Cornelius SERIES 750 (R404a) Service manual

Service Manual

MODULAR FLAKED ICE MAKER

MODELS: SERIES 750 (R404a),

SERIES 1100 (R22),

SERIES 2400 (R404a)

Part No. 166240009

OCTOBER 1994

Revised October, 1996

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION

This Manual must be read and understood before installing or operating this equipment



IMI CORNELIUS INC; 10/94 - 10/95 PRINTED IN U.S.A

TABLE OF CONTENTS

INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1

SPECIFICATIONS 750 AND 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SPECIFICATIONS 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

4

INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

REMOTE CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

STACKING INSTRUCTIONS FOR STACKING KIT 29757 . . . . . . . . . . . . . . . . . . .

TYPICAL WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

TYPICAL REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

BIN THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEARMOTOR START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POWER RELAY / CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

GEARMOTOR DELAY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ON–OFF SWITCH / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FAN CYCLING SWITCH (R404A UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .

HIGH PRESSURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

POTENTIAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CAPACITORS – GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SANITIZING AND CLEANING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WINTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CLEANING THE CONDENSER (AIR COOLED) . . . . . . . . . . . . . . . . . . . . . . . . . . .

TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT WILL NOT RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

COMPRESSOR CYCLES INTERMITTENTLY.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MAKING WET ICE.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT RUNS BUT MAKES NO ICE.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER LEAKS.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WATER LEAKS. (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EXCESSIVE NOISE OR CHATTERING.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MACHINE RUNS WITH FULL BIN OF ICE.

UNIT OFF OR TRIPS CIRCUIT BREAKER.

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

UNIT GOES OFF OR TRIPS CIRCUIT BREAKER. (CONT’D) . . . . . . . . . . . . . . .

PARTS LIST FOR 750 AND 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

PARTS LIST 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

24

24

25

26

27

23

23

24

24

24

21

22

22

22

23

11

11

11

11

11

12

12

12

20

10

11

11

11

11

11

6

8

9

30

32 i

166240009

TABLE OF CONTENTS (cont’d)

LIST OF FIGURES

FIGURE 1. 750 AND 1100 SERIES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. SPECIFICATIONS FOR 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. TYPICAL WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. TYPICAL REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. WIRING DIAGRAM AF/WF–750–MH-R . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. WIRING DIAGRAM AF–750–PMH-50R . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 8. WIRING DIAGRAM AF/WF–1100–MH . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 9. WIRING DIAGRAM RF–1100–MH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. WIRING DIAGRAM AF/WF–1100–MH–3

FIGURE 11. WIRING DIAGRAM AF/WF–1100–MH–50

. . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . .

FIGURE 12. WIRING DIAGRAM 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 13. ILLUSTRATED PARTS BREAKDOWN SERIES 750 – 1100 . . . . . .

FIGURE 14. REMOTE CONDENSER ILLUSTRATED PARTS BREAKDOWN

FOR 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 15. ILLUSTRATED PARTS BREAKDOWN SERIES 2400 . . . . . . . . . . .

Page

10

13

14

15

2

4

7

9

16

17

18

19

28

29

31

LIST OF TABLES

AF-750-P-MHR PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AF-750-P-MH50R PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WF-750-P-MHR PRODUCTION CHART

AF-1100-P-MH PRODUCTION CHART

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WF-1100-P-MH PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

RF-1100-P-MH PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AF-2400-P-MHR PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

3

4

2

2

2

2

166240009 ii

INTRODUCTION

We have strived to produce a quality product. The design has been kept simple thus insuring trouble–free operation.

This manual has been prepared to assist servicemen and users with information concerning installation, construction and maintenance of the ice making equipment. The problems of the serviceman and user have been given special attention in the development and engineering of our ice makers.

If you encounter a problem which is not covered in this manual, please feel free to write or call. We will be happy to assist you in any way we can.

When writing, please state the model and serial number of the machine.

Address all correspondence to:

A Product of IMI Cornelius Inc.

One Cornelius Place

Anoka, MN 55303–1592

Phone 800–554–3526

FAX 612–422–3232

PRINTED IN USA

1 166240009

SPECIFICATIONS 750 AND 1100 SERIES

1 1/2-IN.

4-CM

1 3/4-IN.

4-CM

1 1/2-IN.

4-CM

11 1/2-IN.

29-CM

A

REAR

VIEW

B

C

D

E

2-IN.

5-CM

23 1/8-IN.

59-CM

CHUTE OPENING

23-IN.

58-CM

8 1/4-IN.

21-CM

FRONT

5-IN.

13-CM

BOTTOM

VIEW

26 1/4-IN.

67-CM

A = POWER INLET

B = WATER INLET

C = CONDENSER (WATER IN)

(WC ONLY)

D = CONDENSER (WATER OUT)

(WC ONLY)

E = CHASSIS DRAIN

9-IN.

23-CM

5 1/16-IN.

13-CM

166240009

FIGURE 1. 750 AND 1100 SERIES SPECIFICATIONS

ICE PRODUCTION CAPACITY (approximate)

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AF-750-P-MHR PRODUCTION CHART

AIR TEMPERATURE

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

50

°

F/10

°

C 70

°

F/21

°

C 80

°

F/27

°

C

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

50 ° F/10 ° C

70

°

F/21

°

C

873 lbs/397 kgs 745 lbs/339 kgs 695 lbs/316 kgs

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ


90

°

F/32

°

C 755 lbs/343 kgs 662 lbs/301 kgs 609 lbs/277 kgs

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

AF-750-P-MH50R PRODUCTION CHART

AIR TEMPERATURE

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

50

°

F/10

°

C 70

°

F/21

°

C 80

°

F/27

°

C


50

°

F/10

°

C

70

°

F/21

°

C




90

°

F/32

°




WF-750-P-MHR PRODUCTION CHART

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AIR TEMPERATURE

ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

WATER TEMPERATURE

50

°

F/10

°

C 70

°

F/21

°

C 80

°

F/27

°

C


50

°

F/10

°

C

70

°

F/21

°

C




90

°

F/32

°




AF-1100-P-MH PRODUCTION CHART

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ

AIR TEMPERATURE WATER TEMPERATURE

50

°

F/10

°

C 60

°

F/16

°

C 70

°

F/21

°

C


70 ° F/21 ° C

80

°

F/27

°

C

1202 lbs/545 kgs


1119 lbs/508 kgs

90

°

F/32

°

C 988 lbs/448 kgs



WF-1100-P-MH PRODUCTION CHART

ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ


50 ° F/10 ° C 60 ° F/16 ° C 70 ° F/21 ° C


70 ° F/21 ° C

80

°

F/27

°

C

1151 lbs/523 kgs


1123 lbs/509 kgs

90

°

F/32

°

C 1060 lbs/467 kgs


2

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ


RF-1100-P-MH PRODUCTION CHART



ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ

50

°

F/10

°

C 60

°

F/16

°

C 70

°

F/21

°

C

70

°

F/21

°

C

ÁÁÁÁÁÁ ÁÁÁÁÁÁ

80

°

F/27

°

C

ÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁ

90

°

F/32

°

C

1202 lbs/545 kgs

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

1119 lbs/508 kgs

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

988 lbs/448 kgs

ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

Compressor Electrical Rating

Compressor Model

Condenser

Refrigerant Charge

Refrigerant Control (Air Cooled)

Refrigerant Control (Water Cooled)

Voltage

Total Amp. Draw

Gearmotor Amp. Draw

Gearmotor Electrical Rating

Maximum Fuse Size

750

3/4 hp

Copeland RS64CIE-PAF-214

Air or Water Cooled

AC–21oz R404a

WC–18oz R404a

AXV (30 PSI)

AXV (28 PSI)

115V

16 AMPS

1.6 AMPS

1/8 hp

20 AMPS

1100

2 hp

Copeland CRD-10200PFV

Air or Water Cooled

AC–25 oz R–22

WC–23 oz R–22

AXV (15-17 PSI)

AXV (15-17 PSI)

208/230V 60HZ 1PH

12 AMPS

.7 AMPS

1/7 hp

15 amps

3 166240009

17 1/2-IN.

