IMI CORNELIUS INC g

One Cornelius Place g

Anoka, MN 55303-6234

Telephone (800) 238-3600 Facsimile (800) 535-4231

Installation/Service Manual

UC 701 SERIES CONTINUOUS–FLOW

ICEMAKER

IMPORTANT:

TO THE INSTALLER.

It is the responsibility of the Installer to ensure that the water supply to the dispensing equipment is provided with protection against backflow by an air gap as defined in

ANSI/ASME A112.1.2-1979; or an approved vacuum breaker or other such method as proved effective by test.

Water pipe connections and fixtures directly connected to a potable water supply shall be sized, installed, and maintained according to

Federal, State, and Local

Codes.

Part No. 630460150

February 2001

Revision Date: November 7, 2003

Revision A

THIS DOCUMENT CONTAINS IMPORTANT INFORMATION

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



IMI CORNELIUS INC; 2000–2003

PRINTED IN U.S.A

TABLE OF CONTENTS

SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Page

1

RECOGNIZE SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

UNDERSTAND SIGNAL WORDS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

FOLLOW SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

GENERAL DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

TO THE USER OF THIS MANUAL

DESCRIPTION

DESIGN DATA

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

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

CLAIMS INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY REFERENCE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

SPECIFICATION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3

3

4

7

3

3

3

PRE–INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

FREIGHT DAMAGE CLAIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

COUNTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

ELECTRICAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

DRAIN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

INSTALLATION

INITIAL START UP, CHECKS AND ADJUSTMENT INSTRUCTIONS

GUIDE TO SERVICE

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

. . . . . . . . .

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

8

8

11

ICEMAKER CLEANING AND SANITIZING PROCEDURES . . . . . . . . . . . . . . . . . 11

MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

MONTHLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

QUARTERLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SEMI–ANNUALLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

11

12

WATER LEVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

HOW WATER LEVEL CONTROL WORKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PURPOSE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

TO REPLACE WATER LEVEL CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

TO REPLACE WATER LEVEL SAFETY SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . 13

REFRIGERATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

REFRIGERATION SYSTEM ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

13

13

EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ADJUSTMENT AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER MODULATING VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

CONDENSER MODULATING VALVE REMOVAL

BIN CONTROL

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

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

GEARMOTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

MOTOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

14

14

14

TO REPLACE GEARMOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

AUGER AND EXTRUDING HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

INSTALLATION AND SHAFT SEAL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . .

17

17

18

18

15

15

16

16 i

630460150

TABLE OF CONTENTS (cont’d)

Page

UPPER NUT AND BEARING ASSEMBLY

TO REPLACE BEARING

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

ELECTRICAL CHECKOUT

OVERLOAD CHECK

COMPRESSOR CHECK

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

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

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

19

19

19

CAPACITOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SAFETY CONTROLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

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

19

20

24

THE COMPRESSOR WILL NOT RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THE COMPRESSOR STARTS BUT TRIPS REPEATEDLY ON THE

OVERLOAD PROTECTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

THE COMPRESSOR RUNS BUT WILL NOT REFRIGERATE . . . . . . . . . . . . . . .

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

24

24

24

25

LIST OF FIGURES

FIGURE 1. CLEARANCE REQUIREMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 2. ICEMAKER FLOAT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 3. UPPER NUT AND BEARING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . .

FIGURE 4. EXPANSION VALVE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 5. ADJUSTMENT SCREW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 6. GEARMOTOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 7. AUGER AND EXTRUDING HEAD REMOVAL

FIGURE 8. SHAFT SEAL

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

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

FIGURE 9. OVERLOAD CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 10. COMPRESSOR CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 11. GEAR MOTOR OVERLOAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

FIGURE 12. WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

15

15

17

5

9

17

18

19

19

20

22

LIST OF TABLES

TABLE 1. DESIGN DATA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

630460150 ii

SAFETY INFORMATION

Recognize Safety Information

This is the safety-alert symbol. When you see this symbol on our machine or in this manual, be alert to the potentially of personal injury.

