Cornelius SERIES 750 (R404a) Service manual

MODULAR FLAKED ICE MAKER
Service Manual
MODELS: SERIES 750 (R404a),
SERIES 1100 (R22),
SERIES 2400 (R404a)
Part No. 166240009
OCTOBER 1994
Revised October, 1996
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
 IMI CORNELIUS INC; 10/94 - 10/95
PRINTED IN U.S.A
TABLE OF CONTENTS
Page
INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
SPECIFICATIONS 750 AND 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
SPECIFICATIONS 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5
REMOTE CONDENSER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6
STACKING INSTRUCTIONS FOR STACKING KIT 29757 . . . . . . . . . . . . . . . . . . .
8
TYPICAL WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
TYPICAL REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
ELECTRICAL CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
CIRCUIT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
11
BIN THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
GEARMOTOR START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
POWER RELAY / CONTACTOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
GEARMOTOR DELAY THERMOSTAT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
ON–OFF SWITCH / CIRCUIT BREAKER . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
FAN CYCLING SWITCH (R404A UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
HIGH PRESSURE CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11
COMPRESSOR START RELAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
POTENTIAL RELAYS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
CAPACITORS – GENERAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12
MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
20
SANITIZING AND CLEANING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
21
WATER TREATMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
WINTER STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
CLEANING THE CONDENSER (AIR COOLED) . . . . . . . . . . . . . . . . . . . . . . . . . . .
22
TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
UNIT WILL NOT RUN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
COMPRESSOR CYCLES INTERMITTENTLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
23
MAKING WET ICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
UNIT RUNS BUT MAKES NO ICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
WATER LEAKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
WATER LEAKS. (CONT’D) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
EXCESSIVE NOISE OR CHATTERING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
MACHINE RUNS WITH FULL BIN OF ICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
24
UNIT OFF OR TRIPS CIRCUIT BREAKER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
25
UNIT GOES OFF OR TRIPS CIRCUIT BREAKER. (CONT’D) . . . . . . . . . . . . . . .
26
PARTS LIST FOR 750 AND 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
27
PARTS LIST 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
30
WARRANTY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
32
i
166240009
TABLE OF CONTENTS (cont’d)
LIST OF FIGURES
Page
FIGURE 1. 750 AND 1100 SERIES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . .
2
FIGURE 2. SPECIFICATIONS FOR 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . .
4
FIGURE 3. WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7
FIGURE 4. TYPICAL WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9
FIGURE 5. TYPICAL REFRIGERANT CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . .
10
FIGURE 6. WIRING DIAGRAM AF/WF–750–MH-R . . . . . . . . . . . . . . . . . . . . . . . .
13
FIGURE 7. WIRING DIAGRAM AF–750–PMH-50R . . . . . . . . . . . . . . . . . . . . . . . . .
14
FIGURE 8. WIRING DIAGRAM AF/WF–1100–MH . . . . . . . . . . . . . . . . . . . . . . . . . .
15
FIGURE 9. WIRING DIAGRAM RF–1100–MH . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
16
FIGURE 10. WIRING DIAGRAM AF/WF–1100–MH–3 . . . . . . . . . . . . . . . . . . . . . .
17
FIGURE 11. WIRING DIAGRAM AF/WF–1100–MH–50 . . . . . . . . . . . . . . . . . . . . .
18
FIGURE 12. WIRING DIAGRAM 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . .
19
FIGURE 13. ILLUSTRATED PARTS BREAKDOWN SERIES 750 – 1100 . . . . . .
28
FIGURE 14. REMOTE CONDENSER ILLUSTRATED PARTS BREAKDOWN
FOR 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
29
FIGURE 15. ILLUSTRATED PARTS BREAKDOWN SERIES 2400 . . . . . . . . . . .
31
LIST OF TABLES
AF-750-P-MHR PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
AF-750-P-MH50R PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
WF-750-P-MHR PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
AF-1100-P-MH PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
WF-1100-P-MH PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2
RF-1100-P-MH PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3
AF-2400-P-MHR PRODUCTION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4
166240009
ii
INTRODUCTION
We have strived to produce a quality product. The design has been kept simple thus insuring trouble–free
operation.
This manual has been prepared to assist servicemen and users with information concerning installation,
construction and maintenance of the ice making equipment. The problems of the serviceman and user have
been given special attention in the development and engineering of our ice makers.
If you encounter a problem which is not covered in this manual, please feel free to write or call. We will be
happy to assist you in any way we can.
When writing, please state the model and serial number of the machine.
Address all correspondence to:
A Product of IMI Cornelius Inc.
One Cornelius Place
Anoka, MN 55303–1592
Phone 800–554–3526
FAX 612–422–3232
PRINTED IN USA
1
166240009
SPECIFICATIONS 750 AND 1100 SERIES
23 1/8-IN.
59-CM
CHUTE OPENING
8 1/4-IN.
21-CM
23-IN.
58-CM
1 1/2-IN.
4-CM
1 3/4-IN.
4-CM
1 1/2-IN.
4-CM
A
5-IN.
13-CM
FRONT
BOTTOM
VIEW
B
C
D
E
11 1/2-IN.
29-CM
5 1/16-IN.
13-CM
26 1/4-IN.
67-CM
2-IN.
5-CM
REAR
VIEW
A = POWER INLET
B = WATER INLET
C = CONDENSER (WATER IN)
(WC ONLY)
D = CONDENSER (WATER OUT)
(WC ONLY)
E = CHASSIS DRAIN
9-IN.
