Cornelius XWC1230 Installation Instructions Manual

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Suction Line and Service Valve Assemblies Installation Instructions

INSTALLATION INSTRUCTIONS

SUCTION LINE AND SERVICE VALVE ASSEMBLIES P/N 631500282

This kit applies to the XWC1230 Water Cooled Condenser X-Series Ice Maker

WORK OVERVIEW

1. Disconnect power. Shut off potable water and condenser water supplies.

2. Remove exterior panels. Recover refrigerant in system.

3. Disconnect electrical harnesses and remove structural panels.

4. Remove existing piping assemblies.

5. Place and braze new piping assemblies. Leak test unit.

6. Insulate critical components, replace structural panels, and reconnect electrical harnesses.

7. Turn on condenser water and potable water supply.

8. Evacuate system and recharge with refrigerant.

9. Run test unit.

10. Replace exterior panels.

Release Date: March 21, 2014 www.cornelius.com Revision: B

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Suction Line and Service Valve Assemblies Installation Instructions

LOOSE-SHIPPED PARTS

Item No. Part Number Description Qty.

1 630001159 Suction Line Heat Exchange Assembly 1 2 630001160 Service Valve and Bracket Assembly 1 3 630001178 Suction Line to LH Evaporator (Extension) 1 4 163506001 Wire Tie - 7” 3 5 630900972 Insulation Tape Kit - Expansion Valve Bulb 2 6 164005001 1/8” POP Rivet - Stainless 1

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GENERAL WORK GUIDELINES

• Read and understand all instructions before starting.

• Disconnect all electrical power from unit prior to beginning work.

• Shut off potable and condenser water supplies to unit prior to beginning work.

• Prepare work area so that no brazing material, dirt, metal shavings, or other objects/refuse will enter the ice storage area.

• Save all screws, nuts, bolts, grommets, or other hardware.

Suction Line and Service Valve Assemblies Installation Instructions

• Work is to be performed by a trained,

INSTRUCTIONS

1. DISCONNECT ALL ELECTRICAL POWER FROM UNIT.

2. SHUT OFF WATER SUPPLY - Potable (evaporator supply) AND Condenser supply.

3. Remove the front panel cover (a), top cover (b), and louvered side panel (c) (FIGURE 1).

4. Remove the evaporator splash panel (d) and control box cover (e) [not shown] (FIGURE 2).

EPA certified refrigeration mechanic.

FIGURE 1 FIGURE 2

5. The icemaker should be

the refrigerant, it must be recovered (as defined in ARI Standard 740-91) from the system.

The refrigerant type and charge are indicated on the serial plate, located on the water pan (f)(FIGURE 2).

USE ONLY RECOVERY EQUIPMENT DESIGNATED FOR USE WITH R-404A (HP-62) REFRIGERANT.

Comply with all federal regulations concerning the handling of refrigerants.

WARNING: If the compressor has burned-out, there is a refrigerant leak, moisture is present, or contaminates or other noncondensables are in the system, the refrigerant recovered from this unit may NOT be reused in this product until it has been reclaimed to meet ARI Standard 700-88.

charged with 45 ounces of R-404A (HP-62). Regardless of the condition of

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Suction Line and Service Valve Assemblies Installation Instructions

6. Drain the evaporator water pans (a)(c) by removing the connection tube behind the metal evaporator support (b) (FIGURE 3).

The water MUST be drained from both RIGHT and LEFT pan. Failure to do so will cause the pressure transducer (which controls the harvest cycle) to be set improperly on start up.

DO NOT drain the water into the ice storage area, unless the area is completely free of ice.

Replace the connection tube and metal support when the pans are completely drained.

NOTE: The water pump motor must be protected from water splash. DO NOT introduce water into the motor housing.

Warranty on water pump is VOID if water damaged.