44-CM

SPECIFICATIONS 2400 SERIES

8-IN.

20-CM

23 1/2-IN.

60-CM

ELECTRICAL

WATER INLET

WATER IN (W/C)

WATER OUT (W/C)

44-IN.

112-CM

NOTE: AIR IS EXHAUSTED OUT

BACK AND SIDE OPPOSITE

CONDENSER

OVERALL DIMENSIONS

23-9/16-IN. HIGH x 45-1/8-IN. WIDE x 27-5/16-IN. DEEP

60-CM 115-CM 69-CM

15 1/8-IN.

38-CM

44-IN.

112-CM

14 1/4-IN.

36-CM

15 1/8-IN.

38-CM

9 1/8-IN.

23-CM

AIR IN

A B

8 3/4-IN.

22-CM

27-IN.

69-CM

9 1/8-IN.

23-CM

”A”- ALTERNATE ICE DROP AREA FOR TOP UNIT WHEN TWO ARE STACKED.

”B”-ICE DROP AREA FOR BASIC UNIT.

INDIVIDUAL ”A” & ”B” DIMENSIONS ARE 5-5/32-IN. x 8-9/32-IN.

13-CM 21-CM

RECOMMENDED BIN TOP CUT OUT AS SHOWN ABOVE 14-1/4-IN. x 8-3/4-IN.

36-CM 22-CM

FIGURE 2. SPECIFICATIONS FOR 2400 SERIES


AF-2400-P-MHR PRODUCTION CHART



ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ

50

°

F/10

°

C 70

°

F/21

°

C 80

°

F/27

°

C

50

°

F/10

°

C


70

°

F/21

°

C

2507 lbs/1140 kgs

2495 lbs/1134 kgs

2175 lbs/989 kgs

2045 lbs/930 kgs

2008 lbs/913 kgs

1850 lbs/841 kgs

ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ 90

°

F/32

°


ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ

Compressor Electrical Rating

Compressor Model

Condenser

Refrigerant Charge

Refrigerant Control

Voltage

Inlet Water Supply

Gearmotor Electrical Rating

Gearmotor Amp Draw

Mamimum Fuse Size

Total Amp Draw

2 hp

Copeland CS14K6E-PFV-235

Air Cooled

26 oz R404a/each side

AXV 26-PSI factory setting/Each Side

208/230 1 ph. 60 hz.

3/8” SAE male flare

1/7 hp

.7 amps at 230V

40 amps

30 amps

Refer to serial plate for maximum circuit ampacity and minimum time delay fuse size.

166240009 4

INSTALLATION INSTRUCTIONS

You will get better service from the ice machine, longer life and greater convenience if you choose its location with care.

Here are a few points to consider:

1. Select a location as close as possible to where you are going to use the ice.

2. Allow a minimum of 6” space at sides and rear of machine for ventilation.

3. A kitchen installation is not desirable as a rule. If a kitchen installation is necessary, locate the machine as far away from the cooking area as possible. Grease laden air will form a greasy deposit on the condenser.

This reduces the ice making efficiency and necessitates thorough cleaning quite often.

4. If you install the unit in a storeroom, be sure the room is well ventilated.

NOTE: Do not install where the ambient and incoming water temperature will drop below 50 ° F rise to over 100 ° F.

WARNING: If water pressure exceeds 50 pounds, a water pressure regulator should be installed in water inlet line between water shut–off valve and strainer. Minimum incoming water pressure required is 22 pounds.

5. Uncrate the unit by removing the staples or nails from the bottom of the carton and lift off.

6. Remove the bolts holding the skid to the machine.

7. For units supplied with a bin sealing gasket, cement the gasket to the bottom outside edge of the machine before it is set on the bin. NOTE: This is an N.S.F. requirement and must be done by the installer.

8. Make sure the correct bin adapter has been supplied when used. Then mount the unit on the bin and level both properly.

9. For units not supplied with bin sealing gasket, seal the machine to bin with an N.S.F. approved sealant such as Dow R.T.V. #732, 734, or G.E. #102, 108. This is an N.S.F. requirement and is the responsibility of the installer.

10. The incoming water for the ice making section requires a 3/8” copper line. Connect this water line to the

3/8” male flare fitting on the back of the unit.

NOTE: For water cooled units, a separate 3/8” copper water line is required to be connected to the flare fitting on the back of the unit marked condenser water in. A 3/8” flare connected line will have to be provided from the fitting marked condenser water out to the drain.

A water regulating valve installed at the factory was set to maintain 270 to 310 PSI head pressure for R–404a units and 210 to 225 PSI for R–22 units (Approx. 105 _ to 110 _ F). Check temperatures at condenser outlet and adjust if necessary.

11. Connect a drain hose to the condensate drain stub tube.

NOTE: All plumbing must be done in accordance with national and local codes.

12. Bring the electrical supply into the unit through a handy box located on the back of unit and make connections.

NOTE: NOTE: Make sure the proper voltage and number of wires are provided. See serial plate and make connections.

NOTE: All wiring must conform to national and local codes.

13. Turn on water supply and observe water level in evaporator sections. Water level is to be maintained at the top of the evaporator. (See adjustment procedure)

5 166240009

14. Turn machine on and check for proper voltage and amp draw on the entire unit as well as components such as the gearmotor and fan motor.

15. Check refrigerant circuit and all plumbing connections for leaks, etc.

16. Check bin thermostat or mechanical shut–off for proper operations. In the mid–range the bin thermostat will open at 42 ° and has a 6 ° differential.

REMOTE CONDENSER

Remote condensers should be installed above the ice machine and in a level configuration. They are connected to the ice making unit by copper tubing and line valves. The female half of the line valve is mounted on the ice making unit and the remote condenser. The male half is soldered on the tube ends when tubing kits are provided with the machine. If tubing kits are not provided, the male half of the line valves will be provided in a valve kit and the installer will mount them on the tubing he provides.

NOTE: WHEN VERTICAL LINES ARE INVOLVED IN THE INSTALLATION, FOLLOW STANDARD

REFRIGERATION PRACTICES FOR VERTICAL LINES TO ASSURE POSITIVE OIL RETURN TO

THE COMPRESSOR. VERTICAL LIFT TO BE NO MORE THAN 15 FEET.

NOTE: WE DO NOT RECOMMEND TUBING RUNS OF MORE THAN 40 FEET..

NOTE: The seals for the line valves will be found in an envelope on the remote condenser. Make sure they are used.

