Nordic Ice Maker

Model CCM and CCU Series

www.cornelius.com

Installation, Start-up and Maintenance Manual

Publication Number: 631806051

Revision Date: September 1, 2007

Revision: A

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

for all your Literature needs.

CCM and CCU Series Installation, Start-up and Maintenance Manual Manual Number 631806051

*

How To Use This Manual

Forward

Cornelius provides this manual as an aid to the service technician in installation and maintenance of the

CCM and CCU Series cube ice machines. Do not attempt to perform installation, start-up or maintenance unless you have read and fully understand this manual.

If at any time you encounter conditions that are not addressed in this manual, please contact the Cornelius

Technical Service Department at:

E-Mail: [email protected]

Website :

www.cornelius.com

800-238-3600 All Departments

Any Service communication must include:

• Model Number

• Serial number

• A detailed explanation of the problem

Keep this manual for future reference.

The Cornelius CCM and CCU Series Service Parts Manuals are available separately.

Cornelius icemakers and dispensers are not approved for outdoor installation.

WARNING: Always disconnect electrical power and shut off water supply whenever maintenance or repairs are performed on the ice machine and related equipment.

CAUTION: Always wear protective eyewear whenever maintenance or repairs are performed on the ice machine and related equipment.

Page i

Foreward

Table of Contents

Page i

Table of Contents Page ii

Freight Page iii

How the Machine Works

General Maintenance

Cleaning Procedure

Cabinet Care

Maintenance Record

Page 13

Page 16

Page 17

Page 18

Page 20

Page ii

Freight Claims Important!

Freight Claim Procedure

Inspect Promptly

This merchandise has been carefully inspected and packed in accordance with the carrier’s packing specifications.

Responsibility for safe delivery has been assumed by the carrier. If loss or damage occurs, you as the consignee must file a claim with the carrier and hold the container for carrier’s inspection.

Visible Loss or Damage

Any external evidence of loss or damage must be fully described and noted on your freight bill or express receipt and signed by the carrier’s agent. The claim should be filed on a form available from the carrier.

Concealed Loss or Damage

If loss or damage does not appear until merchandise has been unpacked, make a written request for inspection by the carrier within 15 days of the delivery date. Then file a claim on a form from the carrier.

File Claim Without Delay

Do Not Return Damaged Merchandise to Cornelius

Page iii

Model and Serial Number Format

Sample Data Plate

Model and Serial Number Format

The serial number format and machine specifics are detailed on the data plate.

Model Number

CCM 06 30 A H 1 2

Engineering Rev Level

Voltage:1=115V, 2=230V, 3=230V 3ph 5=50Hz.

Cube Size: H=Half Cube, F=Full Cube

Condenser Type: A=Air, W=Water, R=Remote

Cabinet Width (in inches)

Approximate Production X 10 in 24 hours 70

°F Air / 50°F Water

Series: Cornelius Cuber Modular (U=Undercounter)

Large data plate will be placed on the back of the unit.

Serial Number

87 A 0708 GC 004

Sequencial Serial Number

Product Line

GC=Cuber

GB=Remote Condenser

GA= Dispenser

Date Code, Year Month format. (2007 August 08)

Revision Level (Internal)

Manufacturing Facility

Small data plate will be placed by the service valves .

Note: The date code will change monthly and yearly to reflect the date of manufacture.

Page 1

Installation Guidelines

Installation Guidelines

For proper operation of the Cornelius ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failures, and may void all warranties.

Reference the installation parameters prior to installing the machine:

Ambient Operating Temperatures

Minimum Operating Temperature: 50°F (10°C)

Maximum Operating Temperature 100°F (38°C), 110°F (43°C) on 50 Hz. Models.

Note: Cornelius icemakers and dispensers are not approved for outdoor installation.

Incoming Water Supply (See Electrical and Plumbing Diagrams for line sizing)

Minimum incoming water temperature: 40°F (4.5°C)

Maximum incoming water temperature: 100°F (38°C)

Minimum incoming water pressure: 20 psi (1.4 bar)

Maximum incoming water pressure: 60 psi (4.1 bar)

Note: If water pressure exceeds 60 psi (4.1 bar), a water pressure regulator must be installed.

