IMI Cornelius, Inc. IMD Series Installation Manual

®

COUNTERTOP ICEMAKER

IMD Series

Installation Manual

Release Date: April 8, 2004

Publication Number: 638085277INS

Revision Date: February 16, 2009

Revision: C

Visit the IMI Cornelius web site at www.cornelius.com

for all your Literature needs.

COUNTERTOP ICEMAKER IMD SERIES

INSTALLATION 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:

IMI Cornelius Inc.

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 © 2004-2009, All Rights Reserved, IMI Cornelius Inc.

TABLE OF CONTENTS

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Read and Follow all Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Recognize Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

CO2 (Carbon Dioxide) Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Installation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Remove Icemaker from Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Cabinet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Preparation of Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Water Inlet Hook-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Initial Start Up, Checks & Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Guide To Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Icemaker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Purpose of Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Ice Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

Refrigeration System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Condenser Modulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Condenser Modulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Shaft Seal Installation and Replacement (FIGURE 7) . . . . . . . . . . . . . . . . . . . . . . 12

Auger & Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Installation and Shaft Seal Replacement (FIGURE 9) . . . . . . . . . . . . . . . . . . . . . . 13

Upper Nut and Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

To Replace Bearings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Troubleshooting Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Overload Check - FIGURE 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Compressor Check - FIGURE 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Troubleshooting Gear Motors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

The Gearmotor will not run . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

The Gearmotor Starts but Trips Repeatedly on the Overload Protector . . . . . . 15

The Motor Runs but Output Shaft does not Rotate . . . . . . . . . . . . . . . . . . . . . . 15

Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Guide to Good Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

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 regula­tions 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 three types of safety alerts:

DANGER — Indicates an immediate hazardous situation which if not avoided WILL result in seri-

ous injury, death, or equipment damage.

Countertop Icemaker IMD Series Installation 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.

CO2 (CARBON DIOXIDE) WARNING

WARNING — CO

CO

gas leaks in the entire CO2 and soft drink system. If a CO2 gas leak is suspected, particularly

2

in a small area, immediately ventilate the contaminated area before attempting to repair the leak.
Personnel exposed to high concentration of CO2 gas will experience tremors which are followed

rapidly by loss of consciousness.

Displaces Oxygen. Strict Attention must be observed in the prevention of

2

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.

© 2004-2009, IMI Cornelius Inc. - 1 - Publication Number: 638085277INS

Countertop Icemaker IMD Series Installation Manual

SPECIFICATION CHART

Models Condensing

Unit

IMD300-15A Air Cooled 115 60 1 6 0.82 2 12 R134a 15
IMD302-15A Air Cooled 220/240 50 1 3 .5 1.6 12 R134a 15
IMD300-30A Air Cooled 115 60 1 10.1 1 2 28 R404A 20

IMD300-30W Water Cooled 115 60 1 10.1 N/A 2 13 R404A 20

IMD301-30A Air Cooled 208/230 60 1 5.7 1 1.6 28 R404A 20

IMD301-30W Water Cooled 208/230 60 1 5.7 N/A 1.6 13 R404A 20

IMD302-30A Air Cooled 220/240 50 1 5.3 0.5 1.6 28 R404A 20

IMD302-30W Water Cooled 220/240 50 1 5.3 N/A 1.6 13 R404A 20

IMD600-30A Air Cooled 115 60 1 12 1 2 28 R404A 20
IMD600-30A Water Cooled 115 60 1 12 N/A 2 14 R404A 20

IMD601-30A Air Cooled 208/230 60 1 7.7 1 1.6 28 R404A 20
IMD601-30W Water Cooled 208/230 60 1 7.7 N/A 1.6 14 R404A 20
IMD602-30W Water Cooled 220/240 50 1 8.2 N/A 1.6 14 R404A 20

IMD600-90A Air Cooled 115 60 1 12 1 2 24 R404A 20
IMD600-90W Water Cooled 115 60 1 12 N/A 2 14 R404A 20

IMD601-90A Air Cooled 208/230 60 1 7.7 1 1.6 24 R404A 20
IMD601-90W Water Cooled 208/230 60 1 7.7 N/A 1.6 14 R404A 20

IMD602-90A Air Cooled 220/240 50 1 8.2 0.5 1.6 24 R404A 20
IMD602-90W Water Cooled 220/240 50 1 8.2 N/A 1.6 14 R404A 20

NOTE: FOR UNITS NOT LISTED IN ABOVE CHART, REFER TO NAMEPLATE OR CONTACT FAC­TORY SERVICE.

VAC Hz Ph Comp

RLA

Fan

Amps

Grmtr
Amps

Refrigerant

Oz . Type

Circuit

Fuse

SHIPPING WT. 189 LBS. (APPROX.)

FIGURE 1. DIMENSION DRAWING (15 LB.) IMD 300-15

Publication Number: 638085277INS - 2 - © 2004-2009, IMI Cornelius Inc.

Countertop Icemaker IMD Series Installation Manual

SHIPPING WT. (IMD300--30) 220 LB S. (APPROX.)
S HIP PING WT. (IMD600--30) 240 L BS . (A P P RO X.)

