Cornelius 500 - Series Manual

CONTINUOUS FLOW ICEMAKER
500 - 700 - 1000 - 2000 Series
Installation and Service Manual
Release Date: August 1, 2002
Publication Number: 638085278
Revision Date: March 19, 2014
Revision: F
Visit the Cornelius web site at www.cornelius.com for all your Literature needs.

The products, technical information, and instructions contained in this manual are subject to change without notice.
These instructions are not intended to cover all details or variations of the equipment, nor to provide for every possi-
ble contingency in the installation, operation or maintenance of this equipment. This manual assumes that the per-
son(s) working on the equipment have been trained and are skilled in working with electrical, plumbing, pneumatic,
and mechanical equipment. It is assumed that appropriate safety precautions are taken and that all local safety and
construction requirements are being met, in addition to the information contained in this manual.
This Product is warranted only as provided in Cornelius’ Commercial Warrant applicable to this Product and is sub-
ject to all of the restrictions and limitations contained in the Commercial Warranty.
Cornelius will not be responsible for any repair, replacement or other service required by or loss or damage resulting
from any of the following occurrences, including but not limited to, (1) other than normal and proper use and normal
service conditions with respect to the Product, (2) improper voltage, (3) inadequate wiring, (4) abuse, (5) accident,
(6) alteration, (7) misuse, (8) neglect, (9) unauthorized repair or the failure to utilize suitably qualified and trained per-
sons to perform service and/or repair of the Product, (10) improper cleaning, (11) failure to follow installation, oper-
ating, cleaning or maintenance instructions, (12) use of “non-authorized” parts (i.e., parts that are not 100%
compatible with the Product) which use voids the entire warranty, (13) Product parts in contact with water or the
product dispensed which are adversely impacted by changes in liquid scale or chemical composition.
Contact Information:
To inquire about current revisions of this and other documentation or for assistance with any Cornelius product con-
tact:
www.cornelius.com
800-238-3600
Trademarks and Copyrights:
This document contains proprietary information and it may not be reproduced in any way without permission from
Cornelius.
Printed in U.S.A.

TABLE OF CONTENTS
Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Read and Follow ALL Safety Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Recognition . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Different Types of Alerts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Qualified Service Personnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Shipping and Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Mounting in or on a Counter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
General Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Specification Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
A. Remove Icemaker from Carton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
B. Cabinet Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
C. Preparation of Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
D. Water Inlet Hookup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
E. Drain Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
F. Electrical Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
G. Auger Engagement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
H. Bin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Initial Start Up, Checks and Adjustment Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Guide to service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Icemaker Cleaning and Sanitizing Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Monthly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Quarterly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Semi-Annually . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
How Water Level Control Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Purpose . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
To Replace Water Level Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
To Replace Water Level Safety Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Refrigeration System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Refrigeration System Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Expansion Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Adjustment and Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Condenser Modulating Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Condenser Modulating Valve Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Bin Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Gear Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Start Relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
To Replace Gear Motor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Installation and Shaft Seal Replacement 500 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Auger and Extruding Head Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Installation and Shaft Seal Replacement 700 & 1000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Upper Nut and Bearing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
To Replace Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Electrical Checkout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Overload Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Compressor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Capacitor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Safety Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Guide to Good Ice . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Parts List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Refrigeration and Icemaker Assembly Model 500 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Refrigeration and Icemaker Assembly Model 700 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Refrigeration and Icemaker Assembly Model 1000 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Continuous Flow Icemaker Installation and Service Manual
Publication Number: 638085278 - 1 - © 2002-2014, Cornelius Inc.
SAFETY INSTRUCTIONS
READ AND FOLLOW ALL SAFETY INSTRUCTIONS
Safety Overview
• Read and follow ALL SAFETY INSTRUCTIONS in this manual and any warning/caution labels on the unit (decals, labels or
laminated cards).
• Read and understand ALL applicable OSHA (Occupational Safety and Health Administration) safety regulations before
operating this unit.
Recognition
DIFFERENT TYPES OF ALERTS
!
DANGER:
Indicates an immediate hazardous situation which if not avoided WILL result in serious injury, death or equipment
damage.
!
WARNING:
Indicates a potentially hazardous situation which, if not avoided, COULD result in serious injury, death, or equipment
damage.
CAUTION:
!
Indicates a potentially hazardous situation which, if not avoided, MAY result in minor or moderate injury or equipment
damage.
SAFETY TIPS
• Carefully read and follow all safety messages in this manual and safety signs on the unit.
• Keep safety signs in good condition and replace missing or damaged items.
• Learn how to operate the unit and how to use the controls properly.
• Do not let anyone operate the unit without proper training. This appliance is not intended for use by very young children or
infirm persons without supervision. Young children should be supervised to ensure that they do not play with the appliance.
• Keep your unit in proper working condition and do not allow unauthorized modifications to the unit.
QUALIFIED SERVICE PERSONNEL
!
WARNING:
Only trained and certified electrical, plumbing and refrigeration technicians should service this unit. ALL WIRING
AND PLUMBING MUST CONFORM TO NATIONAL AND LOCAL CODES. FAILURE TO COMPLY COULD
RESULT IN SERIOUS INJURY, DEATH OR EQUIPMENT DAMAGE.
Recognize Safety Alerts
This is the safety alert symbol. When you see it in this manual or on the unit,
be alert to the potential of personal injury or damage to the unit.
!