Drains

All drain lines must be installed per local codes. Flexible tubing is not recommended. Route bin drain, purge drain and water condenser drain individually to a floor drain. The use of condensate pumps for draining water is not recommended by Cornelius. Cornelius assumes no responsibility for improperly installed equipment.

Note: The purge drain fitting is plastic; DO NOT apply heat to the purge drain area.

Water Filtration

A water filter system should be installed with the ice machine.

Clearance Requirements

Self-contained air cooled ice machines must have a minimum of 6 inches (15cm) of clearance at the rear, top, and sides of the ice machine for proper air circulation.

Stacking

If the ice machines are to be stacked, refer to the instructions in the stacking kit. Acme does not endorse stacking aircooled ice machines.

Dispenser Application

A thermostatic bin control kit should be installed if the CCM Series ice machine is placed on a dispenser. A bin top may or may not be required. (Exception is the CHD22 and CHD30 Series Dispenser)

Electrical Specifications

Refer to the serial plate at the rear of the ice machine to make sure proper voltage and circuit breaker size have been supplied. Make sure the machine is on a dedicated circuit. European installations require that the electrical supply fixed wiring must be provided with a disconnect means having a separation of at least 3mm in all poles. The 115 volt

Undercounter series ice makers are supplied with an electrical cord, all other ice makers will need to be installed and wired per local electrical codes.

Adjustments

Level the machine within 1/8 inch in all directions.

Check the bin control for proper adjustment.

Check the water in the water trough for proper level.

Check the ice bridge for proper thickness.

Check the water regulating valve adjustment if water cooled.

Page 2

Secure the machine on top of the bin or dispenser.

Installation Guidelines

Attach the ice machine to the bin with the mounting straps provided with the bin or dispenser. Insure that the back of the ice machine is flush with the back of the bin. Proper functioning of the bin door requires the bin door, when it is opened, to be in a stable position.

If the ice machine is too far forward on the bin, the opened door may not be stable, resulting in an unexpected closing of the bin door. If the ice machine is to be mounted on a bin or dispenser other than a Cornelius, refer to the manufacturers instructions for machine mounting. Cornelius will not be responsible for damage or injury that results from unexpected closing of the bin door as a result of the ice machine being too far forward on the bin.

If the ice machine is to be stacked on top of another ice machine, a stacking kit will need to be installed. Refer to the installation instructions included with the stacking kit.

Important!

A water filtration system should be installed with all ice machines. Check the filter manufacturer's instructions for proper installation.

All water supply lines must be installed per local codes.

Use 1/4 inch O.D. minimum on air cooled machines. On water cooled machines 3/8 inch O.D. minimum tubing must be run to the condenser. The water supply for the float can “T” off from the condenser line using 1/4 inch

O.D. minimum tubing. Make 2 coils of extra tubing so that the machine can be pulled away from the wall if service is needed.

All drain lines must be installed per local codes. The purge drain should be a minimum of 5/8 inch O.D. tubing.

The condenser drain on water cooled units should be 3/8 inch O.D. minimum. The drain line fittings on Cornelius bins are 3/4 FPT. The bin drain should be a minimum of

3/4 inch O.D. Cold water drains should be insulated to prevent condensation from forming.

Warning!

Do not apply heat directly to the back of bin as damage may occur to plastic parts.

Connect power supply to the terminal block in the control box or at the rear junction box if equipped.

Ensure the machine is level within 1/8 inch in all directions.

Remove any shipping or packaging material.

If the machine has a remote condenser, reference the

Remote Condenser Installation Guidelines.

Once the machine has been installed, follow the start-up procedures.

Warning!

IMPORTANT!

Attach the ice machine to the bin or dispenser with the provided mounting hardware. Insure the back of the ice machine is flush with the back of the bin.

Do not apply heat directly to the back of bin as damage may occur to plastic parts.