FIGURE 2. DIMENSION DRAWINGS (30 LBS.) IMD 300-30 AND IMD 600-30

SHIPPING WT. 225 LB S. (APPROX.)

FIGURE 3. DIMENSION DRAWINGS (90 LBS.) IMD600-90

© 2004-2009, IMI Cornelius Inc. - 3 - Publication Number: 638085277INS

Countertop Icemaker IMD Series Installation Manual

INSTALLATION INSTRUCTIONS

REMOVE ICEMAKER FROM CARTON

1. Keep unit in the upright position, remove carton and pallet from unit and inspect unit for damage.
Upon inspection of unit, if any damage is found, file a claim with carrier immediately.

2. Locate Startup Card either on outside of container or on plastic liner. Fill in proper information and
send one copy to factory, and other copy to Distributor. Postage is prepaid.

CABINET REMOVAL

1. Locate and remove the (2) screws from under the front cover. Lift cover forward and up to remove.

2. Lift up front edge of top cover. Slide back about 1/2 inch and remove.

3. Remove (6) screws from the front of the machine.

4. Remove side panels by sliding the front edge out and then back slightly to disengage.

5. Remove the front splash panel by lifting slightly to disengage the front, then tilt forward and remove.

6. Remove bin top and remove shipping insert.

PREPARATION OF INSTALLATION SITE

1. The refrigeration system on air cooled units requires airflow, so a well ventilated area should be
chosen. A minimum of (6) inches must be maintained, free of any obstruction, for air intake. A min­imum of (4) inches clearance is required of air exhaust.

2. With template provided make the necessary provisions in the counter for water, drain and the elec­trical hook-up. Provisions are available for rear and bottom connections of water and electrical.
Use hole plugs provided to plug unused holes.

WATER INLET HOOK-UP

1. Water Inlet - Fitting is a 1/4” SAE male flare located at the rear of the unit. Connect water supply
with a 1/4” or larger copper or flexible tubing.

2. Water Pressure - Unless otherwise specified, the unit is designed to operate on water pressures
between 10 P.S.I. and 90 P.S.I. (NOTE: for pressures above 90 P.S.I. a regulator must be installed).

3. Water Cooled Condensers

A. Inlet to modulating valve uses 3/8” FPT. Use separate 3/8” or larger water line.
B. Outlet is 3/8” FPT.

4. Filter Conditioner are recommended on supply lines to icemakers. Never run the water supply to
water cooled Condenser through Filter/Conditioner, it uses up the cartridge unnecessarily and a
saturated cartridge can starve the icemaker causing premature component damage. Separate
water supplies are recommended.

NOTE: Unit must be installed per local plumbing code.

ELECTRICAL SUPPLY

1. Power Access - Is provided by way of a 7/8” dia. hole in both the base and the rear panel. Route
incoming power in conduit, to icemaker electrical control box. Make connections to wires provided
in control box and ground lug/screw. Plug unused hole.

2. Fused Line - Should be a dedicated circuit checked and sized according to electrical rating shown
on unit nameplate.

NOTE: Unit must be installed per local electrical code.

Publication Number: 638085277INS - 4 - © 2004-2009, IMI Cornelius Inc.

DRAIN CONNECTION

1. Install splash panel on machine and hold in place with (2) screws. Do not tighten at this time.

2. Remove drain tray mounting bracket from their shipping carton.

3. Clip the drain try mounting bracket onto the bottom of the splash panel in the brackets provided.

4. Hook the drain tray into the splash panel and onto the mounting bracket.

5. Push the drain elbow securely onto the drain tray. Do not glue in place.

6. Complete drain hookup according to the instructions provided with unit.

Countertop Icemaker IMD Series Installation Manual

FIGURE 4. FLOAT ASSEMBLY

NOTE: Steps 7 and 8 to be completed only after all start up checks and adjustments are per­formed.

7. Replace side panels tightening all (6) screws (including splash panel screws left loose).

8. Replace top panel and front cover and secure with (2) screws.

NOTE: In those cases where the unit is base mounted and not on legs it should be sealed all
around the base with NSF listed sealant. (IMI Wilshire P/N 04815-B).

AUGER ENGAGEMENT

Be certain that auger is fully engaged to lower drive and that extruding head is fully engaged to evapora­tor.

INITIAL START UP, CHECKS & ADJUSTMENT INSTRUCTIONS

NOTE: Do not start unit before completing above Installation Instructions.

Turn on water supply and main power switch (located on top of electric box). All IMD 30 lb. and 90 lb.
series units are equipped with a 45 second delay timer. This means that the refrigeration system will not
start until 45 seconds of dispense are accumulated in the timer. Start the refrigeration system by
depressing the ice dispense button for 45 seconds. Make the following system checks:

NOTE: If unit will not start be sure water reservoir is full. Low water safety control must be prop­erly adjusted to start and shut down unit. If water level drops below bottom of reservoir, unit
must shut down. Adjustment is made by moving magnet up or down.

Water Level - If necessary adjust Float by bending float arm up or down as needed, push float assembly

down until unit stops running. Release float and unit will restart. Keep water in reservoir at level line
while unit is in operation. See FIGURE 4.

© 2004-2009, IMI Cornelius Inc. - 5 - Publication Number: 638085277INS