Continuous Flow Icemaker Installation and Service Manual
© 2002-2014, Cornelius Inc. - 2 - Publication Number: 638085278
SAFETY PRECAUTIONS
This unit has been specifically designed to provide protection against personal injury. To ensure continued protection
observe the following:
!
WARNING:
Disconnect power to the unit before servicing following all lock out/tag out procedures established by the user. Verify
all of the power is off to the unit before any work is performed.
Failure to disconnect the power could result in serious injury, death or equipment damage.
CAUTION:
!
Always be sure to keep area around the unit clean and free of clutter. Failure to keep this area clean may result in
injury or equipment damage.
SHIPPING AND STORAGE
CAUTION:
!
Before shipping, storing, or relocating the unit, the unit must be sanitized and all sanitizing solution must be drained
from the system. A freezing ambient environment will cause residual sanitizing solution or water remaining inside the
unit to freeze resulting in damage to internal components.
MOUNTING IN OR ON ACOUNTER
!
WARNING:
When installing the unit in or on a counter top, the counter must be able to support a weight in excess of 500 - 169lbs,
700 - 179lbs, 1000 - 231lbs and 2000 - 376lbs.to insure adequate support for the unit.
Failure to Comply Could Result in Serious Injury, Death or Equipment Damage.
NOTE: Many units incorporate the use of additional equipment such as icemakers. When any
addition equipment is used you must check with the equipment manufacturer to determine the
additional weight the counter will need to support to ensure a safe installation.
CAUTION:
!
Very high discharges pressure is present in system. Quick disconnects on your gages will minimize danger and loss
of refrigerant.
CAUTION:
!
Unit requires separate electrical line. See instruction manual for proper fuse size.
!
WARNING:
There must be adequate clearance around icemaker. Allow minimum 6” air intake and 4” air exhaust for air exhaust
and panel removal.
NOTE: Unit must be installed per local plumbing and electrical codes. See installation manual for
unit requirements. Failure to do so may cause damage to unit, which would void unit warranty.
NOTE: Using any parts other than genuine factory manufactured parts relieves the manufacturer
of all liability.
NOTE: Manufacturer reserves the right to change specifications at any time.

