Cornelius | IAC227 | 002966 - Cornelius

THE HOTTEST MACHINES ON ICEt
Installation/Maintenance
Instructions
“I” Series Flaked/Nugget Ice Machines
Model Number
Description
IAF1000 & 650
Flaker/Nugget Modular Head Ice Maker Air Cooled
IWF1000 & 650
Flaker/Nugget Modular Head Ice Maker Water Cooled
IRF1000 & 650
Flaker/Nugget Modular Head Ice Maker Remote Cooled
Part No. 630460003
1/10/97
Revised 4/11/97
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
 IMI CORNELIUS INC; January 1997
PRINTED IN U.S.A
TABLE OF CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
ICE FLAKER SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
ICE FLAKER SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
AVERAGE OPERATING CHARACTERISTICS
IAF1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
AVERAGE OPERATING CHARACTERISTICS
IWF1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
AVERAGE OPERATING CHARACTERISTICS
IRF1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
WATER AND ICE CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
BIN THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
10
10
GEARMOTOR START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
COMPRESSOR CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
GEARMOTOR DELAY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
ON–OFF SWITCH / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
FAN CYCLING SWITCH (R404A UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
HIGH PRESSURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
COMPRESSOR START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
POTENTIAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
CAPACITORS – GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
DUMP SWITCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15
“I” SERIES FLAKER CLEANING
AND SANITIZING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
WINTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
CLEANING THE CONDENSER (AIR COOLED) . . . . . . . . . . . . . . . . . . . . . . . . . . .
17
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
i
6304600003
FIGURE AND ILLUSTRATIONS
FIGURE 1. BIN THERMOSTAT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
FIGURE 2. SERVICE CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
FIGURE 3. INSTRUCTIONS FOR CONVERTING
FLAKED ICE TO NUGGET ICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8
FIGURE 4. WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
FIGURE 5. REFRIGERATION AND WATER SYSTEMS
MODELS IAF1000, IAF650, IAF450 AND IAF200 . . . . . . . . . . . . . . . . . . . . . . . . . .
12
FIGURE 6. REFRIGERATION AND WATER SYSTEMS
MODELS IWF1000, IWF650 AND IWF450 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13
FIGURE 7. REFRIGERATION AND WATER SYSTEM MODELS IRF1000 . . . . .
14
FIGURE 8. WIRING DIAGRAM IAF1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
18
FIGURE 9. WIRING DIAGRAM IWF1000 AND IRF1000 . . . . . . . . . . . . . . . . . . . .
19
FIGURE 10. WIRING DIAGRAM IAF650 AND IWF650 . . . . . . . . . . . . . . . . . . . . . .
20
6304600003
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 the Installer.
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
630460003
ICE FLAKER SPECIFICATION
MODEL
IAF1000
IWF1000
IRF1000
230
1
60
2 plus ground
230
1
60
2 plus ground
230
1
60
2 plus ground
20
20
20
25
25
25
R404a (HP62)
30
851
R404a (HP62)
25
709
R404a (HP62)
170
4820
230
1
60
61
12.5
230
1
60
61
12.5
230
1
60
61
12.5
230
1
60
0.36
6
230
1
60
0.36
6
230
1
60
0.95
1/8
230
1
60
0.95
1/8
UNIT
Volts
Phase
Hertz
No. Wires
MIN. CIRCUIT
Amps
MAX. FUSE SIZE
(HVAC Circuit Breaker Required)
Amps
REFRIGERANT
Type
Weight (oz.)
Weight (g)
COMPRESSOR
Volts
Phase
Hertz
LRA
RLA
CONDENSER FAN MOTOR
Volts
Phase
Hertz
Amps, Running
Watts
230
1
60
1.09
75
AIR CIRCULATION FAN MOTOR
Volts
Phase
Hertz
Amps, Running
Watts
GEAR MOTOR
Volts
Phase
Hertz
Amps, Running
HP
630460003
230
1
60
0.95
1/8
2
ICE FLAKER SPECIFICATION
MODEL
IAF650
IWF650
115
1
60
2 plus ground
115
1
60
2 plus ground
20
20
20
20
R404a (HP62)
25
709
R404a (HP62)
17
482
115
1
60
59
11.6
115
1
60
59
11.6
UNIT
Volts
Phase
Hertz
No. Wires
MIN. CIRCUIT
Amps
MAX. FUSE SIZE
(HVAC Circuit Breaker Required)
Amps
REFRIGERANT
Type
Weight (oz.)