23-CM
FIGURE 1. 750 AND 1100 SERIES SPECIFICATIONS
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Á
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ICE PRODUCTION CAPACITY (approximate)
AIR TEMPERATURE
50°F/10°C
70°F/21°C
90°F/32°C
AIR TEMPERATURE
50°F/10°C
70°F/21°C
90°F/32°C
AIR TEMPERATURE
50°F/10°C
70°F/21°C
90°F/32°C
AIR TEMPERATURE
70°F/21°C
80°F/27°C
90°F/32°C
AIR TEMPERATURE
70°F/21°C
80°F/27°C
90°F/32°C
166240009
AF-750-P-MHR PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
70°F/21°C
873 lbs/397 kgs
745 lbs/339 kgs
869 lbs/395 kgs
738 lbs/335 kgs
755 lbs/343 kgs
662 lbs/301 kgs
80°F/27°C
695 lbs/316 kgs
688 lbs/313 kgs
609 lbs/277 kgs
AF-750-P-MH50R PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
70°F/21°C
748 lbs/340 kgs
643 lbs/292 kgs
739 lbs/336 kgs
635 lbs/289 kgs
678 lbs/308 kgs
586 lbs/266 kgs
80°F/27°C
595 lbs/279 kgs
585 lbs/266 kgs
542 lbs/246 kgs
WF-750-P-MHR PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
70°F/21°C
765 lbs/348 kgs
643 lbs/292 kgs
748 lbs/340 kgs
631 lbs/287 kgs
730 lbs/332 kgs
621 lbs/282 kgs
80°F/27°C
587 lbs/267 kgs
585 lbs/266 kgs
582 lbs/265 kgs
AF-1100-P-MH PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
60°F/16°C
1202 lbs/545 kgs
1119 lbs/508 kgs
70°F/21°C
988 lbs/448 kgs
WF-1100-P-MH PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
60°F/16°C
1151 lbs/523 kgs
1123 lbs/509 kgs
70°F/21°C
1060 lbs/467 kgs
2
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ICE PRODUCTION CAPACITY (approximate)
AIR TEMPERATURE
70°F/21°C
80°F/27°C
90°F/32°C
RF-1100-P-MH PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
60°F/16°C
1202 lbs/545 kgs
1119 lbs/508 kgs
70°F/21°C
988 lbs/448 kgs
750
1100
Compressor Electrical Rating
3/4 hp
2 hp
Compressor Model
Copeland RS64CIE-PAF-214
Copeland CRD-10200PFV
Condenser
Air or Water Cooled
Air or Water Cooled
Refrigerant Charge
AC–21oz R404a
AC–25 oz R–22
WC–18oz R404a
WC–23 oz R–22
Refrigerant Control (Air Cooled)
AXV (30 PSI)
AXV (15-17 PSI)
Refrigerant Control (Water Cooled)
AXV (28 PSI)
AXV (15-17 PSI)
Voltage
115V
208/230V 60HZ 1PH
Total Amp. Draw
16 AMPS
12 AMPS
Gearmotor Amp. Draw
1.6 AMPS
.7 AMPS
Gearmotor Electrical Rating
1/8 hp
1/7 hp
Maximum Fuse Size
20 AMPS
15 amps
3
166240009
SPECIFICATIONS 2400 SERIES
17 1/2-IN.
44-CM
OVERALL DIMENSIONS
23-9/16-IN. HIGH x 45-1/8-IN. WIDE x 27-5/16-IN. DEEP
60-CM
115-CM
69-CM
8-IN.
20-CM
15 1/8-IN.
38-CM
44-IN.
112-CM
14 1/4-IN.
36-CM
15 1/8-IN.
38-CM
ELECTRICAL
WATER OUT (W/C)
AIR IN
44-IN.
112-CM
NOTE:
CONDENSER SIDE
WATER IN (W/C)
WATER INLET
23 1/2-IN.
60-CM
9 1/8-IN.
23-CM
A
B
8 3/4-IN.
22-CM
27-IN.
69-CM
9 1/8-IN.
23-CM
”A”- ALTERNATE ICE DROP AREA FOR TOP UNIT WHEN TWO ARE STACKED.
AIR IS EXHAUSTED OUT
BACK AND SIDE OPPOSITE
CONDENSER
”B”-ICE DROP AREA FOR BASIC UNIT.
INDIVIDUAL ”A” & ”B” DIMENSIONS ARE 5-5/32-IN. x 8-9/32-IN.
13-CM
21-CM
RECOMMENDED BIN TOP CUT OUT AS SHOWN ABOVE 14-1/4-IN. x 8-3/4-IN.
22-CM
36-CM
FIGURE 2. SPECIFICATIONS FOR 2400 SERIES
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁ
ICE PRODUCTION CAPACITY (approximate)
AIR TEMPERATURE
50°F/10°C
70°F/21°C
90°F/32°C
AF-2400-P-MHR PRODUCTION CHART
WATER TEMPERATURE
50°F/10°C
70°F/21°C
2507 lbs/1140 kgs
2175 lbs/989 kgs
2495 lbs/1134 kgs
2045 lbs/930 kgs
2095 lbs/952 kgs
1800 lbs/818 kgs
Compressor Electrical Rating
Compressor Model
Condenser
Refrigerant Charge
Refrigerant Control
80°F/27°C
2008 lbs/913 kgs
1850 lbs/841 kgs
1680 lbs/764 kgs
2 hp
Copeland CS14K6E-PFV-235
Air Cooled
26 oz R404a/each side
AXV 26-PSI factory
setting/Each Side
208/230 1 ph. 60 hz.
3/8” SAE male flare
1/7 hp
.7 amps at 230V
40 amps
30 amps
Voltage
Inlet Water Supply
Gearmotor Electrical Rating
Gearmotor Amp Draw
Mamimum Fuse Size
Total Amp Draw
Refer to serial plate for maximum circuit ampacity and minimum time delay fuse size.
166240009
4
INSTALLATION INSTRUCTIONS
You will get better service from the ice machine, longer life and greater convenience if you choose its location
with care.
Here are a few points to consider:
1. Select a location as close as possible to where you are going to use the ice.
2. Allow a minimum of 6” space at sides and rear of machine for ventilation.
3. A kitchen installation is not desirable as a rule. If a kitchen installation is necessary, locate the machine as
far away from the cooking area as possible. Grease laden air will form a greasy deposit on the condenser.
This reduces the ice making efficiency and necessitates thorough cleaning quite often.
4. If you install the unit in a storeroom, be sure the room is well ventilated.
NOTE: Do not install where the ambient and incoming water temperature will drop below 50° F rise to
over 100° F.
WARNING: If water pressure exceeds 50 pounds, a water pressure regulator should be
installed in water inlet line between water shut–off valve and strainer. Minimum incoming
water pressure required is 22 pounds.
5. Uncrate the unit by removing the staples or nails from the bottom of the carton and lift off.
6. Remove the bolts holding the skid to the machine.
7. For units supplied with a bin sealing gasket, cement the gasket to the bottom outside edge of the machine
before it is set on the bin. NOTE: This is an N.S.F. requirement and must be done by the installer.
8. Make sure the correct bin adapter has been supplied when used. Then mount the unit on the bin and level
both properly.
9. For units not supplied with bin sealing gasket, seal the machine to bin with an N.S.F. approved sealant
such as Dow R.T.V. #732, 734, or G.E. #102, 108. This is an N.S.F. requirement and is the responsibility
of the installer.
10. The incoming water for the ice making section requires a 3/8” copper line. Connect this water line to the
3/8” male flare fitting on the back of the unit.
NOTE: For water cooled units, a separate 3/8” copper water line is required to be connected to the flare
fitting on the back of the unit marked condenser water in. A 3/8” flare connected line will have
to be provided from the fitting marked condenser water out to the drain.
A water regulating valve installed at the factory was set to maintain 270 to 310 PSI head pressure for R–404a
units and 210 to 225 PSI for R–22 units (Approx. 105_ to 110_F). Check temperatures at condenser outlet and
adjust if necessary.
11. Connect a drain hose to the condensate drain stub tube.
NOTE: All plumbing must be done in accordance with national and local codes.
12. Bring the electrical supply into the unit through a handy box located on the back of unit and make
connections.
NOTE: NOTE: Make sure the proper voltage and number of wires are provided. See serial plate and
make connections.
NOTE: All wiring must conform to national and local codes.
13. Turn on water supply and observe water level in evaporator sections. Water level is to be maintained at
the top of the evaporator. (See adjustment procedure)
5
166240009
14. Turn machine on and check for proper voltage and amp draw on the entire unit as well as components
such as the gearmotor and fan motor.