NOTE: REMOVE CAP PLUGS FROM ALL LINE VALVES BEFORE MAKING VALVE CONNECTIONS WITH

THE SEAL.

NOTE: A LOW VOLTAGE ELECTRICAL CONTROL CIRCUIT MUST BE FIELD WIRED BETWEEN THE

ICE MACHINE AND THE REMOTE CONDENSER RELAY. THOSE WIRES SHOULD BE RUN WITH

THE TUBING DURING INSTALLATION. REFER TO APPLICABLE WIRING DIAGRAMS.

NOTE: When the line valves are connected to each other the refrigerant circuit is complete. Each valve half has its own shut-off which must be fully opened to allow the refrigerant to flow though the system before it is started.

The ice making unit utilizing a remote condenser is shipped from the factory with the receiver holding the refrigerant charge. Additional refrigerant may be required upon installation depending upon the ambient conditions the remote condenser is operating under, the condenser and line sizing.

A three way head pressure control valve is used to maintain a relatively consistent head pressure between 175 and 185 PSI for R22 in the receiver in cold ambient conditions. Because of this valve some liquid refrigerant will be held in the condenser.

NOTE: THE HEAD PRESSURE CONTROL VALVE WILL NOT OPERATE CORRECTLY WHEN A TOTAL

PRESSURE DROP OF 14 POUNDS OR MORE IS CREATED BETWEEN THE ICE MAKING UNIT,

THROUGH THE TUBING TO THE REMOTE CONDENSER, THE CONDENSER AND THE RETURN

TUBING TO THE ICE MAKING UNIT.

The remote condenser requires a separate power supply from the ice making unit. Refer to the remote condenser wiring diagram.

166240009 6

WARNING: WATER LEVEL MUST BE MAINTAINED AT THE TOP OF THE EVAPORATOR.

WATER LEVEL ill224

FIGURE 3. WATER LEVEL

1. Remove gearmotor and auger.

2. Adjust float valve to get water level to top seam of the evaporator.

3. Re–install auger. WATER LEVEL WILL RISE WHEN AUGER IS INSERTED BUT WHEN THE MACHINE

IS TURNED BACK ON AND ICE STARTS BEING MADE, THE WATER LEVEL WILL GO BACK TO THE

ORIGINAL SETTING.

4. Re–install gearmotor assembly and start machine.

7 166240009

STACKING INSTRUCTIONS FOR STACKING KIT 29757

The Kit consists of:

1 – #26102 Sealer

2 – #261 1/4-20x5/8 screw

2 – #256 1/4” flat washer

2 – #239 1/4” Lock Washer

1 – #29758 Stacking Chute Extension

1. After uncrating machine to be stacked, remove front and rear panels.

2. Remove top and front panels of bottom machine.

3. Remove alternate chute opening cover from bottom machine.

4. Insert vertical chute extension from kit into alternate chute opening of bottom unit and seal it to the base with sealer provided in the kit.

5. Carefully mount stacking unit reversed 180 ° with the compressor and condenser opposite those of the bottom unit.

NOTE: When mounting, make sure stacking unit vertical chute aligns and inserts correctly with chute extension installed in alternate chute opening of bottom unit. Raise chute bracket to cover opening and tighten bracket screws.

6. Secure both machines together as shown in the illustration utilizing screws and washers provided in the kit.

7. After stacking unit, hook up electrical and water.

NOTE: The two units must operate independently of each other.

8. Connect drain line from tee under the stacked unit to run out of the back of the unit.

9. Replace panels of stacked unit front to front and back to back as the machine is mounted. Replace front panel of bottom unit.

166240009 8

TYPICAL WATER CIRCUIT

The supply water enters the float chamber through a small orifice. The water level rises and lifts the buoyant float with it. The float attached to the float arm seats a valve to shut off any further water supply. As water leaves the float chamber, the level drops along with the float and arm, causing the valve to open and admit more water. Thus the water level is maintained automatically as the machine operates.

Water now flows through a hose connected to the float chamber and enters the opening of the evaporator shell.

The water level in the shell will rise to the same level that is maintained in the float chamber. The water that is in immediate contact with the center post evaporator will be reduced in temperature. As a result, freezing occurs and ice forms on the surface of the evaporator.

As more water is frozen, the thickness of the ice increases until it exceeds the distance allowed between the evaporator and auger. The auger rotates at a slow speed to wipe off the accumulated ice as well as help it to the surface. After the ice reaches the surface it is discharged through the top opening in the shell. An ice chute attached to the shell conveys the ice to the storage bin where it accumulates in the insulated bin until it is used.

The ice will pile up to a point where the bin thermostat tubing is located. When the ice touches this brass tubing, the unit will shut–off and remain off until enough ice is used or melted to reduce the pile. Any ice that melts will pass through the drain and drain hose to an open drain.

WATER IN

FLOAT

CHAMBER

ICE

OUT

EVAPORATOR

CHAMBER

FIGURE 4. TYPICAL WATER CIRCUIT

9 166240009

TYPICAL REFRIGERANT CIRCUIT

Heat always flows from hot to cold and therefore, the ”heat load” supplied to the evaporator section by water gives up its heat to the refrigerant which is at a temperature below the freezing point of water. This refrigerant now passes through the heat exchanger back to the compressor, as a low pressure vapor.

This low pressure vapor is compressed in the compressor, as it leaves the compressor at a high pressure in vapor form it enters the top of the condenser. The condenser has a rapid flow of cool air across it which removes much of the heat from the hot refrigerant vapor.

As the vapor, passing through the condenser, loses heat it condenses back to a liquid since it is still under high pressure and cooler than when it entered the condenser. The liquid refrigerant then passes through the drier/filter still under pressure and goes through the heat exchanger where further cooling takes place. As the refrigerant leaves the automatic expansion valve, the pressure has dropped, causing the refrigerant to vaporize and boil off as it picks up heat in the evaporator and since the pressure is low, the refrigerant will be cold.

EVAPORATOR

AXV

HEAT

EXCHANGER

COMPRESSOR

CONDENSER

DRIER/FILTER

FIGURE 5. TYPICAL REFRIGERANT CIRCUIT

166240009 10

ELECTRICAL CIRCUIT

CIRCUIT DESCRIPTION

As the manual on–off–circuit breaker switch is pushed to ”on”, an electrical circuit is completed to the gearmotor via the circuit breaker gearmotor overload, power relay / contactor, gearmotor delay thermostat and the bin thermostat. After the previous circuit has been completed the condenser fan motor will start as will the compressor (via the high pressure control and the compressor starting relay).

COMPONENT DESCRIPTION

BIN THERMOSTAT

This is electrically in ”series” with the ice making system. when the bin is full, the contact opens, terminating power to the machine.

GEARMOTOR START RELAY

This is a current type relay which means as the gearmotor run winding comes ”on” the line, the current draw initially is relatively heavy through the relay coil (coil is in series with run winding). It then acts like a normal relay and the N.O. start contact ”makes”, completing a circuit through the start capacitor to the start winding.

As the gearmotor picks up speed, the amp draw through the relay coil drops off allowing the armature to return to its normal position (start contact ”opens”). This action removes the start winding from the circuit.

POWER RELAY / CONTACTOR

This relay controls the compressor power only.

