Cornelius 1000-Series Service manual

CONTINUOUS FLOW ICEMAKER
500, 700, 1000, 2000 - Series
Service Manual
Release Date: May 27, 2004
Publication Number: 630460174SER
Revision Date: April 07, 2014
Revision: J
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.
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.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is subject to all of the restrictions and limitations contained in the Commercial Warranty.
Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained persons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, operating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
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:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
This document contains the original instructions for the unit described.
CORNELIUS INC
101 Regency Drive
Glendale Heights, IL
Tel: + 1 800-238-3600
Printed in U.S.A.
TABLE OF CONTENTS
Safety Instructions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping And Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification Chart. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Bin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Gearmotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Icemaker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Monthly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Refrigeration System. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Refrigeration System Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Condenser Modulating Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Condenser Modulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Motor Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
To Replace Gearmotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Installation and Shaft Seal Replacement 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Auger and Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Installation and Shaft Seal Replacement 700 & 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Upper Nut and Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
To Replace Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
GUIDE TO GOOD ICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Continuous Flow Icemaker Service Manual
SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
Safety Overview
•
Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or
laminated cards).
•
Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before
operating this unit.
Recognition
Recognize Safety Alerts
!
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
DIFFERENT TYPES OF ALERTS
! DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
! 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 and follow all safety messages in this manual and safety signs on the unit.
•
Keep safety signs in good condition and replace missing or damaged items.
•
Learn how to operate the unit and how to use the controls properly.
•
Do not let anyone operate the unit 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 unit in proper working condition and do not allow unauthorized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
! WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING
AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD
RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
SAFETY PRECAUTIONS
This unit has been specifically designed to provide protection against personal injury. To ensure continued protection
observe the following:
! WARNING:
Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify
all of the power is off to the unit before any work is performed.
Failure to disconnect the power could result in serious injury, death or equipment damage.
! CAUTION:
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
! CAUTION:
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained
from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.
GENERAL SAFETY INSTRUCTIONS
1. Do not store explosive substances such as aerosol cans with a flammable propellant in this appliance.
2. This appliance is intended to be used in household and similar applications such as
• Staff kitchen areas in shops, offices and other working environments;
• Farm houses and by clients in hotels, motels and other residential type environments;
• Bed and breakfast type environments;
• Catering and similar non-retail applications.
NOTE: If the appliance is to be limited to less than the above, this has to be clearly stated in the
instructions.
! WARNING:
Connect to potable water supply only.
! WARNING:
To avoid a hazard due to instability of the appliance, it must be fixed in accordance with th
e instructions.
Publication Number: 630460174SER
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
GENERAL INFORMATION
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 GRMTR
Amps Amps
Refrigerant
Oz.
Type
Circuit
Fuse
WCC500-A
Air Cooled
115
60
1
2
10.5
1.1
2
20
R404A
20
WCC500-W
Water Cooled
115
60
1
2
10.5
N/A
2
9
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
10.5
1.1
2
20
R404A
20
WCF510-W
Water Cooled
115
60
1
2
10.1
N/A
2
11
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
14.6
1.6
2
17.5
R404A
20
WCC700-W
Water Cooled
115
60
1
2
14.6
N/A
2
11
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
9.4
0.5
1.6
20
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
14.6
1.6
2
17.5
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
10
1.5
2.1
22
R404A
30
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
10
1.5
2.1
22
R404A
30
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
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
Temperature Chart
Figure 1. Series 500 & 700 Dimension Drawing (Shipping Wt. 160 Lbs. Approx).
Publication Number: 630460174SER
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
AIR INLET
AIR EXHAUST
24.00
22.00
W/C INLET
3/8"F PT
27.00
W/C OUTLET 3/8" F PT
REMOTE COND .LIQ.LINE
3/8 PUNCTURE FITTING
(REMOTE)
DISCHARGE LINE
1/2 PUNCTURE FITTING
RECEPTACLE
DRAIN 3/8" ID TUBE
POWER INLET 7/8"DIA
FRONT
WATER INLET
1/4" MALE FLARE
BACK
SIDE
ICE DISCHARGE
2.06
5.87
9.04
BOTTOM VIEW
(VIEWED FROM BOTTOM OF VIEW)
Figure 2. Series 1000 Dimension Drawing (Shipping Wt. 210 Lbs. Approx).