Follow recommended precautions and safe operating practices.

Understand Signal Words

A signal word - DANGER, WARNING, OR CAUTION is used with the safety-alert symbol. DANGER identifies the most serious hazards.

Safety signs with signal word DANGER or WARNING are typically near specific hazards.

General precautions are listed on CAUTION safety signs. CAUTION also calls attention to safety messages in this manual.

DANGER

WARNING

CAUTION

Follow Safety Instructions

Carefully read all safety messages in this manual and on your machine safety signs. Keep safety signs in good condition. Replace missing or damaged safety signs. Learn how to operate the machine and how to use the controls properly. Do not let anyone operate the machine without instructions. Keep your machine in proper working condition. Unauthorized modifications to the machine may impair function and/or safety and affect the machine life.

CAUTION: Very high discharges pressure is present in the system. Quick disconnects on your gages will minimize danger and loss of refrigerant.

CAUTION: The Unit requires a separate electrical line. See Instruction Manual for proper fuse size.

WARNING: There must be adequate clearance around the Icemaker. Allow 25–inches on the front side for service access, 4–inches on side opposite the storage bin, and 4–inches on the back side for air exaust.

NOTE: The Unit must be installed per local plumbing and electrical codes. Failure to do so may cause damage to the Unit which would void the factory warranty.

NOTE: Using parts other thean genuine factory manufactured parts relieves the manufacturer of all liability. The manufacturer reserves the right to change specifications at any time.

1 630460150

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630460150 2

GENERAL DESCRIPTION

TO THE USER OF THIS MANUAL

This manual covers the installation and assembly of the Air–Cooled or Water–Cooled Model UC700 Icemaker with the Model UC150 Dispenser. Refer to Table of Contents for page location of detailed information pertaining to questions that may arise during installation or operation of this equipment.

DESCRIPTION

The UC700 is a chuncklet Icemaker designed to be installed under a counter adjacent to an Ice Dispenser or an

Ice Storage Bin. The Icemaker will deliver ice to either the left or right side. The Icemaker requires a 12–inch by

12–inch opening at the lower front of the Unit for air intake. A minimum of 1.5 sq. ft. opening must be provided out the left or right side and the rear of the machine for air exaust.

CLAIMS INSTRUCTIONS

Claims: In the event of shortage, notify the carrier as well as IMI Cornelius immediately. In the event of damage, notify the carrier. IMI Cornelius is not responsible for damage occurring in transit, but will gladly render assistance necessary to pursue your claim. Merchandise must be inspected for concealed damage within 15 days of receipt.

WARRANTY REFERENCE INFORMATION

Warranty Registration Date

(to be filled out by customer)

Unit Part Number:

Serial Number:

Install Date:

Local Authorized

Service Center:

DESIGN DATA

Table 1. Design Data

Unit Model Number:

UC700–A Series Continuous–Flow Icemaker (Air–Cooled)

UC700–W Series Continuous–Flow Icemaker (Water–Cooled)

Unit Overall Dimensions:

Height

Width

Depth

Clearances Dimensions Required:

Front Side Service Access (Removable front panel to allow removal of

Unit)

Side Opposite Storage Bin for Air Exaust

Rear for Air Exaust

Weights:

Shipping Weight

3

27 inches

13.7 inches

25.5 inches

25 inches

4 inches

4 inches

184 pounds

630460150

Table 1. Design Data (cont’d)

Water Supply–Water inlet fitting is 1/4–inch SAE flare located at the top front of the Unit. The Unit is designed to operate on water pressure between 10 PSI and 90 PSI.

Drain Overflow Line (Located at rear of the Unit) 3/8–inch Flexible Tubing

Ambient Operating Temperature 40 ° F to 100 ° F

Electrical:

Unit Electrical Rating

Recommended Electrical Supply

Models

UC701–A

UC701–W

Air Cooled

Water Cooled

208/230 VAC, 60 Hz, 11.3 Amps,

Single Phase

208/230 VAC, 60 hz, 20 Amps

Dedicated 3–Wire

Grounded Circuit

SPECIFICATION CHART

VAC

208/230

208/230

HZ

60

60

PH

1

1

Wire Comp.