GEARMOTOR DELAY THERMOSTAT

This thermostat keeps the gearmotor running until the suction line temperature reaches 45

_

after the full bin switch terminates power to the power relay / contactor.

ON–OFF SWITCH / CIRCUIT BREAKER

This switch interrupts power to the entire unit. The switch has a circuit breaker incorporated into its’ design.

This circuit breaker will trip out in the event the gearmotor draws to high of amps In such an event the power is interrupted to the unit. To reset the circuit breaker and reestablish power to the unit, push the switch to the ”off” position and then back to the ”on” position.

FAN CYCLING SWITCH (R404a Units)

The function of this switch is to maintain condensing pressures at a satisfactory level during–low ambient conditions. The switch breaks the circuit to the condenser fan motor at 205 PSI and makes the circuit at 275

PSI.

HIGH PRESSURE CONTROL

The high pressure cut out is electrically in series with the power relay. As the head pressure rises to 450 PSIG for R404a charged units and 400 PSIG for R 22 charged units, a preset level, the contact opens thus breaking the circuit to the compressor via the power relay contactor. This control must be reset manually on R404a units.

11 166240009

COMPRESSOR START RELAY

This is a current type relay and contains a N.O. contact which is connected in series with the start winding of the compressor. The relay coil is electrically in series with the run winding. When power is applied, the compressor draws high current which sets up a magnetic field around the magnet coil which causes the relay to operate, closing the relay contact. As the compressor approaches operating speed, the current flowing through the coil decreases, permitting the relay contact to open, thereby opening the starting circuit.

POTENTIAL RELAYS

The potential relay is used as a compressor starting relay, The contact in the potential relay is N.C.. The magnet coil is connected across (parallel) the start winding and is affected by induced voltage, generated by the start winding. As the compressor comes up to design speed, the voltage across the relay coil increases and at running speed is sometimes as much as 2 1/2 times the supply voltage. This voltage sets up a magnetic field which causes the relay to operate. The starting relay is calibrated to remove the start capacitor (open the starting circuit) at approximately 85% of the motor design speed.

NOTE: BOTH TYPES OF RELAYS ARE DESIGNED TO OPERATE WITHIN VERY NARROW LIMITS OF

VOLTAGE AND CURRENT DICTATED BY MOTOR DESIGN, THEREFORE, WHEN MAKING A

REPLACEMENT OF A RELAY ALWAYS PROVIDE AN EXACT REPLACEMENT, RECOMMENDED

BY THE COMPRESSOR MANUFACTURER.

CAPACITORS – GENERAL

An electrical capacitor is a device which stores up electrical energy. Capacitors are used with single phase motors to provide starting torque and improve running characteristics; by feeding this energy to the start winding in step with the run winding.

Any capacitor has three (3) essential parts, two (2) of which are usually foil plates separated and insulated by the third part called the dielectric.

Two general types of capacitors are used with electric motors. The electrolytic starting capacitor usually uses a very thin film of oxide on the metallic plate as the dielectric. The running capacitor usually is of the liquid filled type.

166240009 12

YL

BL YL

BL

OUTLET

BOX

WH

WH

BL

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 2.0 AMPS

GR BL

BK

BL

BL WH

YL

RD

BIN

THERMOSTAT

BL

BL

BL

DELAY

THERMOSTAT

BK

RD

CONTROL

HIGH PRESSURE

WH

CONTACTOR

2

3

4

BL

GEAR MOTOR

START CAPACITOR

64-77 MFD 165 VAC

RD RD

GEAR

MOTOR

M YL

GEAR MOTOR

START RELAY

BK BK

WH

FAN MOTOR

M BK

LOW AMBIENT

SWITCH (A/C ONLY)

COMPRESSOR

OVERLOAD

1

BK

COMPRESSOR

R

C

RD

S YL YL

COMPRESSOR

RUN CAPACITOR

30 MFD 440 VAC

2

BK

5

START CAPACITOR

72-86 MFD 330 VAC

1

COMPRESSOR

OR

COMPRESSOR

START RELAY

WH

WH

AF/WF-750-MH-R

115 VOLTS 60 Hz

FIGURE 6. WIRING DIAGRAM AF/WF–750–MH-R

13 166240009

YL

BL

OUTLET

BOX

LB

BR

RD

BK

GN/Y

YL

RD

BL

BIN

THERMOSTAT

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

RD

BK

BL

BL

RD

DELAY

THERMOSTAT

GEAR MOTOR

START RELAY

BK

3

2 4

BL

RD

GEAR MOTOR

START

CAPACITOR

RD

BL

BL

BR

LB

CONTROL

HIGH PRESSURE

CONTACTOR

RD

GEAR

MOTOR

M YL

YL

GN/Y

RD

BK BK

WIRE NUT

RD

FAN MOTOR

M

FAN SWITCH

COMPRESSOR

OVERLOAD COMPRESSOR

RD

GN/Y

1

C

R

S YL

BK

COMPRESSOR

START CAPACITOR

88-106 MFD 220 V

GN/Y

BK BL

L

S

COMPRESSOR

START RELAY

M

RD

AF750PMH-50-R

220 VOLTS 50 Hz

166240009

FIGURE 7. WIRING DIAGRAM AF–750–PMH-50R

14

YL

BL

OUTLET

BOX

RD

BK

RD

BK

RD

BK

GR

YL

RD

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

BL

RD

BK

BIN

THERMOSTAT

BL

BL

RD

DELAY

THERMOSTAT

BK

4 2

RD

GEAR MOTOR

START

CAPACITOR

RD

GEAR

MOTOR

M

BK

3

GEAR MOTOR

START RELAY

BK

BL

EVAPORATOR HEATER

M

YL

BK

BK

RD

RD

CONTROL

HIGH PRESSURE

(W/C ONLY)

BK

POWER RELAY

RD

RD

COMPRESSOR

R

C

S

RD

COMPRESSOR

RUN

CAPACITOR

YL YL

RD

COMPRESSOR

START

CAPACITOR

BK

BK

COMPRESSOR

START RELAY

5

1

2

OR

RD

RD

AF/WF-1100-MH

208/230 VOLTS 60 Hz

FIGURE 8. WIRING DIAGRAM AF/WF–1100–MH

15 166240009

YL

BL

OUTLET

BOX

RD

BK

RD

BK

RD

BK

GW

YL

RD

BL

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

BIN

THERMOSTAT

RD

BK

BL

BL

RD

DELAY

THERMOSTAT

GEAR MOTOR

START RELAY

BK

3

2 4

BL

RD

GEAR MOTOR

START

CAPACITOR

RD

M

COOLING

FAN MOTOR

BK

GEAR

MOTOR

M YL

BK

RD

BK

CRANKCASE HEATER

RD

CONTACTOR

RD

230V

CONDENSER

POWER

RELAY

M

WH

CLASS II

FAN

MOTOR

RUN

CAPACITOR RD

START

CAPACITOR COMPRESSOR

BK

C

R

S

BK

BK

RD

RD

YL YL

COMPRESSOR

START RELAY

5

1

2

OR

RD

RD

RF-1100-MH

208/230 VOLTS 60 Hz

166240009

FIGURE 9. WIRING DIAGRAM RF–1100–MH

16

YL

BL

OUTLET

BOX

BL

RD

BK

BL

RD

BK

RD

BK

GR

YL

RD

BL

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

BIN

THERMOSTAT

BK

RD

BL

BL

RD

DELAY

THERMOSTAT

GEAR MOTOR

START RELAY

BK

3

2 4

BL

RD

GEAR MOTOR

START

CAPACITOR

RD

FAN MOTOR

M

RD

CONTROL

HIGH PRESSURE

(W/C ONLY)