Weight (g)
COMPRESSOR
Volts
Phase
Hertz
LRA
RLA
CONDENSER FAN MOTOR
115
1
60
1.75
50
Volts
Phase
Hertz
Amps, Running
Watts
AIR CIRCULATION FAN MOTOR
115
1
60
0.36
6
Volts
Phase
Hertz
Amps, Running
Watts
GEAR MOTOR
115
1
60
1.9
1/8
Volts
Phase
Hertz
Amps, Running
HP
3
115
1
60
1.9
1/8
630460003
AVERAGE OPERATING CHARACTERISTICS
IAF1000
IP Units
Ambient
Temp _F
Water Temp _F
Head Pressure
PSIG
Suction
Pressure PSIG
Flaked Ice
Weight Lb/Day
Nugget Ice
Weight Lb/Day
70
50
234
19
883
921
80
70
216
19
786
805
90
70
247
21
761
794
90
80
247
21
720
747
105
70
300
24
664
687
Ambient
Temp _C
Water Temp _C
Head Pressure
kPa
Suction
Pressure kPa
Flaked Ice
Weight kg/Day
Nugget Ice
Weight kg/Day
21
10
1613
131
401
418
27
21
1489
313
357
365
32
21
1703
145
345
360
32
27
1703
145
327
339
41
21
2068
165
301
312
SI Units
AVERAGE OPERATING CHARACTERISTICS
IWF1000
IP Units
Ambient
Temp _F
Water Temp _F
Head Pressure
PSIG
Suction
Pressure PSIG
Flaked Ice
Weight Lb/Day
Nugget Ice
Weight Lb/Day
70
50
271
19
932
935
80
70
277
20
794
806
90
70
277
20
792
798
90
80
280
21
733
744
105
70
277
20
785
789
Ambient
Temp _C
Water Temp _C
Head Pressure
kPa
Suction
Pressure kPa
Flaked Ice
Weight kg/Day
Nugget Ice
Weight kg/Day
21
10
1868
131
423
424
27
21
1910
138
360
366
32
21
1910
138
359
362
32
27
1931
145
332
337
41
21
1910
138
356
358
SI Units
630460003
4
AVERAGE OPERATING CHARACTERISTICS
IRF1000
IP Units
Ambient
Temp _F
Water Temp _F
Head Pressure
PSIG
Suction
Pressure PSIG
Flaked Ice
Weight Lb/Day
Nugget Ice
Weight Lb/Day
70
50
234
19
883
921
80
70
216
19
786
805
90
70
247
21
761
794
90
80
247
21
720
747
105
70
300
24
664
687
Ambient
Temp _C
Water Temp _C
Head Pressure
kPa
Suction
Pressure kPa
Flaked Ice
Weight kg/Day
Nugget Ice
Weight kg/Day
21
10
1613
131
401
418
27
21
1489
131
357
365
32
21
1703
145
345
360
32
27
1703
145
327
339
41
21
2068
165
301
312
SI Units
5
630460003
INSTALLATION INSTRUCTIONS
You will get better service from the ice machine, longer life and greater convenience if you choose its location
with care. Select a location as close as possible to where the highest volume of ice will used.
Here are a few points to consider:
1. Select a location as close as possible to where you are going to use the most 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 or 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 cutting the lower band on the carton and lift the carton off the unit.
6. All “I” series flakers are supplied with bin sealing gasket material. Install the gasket around the bottom
outside edge of the unit by removed the protective paper and pressing in place.
7. Uncrate the ice storage bin and set in place. Connect a drain hose to the bin and level the bin. Install any
required bin adapter(s) at this time.
8. Carefully place the flaker on the bin. Be careful not to damage the flaker gasket material.
9. Remove the flaker front panel. Position the bin thermostat in place and install the hold down screws as
shown in Figure 1.
630460003
FIGURE 1. BIN THERMOSTAT INSTALLATION
6
10. The incoming water for the ice making section requires a 3/8” copper tube. Connect this water tube to the
3/8” male flare fitting on the back of the unit. Make all drain connections. Drain tubes cannot be teed
together. See Figure 2 for location of all plumbing connections.
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 290 to 310 PSI head pressure for R–404a
units. After 10 minutes of operation check the water temperature at condenser outlet and adjust to 100_F,
105_F if necessary.
11. Connect a drain hose to the condensate drain stub tube.
ill371
NOTE: All plumbing must be done in accordance with national and local codes.
ELECTRICAL SERVICE
OPENING(7/8-IN. DIA. HOLE)
22.00
5.25
1.25
POTABLE WATER INLET
(3/8-IN. MALE FLARE)
22.60
27.83
5.25
CONDENSER
DRAIN
4.50
FRONT SIDE
ICE DROP
OPENING
BOTTOM VIEW
DUMP VALVE DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.)
IAF 650
ELECTRICAL SERVICE
OPENING(7/8-IN. DIA. HOLE)
30.00
10.31
5.25
REAR VIEW
GEABOX/WTRPN DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.)
POTABLE WATER INLET
(3/8-IN. MALE FLARE)
22.63
27.83
5.25
CONDENSER
DRAIN
5.20
FRONT SIDE
BOTTOM VIEW
ICE DROP
OPENING
DUMP VALVE DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.)
IAF 1000
REAR VIEW
GEABOX/WTRPN DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.)
FIGURE 2. SERVICE CONNECTIONS
12. Bring the electrical supply (20 Amp.) into the unit at the rear of the cabinet and enters the unit control box.
The power and ground connections are completed to the leads in the control box. Strain relief connections
must be made at the cabinet and at the control box.
NOTE: Make sure the proper voltage and number of wires are provided. See serial plate for proper
configuration.
NOTE: All wiring must conform to national and local codes.
7
630460003
1
2 3
4
5
1. Remove the chute from the evaporator assembly
2. Remove item 1, .50-20 x 1.25 bolt; item 2, .50 lockwasher; item 3, ice paddle, and item 4, flaker cutter
head.
3. Install item 5, nugget ice cutter head, and re-install
items 1, 2, & 3
4. Re-install chute. (RTV must be used around the base
of the chute.)
630460003
FIGURE 3. INSTRUCTIONS FOR CONVERTING FLAKED ICE TO NUGGET ICE.
8
WATER AND ICE CIRCUIT
The supply water enters the float chamber through a small orifice. The water level rises and lifts the float arm on
the float valve and seats the valve, shutting off the water supply when the water is at the desired level. As the
water leaves the float chamber, filling the evaporator, the float drops and allows additional water to enter refilling
the float chamber. Thus the water level is maintained automatically as the unit operates.
The water level in the evaporator shell will rise to the same level as the water in the float chamber. The water in
direct contact with the evaporator wall freezes and forms ice on the evaporator wall. As the freezing continues
the ice becomes thicker and exceeds the space between the evaporator wall and the auger. The auger rotating
at 8 RPM then chips off the ice and moves it to the surface of the shell. When the ice reaches the top surface of
the water in the shell it is pushed upward through the extruder opening into the cutter heads. From the cutter
head the ice enters the drop chute and falls into the storage bin. This action continues until the ice comes in
contact with the bin thermostat and the unit is shut down. The unit will remain off until the ice drops from the bin
thermostat through consumption or melting, at which time the unit will restart.