15. Check refrigerant circuit and all plumbing connections for leaks, etc.
16. Check bin thermostat or mechanical shut–off for proper operations. In the mid–range the bin thermostat
will open at 42° and has a 6° differential.
REMOTE CONDENSER
Remote condensers should be installed above the ice machine and in a level configuration. They are connected
to the ice making unit by copper tubing and line valves. The female half of the line valve is mounted on the ice
making unit and the remote condenser. The male half is soldered on the tube ends when tubing kits are
provided with the machine. If tubing kits are not provided, the male half of the line valves will be provided in a
valve kit and the installer will mount them on the tubing he provides.
NOTE: WHEN VERTICAL LINES ARE INVOLVED IN THE INSTALLATION, FOLLOW STANDARD
REFRIGERATION PRACTICES FOR VERTICAL LINES TO ASSURE POSITIVE OIL RETURN TO
THE COMPRESSOR. VERTICAL LIFT TO BE NO MORE THAN 15 FEET.
NOTE: WE DO NOT RECOMMEND TUBING RUNS OF MORE THAN 40 FEET..
NOTE: The seals for the line valves will be found in an envelope on the remote condenser. Make sure
they are used.
NOTE: REMOVE CAP PLUGS FROM ALL LINE VALVES BEFORE MAKING VALVE CONNECTIONS WITH
THE SEAL.
NOTE: A LOW VOLTAGE ELECTRICAL CONTROL CIRCUIT MUST BE FIELD WIRED BETWEEN THE
ICE MACHINE AND THE REMOTE CONDENSER RELAY. THOSE WIRES SHOULD BE RUN WITH
THE TUBING DURING INSTALLATION. REFER TO APPLICABLE WIRING DIAGRAMS.
NOTE: When the line valves are connected to each other the refrigerant circuit is complete. Each valve
half has its own shut-off which must be fully opened to allow the refrigerant to flow though the
system before it is started.
The ice making unit utilizing a remote condenser is shipped from the factory with the receiver holding the
refrigerant charge. Additional refrigerant may be required upon installation depending upon the ambient
conditions the remote condenser is operating under, the condenser and line sizing.
A three way head pressure control valve is used to maintain a relatively consistent head pressure between 175
and 185 PSI for R22 in the receiver in cold ambient conditions. Because of this valve some liquid refrigerant will
be held in the condenser.
NOTE: THE HEAD PRESSURE CONTROL VALVE WILL NOT OPERATE CORRECTLY WHEN A TOTAL
PRESSURE DROP OF 14 POUNDS OR MORE IS CREATED BETWEEN THE ICE MAKING UNIT,
THROUGH THE TUBING TO THE REMOTE CONDENSER, THE CONDENSER AND THE RETURN
TUBING TO THE ICE MAKING UNIT.
The remote condenser requires a separate power supply from the ice making unit. Refer to the remote
condenser wiring diagram.
166240009
6
WARNING: WATER LEVEL MUST BE MAINTAINED AT THE TOP OF THE EVAPORATOR.
WATER LEVEL
ill224
FIGURE 3. WATER LEVEL
1. Remove gearmotor and auger.
2. Adjust float valve to get water level to top seam of the evaporator.
3. Re–install auger. WATER LEVEL WILL RISE WHEN AUGER IS INSERTED BUT WHEN THE MACHINE
IS TURNED BACK ON AND ICE STARTS BEING MADE, THE WATER LEVEL WILL GO BACK TO THE
ORIGINAL SETTING.
4. Re–install gearmotor assembly and start machine.
7
166240009
STACKING INSTRUCTIONS FOR STACKING KIT 29757
The Kit consists of:
1 – #26102 Sealer
2 – #261 1/4-20x5/8 screw
2 – #256 1/4” flat washer
2 – #239 1/4” Lock Washer
1 – #29758 Stacking Chute Extension
1. After uncrating machine to be stacked, remove front and rear panels.
2. Remove top and front panels of bottom machine.
3. Remove alternate chute opening cover from bottom machine.
4. Insert vertical chute extension from kit into alternate chute opening of bottom unit and seal it to the base
with sealer provided in the kit.
5. Carefully mount stacking unit reversed 180° with the compressor and condenser opposite those of the
bottom unit.
NOTE: When mounting, make sure stacking unit vertical chute aligns and inserts correctly with chute
extension installed in alternate chute opening of bottom unit. Raise chute bracket to cover
opening and tighten bracket screws.
6. Secure both machines together as shown in the illustration utilizing screws and washers provided in the kit.
7. After stacking unit, hook up electrical and water.
NOTE: The two units must operate independently of each other.
8. Connect drain line from tee under the stacked unit to run out of the back of the unit.
9. Replace panels of stacked unit front to front and back to back as the machine is mounted. Replace front
panel of bottom unit.
166240009
8
TYPICAL WATER CIRCUIT
The supply water enters the float chamber through a small orifice. The water level rises and lifts the buoyant
float with it. The float attached to the float arm seats a valve to shut off any further water supply. As water
leaves the float chamber, the level drops along with the float and arm, causing the valve to open and admit
more water. Thus the water level is maintained automatically as the machine operates.
Water now flows through a hose connected to the float chamber and enters the opening of the evaporator shell.
The water level in the shell will rise to the same level that is maintained in the float chamber. The water that is
in immediate contact with the center post evaporator will be reduced in temperature. As a result, freezing
occurs and ice forms on the surface of the evaporator.
As more water is frozen, the thickness of the ice increases until it exceeds the distance allowed between the
evaporator and auger. The auger rotates at a slow speed to wipe off the accumulated ice as well as help it to
the surface. After the ice reaches the surface it is discharged through the top opening in the shell. An ice chute
attached to the shell conveys the ice to the storage bin where it accumulates in the insulated bin until it is used.
The ice will pile up to a point where the bin thermostat tubing is located. When the ice touches this brass
tubing, the unit will shut–off and remain off until enough ice is used or melted to reduce the pile. Any ice that
melts will pass through the drain and drain hose to an open drain.
WATER IN
ICE
OUT
FLOAT
CHAMBER
EVAPORATOR
CHAMBER
FIGURE 4. TYPICAL WATER CIRCUIT
9
166240009
TYPICAL REFRIGERANT CIRCUIT
Heat always flows from hot to cold and therefore, the ”heat load” supplied to the evaporator section by water
gives up its heat to the refrigerant which is at a temperature below the freezing point of water. This refrigerant
now passes through the heat exchanger back to the compressor, as a low pressure vapor.
This low pressure vapor is compressed in the compressor, as it leaves the compressor at a high pressure in
vapor form it enters the top of the condenser. The condenser has a rapid flow of cool air across it which
removes much of the heat from the hot refrigerant vapor.
As the vapor, passing through the condenser, loses heat it condenses back to a liquid since it is still under high
pressure and cooler than when it entered the condenser. The liquid refrigerant then passes through the
drier/filter still under pressure and goes through the heat exchanger where further cooling takes place. As the
refrigerant leaves the automatic expansion valve, the pressure has dropped, causing the refrigerant to vaporize
and boil off as it picks up heat in the evaporator and since the pressure is low, the refrigerant will be cold.