RLA A

Fan

GRMTR

A

2 7.7

1.6

2

2 7.7

N/A 2

Refrigerant

Oz.

13

13

Type

R404A

R404A

Circuit

20

20

UC700

90 80 70 60

Water Temperature Deg. F

–50 –70 –90 –100

50

Air Temperature Deg. F

650

600

550

500

450

400

350

630460150 4

FIGURE 1. CLEARANCE REQUIREMENTS

5

630460150

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630460150 6

INSTALLATION

PRE–INSTALLATION

Freight Damage Claim

The delivery of your equipment (Frieght Company, Distributor, or dealer) is responsible for loss or damage of your shipment. All claims must be filed with the deliverer of your equipment. Please follow the steps below to determine if your shipment is satisfactory or if a claim must be filed:

1. Check the number of products delivered against the number of products listed on the delivery receipt.

Should the totals not match, have the driver note all errors on both copies and both you and the driver sign and date said notation.

2. Inspect all cartons for visible damage. Open and inspect as required before the driver leaves and have him or her note any damage on the receipts. All damaged claims must be inspected within 15 days of delivery.

Notify your carrier immediately if concealed damage is found after delivery.

3. Should concealed damage be found when the product is unpacked, retain the packing material and the product and request an inspection from the deliverer.

4. All claims for loss or damage should be filed at once. Delays in filing will reduce the chance of achieving a satisfactory resolution to the claim.

Counter

1. A flat and level counter space sufficiently strong to support the weight of the Dispenser and the Icemaker.

The Icemaker may be installed on the left or the right side of the Dispenser.

2. General Requirements:

A.

The front of the Icemaker must be free of obstructions.

B.

Allow a 4–inch minimum clearance between exaust side of the Icemaker and adjacent equipment.

C.

A louvered front panel (12–inches X 12–inches) aligned with the air inlet of the Icemaker and adequate ventilation (1.5 Sq. feet opening) in the counter for exaust air.

D.

A removable panel in the counter face (from 2–inches below the top of the counter to the floor, a minimum of 17–inches wide) to allow removal of the Icemaker.

Electrical

Two separate 20 amp, 120VAC, 60 Hz electrical circuits.

Drain

One drain beneath the counter at floor level which will accomodate both the drain from the Icemaker and the

Dispenser.

7 630460150

INSTALLATION

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

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

3. Install the Dispenser first, following installation instructions supplied with the Dispenser.

4. Remove the two hole plugs from the side of the dispenser.

A.

The plugs are pressed in and sealed with a silastic sealant. To remove pry the outside cap off and then press the inside plug into the bin. Discard both plugs.

B.

Install the icemaker alignment brackets (Supplied with icemaker) to the dispenser (See Figure 2).

5. Install the Icemaker:

A.

Install the icemaker alignment brackets (Supplied with icemaker) to the icemaker (See Figure 2).

B.

Roll the Icemaker into the cabinet alongside the Dispenser.

C.

Level and align the icemaker to the dispenser using the four level adjustment bolts located on the lower front of the Icemaker.

D.

Install the locking bolt on the lower front of the icemaker.

E.

Connect drain, power and water.

6. Install transport tube:

A.

Insert the ice transport tube through the bin into the transport elbow on the Icemaker. (Note: The icemaker is equipped with a safety switch located at the base of the elbow, this switch will prevent the icemaker from running if the elbow is not properly installed) .

B.

Align the nylon lock screw on the elbow with the recess on the tube. Install lock screw.

7. Connect bin thermostat:

A.

Locate bin thermostat cable supplied with the icemaker (Black cable) and connect to electrical box on the UC700 and the receptacle on the side of the dispenser.

ATTACH TO BIN

ATTACH TO BIN

630460150

RIGHT SIDE INSTALL LEFT SIDE INSTALL

FIGURE 2. SIDE BRACKET INSTALLATION

8

INITIAL START UP, CHECKS AND ADJUSTMENT INSTRUCTIONS

NOTE: Do not start Icemaker before completing installation steps on pages 7 and 9.