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
18.13
30.00
WATER IN
ELECTRICAL 7/8 DIA.
28.06
23.50
AIR INLET
DRAIN 3/8 I.D. TUBE
2.25
BACK
FRONT
2.06
24.00
ICE DISCHARGE
9.50
2.06
20.13
3.81
FRONT
2.06
SIDE
BOTTOM
VIEWED FROM BOTTOM OF MACHINE
Figure 3. Series WCC2001-A and WCF2201-A Dimension Drawings
Publication Number: 630460174SER
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
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.
BIN CONTROL
SWITCH TERMINALS
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.
Figure 4. Bin Control Switch
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.
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.
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
CLEANING AND SANITIZING
ICEMAKER CLEANING AND SANITIZING PROCEDURES
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
!
WARNING:
Do not use any of the ice made during cleaning operations.
Clean and sanitize ice storage area when cleaning icemaker.
1. Turn machine off.
2. Shut off water supply.
3. Remove ice from storage bin.
4. Mix approved cleaner (2 gallons as directed). Recommended cleaner: Nu-Calgon liquid ice machine cleaner.
Mixture: 3-1/3 ounces per gallon of water.
! WARNING:
Cleaner must be safe for stainless steel. NO EXCEPTIONS.
5. Clean auger/diverter assembly and ice transition/drop tube in a sink using cleaner mixture and reinstall in icemaker. Using cleaner, wipe down the dispense tray.
6. Turn machine on and add cleaner solution to water level control until 2 gallons have been used.
7. Turn on water supply and run machine for 15 minutes.
8. Turn off machine and remove all ice.
9.
Sanitize using household liquid bleach (50 ppm chlorine). Mixture: 1 fluid ounce per gallon room temperature
water. 2 minute exposure time.
10. Sanitize auger/diverter assembly and ice transition/drop tube in a sink using sanitizing solution and reinstall in
icemaker. Using sanitizer, wipe down the dispense tray.
11. Fill icemaker with sanitizer by slowly pouring solution into water feed reservoir until full. Solution will drain
through overflow tube. Do not run machine. Allow to air dry.
12. If icemaker is used in conjunction with ice dispenser or storage bin, follow manufacturer’s recommended cleaning instructions at this time.
MAINTENANCE
Preventive maintenance can increase the trouble free life of your icemaker. Many authorized service agencies offer
service contracts for your icemaker. Contact your local distributor for further information.
Monthly
1. Clean the condenser. Use a brush, vacuum cleaner or blow from inside with air or CO2 gas.
2. Inspect water feed reservoir at lease once a month until a definite pattern for cleaning and sanitizing has been
established.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
Quarterly
This is the maximum period of time between cleaning and sanitizing the icemaker. In addition to recommended
monthly procedure, and if a more frequent cleaning and sanitizing pattern has not been established, unit must be
cleaned and sanitized.
Semi-Annually
Semi–Annually in addition to all previously established service procedures perform the following:
1. Check for water leaks in tube connections, water fittings and lower icemaker water seal.
2. Check drain tubes for clogs and aged tubes. Replace if tubes are stained or brittle.
3. Check for signs of condensation. Clean where necessary and replace insulation properly.
4. Check safety circuits for proper operation.
5. Check refrigeration system.
6. Check unit for abnormal noise. Tighten machine and cabinet screws, if necessary.
7. Check white upper bearings on auger assembly. If bearings are less than 1/16” thick, replace.
REPLACE
OK
1/16
1/16
OK
REPLACE
Figure 5. Upper Nut and Bearing Assembly
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
WATER LEVEL CONTROL
HOW WATER LEVEL CONTROL WORKS
When water is introduced through the inlet fitting the float rises. The float pushes against a lever which in turn
forces the poppet assembly against the inlet fitting valve seat which seals the water off. Before the water inlet is
sealed the safety switch is operated. In the event of a water failure the float would drop down and operate the safety
switch to shut off the machine.
