during the proper cycle.
October 17, 2005 13
DEFROST LEVEL (B)
DUMP LEVEL (C)
3. During Defrost cycle, water level lowers to (C).
4. When Proximity Switches closes, the fill
valve opens and water level rises to (A).
TP00952
Xtreme Ice Training Manual
START UP SEQUENCE (PRIMARY)
1. Check all connections.
2. Water pan must be empty at the start of the initial fill cycle.
3. Turn on the main power switch, the red LED will flash 6 times then remains on for 4 seconds.
NOTE: If there is a very large slab of ice on the evaporator you will need to push the manual harvest button to remove it.
SECONDARY START UP
1. Compressor starts after ERROR LED extinguishes, and the green COMP LED turns on.
2. Compressor runs continuously after secondary start up sequence.
3. Hot gas valve opens for a 45 second period.
4. Green GAS LED is on when the hot gas valve opens.
5. After 45 seconds, the hot gas valve de–energizes.
NOTE: If there is a very large slab of ice on the evaporator you will need to push the manual harvest button to remove it.
6. Compressor starts then the unit will go through a 45 second hot gas defrost to remove any ice
that might be on the evaporator.
7. The water inlet solenoid makes its initial fill.
8. There will be approximately a (45) second evaporator pre chill, then the water pump will start,
and the freeze cycle begins.
DUMP CYCLE
1. The dump cycle can be changed by moving the setting on the dump cycle dip switches.
2. If both switches are off, the machine dumps water after each cycle. This is the factory set point.
3. If switch 1 is on and switch 2 is off, the machine dumps after every third harvest.
4. If switch 1 is off and switch 2 is on, the machine dumps after every seventh harvest.
WATER FILL CYCLE
1. The fill valve opens.
2. The green FILL LED is on when the fill valve energizes.
3. Once the water level reaches the maximum level the fill valve de–energizes.
NOTE: During the initial filling of the water pan, air is captured inside the pressure sensor pick
up. When the pressure inside the pressure sensor pick up rises to a predetermined value, the
pressure transducer shuts off the water fill valve and starts the prechill cycle then the freeze
cycle.
PRECHILL CYCLE (300’S, 500’S, 600’S, 800’S, 1000’S, AND 1200’S)
1. The water pump turns on 45 seconds into the cycle.
2. After another 45 seconds, the fill valve turns on and tops off the water level.
3. Once the water level reaches the maximum level the fill valve de–energizes.
4. During normal operation, as the water pan fills the D.C. voltage will range from .25 to 3.5 VDC at
center and left pins, on the J9 connector (See Figure 8).
TP00952
14
October 17, 2005
Xtreme Ice Training Manual
PRECHILL CYCLE (1400’S AND 1800’S)
1. After the water fill cycle is complete, the water pump turns on.
2. When the water temperature reaches 40_F, the pump turns off.
3. After one minute, the pump comes back on.
4. After another ten seconds, the fill valve opens.
5. Once the water level reaches the maximum level, the fill valve closes.
FIGURE 8
FREEZE CYCLE
1. Ten seconds after the fill valve turns off, the microprocessor records the water level.
2. Using the recorded high water level, the calibration level and the ice thickness level, the microprocessor calculates a harvest level.
3. The microprocessor monitors the water level until it reaches the harvest level.
NOTE: There are two revisions of control boards that have a five minute timer built into the freeze
cycle. This timer prevents the unit from going into a defrost cycle until the compressor has been
running for a minimum of five minutes.
The control board revisions number are: 100592 CRN; 100795 CRN.
NOTE: As ice builds on the evaporator the water level in the water pan drops. This is called
batch harvesting.
HARVEST CYCLE
1. The hot gas solenoid opens, the dump solenoid opens, and the water pump remains running for 15
seconds.
2. The microprocessor monitors the proximity switches waiting for the circuit to open.
3. Once all of the proximity switch circuits have opened, the hot gas solenoid closes.
4. The microprocessor monitors the proximity switches to close.
5. Once all the proximity switch circuits close, the harvest cycle terminates.
NOTE: When the pressure inside, the pressure sensor pick up lowers to a predetermined value,
the pressure transducer starts the harvest cycle.
FAN CONTROL
1. Fan control operates when the hot gas solenoid is closed.
2. The fan turns off when the condenser temperature is below 88_F.
3. The fan turns on when the condenser temperature is above 100_F.
October 17, 2005 15
TP00952
Xtreme Ice Training Manual
ADJUSTING BRIDGE THICKNESS
For optimum ice production and maximum cube separation, the ice connecting the individual cubes
should be a minimum of 1/8I (.32cm.) thick (See Figure 9). When adjusting the ice thickness, the adjust
Led is on the control board, it will be on for four seconds when it is at nominal voltage 2.4 to 2.5 VDC
2% (See Figure 8 for location of the J9 connector).
BRIDGE 1/8I (0.32 cm.)
FIGURE 9
Should a different thickness of the bridge be desired, it will be required to adjust the ice thickness “POT”,
located on the circuit board, as follows:
1. Thinner Bridge – turn the ice thickness “pot” adjustment screw C.W. one full turn. Allow two cycles
before determining if additional adjustments are required.
2. Thicker Bridge – turn the ice thickness “pot” adjusting screw C.C.W. one full turn. Allow two cycles
before determining if additional adjustments are required.
NOTE: Steady light indicates nominal setting, flashing light indicates the end of the adjustment
range.
NOTE: Never judge the thickness of the ice from the first batch of the ice produced – the first
cycle is a balance cycle. Always wait for the second cycle before making any adjustments.
TOTAL ICE CAPACITY
Ice capacity of any ice maker is affected by many operating conditions, such as water and air temperature and location factors. Please review the capacity tables in this manual for average 24-hour capacity
under various conditions.
NOTE: All printed capacity ratings are 10% except 50 HZ units. These products have 12% increase in cycle time and capacity decrease of approximately 17%.
ICE PRODUCTION CHECK
If air cooled:
S Take the air temperature at the intake of the condenser, 2I from the condenser fins.
S Take the incoming water temperature at the outlet of the “fill” valve.*
Cycle time (CT) = freeze time plus harvest time, in minutes and seconds. 1440 divided by CT = number
of cycles per 24 hours.
Measure weight of ice from one cycle in pounds and fractions of a pound.
EXAMPLE: Weight/cycle x cycles/day = total production/24 hrs. Compare to the production
tables.
* If water cooled, be certain water regulator valve is set to maintain 260 - 271 PSI head pressure, or set
condenser outlet temperature to 108_F – 111_F
TP00952
16
October 17, 2005
Xtreme Ice Training Manual
GR
CONTACTOR
BK BR
BK
WH
WH
COMPRESSOR
R
C
S
COMPRESSOR
EXTERNAL
OVERLOAD
RD
25 mfd
370V 60 HZ
YL
COMPRESSOR
RUN
CAPACITOR
YL
RD
72–88 mfd
250V 60 HZ
COMPRESSOR
START
CAPACITOR
OR
Bin
UNIT
SWITCH
RH Evap.
Switch
N
S
N
S
LH Evap.
Switch
Stacking
Cable
Plug
Harvest
Unit
Selection
Switch
S3–2
Off
3
On
Off
On
1
1
BL
3
OFF
ON
BR
(White Lead)
Condenser Sensor
See note
DELAY
ERROR
12
S3–1
5
4
3
2
In
Com
CLEAN
Bridge
Thickness
pot.
Micro
Processor
(Manufacturing Date)
36430001
YL
YL
YL
YL
StackOut
450 PSIG
Triac
BR
Valve
CO
RD
GR
Dump
GR
Fan
GR
Comp
GR
Pump
GR
Gas
GR
Transformer
MANUAL RESET
HIGH PRESSURE
CONTROL(W/C ONLY)
BL
(Black Lead)
Water Temp Sensor
Water Pressure Line
#7
#6
#5
#4
#3
#2
#1
BK
YL
BK
BL
WH
RD
WH
BR
BR
POTENTIAL
START RELAY
2
5
1
WH
WATER FILL
BK
YL
WATER DUMP
VALV E
CONDENSER
WH
WH
WH
FAN MOTOR
(A/C ONLY)
M
BK
BK
WH
WH
WH
WH
PUMP
CORD
WH
HOT GAS
SOLENOID
WATER
PUMP
M
FIGURE 10
NOTE: CONDENSER SENSOR USED ONLY ON A/C UNITS. 1.8 ohm RESISTOR USED ONLY ON
W/C AND R/C UNITS. EVAPORATOR SWITCHES MUST USE THE TOP CONNECTOR DOWN.
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LED INDICATORS
The LEDs are board circuit indicators. If the LED in the functional board circuit is complete, check component.
Example: Contactor does not energize and LED is “ON”, board circuit is OK. Check contactor, coil, leads,
& connections.
Yellow:
S Evaporator switch(s) (proximity)
S Delay (located on the electrical box front).