Water Inlet Fitting
Water Pressure Switch
Strainer
Water Level
Float Valve
Evaporator
Gear Motor
Water Dump Valve
FIGURE 4. WATER LEVEL
9
630460003
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 fan motor will start when the head pressure
reaches 270 PSI and will cycle off at 205 PSI. The compressor will start 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.
CAUTION: Setting the bin thermostat to the coldest position may cause excessive ice
build-up in the chute and it can possibly cause the chute to pop-off from ice build-up.
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.
COMPRESSOR CONTACTOR
Controls the compressor input power only.
GEARMOTOR DELAY THERMOSTAT
The purpose of the Delay Thermostat is to allow an electrical path to the gearmotor for continuous operation to
clear the evaporator of ice to prevent auger freeze up. As the ice from the evaporator is augered up, the suction
line of the evaporator will warm-up causing the Delay Thermostat to open, cancelling the gearmotor electrical
circuit.
CAUTION: The Delay Thermostat must be insulated to prevent biasing action of room and compressor area
temperatures.
This thermostat keeps the gearmotor running until the suction line temperature reaches 45_ F after the bin
thermostat terminates power to the 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.
630460003
10
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 contactor. As the head pressure rises to 450 PSIG,
for R404a charged units, a preset level the contact opens thus breaking the circuit to the compressor via the
contactor. This control must be reset manually on R404a units.
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 80% of the compressor operating 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. and remains in the circuit during both the start and run operation.
DUMP SWITCH
This switch activates the evaporator dump valve manually. This allows the draining of the evaporator for service
or cleaning. Dumping the water every 24 or 48 hours will reduce the down time for cleaning in high mineral
content water areas.
11
630460003
WATER INLET FITTING
WATER PRESSURE SWITCH
HIGH SIDE
SERVICE
VALVE
STRAINER
FAN MOTOR
LOW SIDE
SERVICE
VALVE
HIGH
PRESSURE
SWITCH
EVAPORATOR
FAN
FAN
CYCLE
SWITCH
FLOAT
VALVE
AIR
COOLED
CONDENSER
COMPRESSOR
GEAR
MOTOR
FILTER/DRYER
WATER
DUMP
VALVE
630460003
THERMOSTATIC
EXPANSION
VALVE
HEAT EXCHANGER
FIGURE 5. REFRIGERATION AND WATER SYSTEMS
MODELS IAF1000, IAF650, IAF450 AND IAF200
12
WATER
REGULATING
VALVE
WATER INLET FITTING
WATER PRESSURE SWITCH
STRAINER
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
HIGH
PRESSURE
SWITCH
EVAPORATOR
DRAIN
WATER INLET
FLOAT
VALVE
WATER
COOLED
CONDENSER
COMPRESSOR
GEAR
MOTOR
FILTER/DRYER
WATER
DUMP
VALVE
THERMOSTATIC
EXPANSION
VALVE
HEAT EXCHANGER
FIGURE 6. REFRIGERATION AND WATER SYSTEMS
MODELS IWF1000, IWF650 AND IWF450
13
630460003
FAN CYCLE SWITCH
WATER INLET FITTING
WATER PRESSURE SWITCH
STRAINER
EVAPORATOR
HIGH SIDE
SERVICEVALVE
FAN MOTOR
LOW SIDE
SERVICE
VALVE
HIGH
PRESSURE
SWITCH
FAN
CHECK
VALVE
FLOAT
VALVE
HEAD PRESSURE
CONTROL
CONDENSER
COIL
REMOTE
CONDENSER
COMPRESSOR
S
GEAR
MOTOR
LIQUID SOLENOID
VALVE
WATER
DUMP
VALVE
THERMOSTATIC
EXPANSION
VALVE
HEAT EXCHANGER
FILTER/DRYER
RECEIVER
630460003
FIGURE 7. REFRIGERATION AND WATER SYSTEM MODELS IRF1000
14
MAINTENANCE
THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED AT LEAST EVERY SIX MONTHS ON
FLAKED ICE MACHINES:
1. Check the incoming electrical power supply while the machine is starting. Voltage must not drop lower than
–5% of the rated name plate voltage. Conditions below the –5% limit will reduce the life of the start components, the compressor and the gear motor.
2. Check water level in the float tank. The water level must be maintained at the top of the evaporator. adjust
as necessary. (see illustration.)
3. Clean the air–cooled condenser with a stiff brush and vacuum cleaner.
CAUTION: Condenser fins are sharp. Use caution when cleaning.
4. Clean the ice storage bin and flush the bin drain.
5. If water filter(s) are installed in the inlet water supply, check these filters and replace as necessary. Also
clean the strainer screen at the float chamber inlet.
6. If heavy mineral deposits (scale) are present on the auger or the inside surface of the evaporator clean and
sanitize following the procedure outlined in the Cleaning and Sanitizing section is this manual.
7. Remove the ice chute hold-down nuts and remove the chute from the evaporator shell. Be careful not to
damage the bin thermostat capillary.
A.
Remove the cutter head hold down bolt. Mark the extruder head at one of it’s 3 mounting bolts and
remove all three extruder head mounting bolts. Grasp the extruder head and remove it by pulling upward.
B.
Check the extruder head bearing for wear or scoring patterns. Should the bearing surface appear
okay, reinstall the extruder. Rotate the extruder 120_ when installing, using the reference mark you
made on the extruder in step A above. See the drawing below.
ROTATE 120_
A
C.
B
C
Should the extruder bearing appear worn or scored, check the bearing with the GO-NO-GO gauge
P/N 630900056. If the gauge passes into the bearing more than 1/2I, replace the extruder head assembly with an exchanged head and bearing assembly from your local distributor.
NOTE: High mineral content in the water may increase the extruder head bearing wear if proper water
treatment is not installed.
8. Activate the dump valve switch several times and be certain the valve opens and fully closes with each activation. Should the valve fail to completely close, replace the plunger and diaphram with a replacement kit.
9. Replace the ice chute and check for proper alignment making sure the chute is not blocking the ice flow
path.