If water level control will not shut off and seal at level as indicated, be sure inlet pressure does not exceed
recommended factory operating range.
Under ordinary circumstances adjustment should not be necessary providing it was properly adjusted when unit
was installed or relocated. If, however, the control becomes inoperative, repair or replace. See Start–Up
Adjustment in the Installation Manual.
PURPOSE
1. To automatically maintain proper water level in the evaporator when unit is running and making ice.
2. A safety switch is operated in the event of an interruption in water supply. The switch shuts off the electricalpower to the icemaker and its refrigeration system. Switch will reset as soon as cause of water failure has been
corrected and proper water level in icemaker has again been reached.
3. The transparent bowl not only provides a visible check of water level, but also is a good guide to the internal
conditions which exist within the icemaker assembly itself. (See Cleaning Procedure.)
TO REPLACE WATER LEVEL CONTROL
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Shut off the water supply. Shut off the main power switch or unplug the ice dispenser from electrical outlet.
2. Remove the flexible tubing from bottom of water level control and drain water from water level control and evaporator.
3. Remove flexible tubing at bottom of water level bowl connected to the overflow.
4. Hold water inlet fitting with proper tool to prevent it from rotating when disconnecting the water inlet.
5. Remove wing nut holding water control to its mounting bracket. Control can be removed by lifting straight up.
TO REPLACE WATER LEVEL SAFETY SWITCH
!
WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Shut off main power switch or unplug the ice dispenser from electrical outlet.
2. Unplug molex connector connecting switch to electrical box.
3. Remove the 2 screws anchoring the water level safety switch to the bottom of the water level control mounting
bracket.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
ELECTRICAL
Figure 6. Schematic and Wiring Diagram WCC2001-A and WCF2201-A
Figure 7. Schematic and Wiring Diagram WCC500-A, WCC500-W, WCC700-A, WCC700-W, WCF510-A, WCF510-W,
WCF710-A, & WCF710-W
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
Figure 8. Schematic and Wiring Diagram WCC701-A, WCC701-W, WCC1001-A, WCC1001-W, WCF711-A, WCF711-W,
WCF1101-A, & WCF1101-W
Figure 9. Schematic and Wiring Diagram WCF1101R, WCC1001R, WCF1102R, & WCC1102R
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
Figure 10. Schematic and Wiring Diagram WCC502, WCC702, WCC1002, WCF512, WCF712, & WCF1102
Figure 11. Schematic and Wiring Diagram WCC2001-R and WCF2201-R
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
REFRIGERATION SYSTEM
REFRIGERATION SYSTEM ADJUSTMENTS
A complete understanding of the icemaker and hermetic refrigeration system is necessary before any adjustments
are made. The refrigeration technician must use high and low side pressure readings, water and air temperatures,
plus general conditions of cleanliness to assess the refrigeration system status when making any adjustments.
All icemaker products are tested and adjusted at the factory prior to shipment where the ambient temperature
ranges from 65° to 90°F, depending on the season of the year.
Whenever a new icemaker product is initially installed and started–up, it is imperative that the start–up operation
make the following checks and/or readjustments for local conditions.
EXPANSION VALVE
You will find a thermostatic expansion valve on icemakers, which is used to control the amount of refrigerant flowing
through the evaporator. Improperly installed or defective expansion valves may cause low production, soft ice,
squeaking from evaporator and excessive load inside evaporator.
By using general refrigeration system troubleshooting along with the pressure charts you can easily determine
whether or not the expansion valve is working properly.
ADJUSTMENT AND TROUBLESHOOTING
When troubleshooting the expansion valve you must first be sure you have adequate water flowing into evaporator,
a clean condenser, unit is properly ventilated, and system is properly charged and free from any restrictions. Also
be sure compressor is operating properly.