Green:
S Water dump valve
S Compressor contactor
S Water Pump
S Hot Gas Valve
S Condenser Fan (cycles on & off with fan)
S Fill Valve
Red:
S Error (located on the electrical box front).
S Ice thickness Adjustment.
Refer to flash codes for control and system diagnostics. Add the flash codes before status indicators (See Figure
11).
Red
Error LED
Yellow
Delay LED
FIGURE 11
STATUS INDICATOR
Green LED Condenser Fan
Yellow LED Left Water Curtain
Green LED Hot Gas Valve
Green LED Water Pump
Yellow LED Right Water Curtain
Green LED Compressor Contactor
Red LED Error
Green LED Dump Valve
Green LED Fill Valve
Yellow LED Delay
Red LED Ice Thickness Adjustment
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Curtain Open
Yellow LED off Right evaporator curtain open.
Yellow LED off Left evaporator curtain open.
Prechill Mode
Condenser Fan Green LED (on or off) Condenser fan cycles on and off depending upon condenser temperature.
Compressor Green LED (on) Compressor contactor activeĆcompressor running.
Right Curtain Yellow LED (on) Right evaporator curtain closed.
Left Curtain Yellow LED (on) Left evaporator curtain closed (only if unit has two evaporators).
Fill Valve Green LED (on) Fill valve open.
Dump Valve Green LED (on) Dump valve open.
Ice-Making Mode
Green LED (on or off) Condenser fan cycles on and off depending upon condenser temperature.
Green LED (on) Water pump active.
Green LED (on) Compressor contactor active - compressor running.
Yellow LED (on) Right evaporator curtain closed.
Yellow LED (on) Left evaporator curtain closed (only if unit has two evaporators).
Harvest Mode
Hot Gas Green LED (on) Hot gas valve open.
Compressor Green LED (on) Compressor contactor activeĆcompressor running.
Yellow LED (on) Right evaporator curtain closed. When the ice falls and the curtain opens, the
Yellow LED (on) Same as above if there is a second (left) evaporator.
LED will turn off.
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HARVEST BUTTON
The Harvest Button is located on the control board (See Figure 5 in the Cleaning Procedures chapter.
Manual Harvest
1. At any time after secondary start up, the machine can be put into the harvest cycle by depressing
the harvest button.
2. Pressing the harvest button will tell the microprocessor to skip directly to the harvest cycle.
3. Once the harvest cycle completes, the machine continues with normal operations.
Unit Check
1. Like manual harvest, any time after secondary start up the microprocessor monitors the harvest button.
2. If the harvest button is depressed and held for 5 seconds, the unit goes into a diagnostics mode.
3. All outputs are initially turned off.
4. Then the microprocessor powers each output individually for one second.
5. This continues from 10 minutes or until the power is cycled.
CLEAN CYCLE
1. The clean cycle can only be initiated during the 45 second hot gas cycle in Secondary Start Up.
2. The clean cycle starts when the CLEAN button is pressed twice (See Figure 12).
Clean Button
FIGURE 12
3. The hot gas valve opens.
4. The microprocessor monitors the proximity switch circuits, waiting for all circuits to open.
5. Once all circuits have opened, the hot gas valve closes.
6. If all of the proximity switch circuits do not open in 4 minutes, the hot gas valve closes.
7. The fill valve opens.
8. Once the water level reaches the maximum water level, the fill valve closes.
9. The water pump turns on.
10. After 10 minutes the dump valve opens.
11. Once the water reaches the minimum level, the water pump turns off and the dump valve closes.
12. The fill valve opens.
13. Once the water reaches the maximum water level, the fill valve closes.
14. The water pump turns on, and the dump valve opens.
15. Once the water reaches the minimum water level, the water pump turns off and the dump valve
closes.
16. The fill valve opens.
17. Once the water reaches the maximum water level, the fill valve closes.
18. The water pump turns on, and the dump valve opens.
19. Once the water reaches the minimum water level, the water pump turns off and the dump valve
closes.
20. All outputs turn off.
21. The ERROR LED flashes 8 times at 4 second intervals.
22. The machine will not run until the power is cycled off and back on.
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SAFETY (OLD SOFTWARE)
NOTE: Prior to S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote
units.
SAFETY FEATURES
1. Water Fill Time Out
2. Maximum Freeze Time Out
3. Harvest Time Out
4. Bin Full Delay
5. Low Condenser Temperature Delay
6. High Condenser Temperature
7. Open Condenser Thermistor
8. Failed Water Temperature
9. Open Water Thermistor
FLASHING CODE FOR SELF DIAGNOSTICS (300’S, 500’S, 600’S,
800’S, 1000’S, AND 1200’S)
NOTE: Prior to S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote
units.
Delay LED “Yellow” Error LED “Red”
1 High Condenser Temperature Delay 1 High Condenser Temp. Shut Down
2 Water Fill Time Out Delay 2 Water Fill Time Out Shut Down
3 Failed Harvest Delay 3 Failed Harvest Shut Down
4 Maximum Freeze Time Out Delay 4 Maximum Freeze Time Out Shut Down
6 Low Condenser Temperature Delay 6 Low Condenser Temperature Shut Down
7 Open Thermistor Shut Down
8 End of Clean Cycle Shut Down
FLASHING CODE FOR SELF DIAGNOSTICS (1400’S AND 1800’S)
NOTE: Prior to S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote
units.
1
High Condenser Temperature Delay 1 High Condenser Temp. Error
2 Water Fill Time Out Delay 2 Water Fill Time Out Error
3 Failed Harvest Delay 3 Failed Harvest Error
4 Maximum Freeze Time Out Delay 4 Maximum Freeze Time Out Error
5 Failed Water Temperature Delay 5 Failed Water Temperature Error
6 Low Condenser Temperature Delay 6 Low Condenser Temperature Error
7 Open Condenser Thermistor Error
8 End of Clean Cycle Error
9 Open Water Thermistor Error
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WATER FILL TIME OUT
1. During the fill cycle if the water level does not reach the maximum level in 4 minutes the machine
goes into a delay sequence.
2. After each delay, the machine restarts at the secondary start up.
3. The sequence continues as follows:
S Fill try, 30 min delay, fill try, 30 min delay, fill try, 2 hr delay.
S Fill try, 30 min delay, fill try, 30 min delay, fill try, 2 hr delay.
S Fill try, 30 min delay, fill try, 30 min delay, fill try, 2 hr delay.
S Fill try, 30 min delay, fill try, 30 min delay, fill try, 2 hr delay.
S Fill try, 30 min delay, fill try, 30 min delay, fill try, shut down.
4. During the delay times, the DELAY LED flashes 2 times at 4 second intervals.
5. Once the machine reaches shut down position, all outputs turn off.
6. At the shut down time, the ERROR LED flashes 2 times at 4 second intervals.
7. The machine will not run until the power is cycled.
8. The delay sequence resets after each successful harvest.
Possible Causes
1. Low inlet water pressure
2. Fill valve failure
3. Plugged fill valve screen
4. Pressure tube disconnected or cut
5. Pressure sensor failure
6. Leak in water pan
7. Water pan cap removed
MAXIMUM FREEZE TIME OUT
1. At the beginning of the prechill cycle, the microprocessor starts a timer.
2. If the timer reaches 50 minutes before a harvest cycle can be initiated, the machine enters a delay
sequence.
3. After each delay, the machine restarts at the secondary start up.
4. The delay sequence continues as follows:
S Freeze try, 30 min delay, freeze try, 30 min delay, freeze try, 2 hr delay,
S Freeze try, 30 min delay, freeze try, 30 min delay, freeze try, 2 hr delay,
S Freeze try, 30 min delay, freeze try, 30 min delay, freeze try, 2 hr delay,
S Freeze try, 30 min delay, freeze try, 30 min delay, freeze try, 2 hr delay,
S Freeze try, 30 min delay, freeze try, 30 min delay, freeze try, shut down.
5. During the delay times, the DELAY LED flashes 4 times at 4 second intervals.
6. Once the Machine reaches shut down position all out puts turn off.
7. At the shut down time, the ERROR LED flashes 4 times at 4 second intervals.
8. The machine will not run until the power is cycled.
9. The delay sequence resets after each successful harvest.
Possible Causes
1. Water pump failure
2. Low refrigerant charge
3. Leak in refrigerant lines
4. Compressor failure
5. Hot gas valve leaking
6. Dirty evaporator
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HARVEST TIME OUT
1. If the microprocessor does not recognize all proximity switch circuits opening 4 minutes after the hot
gas valve opens during the harvest cycle, the machine enters a delay sequence.
2. After each delay, the machine restarts at the secondary start up.
3. The delay sequence continues as follows:
S Harvest try, 30 min delay, harvest try, 30 min delay, harvest try, 2 hr delay.
S Harvest try, 30 min delay, harvest try, 30 min delay, harvest try, 2 hr delay.
S Harvest try, 30 min delay, harvest try, 30 min delay, harvest try, 2 hr delay.