10. Check the bin thermostat operation by holding ice against the capillary to open the control thus shutting
down the machine operation.
15
630460003
“I” SERIES FLAKER CLEANING
AND SANITIZING PROCEDURE
1. To eliminate water from entering the reservoir, block up the float located inside the reservoir, activate the
dump switch to the “ON” position and turn the power switch to “ON”. Allow the evaporator to drain. Turn the
power switch to the “OFF” position.
2. Remove the ice chute by removing the hold-down nuts at the base and the self-clamping bolt at the top. Lift
the chute clear of the evaporator assembly.
3. Return the float to it’s normal position. As the float chamber refills with water and fills the evaporator, add 3
oz. of Calgon Nickel-Safe ice machine cleaner to the float chamber. (Gravity will feed the cleaner to the
evaporator.)
NOTE: Do not remove the auger, extruder head, or other parts from the evaporator assembly.
4. Allow the cleaning solution to stand in the evaporator for 20 - 30 minutes. Block up the float and drain the
evaporator as in step 1.
5. Rinse/flush by carefully filling with warm water (100_F) and drain by following step 1 again. Repeat at least
3 times. During the final rinse/flush cycle, add 1 tablespoon of regular Baking Soda and allow it to stand for
10 - 15 minutes.
6. Drain the evaporator and rinse/flush one more time.
7. Install the ice chute and panels. (RTV must be used around the base of the chute.)
CAUTION: Should sanitizing be required, DO NOT use a mixture of household bleach and
water Chlorine will attack stainless steel. Use only a commercial ice machine sanitizer such
as Calgon Sanitizer for ice machines, following the directions on the container.
NOTE: When cleaning and/or sanitizing is complete return the machine back to an ice making cycle.
Discard the first 30 minutes of ice production. DO NOT allow any ice that has been in contact
with sanitizer to ever be used.
630460003
16
WATER TREATMENT
During the freezing process, as water passes over the evaporator, 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 float valve mechanism and other parts in the water system. If the concentration of impurities is high, mushy ice may be the result.
Parts of the Flaker, 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 most water supplies.
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, it 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.
With a vacuum cleaner, remove all accumulated dust and lint that has adhered to the finned condenser at the
rear of the unit. The use of a stiff bristle brush may be helpful.
CAUTION: CONDENSER COOLING FINS ARE SHARP. USE CARE WHEN CLEANING.
17
630460003
BL
GW
CONTROL
LOW PRESSURE
C.I. 20 PSIG
C.O. 10 PSIG
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
RD
BK
BL
RD
BL
BK
BIN
THERMOSTAT
BL
GEAR MOTOR
START RELAY
DELAY
THERMOSTAT
BK
BK
2
RD
RD
WATER DUMP
VALVE
BK
BK
COMPRESSOR
C
WATER DUMP
SWITCH
2
1 3
R
S
RD
COMPRESSOR
RUN
CAPACITOR
35MFD 370V
WH
COMPRESSOR
START
CAPACITOR
145-174MFD 250V
RD
YL
YL
OR
BR
BK
BL
COMPRESSOR
START RELAY
RD
BK
CONTACTOR
BK
BK
FAN SWITCH
CI 275
CO 205
1
5
2
M
CONDENSER
FAN MOTOR
BK
RD
208/230 VOLTS 60 Hz
FIGURE 8. WIRING DIAGRAM IAF1000
630460003
1
WH
RD
RD
M
4
RD
T/D
3
RD
CONTROL
HIGH
PRESSURE
C.O. 450 PSIG
BL
GEAR
BK
BL
BK
YL
3
18
RD
BK
Crankcase Heater
(IRF Only)
BL
BK
ON-OFF Switch
Circuit Breaker
Rated 1.5 Amps
GW
Control
Low Pressure
CI 20 PSIG
CO 10 PSIG
BK
RD
BK
BL
RD
BL
BK
Gear Motor
Start Relay
BL
Delay
Thermostat
Bin
Thermostat
YL
BK
M
WH
BK
RD
RD
RD
T/D
BK
BK
BK
Cooling Fan
Motor
BL
Water Dump
Valve
Control
High Pressure
CO 450 PSIG
M
WH
BK
RD
RD
BK
BL
RD
BK
Water Dump
Switch
2
1 3
Compressor
BL
RD
BR
R
C
S
Compressor Run
Capacitor
35MFD 370 V
RD
RD
YL
Compressor Start
Capacitor
145-174MFD 250 V
YL
OR RD
Contactor
BK
BK
RD
Compressor
Start Relay
RD
Liquid Line
Solenoid
(IRF Only)
FIGURE 9. WIRING DIAGRAM IWF1000 AND IRF1000
19
630460003
WH
GW
WH
22i
12k
11
BK
21
BK
WH
CONTROL
LOW PRESSURE
C.I. 20 PSIG
C.O. 10 PSIG
BK
ON–OFF SWITCH
CIRCUIT BREAKER
RATED 2.0 AMPS
BL
WH
WH
BL
BL
BK
BIN
THERMOSTAT
BL
GEAR MOTOR
START RELAY
DELAY
THERMOSTAT
YL
3
BK
M
4
RD
BK
BK
CONTROL
HIGH
PRESSURE
C.O. 450 PSIG
BK
M
WATER DUMP
VALVE
BL
COOLING
FAN MOTOR
IWF ONLY
WH
WH
BK
WH
BL
BK
BK
BL
BK
WATER DUMP
SWITCH
2
1
LOW AMBIENT
SWITCH (A/C ONLY)
CI275 C0205
3
BR
BL
R
C
M
BK
S
COMPRESSOR
BK
CONDENSOR FAN MOTOR
(A/C ONLY)
RUN
COMPRESSOR
CAPACITOR
30MFD 440V
RD
RD
WH
CONTACTOR
YL
COMPRESSOR
START
CAPACITOR
YL
OR
BR
COMPRESSOR
START RELAY
1
5
2
FIGURE 10. WIRING DIAGRAM IAF650 AND IWF650
630460003
WH
T/D
3
1
BK
2
RD
GEAR
20
TROUBLESHOOTING
Trouble
UNIT WILL NOT RUN
COMPRESSOR CYCLES
INTERMITTENTLY.