Second, take reservoir water temperature and air temperature from condenser inlet and determine at what
pressure unit should be running. Machines are equipped with thermostatic valves, there is NO adjustment. If
correct pressure cannot be obtained, first be sure system has time to stabilize 10–15 minutes. Second, be sure
sensing bulb is located at 12:00 position on outlet side of evaporator about 3–4 inches away from evaporator and
be sure to insulate well and clamp tightly to tubing. If system pressures are still not adequate, take a second water
and air temperature reading and go over other parts of system for possible problems. If proper charge is
questionable evacuate and recharge to nameplate and leak check. If valve still malfunctions replace valve.
When replacing valve be sure to bleed refrigerant gas from low side port so as not to lose refrigerant oil. Use
general refrigerant system practices when replacing and recharging unit. After new valve is in place, go through
previous monitored adjustments and troubleshooting to be sure valve is functioning properly.
NOTE: Units with thermostatic expansion valve—valve is located on bottom refrigerant line. Sensing bulb is located on top refrigerant line. On water cooled units adjust condenser modulating
valve before troubleshooting expansion valve.
! CAUTION:
Very High discharge pressure is present in system. Quick disconnects on you gauges will minimize danger and loss of
refrigerant. Comply with federal regulations for reclaiming refrigerant.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
CONDENSER MODULATING VALVE
The reason for using a water modulating valve is to supply the correct amount of water to the condenser. and to
maintain a proper operating pressure to refrigeration system high side.
The flow of water through the valve is increased as the high side pressure rises and is decreased as high side
pressure lowers.
To calibrate the amount of water flow with the refrigeration system high side pressure, turn adjustment screw
located on end of valve opposite of bellows. Turn screw counterclockwise to raise opening point or clockwise to
lower opening point. Opening point of valve should be set to maintain proper operating pressure in refrigeration
system high side. Refer to Pressure Chart on. Closing point of valve should be set low enough to close valve during
compressor stand–by periods.
NOTE: Cold water will absorb heat faster than warm water. The water flow will therefore automatically increase as inlet temperature increases.
Figure 12. Expansion Valve
Figure 13. Adjustment Screw
CONDENSER MODULATING VALVE REMOVAL
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Shut off water supply to condenser and evacuate refrigerant from system.
2. Remove inlet water line from Condenser Modulating Valve. Also remove tube from high side refrigerant line.
3. Remove Condenser Modulating Valve and bracket from unit.
4. Remove valve from bracket.
5. Replace Condenser Modulating Valve by reversing Steps 2 through 4. Then pull system into vacuum.
6. Charge unit with proper amount of refrigeration.
7. Turn power and water on to unit.
8. With unit running, adjust modulating valve to proper setting.
9. Go through a complete system check.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
GEARMOTOR
OVERLOAD TRIPPED
Check water level control
and evaporator water tube
for the build-up restrictions
CAUTION
CLEAN
Clear ice from
Evaporator and Auger before
Resetting overload
See Instruction
Reset Overload
IMPORTANT
Icemaker runs when
Reset but problem has
Not been found
Continue checking for
Overload as follows to
Guard against future problems
Icemaker
runs
Reset but
Motor does
Not run
Short run. Trips
Again in 2
Minutes. Check
Gear motor Circuit
OVERLOAD GUIDE
ELECTRICAL:
Reset but
Motor does
Not run
High or low voltage. Weak power lines can cause overloads on icemakers restarts
High running current(2.4amps or above) Check motor circuits and start relay
Auger delay failed
ICEMAKER
Mechanical parts worn, scored evaporator or auger worn thrust bearing
Icemaker not run off. Failed level control
Over compression. Low water inlet temperature. Restrictions in water line from reservoir
Check
Gear motor
circuits
Will not
Reset
Overload
Hot try
again
Will not
Reset.
Replace
overload
Refrigerant
Contaminated charge or bad compressor
Low charge or gas leak
Low suction pressure, improper expansion valve, Sensing bulb location or insulation
And/or defective expansion valve
MOTOR CHECK
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
!
WARNING:
The resistance readings on the winding will be between 5 to 25 ohms. A meter capable of these low readings must be
used. The start relay cover must be removed.