Turn on water supply (if Icemaker is water cooled turn water on to condenser also) turn on main power switch

(located on top of electrical box), and make the following system checks:

NOTE: If Icemaker will not start be sure water reservoir is full. Low water safety control must be properly adjusted to start and shut down the Icemaker. If water level drops below bottom of reservoir, the

Icemaker 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 Icemaker stops running. Release float and Icemaker will restart. Keep water in reservoir at level line while the Icemaker is in operation. See Figure 3

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.

NOTE: For altitudes over 1000 feet above sea level, adjust range screw (behind end cover). Half turn max. raises setting 4 _ F approx.

FIGURE 3. ICEMAKER FLOAT ASSEMBLY

Water modulating valve (water cooled units only)—Opening point of condenser water modulating valve should be set to maintain proper operating pressure in the refrigeration system high side. (see chart on page 13). Closing point of valve should be set low enough to close valve during compressor stand by periods.

To raise, turn counterclockwise, to lower turn clockwise.

9 630460150

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630460150 10

GUIDE TO SERVICE

WARNING: Disconnect electrical power to the Icemaker to prevent personal injury before attempting any internal maintenance. Only qualified personnel should service internal components or electrical wiring.

ICEMAKER CLEANING AND SANITIZING PROCEDURES

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: Calgon Corp. of Virginia Chemicals, ice machine cleaner. Mixture: 3-1/3 ounces per gallon of water.

5. Clean auger assembly and ice transition tube in a sink using cleaner mixture and reinstall in icemaker.

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 assembly and ice transition tube in a sink using sanitizing solution and reinstall in icemaker.

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 CO

2

gas.

2. Inspect water feed reservoir at lease 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.

11 630460150

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 (see page 13).

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 Ȃ thick, replace. See Figure 4

OK

1/16

Ȃ

REPLACE

REPLACE

1/16

Ȃ

OK

FIGURE 4. UPPER NUT AND BEARING ASSEMBLY

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. See Figure 3 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, page 9.

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 electrical power 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.

630460150 12

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

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

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.

REFRIGERATION SYSTEM

NOTE: Thermostatic Expansion Valve No Adjustment

+

10 Lbs Discharge Pressure

WATER TEMPERATURE

A

I

R

T

E

M

P

50 °

60 °

70

°

80 °

90 °

100

°

40

°

174

202

230

265

300

328

65

°

177

205

233

269

304

334

90

°

180

208

236

272

307

340

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.

13 630460150

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—The 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 your gauges will minimize danger and loss of refrigerant. Comply with federal regulations for reclaiming refrigerant.

CONDENSER MODULATING VALVE

The reason for using a water modulating valve is to supply the correct amount of water to the condenser. and to maintain a proper operating pressure to refrigeration system high side.

The flow of water through the valve is increased as the high side pressure rises and is decreased as high side pressure lowers.

To calibrate the amount of water flow with the refrigeration system high side pressure, turn adjustment screw located on end of valve opposite of bellows. See Figure 6. Turn screw counterclockwise to raise opening point or clockwise to lower opening point. Opening point of valve should be set to maintain proper operating pressure in refrigeration system high side. Refer to Pressure Chart on page 3. Closing point of valve should be set low enough to close valve during compressor stand-by periods.

NOTE: Cold water will absorb heat faster than warm water. The water flow will therefore automatically increase as inlet temperature increases.

630460150 14

SIGHT

GLASS

THERMOSTATIC

EXPANSION VALVE

FIGURE 5. EXPANSION VALVE

FIGURE 6. ADJUSTMENT SCREW

CONDENSER MODULATING VALVE REMOVAL

1. Disconnect power to unit, then shut off water supply to condenser and evacuate refrigerant from system.

2. Remove inlet water line from Condenser Modulating Valve. Also remove tube from high side refrigerant line.

3. Remove Condenser Modulating Valve and bracket from unit.

4. Remove valve from bracket.

5. Replace Condenser Modulating Valve by reversing Steps 2 thru 4. Then pull system into vacuum.

6. Charge unit with proper amount of refrigeration.

7. Turn power and water on to unit.

8. With unit running, adjust modulating valve to proper setting.

9. Go through a complete system check.

BIN CONTROL

The type of bin control used on all UC Models is thermostatically controlled. The switch itself is inside the electrical box of the Dispenser and can be serviced from the front of the unit. The cap tube bulb is located in the thermostat well directly under the ice inlet.

