IMI Cornelius, Inc. 500 Series Service Manual
®
CONTINUOUS FLOW ICEMAKER
500, 700, 1000, 2000 - Series
Service Manual
Release Date: May 27, 2004
Publication Number: 630460174SER
Revision Date: September 24, 2008
Revision: D
Visit the IMI Cornelius web site at www.cornelius.com
for all your Literature needs.
CONTINUOUS FLOW ICEMAKER
SERVICE MANUAL
The products, technical information, and instructions contained in this manual are subject
to change without notice. These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possible contingency in the installation,
operation or maintenance of this equipment. This manual assumes that the person(s)
working on the equipment have been trained and are skilled in working with electrical,
plumbing, pneumatic, and mechanical equipment. It is assumed that appropriate safety
precautions are taken and that all local safety and construction requirements are being
met, in addition to the information contained in this manual.
To inquire about current revisions of this and other documentation or for assistance with
any Cornelius product contact:
www.cornelius.com
800-238-3600
Trademarks and copyrights:
Aurora, Cornelius, Decade, Hydro Boost, Sitco, Spirit, UF-1, Vanguard, Venture, Olympus, and Vista are registered trademarks of IMI Cornelius Inc.
Optifill trademark is pending.
This document contains proprietary information and it may not be
reproduced in any way without permission from Cornelius.
Printed in U.S.A.
Copyright © 2004-2008, All Rights Reserved, IMI Cornelius, Inc.
Continuous Flow Icemaker Service Manual
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Recognize Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Bin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Gearmotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5
Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Icemaker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
Semi-annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Refrigeration System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12
Condenser Modulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .13
Condenser Modulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .14
Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
To Replace Gearmotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .15
Installation and Shaft Seal Replacement 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Auger and Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .16
Installation and Shaft Seal Replacement 700 & 1000 . . . . . . . . . . . . . . . . . . . . . . . .17
Upper Nut and Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
To Replace Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17
Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .18
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .19
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .21
© 2004-2005, IMI Cornelius Inc. - i - Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
Publication Number: 630460174SER - ii - © 2004-2005, IMI Cornelius Inc.
SAFETY
SAFETY INSTRUCTIONS
Read and Follow all Safety Instructions
Read and follow all safety instructions in this manual and on the machine (decals, labels, and laminated
cards).
Read and understand all applicable OSHA (Occupation Safety and Health Administration) safety regula-
tions before operating the machine.
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the machine be
alert to the potential of personal injury or damage to the machine.
Different Types of Alerts
There are 3 types of safety alerts:
DANGER — Indicates an immediate hazardous situation which if not avoided WILL result in seri-
ous injury, death, or equipment damage.
Continuous Flow Icemaker Service Manual
WARNING — Indicates a potentially hazardous situation which, if not avoided, COULD result in
serious injury, death, or equipment damage.
CAUTION — Indicates a potentially hazardous situation which, if not avoided, MAY result in
minor or moderate injury or equipment damage.
SAFETY TIPS
• Carefully read all safety messages in this manual and safety signs on the machine.
• Keep safety signs in good condition and replace missing or damaged safety signs.
• Learn how to operate the machine and how to use the controls properly.
• Do not let anyone operate the machine without proper training. This appliance is not intended for use
by very young children or infirm persons without supervision. Young children should be supervised to
ensure that they do not play with the appliance.
• Keep your machine in proper working condition and do not allow unauthorized modifications to the
machine.
QUALIFIED SERVICE PERSONNEL
CAUTION — Only trained and certified electrical, plumbing and refrigeration technicians should
service this unit. ALL WIRING AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL
CODES.
SHIPPING AND STORAGE
CAUTION — Before shipping, storing, or relocating the Unit, syrup systems must be sanitized
and all sanitizing solution must be purged from the syrup systems. All liquids, after sanitizing, must
be purged from the unit. A freezing ambient environment will cause residual sanitizing solution or
water remaining inside the Unit to freeze resulting in damage to the internal components.
© 2004-2005, IMI Cornelius Inc. - 1 - Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
GENERAL DESCRIPTION
This section gives the Unit description, theory of operation, and design data for continuous flow icemaker
series 500, 700, 1000, and 2000.
SPECIFICATION CHART
Models
Condensing
Unit
VAC HZ PH Wire
Comp.