Continuous Flow Icemaker Installation and Service Manual
Publication Number: 638085278 - 3 - © 2002-2014, Cornelius Inc.
GENERAL INFORMATION
GENERAL DESCRIPTION
This section gives the Unit description, theory of operation, and design data for continuous flow icemaker series 500,
700, 1000, and 2000.
IMPORTANT: To the user of this manual - This manual is a guide for installing, operating, and maintaining
this equipment. Refer to the Table of Contents for page location for detailed information pertaining
to questions that arise during installation, operation, service, or maintenance of this equipment.
SPECIFICATION CHART
NOTE: For units not listed in above chart, refer to nameplate or contact factory service.
Models Condensing
Unit VAC HZ PH Wire Comp.
RLA
Fan
Amps
GRMTR
Amps
Refrigerant Circuit
Fuse
Oz. Type
WCC500-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20
WCC500-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20
WCC502-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20
WCC502-W Water Cooled 220/240 50 1 2 5.3 N/A 1.6 11 R404A 20
WCC510-A Air Cooled 115 60 1 2 10.1 1.1 2 24 R404A 20
WCC510-W Water Cooled 115 60 1 2 10.1 N/A 2 11 R404A 20
WCC512-A Air Cooled 220/240 50 1 2 5.3 0.5 1.6 24 R404A 20
WCC512-W Water Cooled 220/240 50 1 2 5.3 N/A 1.6 11 R404A 20
WCC700-A Air Cooled 115 60 1 2 12 1.6 2 24 R404A 20
WCC700-W Water Cooled 115 60 1 2 12 N/A 2 13 R404A 20
WCC701-A Air Cooled 208/230 60 1 2 7.7 1.6 2 24 R404A 20
WCC701-W Water Cooled 208/230 60 1 2 7.7 N/A 2 13 R404A 20
WCC702-A Air Cooled 220/240 50 1 2 8.2 0.5 1.6 24 R404A 20
WCC702-W Water Cooled 220/240 50 1 2 8.2 N/A 1.6 13 R404A 20
WCF710-A Air Cooled 115 60 1 2 12 1.6 2 24 R404A 20
WCF710-W Water Cooled 115 60 1 2 12 N/A 2 13 R404A 20
WCC711-A Air Cooled 208/230 60 1 2 7.7 1.6 2 24 R404A 20
WCC711-W Water Cooled 208/230 60 1 2 7.7 N/A 2 13 R404A 20
WCF712-A Air Cooled 220/240 50 1 2 8.2 0.5 1.6 24 R404A 20
WCF712-W Water Cooled 220/240 50 1 2 8.2 N/A 1.6 13 R404A 20
WCC1001-A Air Cooled 208/230 60 1 2 7.5 0.85 2 26 R404A 20
WCC1001-W Water Cooled 208/230 60 1 2 7.5 N/A 2 17 R404A 20
WCC1002-A Air Cooled 220/240 50 1 2 8.9 0.85 2 26 R404A 20
WCC1101-A Air Cooled 208/230 60 1 2 7.5 0.85 2 26 R404A 20
WCC1101-W Water Cooled 208/230 60 1 2 7.5 N/A 2 17 R404A 20
WCF1102-A Air Cooled 220/240 50 1 2 8.9 0.85 2 26 R404A 20
WCC1001-R Remote 220/240 60 1 2 7.5 N/A 2 120 R404A 15
WCF1101-R Remote 208/230 60 1 2 7.5 N/A 2 120 R404A 15
WCC2001-A Air Cooled 208/230 60 1 2 12.9 0.85 (2) 2 46 R404A 25
WCC2001-R Remote 220/240 60 1 2 12.9 1.7 (2) 2 220 R404A 25
WCC2001-W Water Cooled 208/230 60 1 2 12.9 N/A (2) 2 28 R404A 25
WCC2002-A Air Cooled 220/240 50 1 2 11.4 0.85 (2) 2 46 R404A 25
WCF2201-A Air Cooled 208/230 60 1 2 12.9 0.85 (2) 2 46 R404A 25
WCF2201-W Water Cooled 208/230 60 1 2 12.9 N/A (2) 2 28 R404A 25
WCF2202-A Air Cooled 220/240 50 1 2 11.4 0.85 (2) 2 46 R404A 25

Continuous Flow Icemaker Installation and Service Manual
© 2002-2014, Cornelius Inc. - 4 - Publication Number: 638085278
Temperature Charts
Figure 1. Series 500 & 700 Dimension Drawing (Shipping Wt. Approx. 160 lbs.)