To test switch, disconnect power to unit and remove one wire from switch. Connect both leads of your ohmmeter to the Bin Control Switch terminals. With control bulb at room temperature ohmmeter should read “Closed

Circuit”.

Now cover the control bulb with ice, within 1 minute switch should “click” and ohmmeter should read “Open Circuit.” The Bin control is in electrical series with a 24 volt transformer located in the ice dispenser and a 24 volt control relay located in the Icemaker.

The Bin 24 volt control relay 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. Control bulb is positioned under ice chute and can be replaced by removing the capillary from the thermostat well.

The most important thing to remember when replacing probe is to be careful not to cut or kink probe and be sure sensor bulb is located in a position to shut unit down before ice reaches ice chute.

This icemaker is equipped with a safety ice level sensor. This sensor control is located on top of theevaporator.

This switch is also in electrical series with the anti-freeze relay and other safety circuitry.

15 630460150

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.

GEARMOTOR

OVERLOAD TRIPPED

Check water level control and evaporator water tube for line build-up restrictions.

NO

CAUTION

Clear ice from evaporator and auger before resetting overload.

YES

CLEAN

See Instructions.

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.

Resets but motor does not run.

Short run. Trips again in 2 minutes. Check gearmotor circuits.

Resets but motor does not run.

OVERLOAD GUIDE

ELECTRICAL:

S High or low voltage. Weak power lines can cause overloads on icemakers restarts.

S High running current (2.4amps or above). Check motor circuits and start relay.

S Auger delay failed.

ICEMAKER

S Mechanical parts worn. Scored evaporator or auger. Worn thrust bearing.

S Icemaker not turning off. Failed ice level control.

S Over compression. Low water inlet temperature. Restrictions in water line from reservoir.

REFRIGERANT

S Contaminated charge or bad compressor.

S Low charge or gas leak.

S

Low suction pressure. Improper expansion valve. Sensing bulb location or insulation and/or defective expansion valve.

Check gearmotor circuits.

Will not

Reset.

Overload hot try again.

Will not reset.

Replace overload.

MOTOR CHECK

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. (See Figure 7).

If no continuity on start or run winding test, replace gearmotor. If continuity on grounded motor test, replace gearmotor.

630460150 16

START RELAY

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 7. GEARMOTOR ASSEMBLY

TO REPLACE GEARMOTOR ASSEMBLY

1. Disconnect the icemaker from the electrical power source.

2. Disconnect the transmission cable from the electrical box.

3. Remove the 4 hex head bolts securing the evaporator to the top of the transmission.

4. 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.

5. When replacing the transmission, it may be necessary to rotate the auger back and forth to align the motor shaft and auger.

BEARING DELRIN

AUGER NUT

BEARING NYLON

GROOVE

EXTRUDING

HEAD

ANTI–ROTATION

RIB – 3 PLACES

FIGURE 8. AUGER AND EXTRUDING HEAD REMOVAL

17

AUGER

“D” DRIVE

630460150

AUGER AND EXTRUDING HEAD REMOVAL

1. Disconnect unit from power supply.

2. Remove storage container cover and put aside.

3. Turn off water supply to icemaker.

4. After ice has melted from head take hold of the auger nut and lift straight up to disengage from icemaker.

5. When replacing the auger assembly, make certain that both the auger engages the output shaft drive and the extruding head ribs engage the evaporator tube. (See Figures 8 )

E–RING

WASHER, PLAIN FLAT

SHAFT SEAL

MOUNT, SHAFT

SEAL

SEAT, SHAFT SEAL

GEARMOTOR

FIGURE 9. SHAFT SEAL

INSTALLATION AND SHAFT SEAL REPLACEMENT

(See Figure 9)

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.