MAKING WET ICE.
Probable Cause
Remedy
A.
On–off switch in ”off” position.
A.
Turn switch to ”on”.
B.
Defective on–off switch.
B.
Check and replace.
C.
Blown fuse.
C.
Replace fuse and check for cause
of blown fuse.
D.
Thermostat set too warm for
ambient.
D.
Adjust colder.
E.
Contactor contacts corroded.
E.
Check and clean.
F.
Defective thermostat.
F.
Check and replace.
G.
Loose electrical connection.
G.
Check wiring.
H.
Gearmotor overload protector
has cut off machine.
H.
Turn switch to off then to on.
A.
Low voltage.
A.
Check Load voltage.
B.
Dirty condenser.
B.
Clean condenser.
C.
Air circulation restricted.
C.
Remove restriction.
D.
Defective condenser fan
motor.
D.
Check and replace.
E.
Defective relay, overload
protector or starting capacitor.
E.
Check and replace.
F.
Loose electrical connection
F.
Check wiring.
A.
Surrounding air temperature
too high.
A.
Correct or move unit
B.
High water level in float
reservoir.
B.
Lower water level
C.
Scale on the evaporator
C.
Clean
D.
Dirty condenser.
D.
Clean condenser
E.
Faulty compressor.
E.
Check and replace*
F.
Refrigerant leak.
F.
Check and repair*
*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. Also ALCO EKH Series recommended.
UNIT RUNS BUT MAKES NO
ICE.
A.
Leak in refrigerant system.
A.
Check and repair.
B.
Moisture in system.
B.
Check, evacuate and replace
drier in system.
C.
No water.
C.
Check water supply.
D.
”O” ring leaking at bottom of
evaporator shell mounting
support.
21
D.
Check and replace ”O” ring.
630460003
Trouble
UNIT RUNS BUT MAKES NO
ICE. (CONT’D)
WATER LEAKS.
EXCESSIVE NOISE OR
CHATTERING.
MACHINE RUNS WITH FULL
BIN OF ICE, OR ICE CHUTE
IS FORCED OFF THE
EVAPORATOR.
630460003
Probable Cause
Remedy
E.
Compressor not running.
E.
Check wiring, start components,
compressor. Repair or replace as
required.
A.
Worn or bad float valve.
A.
Check and replace.
B.
Float and arm assembly stuck.
B.
Check and adjust or replace.
C.
O-ring leaking at bottom of
evaporator shell.
C.
Check and replace.
D.
Auger seal assembly.
D.
Check and replace.
E.
Storage bin drain and tubing.
E.
Check and repair.
A.
Mineral or scale deposits on
inside of evaporator shell.
A.
Clean inside surfaces by filling
evaporator shell with ice machine
cleaner.
B.
Intermittent water supply .
B.
Check inlet water line .
C.
Water level in float tank too
low.
C.
Check and adjust water level.
D.
Auger gearmotor end–play or
worn bearings.
D.
Repair or replace.
E.
Air lock in gravity water supply
line from float tank to
evaporator shell.
E.
Check and adjust traps from
supply.
A.
Storage bin thermostat set too
cold or defective.
A.
Check and adjust warmer or
replace as required.
B.
Bin thermostat thermowell out
of path of ice.
B.
Adjust thermowell.
22
Trouble
Probable Cause
Remedy
A.
Ice jams up in evaporator
shell.
A.
Clean inside surface of
evaporator shell.
B.
Bin thermostat will not shut–off
machine. Set too cold.
B.
Check and adjust or replace .
C.
Auger motor has worn
bearings.
C.
Check and replace.
D.
Ice chute out of alignment,
restricted ice flow out of
evaporator section.
D.
Re–align.
E.
Ice chute restricting ice flow.
E.
Align or replace ice chute if
damaged.
F.
Incoming water temperature
too cold.
F.
Maintain temperature above 50°F.
G.
Bin thermostat does not
shut–off when bin is full of ice.
G.
Adjust or replace bin thermostat if
necessary.
H.
Mineral or scale deposits on
inside of evaporator shell and
evaporator.
H.
Inspect and clean.
I.
Low ambient temperature in
room where unit is located.
I.
Maintain temperature above 50°.
J.
Gearmotor sticking which
causes it to draw excessive
amperage.
J.
Check and replace.
UNIT GOES OFF OR TRIPS
K.
CIRCUIT BREAKER. (CONT’D)
Plugged expansion valve
causing low back pressure.
K.
Replace the drier-filter, evacuate
and recharge the system.
L.
Refrigerant leak causing low
back pressure.
L.
Find and repair leak. Replace the
drier-filter, evacuate and recharge
the system
M.
Auger out of line.
M.
Check extruder bearing and
exchange as needed.
N.
Broken auger
N.
Replace auger.
O.
Low water level in float tank
reservoir.
O.
Adjust float arm to maintain
correct water level.
P.
Gearmotor Delay Thermostat
does not keep gearmotor
running after Bin Thermostat
opens.
P.
Check operation and / or replace.
UNIT OFF OR TRIPS CIRCUIT
BREAKER.
23
630460003
“I” Series “Remote”
Ice Machine
630460003
24
25
630460003
CAPACITOR
2 mfd 440 VAC
RED
COLORED
BAND
M
BK
GR
BK
CONDENSER
FAN MOTOR
HEAT SHRINK TAPE
HEAT SHRINK
TAPE
FAN CYCLING
SWITCH
BK
RD
GR
HEAT SHRINK TAPE
CR800, CR1200, & CR1400 REMOTE CONDENSERS
208/230 VOLTS 60 HZ
26
630460003
Installation Instructions Remote Condensers
1/4-20 SCREW
UNIT
1. Follow the standard installation instructions supplied with
flaker. Do not hook flaker into the power source until the remote condenser and line set installation is complete.