Page 3

Remote Condenser Installation

Remote Condenser Guidelines

For proper operation of the Cornelius ice machine, the following installation guidelines must be followed. Failure to do so may result in loss of production capacity, premature part failure, and may void all warranties.

Remote condensers must be installed per local building codes. A two to four inch diameter roof penetration will be needed for refrigerant lines and electrical conduit. The penetration should be within two feet of where the condenser will be located. A roof jack must be installed at the penetration.

Installation Guidelines

Ambient operating temperatures: -20°F (-28.9°C) to 120°F (48.9°C)

Maximum refrigerant line length: 60 ft. (18.29 Meters) RC14

Maximum vertical rise: 16 ft. (4.88 Meters)

Minimum condenser height: CCM Series ice machine remote condensers must not be installed more than 6 feet

(1.3 meters) below the refrigerant line quick connects at the rear of the ice machine. No part of the refrigerant lines, between the ice machine and the remote condenser, should fall below this point. Condensers must have a

vertical airflow.

Air Flow

Page 4

Remote Condenser Guidelines

The CCM0530R, CCM0630R, CCM0830R, CCM1030R and CCM1530R remote ice makers incorporate the mixing valve in the condenser. This configuration allows up to a 100 foot calculated remote line set run. Reference the diagram below to calculate the maximum 100 foot line set run.

ICE Machine Model Number Remote Condenser Model Number

CCM1530R

CCM1030R

CCM0830R

CCM0630R

RC15002

RC08002

RC08002

RC06002

RC05001 CCM0530R

Limitations for new remote machines that have the headmaster mounted in the condenser.

Maximum Rise is 35 feet.

Maximum Drop is 15 feet.

Maximum equivalent run is 100 feet.

Formula for figuring maximum equivalent run is as follows:

Rise x 1.7 + Drop x 6.6 + horizontal run = equivalent run.

Examples: 35 ft. rise x 1.7 + 40 ft. horizontal = 99.5 equivalent feet line run

35 ft. rise

40 ft. horizontal

34 ft. horizontal

10 ft. drop

10 ft. drop x 6.6 + 34 ft horizontal = 100 equivalent feet line run

Page 5

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements: CCU0150, and CCU0220

(Includes 50Hz. and 230 Volt Units)

Note: The CCU Undercounter series do not have a splash curtain.

These models utilize a thermostatic bin control in place of a mechanical bin switch.

ON-OFF-WASH Switch is located in the control box.

Remove the grill screws to access the control box.

Page 6

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements: CCU0300

(Includes 50Hz.Units)

Note: The CCU Undercounter

Series do not have a splash curtain.

These models utilize a thermostatic bin control in place of a mechanical bin switch.

ON-OFF-WASH Switch is located in the control box.

Remove the grill screws to access the control box.

Page 7

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements:

CCM0330, CCM0430, CCM0530, CCM0630

(Includes 50Hz. Units)

Page 8

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements: CCM0830 and CCM1030

(Includes 50Hz. And 3 Phase Units)

Page 9

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements: CCM1448, CCM1848 AND CCM2148

(Includes 50Hz. and 3 Phase Units)

Page 10

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements: CCM0322 AND CCM0522 (Includes 50Hz.Units)

Page 11

Electrical and Plumbing Requirements

Electrical and Plumbing Requirements: CCM1530 Remote

Page 12

How the CCM Ice Machine Works

How the Ice Machine Works

A general description of how the CCM Series cubers works is given below. With the ICE/OFF/WASH switch in the

ICE position, the compressor, water pump and condenser fan motor (when applicable) will energize starting the freeze cycle.

During the freeze cycle, water is circulated over the evaporator(s) where the ice cubes are formed. When the suction pressure has pulled down to the proper cut-in pressure of the timer initiate (pressure control), the contacts will close and energize the time delay module (timer). At this time, the cubes will be close to completion.

The remaining portion of the freeze cycle is determined by the timer setting. The timer is pre-set at the factory to achieve the proper ice bridge thickness but may need to be adjusted upon initial start-up, see Page 14 for timer adjustment.