S Harvest try, 30 min delay, harvest try, 30 min delay, harvest try, 2 hr delay.
S Harvest try, 30 min delay, harvest try, 30 min delay, harvest try, shut down.
4. During the delay times, the DELAY LED flashes 3 times at 4 second intervals.
5. Once the machine reaches shut down position all out puts turn off.
6. At the shut down time, the ERROR LED flashes 3 times at 4 second intervals.
7. The machine will not run until the power is cycled.
8. The delay sequence resets after each successful harvest.
Possible Causes
1. Hot gas valve failure
2. Low refrigerant charge
3. Prox. Switch
4. Compressor failure
BIN FULL DELAY
1. During the harvest cycle if the microprocessor does not recognize all proximity switch circuits close 5
second after the last one opens, the machine enters a delay sequence.
2. The machine turns off all outputs except the bin full output.
3. The microprocessor monitors the proximity switch circuits waiting for all circuits to close.
4. After all circuits close, the machine continues with the dump cycle.
LOW CONDENSER TEMPERATURE DELAY
1. After initial start up, the microprocessor continuously monitors the condenser temperature.
2. If the condenser temperature falls to 36_F, all outputs turn off.
3. The machine stays in a delay mode as the microprocessor continues to monitor the condenser temperature.
4. During the delay time, the DELAY LED flashes 6 times at 4 second intervals.
5. If the condenser temperature rises to 42_F while in this delay mode, the machine will restart at secondary start.
Possible Causes
1. Cold ambient temperature 50_F or below.
HIGH CONDENSER TEMPERATURE
1. While monitoring the condenser temperature, the microprocessor monitors high temperatures.
2. If the condenser temperature rises to 150_F, all outputs turn off.
3. The machine delays for 30 minutes, and a restart ensues at secondary start up.
4. If the condenser temperature rises to 150_F again, all outputs turn off.
5. The machine delays for 30 minutes, and a restart ensues at secondary start up.
6. If the condenser temperature rises to 150_F a third time, the unit shuts down.
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7. During delay period, the DELAY LED flashes 1 times at 4 second intervals.
8. Once the machine reaches shut down, all outputs turn off.
9. At the shut down time, the ERROR LED flashes 1 times at 4 second intervals.
10. The machine will not run until the power is cycled.
11. The delay sequence resets after each successful harvest.
Possible Causes
1. Above 100_F ambient temperature
2. Fan motor failure
3. Clogged condenser
4. No water flow (water coiled condenser)
OPEN CONDENSER THERMISTOR
1. While monitoring the condenser temperature, the microprocessor also monitors for an open signal.
2. If the signal from the thermistor reads open for a continuous 19 seconds, all outputs turn off.
3. The ERROR LED flashes 7 times at 4 second intervals.
4. The machine will not run until the power is cycled, Off and On to reset the control board.
Possible Causes
1. Thermistor wire removed
2. Thermistor failure
FAILED WATER TEMPERATURE
1. After initial start–up, the microprocessor continuously monitors the water temperature.
2. If the water temperature does not reach 40_F within 5.5 minutes, all outputs turn off and the machine shuts down.
3. At. the shut down time, the ERROR LED flashes 5 times at 4–second intervals.
Possible Causes
1. Water pump failure
2. Low refrigerant charge
3. Leak in refrigerant lines
4. Compressor failure
5. Hot gas valve leaking
OPEN WATER THERMISTOR
1. While monitoring the water temperature, the microprocessor also monitors for an open signal.
2. If the signal from the thermistor reads open for 19 seconds, all output turn off.
3. The ERROR LED flashes 9 times at 4–second intervals.
4. The machine will not run until the power is cycled, Off and On to reset the control board.
Possible Causes
1. Thermistor wire removed
2. Thermistor failure
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SAFETY (NEW SOFTWARE)
NOTE: After S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote units.
SAFETY FEATURES
1. Failed Freeze Shutdown
2. Failed Harvest Shutdown
3. Bin Full Delay
4. Low Condenser Temperature Warning
5. High Condenser Temperature Warning and Shutdown
6. Open Condenser Thermistor Shutdown
7. Inlet Warning
8. Failed Water System Shutdown
9. Failed Water Temperature Shutdown
10. Open Water Thermistor Shutdown
FLASHING CODE FOR SELF DIAGNOSTICS (300’S, 500’S, 600’S,
800’S, 1000’S, AND 1200’S)
NOTE: After S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote units.
Warning LED Error LED
1 High Condenser Temperature Warning 1 High Condenser Temp. Shutdown
2 Failed Freeze Time Out Shutdown
3 Failed Harvest Shutdown
4 Low Condenser Temperature Warning
5 Water Inlet Warning 5 Failed Water System Shutdown
6 End of Clean Cycle Shutdown
8 Open Condenser Thermistor Shutdown
FLASHING CODE FOR SELF DIAGNOSTICS (1400’S AND 1800’S)
NOTE: After S/N 63K0344BC050 for self–contained units and S/N 63M0351BC056 for remote units.
Warning LED Error LED
1 High Condenser Temperature Warning 1 High Condenser Temp. Shutdown
2 Failed Freeze Time Out Shutdown
3 Failed Harvest Shutdown
4 Low Condenser Temperature Warning 4 Failed Water Temperature Shutdown
5 Water Inlet Warning 5 Failed Water System Shutdown
6 End of Clean Cycle Shutdown
7 Open Water Thermistor Shutdown
8 Open Condenser Thermistor Shutdown
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FAILED FREEZE TIME OUT SHUTDOWN
1. If the freeze time reaches 50 minutes before a harvest cycle is initiated, the machine goes into the
harvest cycle.
2. After a successful harvest cycle, the machine goes into another water fill and freeze cycle.
3. If the freeze time reaches 50 minutes again, the machine again goes into the harvest cycle.
4. After a successful harvest cycle, the machine goes into another water fill and freeze cycle.
5. If the freeze time reaches 50 minutes again, the machine shuts down.
6. While shut down, the ERROR LED flashes 2 times at 4–second intervals.
7. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Water pump failure.
2. Low refrigerant charge.
3. Leak in refrigerant lines.
4. Compressor failure.
5. Hot gas valve leaking.
6. Dirty evaporator.
FAILED HARVEST SHUTDOWN
1. During the harvest cycle, if the proximity switches remain closed for 4 minutes after the hot gas valve
opens, the machine goes into another water fill and freeze cycle.
2. If the harvest time again exceeds 4 minutes, the machine goes into another water fill and freeze
cycle.
3. If the harvest time again exceeds 4 minutes, the machine shuts down.
4. While shut down, the ERROR LED flashes 3 times at 4–second intervals.
5. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Hot gas valve failure.
2. Low refrigerant charge.
3. Proximity switch failure.
4. Compressor failure.
BIN FULL DELAY
1. During the harvest cycle, if the proximity switches remain open for more than 5 seconds after the last
switch opens, the machines enters a delay sequence.
2. The machine remains in a delay until all proximity switches close. Once all switches are closed, the
machine goes into a water fill and freeze cycle.
LOW CONDENSER TEMPERATURE WARNING
1. If the condenser temperature falls below 36_F, the machine shuts down.
2. While shut down, the WARNING LED flashes 4 times at 4–second intervals.
3. If the condenser temperature rises above 42
Possible Causes
1. Ambient temperature below 50_F.
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HIGH CONDENSER TEMPERATURE WARNING AND SHUTDOWN
1. If the condenser temperature rises above 160_F, the machine shuts down.
2. While shut down, the WARNING LED flashes 1 time at 4–second intervals.
3. If the condenser temperature falls below 110
4. If the condenser temperature rises above 160
5. While shut down, the WARNING LED flashes 1 time at 4–second intervals.
6. If the condenser temperature falls below 110
startup cycle.
7. If the condenser temperature rises above 160
8. While shut down, the ERROR LED flashes 1 time at 4–second intervals.
9. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Ambient temperatures above 100_F.
2. Fan motor failure.
3. Plugged condenser.
4. No water flow (water–cooled units only).
_F, the machine goes into a secondary startup cycle.
_F again, the machine shuts down again.
_F again, the machine goes into another secondary
_F again, the machine shuts down.
OPEN CONDENSER THERMISTOR SHUTDOWN
1. If the condenser temperature thermistor is open, the machine shuts down.
2. While shut down, the ERROR LED flashes 8 times at 4–second intervals.
3. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Thermistor wire removed.
2. Thermistor failure.
WATER INLET WARNING
1. If the water pan does not fill at a given rate during the water fill cycle, the machine shuts down.
2. While shut down, the WARNING LED flashes 5 times at 4–second intervals.
3. If the water level eventually reaches a given level, the machine goes into a freeze cycle.
Possible Causes
1. Low inlet water pressure.
2. Water fill valve failure.
3. Plugged water fill valve screen.
FAILED WATER SYSTEM SHUTDOWN
1. If the water pan does not fill to a given level, the machine shuts down.
2. While shut down, the ERROR LED flashes 5 times at 4–second intervals.
3. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Pressure tube disconnected or cut.