BK

RD

RD

BL

BK COMPRESSOR

M

CONTACTOR

GEAR

MOTOR

M YL

RD

RD

BK

AF/WF-1100-MH-3

3 PHASE 208/230 VOLTS 60 Hz

FIGURE 10. WIRING DIAGRAM AF/WF–1100–MH–3

17 166240009

YL

BL

OUTLET

BOX

LB

BR

LB

BR

RD

BK

GW

YL

RD

BL

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

BIN

THERMOSTAT

RD

BK

BL

BL DELAY

THERMOSTAT

GEAR MOTOR

START RELAY

BK

3

2 4

BL

RD

GEAR MOTOR

START

CAPACITOR

RD

RD

FAN MOTOR

M

RD

CONTROL

HIGH PRESSURE

(W/C ONLY)

BK

CONTACTOR

RD

GEAR

MOTOR

M

BK

RD

YL

RD

COMPRESSOR

R

C

S YL

RD

COMPRESSOR

RUN

CAPACITOR

RD

YL

RD

BK

BK

COMPRESSOR

START RELAY

5

2

1

COMPRESSOR

START

CAPACITOR

OR

RD

AF/WF-1100-MH-50

240 VOLTS 50 Hz

166240009

FIGURE 11. WIRING DIAGRAM AF/WF–1100–MH–50

18

RD

COMPRESSOR

START

CAPACITOR

145-174 MFD

250V

WH

5

RD

RD

COMPRESSOR

RUN

CAPACITOR

35 MFD

370V

RD

COMPRESSOR

YL YL

R

S

C

BK

2

BK

1

YL

SWITCH

CO 450

BL

YL

YL

GEAR

MOTOR

START

RELAY

2 3

4

GEAR

MOTOR

M

BK

BL

RD

GEAR MOTOR

DELAY

THERMOSTAT

RD

GEAR

MOTOR

START

CAPACITOR

BL

YL

BK

GW

SYSTEM 1

CONTACTOR

RD

BK RD

BK

BL

RD

ON-OFF

SWITCH

BK

ON-OFF SWITCH

CIRCUIT BREAKER

RATED 1.5 AMPS

BK

RD

OR

BIN LIMIT

THERMOSTAT

BIN

THERMOSTAT

BL

BL

RD

BK

BL

RD

BK

SYSTEM 1 LOW AMBIENT

PRESSURE

BK

SWITCHES

CI 275

CO 205

BK

BK

BK

SYSTEM 2

M COND.

FAN

WH

A/C

ONLY

OR

GEAR MOTOR

& COMPRESSOR

CONTROL RELAY

1

3

4

6

RD

YL

RD

YL

SYSTEM 2

CONTACTOR

COMPRESSOR

R

C

S

BK

BK

RD

RD

COMPRESSOR

RUN

CAPACITOR

35 MFD

370V

RD

YL YL

YL

COMPRESSOR

START RELAY

5

1

2

BL

ON-OFF SWITCH

RATED 1.5 AMPS

YL

BL

HIGH

PRESSURE

SWITCH

CO 450

BK

BK

COMPRESSOR

START

CAPACITOR

145-174 MFD

250V

WH

YL

BL

GEAR

MOTOR

M

RD

GEAR

MOTOR

START

CAPACITOR

RD

BL

BL

GEAR

MOTOR

START

RELAY

4

3 2

GEAR MOTOR

DELAY

THERMOSTAT

BK

YL

AF/WF-2400 PMHR DUAL COMPRESSORS

208/230 VOLTS 1 PHASE

FIGURE 12. WIRING DIAGRAM 2400 SERIES

MAINTENANCE

THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED AT LEAST EVERY SIX MONTHS ON

FLAKED ICE MACHINES:

1. Check power supply with machine running for proper voltage.

2. Check water level in the float tank reservoir. Water level should be maintained at the top of the evaporator.

Adjust if necessary. (See illustration and adjustment procedure)

3. Clean the air–cooled condenser coil with a stiff brush or vacuum cleaner (See procedure)

CAUTION: CONDENSER COOLING FINS ARE SHARP, USE CARE WHEN CLEANING.

4. Clean the ice storage bin and flush the bin drain at least once a month.

5. If a water conditioner is installed in the inlet water line, change, replace, or clean the filter, strainer or cartridge as required.

6. If heavy mineral deposits on the auger and evaporator shell are encountered due to bad local water conditions, follow sanitizing and cleaning procedure.

7. Loosen hold–down cam locks and remove gearmotor assembly.

8. Check thrust washer; replace if noticeably worn.

9. Lift out auger and examine for wear. The corkscrew auger guide bushing pressed into the drive block should be checked for wear. Replace if loose or if worn flat with auger drive block. If the Helix auger on the corkscrew auger round bar becomes flat on the inside more than 1/8 of an inch over a length of two inches or more it should be replaced.

NOTE: HELIX AUGERS DO HAVE MACHINED FLAT RELIEF SURFACES. DON’T CONFUSE THEM WITH

WORN FLAT AREAS.

Check the insert in the bottom ring of the Helix auger and replace if excessively worn.

10. Check shell vertical strips for wear. Replace the shell if excessive wear is shown.

11. Check O–Ring, replace if worn or cut.

12. Re–assemble, steps 7through 11.

CAUTION: IN RE–ASSEMBLING THE AUGER GEARMOTOR, THE HOLD DOWN CLAMPS

MUST BE RIGHT AND SECURE. IN RE–INSTALLING THE EVAPORATOR SHELL, BE

ABSOLUTELY SURE THAT THE ”O” RING IS NOT PINCHED OFF AS THIS WOULD CAUSE A

WATER LEAK AROUND THE BASE OF THE EVAPORATOR. LUBRICATE THE ”O” RING WITH

FOOD GRADE LUBRICANT BEFORE RE–ASSEMBLING SHELL.

13. Check for alignment of ice chute. Make sure chute gasket is not blocking path of ice flow.

14. Check bin thermostat operation. In the mid–range position the bin thermostat will open at 42 _ and has a

6 _ differential.

166240009 20

SANITIZING AND CLEANING PROCEDURE

1. Turn switch to ”OFF” to stop unit.

2. Remove top cabinet panel.

CAUTION: Hazardous moving parts. Do not operate unit with panel removed.

3. Mix sanitizing solution by using 0.5-ounces of household liquid bleach (such as Hi-Lex or Chlorox) to one gallon of potable water. This mixture must not exceed 200-ppm of chlorine.

4. Turn water ”OFF”. Remove water hose from float chamber and allow all water to drain from the float chamber and evaporator. Restore hose to float chamber and add sanitizing solution to the float chamber.

Turn water ”ON”.

OR

Remove float chamber cover and while holding float up to prevent water from entering the chamber, remove water hose and allow all water to drain from the float chamber and evaporator. Restore hose to float chamber and add sanitizing solution to the float chamber.

