Cornelius 1400 Manual

CONTINUOUS FLOW ICEMAKER
1400 - Series
Owner’s Manual
Released Date: April 1, 2019
Publication Number: 548000109
Revision Date: April 1, 2019
Revision: A
Visit the Cornelius web site at http://ice.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.
Continuous Flow Icemaker Owner’s Manual
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
Power Cord . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Unit Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
WCC1401R Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CR1101 Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
WCC1400 Rack Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
WCC1401R Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
CR1101 Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
WCC1400 Rack Schematic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Refrigeration Schematic For WCC1400Rack System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Installation instruction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Remove Ice maker from Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Cabinet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Icemaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Preparation of Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Icemaker . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Condensing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Water Inlet Hook-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Initial Start Up, Checks and Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
For WCC1401-R Only. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Bin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Gearmotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Install Bin control sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning and Sanitizing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Icemaker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
© 2019, Cornelius Inc.
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Continuous Flow Icemaker Owner’s Manual
Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
20
20
20
20
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Refrigeration System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Replace Gearmotor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auger and Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installation and Shaft Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Upper Nut and Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
To Replace Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
21
21
21
22
23
23
24
24
26
26
26
27
27
27
28
28
GUIDE TO GOOD ICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s 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.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s 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.
POWER CORD
! CAUTION:
If the power cord is damaged, it must be replaced by a special cord available from the manufacturer or its service
agent.
UNIT LOCATION
! CAUTION:
Appliance is not suitable for installation in an area where a water jet could be used.
!
CAUTION:
The appliance must be placed in a horizontal position.
! CAUTION:
This unit is not designed for use in outdoor locations. “Except where otherwise noted”.
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
GENERAL INFORMATION
GENERAL DESCRIPTION
This section gives the Unit description, theory of operation, and design data for continuous flow icemaker
1400-series.
SPECIFICATION CHART
Models
Condensing
VAC
Unit
HZ
PH
Number Comp.
of Wires RLA
Fan GRMTR
Amps Amps
Refrigerant
Oz.
Type
Circuit
Fuse
WCC1401R
Ice Maker
230
60
1
2
12.2
N/A
2.0 (2)
180
R404A
20
WCC1400
RACK
Ice Maker
115
60
1
2
N/A
N/A
2.0 (2)
N/A
R404A
20
CR1101
Cond. Unit
230
60
1
2
N/A
1.35
N/A
N/A
R404A
20
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WCC1401R UNIT DIMENSIONS
Figure 1
CR1101 UNIT DIMENSIONS
Figure 2
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Continuous Flow Icemaker Owner’s Manual
WCC1400 RACK UNIT DIMENSIONS
Figure 3
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Continuous Flow Icemaker Owner’s Manual
ELECTRICAL
WCC1401R SCHEMATIC
230 VAC, 60Hz
ON/OFF
SWITCH
WHT
WHT
RED
HP CTRL
BLK
BLK
BLK
WHT
BLK
BLK
WHT
X4
GRY
BLK
SOL
X3
BRN
WHT
X1
AUX. BIN
CTRL
WTR.
CTRL
LP CTRL
RED
X2
B
WHT
A
WHT
7
8
4
5
6
1
2
3
BLK
9
BLK
GRY
GRY
WHT
BIN CTRL
WHT
ANTIFREEZE
RELAY
BLK
2
1
BRN
GEAR
MOTOR
BRN
POST RUN
AUGER DELAY
BLK
BLK
BLK
WHT
RED
RED
WHT
RED
BLK
3
WHT
5
GRY
RED
RED
RED
MAIN
CONTACTOR
B
WHT
T1
WHT
L2
L3
T2
WHT
T3
RED
WHT
RED
BLK
PRE RUN TIMER
COMPRESSOR
RELAY
BLK
A
L1
RED
1
3
BLK
BLK
GRY
WHT
RED
RED
RED
RED
WHT
2
RED
BLK
2
YLW
S
BLK
RELAY
C
BLK
RED
A
RUN
CAPACITOR
ORG
B
2
1
1
PRE RUN
CONTACTOR
3
START
CAPACITOR
2
5
4
RED
RED
BLK
1
BLK
1
BLK
RED
WHT
WHT
R
R
COMPRESSOR
WIRING SCHEMATIC WCC1401R
620070600 REV. Figure 4
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Continuous Flow Icemaker Owner’s Manual
CR1101 SCHEMATIC
Figure 5
© 2019, Cornelius Inc.
