Cornelius TS-009 Operating instructions

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 1of 1
Issue 02
HOME ICE
CREAM MAKER
MODEL TS-009
REPAIR MANUAL
© The images and text within this document are the copyright of Refrigeration
Installations Limited. No part of this document may be reproduced in any form or by
any means without the prior written permission of the copyright owners.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 2of 2
Issue 02
Index
1. Revision Status and Authority for Issue
2. Purpose
3. Scope
4. Responsibilities
5. Health and Safety
6. Abbreviations and Definitions
7. Parts Overview
8. Fault Identification
9. Unit Dismantling
10. Repair
10.1 Motor Replacement
10.2 Cooling Fan Replacement
10.3 On/Off Switch Replacement
10.4 PCB and Motor Connector Replacement
10.5 Mains Lead Replacement
10.6 Compressor Replacement
11. Unit Reassembly
12. Test

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 3of 3
Issue 02
1. Revision Status and Authority for Issue
Document
Issue Level Comments Changed By Date
01 First issue Raised by CRP 08-04-05
02
Reviewed,
Updated and
Minor Errors
Corrected.
CRP 23-05-05
Authority to release Issue 02:
S LLoyd Managing Director 23-05-05
Name Position Date

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 4of 4
Issue 02
2. Purpose
The purpose of this document is to provide a reference to facilitate
the diagnosis and repair of faults to the TS-009 Home Ice Cream
Maker.
3. Scope
This document covers versions of the Home Ice Cream Maker
Model TS-009 supplied by Refrigeration Installations Limited. All
versions are covered by these instructions, although most
photographs show the TS-009AS, and there may be slight
variations in functionality, such as the Control Panel Display and
detailed internal layout, however the basics of machine
dismantling, repair and reassembly are generally applicable. If in
doubt contact Refrigeration Installations Limited.
4. Responsibilities
The responsibility for the preparation of and modifications to this
document rests with RIL.
Repair to any Home Ice Cream Maker should only be carried out
by competent qualified personnel and we recommend that any
spare or replacement parts fitted be either supplied by, or
approved by, RIL.
The use of spare or replacement parts from other sources may
invalidate any guarantee or warranty on machines purchased in
the UK from RIL or one of its approved distributors.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 5of 5
Issue 02
5. Health and Safety
The Home Ice Cream Maker is mains electricity powered and any
checks or repairs must be carried out by qualified personnel and in
full compliance with any relevant national or local legislation or
codes of practice concerning the safety of personnel working with
electrical equipment.
6. Abbreviations and Definitions
Front The side of the unit nearest to the refrigeration barrel
Left The left hand side of the unit when viewed from the
Front
IC Integrated Circuit (A complex semiconductor circuit)
PCB Printed Circuit Board
Rear The side of the unit nearest the Control Panel Display
Right The right hand side of the unit when viewed from the
Front
RIL Refrigeration Installations Limited
SSD Static Sensitive Device (An electronic component such
as an IC or transistor which may be damaged if a build
up of static electricity is discharged through the
component)

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 6of 6
Issue 02
7. Parts Overview
ATop Motor Assembly BIce Cream Container
CPaddle DRefrigeration Barrel
EControl Panel Display FAppliance Body
GOn/Off Switch HMains Entry Cable
A
B
C
D
E
F
G
H