5. Reinstall float chamber cover.

6. Remove vertical ice chute cover.

7. With a plastic bristle brush and sanitizing solution, scrub the interior of the vertical ice chute, including the interior and exterior of the evaporator chute that extends into the vertical chute. Also scrub the vertical chute cover and sensor tube. Allow all parts to air dry.

8. Reinstall the vertical chute cover and cabinet top panel.

9. Turn switch to ”ON” and allow unit to make ice.

10. Remove or melt with warm water, all ice inside of bin.

11. Using the sanitizing solution from step 7 and brush, scrub the interior of the ice bin including the underside of the ice bin cover. Scrub the outside of the ice chute that protrudes into the ice bin, and the inside and outside of the ice bin door.

12. Rinse interior of the ice bin with clean water.

13. Allow machine to make ice for at least 1/2 hour then discard all the ice made. DO NOT ALLOW ICE WITH

SANITIZER IN IT TO BE USED.

21 166240009

WATER TREATMENT

During the freezing process, as water passes under the freezing plate, the impurities in the water have a tendency to be rejected and the plate will freeze only the pure water.

However, the more dissolved solids in the water, the more troublesome the freezing operation will be. Bicarbonates in the water are the most troublesome of the impurities. These impurities will cause scaling on the evaporator, clogging of the water distributor head, float valve mechanism and other parts in the water system. If the concentration of impurities is high, cloudy cubes or mushy ice may be the result.

Parts of the ice maker, that are in contact with the water or ice, may corrode if the water is high in acidity. In some areas, water may have to be treated in order to overcome some of the problems that arise because of the mineral content.

IMI Cornelius has water filter/treatment systems available to control impurities found in your water supply. Contact your local dealer for more information.

WINTER STORAGE

If the unit is to be stored in an area where the temperature will drop below freezing, it is most important that all water lines be drained to prevent them from freezing and possible rupture.

To blow out the water line, disconnect the water supply at the cabinet inlet and use air pressure to force the water into the water reservoir pan. This can then be removed from the water pan.

WATER COOLED CONDENSER – To remove water from condenser unhook water supply and attach compressed air hose. Start machine. As head pressure reaches the appropriate level opening the water regulating valve, the compressed air will force the water out. Do not let the machine operate longer than necessary.

CLEANING THE CONDENSER (AIR COOLED)

In order to produce at full capacity, the refrigeration condenser must be kept clean. The frequency of cleaning will be determined by surrounding condition. A good maintenance plan calls for an inspection at least every two months.

Remove the unit compartment grill at the front. With a vacuum cleaner, remove all accumulated dust and lint that has adhered to the finned condenser.

CAUTION: CONDENSER COOLING FINS ARE SHARP. USE CARE WHEN CLEANING.

166240009 22

TROUBLESHOOTING

Trouble

UNIT WILL NOT RUN

COMPRESSOR CYCLES

INTERMITTENTLY.

Probable Cause Remedy

A.

On–off switch in ”off” position.

A.

Turn switch to ”on”.

B.

Defective on–off switch.

C.

Blown fuse.

B.

Check and replace.

C.

Replace fuse and check for cause of blown fuse.

D.

Adjust colder.

D.

Thermostat set too warm for ambient.

E.

Power relay contacts corroded.

F.

Defective thermostat.

G.

Loose electrical connection.

E.

F.

G.

Check and clean.

Check and replace.

Check wiring.

H.

Turn switch to off then to on.

H.

Gearmotor overload protector has cut off machine.

A.

Low voltage.

A.

Check line voltage.

B.

Dirty condenser.

C.

Air circulation restricted.

D.

Defective condenser fan motor.

E.

Defective relay, overload protector or starting capacitor.

F.

Loose electrical connection

B.

Clean condenser.

C.

Remove restriction.

D.

Check and replace.

E.

Check and replace.

F.

Check wiring.

23 166240009

Trouble

MAKING WET ICE.

Probable Cause

A.

Surrounding air temperature too high.

A.

Remedy

Correct or move unit

B.

High water level in float reservoir.

C.

Dirty condenser.

B.

Lower water level, see step 2, page 5

C.

Clean condenser

D.

Faulty compressor.

E.

Refrigerant leak.

D.

Check and replace

E.

Check and repair

F.

”O” ring leaking at bottom of evaporator shell.

F.

Check and replace

*NOTE: Special care must be used with R404a (HP62) charged systems using (POE) Polyolester oil.

The refrigeration system must not be open longer than 15 min., and the appropriate drier must be used due to the moisture absorption properties of the POE oil.

UNIT RUNS BUT MAKES NO

ICE.

A.

Leak in refrigerant system.

A.

Check and repair.

WATER LEAKS.

EXCESSIVE NOISE OR

CHATTERING.

MACHINE RUNS WITH FULL

BIN OF ICE.

B.

Moisture in system.

C.

No water.

D.


E.

Compressor not running.

B.

Check, dehydrate and add drier to system.

C.

Check water supply.

D.

Check and replace ”O” ring.

E.

Check and replace ”O” ring

A.

Worn or bad float valve.

A.

Check and replace.

B.

Float and arm assembly stuck.

B.

Check and adjust or replace.

C.


C.

Check and replace.

D.

Storage bin drain and tubing.

D.

Check and repair.

A.

Mineral or scale deposits on inside of evaporator shell.

B.

Intermittent water supply .

A.

Remove and clean inside surfaces by immersing evaporator shell in ice machine cleaner.

B.

Check inlet water line .

C.

Check and adjust water level.

C.

Water level in float tank too low.

D.

Auger gearmotor end–play or worn bearings.

E.

Air lock in gravity water supply line from float tank to evaporator shell.

A.

Storage bin thermostat set too cold.

D.

E.

A.

Repair or replace.

Check and adjust warmer.

Check and adjust warmer.

B.

Bin thermostat thermowell out of path of ice.

B.

Adjust thermowell.

166240009 24

Trouble

UNIT OFF OR TRIPS CIRCUIT

BREAKER.

Probable Cause

A.

Ice jams up in evaporator shell.

B.

Bin thermostat will not shut–off machine. Set too cold.

C.

Auger motor has worn bearings.

D.

Ice chute out of alignment, restricted ice flow out of evaporator section.

E.

Ice chute center separator bent restricting ice flow out of evaporator section .

F.

Incoming water temperature too cold.

G.

Bin thermostat does not shut–off when bin is full of ice.

H.

Mineral or scale deposits on inside of evaporator shell and evaporator.

I.

Strips loose or missing on inside of evaporator shell.

J.

Low ambient temperature in room where unit is located.

K.

Gearmotor sticking which causes it to draw excessive amperage.

Remedy

A.

Clean inside surface of evaporator shell.

B.

Check and adjust or replace .

C.

Check and replace.

D.

Re–align.

E.

Replace ice chute .

F.

Maintain temperature above 50

°

F.

G.

Replace bin thermostat if necessary.

H.

Inspect and clean.

I.

Inspect and replace evaporator shell if necessary.

J.

Maintain temperature above 50

°.

K.

Check amp draw of gearmotor with an amprobe (1.6 amps) at

115V, (.7 amps) 230V for normal loaded amps.

25 166240009

Trouble

UNIT GOES OFF OR TRIPS

CIRCUIT BREAKER. (CONT’D)

Probable Cause

L.

Plugged expansion valve, or capillary tube causing low back pressure.