2. Leak in water pan.
3. Water pan cap removed.
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FAILED WATER TEMPERATURE SHUTDOWN
1. If the water temperature does not reach 40_F within 5.5 minutes, the machine shuts down.
2. While shut down, the ERROR LED flashes 4 times at 4 second intervals.
3. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Water pump failure.
2. Low refrigerant charge.
3. Leak in refrigerant lines.
4. Compressor failure.
5. Hot gas valve leaking.
OPEN WATER TEMPERATURE THERMISTOR
1. If the water temperature thermistor is open, the machine shuts down.
2. While shut down, the ERROR LED flashes 7 times at 4–second intervals.
3. The machine will not run until the power is cycled OFF and then ON.
Possible Causes
1. Thermistor wire removed.
2. Thermistor failure.
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COMPONENT FUNCTION (CIRCUIT BOARD, ETC.)
SENSORS
Condenser sensor (WHITE) is a thermistor rated at 2618 ohms to 3032 ohms at 32_F (0_C).
Condenser sensor signals the circuit board for fan cycling and also serves as the high temperature safety
shut down. The red “DELAY LED” will flash on and off every second, during high temperature safety
delay. The yellow “ERROR LED” will flash on and off every second, during high temperature safety error.
Product is functionally shut down. Reset procedure must be performed to restart product operation.
RESET OPERATION
When Cuber is functionally shut down and red “Error LED” is operational, the Cuber power switch must
be turned off for 5 seconds and returned to the ON position to reset the circuit board and allow the Cuber
to restart operation.
Evaporator Switches
Proximity Switches are mounted to the evaporator, and the magnet is mounted to the side rail.
Switch Notes:
1. Manually holding the curtain open during freeze mode will shut the Cuber down in 5 seconds.
2. During harvest cycle, if curtain is open for 5 seconds, the water pump and the compressor will stop.
When the water curtain is closed, the Cuber will begin the normal start up process.
3. In single evaporator machines, the proximity switch connection must be on the top (RH) connection
on the circuit board.
4. In dual evaporator machines, both RH and LH switches must open and reset to start the next freeze
mode.
VOLTAGE CHECKS
Evaporator Proximity Switch Pins and Condenser Thermistor Pins
Turn Cuber power switch OFF. Disconnect proximity switch plug(s) and condenser sensor plug from the
circuit board. Use a digital multimeter set for D.C. Voltage; turn power switch ON, connect leads of meter
across the top two terminal pins on the board, (for the switch being tested), meter should read 5VDC ±
0.2 output voltage. If not, replace the circuit board.
STACKING CABLE
When stacking the Xtreme Ice Machine the connecting cable (connecting the two (2) circuit boards) will
allow: the bottom Unit to shut off on the full bin signal (or any error code), the top Unit will then finish the
cycle it is in and shut down. The Xtreme Ice Machine should never be stacked more than two high.
SENSOR [THERMISTOR] DIAGNOSIS
Condenser sensor – Turn Cuber power switch OFF. Disconnect sensor plug from board. Install test
lead part no. 164984009 and use digital multimeter set for D.C. Voltage. Turn power switch ON. Connect the leads of the meter across the two leads of the test lead being checked. The meter should read 5
VDC ± 0.25 output voltage from the board. If voltage is not correct, replace the circuit board.
Should the cuber operation indicate there may be a fault in the sensor [thermistor] or the control board
circuit proceed as follows:
1. Condenser Sensor (white leads) - self-contained air-cooled only - water cooled and remote systems
use a resistor plug on the control board.
2. Shorted sensor – a steady low millivolt reading will be recorded. The reading will not change.
3. Open sensor – the multimeter will record control board output voltage of 5.0 VDC.
4. Should sensor (thermistor) pass the voltage test proceed to the control board diagnosis for LED sequence.
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NOTE: The sensor controls the condenser fan cycling from 88/100 degree Fahrenheit. Thus any
defects in the condenser circuit will effect the fan cycling rate.
CONDENSER FAN CYCLING CONTROL
The condenser fan on air-cooled cubers is cycled by the circuit board. The condenser sensor signals the
circuit board when the condenser temperature reaches 100°F (38°C) the fan starts and continues to run
until the temperature is reduced to 88°F (31°C).
NOTE: There is no pressure control used to cycle the fan motor on integral condenser unit.
THERMOSTATIC EXPANSION VALVES
The following suggestions for diagnosis of automatic Thermostatic Expansion Valve (TXV) are given with
the understanding that the following have been checked and are correct and/or have been corrected prior
to proceeding.
1. The condenser and fan blade are clean and have proper operating conditions.
2. Water supply to the product is correct and flow over the evaporator is correct.
3. Cuber refrigerant charge is correct.
4. TXV sensing bulb is properly located and secured to the suction line and correctly insulated.
5. Hot gas valve(s) are not leaking and/or seeping through.
Starving TXV - Product Symptoms
1. Suction pressure lower than normal for the operating conditions.
2. Ice production lower than normal and/or none.
3. Ice pattern on evaporator (if any) thin at top and thick at bottom.
Flooding TXV - Product Symptoms
1. Suction pressure stabilizes at higher than normal pressure for operating conditions. Suction pressure
does not modulate and may start to slowly rise.
2. Ice pattern will be very heavy at the bottom and thin at the top of the evaporator. Product may not
enter harvest cycle because of higher than normal suction line temperature.
IMPORTANT: Frost on the suction line may be normal on medium temperature refrigeration
equipment. Frost should be considered a red flag, long run times will normally produce some
type of frost pattern. Before checking the sealed refrigeration system, the external conditions
that could lead to frost follow:
1. Dirty condenser
2. Dirty condenser fan blade
3. Improper air clearance around Cuber
4. Loose TXV bulb mount
5. Poor water flow over evaporator
6. Ventilation problems
The expansion valves used on Cornelius “X” series ice equipment have special super heat settings and
bulb charge designed for the product load and HP 62 refrigerant. Should the need arise to replace this or
any refrigerant components, be certain to use only components recommended by Cornelius for the model
of the Cuber being serviced. Use of non–approved components will compound system difficulties and
may void product warranty.
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WATER REGULATING VALVE
The water regulating valve is used on water-cooled cubers only. The valve is installed in the condenser
outlet water line. It’s function is to control the proper operating head pressure by regulating the amount of
water flowing through the condenser. The valve is adjustable and factory set to maintain condenser discharge water temperature @ 108/112_F (42-44_C). Setting the water regulating valve to maintain discharge water temperature eliminates the need to enter the sealed refrigeration system. When checking
the valve, the water temperature should be taken as close to the condenser discharged as possible. The
water temperature will equate to operating head pressure of approximately 260 – 271 PSI (21.1 BAR).
Should adjustment be required, the valve has an adjustment stem on the top of the valve. After allowing
the cuber to operate for 10 minutes in the icemaking mode to balance the system, turning the adjusting
stem CW
ter temperature.
The water regulating valve must close off condenser water flow completely during the “hot gas” harvest
cycle. There should be no discharge water flowing out of the condenser during the harvest cycle. Should
the valve fail to close during the harvest mode, the condenser will continue to condense the compressor
discharge vapor needed for the harvest cycle and this will result in long harvest times.
Also discharge water temperature below 108_F /112_F will result in long harvest times.
Leaking (bypassing) water regulating valves are normally the result of scale build-up on the valve diaphragm and the valve should be flushed, not replaced. To flush the valve, open the adjusting stem wide
open CCW (or force the valve spring up with a screwdriver), open and close the water supply to the condenser resulting in the flushing action. Should this not correct the problem, replace the valve diaphragm.
This can be done without entering the sealed refrigeration system.
Damage to the water regulating valve may also be caused by water hammer. Water hammer will result
from the condenser inlet and outlet water lines being reversed or defective valve stops in the water supply
line. Proper installation of water cooled equipment should always include an anti-water hammer standpipe
in the supply inlet line as close to the cuber as possible.
will increase the discharge water temperature, and CCW will decrease the discharge wa-
FIGURE 13
SERVICE STEM VALVES
When closing the service stem valves to remove your gauge and manifold set always close the high side
stem valve first. Following this procedure will allow the system to “PULL” the refrigerant vapor from your
manifold set reducing refrigerant loss. When the pressure has been reduced, close the low side stem
valve.
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MOISTURE CONTAMINATION
With the major changes in refrigerants in today’s marketplace and the use of hydroscopic oils the control
of moisture and contaminates have become more critical to safeguard against than ever before in the
history of mechanical refrigeration.
Contaminates are also the most difficult of all problems to determine. A Meg-Ohm meter “Megger” can be
a valuable tool to aid in the analysis of this problem. A Meg-Ohm reading log may be started any time
after 90 days of operation of the product. To perform the test, proceed as listed.