2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and push down until seal nest in recess of shaft seal mount. (lubricate rubber on ceramic seal with rubber lubricant).

3. Place shaft seal with carbon face down (spring up) over output shaft and push (gently) downward until seal rests on carbon face of the output shaft seal.

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.

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 Ȃ thick. When they wear below 1/16 Ȃ they should be replaced. Bearings to be inspected for wear during quarterly maintenance. (See Figure 4)

To Replace Bearing

1. Disconnect unit from electric power.

2. Remove top panels.

630460150 18

3. Remove Dispense Tray Cover.

4. Use an open end wrench on auger nut connected to bearing and turn counterclockwise to remove assembly.

5. 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.

FIGURE 10. OVERLOAD CHECK

FIGURE 11. COMPRESSOR CHECK

ELECTRICAL CHECKOUT

1. Be sure the unit is disconnected from the power source. 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

(See Figure 10)

1. 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.

COMPRESSOR CHECK

(See Figure 11)

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.

3. Check between “C” and “R” or “S” and the shell of the compressor. If there is continuity, replace the compressor as the motor is grounded.

4. Check between screw terminal on the overload and “C” on the compressor. Check and repair the lead or connections if there is no continuity.

CAPACITOR CHECK

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.

19 630460150

FIGURE 12. GEAR MOTOR OVERLOAD

SAFETY CONTROLS

Your icemaker unit has several safety and control devices incorporated into its design.

WARNING: None of the below described devices should ever be “bypassed” to allow the unit to function.

The safety and control system shut-off devices are:

1. Low water shut off reed switch located in icemaker float assembly. (Automatic reset type.)

See Figure 3

2. Gearmotor thermal overload, manual reset type (red button on motor). See Wiring Diagram Figure 13.

3. Compressor thermal overload, automatic reset type. See Figure 10

4. Anti-freeze relay and associated circuit. See Wiring Diagram Figure 13.

5. Main service switch located on top of the control box. See Wiring diagram Figure 13.

6. Bin Control.

7. High pressure cut out (water cooled only).

630460150 20

CUSTOMER

COMMENTS

“It runs but the ice is too soft.”

“The icemaker is not producing enough ice.”

“The ice is too wet.”

GUIDE TO GOOD ICE

CHECK ICEMAKER

LOCATION CONDITIONS

FIRST

S

Proper air flow for condensing system.

S Location too close to high units such as coffee urns, deep fryers, grills, etc.

S

Supply water conditions

Water too warm

(above 90

_

F).

Water artificially softened above 262 ppm sodium chloride.

Normal water supply too high in total dissolved solids

(above 500 PPM).

CHECK ICE MAKER

S

Use gauges for checking suction and head pressures. See manual for correct reading and conditions. Check frost line and sight glass.

S

Check water level for proper adjustment and restrictions. See

Manual.

S Check evaporator assembly for worn parts, bearings, scored evaporator and auger, bad expansion valve.

etc.

“It makes too much noise.”

(With this comment the ice is usually extremely hard and larger than normal.)

Over

Compression

S Check to see if noise objection is normal fan and air flow noise.

S Supply water conditions.

Water too cold (below

50

_

F). (Possibly running from pre-cooler.)

S Obstructions partially blocking ice exit from top of evaporator.

S

Check fan and fan shroud.

S Check for loose parts and screws rattling.

S Check evaporator assembly for worn parts, bearings, scored evaporator and auger, bad expansion valve, etc.

21 630460150

FIGURE 13. WIRING DIAGRAM

NO POWER ICEMAKER RUNS BUT

DOES NOT MAKE ICE

LOW WATER SAFETY

SWITCH OPEN

Check electrical wiring in control box for loose connections.

Check for failed service switch or relay.

Check power to machine.

High pressure switch open or cycling on and off.

Remote condenser units only

Remote condenser not running.