AXV
HEAT
EXCHANGER
EVAPORATOR
COMPRESSOR
CONDENSER
DRIER/FILTER
FIGURE 5. TYPICAL REFRIGERANT CIRCUIT
166240009
10
ELECTRICAL CIRCUIT
CIRCUIT DESCRIPTION
As the manual on–off–circuit breaker switch is pushed to ”on”, an electrical circuit is completed to the
gearmotor via the circuit breaker gearmotor overload, power relay / contactor, gearmotor delay thermostat and
the bin thermostat. After the previous circuit has been completed the condenser fan motor will start as will the
compressor (via the high pressure control and the compressor starting relay).
COMPONENT DESCRIPTION
BIN THERMOSTAT
This is electrically in ”series” with the ice making system. when the bin is full, the contact opens, terminating
power to the machine.
GEARMOTOR START RELAY
This is a current type relay which means as the gearmotor run winding comes ”on” the line, the current draw
initially is relatively heavy through the relay coil (coil is in series with run winding). It then acts like a normal
relay and the N.O. start contact ”makes”, completing a circuit through the start capacitor to the start winding.
As the gearmotor picks up speed, the amp draw through the relay coil drops off allowing the armature to return
to its normal position (start contact ”opens”). This action removes the start winding from the circuit.
POWER RELAY / CONTACTOR
This relay controls the compressor power only.
GEARMOTOR DELAY THERMOSTAT
This thermostat keeps the gearmotor running until the suction line temperature reaches 45_ after the full bin
switch terminates power to the power relay / contactor.
ON–OFF SWITCH / CIRCUIT BREAKER
This switch interrupts power to the entire unit. The switch has a circuit breaker incorporated into its’ design.
This circuit breaker will trip out in the event the gearmotor draws to high of amps In such an event the power is
interrupted to the unit. To reset the circuit breaker and reestablish power to the unit, push the switch to the ”off”
position and then back to the ”on” position.
FAN CYCLING SWITCH (R404a Units)
The function of this switch is to maintain condensing pressures at a satisfactory level during–low ambient
conditions. The switch breaks the circuit to the condenser fan motor at 205 PSI and makes the circuit at 275
PSI.
HIGH PRESSURE CONTROL
The high pressure cut out is electrically in series with the power relay. As the head pressure rises to 450 PSIG
for R404a charged units and 400 PSIG for R 22 charged units, a preset level, the contact opens thus breaking
the circuit to the compressor via the power relay contactor. This control must be reset manually on R404a units.
11
166240009
COMPRESSOR START RELAY
This is a current type relay and contains a N.O. contact which is connected in series with the start winding of the
compressor. The relay coil is electrically in series with the run winding. When power is applied, the compressor
draws high current which sets up a magnetic field around the magnet coil which causes the relay to operate,
closing the relay contact. As the compressor approaches operating speed, the current flowing through the coil
decreases, permitting the relay contact to open, thereby opening the starting circuit.
POTENTIAL RELAYS
The potential relay is used as a compressor starting relay, The contact in the potential relay is N.C.. The
magnet coil is connected across (parallel) the start winding and is affected by induced voltage, generated by the
start winding. As the compressor comes up to design speed, the voltage across the relay coil increases and at
running speed is sometimes as much as 2 1/2 times the supply voltage. This voltage sets up a magnetic field
which causes the relay to operate. The starting relay is calibrated to remove the start capacitor (open the
starting circuit) at approximately 85% of the motor design speed.
NOTE: BOTH TYPES OF RELAYS ARE DESIGNED TO OPERATE WITHIN VERY NARROW LIMITS OF
VOLTAGE AND CURRENT DICTATED BY MOTOR DESIGN, THEREFORE, WHEN MAKING A
REPLACEMENT OF A RELAY ALWAYS PROVIDE AN EXACT REPLACEMENT, RECOMMENDED
BY THE COMPRESSOR MANUFACTURER.
CAPACITORS – GENERAL
An electrical capacitor is a device which stores up electrical energy. Capacitors are used with single phase
motors to provide starting torque and improve running characteristics; by feeding this energy to the start winding
in step with the run winding.
Any capacitor has three (3) essential parts, two (2) of which are usually foil plates separated and insulated by
the third part called the dielectric.
Two general types of capacitors are used with electric motors. The electrolytic starting capacitor usually uses a
very thin film of oxide on the metallic plate as the dielectric. The running capacitor usually is of the liquid filled
type.
166240009
12
YL
BL
BL
OUTLET
BOX
YL
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 2.0 AMPS
GR
BL
BK
BL
BL
WH
WH
YL
BL
BIN
THERMOSTAT
DELAY
THERMOSTAT
BL
GEAR MOTOR
START CAPACITOR
64-77 MFD 165 VAC
RD
RD
3
BK
2
4
RD
RD
GEAR MOTOR
START RELAY
GEAR
MOTOR
YL
M
WH
FAN MOTOR
BK
BL
CONTROL
HIGH PRESSURE
BK
LOW AMBIENT