Disconnect all three (3) compressor leads, take a Meg-Ohm meter reading from each compressor terminal to a good chassis ground. Compare reading to chart below:
Meter Reading
MegĆOhm
100 Ć ∞
50 to 100 Moisture present Replace drier.
20 to 50 Severe moisture & possible contaminated oil
.5 to 20 System has severe contamination Remove compressor oil and refrigerant
Okay None needed.
with acid present
Compressor Condition Maintenance Required
Replace drier with acid hold type. Run 24
hours, change to regular drier.
charge. Evacuate, install liquid and suction
line driers (acid hold type). Recharge with
new oil and refrigerant. Run 24 hours. DisĆ
charge system, discard suction line drier,
replace the liquid line drier. Evacuate and
recharge.
Readings in the range listed below 100 Meg-Ohm would be an indicator that the system being tested may
have a contamination problem. Where does the problem come from? As an example, the filter drier may
become saturated and hold large percentages of moisture and the system function without a problem until such time as the product operating conditions change. Should the room temperature increase, or the
condenser plug-up etc., the higher operating pressures and temperatures may cause the drier filter to
release a portion of it’s held moisture. It is also imperative to avoid opening the sealed refrigeration system whenever possible and when it is done to be certain the true problem is correctly diagnosed and repaired. Remember, service gauge sets should only be installed after all external checks have been performed.
CAUTION: Megger checks should NEVER be performed on any compressor
that is under a vacuum.
COMPRESSOR CONTACTOR
The contactor serves as the voltage supply switch for the compressor circuit. Voltage to the coil of the
contactor is supplied by the circuit board.
Check Out:
The two (2)* line supply screws of the contactor should always have supply voltage present when voltage
is on to the product.
The other two (2)* screws (load) should have line voltage when the contactor is energized. The contactor
coil receives its supply voltage from the circuit board. Should the contactor fail to energize:
Check for supply voltage from circuit board, lead connections to contactor coil, and ohms value of coil.
* (3) if the product is 3 phase
NOTE: See compressor run-on condition check procedure on page 36.
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COMPRESSOR & STARTING COMPONENT CHECK-OUT PROCEDURE
When a compressor fails to start or run properly, it is normally the external electrical supply or the compressor start components that are defective – the overload protector, start and/or run capacitor, relay,
circuit board, safety controls, etc.
1. Check voltage at compressor terminals. NO voltage will require checking the electrical circuit working back from the compressor to determine where the voltage supply is interrupted and correct as
required. The load voltage, while compressor is trying to start, should not be less than 90% of rated
required voltage.
Line voltage and wire size effect the life expectancy of the electrical components, compressor, motor
winding, solenoid coils, etc.
Poor line quality voltage will cause many erratic electrical problems. Remember every electrical product,
ice machine, dispenser, walk-in, reach-in, air conditioner, etc. required proper power supply to operate.
Be certain when voltage checks are performed that you are measuring load voltage, not line voltage.
2. A defective capacitor or start relay may prevent the compressor from starting. Should the compressor attempt to start, but is unable to do so, or if the compressor hums or trips off on the over protector, check the following:
NOTE: For 50 HZ application on dual rated 50/60 HZ models, load voltage while compressor is
starting must not be less than 90% of 50 HZ rating.
Relay
Potential –
For the potential type, contacts are normally closed. The start contacts open by C.E.M.F. generated by
the compressor at approximately 80% of the normal operating speed. The run winding and the run capacitor remain in the circuit. This relay may or may not be directional in mounting.
Current –
For the current type, contacts are normally open. The start contacts close by the high current draw from
the locked rotor condition with only the run winding in the circuit. As the contacts close, the start capacitor
and the start winding is energized and the compressor starts. At approximately 80% of its operating
speed the current draw drops off, the relay contacts open removing the start winding and start capacitor
from the circuit. (Remember, current relays are directional in their mounting to allow contacts to
lift and close).
Capacitors
A quick check is to replace suspected defective capacitors with known good capacitors being careful to
stay within the range for substitute values. Should those values be unknown, a basic rule for capacity is:
for start capacitors 10% and run capacitors 5% of the rating on the defective original capacitor being
replaced. Voltage should always try and be matched; if it cannot be, it is acceptable to increase up to
10% higher than the voltage listed on the capacitor being replaced. NEVER put a capacitor on a product
with a voltage rating lower than the original being replaced. If a capacitor analyzer is not available, an
ohm meter may be used to check a capacitor for short or open circuits. Set the ohm meter to its highest
scale and connect its leads to the capacitor terminals.
1. With a capacitor, without plate defect, the indicator should first move to zero (0) and then gradually
increase to infinity.
2. If there is no movement of the ohm meter indicator, an open circuit is indicated.
3. If the ohm meter indicator moves to zero (0) and remains there, or on a low resistance reading, a
short circuit is indicated.
4. Please note this check does not determine if the capacitor will deliver the proper rated MFD/UFD
required, it only shows if the capacitor has shorted or open circuits.
5. Capacitors that show any signs of leakage of electrolyte, or damage of the can, should be replaced.
DO NOT TEST!
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Compressor
1. Using an ohm meter, check for continuity from compressor terminal C to R and C to S. If the compressor is hot, wait one (1) hour for compressor to cool and recheck. An open internal overload protector can cause a lack of continuity. If continuity cannot be measured through all windings, the compressor must be replaced.
2. To check the compressor motor for accidental ground, perform a continuity check between terminals
C, R and S to the compressor shell or a copper line of the refrigeration system (do not use a painted
surface). Continuity present, the compressor windings are grounded and the compressor must be
replaced.
If the compressor starts, but trips repeatedly on the overload protector, remember that the overload is
both temperature and current activated. Be sure to check:
S Low voltage
S Undersized supply lines
S High head pressure
S High suction pressure
S Defective capacitors
S Compressor mechanical problems
S Low refrigerant charge
LEAK DETECTION
The new non-chlorine based refrigerants such as [HP - 62/R 404A] require special leak detection devices
other than what has been standard for the CFC’s.
While the instruments for leak detection are different, the processes have not changed.
Basics to remember:
1. Look for signs of oil when you visually start your leak check process. Oil is carried with the refrigerant. If the oil has leaked out so will the refrigerant.
2. Refrigerant vapor is heavier than air. When leak checking suspect areas, probe below the joints or
connections.
A. Always check the high-side of the system with the compressor operational.
B. Check the low-side of the system, with the system idle.
C. Following a & b will normally allow the highest pressure on each portion of the system for the
best detection.
3. Systems short of refrigerant will show improper operational results in both the freeze and harvest
cycles. Many systems will appear normal in higher operating temperatures and change drastically in
cooler condenser temperatures.
4. Many new and reworked leak detection instruments have the ability to detect CFC’s, HCFC’s and
the new HFC’s by making a simple switch selection. This type of detector will be more sensitive on
one setting than the other. This results in finding some leaks that are so small it may take years before the actual leak rate would create adverse operating conditions in the product.
A bubble test and/or additives with UV lamp may be the best team for the most positive leak testing
results.
5. Never pressurize a system with oxygen or a mixture of refrigerant and air.
WARNING: Either of these methods may cause a system explosion to occur.
6. Pressurizing systems to leak test should only be done with dry nitrogen. Be sure the regulator setting does not exceed the recommended system pressure.
CAUTION: A full cylinder of nitrogen will have pressure of approximately 2700 PSI.
7. Failure to correct leaks will also cause shorter compressor life as a result of the higher operating
temperatures. Always check the total system for leak, there may be more than one leak.
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SYSTEM EVACUATION & RECHARGING
Should service work ever be required on a product where the sealed refrigeration is opened for any reason, the refrigerant must be recovered, drier/filter replaced, evacuated and recharged. The old method of
“purging” is NOT ACCEPTABLE. Always evacuate the system through both the high and low side service
valves. Be certain both valves are completely open when evacuating and the drier/filter has been replaced.
SELF-CONTAINED PRODUCTS
With the new POE [Polyol Ester] oils, the refrigeration system is more prone to moisture problems than
the CFC systems. Every effort should be made to never have the system open to the atmosphere for
longer than 15 minutes, and the replacement of the drier/filter is no longer an option, [IT IS MANDATORY].
A good vacuum is not always easy to measure, however the goal is to have less then 1% non-condensible vapors in the system at the completion of the evacuation. Basic guidelines with a good pump would
be to evacuate a self–contained product 30 to 45 minutes and a remote product no less than 60 minutes.
The system should be evacuated to approximately 200/250 microns. Then perform a 5 minute holding
test. You may expect a low grade loss of the vacuum as normal. However, a rapid rise to normal atmospheric pressure would signal a system leak is present and must be located and repaired before recharging the product. A slower pressure rise to approximately 1500 microns would signal moisture still present
in the refrigeration system.
On a “WET” system, it would be beneficial to use heat lamps to raise the temperature of the compressor
dome and evaporator surface area during the evacuation.