Check electrical wiring in control box for loose connections.

Check power to condenser.

Condenser fan running but compressor not running

Check line voltage.

Check compressor winding

& components.

Check that water is turned on.

Check for restriction in water line.

Check incoming water pressure

(minimum 10 lbs.).

Check water safety switch.

Evaporator water tube may have an air bubble.

Clear air bubble from tube.

High suction pressure

(30 lbs. or above).

Low suction pressure

(20 lbs. or below).

Discharge king valve partially closed.

Non-condensible in system.

Too much refrigerant in system.

Condenser fan not running.

Condenser dirty or restricted.

Open valve

Evacuate and recharge system.

Clean condenser.

Low pressure switch open or cycling on and off.

Check electrical circuit to fan motor.

Check fan motor.

TROUBLESHOOTING CHART – ICEMAKER NOT OPERATING

Head

Pressure high.

Valve stuck open.

Replace valve.

ICEMAKER OPERATING BUT

SOFT ICE

GEARMOTOR OVERLOAD

TRIPPED

Check water level control and evaporator water tube for lime build up restriction.

Check bin switch

Yes No

No

Clean all related drain lines.

Refer to guide to Good Ice in service manual.

CAUTION

Clear ice from evaporator and auger before resetting overload.

Reset overload.

Yes

CLEAN see instructions.

TXV not operating properly.

Bulb loose.

Clean and tighten.

Suction line not insulated.

Bulb uninsulated.

Clean and insulate.

TXV bulb lost charge.

Replace valve evacuate and recharge.

IMPORTANT

Icemaker runs when reset but problem has not been found.

Continue checking for overload as follows to guard against future problems

Icemaker runs

Short run trips again in 2 minutes. Check gearmotor circuit.

Reset but motor does not run.

Check gearmotor circuit.

Will not reset.

Overload hot try again.

Will not reset replace overload

Low on refrigerant.

Remote condenser units only

Check for leaks.

LAC not operating properly (minimum discharge pressure

180 lbs.).

Replace LAC valve, evacuate and recharge system.

Plugged liquid line dryer.

Replace dryer.

Evacuate and recharge system.

Restricted liquid line.

Plugged or faulty TXV.

Check for kinks or damage to liquid line.

Replace valve.

Evacuate and recharge system.

Icemaker froze up.

Check if auger is turning.

No

OVERLOAD GUIDE

ELECTRICAL

High or low voltage weak power lines can cause overloads on icemaker restarts

High running current. Check motor circuits and start relay – Auger delay failed.

ICEMAKER

Mechanical parts worn. Scored evaporator or auger. Worn thrust bearing.

Ice maker not turning off. Failed ice level control.

Over compression. Low water inlet temperature. Restriction in water line from reservoir.

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

Check drive on gearmotor.

Check gears in gearbox.

Check if extruding head is down in evaporator tube.

TROUBLESHOOTING

IMPORTANT: Only qualified personnel should service internal components or electrical wiring.

TROUBLESHOOTING COMPRESSORS

Trouble Probable Cause

Basically the compressor problems can be narrowed down to three areas of checkout.

Remedy

THE COMPRESSOR WILL

NOT RUN

A.

No voltage to the compressor terminals.

B.

Low voltage.

A.

Check circuit.

C.

Problems in the compressor electrical circuit.

B.

Below 90% of nameplate rated voltage.

C.

See electrical checkout instructions.

THE COMPRESSOR STARTS

BUT TRIPS REPEATEDLY ON

A.

PROTECTOR

B.

C.

Voltage.

A.

Check for proper fan operation and clean condenser.

B.

Check the compressor suction and discharge pressures.

C.

Voltage should be within 10% of the rated nameplate voltage.

D.

High compressor amperage draw.

THE COMPRESSOR RUNS

BUT WILL NOT

REFRIGERATE

A.

Compressor not working.

D.

It should never exceed 120% of the rated nameplate amperage.

See electrical checkout instructions.

A.

Check the compressor suctions and discharge pressures. See chart on page 13.