Continuous Flow Icemaker Installation and Service Manual
Publication Number: 638085278 - 5 - © 2002-2014, Cornelius Inc.
Figure 2. Series 1000 Dimension Drawing (Shipping Wt. Approx. 120 lbs.)

Continuous Flow Icemaker Installation and Service Manual
© 2002-2014, Cornelius Inc. - 6 - Publication Number: 638085278
Figure 3. Series WCC2001-A and WCF2201-A Dimension Drawings

Continuous Flow Icemaker Installation and Service Manual
Publication Number: 638085278 - 7 - © 2002-2014, Cornelius Inc.
INSTALLATION
This section covers unpacking and inspection, selecting location, installing unit, preparing for operation, and
operation.
A. REMOVE ICEMAKER FROM CARTON
1. Keep unit in the upright position, remove carton and pallet from unit and inspect unit for damage. Upon inspection
of unit, if any damage is found, file a claim with carrier immediately.
2. Locate startup card either on outside of container or on plastic liner. Fill in proper information and send one
copy to factory, and other copy to distributor. Postage is prepaid.
B. CABINET REMOVAL
1. Front Panel—Remove 4 screws and pull forward.
2. Top Panel—Remove screws and lift upward. 4 screws 500/700, 6 screws 1000.
3. Side Panel—Remove 4 screws and pull forward.
4. Back Panel—Should not be removed.
C. PREPARATION OF INSTALLATION SITE
1. The refrigeration system on air cooled units requires airflow, so a well ventilated area should be chosen. A min-
imum of 6 inches must be maintained, free of any obstructions, for air intake. A minimum of 4 inches clearance
is required for air exhaust.
2. The unit can be installed either on an ice storage bin or ice dispenser using the proper adapter kits. (Refer to
sales literature for information.) The install is kit provided with each icemaker and adapter kits will supply every-
thing to locate unit correctly. In all cases the icemaker should be sealed all around the base with an NSF listed
sealant. (63804815B)
D. WATER INLET HOOKUP
1. Water Inlet—fitting is a 1/4 SAE male flare located at the rear of the unit. Connect water supply with a 1/4 SAE
flare nut and 1/4” copper or flexible tubing or larger.
2. Water Pressure—Unless otherwise specified, the unit is designed to operate on water pressures between 10
P.S.I. and 90 P.S.I. (NOTE: for pressures above 90 P.S.I. a regulator must be installed.)
3. Condenser Inlet Connections—Use a separate 3/8” copper line or larger water line. Connect to 3/8 FPT fit-
ting on water modulating valve.
4. Filter/Conditioners are recommended on supply lines to icemakers. Never run the water supply to water cooled
condenser through filter/conditioner, it uses up the cartridge unnecessarily and a saturated cartridge can
starve the icemaker causing premature component damage. Separate water supplies are recommended.
NOTE: Unit must be installed per local plumbing code BOCA.
E. DRAIN CONNECTION
1. Overflow Line—is a 3/8” I.D. flexible tube located at the rear of the unit. Extend this line to proper drain.
2. Condenser Outlet—is a 3/8” FPT located on the rear panel.
NOTE: Unit must be installed per local plumbing code BOCA.