To assure a properly recharged product, the refrigerant charge must be weighed into the product using an
electronic charging scale or dial-a-charge. On air- and water-cooled products the charge should be
introduced into the high side service valve. On remote systems, the charge should be introduced into the
product receiver.
OPEN
VACUUM
PUMP
OPEN
MANIFOLD SET
OPEN
OPEN
CHARGING
CYLINDER
CLOSED
HIGH SIDE
SERVICE
VA LV E
LOW SIDE
SERVICE
VA LV E
CLOSED
ELECTRONIC
SCALE
OPEN
VACUUM
PUMP
MANIFOLD SET
CLOSED
CLOSED
HIGH SIDE
SERVICE
VA LV E
LOW SIDE
SERVICE
VA LV E
OPEN
CHARGING
CYLINDER
CLOSED
OPEN
ELECTRONIC
SCALE
FIGURE 14
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IMPORTANT: Service personnel are held responsible for all aspects of the clean air act of July,
1992.
REFRIGERANT DEFINITIONS (ASHRAE 3-1990)
RECOVERY
To remove refrigerant in any condition from a system and store it in an external container without necessarily testing or processing it in any way.
RECYCLING
To clean refrigerant for reuse by oil separation and single or multiple passes through devices, such as
replaceable core filter-driers, which reduce moisture, acidity, and particulate matter. This term usually applies to procedures implemented at the field job site or at a local service shop.
RECLAIM
To reprocess refrigerant to new product specifications by means which may include distillation. Will require chemical analysis of the refrigerant to determine that appropriate product specifications are met.
This term usually implies the use of processes or procedures available only at a reprocessing or
manufacturing facility.
NOTES REGARDING RECLAIM:
“New product specifications” currently means ARI standard 700-88. Note that chemical analysis is required to assure that this standard is met.
Chemical analysis is the key requirement to the definition of “Reclaim”. Regardless of the purity levels
reached by a re-processing method, the refrigerant is not “reclaimed” unless it has been chemically analyzed and meets ARI Standard.
HIGH PRESSURE SAFETY SWITCH
All water-cooled, remote products and air cooled 500’s contain a high pressure safety cut-out switch. The
function of this switch is to shut down the cuber should excessive pressure develop in the high side of the
refrigeration system. This switch will open the power supply at 450 PSI (30.61 BAR) high side pressure.
Should this control open, it must be reset manually and the cause for the increase in pressure determined.
COMPRESSOR RUN-ON
Contactor remains energized when curtains are in a full bin condition – compressor runs but water pump
and condenser fan (AC) are off.
1. Check VAC at contactor coil with an analog voltmeter (dial type, not digital).
A. Voltage at the contactor coil 12 VAC or higher may hold the coil energized. Turn the power
switch OFF, if contactor de-energizes, replace the circuit board, the snubber circuit is leaking.
B. Should you find 1/2 normal line voltage, replace the circuit board, the triac is shorted.
C. If no voltage or very low voltage (6 VAC or less) is present and plunger is still closed, replace
the contactor.
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TROUBLESHOOTING
IMPORTANT: Only qualified personnel should service internal components or electrical wiring.
Trouble Probable Cause Remedy
CUBER NOT OPERATING
CUBER NOT OPERATING,
INDICATOR LIGHTS “OFF”,
NO POWER TO CIRCUIT
BOARD
CUBER NOT OPERATING,
INDICATOR LIGHTS “OFF”,
POWER TO THE CIRCUIT
BOARD
PROXIMITY SWITCH LIGHT
“OUT”
A. Power switch in “OFF”
position.
A. Test power switch and leads. A. If defective, replace.
A. Magnet not in proximity switch
field.
B. No curtain movement. B. Adjust proximity switch.
C. Faulty proximity switch. C. Replace proximity switch.
D. Unit “OFF” due to bin full. D. Remove ice from curtain.
A. Loose wire connection at
circuit board.
B. Proximity switch defective, see
check-out procedure.
A. Place switch in “ON” position.
A. Water curtain drifting out of switch
range. Reduce clearance between
curtain and proximity switch.
Eliminate curtain restriction.
A. Tighten, reattach wire.
B. Replace as needed.
COMPRESSOR DOES NOT
RUN, CIRCUIT BOARD
INDICATOR LIGHTS “ON”
October 17, 2005 37
C. Water curtain stuck, curtain
frozen to ice on evaporator.
Curtain hung on water pan,
proximity switch out of range.
A. Check contactor and leads. A. Replace if defective.
B. Compressor overload “open”. B. Permit overload to cool and reset
C. High pressure cut-out open.
(water cooled or remote
systems)
D. Check compressor and start
components.
C. Check and adjust as needed.
or replace.
C. Press manual reset.
Determine cause:
Water supply shut off; water
pressure too low; water valve
defective or out of adjustment;
water condenser dirty or
corroded; unit overcharged; water
inlet pressure too high. Replace
defective component as needed.
D. Replace as needed.
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Trouble Probable Cause Remedy
COMPRESSOR RUNS BUT
DOES NOT COOL, CIRCUIT
BOARD INDICATOR LIGHTS
“ON”
CUBER DOESN’T GO INTO
FREEZE CYCLE
CUBER REMAINS IN THE
FREEZE CYCLE
A. Low charge. A. Leak check – Recharge.
B. Hot gas solenoid leaking. B. Replace.
C. Defective expansion valve. C. Replace.
D. Inefficient compressor. D. Replace.
E. Internal by-pass open,
E. Permit pressures to equalize.
compressor noisy.
A. Ice bridge setting too low. A. Adjust per bridge adjustment
instructions.
B. Expansion valve failure (will
not pull down).
B. Tighten bulb, replace as needed.
See check-out procedure.
A. Low inlet water pressure A. Check for restriction in the water
supply line or filter.
B. Fill valve failure
C. Pressure tube failure.
B. Replace as needed.
C. Ensure that pressure tube is
connected and free of cuts or
kinks.
LONG FREEZE CYCLE
GENERAL
D. Pressure sensor failure.
E. Water leak.
D. Replace control board as needed.
E. Check for leaks in the water
distribution system and repair as
needed.
F. High or low ambient
temperature.
F. Ensure air ambient temperature is
from 50 to 100 degrees.
A. Water inlet valve leaking. A. Repair or replace.
B. Dirty condenser or fan blade. B. Clean as required.
C. Louvers at condenser
C. Remove obstruction.
obstructed.
D. Ambient air temperature too
D. Advise customer.
high.
E. Condenser discharge air
E. Install condenser baffle.
re-circulating.
F. Low charge. F. Check for leak, correct, evacuate
and recharge.
G. Hot gas solenoid valve leaking
G. Replace.
(not seating).
TP00952
H. Water regulator valve set too
high or stuck (water cooled
units only).
38
H. Adjust, clean or replace (setting to
be 260 to 271 PSI).
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Trouble Probable Cause Remedy
LONG HARVEST CYCLES A. Ice weight set too light. A. Adjust bridge per adjustment
instructions.
B. Unit not level. B. Level the unit.
SOFT WHITE ICE OR WATER
PUMP NOT PUMPING
C. Water curtain movement
C. Remove restriction.
restricted.
D. Low head pressure: ambient
too low.
E. Low head pressure; water
valve set too low (water cooled
D. Minimum ambient temperature
50_F (10_C).
E. Adjust water regulator valve or
replace (260 to 271 PSI).
units only) or leaking during
harvest.
F. Scale build-up on evaporator. F. Clean per instructions.
G. Hot gas solenoid valve not
G. Replace valve.
opening. Slow rise of low side
pressure.
H. Expansion valve leaking. H. Replace valve.
A. Distribution tube or water
system scaled.
A. Clean distribution system as
required.
B. Water temperature too cold. B. 50_F (10_ C) minimum.
C. Inadequate water system;
C. Correct.
water pressure too low (below
20 PSI).
D. Inadequate water system; fill
D. Replace.
valve plugged or damaged.
Water supply filter plugged.
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Trouble Probable Cause Remedy
LEAKING WATER PAN A. Damaged water pan. A. Replace water pan (see Kit
Instructions, number below, for
Water Pan Replacement).
Model # Kit #
300 631500152
500/600/800/1000 631500153
1200 631500154
Pull tab toward you. Turn pump clockwise and lift.
FIGURE 15
NOTE: Remove pump tubing from the dump solenoid, after the pump has been lifted out of the reservoir, disconnect the distributor tubing at the tee fitting and lift pump out.
ICE WILL NOT HARVEST
A. Grid separation.
A. Replace evaporator (see Kit
Instructions, number below, for
Evaporator Replacement).
B. Defective plating.
B. Replace evaporator (see Kit
Instructions, number below, for
Evaporator Replacement).