SWITCH (A/C ONLY)
COMPRESSOR
OVERLOAD
BL
WH
BK
COMPRESSOR
C
1
BL
WH
BK
M
BK
COMPRESSOR
START CAPACITOR
72-86 MFD 330 VAC
RD
WH
R
S
YL
YL
COMPRESSOR
RUN CAPACITOR
30 MFD 440 VAC
CONTACTOR
OR
1
2
WH
5
COMPRESSOR
START RELAY
AF/WF-750-MH-R
115 VOLTS 60 Hz
FIGURE 6. WIRING DIAGRAM AF/WF–750–MH-R
13
166240009
YL
BL
OUTLET
BOX
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
BL
GN/Y
RD
LB
BK
BR
BL
YL
BL
BIN
THERMOSTAT
DELAY
THERMOSTAT
GEAR MOTOR
START RELAY
3
BK
2
RD
4
RD
BL
YL
GEAR
MOTOR
GEAR MOTOR
START
CAPACITOR
RD
RD
M
YL
GN/Y
RD
FAN MOTOR
BK
BL
BK
FAN SWITCH
CONTROL
HIGH PRESSURE
COMPRESSOR
OVERLOAD
COMPRESSOR
1
BL
RD
BK
RD
BR
BK
RD
LB
CONTACTOR
S
RD
COMPRESSOR
START CAPACITOR
88-106 MFD 220 V
YL
GN/Y
BL
L
COMPRESSOR
START RELAY
AF750PMH-50-R
220 VOLTS 50 Hz
166240009
GN/Y
R
C
BK
M
WIRE NUT
FIGURE 7. WIRING DIAGRAM AF–750–PMH-50R
14
S
M
RD
YL
BL
OUTLET
BOX
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
GR
BL
RD
BK
BL
RD
YL
BK
BL
BIN
THERMOSTAT
DELAY
THERMOSTAT
BK
4
BK
M
BL
3
RD
RD
2
GEAR MOTOR
START
GEAR
CAPACITOR
MOTOR
RD
RD
FAN MOTOR
A/C ONLY
GEAR MOTOR
START RELAY
BK
RD
YL
BK
M
BK
EVAPORATOR HEATER
RD
RD
CONTROL
HIGH PRESSURE
(W/C ONLY)
RD
BK
RD
COMPRESSOR
COMPRESSOR
RUN
CAPACITOR
RD
COMPRESSOR
START
CAPACITOR
RD
R
BK
C
BK
RD
BK
RD
POWER RELAY
S
YL
YL
OR
BK
COMPRESSOR
START RELAY
2
5
RD
1
AF/WF-1100-MH
208/230 VOLTS 60 Hz
FIGURE 8. WIRING DIAGRAM AF/WF–1100–MH
15
166240009
YL
BL
OUTLET
BOX
GW
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
BL
RD
BK
BL
RD
YL
BK
GEAR MOTOR
BL
BIN
THERMOSTAT
START RELAY
DELAY
THERMOSTAT
3
BK
2
RD
4
RD
BL
GEAR MOTOR
START
CAPACITOR
RD
RD
M
24V FIELD
WIRING
RD
CONTROL
HIGH PRESSURE
230V
REMOTE
CONDENSER
RD
BK
BK
RD
BK
COMPRESSOR
BK
R
RD
C
BK
RD
CRANKCASE HEATER
CONTACTOR
S
RD
M
YL
BK
COOLING
FAN MOTOR
BK
WH
POWER
RELAY
CLASS II
TRANSFORMER
FAN
MOTOR
M
YL
RD
COMPRESSOR
START
CAPACITOR
COMPRESSOR
RUN
CAPACITOR RD
YL
BK
1
5
COMPRESSOR
START RELAY
RF-1100-MH
208/230 VOLTS 60 Hz
166240009
RD
GEAR
MOTOR
FIGURE 9. WIRING DIAGRAM RF–1100–MH
16
2
OR
RD
YL
BL
OUTLET
BOX
GR
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
BL
RD
BK
BL
RD
BL
YL
BK
GEAR MOTOR
BL
BIN
THERMOSTAT
START RELAY
DELAY
THERMOSTAT
3
BK
2
RD
RD
4
BL
GEAR MOTOR
START
CAPACITOR
RD
RD
GEAR
MOTOR
M
RD
YL
RD
FAN MOTOR
M
BK
RD
CONTROL
HIGH PRESSURE
(W/C ONLY)
BL
RD
BK
RD
BK
BK
RD
BK
RD
BL
COMPRESSOR
M
CONTACTOR
AF/WF-1100-MH-3
3 PHASE 208/230 VOLTS 60 Hz
FIGURE 10. WIRING DIAGRAM AF/WF–1100–MH–3
17
166240009
YL
BL
OUTLET
BOX
GW
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
BL
RD
BK
BL
LB
YL
BR
BL
BIN
THERMOSTAT
DELAY
THERMOSTAT
GEAR MOTOR
START RELAY
3
BK
2
RD
4
RD
BL
GEAR MOTOR
START
CAPACITOR
RD
RD
GEAR
MOTOR
M
RD
YL
RD
FAN MOTOR
M
BK
RD
CONTROL
HIGH PRESSURE
(W/C ONLY)
LB
COMPRESSOR
BR
COMPRESSOR
RUN
CAPACITOR
RD
RD
YL
YL
R
C
RD
BK
BK
RD
CONTACTOR
S
BK
RD
OR
BK
1
5
COMPRESSOR
START RELAY
AF/WF-1100-MH-50
240 VOLTS 50 Hz
166240009
COMPRESSOR
START
CAPACITOR
FIGURE 11. WIRING DIAGRAM AF/WF–1100–MH–50
18
2
RD
RD
RD
RD
BK
COMPRESSOR
RUN
CAPACITOR
35 MFD
370V RD COMPRESSOR
RD
COMPRESSOR
START
CAPACITOR
145-174 MFD
250V
GW
COMPRESSOR
YL
WH
5
C
S
BK
RD
YL
MAIN
ON-OFF
SWITCH
RD
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
YL
YL
BK
YL
19
2
RD
RD
GEAR MOTOR
DELAY
THERMOSTAT
BL
BL
RD
BL
BK
4
BK
WH
2
COMPRESSOR
START RELAY
GEAR
MOTOR
START
CAPACITOR
YL
OR
BK
ON-OFF SWITCH
CIRCUIT BREAKER
RATED 1.5 AMPS
BIN
THERMOSTAT
LOW
WATER
BK
PRESSURE
SWITCH
CI 20 CO 10
M COND.
FAN
SYSTEM 1
LOW AMBIENT
PRESSURE
SWITCHES
WH
BK
CI 275
CO 205
BK
A/C
BK
ONLY
BK
SYSTEM 2
YL
BL
YL
YL
GEAR
MOTOR
BK
BL
BK
M
GEAR
MOTOR
START
RD CAPACITOR
RD
GEAR
MOTOR
START
RELAY
4
BL
3
BL
RD
YL
1
4
3
6
1
HIGH
PRESSURE
SWITCH
CO 450
GEAR MOTOR
& COMPRESSOR
CONTROL RELAY
OR
5
BL
RD
BIN LIMIT
THERMOSTAT
M
BL
3
RD
YL
BK
BK
HIGH
PRESSURE
SWITCH
CO 450
BL
GEAR
MOTOR
YL
S
BK
RD
BL
GEAR
MOTOR
START
RELAY
C
SYSTEM 2
CONTACTOR
BK
COMPRESSOR
START RELAY
1
SYSTEM 1
CONTACTOR
BK
2
COMPRESSOR
START
CAPACITOR
145-174 MFD
250V
R
R
YL
COMPRESSOR
RUN
CAPACITOR
35 MFD
370V
RD
RD
2
BK
BL
RD
YL
166240009
AF/WF-2400 PMHR DUAL COMPRESSORS
208/230 VOLTS 1 PHASE
FIGURE 12. WIRING DIAGRAM 2400 SERIES
GEAR MOTOR
DELAY
THERMOSTAT
MAINTENANCE
THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED AT LEAST EVERY SIX MONTHS ON
FLAKED ICE MACHINES:
1. Check power supply with machine running for proper voltage.
2. Check water level in the float tank reservoir. Water level should be maintained at the top of the evaporator.
Adjust if necessary. (See illustration and adjustment procedure)
3. Clean the air–cooled condenser coil with a stiff brush or vacuum cleaner (See procedure)
CAUTION: CONDENSER COOLING FINS ARE SHARP, USE CARE WHEN CLEANING.
4. Clean the ice storage bin and flush the bin drain at least once a month.
5. If a water conditioner is installed in the inlet water line, change, replace, or clean the filter, strainer or cartridge as required.
6. If heavy mineral deposits on the auger and evaporator shell are encountered due to bad local water conditions, follow sanitizing and cleaning procedure.