630460150

24

IMI CORNELIUS

CERTIFICATE OF WARRANTY

TWO YEAR LIMITED ICE EQUIPMENT WARRANTY

IMI Cornelius warranty to the original commercial purchaser/user, that any commercial product of its manufacture bearing the name Cornelius will be free from defect in material and/or factory workmanship, and that if properly installed, maintained, and serviced in accordance with the Service

Manual furnished with the product, it will perform adequately under normal use. This product warranty shall be effective for a period of two years from the date of original installation of 27 months from the date of original shipment by IMI Cornelius, whichever period elapses first, provided the warranty registration card is completed and returned to IMI Cornelius within 30 days from the date of installation.

IMI Cornelius obligation under this warranty is limited to the repair or replacement, including reasonable labor charges, of any part of parts which the purchaser/user returns to IMI Cornelius factory, transportation costs prepaid, and which IMI Cornelius finds to be defective in workmanship and/ or material within the warranty period. To be reimbursable under this warranty, labor charges must be submitted to IMI Cornelius within 30 days from the date of service, must be performed by a qualified company acceptable to IMI Cornelius, and must be for reasonable and customary straight time labor charges only. No travel time, mileage, or other charges in excess of straight time charges will be accepted. Any replacement parts must be approved IMI Cornelius parts. The serial and model numbers and date of original installation of the product must be given.

ADDITIONAL THREE YEAR LIMITED WARRANTY ON COMPRESSOR

The hermetically sealed refrigeration compressor is covered by the above two year limited warranty. In addition to that warranty, if the compressor fails because of a defect in materials or workmanship during the third through fifth year from the date of installation, IMI Cornelius will repair or at its option, replace the compressor. Labor charges and the cost of relays, overloads and capacitors are not included.

This warranty does not include failure or other damage resulting from:

S Electrical power failure to the ice machine for any reason

S

Water supply failure to the ice machine for any reason

S

Adverse operating conditions as set forth in your Service Manual

S

Drain line malfunctions as set forth in your Service Manual

S

Failure to clean and maintain the ice machine as set forth in your Service Manual

S

Use of non-authorized replacements parts

S

Unauthorized modification of the ice machine

S

Any product installed outside the U.S.A. or Canada

No part or assembly which has be subject to accident, alteration or misuse or which is not installed, maintained, or serviced in accordance with the

S ervice Manual furnished with the product, or which is from a machine on which the serial number has been altered or removed, shall be covered by this warranty.

THIS WARRANTY DOES NOT COVER DAMAGE CAUSED BY LACK OF PREVENTATIVE MAINTENANCE, IMPROPER INSTALLATION,

ACCIDENT, MISUSE, NEGLIGENCE, ALTERATION, FIRE, FLOOD, OR ACTS OF GOD. In those jurisdictions where liability for damages cannot be disclaimed, original purchasers recovery shall not exceed the cost of the warranted product.

IMI CORNELIUS ASSUMES NO LIABILITY FOR INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND, INCLUDING, BUT NOT LIM-

ITED TO, SPOILED PRODUCT, LOST PROFITS, OR DAMAGE TO OTHER PROPERTY.

THIS WARRANTY IS EXCLUSIVE AND IN LIEU OF ALL OTHER WARRANTIES, WHETHER WRITTEN, ORAL, OR IMPLIED, INCLUDING ANY

WARRANTY OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR PURPOSE, AND SUPERSEDES AND EXCLUDES ANY ORAL

WARRANTIES OR REPRESENTATIONS OR WRITTEN LANGUAGE IN ANY MANUAL, LITERATURE, ADVERTISING BROCHURE OR

OTHER MATERIALS NOT EXPRESSLY DESIGNATED IN WRITING AS A “WARRANTY

IMI CORNELIUS

25

630460150

THIS PAGE LEFT BLANK INTENTIONALLY

27

IMI CORNELIUS INC.

Corporate Headquarters:

One Cornelius Place

Anoka, Minnesota 55303-6234

Telephone (800) 238-3600

Facsimile (763) 422-3246

630460150