Model # Kit #
300 631500121
500 631500119
600/800/1000 631500135
1200 Right 631500119
1200 Left 631500141
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AIR COOLED CONDENSER
FAN BLADES
FILTER/DRIER
FAN MOTOR
HEAT EXCHANGER
EVAPORATOR
COMPRESSOR
LOW SIDE
SERVICE
VALV E
S
HOT GAS
SOLENOID
THERMOSTATIC
EXPANSION VALVE
WATER
DUMP VALVE
VALV E
HIGH SIDE
SERVICE
VALV E
FIGURE 16
October 17, 2005 41
WATER PUMP
REFRIGERATION AND WATER SYSTEMS
MODELS XAC322, XAC330, XAC522, XAC530, XAC630, XAC830
TP00952
WATER REGULATING VALVE
WATER-COOLED CONDENSER
Xtreme Ice Training Manual
FILTER/DRIER
WATER INLET
HEAT EXCHANGER
EVAPORATOR
THERMOSTATIC
EXPANSION VALVE
PRESSURE
SWITCH
HOT GAS
SOLENOID
VALV E
WATER
S
DUMP VALVE
LOW SIDE
SERVICE
VALV E
HIGH SIDE
SERVICE
VALV E
COMPRESSOR
FIGURE 17
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WATER PUMP
Refrigeration and Water Systems
Models XWC322, XWC330, XWC522, XWC530 , XWC630, XWC830
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Xtreme Ice Training Manual
XTREME ICE – KITS
BIN STAT KIT, P/N 630000408
Installation Instructions
These Bin Stat kits apply to all “X” Series Ice makers.
Loose–Shipped Parts
Item No. Part No. Name Qty.
1 630000837 Thermostat Asy 1
2 07578 Screw TC 08–32 2
3 630460162 Installation Instruction, Thermostat 1
4 630900895 Hex Nut 8–32 SS Keps 2
5 620045454 or
620045455 or
620045456 or
620045457
Bin Stat Support 1
1. Disconnect power.
2. Remove front cover of the unit and the electrical box cover plate. For 22” wide units you will need to
remove the Grill from the right side of the unit.
3. To mount bin thermostat in electrical box:
A. Route wires and connector through grommet in electrical box (see Figure 18).
B. Attach bin thermostat to electrical box with two 08–32 TC screws provided (see Figure 18).
4. Connect the bin thermostat lead to the circuit board (see Figure 19).
5. Straighten approximately 12” of capillary tube to go through hole in chassis base. Re–coil the remainder. Do not disturb the tightly coiled end.
6. Insert the “1/4” diameter wire Bin Stat support into the coiled end of capillary tube. Carefully wrap 5
turns of free capillary tube tightly around the Bin Stat support. Insert the assembly through the hole
in the chassis base. Route capillary tube to follow the Bin Stat support as closely as possible (see
Figure 20).
7. Slip eye of Bin Stat support over the 8–32 weld stud in the chassis base. If a nut exists on this weld
stud remove before assembling the Bin Stat support. Secure the Bin Stat support with the 8–32
Keps nut provided in the kit (see Figure 20).
8. Any excess capillary tubing must be carefully pulled back into the compressor compartment to prevent ice from damaging it during dispenser operation.
9. Seal ½” diameter hole with sealant (RTV).
10. Turn bin stat adjustment screw clockwise until it stops. Then turn it counterclockwise 1/8 of a turn.
11. Reinstall the front cover of the electrical box and the ice machine and reconnect the power. Verify
that the Bin Stat is working by holding ice on the coiled bare capillary tube. The bin stat will allow the
ice machine cycle to complete and harvest ice. Then the ice machine will shut down. Remove the ice
from the capillary tube and warm the tube with hand heat. The ice machine should start in approximately 60 seconds. Reinstall front cover and grill (22” units only).
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ELECTRICAL BOX ASY
SCREW TC 08–32
TO CHASSIS BASE
FIGURE 18
TO CIRCUIT BOARD
THERMOSTAT KIT ASY
631500074
COIL
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ERROR
DELAY
CLEAN
(White Lead)
Condenser Sensor
See note 1
PRESSURE Transducer
J9
Bin
Switches
Harvest
Unit
Selection
Switch
S3–2
RH Evap.
Switch
N
S
N
S
LH Evap.
Switch
Plug Bin Thermostat on Top
Two Pins of Stacking Cable Plug
Adjust
Valve
GR
Dump
GR
Fan
GR
Comp
GR
Pump
GR
Gas
GR
RD
Transformer
#8
#7
#6
#5
#4
#3
#2
#1
FILL VALVE
DUMP VALVE
FAN MOTOR (AIR COOLED)
COMPRESSOR
WATER PUMP
HOT GAS
NEUTRAL
POWER
12
S3–1
In
Out
Com
Bridge
Thickness
pot.
Micro
Processor
(Manufacturing Date)
36430001
YL
YL
YL
YL
Stack
Triac
Off
3
On
Off
On
5
4
3
2
1
FIGURE 19
October 17, 2005 45
TP00952
BIN STAT SUPPORT
INSERT COIL AROUND
8–32 HEX
NUT
BIN STAT
SUPPORT
Xtreme Ice Training Manual
DETAIL A
SCALE 1:2
FIGURE 20
CAPILLARY TUBE
SEE DETAIL
BIN STAT SUPPORT
A
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REMOTE CONDENSERS
Installation Instructions
UNIT
LEG
1/4-20 SCREW
LEG
BRACE
FIGURE 21
1. Follow the standard installation instructions supplied with cuber. Do not hook cuber into the power
source until the remote condenser and line set installation is complete.
2. Assembly of remote condenser (See the following Figures):
A. Assemble legs to base panel. Install leg supports on legs.
B. Locate the remote condenser in a well–ventilated area on the roof away from other refrigeration
equipment’s condenser discharge air flow.
C. Use the mounting holes provided to secure the remote condenser to the roof. Seal over heads
of bolts or fasteners with tar or pitch to prevent entrance of moisture.
REMOTE CONDENSER
FIGURE 22
October 17, 2005 47
LEG
LEG SUPPORT
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3. Remote condenser electrical hook-up:
A. Connect remote condenser to a power source (208/230VAC, 60 HZ) separate from the cuber.
An external disconnect switch must be used.
B. Make sure the electrical connections follow all local and
national codes.
C. DO NOT turn condenser on until cuber install and refrigerant line connections are com-
plete!
D. Never wire condenser into cuber section. The condenser is an independent electrical connec-
tion.
E. Fan motor will not start until pressure rises to 205 PSIG [14.07 Bars] closing fan cycling switch.
F. The condenser fan may cycle off during the harvest cycle – this would be normal.
NOTE: Installing an IMI Cornelius remote cuber with other than an IMI Cornelius remote condenser and line set may be reason to void the cuber warranty.
LIQUID
REFRIGERANT
LINE
DISCHARGE
LINE
CORRECT
FIGURE 23
4. Each condenser and cuber is connected with two (2) *pre-charged lines (See Figure 23).
A. The pre-charged lines are ordered separately from the condenser to suit each individual ap-
plication (contact your service provider for more information).
B. The pre-charged line lengths are 20 feet [6.096 meters], 35 feet [10.66 meters] and 55 feet
[16.76 meters] (contact your service provider for more information).
NOTE: Pre-charged is defined as a vapor holding charge – not a portion of the system charge.
5. Installation of line kits (see drawing). Remove the tubing from the carton. Carefully uncoil the lines so
the tubing doesn’t become kinked, and route lines to cuber and condenser.
6. Keep line-set as short as possible. Place a 3-foot service loop behind cuber to allow for rear service
should it ever be required.
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REMOTE CONDENSER LOCATION
1. Physical Line-Set Length: 55 Ft. Maximum [16.764 meters]
The ice machine compressor must have the proper oil return. Line-set rises, drop, or horizontal runs
greater than the maximum distance allowed will exceed the compressor start up and pumping design
limits, and will result in poor oil return to the compressor.
Line-Set Rise: 35 Ft. Maximum [10.66 meters]
Line-Set Drop: 15 Ft. Maximum [4.57 meters]
2. Calculated Line-Set Distance: 100 Ft. [30.48 meters] (See Figure 24)
To prevent the combination of rises, drops and horizontal runs exceeding the compressor start-up
and pumping design limit, the following calculations should be made:
NOTE: Max. line–set for IMI Cornelius cubers is 55 ft. Do not confuse line length with calculated
line distance
B
A
B
A - (RISE) CONDENSER HIGHER THAN EVAP.
MAX. 35 FT.
B - LINE LENGTH 15 FT.: EXAMPLE
B - LINE LENGTH 35 FT.
C - (DROP) CONDENSER LOWER THAN EVAP. 15 FT.:
: EXAMPLE
FIGURE 24
Maximum Line-Set Distance Formula
A. Measured rise x 1.7= Calculated Rise 35 ft. Max) [10.66 meters]
B. Measured drop x 6.6= Calculated Drop 15 ft. Max) [4.57 meters]
C. Measured Horizontal Distance = actual measurement.
D. Total Calculated Distance (A+B+C)=Total Calculated Distance (100 ft. Max.) [30.48 meters]
Examples:
a. Insert measured rise (R) into the formula and multiply it by 1.7 to get a calculated rise (See
Figure 25).
example: A condenser located 15 ft. [4.572 meters] above the ice machine has a 25.5 ft.