M.

Slight leak, causing low back pressure.

Remedy

L.

Check back pressure, replace valve or capillary tube. Evacuate and re–charge system, replace drier–strainer.

M.

Check back pressure, find gas leak, repair leak, evacuate system, add drier and recharge.

N.

Check and tighten or replace.

O.

Replace auger.

N.

Loose hold–down assy.

O.

Auger worn excessively on the inside surfaces causing thicker flaked ice to be made.

P.

Auger out of line causing excessive wear on the lower outside surface where it rubs against evaporator shell liner at the bottom.

Q.

Broken auger

R.

Evaporator surfaces worn or gouged, causing thicker ice to be made.

S.

Auger guide bushing worn down.

T.

Loose gearmotor mounting place.

U.

Low water level in float tank reservoir.

V.

Worn thrust washer.

W.

Gearmotor Delay Thermostat does not keep gearmotor running after Bin Thermostat shuts down.

P.

Q.

Replace auger and evaporator shell.

Replace auger.

R.

Inspect and replace evaporator if

S.

T.

necessary.

Replace auger guide bushing

(corkscrew type augers only).

Check and tighten.

U.

Adjust float arm to maintain

V.

W.

correct water level.

Replace.

Check operation and / or replace.

166240009 26

PARTS LIST FOR 750 AND 1100 SERIES

30

31

32

33

43

44

45

39

40

41

42

34

35

36

37

38

ILL.

NO .

24

25

26

27

28

29

20

21

22

23

16

17

18

19

9

10

11

12

13

14

15

7

8

5

6

3

4

1

2

46

47

48

49

50

51

DESCRIPTION

Shroud, condenser

Condenser

Bracket, fan motor

Blade, condenser fan

Motor, condenser fan

Coil, condenser

Clamp, condenser coil

Bracket, coil mounting

Drier

Valve, water regulating

Clip, delay thermostat

Thermostat, gearmotor delay

Pad

Hold–down, evaporator

Evaporator

O–Ring

Auger

Shell

Valve, automatic expansion

Thrust washer

Gearmotor assembly

Disc, centering

Chute, vertical

Float tank assembly

Float & valve only

Screw, wing

Gasket, chute

Chute, inclined ice

Compressor (1PH)

Compressor (3PH)

Cover, vertical chute

Control, high pressure

Control, low ambient fan

Relay, power (1PH)

Relay, power (3PH)

Compressor cooling fan motor (not shown)

Thermostat, bin

Capacitor, compressor run

Capacitor, compressor start

Capacitor, gearmotor start

Switch, on–off / Circuit Breaker

Relay, compressor start

Relay, gearmotor start

Compressor cooling fan blade (not shown)

Plate, gearmotor mounting

Valve, Service

Top panel

Top panel, stainless steel

Front panel

Front panel, stainless steel

Left side panel

Left side panel, stainless steel

Right side panel

Right side panel, stainless steel

Back panel

Back panel, stainless steel

Switch, Fan Cycling

Switch, High Pressure Control

750

03120

03796

09182

161921004

08043

164826001

20956

27598

21789

21924

00890

08065

09287

162964013

N/A

29299

161890012

161870004

163183006

165595003

161871003

22429

35987

36836

166184002

164980002

25871

25864

26124

163277002

41100

165677006

165677005

164884002

N/A

N/A

09570

161192004

161165008

161165000

166220001

161998009

161627001

N/A

03163

162978003

163652068

27654

163498068

27655

163653068

27657

163654069

27670

163499068

27656

165677005

165677006

1100

03120

21078

162966001

27653

21711

164826003

20956

27599

21789

21924

00890

08065

20885

40569

41166

42316

27597

26266

37977

23527

35961

22499

35987

36836

21850

01211

25871

25864

26124

163277003

42597

07024

23838

40713

35547

23308

09570

27765

40284

37909

166220000

40285

161627003

09355

03163

N/A

163652068

27654

163498068

27655

163653068

27657

163654068

27670

163499068

27656

N/A

N/A

27

1100–50Hz

03120

21078

162966001

27653

21711

164826003

20956

27599

21789

21924

00890

08065

20885

40569

N/A

42316

27597

26266

37977

23527

35961

22499

35987

36836

21850

01211

25871

25864

26124

163270003

42597

07024

23838

40713

N/A

23308

09570

27765

40284

37909

166220000

40285

161627003

09355

03163

N/A

163652068

27654

163498068

27655

163653068

27657

163654068

27670

163499068

27656

N/A

N/A

750–50Hz

03120

03796

09182

161921004

08043

164826002

20956

27599

21789

21924

00890

08065

09287

162964041

N/A

29299

161890012

161870004

163183006

165595003

161871003

N/A

N/A

N/A

166184002

N/A

25871

25864

26124

163270002

41100

165677006

165677005

40713

N/A

N/A

09570

N/A

25335

29519

166220000

161998012

161627003

N/A

03163

162978003

163652068

N/A

163498068

N/A

163653068

N/A

163654069

N/A

163499068

N/A

165677005

165677006

166240009

45

49

47

21

22

5

12

11

43

28

24

25

29

9

30

19

23

2

3

4

18

27

20

26

16

15

14

13

31

32

35

46

44

17

33

34

41

42

36

37

38

40

51 10

50

39

48

7

6

1

8 ill227

166240009

FIGURE 13. ILLUSTRATED PARTS BREAKDOWN SERIES 750 – 1100

28

1

2

3

4

5

6

7

9

8

ILL. NO.

1

10

11

8

9

12

13

4

5

2

3

6

7

14

13

14

12

11

10

FIGURE 14. REMOTE CONDENSER ILLUSTRATED PARTS BREAKDOWN FOR 1100 SERIES

PART NO.

27334

27379

27345

42145

42624

42202

42278

27149

27576

27183

27185

27384

27181

42277

DESCRIPTION

Condenser

Shroud

Frame assy

Fan blade

Motor, fan

Bracket, fan motor mounting

Relay

Cover, electrical box

Electrical box assy

CNN–Quick, male

CNN–Quick, male

Bracket, connector

Tube Condenser In

Tube Condenser Out

29 166240009

ITEM NO

1

2

3

4

34

35

36

37

30

31

32

33

38

39

40

41

42

43

44

22

23

24

25

18

19

20

21

26

27

28

29

9

10

11

12

7

8

5

6

13

14

15

16

17

166240009

PARTS LIST 2400 SERIES

DESCRIPTION

Condenser A/C

Fan mounting bracket

Fan motor

Fan blade

Drier

Masonite Pad

Hold–down

Evaporator

Evaporator O–Ring

Auger

Shell L.H.

Shell R.H.

Automatic expansion valve

Thrust washer

Gearmotor

Vertical chute cover

Vertical chute

Water reservoir

Float & valve

Hose

Float mounting bracket

Compressor

Thermowell end cap

Fan Cycling Switch

Delay thermostat

Delay thermostat clip

Contactor

Capacitor, compressor start

Gearmotor start relay

Gearmotor–compressor control relay

Bin thermostat

On–off switch/Circuit breaker

Gearmotor start capacitor

Water pressure switch

Compressor run capacitor

Gearmotor mounting plate

Centering disc

Compressor start relay

Main power switch

Reservoir cover

High pressure control switch

Chute

Chute gasket

Screw, chute mounting

CABINET PARTS NOT ILLUSTRATED 2400 SERIES

Description Part No.