FIGURE 3

7. Disconnect the electrical plug from the Water Fill Valve (d) and Water Dump Valve (e) (FIGURE 4).

8. Disconnect the Water Pump plug (f) and Transducer Pressure Hose (g) (FIGURE 5).

FIGURE 4 FIGURE 5

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Suction Line and Service Valve Assemblies Installation Instructions

Yellow

Red

Black

9. Disconnect the plugs from the Hot Gas Solenoid Valve (FIGURE 6).

Remove the compressor junction box cover and disconnect all electrical leads (FIGURE 7 and FIGURE 8).

Remove the ground wire from the screw post on the chassis, by the compressor.

FIGURE 6

FIGURE 7 FIGURE 8

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Suction Line and Service Valve Assemblies Installation Instructions

10. Disconnect and remove the leads from the junction box (FIGURE 9) for the: A. Curtain Switches - 2 white low voltage plug harnesses (Control board) B. High Pressure Cutout - 2 blue wires (Contactor and #5 pin on control board)

11. Remove the 2 screws connecting the service valve bracket (c) to the control box (FIGURE 10).

FIGURE 9

FIGURE 10

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Installation Instructions Suction Line and Service Valve Assemblies

12. Remove the 2 screws connecting the top support brace (a) to the evaporator bulkhead (FIGURE

11).

13. Drill out the rivet attaching the right side panel to the base (FIGURE 12). A 1/8”drill bit is recommended.

14. Remove the 5 screws attaching the right side panel to the rear panel (FIGURE 13).

FIGURE 11 FIGURE 12

15. Lift and set aside the right side panel, control box, and support brace assembly (a).

16. Remove the 2 screws holding the 2 piping access covers (b) to the wrap panel (FIGURE 13).

FIGURE 13

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Installation Instructions Suction Line and Service Valve Assemblies

Ring Seal

17. Remove the bulkhead seals at the front of the evaporator assembly.

Remove the insulation from the evaporator inlet and outlet lines (FIGURE 14).

Remove enough insulation to safely disconnect these lines.

WARNING: All plastic, electrical, or sensing components, assemblies, or harnesses must be protected when heating the refrigeration lines. Failure to take appropriate actions may result in damage to the unit.

THE REFRIGERANT IN THE SYSTEM SHOULD BE RECOVERED AND THE SYSTEM PURGED WITH NITROGEN PRIOR TO ANY BRAZING OPERATIONS. Failure to take appropriate actions may cause damage to the unit and result in personal injury or death.

18. If the refrigerant in the system has been fully recovered, open the high side service valve.

FIGURE 14

Attach a nitrogen feed (a) to the low side service valve (5-10 psi) (FIGURE 14).

Open the low side service valve to purge the system with nitrogen.

As power to the unit has been disconnected, disassemble the hot gas valve to allow nitrogen to flow through the entire system (FIGURE 15).

19. Protecting the water pump and plastic bulkhead from heat, remove the evaporator piping at the bulkhead (FIGURE 14).

FIGURE 15

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Installation Instructions Suction Line and Service Valve Assemblies

20. Move the nitrogen feed to the high side service valve.

21. Remove the suction line (a) from the water cooled condenser (FIGURE 17).

DO NOT remove the water lines from the condenser.

WARNING: DO NOT apply excessive heat to the water side of the condenser. Protect in the same manner as an expansion valve or other heat sensitive equipment.

Remove the liquid line (b) from the water cooled condenser, and the water control valve capillary (c) from the suction line assembly.

FIGURE 16

22. At the rear of the unit, remove the suction line (d) from the left evaporator. Do not remove the line extension (e) (FIGURE

17).

FIGURE 17

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Installation Instructions Suction Line and Service Valve Assemblies

Elbow

Remove the liquid line (f) AND the extension (g) from the left evaporator. LEAVE the elbow fitting on the evaporator (FIGURE 18).

23. Move the nitrogen feed to the low side service valve.

24. Remove the insulation from the suction inlet (a) to allow safe removal of the line from the compressor (FIGURE 19)

25. Remove the suction line inlet (a) and the compressor discharge (b) from the compressor.

26. Remove the service valve line (c) from the compressor.

Remove and discard the service line and suction line assembly.