Continuous Flow Icemaker Installation and Service Manual
© 2002-2014, Cornelius Inc. - 8 - Publication Number: 638085278
F. ELECTRICAL SUPPLY
1. Power Access—is provided with a 7/8” dia. knockout hole in the rear panel. Route incoming power in conduit,
through rear panel to icemaker electrical control box. Make connections to wires provided in the control box
and ground lug/screw.
2. Fused Line—should be checked and sized according to electrical rating shown on unit nameplate.
G. AUGER ENGAGEMENT
1. Be certain that auger is fully engaged to lower drive and extruding head is fully engaged into evaporator.
H. BIN CONTROL
1. Remove tape holding control to white ice chute and also remove control bracket mounting screw located in
base of unit behind electrical box. (Screw will be used later to fasten bin control bracket to base of unit).
2. Slide control and bracket down chute to base of unit. very carefully
guide control and bracket through 1/2” hole
in front of ice chute. Use CAUTION to be sure control goes into bin, not between base of unit and bin top.
3. Check location of bin control, it should be directly under ice chute at a 45° angle. With control in place use
mounting screw that was removed in Step 1 to secure bracket to base. See Figure 4.
Figure 4. Bin Control
INITIAL START UP, CHECKS AND ADJUSTMENT INSTRUCTIONS
NOTE: Do not start unit before completing installation steps on pages 6 through 8.
Turn on water supply (if unit is water cooled turn water on to condenser also) turn on main power switch (located on
top of electrical box), and make the following system checks:
NOTE: If unit will not start be sure water reservoir is full. Low water safety control must be properly
adjusted to start and shut down unit. If water level drops below bottom of reservoir, unit must shut
down. Adjustment is made by moving magnet up or down.
Water Level—If necessary adjust float by bending float arm up or down as needed, push float assembly down until
unit stops running. Release float and unit will restart. Keep water in reservoir at level line while unit is in operation. See
Figure 5.
Low Water Safety Control—Adjust magnet by bending magnet arm as needed to shut unit down if water level drops
below bottom of reservoir.
Bin Control—Place ice around probe, unit should shut down in one minute. Remove ice from around probe, unit
should start in two minutes.
NOTE: For altitudes over 1000 feet above sea level, adjust range screw (behind end cover). Half
turn max. raises setting 4° F approx.

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Figure 5. Icemaker Float Assembly
Water modulating valve (water cooled units only)—Opening point of condenser water modulating valve should be
set to maintain proper operating pressure in the refrigeration system high side. (see chart on page 15). Closing point
of valve should be set low enough to close valve during compressor stand by periods. To raise, turn counterclockwise,
to lower turn clockwise.
NOTE: If any of these checks or adjustments cannot be achieved, refer to Troubleshooting Section
of this manual or call for factory assistance at 1-800-Service.
Figure 6. Schematic and Wiring Diagram WCC2001-A and WCF2201-A

Continuous Flow Icemaker Installation and Service Manual
© 2002-2014, Cornelius Inc. - 10 - Publication Number: 638085278
Figure 7. Schematic and Wiring Diagram for WC500-A, WCC 500-W, WCC700-A, WCC700-W,
WCF510-A, WCF510-W, WCF710-A and WCF710-W
Figure 8. Schematic and Wiring Diagram for WCC701-A, WCC701-W,
WCF1001-A, WCF1001-W, WCF711-A, WCF711-W, WCF1101-A and WCF1101-W

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Figure 9. Schematic and Wiring Diagram WCF1101R, WCC1001R, WCF1102R, & WCC1102R
Figure 10. Schematic and Wiring Diagram WCC502, WCC702, WCC1002, WCF512, WCF712, & WCF1102

Continuous Flow Icemaker Installation and Service Manual
© 2002-2014, Cornelius Inc. - 12 - Publication Number: 638085278
Figure 11. Schematic and Wiring Diagram WCC2001-R and WCF2201-R