[8.874 meters] calculated total (15 ft. x 1.7 = 25.5).
C
MAX.
FIGURE 25
October 17, 2005 49
H
AIR
FLOW
R
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b. Insert measured drop (D) into formula and multiply by 6.6 to get a calculated drop (See
Figure 26).
example: A condenser located 8 ft. [2.438 meters] below the ice machine has a 52.8 ft.
[16.093 meters] calculated total (8 ft. x 6.6 = 52.8 ft.).
COMBINATION OF
DROP(S)
WITH HORIZONTAL
H
D
AIR
FLOW
FIGURE 26
c. Insert measured horizontal distance into formula. No calculation is necessary. (6 ft.) [1.828
meters].
d. Add the calculated rise, calculated drop, and horizontal distance together to get the total
calculated distance (25.5 + 52.8 + 6) equals 84.3 ft. [25.694 meters]. If 100 ft. [30.48 meters] total calculated distance is exceeded, the condenser must be moved to a new location which permits proper equipment operation (See Figure 27).
COMBINATION OF RISE AND
DROP(S)WITH HORIZONTAL
H
R
D
AIR
FLOW
FIGURE 27
CAUTION: If a line-set rise is followed by a line-set drop, a second line-set rise cannot
be made. Or If a line-set drop is followed by a line-set rise, a second line-set drop
cannot be made.
3. Lengthening or Reducing the Line-Set Lengths
In most cases, by routing the line-set properly, shortening will not be necessary (refer to illustration).
However, when shortening or lengthening is required, do so before connecting the line-set to the ice
machine or the remote condenser. This prevents the loss of refrigerant from the ice machine or the
condenser.
The quick connect fittings on the line-sets are equipped with Schrader Valves. Use these valves to
recover any vapor charge from the line-set. When lengthening or shortening lines, apply good refrigeration practices and insulate new tubing. Do not change the tube sizes. Evacuate the lines and
place approximately 5 oz. of vapor refrigerant charge in each line (See Figure 28).
Schrader Valve
Parent Metal Seal
FIGURE 28
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4. Connection of Line-Set
A. Remove the plastic caps from the line-set, the condenser, and the ice machine.
B. Apply refrigeration oil to the threads on the quick connect couplers before connecting them to
the condenser.
C. Carefully thread the female fitting onto the condenser or ice machine by hand.
D. Using the proper size wrench, tighten the couplings until they bottom out. Turn an additional 1/4
turn to ensure proper brass-to-brass seating.
E. Check all fittings for leaks.
5. Final Installation:
A. Remove grill from the right-hand side panel of cuber.
B. Turn service port on receiver tank to open position releasing refrigerant to the balance of the
system.
C. Leak check line-set connections at cuber and condenser.
D. Replace grill.
E. Connect cuber to power source.
F. Make sure electrical connections follow all local and national codes.
6. Start Up:
A. Use standard procedures from cuber installation instructions.
B. After the cuber is running, check the remote condenser and verify that the condenser fan is run-
ning.
CAUTION: Once the refrigerant lines are connected, the seal is broken in the
fittings. If the lines are removed or loosened from the cuber or remote condenser,
the refrigerant charge will be discharged to the atmosphere. DISCHARGING TO
THE ATMOSPHERE IS IN VIOLATION OF THE CLEAN AIR ACT OF JULY, 1992.
HEAD PRESSURE CONTROL [HEADMASTER]
discharge
receiver
discharge
condenser
receiver
condenser
above 70°F normal
FIGURE 29
The Cornelius series remote systems use an Alco Head Pressure Control, normally referred to as a
headmaster. This control is mounted in the remote condenser with a fan cycling control switch. Using
both these controls gives the system positive operation under a wide range of condensing temperatures.
The cycling control starts the fan at 270 PSI and stops it at 205 PSI allowing a positive efficient operation
at the high temperature operating ranges (See Figure 29).
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The headmaster controls the operation when the condensing temperature drops below 70°F. The refrigerant charge is HP - 62 [R - 404A] and the headmaster dome charge setting is 200 PSI of nitrogen pressure making it stable under the low temperature operating range down to - 20°F.
The normal flow pattern through the headmaster is from the condenser port to the receiver port. When
this flow pattern is unable to maintain a receiver outlet pressure equal to or above the dome pressure setting of the valve, the dome pressure will force the valve portage to change closing the condenser port and
opening the bypass port from the compressor discharge line. This allows the high pressure vapor from
the discharge port to “buck” the receiver pressure back up. With the condenser port closed, the refrigerant is backed up in the condenser, basically reducing the condenser size, assisting in maintaining the discharge portage flow and increasing the head pressure.
Remember, sense of touch to the lines of the headmaster will determine the flow path the headmaster is
in, condenser to receive, or bypass to receiver.
High side gauge installed at the receiver outlet valve will determine if the headmaster is functioning to
maintain the proper operating pressure.
In the event the control appears to be “stuck in bypass”, the pressure drop across the headmaster must
be measured. With a gauge installed at the receiver outlet valve and the high side service valve, the pressure difference at these two points must be less than the 15 PSI. The three most common causes of an
excessive pressure drop are shortage of refrigerant, kinked remote lines, and excessive line length.
Eliminate refrigerant shortage first. Add refrigerant in two-pound increments (not to exceed six pounds)
to determine if it corrects the pressure drop. If pressure drop is not corrected, inspect line set for sharp
bends or kinks and correct as required. If adding refrigerant does not correct continued (bypass) condition
and line set is not damaged, replace headmaster.
REMOTE SYSTEM EVACUATION/RE-CHARGE
All field repairs to the sealed system must start with a total discharge of the system following the requirements of the Clean Air Act of July, 1992.
Proper evacuation of the total remote system will require a three (3) point hook-up of your manifold and
hose set, (See Figure 30):
Point #1 - Cuber receiver outlet valve
Point #2 - Cuber high side service valve
Point #3 - Cuber low side service valve
Evacuation:
1. With cuber power supply turned “OFF” disconnect and insulate all 3 compressor leads at the compressor. Turn power supply on, place power switch in the “on” position. This will energize (open) the
Liquid Line solenoid allowing evacuation of the Liquid Line between the solenoid and the expansion
valve(s).
2. Evacuate system to 200/250 microns or less. At this point, there should be a holding test of five(5)
minutes. You may expect a slight loss of vacuum as normal. A rapid rise to normal atmospheric
pressure indicates moisture still present in the system. On a “wet” system, it will prove beneficial to
use heat lamps to warm the compressor dome and evaporator surface during evacuation.
3. Turn cuber power switch OFF. Reconnect compressor leads.
4. *After proper evacuation hold test has been performed, the refrigerant charge should be “dumped”
into the receiver until the pressure equalizes, stopping the flow. Do not try to throttle the refrigerant
flow. Doing so will allow system pressure to balance too soon. The high-side service valve should be
closed and the balance of the charge fed slowly through the suction side service valve with the compressor operational. Control the feed rate at no faster than four (4) ounces [113.g] per minute to ensure the compressor oil does not become too saturated with refrigerant resulting in a loss of compressor lubrication.
5. All refrigerant re-charging must be weighed into the system, utilizing an electronic charging scale.
DO NOT attempt to recharge the system by sight glass, system pressure, amperage, frost line or
sweat patterns.
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6. Always leak check entire system after recharge.
CAUTION: Before programming the electronic scales to “dump” the charge, de-energize
the liquid line solenoid, close the shut-off valve on vacuum pump and low side of the
manifold set.
OPEN
RECEIVER
OPEN
RECEIVER
OUTLET
VALVE
VACUUM
PUMP
EVACUATION
MANIFOLD SET
OPEN
OPEN
CHARGING
CYLINDER
OPEN
CLOSED
FIGURE 30
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
CLOSED
ELECTRONIC
SCALE
1ST STAGE CHARGING
OPEN
RECEIVER
OPEN
RECEIVER
OUTLET
VALVE
CLOSED
VACUUM
PUMP
MANIFOLD SET
CLOSED
CLOSED
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
OPEN
CHARGING
CYLINDER
OPEN
ELECTRONIC
SCALE
CLOSED
RECEIVER
CLOSED
RECEIVER
OUTLET
VALVE
VACUUM
PUMP
2ND STAGE CHARGING
COMPRESSOR OPERATING
MANIFOLD SET
OPEN
CLOSED
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
OPEN
CHARGING
CYLINDER
CLOSED
OPEN
ELECTRONIC
SCALE
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Distributed By:
Commercial Refrigeration Service, Inc.
WWW.CorneliusParts.COM
WWW.IceCubes.NET
(866) 423-6253
(623) 869-8881
October 17, 2005 55
IMI CORNELIUS INC.
CORPORATE HEADQUARTERS:
One Cornelius Place
Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600
TP00952
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