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Continuous Flow Icemaker Owner’s Manual
WCC1400 RACK SCHEMATIC
Figure 6
REFRIGERATION SCHEMATIC FOR WCC1400RACK SYSTEM
Evaporator
Evaporator
Thermal Expansion valve
Suction line
Flow
Drier
Liquid in
Thermal Expansion valve
Liquid line solenoid
Figure 7
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
INSTALLATION INSTRUCTION
This manual covers unpacking, inspection, selecting location, installing unit and preparing for operation.
The unit is a split system; it consists of a condensing unit, an icemaker and a line kit.
•
The condensing unit is an outdoor component; it contains the condenser and fan motor. It is controlled by a
low-pressure switch.
•
a) The 1401R Icemaker is an indoor component; it contains one gear motors, one evaporators, one water
level control, compressor, receiver and one bin thermostat. The bin thermostats control a liquid line solenoid.
b) The 1400Rack Icemaker is an indoor component; it contains two gear motors, two evaporators, two
water level controls and works with rack refrigeration systems.
•
Line Kit: Precharged 3/8” liquid line and 3/4” suction line.
NOTE: In a rack refrigeration application, only the ice making head is required (condensing unit and
line kit are not used). Ice making head installed on a -23° F (-30.56° C) low state saturation temperature (14 psig saturation pressure for R404A) requires the installation of one EPR valve, set at 20 psig
downstream of the common suction line of WCC-1400R and WCC-1400Rack unit. Approved EPR
model is ORIT-6-0/50.
REMOVE ICE MAKER FROM CARTON
1. Keep unit in the upright position, remove carton and pallet from unit and inspect unit for damage.
2. Upon inspection of unit, if any damage found, file a claim with carrier immediately.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
CABINET REMOVAL
Icemaker
Item
1
2
Action
a) WCC1401R
b) WCC1400rack
Figure 8
Figure 9
Figure 10
Figure 11
Front Panel
a) Remove 2 screws.
b) Remove 4 screws
and pull forward.
Top Panel
a) Slide back and lift
upwards.
b) Remove 4 screws,
and lift upwards.
1
3
Cross Bar
a) To remove cross
bar 1, remove 2
screws from each
side and lift upward.
b) To remove cross
bar 2 just lift upward.
2
Figure 12
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
4
Side Panels
Remove all screws
and pull forward.
5
Back Panel - Should
not be removed.
Figure 13
Figure 14
Condensing Unit
1. Remove all screws and lift upward.
Figure 15
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
PREPARATION OF INSTALLATION SITE
Icemaker
1. Maintain a minimum of 4inches clearance on all the sides of the units free of obstruction for air flow.
2. The unit can be installed either on an ice storage bin or ice dispenser using proper adapter kits. (Refer to
sales literature for information.) The install kit provided with each icemaker and adapter kits will supply
everything to locate unit correctly. In all cases the icemaker should be sealed all around the base with an
NSF listed sealant. (63804815B).
Condensing Unit
The refrigeration system is air-cooled, it requires airflow, so a well-ventilated area should be chosen. A minimum of
4 feet must be maintained for air intake and exhaust.
WATER INLET HOOK-UP
1. Water Inlet - Fitting is a 1/4” (6.35mm) SAE male flare located at the rear of the unit. Connect water supply
with a 1/4” (6.35mm) or larger copper or flexible tubing.
! CAUTION:
Unit must be installed with only potable water.
NOTE: A shut-off valve with a loop of additional tubing for service is recommended.
2. Water Pressure - Unless otherwise specified, the unit is designed to operate on water pressures between
10 P.S.I. (0.69 Mpa) - 90 P.S.I. (0.62 Mpa), A recommended water supply is with temperatures between
50° F - 90° F (10° C - 32° C) with a pressure between 20-70 P.S.I (0.138 - 0.48 Mpa).
NOTE: For pressures above 90 P.S.I. (0.62 Mpa) a regulator must be installed.
NOTE: This equipment must be installed with adequate backflow protection to comply with applicable federal state and local codes.
3. Filter - IMF (Phosphate Feeder) Water Filters and Scale inhibitors are not recommended for use with the
Continuous Flow Ice-Maker, Taste & Odour only should be used. Total dissolved solids in the water should
be within the below specified limit.
MIN dissolved solids = 270 PPM(TDS).
Max dissolved solids = 500 PPM(TDS).
NOTE: Water inlet for the Ice Maker should not be with RO Filtration System.