Once the amount of time on the timer has passed, the control relay will be energized and the machine will enter harvest. Power is now supplied to the water purge valve, hot gas valve, and the harvest motor.

The water purge valve opens, and allows the water pump to purge the water remaining in the water trough, removing impurities and sediment. This allows the machine to produce clear ice cubes and keep mineral build up at a minimum.

The hot gas solenoid opens allowing hot gas to go directly to the evaporator, heating the evaporator and breaking the bond between the evaporator and the ice slab.

The harvest assist motor, which is also energized during harvest, turns a slip clutch, which pushes a probe against the back of the ice slab. Once the evaporator has reached approximately 40

°F (4.5°F) in temperature, the slip clutch overcomes the bonding of the ice to the evaporator and pushes the slab of ice off of the evaporator and into the storage bin.

The clutch also actuates a switch that rides on the outer edge of the clutch. When the clutch completes one revolution, the switch is tripped and the machine enters the next freeze cycle.

When ice drops into a full bin during harvest, the splash curtain is held open which activates a bin switch shutting the machine off. When ice is removed from the bin, the splash curtain will close and the machine will come back on.

Note: The CCU Undercounter Series does not have a splash curtain. These models utilize a thermostatic bin control in place of a mechanical bin switch.

Page 13

Start-Up Procedure

Start-Up Procedure

Before starting the machine, make sure the machine is level within 1/8 inch in all directions, the bin or dispenser leg height can be adjusted by rotating the leg foot.

Check the water level in the water trough. It should be approximately ½ inch above the top of the water pump impeller housing. The water level can be adjusted by bending the float arm.

Move the ICE-OFF-WASH switch to the ICE position. The switch is located in the control box. Remove the ice machine front panel or remove the lower grill on the under counter models to access the control box.

Check for proper water flow over the evaporator(s). There should be an even flow of water over the evaporator(s).

Check the water regulating valve (water cooled machine) for proper adjustment by measuring the water temperature at the outlet of the condenser. It should be between 100

°F and 110°F (38°C and 43°C). Adjust the water regulating valve as required.

As ice begins to form on the evaporators, check the freeze pattern of the ice. Ice should form evenly across the evaporator. Models CCM0830, CCM1030, CCM1848 and CCM2148 machines will have a slight variance from the top to the bottom of the evaporator(s).

Bridge Thickness and Timer Adjustment

Once the ice drops off the evaporator(s) during harvest, check the bridge thickness of the ice slab. The bridge should be 3/16 of an inch on Undercounter and CCM0330 units. The bridge should be 1/8 of an inch on all other units. If the bridge thickness is incorrect, the timer will need adjustment.

The ice bridge thickness is controlled by the freeze timer located in the control box. To check the timer setting, add the seconds of each dipswitch turned to the “ON” position. The number beside the each dipswitch represents seconds.

To increase the bridge thickness, increase the timer setting. To decrease the bridge thickness, decrease the timer setting. The freeze timer can be adjusted by sliding one or more switches to either the “ON” or “OFF” position to obtain the desired setting.

Note: The right hand timer on the CCM1448, CCM1848 and CCM2148 units should be set at 4 seconds only,

do not adjust this timer.

Bridge Thickness

Combine time in seconds

Timer shown is set for 31 seconds.

(EXAMPLE ONLY)

Page 14

Start-Up Procedure

Bin Control Operation

The bin control is used to shut the machine off when the bin fills with ice. The bin control must be checked upon installation or initial start-up and when performing maintenance.

There is one bin switch for each evaporator. The actuator arm of the bin switch comes in contact with the splash curtain. When the bin is full of ice, the splash curtain is held open when ice drops off of the evaporator. This releases the pressure of the bin switch actuator arm allowing the switch to open.

Single evaporator machines: (Including the CCM1530) If the bin switch opens during freeze or the first part of harvest, relay 2 bypasses the bin switch and the machine will continue running. If the bin switch is opened during harvest when the cam switch is lifted onto the high part of the cam, the machine will shut off. When the bin switch closes again, the machine will restart.