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 7of 7
Issue 02
7. Parts Overview (Continued)
Detail of Control Panel Displays:
TS-009AS TS-009A
8. Fault Identification
8.1 Machines returned for repair will rarely have an accurate
technical description of the suspected fault. ‘Not Working’, ‘Not
Freezing’, ‘Noisy’ or no stated reason are the most common
complaints. Normally any reported faults should not be believed,
although they should be borne in mind whilst carrying out the
following fault identification methodology. The order in which the
checks are to be carried out is a recommended sequence,
experience may lead to faster ways of finding faults. However as a
full record of checks and inspections carried out may need to be
kept, it is suggested that this sequence is followed.
8.2 The first step is a visual inspection of the equipment in order to
determine any physical damage to the unit and its mains electricity
lead, and to determine the condition of the 13 Ampere fuse. Mains
leads and fuses should be replaced as appropriate.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 8of 8
Issue 02
8. Fault Identification (Continued)
8.3 Plug the machine into the mains electrical supply and switch on
the On/Off switch located in the rear of the right hand panel. The
On/Off switch should illuminate.
8.4 If the Control Panel Display is type AS (with separate
START/STOP button) the timer will show a setting between 0 and
60 minutes. Press the TIMER SET button and the display should
count down to 0 from its initial value and then reset to 60. Reset to
10 minutes then press the START/STOP button. The paddle will
start to turn and freezing of the Ice Cream Container will
commence. Allow the machine to run for the setting time of 10
minutes and ensure it stops. During the running time confirm that
the Ice Cream Container/Refrigeration Barrel are freezing.
8.5 If the Control Panel Display is of the A type (no separate
START/STOP button) the timer will indicate a number of minutes,
normally 25 but the value is not critical. Pressing the up and down
buttons will increase and decrease the set time. Ensure that both
work and then set the time to 10 minutes. Machine start up (the
Paddle will begin to turn) is automatic after about 10 seconds from
switch on or ten seconds after the last timer adjustment. As in 8.4
ensure the Ice Cream Container is freezing.
8.6 Lack of freezing could indicate a compressor fault, cooling
system fault or cooling fan fault. See Section 9.
8.7 If the Paddle fails to turn a motor failure or connection problem
may be the cause. One of the most common problems reported by
users is the paddle not turning and this is normally due to a bad
electrical connection or lack of electrical connection between the
contacts in the Top Motor Assembly and the Appliance Body. If the
Top Motor Assembly is not seated fully and correctly there is a
high possibility of open circuits. The reasons for Top Motor
Assembly seating problems are incorrect positioning of the seal
and incorrect Ice Cream Container orientation and handle position.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 9of 9
Issue 02
8. Fault Identification (Continued)
8.8 The positioning of the Ice Cream Container and its handle, and
the positioning of the clear sealing ring on the top of the
Refrigeration Barrel are critical. The seal must be positioned as
shown and the Ice Cream Container must be orientated with the
handle lugs as shown and with the handle folded forwards.
Appliance Body
Motor Connector
Clear Sealing Ring with the
thickest section to the rear
and the two cut-outs (marked
X) at approximately ’10
minutes past’ and ’20
minutes to the hour.
Handle folded forwards
X
X
Handle lugs
Top Motor Assembly
Electrical Contacts

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 10 of 10
Issue 02
8. Fault Identification (Continued)
8.9 If the Paddle fails to turn and it is not due to the Top Motor
Assembly seating incorrectly then, providing the motor is being
supplied with power, the motor itself will need changing. See
Section 10.
8.10 Confirm a suspected motor fault by checking the electrical
supply to the motor. Remove the Top Motor Assembly and push
down on the spring loaded section of the Appliance Body Motor
Connector using (insulated) multimeter probes and confirming
mains voltage between the outer metal contact and the inner metal
contact.
Checking for mains supply to the motor

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 11 of 11
Issue 02
9. Unit Dismantling
IMPORTANT NOTE: The Home Ice Cream Maker has a combined
mains distribution and logic control PCB that includes SSD’s.
When handling PCB’s either in or out of the unit it is recommended
that anti-static handling precautions be taken.
Ensure the unit is disconnected from the mains electricity and
remove the Top Motor Assembly and the Ice Cream Container.
Electric motor replacement does not require full unit dismantling.
The only special tools required to enable the unit to be dismantled
are a bifurcated (two-pronged) screwdriver to release tamperproof
screws used in a number of locations as detailed in the text.
Otherwise standard types of tool are all that is required.
Screwdrivers for tamperproof screws
The blue handled screwdriver is a commercially available product.
The black handled screwdriver is a filed-down standard slotted
screwdriver –a cheaper alternative.
9.1 Remove three self adhesive screw covers and three
tamperproof screws that secure the upper body moulding as
shown in the following pictures.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 12 of 12
Issue 02
9. Unit Dismantling (Continued)
Right hand side panel screw Rear panel screw
Front panel screw
9.2 Lift the appliance upper moulding from the unit by holding it low
down on the right and left hand sides. Some degree of panel
manœuvering may be necessary as there is not a lot of slack in
internal cables and wires. Place the upper moulding behind the
unit and stabilise if necessary.
9.3 Access to internal parts is now possible.
Compressor
Condenser coil

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 13 of 13
Issue 02
10. Repair
10.1 Motor Replacement
10.1.1 Remove the Top Motor Assembly from the appliance and
pull the Paddle out of its seating. Remove the two Philips head
cover retaining screws that attach the clear plastic cover to the
motor housing and remove the cover.
10.1.2 Remove the four tamperproof screws and, holding the
assembly firmly to stop it falling apart, turn the assembly over so
that it sits upright (in the same attitude as when it is on the
appliance). There are three mouldings that form the Top Motor
Assembly (apart from the clear cover). The top ventilated
moulding, the centre moulding on which the motor is mounted, and
the bottom moulding into which the Paddle drive cogs locate. If the
unit is allowed to fall apart the drive cogs will fall loose and make
re-assembly more difficult.
10.1.1
Cover
retaining
screws
10.1.2
Tamperproof screws