Top cover

Front panel

Right side panel

163494068

163493068

163492068

Left side panel

Rear panel

163491068

163490068

30

PART NO.

161870011

164820021

27185

27183

35548

09570

166220000

37909

165677007

27765

03163

20956

40285

35546

35230

165677005

20885

08065

00890

35225

27156

35771

35231

162964029

20421

165677006

25864

25871

40713

40284

161627003

166184002

26124

163277003

42597

03120

21078

162966001

162966002

161921010

21711

164826003

166205001

42328

41

25

10

12

37

26

14

36

24

15

43

23

37

16

17

9

20

42

36

14

11

34

10

44

13

21

32

39

19

18

20

35

33

28

38

29

32

40

8 3

5 4

27

30 29

38

31

7

6

22

13

8

7

6

5

1

2

35

33

28

FIGURE 15. ILLUSTRATED PARTS BREAKDOWN SERIES 2400

31 166240009

CORNELIUS LIMITED COMMERCIAL WARRANTY PLAN

TO THE ORIGINAL OWNER OF A CORNELIUS COMMERCIAL FLAKE ICEMAKER

This warranty applies to Icemakers installed within the United States, Canada, Mexico and Puerto Rico only.

For warranty information outside the U.S., Canada, Mexico and Puerto Rico, contact your nearest IMI Cornelius

Sales Office.

PARTS WARRANTY PERIOD

IMI CORNELIUS INC., hereinafter referred to as CORNELIUS, warrants to the original owner of a new CORNELIUS commercial flake ice machine (“Machine”) who buys solely for commercial uses, that the Machine shall be free from defects in material and/or factory workmanship if properly installed, operated and maintained, under normal and proper use and service conditions with competent supervision. The parts warranty period is two years (24 months) from the date of installation or 27 months from the date of shipment by CORNELIUS whichever time period elapses first. With respect to compressor and the evaporator, and the evaporator only for refrigeration leaks and restrictions which would effect the normal operation of the unit, the warranty period will be five years (60 months) from the date of installation or 63 months from the date of shipment by CORNELIUS whichever time period elapses first. The obligation of CORNELIUS under this warranty is limited to repair or replacement (at the option of CORNELIUS) FOB factory in Mason City, Iowa of the part (or Parts) of any Machine that is proven defective.

LIMITED LABOR WARRANTY PERIOD

In addition to the parts warranty, CORNELIUS will pay scheduled straight time labor to repair or replace a defective component when failure occurs within one year (12 months) from the date of installation or 15 months from the date of shipment by CORNELIUS whichever time period elapses first. With respect to the compressor, evaporator, refrigeration condenser, condenser fan motor, and auger gearmotor, the labor warranty period will be two years (24 months) from the date of installation or 27 months from the date of shipment by CORNELIUS whichever time period elapses first. Time and rate schedules for labor compensation will be published periodically by CORNELIUS. Additional expenses including but not limited to travel time, truck charges, overtime charges, material cost, accessing or removal of the ice machine, normal prescribed maintenance cleaning, adjustments, and ice purchases are the responsibility of the original owner.

No parts warranty or labor allowance on the motor compressor assembly will apply when the ice machine’s refrigeration system is modified with a condenser heat reclaim device, or parts and assemblies not provided by CORNELIUS, unless CORNELIUS provides approval, in writing, for these modifications for specific locations.

The parts warranty shall not apply when destruction or damage is caused by alterations, unauthorized service, using other than factory authorized replacement parts, risks of transportation, accidents, misuse, damage by fire, flood or acts of God. No components or assembly from which the serial number or identification number has been altered or removed will be covered. Any defective parts to be repaired or replaced must be returned to us through a CORNELIUS distributor/dealer, transportation charges prepaid, and they must be properly sealed and tagged. The serial and model number of the Machine and the date of original installation of such Machine must be given. The warranty of repaired or replaced parts will not extend beyond the period of the original warranty. The decision of the CORNELIUS Service Department regarding the warrantability of parts and eligibility for the labor allowance will be final.

No representative, distributor/dealer or any other person is authorized or permitted to make any other warranty or obligate CORNELIUS to make any other warranty or obligate CORNELIUS to any liability not strictly in accordance with this policy. This warranty is in lieu of all other warranties expressed or implied and of all other obligations or of liabilities on our parts.

OUR LIABILITIES ARE LIMITED SOLELY AND EXCLUSIVELY TO REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT. WE ARE

NOT LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER. In those jurisdictions where liability for damages cannot be disclaimed, original purchaser’s recovery shall not exceed the cost of the warranted product.

Except for descriptions of size, quantity and type, which may appear on CORNELIUS product with specifications of certain industry, government or professional organizations standards which may appear as product information disclosures in CORNELIUS literature and other documents from time to time, THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,

INCLUDING WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

CORNELIUS MAKES NO WRITTEN WARRANTY TO ANY PURCHASER WHO BUYS FOR PERSONAL, FAMILY OR HOUSEHOLD USE.

IMI CORNELIUS INC.

ONE CORNELIUS PLACE

ANOKA, MINNESOTA 55303-6234

166240010 32

P/N 163238002

Effective March. 1, 1996

Starting with Production

Serial

Number Code 9603

THIS PAGE LEFT BLANK INTENTIONALLY

166240010 33

34

IMI CORNELIUS INC.

Corporate Headquarters:

One Cornelius Place

Anoka, Minnesota 55303-6234

(763) 421-6120

(800) 238-3600

166240010

Cornelius SERIES 750 (R404a) Service manual

Service Manual

MODULAR FLAKED ICE MAKER

MODELS: SERIES 750 (R404a),

SERIES 1100 (R22),

SERIES 2400 (R404a)

TABLE OF CONTENTS

TABLE OF CONTENTS (cont’d)

INTRODUCTION

SPECIFICATIONS 750 AND 1100 SERIES

ICE PRODUCTION CAPACITY (approximate)

ICE PRODUCTION CAPACITY (approximate)

SPECIFICATIONS 2400 SERIES

A B

ICE PRODUCTION CAPACITY (approximate)

INSTALLATION INSTRUCTIONS

REMOTE CONDENSER

STACKING INSTRUCTIONS FOR STACKING KIT 29757

TYPICAL WATER CIRCUIT

TYPICAL REFRIGERANT CIRCUIT

ELECTRICAL CIRCUIT

CIRCUIT DESCRIPTION

COMPONENT DESCRIPTION

BIN THERMOSTAT

GEARMOTOR START RELAY

POWER RELAY / CONTACTOR

GEARMOTOR DELAY THERMOSTAT

ON–OFF SWITCH / CIRCUIT BREAKER

FAN CYCLING SWITCH (R404a Units)

HIGH PRESSURE CONTROL

COMPRESSOR START RELAY

POTENTIAL RELAYS

CAPACITORS – GENERAL

MAINTENANCE

SANITIZING AND CLEANING PROCEDURE

WATER TREATMENT

WINTER STORAGE

CLEANING THE CONDENSER (AIR COOLED)

TROUBLESHOOTING

PARTS LIST FOR 750 AND 1100 SERIES

PARTS LIST 2400 SERIES

IMI CORNELIUS INC.

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725