2. Assembly of remote condenser (see drawing):
a. Assemble legs to base panel.
Install leg supports on legs.
b. Locate the remote condenser in a well–ventilated area
on the roof away from other refrigeration equipment’s
condenser discharge air flow.
LEG
c. Use the mounting holes provided to secure the remote
condenser to the roof. Seal over heads of bolts or fasteners with tar or pitch to prevent entrance of moisture.
BRACE
LEG
REMOTE CONDENSER
3. Remote condenser electrical hook-up:
a. Connect remote condenser to a power source
(208/230VAC, 60 HZ) separate from the flaker. An external disconnect switch must be used.
b. Make sure the electrical connections follow all local and
national codes.
c. DO NOT turn condenser on until flaker install and refrigerant line connections are complete!
a. Never wire condenser into flaker section. The condenser is an independent electrical connection.
b. Fan motor will not start until pressure rises to 205
PSIG [14.07 Bars] closing fan cycling switch.
c. The condenser fan may cycle off during the harvest
cycle – this would be normal.
Note: Installing an IMI Cornelius remote flaker with other
than an IMI Cornelius remote condenser and line set
may be reason to void the warranty.
LEG SUPPORT
LEG
27
630460003
4. Each condenser and flaker is connected with two (2) *precharged lines.
a. The pre-charged lines are ordered separately from the
condenser to suit each individual application.
b. The pre-charged line lengths are 20 feet [6.096 meters],
35 feet [10.66 meters] and 55 feet [16.76 meters].
Note: *(Pre-charged is defined as a vapor holding charge –
not a portion of the system charge.)
LIQUID
REFRIGERANT
LINE
DISCHARGE
LINE
5. Installation of line kits (see drawing). Remove the tubing
from the carton. Carefully uncoil the lines so the tubing
doesn’t become kinked, and route lines to flaker and condenser.
6. Keep line-set as short as possible. Place a 3-foot service
loop behind flaker to allow for rear service should it ever be
required.
CORRECT
630460003
28
Remote Condenser Location
1. Physical Line-Set Length: 55 Ft. Maximum [16.764 meters]
The ice machine compressor must have the proper oil return. Line-set rises, drop, or horizontal runs greater than the
maximum distance allowed will exceed the compressor startup and pumping design limits, and will result in poor oil return to the compressor.
NOTE: MAX. LINE-SET
LENGTH FOR IMI CORNELIUS
FLAKERS IS 55 FT.
DO NOT CONFUSE LINE
LENGTH WITH CALCULATED
LINE DISTANCE.
Line-Set Rise: 35 Ft. Maximum [10.66 meters]
Line-Set Drop: 15 Ft. Maximum [4.57 meters]
2. Calculated Line-Set Distance: 100 Ft. [30.48 meters]
To prevent the combination of rises, drops and horizontal
runs exceeding the compressor start-up and pumping design
limit, the following calculations should be made:
B
A
C
B
A - (RISE) CONDENSER HIGHER THAN EVAP.
MAX. 35 FT.
B - LINE LENGTH 15 FT.: EXAMPLE
B - LINE LENGTH 35 FT.: EXAMPLE
C - (DROP) CONDENSER LOWER THAN EVAP. 15 FT.: MAX.
29
630460003
Maximum Line-Set Distance Formula
a. Measured rise
x 1.7=
Rise 35 ft. Max) [10.66 meters]
Calculated
b. Measured drop
x 6.6=
Drop 15 ft. Max) [4.57 meters]
Calculated
c. Measured Horizontal Distance = actual measurement.
d. Total Calculated Distance (A+B+C)=Total
Calculated Distance (100 ft. Max.) [30.48 meters]
EXAMPLES:
H
AIR
FLOW
R
a. Insert measured rise (R) into the formula and multiply
it by 1.7 to get a calculated rise.
example: A condenser located 15 ft. [4.572 meters]
above the ice machine has a 25.5 ft. [8.874 meters]
calculated total (15 ft. x 1.7 = 25.5).
COMBINATION OF
DROP(S)
WITH HORIZONTAL
H
b. Insert measured drop (D) into formula and multiply by
6.6 to get a calculated drop.
D
AIR
FLOW
example: A condenser located 8 ft. [2.438 meters]
below the ice machine has a 52.8 ft. [16.093 meters]
calculated total (8 ft. x 6.6 = 52.8 ft.).
COMBINATION OF RISE AND
DROP(S)WITH HORIZONTAL
H
c. Insert measured horizontal distance into formula. No
calculation is necessary. (6 ft.) [1.828 meters].
R
D
AIR
FLOW
d. Add the calculated rise, calculated drop, and horizontal distance together to get the total calculated
distance (25.5 + 52.8 + 6) equals 84.3 ft. [25.694 meters]. If 100 ft. [30.48 meters] total calculated distance is exceeded, the condenser must be moved to
a new location which permits proper equipment operation.
Caution
If a line-set rise is followed by a line-set drop, a second
line-set rise cannot be made.
Or
If a line-set drop is followed by a line-set rise, a second
line-set drop cannot be made.
3. Lengthening or Reducing the Line-Set Lengths
In most cases, by routing the line-set properly, shortening
630460003
30
will not be necessary (refer to illustration). However, when
shortening or lengthening is required, do so before connecting the line-set to the ice machine or the remote condenser.
This prevents the loss of refrigerant from the ice machine or
the condenser.
The quick connect fittings on the line-sets are equipped with
Schrader Valves. Use these valves to recover any vapor
charge from the line-set. When lengthening or shortening
lines, apply good refrigeration practices and insulate new
tubing. Do not change the tube sizes. Evacuate the lines
and place approximately 5 oz. of
vapor refrigerant charge in each line.