Continuous Flow Icemaker Installation and Service Manual
Publication Number: 638085278 - 13 - © 2002-2014, Cornelius Inc.
GUIDE TO SERVICE
ICEMAKER CLEANING AND SANITIZING PROCEDURES
Do not use any of the ice made during cleaning operations.
Clean and sanitize ice storage area when cleaning icemaker.
1. Turn off Machine.
2. Shut off water supply.
3. Remove ice from storage bin.
4. Mix approved cleaner (2 gallons as directed). Recommended cleaner: Calgon Corp. of Virginia Chemicals,
ice machine cleaner. Mixture: 3-1/3 ounces per gallon of water.
5. Clean auger/diverter assembly and ice transition/drop tube in a sink using cleaner mixture and reinstall in ice-
maker. Using cleaner, wipe down the dispense tray.
6. Turn machine on and add cleaner solution to water level control until 2 gallons have been used.
7. Turn on water supply and run machine for 15 minutes.
8. Turn off machine and remove all ice.
9. Sanitize using household liquid bleach (50 ppm chlorine). Mixture: 1 fluid ounce per gallon room temperature
water. 2 minute exposure time.
10. Sanitize auger/diverter assembly and ice transition/drop tube in a sink using sanitizing solution and reinstall in
icemaker. Using sanitizer, wipe down the dispense tray.
11. Fill icemaker with sanitizer by slowly pouring solution into water feed reservoir until full. Solution will drain
through overflow tube. Do not run machine. Allow to air dry.
12. If icemaker is used in conjunction with ice dispenser or storage bin, follow manufacturer’s recommended clean-
ing instructions at this time.
MAINTENANCE
Preventive maintenance can increase the trouble free life of your icemaker. Many authorized service agencies offer
service contracts for your icemaker. Contact your local distributor for further information.
Monthly
1. Clean the condenser. Use a brush, vacuum cleaner or blow from inside with air or CO2gas.
2. Inspect water feed reservoir at lease once a month until a definite pattern for cleaning and sanitizing has been
established.
Quarterly
This is the maximum period of time between cleaning and sanitizing the icemaker. In addition to recommended
monthly procedure, and if a more frequent cleaning and sanitizing pattern has not been established, unit must be
cleaned and sanitized.

Continuous Flow Icemaker Installation and Service Manual
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Semi-Annually
Semi-Annually in addition to all previously established service procedures perform the following:
1. Check for water leaks in tube connections, water fittings and lower icemaker water seal.
2. Check drain tubes for clogs and aged tubes. Replace if tubes are stained or brittle.
3. Check for signs of condensation. Clean where necessary and replace insulation properly.
4. Check safety circuits for proper operation.
5. Check refrigeration system (see page 15).
6. Check unit for abnormal noise. Tighten machine and cabinet screws, if necessary.
7. Check white upper bearings on auger assembly. If bearings are less than 1/16” thick, replace. See Figure 12.
Figure 12. Upper Nut and Bearing Assembly

Continuous Flow Icemaker Installation and Service Manual
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WATER LEVEL CONTROL
HOW WATER LEVEL CONTROL WORKS
When water is introduced through the inlet fitting the float rises. the float pushes against a lever which in turn forces
the poppet assembly against the inlet fitting valve seat which seals the water off. See Figure 5. Before the water inlet
is sealed the safety switch is operated. In the event of a water failure the float would drop down and operate the safety
switch to shut off the machine.
If the water level control does not shut off and seal at level, as indicated, be sure inlet pressure does not exceed
recommended factory operating range.
Under ordinary circumstances adjustment should not be necessary providing it was properly adjusted when the unit
was installed or relocated. If however, the control becomes inoperative, repair or replace it. See Start-Up Adjustment,
page 7.
PURPOSE
1. To automatically maintain proper water level in the evaporator when unit is running and making ice.
2. A safety switch is operated in the event of an interruption in water supply. The switch shuts off the electrical
power to the icemaker and its refrigeration system. Switch will reset as soon as cause of water failure has been
corrected and proper water level in icemaker has again been reached.
3. The transparent bowl not only provides a visible check of water level, but also is a good guide to the internal
conditions which exist within the icemaker assembly itself. (See Cleaning Procedure.)
TOREPLACE WATER LEVEL CONTROL
1. Shut off the water supply, Shut off the main power switch or unplug the ice dispenser from electrical outlet.
2. Remove the flexible tubing from bottom of water level control and drain water from water level control and evap-
orator.
3. Remove flexible tubing at bottom of water level bowl connected to the overflow.
4. Hold water inlet fitting with proper tool to prevent it from rotating when disconnecting the water inlet.
5. Remove the wing nut holding the water control to its mounting bracket. Control can be removed by lifting
straight up.
TOREPLACE WATER LEVEL SAFETY SWITCH
1. Shut off the main power switch or unplug the ice dispenser from electrical outlet.
2. Unplug molex connector connecting switch to electrical box.
3. Remove the two (2) screws anchoring the water level safety switch to the bottom of the water level control
mounting bracket.