If no continuity on start or run winding test, replace gearmotor. If continuity on grounded motor test, replace
gearmotor.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
START RELAY
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Check between “2” and “4” on relay (with relay unplugged). If there is continuity replace the relay, as the relay
contacts should be open.
2. Check between “3” and “4” on relay, if no continuity replace the relay.
Figure 14. Gearmotor Assembly
TO REPLACE GEARMOTOR ASSEMBLY
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Disconnect the transmission cable from the electrical box.
2. Remove the 4 hex head bolts securing the evaporator to the top of the transmission.
3. Remove the 4 bolt’s holding the transmission and bracket to frame base, while supporting the weight of the
evaporator. Remove the transmission from the unit.
4. When replacing the transmission, it may be necessary to rotate the auger back and forth to align the motor
shaft and auger.
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Continuous Flow Icemaker Service Manual
AUGER NUT
AUGER
BEARING NYLON
BEARING DELRIN
“D” DRIVE
GROOVE
EXTRUDING
HEAD
ANTI–ROTATION
RIB – 3 PLACES
Figure 15. Auger and Extruding Head Removal
INSTALLATION AND SHAFT SEAL REPLACEMENT 500
1. Place shaft seal locator seat over gear motor output
shaft, embossed side down, and push down until
shaft seal seat rests flush on top of gear motor.
2. Place rubber coated ceramic seal (important:
ceramic face up) over output shaft and push down
until seal rests on top of the shaft seal seat. (Lubricate rubber on ceramic seal with rubber lubricant.)
E–RING
WASHER, PLAIN FLAT
SHAFT SEAL
LOCATOR SEAL
3. Place shaft seal with carbon face down (spring up)
over output shaft and push (gently) downward until
seal rests on ceramic face of the output shaft seal.
4. Place flat washer over output shaft and let rest on
the output shaft seal. Push down on the washer
compressing the spring on the output shaft seal.
While holding the seals (down) in place slide the E–
ring into the groove on the output shaft.
GEARMOTOR
Figure 16. Shaft Seal 500
AUGER AND EXTRUDING HEAD REMOVAL
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Remove storage container cover and put aside.
2. Turn off water supply to icemaker.
3. After ice has melted from head take hold of the auger nut and lift straight up to disengage from icemaker.
4. When replacing the auger assembly, perform the Auger Engagement procedure to ensure that the extruder
head is fully engaged into the evaporator.
AUGER ENGAGEMENT
1.
Install the extruder head on top of the evaporator, as shown in Figure 17.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
Auger/
Extruder
Head
Figure 17.
2. When the auger is lowered into the evaporator, rotate the auger to engage the motor drive shaft, see Figure 18.
Extruder
Head
Evaporator
Figure 18.
3. Carefully rotate the extruder head until the tabs on the extruder head drop into the slots on the evaporator
plate, as shown in Figure 19. When the auger/extruder head assembly is rotated to the proper position, it will
drop about 1/4 inch to more fully engage the motor drive shaft.
NOTE: Not all the tabs are the same width. Therefore, you must rotate the auger until all the tabs
are properly aligned with the evaporator slots. This may require almost a complete rotation
of the extruder head to complete.
! CAUTION:
Keep hands out of the way when rotating the extruder head. When the auger is aligned, it drops down quickly and a
finger may be pinched due to the weight of the auger/extruder head assembly.
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
Failure to lock the extruder head tabs into the evaporator slots causes the auger to be out of proper alignment with
the evaporator. This may cause excessive loads on the auger that can potentially result in excessive noise and
tripping the drive motor overload.
All tabs &
slots engaged
Figure 19.
INSTALLATION AND SHAFT SEAL REPLACEMENT 700 & 1000
1. Place shaft seal locator seat and shaft seal mount
over gearmotor output shaft and push down until
shaft seal seat and shaft seal mount rest flush on
top of gearmotor.
E–RING
WASHER, PLAIN FLAT
2. Place rubber coated ceramic seal (important:
ceramic face up) over output shaft and push down
until seal nest in recess of shaft seal mount. (lubricate rubber on ceramic seal with rubber lubricant).