Dual evaporator machines: If either bin switch opens during the freeze cycle, the machine will shut off. Relay 1 and relay 2 will bypass the bin switches during defrost. If either bin switch is open when the machine returns to the freeze cycle, the machine will shut off.

Undercounter machines: A thermostatic bin control is used on the undercounter models. The bin thermostat is located in the control box with a capillary tube,

Bin Switch

Adjustment

Nuts which is in a brass thermo-well mounted to the water trough. When ice comes in contact with the capillary tube thermo-well, the bin thermostat opens and the machine will shut off.

Bin Control Adjustment

All Models (Except Undercounter Models): Check the bin switch for proper adjustment by swinging the bottom of the curtain away from the evaporator.

Slowly bring the curtain towards the evaporator. The switch should close when the bottom edge of the curtain is even with the outer edge of the water trough.

Adjust the switch by loosening the nuts that hold the switch in place. Move the switch to the proper position and retighten the nuts. Recheck the adjustment.

Undercounter Models

Turn the machine to the ICE or WASH position. Hold ice against the brass thermal-well mounted to the water trough making sure the ice is in contact with at least 6 inches (15 cm) of the thermal-well. The machine should shut off in approximately 1 minute. Remove

Thermal -well the ice. The machine should restart in approximately 3 minutes. If a major adjustment is required, turn the adjustment screw counterclockwise (warmer) until it stops then turn the adjustment screw clockwise

(colder) 1/8 of a turn. This

Thermostatic

Bin Control should put the control close to the proper adjustment, recheck and make a minor adjustment if needed. If a minor adjustment is required, turn the adjustment screw clockwise (colder) or counterclockwise (warmer).

Splash Curtain

Evaporator

The bin switch contacts must be closed when the bottom edge of the curtain is flush with the edge of the water trough

Page 15

General Maintenance

Electrical shock and/or injury from moving parts inside this machine can cause serious injury. Disconnect electrical supply to machine prior to performing any adjustments or repairs.

Failure to perform the required maintenance at the frequency specified will void warranty coverage in the event of a related failure.

General Maintenance Procedure

To insure economical, trouble free operation of your machine, it is recommended that the following maintenance be performed every 6 months.

1. Clean the ice-making section per the instructions below. Cleaning should be performed a minimum of every 6 months. Local water conditions may require that cleaning be performed more often.

2. Check ice bridge thickness. See page 14 for proper thickness and adjustment procedure.

3. Check water level in trough. See page 14 for proper water level and adjustment.

4. Clean the condenser (air-cooled machines) to insure unobstructed air flow.

5. Check for leaks of any kind: Water, Refrigerant, Oil, Etc.

6. Check the bin control switch for proper adjustment. See page 15 for bin switch adjustment.

7. Check the water valve (water-cooled machines) for proper adjustment by measuring the water temperature at the outlet of the condenser. It should be between 100

°F and 110°F. (38°C and 43°C)

8. Check all electrical connections.

9. Oil the fan motor if the motor has an oil fitting. (Self contained air-cooled models only)

10. Check the water filter (if applicable) and replace if dirty or restricted.

11. Inspect the evaporator water distribution tube to insure even distribution of water across the face of the evaporator.

Page 16

Cleaning Procedure

Ice Machine Cleaning and Sanitizing Instructions

1. Remove the ice machine front panel.

2. Make sure that all the ice is off of the evaporator. If ice is being made, wait for cycle completion then turn the machine “OFF” at the ICE/OFF/WASH selector switch.

3. Remove or melt all ice in the storage bin.

4. Add recommended amount of approved nickel safe ice machine cleaner to the water trough according to label instructions on the container.

5. Initiate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “WASH” position. Allow the cleaner to circulate for approximately 15 minutes to remove mineral deposits.

6. Depress the purge switch and hold until the ice machine cleaner has been flushed down the drain and diluted by fresh incoming water.