NOTE: Unit must be installed per local plumbing code.
DRAIN CONNECTION
Overflow Line – is a 3/8” I.D. flexible tube located at the rear of the icemaker. Extend this line to proper drain.
NOTE: Unit must be installed per local plumbing code BOCA.
ELECTRICAL SUPPLY
1. Power Access — is provided with a 7/8” diameter. knockout hole in the rear panel. Route incoming power
in conduit, through rear panel to icemaker electrical control box. Make connections to wires provided in the
control box and ground lug/screw.
2. Fused Line — should be checked and sized according to electrical rating shown on unit nameplate.
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
AUGER ENGAGEMENT
Be certain that the auger is fully engaged to lower drive and extruder head is fully engaged into evaporator. Perform
the following procedure to engage the auger properly.
1. Install the extruder head on top of the evaporator, as shown in Figure 8
Auger
Extruder
Head
Figure 16
2. When the auger is lowered into the evaporator, rotate the auger to engage the motor drive shaft, as shown in
Figure 9
Extruder
Head
Evaporator
Figure 17
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
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 16. 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.
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 18
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
INITIAL START UP, CHECKS AND ADJUSTMENT INSTRUCTIONS
NOTE: Do not start unit before completing installation steps on the previous page.
Turn on water supply turn on main power switch (located on top of electrical box), and make the following system
checks:
NOTE: If the unit will not start, be sure the 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.
Low Water Safety Control — Adjust magnet by bending magnet arm as needed to shut unit down if water level
drops below bottom of reservoir.
Bin Control — Place ice around probe, unit should shut down in one minute. Remove ice from around probe, unit
should start in two minutes.
Figure 19 Icemaker Float Assembly
NOTE: If any of these checks or adjustments cannot be achieved, refer to Service Manual or call for
factory assistance at 1-800-238-3600.
FOR WCC1401-R ONLY.
1. The WCC1401-R is equipped with a compressor start delay. The auger motor will run before compressor
start for approximately 2 minutes. This is to clear out the evaporators and is normal.
2. The WCC1401-R is equipped with a auger motor run delay. he auger motor will run after compressor shut
down for approximately 3 minutes. This is to clear out the evaporators and is normal.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s 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 20. 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.
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
Install Bin control sensor
Sensing
Bulb
When shipping the sensing tube is on the base of the
ice maker.
Figure 21
Slide the bulb through the larger hole in front of the drop tube
and secure the mounting bracket with supplied screw.
Figure 22
The sensing bulb should be directly under the drop tube.
Figure 23
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
CLEANING AND SANITIZING
ICEMAKER CLEANING AND SANITIZING PROCEDURES
! 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 least once a month until a definite pattern for cleaning and sanitizing has
been established.
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.
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
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 24. Upper Nut and Bearing Assembly
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s 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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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s 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.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s 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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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s 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 25. 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.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
AUGER NUT
AUGER
BEARING NYLON
BEARING DELRIN
“D” DRIVE
GROOVE
EXTRUDING
HEAD
ANTI–ROTATION
RIB – 3 PLACES
Figure 26. Auger and Extruding Head Removal
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 27.
Auger/
Extruder
Head
Figure 27.
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
2. When the auger is lowered into the evaporator, rotate the auger to engage the motor drive shaft, see Figure
28.
Extruder
Head
Evaporator
Figure 28.
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 29. 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.
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 29.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
INSTALLATION AND SHAFT SEAL REPLACEMENT
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
SHAFT SEAL
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).
MOUNT, SHAFT
SEAL
SEAT, SHAFT SEAL
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.
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 30. Shaft Seal
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.
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 counter-clockwise 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.
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
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 31. 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.
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 32. 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.
© 2019, Cornelius Inc.
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Publication Number: 548000109
Continuous Flow Icemaker Owner’s Manual
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.
2. Check or replace run capacitor (if supplied)
check for shorted capacitor or either terminal
grounded to case.
GEAR MOTOR OVERLAY
Figure 33. 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.
5. Main service switch located on top of the control box.
6. Bin Control.
7. High pressure cut out (water cooled only).
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© 2019, Cornelius Inc.
Continuous Flow Icemaker Owner’s Manual
GUIDE TO GOOD ICE
© 2019, Cornelius Inc.
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Figure 26. Troubleshooting Chart
Continuous Flow Icemaker Owner’s Manual
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© 2019, Cornelius Inc.
Cornelius Inc.
www.cornelius.com