7. Loosen hold–down cam locks and remove gearmotor assembly.
8. Check thrust washer; replace if noticeably worn.
9. Lift out auger and examine for wear. The corkscrew auger guide bushing pressed into the drive block
should be checked for wear. Replace if loose or if worn flat with auger drive block. If the Helix auger on
the corkscrew auger round bar becomes flat on the inside more than 1/8 of an inch over a length of two
inches or more it should be replaced.
NOTE: HELIX AUGERS DO HAVE MACHINED FLAT RELIEF SURFACES. DON’T CONFUSE THEM WITH
WORN FLAT AREAS.
Check the insert in the bottom ring of the Helix auger and replace if excessively worn.
10. Check shell vertical strips for wear. Replace the shell if excessive wear is shown.
11. Check O–Ring, replace if worn or cut.
12. Re–assemble, steps 7through 11.
CAUTION: IN RE–ASSEMBLING THE AUGER GEARMOTOR, THE HOLD DOWN CLAMPS
MUST BE RIGHT AND SECURE. IN RE–INSTALLING THE EVAPORATOR SHELL, BE
ABSOLUTELY SURE THAT THE ”O” RING IS NOT PINCHED OFF AS THIS WOULD CAUSE A
WATER LEAK AROUND THE BASE OF THE EVAPORATOR. LUBRICATE THE ”O” RING WITH
FOOD GRADE LUBRICANT BEFORE RE–ASSEMBLING SHELL.
13. Check for alignment of ice chute. Make sure chute gasket is not blocking path of ice flow.
14. Check bin thermostat operation. In the mid–range position the bin thermostat will open at 42_ and has a
6_ differential.
166240009
20
SANITIZING AND CLEANING PROCEDURE
1. Turn switch to ”OFF” to stop unit.
2. Remove top cabinet panel.
CAUTION: Hazardous moving parts. Do not operate unit with panel removed.
3. Mix sanitizing solution by using 0.5-ounces of household liquid bleach (such as Hi-Lex or Chlorox) to one
gallon of potable water. This mixture must not exceed 200-ppm of chlorine.
4. Turn water ”OFF”. Remove water hose from float chamber and allow all water to drain from the float
chamber and evaporator. Restore hose to float chamber and add sanitizing solution to the float chamber.
Turn water ”ON”.
OR
Remove float chamber cover and while holding float up to prevent water from entering the chamber, remove water hose and allow all water to drain from the float chamber and evaporator. Restore hose to float
chamber and add sanitizing solution to the float chamber.
5. Reinstall float chamber cover.
6. Remove vertical ice chute cover.
7. With a plastic bristle brush and sanitizing solution, scrub the interior of the vertical ice chute, including the
interior and exterior of the evaporator chute that extends into the vertical chute. Also scrub the vertical
chute cover and sensor tube. Allow all parts to air dry.
8. Reinstall the vertical chute cover and cabinet top panel.
9. Turn switch to ”ON” and allow unit to make ice.
10. Remove or melt with warm water, all ice inside of bin.
11. Using the sanitizing solution from step 7 and brush, scrub the interior of the ice bin including the underside
of the ice bin cover. Scrub the outside of the ice chute that protrudes into the ice bin, and the inside and
outside of the ice bin door.
12. Rinse interior of the ice bin with clean water.
13. Allow machine to make ice for at least 1/2 hour then discard all the ice made. DO NOT ALLOW ICE WITH
SANITIZER IN IT TO BE USED.
21
166240009
WATER TREATMENT
During the freezing process, as water passes under the freezing plate, the impurities in the water have a tendency to be rejected and the plate will freeze only the pure water.
However, the more dissolved solids in the water, the more troublesome the freezing operation will be. Bicarbonates in the water are the most troublesome of the impurities. These impurities will cause scaling on the evaporator, clogging of the water distributor head, float valve mechanism and other parts in the water system. If the
concentration of impurities is high, cloudy cubes or mushy ice may be the result.
Parts of the ice maker, that are in contact with the water or ice, may corrode if the water is high in acidity. In
some areas, water may have to be treated in order to overcome some of the problems that arise because of the
mineral content.
IMI Cornelius has water filter/treatment systems available to control impurities found in your water supply. Contact your local dealer for more information.
WINTER STORAGE
If the unit is to be stored in an area where the temperature will drop below freezing, it is most important that all
water lines be drained to prevent them from freezing and possible rupture.
To blow out the water line, disconnect the water supply at the cabinet inlet and use air pressure to force the water into the water reservoir pan. This can then be removed from the water pan.
WATER COOLED CONDENSER – To remove water from condenser unhook water supply and attach compressed air hose. Start machine. As head pressure reaches the appropriate level opening the water regulating
valve, the compressed air will force the water out. Do not let the machine operate longer than necessary.
CLEANING THE CONDENSER (AIR COOLED)
In order to produce at full capacity, the refrigeration condenser must be kept clean. The frequency of cleaning
will be determined by surrounding condition. A good maintenance plan calls for an inspection at least every two
months.
Remove the unit compartment grill at the front. With a vacuum cleaner, remove all accumulated dust and lint
that has adhered to the finned condenser.
CAUTION: CONDENSER COOLING FINS ARE SHARP. USE CARE WHEN CLEANING.
166240009
22
TROUBLESHOOTING
Trouble
UNIT WILL NOT RUN
COMPRESSOR CYCLES
INTERMITTENTLY.
Probable Cause
Remedy
A.
On–off switch in ”off” position.
A.
Turn switch to ”on”.
B.
Defective on–off switch.
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.
Power relay 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 line 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.
23
166240009
Trouble
MAKING WET ICE.
Probable Cause
Remedy
A.
Surrounding air temperature
too high.
A.
Correct or move unit
B.
High water level in float
reservoir.
B.
Lower water level, see step 2,
page 5
C.
Dirty condenser.
C.
Clean condenser
D.
Faulty compressor.
D.
Check and replace
E.
Refrigerant leak.
E.
Check and repair
F.
”O” ring leaking at bottom of
evaporator shell.
F.
Check and replace
*NOTE: Special care must be used with R404a (HP62) charged systems using (POE) Polyolester oil.
The refrigeration system must not be open longer than 15 min., and the appropriate drier must be used
due to the moisture absorption properties of the POE oil.
UNIT RUNS BUT MAKES NO
ICE.
WATER LEAKS.
EXCESSIVE NOISE OR
CHATTERING.
MACHINE RUNS WITH FULL
BIN OF ICE.
166240009
A.
Leak in refrigerant system.
A.
Check and repair.
B.
Moisture in system.
B.
Check, dehydrate and add drier to
system.
C.
No water.
C.
Check water supply.
D.
”O” ring leaking at bottom of
evaporator shell.
D.
Check and replace ”O” ring.
E.
Compressor not running.
E.
Check and replace ”O” ring
A.
Worn or bad float valve.
A.
Check and replace.
B.
Float and arm assembly stuck.
B.
Check and adjust or replace.
C.
”O” ring leaking at bottom of
evaporator shell.
C.
Check and replace.
D.
Storage bin drain and tubing.
D.
Check and repair.
A.