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REFRIGERATION SYSTEM
NOTE: Thermostatic Expansion valve is non-adjustable on all models.
REFRIGERATION SYSTEM ADJUSTMENTS
A complete understanding of the icemaker and hermetic refrigeration system is necessary before any adjustments
are made. The refrigeration technician must use high and low side pressure readings, water and air temperatures,
plus general conditions of cleanliness to assess the refrigeration system status when making any adjustments.
All icemaker products are tested and adjusted at the factory prior to shipment where the ambient temperature ranges
from 65° to 90° F, depending on the season of the year.
Whenever a new icemaker product is initially installed and started-up, it is imperative that the start-up operation make
the following checks and/or readjustments for local conditions.
EXPANSION VALVE
You will find a thermostatic expansion valve on icemakers, which is used to control the amount of refrigerant flowing
through the evaporator. Improperly installed or defective expansion valves may cause low production, soft ice,
squeaking from evaporator and excessive load inside evaporator.
By using general refrigeration system troubleshooting along with the pressure charts you can easily determine
whether or not the expansion valve is working properly.
ADJUSTMENT AND TROUBLESHOOTING
When troubleshooting the expansion valve you must first be sure you have adequate water flowing into evaporator, a
clean condenser, unit is properly ventilated, and system is properly charged and free from any restrictions. Also be
sure compressor is operating properly.
Second, take reservoir water temperature and air temperature from condenser inlet and determine at what pressure
unit should be running. Machines are equipped with thermostatic valves, there is NO adjustment. If correct pressure
cannot be obtained, first be sure system has time to stabilize 10-15 minutes. Second, be sure sensing bulb is located
at 12:00 position on outlet side of evaporator about 3-4 inches away from evaporator and be sure to insulate well and
clamp tightly to tubing. If system pressures are still not adequate, take a second water and air temperature reading
and go over other parts of system for possible problems. If proper charge is questionable evacuate and recharge to
nameplate and leak check. If valve still malfunctions replace valve.
When replacing valve be sure to bleed refrigerant gas from low side port so as not to lose refrigerant oil. Use general
refrigerant system practices when replacing and recharging unit. After new valve is in place, go through previous
monitored adjustments and troubleshooting to be sure valve is functioning properly.
NOTE: Units with thermostatic expansion valve-valve is located on bottom refrigerant line.
Sensing bulb is located on top refrigerant line. On water cooled units adjust condenser modulating
valve before troubleshooting expansion valve.
REFRIGERANT
TYPE R404A
±10 lbs. Discharge Pressure
Water Temperature (°F)
WCC 500 WCC 700 WCC 1000 WCC 2200
40 65 90 40 65 90 40 65 90 40 65 90
Air Temperature (°F)
50 162 166 168 174 177 180 170 171 172 200 201 203
60 188 192 194 202 205 208 198 199 200 218 219 220
70 214 218 220 230 233 236 226 227 228 251 253 254
80 245 249 251 265 269 272 261 263 264 297 298 300
90 275 279 281 300 304 307 296 298 299 308 330 332
100 309 313 315 328 334 340 324 328 332 362 364 366