SCHRADER
VALVE
4. Connection of Line-Set
PARENT
METAL
SEAL
INTERMEDIATE
SEAL
a. Remove the plastic caps from the line-set, the condenser, and the ice machine.
b. Apply refrigeration oil to the threads on the quick connect
couplers before connecting them to the condenser.
c. Carefully thread the female fitting onto the condenser or
ice machine by hand.
d. Using the proper size wrench, tighten the couplings until
they bottom out. Turn an additional 1/4 turn to ensure
proper brass-to-brass seating.
e. Check all fittings for leaks.
5. Final Installation:
a. Remove grill from the right-hand side panel of flaker.
b. Turn service port on receiver tank to open position releasing refrigerant to the balance of the system.
c. Leak check line-set connections at flaker and condenser.
d. Replace grill.
e. Connect flaker to power source.
f. Make sure electrical connections follow all local and national codes.
6. Start Up:
a. Use standard procedures from flaker installation instructions.
b. After the flaker is running, check the remote condenser
and verify that the condenser fan is running.
Caution
Once the refrigerant lines are connected, the seal is broken in
the fittings. If the lines are removed or loosened from the flaker
or remote condenser, the refrigerant charge will be discharged
to the atmosphere. DISCHARGING TO THE ATMOSPHERE IS IN
VIOLATION OF THE CLEAN AIR ACT OF JULY, 1992.
31
630460003
Head Pressure Control [Headmaster]
The Cornelius “I” series remote systems use an Alco Head Pressure
Control, normally referred to as a headmaster. This control is
mounted in the remote condenser with a fan cycling control switch.
Using both these controls gives the system positive operation under
a wide range of condensing temperatures.
The cycling control starts the fan at 270 PSI and stops it at 205 PSI
allowing a positive efficient operation at the high temperature operating ranges.
receiver
discharge
The headmaster controls the operation when the condensing temperature drops below 70°F. The “I” series refrigerant charge is HP 62 [R - 404A] and the headmaster dome charge setting is 200 PSI
of nitrogen pressure making it stable under the low temperature operating range down to - 20°F.
The normal flow pattern through the headmaster is from the condenser port to the receiver port. When this flow pattern is unable to
maintain a receiver outlet pressure equal to or above the dome
pressure setting of the valve, the dome pressure will force the valve
portage to change closing the condenser port and opening the bypass port from the compressor discharge line. This allows the high
pressure vapor from the discharge port to “buck” the receiver pressure back up. With the condenser port closed, the refrigerant is
backed up in the condenser, basically reducing the condenser size,
assisting in maintaining the discharge portage flow and increasing
the head pressure.
condenser
above 70°F
normal
Remember, sense of touch to the lines of the headmaster will determine the flow path the headmaster is in, condenser to receive, or
bypass to receiver.
High side gauge installed at the receiver outlet valve will determine
if the headmaster is functioning to maintain the proper operating
pressure.
receiver
discharge
condenser
below 70°F by-pass
630460003
In the event the control appears to be “stuck in bypass”, the pressure drop across the headmaster must be measured. With a gauge
installed at the receiver outlet valve and the high side service valve,
the pressure difference at these two points must be less than the 15
PSI. The three most common causes of an excessive pressure drop
are shortage of refrigerant, kinked remote lines, and excessive line
length.
Eliminate refrigerant shortage first. Add refrigerant in two-pound increments (not to exceed six pounds) to determine if it corrects the
pressure drop. If pressure drop is not corrected, inspect line set for
sharp bends or kinks and correct as required. If adding refrigerant
does not correct continued (bypass) condition and line set is not
damaged, replace headmaster.
32
Remote System Evacuation/Re-charge
All field repairs to the sealed system must start with a total discharge of the system following the requirements of the Clean Air Act
of July, 1992.
Proper evacuation of the total remote system will require a three (3)
point hook-up of your manifold and hose set, (see drawing):
Point #1 - flaker receiver outlet valve
Point #2 - flaker high side service valve
Point #3 - flaker low side service valve
Evacuation:
1. With flaker power supply turned “OFF” disconnect and insulate all 3 compressor leads at the compressor. Turn power
supply on, place power switch in the “on” position. This will
energize (open) the Liquid Line solenoid allowing evacuation
of the Liquid Line between the solenoid and the expansion
valve(s).
2. Evacuate system to 200/250 microns or less. At this point,
there should be a holding test of five(5) minutes. You may
expect a slight loss of vacuum as normal. A rapid rise to normal atmospheric pressure indicates moisture still present in
the system. On a “wet” system, it will prove beneficial to use
heat lamps to warm the compressor dome and evaporator
surface during evacuation.
3. Turn flaker power switch OFF. Reconnect compressor leads.
33
630460003
MANIFOLD SET
MANIFOLD SET
OPEN
OPEN
OPEN
LOW
SIDE
SERVICE
VALVE
RECEIVER
OUTLET
VALVE
CLOSED
OPEN
VACUUM
PUMP
RECEIVER
LOW
SIDE
SERVICE
VALVE
RECEIVER
OUTLET
VALVE
OPEN
CLOSED
VACUUM
PUMP
CLOSED
HIGH SIDE
SERVICE
VALVE
OPEN
CHARGING
CYLINDER
ELECTRONIC
SCALE
630460003
OPEN
CLOSED
HIGH SIDE
SERVICE
VALVE
OPEN
MANIFOLD SET
CLOSED
CLOSED
OPEN
RECEIVER
2ND STAGE CHARGING
COMPRESSOR OPERATING
1ST STAGE CHARGING
EVACUATION
CLOSED
RECEIVER
CLOSED
HIGH SIDE
SERVICE
VALVE
LOW
SIDE
SERVICE
VALVE
RECEIVER
OUTLET
VALVE
CHARGING
CYLINDER
OPEN
CHARGING
CYLINDER
CLOSED
OPEN
ELECTRONIC
SCALE
34
VACUUM
PUMP
OPEN
ELECTRONIC
SCALE
4. *After proper evacuation hold test has been performed, the
refrigerant charge should be “dumped” into the receiver until
the pressure equalizes, stopping the flow. Do not try to
throttle the refrigerant flow. Doing so will allow system
pressure to balance too soon. The high-side service valve
should be closed and the balance of the charge fed slowly
through the suction side service valve with the compressor
operational. Control the feed rate at no faster than four (4)
ounces [113.g] per minute to ensure the compressor oil does
not become too saturated with refrigerant resulting in a loss
of compressor lubrication.