7. Terminate the wash cycle at the ICE/OFF/WASH switch by placing the switch in the “OFF” position. Remove the splash curtain and inspect the evaporator and water spillway to ensure all mineral residue has been removed.

8. If necessary, wipe the evaporator, spillway and other water transport surfaces with a clean soft cloth to remove any remaining residue. If necessary, remove the water distribution tube, disassemble and clean with a bottlebrush.

Reassemble all components and repeat steps 4 through 7 as required to remove residue.

9. Turn OFF ice machine water supply and clean the water trough thoroughly to remove all scale or slime build-up. If necessary, remove the water trough to reach all splash areas and float.

10. Prepare 1½ to 2 gallons (5.7 to 7.5 liters) of approved (EPA/FDA) sodium hypochloride food equipment sanitizer to form a solution with 100 to 200 max. ppm free chlorine yield.

11. Add enough sanitizing solution to fill the water trough to overflowing and place the ICE/OFF/WASH switch to the

“WASH” position and allow circulation to occur for 10 minutes and inspect all disassembled fittings for leaks.

During this time, wipe down all other ice machine splash areas, plus the interior surfaces of the bin, deflector and door with the remaining sanitizing solution. Inspect to insure that all functional parts, fasteners, thermostat bulbs (if used), etc. are in the correct position.

12. Depress the purge switch and hold until sanitizer has been flushed down the drain. Turn ON the ice machine water supply and continue to purge to the diluted sanitizing solution for another 1 to 2 minutes.

13. Place the ICE/OFF/WASH switch to the “ICE” position and replace the front panel.

14. Discard the first two ice harvests.

Page 17

Cabinet Care

Cleaning stainless steel

Commercial grades of stainless steel are susceptible to rusting if not properly maintained. It is important that you properly care for the stainless steel surfaces of your ice machine and bin to avoid the possibility of rust or corrosion.

Use the following recommended guidelines for keeping your stainless steel looking like new:

1. Clean the stainless steel thoroughly once a week. Clean frequently to avoid build-up of hard, stubborn stains.

Also, hard water stains left to sit can weaken the steel's corrosion resistance and lead to rust. Use a nonabrasive cloth or sponge, working with, not across, the grain.

2. Don't use abrasive tools to clean the steel surface. Do not use steel wool, abrasive sponge pads, wire brushes or scrapers to clean the steel. Such tools can break through the "passivation" layer - the thin layer on the surface of stainless steel that protects it from corrosion.

3. Don't use cleaners that use chlorine or chlorides. Don't use chlorine bleach or products like Comet to clean the steel. Chlorides break down the passivation layer and can cause rusting.

4. Rinse with clean water. If chlorinated cleansers are used, you must thoroughly rinse the surface with clean water and wipe dry immediately.

5. Use the right cleaning agent. The table below lists the recommended cleaning agents for common stainless steel cleaning problems:

Routine cleaning Soap, Ammonia, Windex, or Apply with a clean cloth sponge. with

Removing grease or

Liquid are also approve for

Stainless Steel.

Easy-Off or similar oven Apply generously, allow

Removing hard water spots and scale.

Vinegar

Repeat as required.

Swab or wipe with clean cloth.

Rinse with clean water and dry.

Page 18

Winterizing Procedure

Winterizing Procedures

Important!

Whenever the ice machine is taken out of operation during the winter months, the procedure below must be performed. Failure to do so may cause serious damage and will void all warranties.

1. Turn off water to machine.

2. Make sure all ice is off of the evaporator(s). If ice is being made, initiate harvest or wait for cycle completion.

3. Place the ICE/OFF/WASH switch to the “OFF” position. The switch is located in the control box.

4. Disconnect the tubing between the water pump discharge and water distribution tube.

5. Drain the water system completely.

6. On water cooled machines, hold the water regulating valve open by prying upward on the water valve spring with a screwdriver while using compressed air to blow all the water out of the condenser.

7. Remove all of the ice in the storage bin and discard.

Page 19

Service History

Service History

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