FIGURE 18

FIGURE 19

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Installation Instructions Suction Line and Service Valve Assemblies

27. At the back of the unit, place the new evaporator extension (d) into the bottom elbow fitting of the left evaporator (FIGURE 20).

Feeding nitrogen into the suction side of the evaporator, braze extension (d) into place.

FIGURE 20

DO NOT braze new piping assemblies until all components have been placed in the unit.

28. Place the Heat Exchange Suction Line in the unit (FIGURE 21).

Connect the tubing to the right hand evaporator (a) (b), and condenser (c) (d).

FIGURE 21

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Installation Instructions Suction Line and Service Valve Assemblies

29. At the rear of the unit, connect the Heat Exchange Suction Line to the left hand evaporator (e) (f)(FIGURE 22).

30. As power to the unit has been disconnected, disassemble the hot gas valve to allow nitrogen to flow through the entire system (FIGURE 23).

31. Place the nitrogen feed on the low side (a) service valve (FIGURE 23).

FIGURE 22

FIGURE 23

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Installation Instructions Suction Line and Service Valve Assemblies

32. Braze the service valve into the process port (a) on the compressor. Braze the valve into the liquid line (b) on the suction line assembly (FIGURE 24).

33. Braze the discharge line into the compressor discharge port (c).

34. Using clamps or other means, secure the insulation away from the joint and braze the suction line into the suction inlet (d) on the compressor.

35. Braze the water control valve capillary (e) into the suction line assembly at the high pressure cutout.

FIGURE 24

36. Using clamps or other means, secure the insulation away from the joints, and braze the Heat Exchange Suction Line to the left hand evaporator inlet (a) and outlet (b) (FIGURE 25).

Protect the water pan, pump motor, and evaporator bulkheads during brazing operations.

WARNING: All plastic, electrical, or sensing components, assemblies, or harnesses must be protected when heating the refrigeration lines.

Failure to take appropriate actions may result in damage to the unit.

FIGURE 25

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Installation Instructions Suction Line and Service Valve Assemblies

37. Using clamps or other means, secure the insulation away from the joints, and braze the Heat Exchange Suction Line to the right hand evaporator inlet (c) and outlet (d) (FIGURE 26).

Protect the evaporator bulkheads during brazing operations.

38. Braze the liquid line (e) and suction line (f) into the water cooled condenser (FIGURE

27).

FIGURE 26

39. Re-assemble the hot gas solenoid valve.

40. Use nitrogen to pressure test the system to 150 psig. The system may not be evacuated or charged with refrigerant until passing a pressure test.

It will be necessary to use the high side and the low side service valves to pressurize the system, unless power is brought to the hot gas solenoid.

41. Once the system has passed a leak test, cover both expansion valve bulbs (a) with the insulation tape kit (FIGURE 28).

FIGURE 27

FIGURE 28

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Installation Instructions Suction Line and Service Valve Assemblies

Ring Seal

42. Replace the bulkhead ring seals at the evaporator inlet and outlet (FIGURE 29).

43. Remove all tools, loose wiring, solder drippings, dust, dirt, or other foreign objects from the unit interior.

FIGURE 29

44. Place the right side panel/brace/electrical box assembly (b) (FIGURE 30). Attach the right side panel to the base with the 1/8” Stainless POP Rivet (FIGURE 31).

FIGURE 30 FIGURE 31

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Installation Instructions Suction Line and Service Valve Assemblies

45. Replace the 5 hex head screws attaching the rear panel to the right side panel.

Replace the 6 hex head screws attaching the rear panel to the left side panel.

Attach the water line to the Heat Exchange Suction Line with the 7” wire tie (FIGURE

32).

46. Use 2 hex head screws to attach the service valve bracket (a) to the electrical control box (FIGURE 33).

FIGURE 32

FIGURE 33

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Installation Instructions Suction Line and Service Valve Assemblies

bcRed

Black

Yellow

47. Attach the support brace (b) to the evaporator bulkhead (c) with 2 Phillips Head Screws (FIGURE 34).

WARNING: VERIFY ALL ELECTRICAL CONNECTIONS AGAINST THE UNIT WIRING DIAGRAM.