Mineral or scale deposits on
inside of evaporator shell.
A.
Remove and clean inside
surfaces by immersing evaporator
shell in 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 warmer.
A.
Storage bin thermostat set too
cold.
A.
Check and adjust warmer.
B.
Bin thermostat thermowell out
of path of ice.
B.
Adjust thermowell.
24
Trouble
UNIT OFF OR TRIPS CIRCUIT
BREAKER.
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 center separator
bent restricting ice flow out of
evaporator section .
E.
Replace ice chute .
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.
Replace bin thermostat if
necessary.
H.
Mineral or scale deposits on
inside of evaporator shell and
evaporator.
H.
Inspect and clean.
I.
Strips loose or missing on
inside of evaporator shell.
I.
Inspect and replace evaporator
shell if necessary.
J.
Low ambient temperature in
room where unit is located.
J.
Maintain temperature above 50°.
K.
Gearmotor sticking which
causes it to draw excessive
amperage.
K.
Check amp draw of gearmotor
with an amprobe (1.6 amps) at
115V, (.7 amps) 230V for normal
loaded amps.
25
166240009
Trouble
Probable Cause
L.
UNIT GOES OFF OR TRIPS
CIRCUIT BREAKER. (CONT’D)
Plugged expansion valve, or
L.
capillary tube causing low back
pressure.
Check back pressure, replace
valve or capillary tube. Evacuate
and re–charge system, replace
drier–strainer.
M.
Slight leak, causing low back
pressure.
M.
Check back pressure, find gas
leak, repair leak, evacuate
system, add drier and recharge.
N.
Loose hold–down assy.
N.
Check and tighten or replace.
O.
Auger worn excessively on the
inside surfaces causing thicker
flaked ice to be made.
O.
Replace auger.
P.
Auger out of line causing
excessive wear on the lower
outside surface where it rubs
against evaporator shell liner
at the bottom.
P.
Replace auger and evaporator
shell.
Q.
Broken auger
Q.
Replace auger.
R.
Evaporator surfaces worn or
gouged, causing thicker ice to
be made.
R.
Inspect and replace evaporator if
necessary.
S.
Auger guide bushing worn
down.
S.
Replace auger guide bushing
(corkscrew type augers only).
T.
Loose gearmotor mounting
place.
T.
Check and tighten.
U.
Low water level in float tank
reservoir.
U.
Adjust float arm to maintain
correct water level.
V.
Worn thrust washer.
V.
Replace.
W. Gearmotor Delay Thermostat
does not keep gearmotor
running after Bin Thermostat
shuts down.
166240009
Remedy
26
W. Check operation and / or replace.
PARTS LIST FOR 750 AND 1100 SERIES
ILL.
NO .
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
DESCRIPTION
Shroud, condenser
Condenser
Bracket, fan motor
Blade, condenser fan
Motor, condenser fan
Coil, condenser
Clamp, condenser coil
Bracket, coil mounting
Drier
Valve, water regulating
Clip, delay thermostat
Thermostat, gearmotor delay
Pad
Hold–down, evaporator
Evaporator
O–Ring
Auger
Shell
Valve, automatic expansion
Thrust washer
Gearmotor assembly
Disc, centering
Chute, vertical
Float tank assembly
Float & valve only
Screw, wing
Gasket, chute
Chute, inclined ice
Compressor (1PH)
Compressor (3PH)
Cover, vertical chute
Control, high pressure
Control, low ambient fan
Relay, power (1PH)
Relay, power (3PH)
Compressor cooling fan motor (not shown)
Thermostat, bin
Capacitor, compressor run
Capacitor, compressor start
Capacitor, gearmotor start
Switch, on–off / Circuit Breaker
Relay, compressor start
Relay, gearmotor start
Compressor cooling fan blade (not shown)
Plate, gearmotor mounting
Valve, Service
Top panel
Top panel, stainless steel
Front panel
Front panel, stainless steel
Left side panel
Left side panel, stainless steel
Right side panel
Right side panel, stainless steel
Back panel
Back panel, stainless steel
Switch, Fan Cycling
Switch, High Pressure Control
1100
27597
26266
37977
23527
35961
22499
35987
36836
21850
01211
25871
25864
26124
163277003
42597
03120
21078
162966001
27653
21711
164826003
20956
27599
21789
21924
00890
08065
20885
40569
41166
42316
07024
23838
40713
35547
23308
09570
27765
40284
37909
166220000
40285
161627003
09355
03163
N/A
163652068
27654
163498068
27655
163653068
27657
163654068
27670
163499068
27656
N/A
N/A
27
750
161890012
161870004
163183006
165595003
161871003
22429
35987
36836
166184002
164980002
25871
25864
26124
163277002
41100
03120
03796
09182
161921004
08043
164826001
20956
27598
21789
21924
00890
08065
09287
162964013
N/A
29299
165677006
165677005
164884002
N/A
N/A
09570
161192004
161165008
161165000
166220001
161998009
161627001
N/A
03163
162978003
163652068
27654
163498068
27655
163653068
27657
163654069
27670
163499068
27656
165677005
165677006
1100–50Hz
750–50Hz
27597
26266
37977
23527
35961
22499
35987
36836
21850
01211
25871
25864
26124
163270003
42597
03120
21078
162966001
27653
21711
164826003
20956
27599
21789
21924
00890
08065
20885
40569
N/A
42316
07024
23838
40713
N/A
23308
09570
27765
40284
37909
166220000
40285
161627003
09355
03163
N/A
163652068
27654
163498068
27655
163653068
27657
163654068
27670
163499068
27656
N/A
N/A
161890012
161870004
163183006
165595003
161871003
N/A
N/A
N/A
166184002
N/A
25871
25864
26124
163270002
41100
03120
03796
09182
161921004
08043
164826002
20956
27599
21789
21924
00890
08065
09287
162964041
N/A
29299
165677006
165677005
40713
N/A
N/A
09570
N/A
25335
29519
166220000
161998012
161627003
N/A
03163
162978003
163652068
N/A
163498068
N/A
163653068
N/A
163654069
N/A
163499068
N/A
165677005
165677006
166240009
45
49
47
5
25
7
9
29
24
30
4
12
3
11
21
2
19
8
28
6
43
1
23
22
27
20
26
16
15
14
13
31
33
32
34
41
35
42
18
39
36
37
46
38
17
44
51
40
48
10
50
ill227
166240009
FIGURE 13. ILLUSTRATED PARTS BREAKDOWN SERIES 750 – 1100
28
1
2
3
4
5
6
7
9
8
13
14
12
10
11
FIGURE 14. REMOTE CONDENSER ILLUSTRATED PARTS BREAKDOWN FOR 1100 SERIES
ILL. NO.
PART NO.
DESCRIPTION
1
27334
Condenser
2
27149
Shroud
3
27576
Frame assy
4
27183
Fan blade
5
27185
Motor, fan
6
27384
Bracket, fan motor mounting
7
27181
Relay
8
27379
Cover, electrical box
9
27345
Electrical box assy
10
42145
CNN–Quick, male
11
42624
CNN–Quick, male
12
42202
Bracket, connector
13
42278
Tube Condenser In
14
42277
Tube Condenser Out
29
166240009
PARTS LIST 2400 SERIES
ITEM NO
DESCRIPTION
PART NO.