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 14 of 14
Issue 02
10.1 Motor Replacement (Continued)
10.1.3 Carefully lift the top ventilated moulding away to reveal the
motor and its wiring. The centre moulding and bottom moulding
should be kept in close contact.
10.1.4 Disconnect the three wires from the spade terminals on
the base of the motor supply connector and gently lift off the centre
moulding complete with motor, toothed drive belt and the primary
drive cog. The larger secondary drive cogs should remain in the
bottom moulding.
Motor
Motor wiring
Motor supply
connector
Top
ventilated
moulding
Centre moulding
(motor mounted on
other side)
Toothed drive belt
Primary drive cog
Secondary
drive cogs

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 15 of 15
Issue 02
10.1 Motor Replacement (Continued)
10.1.5 Remove the primary drive cog from its location socket and
the toothed drive belt. Turn the assembly over and remove the four
Philips head mounting screws complete with nut and shakeproof
washer. It may be necessary to slacken off the motor earth lead to
gain access to two of the screws.
10.1.6 The motor can now be lifted away from the centre moulding.
10.1.7 Replacement is the reverse of removal. Care should be
taken to ensure correct positioning and assembly of the drive cogs
and toothed belt.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 16 of 16
Issue 02
10.2 Cooling Fan Replacement
10.2.1 Remove the three Philips head screws that hold the fan
mounting bracket to the base of the unit. Remove the cable ties
from the wiring and lift the connector block out of its seating.
Loosen the two screws clamping the two fan supply wires and
release them from the connector block. Remove the screw, nut
and shakeproof washer securing the fan ground cable to the fan
laminations and withdraw the fan and mounting bracket.
Fan mounting bracket screws
Connector
block
Fan supply
wires
Fan
ground
cable

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 17 of 17
Issue 02
10.2 Cooling Fan Replacement (Continued)
10.2.2 The fan can now be separated from the bracket by
removing the two Philips head fan fixing screws.
10.2.3 Fan replacement is the reverse of the removal process.
10.3 On/Off Switch Replacement
10.3.1 Following unit dismantling the On/Off switch can be seen in
the right hand rear panel. The switch is a push fit into the panel
and is also glued in.
Fan
fixing
screws

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 18 of 18
Issue 02
10.3 On/Off Switch Replacement (Continued)
10.3.2 Note the position of the four wires on the back of the switch
and remove them from the spade terminals. Cut away as much of
the glue as possible and push the switch out of its recess from
inside the panel.
10.3.3 Replacement of the switch is the reverse of the removal
process.
10.4 Printed Circuit Board and Motor Connector Replacement
NOTE: As stated at the beginning of Section 9 anti-static handling
precautions should be taken if the PCB is to be handled or
removed.
10.4.1 If the Motor Connector only is to be replaced remove the
two Philips head screws (X on the picture) and the retaining
bracket. Disconnect the three wires and replace the connector.
XY
Z

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 19 of 19
Issue 02
10.4 PCB and Motor Connector Replacement (Continued)
10.4.1 If the PCB or other parts are to be replaced remove the two
Philips head screws (X in the previous picture) and remove the
motor connector retaining bracket. Remove the Philips head screw
(Y) attaching the cable clamp and remove the clamp. Remove the
three Philips head screws (Z) that hold the PCB and its plastic
cover in place. Lift away the PCB, its cover and the Motor
Connector.
10.4.2 Only two of the wires on the PCB are attached with spade
connectors. The remainder are soldered and will require de-
soldering to replace the PCB. As with all PCB hand soldering care
must be taken to avoid damage to the PCB, in particular in
avoiding raised circuitry by applying too much heat.
10.4.2 The plastic PCB cover accommodates the transformer and
the buzzer. If either of these requires replacement the method of
attachment to the cover is clear and again they require soldering.

REFRIGERATION INSTALLATIONS LIMITED
Unit D9 Newton Business Park
Cartwright Street
Hyde
Cheshire SK14 4EH
Telephone: [phone] Fax: [phone]
Document Reference: WI 9 Page 20 of 20
Issue 02
10.4 PCB and Motor Connector Replacement (Continued)
10.4.2 Continued
10.5 Mains Lead Replacement
10.5.1 Remove the two Philips head screws that attach the cable
clamp and remove the clamp. Remove the glue from around the
cable entry grommet and slide the grommet out of its slot. Remove
any necessary cable ties to allow the connector block to be
removed from its seating and release the three mains lead
conductors from the block. Replacement is the reverse process.
Transformer
Buzzer
Cable
clamp and
screws
Connector
block
Cable entry
grommet