48. Connect the compressor leads (FIGURE

35) and replace the junction box cover.

FIGURE 34

FIGURE 35

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Installation Instructions Suction Line and Service Valve Assemblies

Pin #5

49. Connect the leads for the: A. Curtain Switches - 2 white low voltage plug harnesses (Control Board). B. High Pressure Cutout - 2 blue wires (Contactor and #5 pin on control board)(FIGURE 36).

50. Connect the water fill valve harness (a)

FIGURE 36

(black & white leads) and the water dump valve harness (b) (yellow & white leads)(FIGURE 37).

FIGURE 37

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Installation Instructions Suction Line and Service Valve Assemblies

51. Connect the hot gas valve harness (c) (white & red leads) to the hot gas valve (FIGURE 38).

52. Connect the pressure transducer tube (d) to the water pan and connect the water pump motor harness (e)(FIGURE 39).

WARNING: DO NOT fill the water pan.

FIGURE 38

53. Connect the ground lead from the control box to the base plate, by the compressor.

WARNING: VERIFY ALL ELECTRICAL CONNECTIONS AGAINST THE UNIT WIRING DIAGRAM.

FIGURE 39

54. Evacuate the system, in preparation for charging with refrigerant. Recommended pre-charge system state is 150 microns.

DO NOT run the compressor with the system in vacuum.

55. TURN ON ALL WATER SUPPLY - Potable (evaporator) AND Condenser supply.

56. Crack the system with R-404A (HP-62) on the low side service valve.

DO NOT introduce liquid refrigerant into the low side service valve, or any other part of the system.

57. Charge the unit with R-404A (HP-62) refrigerant to the specification on the serial plate on the icemaker.

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Installation Instructions Suction Line and Service Valve Assemblies

It is the policy of Cornelius, Inc. to:

A. Comply with all federal regulations concerning the handling of refrigerants. B. Allow only virgin or reclaimed refrigerant (as defined by ARI Standard 740-91) to be used as or

added to an original system charge.

C. Allow recycled refrigerant to be used only in the system from which it was originally recovered;

and only if that system did NOT have a compressor burn out or refrigeration leak; and only if moisture, non-condensables, or other contaminates were NOT present in that system.

D. Refrigerant recovered from a contaminated system such as a compressor burn-out, refrigerant

leak, or one that has moisture, air, or other non-condensables present, must be disposed of in an appropriate manner and cannot, under any circumstances, be reused in any Cornelius product. If the refrigerant has been reclaimed and meets ARI Standard 700-88, it can be used.

E. The refrigerant used to recharge a Cornelius product must be of the type specified on the serial

nameplate of that product. All refrigerants must be weighed into the system so the amount of the charge is known and agrees with the product serial nameplate.

IMPORTANT: The service contractor is responsible for determining if the refrigerant is contaminated. It is also their responsibility to assure their recycling equipment and procedures will guarantee that the refrigerant is clean, moisture and non-condensable free and meets the appropriate standard. If the refrigerant is not cleaned to the appropriate standard, the warranty will be voided and the repair will become the responsibility of the service contractor.

Always follow safe and acceptable refrigeration procedures.

58. Once the system has been properly charged, monitor the unit for 3-4 freeze/harvest cycles. Refer to the operating manual for details on proper unit operation and performance.

59. After verifying the proper operation of the unit, replace the electrical control box cover (a) using (1) Phillips head screw.

Replace the evaporator splash panel (b) (FIGURE 40).

FIGURE 40

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Installation Instructions Suction Line and Service Valve Assemblies

cde

60. Replace the top cover (c) and the front panel (b). Attach the louvered panel with (4) black, hex head screws.

FIGURE 41

Cornelius XWC1230 Installation Instructions Manual

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