1
Condenser A/C
161870011
2
Fan mounting bracket
164820021
3
Fan motor
4
Fan blade
5
Drier
6
Masonite Pad
7
Hold–down
27185
27183
166184002
26124
163277003
8
Evaporator
42597
9
Evaporator O–Ring
03120
10
Auger
11
Shell L.H.
162966001
21078
12
Shell R.H.
162966002
13
Automatic expansion valve
161921010
14
Thrust washer
15
Gearmotor
164826003
16
Vertical chute cover
166205001
17
Vertical chute
42328
18
Water reservoir
35225
19
Float & valve
27156
20
Hose
35771
21
Float mounting bracket
22
Compressor
21711
35231
162964029
23
Thermowell end cap
20421
24
Fan Cycling Switch
165677006
25
Delay thermostat
26
Delay thermostat clip
25864
25871
27
Contactor
40713
28
Capacitor, compressor start
29
Gearmotor start relay
40284
161627003
30
Gearmotor–compressor control relay
35548
31
Bin thermostat
09570
32
On–off switch/Circuit breaker
33
Gearmotor start capacitor
166220000
34
Water pressure switch
35
Compressor run capacitor
27765
03163
37909
165677007
36
Gearmotor mounting plate
37
Centering disc
20956
38
Compressor start relay
40285
39
Main power switch
35546
40
Reservoir cover
35230
41
High pressure control switch
42
Chute
43
Chute gasket
08065
44
Screw, chute mounting
00890
165677005
20885
CABINET PARTS NOT ILLUSTRATED 2400 SERIES
Description
Part No.
166240009
Top cover
163494068
Front panel
163493068
Right side panel
163492068
Left side panel
163491068
Rear panel
163490068
30
41
24
43
15
36
42
25
35
33
28
37
16
38
38
27
35
33
28
36
14
11
44
34
37
10
26
12
14
32
10
21
23
39
13
19
29
18
32
30
29
31
20
40
17
8
3
5
4
9
20
6
7
22
13
8
7
6
5
2
1
FIGURE 15. ILLUSTRATED PARTS BREAKDOWN SERIES 2400
31
166240009
CORNELIUS LIMITED COMMERCIAL WARRANTY PLAN
TO THE ORIGINAL OWNER OF A CORNELIUS COMMERCIAL FLAKE ICEMAKER
This warranty applies to Icemakers installed within the United States, Canada, Mexico and Puerto Rico
only.
For warranty information outside the U.S., Canada, Mexico and Puerto Rico, contact your nearest IMI Cornelius
Sales Office.
PARTS WARRANTY PERIOD
IMI CORNELIUS INC., hereinafter referred to as CORNELIUS, warrants to the original owner of a new CORNELIUS commercial flake ice
machine (“Machine”) who buys solely for commercial uses, that the Machine shall be free from defects in material and/or factory workmanship if
properly installed, operated and maintained, under normal and proper use and service conditions with competent supervision. The parts
warranty period is two years (24 months) from the date of installation or 27 months from the date of shipment by CORNELIUS whichever time
period elapses first. With respect to compressor and the evaporator, and the evaporator only for refrigeration leaks and restrictions which
would effect the normal operation of the unit, the warranty period will be five years (60 months) from the date of installation or 63 months from
the date of shipment by CORNELIUS whichever time period elapses first. The obligation of CORNELIUS under this warranty is limited to repair
or replacement (at the option of CORNELIUS) FOB factory in Mason City, Iowa of the part (or Parts) of any Machine that is proven defective.
LIMITED LABOR WARRANTY PERIOD
In addition to the parts warranty, CORNELIUS will pay scheduled straight time labor to repair or replace a defective component when failure
occurs within one year (12 months) from the date of installation or 15 months from the date of shipment by CORNELIUS whichever time period
elapses first. With respect to the compressor, evaporator, refrigeration condenser, condenser fan motor, and auger gearmotor, the labor
warranty period will be two years (24 months) from the date of installation or 27 months from the date of shipment by CORNELIUS whichever
time period elapses first. Time and rate schedules for labor compensation will be published periodically by CORNELIUS. Additional expenses
including but not limited to travel time, truck charges, overtime charges, material cost, accessing or removal of the ice machine,
normal prescribed maintenance cleaning, adjustments, and ice purchases are the responsibility of the original owner.
No parts warranty or labor allowance on the motor compressor assembly will apply when the ice machine’s refrigeration system is modified with
a condenser heat reclaim device, or parts and assemblies not provided by CORNELIUS, unless CORNELIUS provides approval, in writing, for
these modifications for specific locations.
The parts warranty shall not apply when destruction or damage is caused by alterations, unauthorized service, using other than factory
authorized replacement parts, risks of transportation, accidents, misuse, damage by fire, flood or acts of God. No components or assembly
from which the serial number or identification number has been altered or removed will be covered. Any defective parts to be repaired or
replaced must be returned to us through a CORNELIUS distributor/dealer, transportation charges prepaid, and they must be properly sealed
and tagged. The serial and model number of the Machine and the date of original installation of such Machine must be given. The warranty of
repaired or replaced parts will not extend beyond the period of the original warranty. The decision of the CORNELIUS Service Department
regarding the warrantability of parts and eligibility for the labor allowance will be final.
No representative, distributor/dealer or any other person is authorized or permitted to make any other warranty or obligate CORNELIUS to
make any other warranty or obligate CORNELIUS to any liability not strictly in accordance with this policy. This warranty is in lieu of all other
warranties expressed or implied and of all other obligations or of liabilities on our parts.
OUR LIABILITIES ARE LIMITED SOLELY AND EXCLUSIVELY TO REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT. WE ARE
NOT LIABLE FOR ANY SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES OF ANY KIND WHATSOEVER. In those jurisdictions
where liability for damages cannot be disclaimed, original purchaser’s recovery shall not exceed the cost of the warranted product.
Except for descriptions of size, quantity and type, which may appear on CORNELIUS product with specifications of certain industry,
government or professional organizations standards which may appear as product information disclosures in CORNELIUS literature and other
documents from time to time, THIS WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED,
INCLUDING WARRANTIES OR MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.
CORNELIUS MAKES NO WRITTEN WARRANTY TO ANY PURCHASER WHO BUYS FOR PERSONAL, FAMILY OR HOUSEHOLD USE.
P/N 163238002
Effective March. 1, 1996
Starting with Production
Serial
Number Code 9603
IMI CORNELIUS INC.
ONE CORNELIUS PLACE
ANOKA, MINNESOTA 55303-6234
166240010
32
THIS PAGE LEFT BLANK INTENTIONALLY
166240010
33
IMI CORNELIUS INC.
Corporate Headquarters:
One Cornelius Place
Anoka, Minnesota 55303-6234
(763) 421-6120
(800) 238-3600
34
166240010