RLA
Fan
Amps
GRMT
R
Amps
Refrigerant
Oz. Type
Circuit
Fuse
WCC500-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20
WCC500-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20
WCC502-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20
WCC502-W Water Cooled 220/240 50 1 2 5.3 N/A 1.6 11 R404A 20
WCF510-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20
WCF510-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20
WCF512-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20
WCF512-W Water Cooled 220/240 50 1 2 5.3 N/A 1.6 11 R404A 20
WCC700-A Air Cooled 115 60 1 2 12 1.6 2 24 R404A 20
WCC700-W Water Cooled 115 60 1 2 12 N/A 2 13 R404A 20
WCC701-A Air Cooled 208/230 60 1 2 7.7 1.6 2 24 R404A 20
WCC701-W Water Cooled 208/230 60 1 2 7.7 N/A 2 13 R404A 20
WCC702-A Air Cooled 220/240 50 1 2 8.2 0.5 1.6 24 R404A 20
WCC702-W Water Cooled 220/240 50 1 2 8.2 N/A 1.6 13 R404A 20
WCF710-A Air Cooled 115 60 1 2 12 1.6 2 24 R404A 20
WCF710-W Water Cooled 115 60 1 2 12 N/A 2 13 R404A 20
WCC711-A Air Cooled 208/230 60 1 2 7.7 1.6 2 24 R404A 20
WCC711-W Water Cooled 208/230 60 1 2 7.7 N/A 2 13 R404A 20
WCF712-A Air Cooled 220/240 50 1 2 8.2 0.5 1.6 24 R404A 20
WCF712-W Water Cooled 220/240 50 1 2 8.2 N/A 1.6 13 R404A 20
WCC1001-A Air Cooled 208/230 60 1 2 7.5 0.85 2 26 R404A 20
WCC1001-W Water Cooled 208/230 60 1 2 7.5 N/A 2 17 R404A 20
WCC1002-A Air Cooled 220/240 50 1 2 8.9 0.85 2 26 R404A 20
WCF1101-A Air Cooled 208/230 60 1 2 7.5 0.85 2 26 R404A 20
WCF1101-W Water Cooled 208/230 60 1 2 7.5 N/A 2 17 R404A 20
WCF1102-A Air Cooled 220/240 50 1 2 8.9 0.85 2 26 R404A 20
WCC1001-R Remote 220/240 60 1 2 7.5 N/A 2 120 R404A 15
WCF1101-R Remote 208/230 60 1 2 7.5 N/A 2 120 R404A 15
WCC2001–A Air–Cooled 208/230 60 1 2 12.9 .85 (2) 2 46 R404A 25
WCC2001–R Remote 208/230 60 1 2 12.9 1.7 (2) 2 220 R404A 25
WCC2001–W Water Cooled 208/230 60 1 2 12.9 N/A (2) 2 28 R404A 25
WCC2002–A Air Cooled 220/240 50 1 2 11.4 .85 (2) 2 46 R404A 25
WCF2201–A Air–Cooled 208/230 60 1 2 12.9 .85 (2) 2 46 R404A 25
WCF2201–W Water Cooled 208/230 60 1 2 12.9 N/A (2) 2 28 R404A 25
WCF2202–A Air Cooled 220/240 50 1 2 11.4 .85 (2) 2 46 R404A 25
NOTE: For units not listed in above chart, refer to nameplate or contact factory service.
WCC500
400
380
360
340
320
300
280
Capacity Lbs./24 hr.
260
240
90 80
Publication Number: 630460174SER - 2 - © 2004-2005, IMI Cornelius Inc.
70 60
Water Temperature Deg. F
–50 –70 –90 –100
Air Temperature Deg. F
50
90 80 70 60 50
WCC700
Water Temperature Deg. F
–50 –70 –90 –100
Air Temperature Deg. F
650
600
550
500
450
400
350
Capacity Lbs./24 hr.
90 80 70 60 50
WCC1000
Water Temperature Deg. F
–50 –70 –90 –100
Air Temperature Deg. F
1100
1000
900
800
700
600
Capacity Lbs./24 hr.