3. Place shaft seal with carbon face down (spring up)
over output shaft and push (gently) downward until
seal rests on carbon face of the output shaft seal.
SHAFT SEAL
MOUNT, SHAFT
SEAL
SEAT, SHAFT SEAL
GEARMOTOR
4. Place flat washer over output shaft and let rest on
the output shaft seal. Push down on the washer
compressing the spring on the output shaft seal.
While holding the seals (down) in place slide the E–
ring into the groove on the output shaft
Figure 20. Shaft Seal 700 and 1000
UPPER NUT AND BEARING ASSEMBLY
The upper white bearing located on top of the auger is used to absorb the force between the auger and extruding
head.
NOTE: The bearings are 3/32 thick. When they wear below 1/16 they should be replaced. Bearings
to be inspected for wear during quarterly maintenance.
To Replace Bearing
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
Failure to comply could result in serious injury, death or damage to the equipment.
1. Remove top panels.
2. Remove Dispense Tray Cover.
3. Use an open end wrench on auger nut connected to bearing and turn counterclockwise to remove 
assembly.
4. Remove worn bearings. Replace with new bearings and then reinstall assembly.
NOTE: If auger turns with nut, remove cover on top of gearmotor stator and hold motor while loosening nut.
ELECTRICAL CHECKOUT
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Remove the compressor electrical box cover. Check for obvious damage and loose wires.
2. Disconnect the fan motor leads. Since capacitors store energy, short the capacitor with a screwdriver. This will
prevent shocks.
3. Disconnect the compressor terminal wires.
OVERLOAD CHECK
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
Using a volt–ohmmeter check the continuity across the
overload, contact #1 and #3. If none, wait for unit to cool
down and try again. If still no continuity, the overload
protector is defective and should be replaced.
Figure 21. Overload Check
COMPRESSOR CHECK
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Continuous Flow Icemaker Service Manual
The resistance readings on the windings will be
between 0.25 to 10.00 ohms, a meter capable of these
low readings must be used.
1. Check between “C” and “R.” Replace the compressor if there is no continuity as the run windings are
open.
2. Check between “C” and “S.” Replace the compressor if there is no continuity as the start windings are
open.
Figure 22. Compressor Check
3. Check between “C” and “R” or “S” and the shell of the compressor. If there is continuity, replace the compressor as the motor is grounded.
4. Check between screw terminal on the overload and “C” on the compressor. Check and repair the lead or
connections if there is no continuity.
CAPACITOR CHECK
! WARNING:
Disconnect power to the unit before servicing. Follow all lock out/tag out procedures established by the user. Verify all
power is off to the unit before performing any work.
Failure to comply could result in serious injury, death or damage to the equipment.
1. Check or replace start capacitor, disconnect bleed
resistor before checking for shorted capacitor.
GEAR MOTOR OVERLAY
2. Check or replace run capacitor (if supplied) check
for shorted capacitor or either terminal grounded to
case.
Figure 23. Gear Motor Overload
SAFETY CONTROLS
Your icemaker unit has several safety and control devices incorporated into its design.
! WARNING:
None of the devices described below should ever be “bypassed” to allow the unit to function.
Failure to comply could result in serious injury, death or damage to the equipment.
The safety and control system shut–off devices are:
1. Low water shut off reed switch located in icemaker float assembly. (Automatic reset type.)
2. Gearmotor thermal overload, manual reset type (red button on motor).
3. Compressor thermal overload, automatic reset type.
4. Anti–freeze relay and associated circuit. See wiring diagrams.
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© 2004-2014, Cornelius Inc.
Continuous Flow Icemaker Service Manual
5. Main service switch located on top of the control box.
6. Bin Control.
7. High pressure cut out (water cooled only).
GUIDE TO GOOD ICE
© 2004-2014, Cornelius Inc.
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Publication Number: 630460174SER
Figure 21. Troubleshooting Chart
Continuous Flow Icemaker Service Manual
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© 2004-2014, Cornelius Inc.
Cornelius Inc.
www.cornelius.com