5. All refrigerant re-charging must be weighed into the system,
utilizing an electronic charging scale. DO NOT attempt to
recharge the system by sight glass, system pressure, amperage, frost line or sweat patterns.
6. Always leak check entire system after recharge.
Caution
Before programming the electronic scales to “dump” the
charge,
de-energize the liquid line solenoid, close the shut-off valve on
vacuum pump and low side of the manifold set.
35
630460003
630460003
AIR COOLED CONDENSER
FAN BLADES
FAN MOTOR
EVAPORATOR
HEAT EXCHANGER
WATER
FLOAT
VALVE
WATER
DUMP VALVE
WATER PUMP
ÄÄÄ
ÄÄÄ
THERMOSTATIC
EXPANSION VALVE
HOT GAS
SOLENOID
VALVE
FILTER/DRIER
36
S
HIGH
SIDE SERVICE
VALVE
REFRIGERATION AND WATER SYSTEMS
MODELS IAC227, IAC322, IAC330, IAC522, AND
IAC530
MODELS IAC630, AND IAC830
MODEL IWCS227
LOW
SIDE
SERVICE
VALVE
COMPRESSOR
AIR COOLED CONDENSER
FAN BLADES
EVAPORATOR
FAN MOTOR
THERMOSTATIC
EXPANSION
VALVE
ÄÄÄ
ÄÄÄ
FILTER/DRIER
HEAT EXCHANGER
WATER
DUMP VALVE
WATER PUMP
WATER
FLOAT VALVE
HOT GAS
SOLENOID VALVE
37
HIGH SIDE
SERVICE
VALVE
EVAPORATOR
THERMOSTATIC
EXPANSION
VALVE
Refrigeration and water system
Models IAC1030, IAC1230, and IAC1448
August 3, 1994
LOW SIDE
SERVICE
VALVE
COMPRESSOR
630460003
630460003
WATER REGULATING
VALVE
WATER-COOLED CONDENSER
WATER INLET
EVAPORATOR
HEAT EXCHANGER
WATER
FLOAT
VALVE
S
THERMOSTATIC
EXPANSION VALVE
WATER
DUMP VALVE
WATER PUMP
HOT GAS
SOLENOID
VALVE
PRESSURE SWITCH
38
S
HIGH SIDE
SERVICE
VALVE
Refrigeration and Water Systems
Models IWC322, IWC330, IWC522, and IWC530
Models IWC603, and IWC830
Model IWCS227
August 3, 1994
LOW SIDE
SERVICE
VALVE
COMPRESSOR
ÄÄ
ÄÄ
FILTER/DRIER
WATER REGULATING
VALVE
W
WATER INLET
EVAPORATOR
THERMOSTATIC
EXPANSION VALVE
WATER-COOLED CONDENSER
S
HEAT EXCHANGER
WATER
DUMP VALVE
WATER PUMP
WATER
FLOAT
VAVLE
HOT GAS
SOLENOID
VALVE
ÄÄ
ÄÄ
FILTER/DRIER
S
39
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
PRESSURE
SWITCH
EVAPORATOR
THERMOSTATIC
EXPANSION VALVE
REFRIGERATION AND WATER SYSTEM
MODELS IWC1030, IWC1230 AND 1WC1448
AUGUST 3, 1994
COMPRESSOR
630460003
630460003
FAN BLADES
PRESSURE SWITCH
HEAD PRESSURE
CONTROL
EVAPORATOR
THERMOSTATIC
EXPANSION VALVE
FAN MOTOR
S
REMOTE CONDENSER
WATER
DUMP VALVE
WATER PUMP
WATER
FLOAT
VALVE
HOT GAS
SOLENOID
VALVE
S
LIQUID SOLENOID
VALVE
HEAT EXCHANGER
S
ÄÄ
ÄÄ
FILTER/DRIER
COUPLINGS
VALVES
RECEIVER
PRESSURE SWITCH
SERVICE VALVE
40
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
CHECK
VALVE
COMPRESSOR
REFRIGERATION AND WATER SYSTEMS
MODELS IRC630 AND IRC830
AUGUST 3, 1994
FAN BLADES
EVAPORATOR
WATER
DUMP
VALVE
WATER PUMP
WATER
FLOAT
VALVE
THERMOSTATIC
EXPANSION VALVE
PRESSURE SWITCH
HEAD
PRESSURE
CONTROL
FAN MOTOR
REMOTE CONDENSER
HOT GAS
SOLENOID
VALVE
FILTER/DRIER RECEIVER
LIQUID SOLENOID
VALVE
HEAT EXCHANGER
COUPLINGS
VALVES
ÄÄÄ
PRESSURE SWITCH
SERVICE VALVE
41
HIGH SIDE
SERVICE
VALVE
LOW SIDE
SERVICE
VALVE
CHECK
VALVE
EVAPORATOR
THERMOSTATIC
EXPANSION VALVE
REFRIGERATION AND WATER SYSTEM
MODELS IRC1030, IRC1230 AND IRD1448
AUGUST 3, 1994
COMPRESSOR
630460003
630460003
PRESSURE SWITCH
FAN BLADES
HEAD PRESSURE
CONTROL
FAN MOTOR
42
COUPLINGS
VALVES
REMOTE CONDENSER
MODELS CR800, CR1200, AND
CR1400
AUGUST 5, 1994
IMI CORNELIUS INC.
Corporate Headquarters:
One Cornelius Place
Anoka, Minnesota 55303-6234
(612) 421-6120
(800) 238-3600
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