Continuous Flow Icemaker Service Manual
24.50
14.50
FRONT
3.50
FRONT
25.00 1.38
10.15
WATER IN 1/4 FLARE
1.50
1.81
SIDE
1.19
AIR OR WATER COOLED
ICE DISCHARGE
1.75
INLET 3/8 FLARED
WATER COOLED ONLY
OUTLET 3/8 FLRE
WATER COOLED ONLY
DRAIN 3/8 ID TYGON TUBE
ELECTRIC 7/8 DIA
2.12
2.50
BACK VIEW
27.00
FIGURE 1. SERIES 500 & 700 DIMENSION DRAWING (SHIPPING WT. 160 LBS. APPROX).
22.00
FRONT
FRONT
9.04
(VIEWED FROM BOTTOM OF MACHINE)
24.00
SIDE
ICE DISCHARGE
2.06
BOTTOM VIEW
5.87
2.25
0.94 13.94
W/C INLET
3/8” FPT
POWER INLET
7/8” DIA.
4.50
1.88
AIR EXHAUST
2.19
9.00
BACK VIEW
(AIR COOLED)
ELECTRICAL 7/8” DIA.
10.44
WATER UB 1/4” MALE FLARE
DRAIN 3/8” ID TYGON TUBE
2.25
(REMOTE)
DISCHARGE LINE
1/2 PUNCTURE FITTING
W/C OUTLET 3/8” FPT OR
REMOTE COND. LIQ. LINE
3/8 PUCTURE FITTING
DRAIN 3/8” ID TUBE
WATER INLET
1/4” MALE FLARE
2.50
1.00
FIGURE 2. SERIES 1000 DIMENSION DRAWING (SHIPPING WT. 210 LBS. APPROX).
© 2004-2005, IMI Cornelius Inc. - 3 - Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
28.06
9.50
30.00
AIR INLET
FRONT
23.50
2.25
ICE DISCHARGE
18.13
WATER IN
ELECTRICAL 7/8 DIA.
DRAIN 3/8 I.D. TUBE
BACK
2.06
24.00
2.06
20.13
3.81
BOTTOM
VIEWED FROM BOTTOM OF MACHINE
2.06
FRONT
FIGURE 3. SERIES WCC2001-A AND WCF2201-A DIMENSION DRAWINGS
SIDE
Publication Number: 630460174SER - 4 - © 2004-2005, IMI Cornelius Inc.
BIN CONTROL
The type of bin control used on all WCC & WCF
Models is an electronic control. The control is
supplied with power to terminals X1 and X2.
Terminals X3 and X4 are a normally closed
switch which open when the thermostat sensor
bulb senses ice.
The sensing element is located in a 5/16”
stainless steel tube which hangs from the
dispense tray cover down through the center of
the drop tube.
To test switch, start the icemaker and block the
outlet tube. When the ice fills the drop tube
about 1/2 full the icemaker should shut off.
When tube is cleared the ice maker should
restart within 5 min.
The Bin control is in electrical series with coil on antifreeze relay along with the low water safety. If unit is
water cooled, the condenser high pressure cut out is also in series.
The Control Switch is held in place inside electrical box by 2 screws. The Control bulb is in the drop tube.
It can be removed by pulling the cable located on the top of the dispense tray cover. When replacing the
sensor make sure the bulb is inserted to the bottom of the thermostat well.
Continuous Flow Icemaker Service Manual
BIN CONTROL
SWITCH TERMINALS
FIGURE 4. BIN CONTROL SWITCH
GEARMOTOR
The gearmotor is equipped with a start relay and a manual reset overload.
When current is applied, the relay energizes and completes the circuit to the start winding. The motor
reaches a predetermined speed and the relay drops out, disconnecting the start winding. The run
winding remains in the circuit as long as current is applied.
The purpose of the overload is to automatically shut off the motor in the event of a mechanical bind of the
transmission, an overload condition within the evaporator or an electrical malfunction. It does this by
sensing amperage draw. If the motor stalls the start relay would energize and stay energized. The
amperage would surge 5 to 6 times greater than the normal draw. In this event the overload would shut
off the transmission in 4 to 8 seconds.
If the motor is subjected to an abnormal load, but does not reach a stall condition, the overload will react,
but over a greater period of time. The reaction time depends upon the amperage to which it is subjected.
The overload, through the safety circuit, also shuts off the compressor.
© 2004-2005, IMI Cornelius Inc. - 5 - Publication Number: 630460174SER
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