Cornelius 700 - Series User manual

Service Manual
SERIES 700
MODULAR
CUBED
ICE MAKER
6/90
161951804

INTRODUCTION
We have strived to produce a quality product.
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 icwakers.
The design has been kept simple,
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
a1 1 correspondence to:
- -
A Product of IMI Cornelius lnc.
One Cornelius Place
Anoka,
MN 55303-1592
Phone [phone]
Fax
61 2-422-3232
PRINTED IN USA
1

TABLE OF CONTENTS
INTRODUCTION
.......................... 1
TABLE OF CONTENTS ....................... 2 ..
SPECIFICATIONS ......................... 3
INSTALLATION AND START-UP ................... 4-10
REFRIGERANT CIRCUIT REMOTE CONDENSER UNITS ........... 11
ELECTRICAL CIRCUIT SEQUENCE OF OPERATION ............ 12
ADJUSTMENT FOR ICE BRIDGE THICKNESS .............. 12
ADJUSTMENT AND CHECK-OUT FOR OPTICAL HARVEST . BIN SENSOR ... 13
WIRING AND SCHEMATIC DIAGRAMS ................. 14-16
SANITIZING AND CLEANING PROCEDURE ............... 17
WATER TREATMENT
........................ 18
WINTER STORAGE ......................... 19
CLEANING THE CONDENSER ..................... 19
SERVICE ANALYSIS ........................ 20-22
INSTRUCTIONS FOR REMOVAL AND RE-INSTALLATION
OF SOLID STATE CONTROL
.................. 23
PARTSLIST ........................... 24
ILLUSTRATED PARTS BREAKDOWN .................. 25
REMOTE CONDENSER ILLUSTRATED PARTS BREAKDOWN .......... 26
2

Specifications
:Remocc-Air)
NOTE: REMOTE
UNJTDESJGNED
FOR USE WITH
CS* I20 REMOTE
CONDENSER
SERIES 700
ouoide
& 'F
SO' 625 353 5 30
70' 613 543 5 20
570 505 480
I IO' 500 4 50 425
MU VIEW
6 WIN
C €L€ClM%L CONNECTION
I I I I I
umou ww
--
ar.n
METRICDIMENSIONS
SHOWN IN PARENTHESES
L
COMPRESSOR ELECTRICAL RATING .......... 1 H. P.
COMPRESSOR MODEL ................ Tee. AJ-7510K
CONDENSER. ................... Air or water cooled
REFRIGERBNT CHARGE
............... Air cooled-31 02. R502
Water cooled-24
02. R502
REFRIGERANT CONTROL. ....
TXV SUPERHEAT SETTING ...
VOLTAGE. ..........
INLET WATER SUPPLY .....
TOTAL AMP DRAW .......
DRAIN STUB ....
CRANKC AS E PK E'S S'u <E KE GUL AT o R
....
....
....
....
....
....
SETTING
Remote ai r cooled-270
TXV
6O
3/8" SAE male flare
11.5
T/2" 0.0. tube
50 PSI
208-230/ 60/ 1
R502
3

IN$TALLAlION INSTRUCTIONS
A. UNPACKING
1. Uncrate machine and/or bin by removing the staples from around the bottom
of cardboard crate and
lift off.
Remove bolts fastening the crate skid to the bottom
of the unit.
auxiliary.legs have been purchased for the bin, they should be installed
at this time.
2.
If
8. LEVELING
If legs are used,.adjust the leveling legs of the storage bin until the
unit is level and all four
(4) legs are insolid contact with the floor.
Leveling is very important to obtain proper draining and to maintain the ;
proper level in the water pan of the ice cuber.
NOTE:
If the bin is to be installed flush to the floor, the machine must
be sealed to the floor
with an approved mastic such as Sears 13803-0 Caulk,
Dow R.T.V. 101, 102 or G. E, 731, 732. This is an N.S.F. requirement and
is the responsibility of the installer.
c. UNIT LOCATION
1. Allow at least a minimum of six (6) inches at the rear and side of the
ice machine for proper
air circulation.
This unit has been designed to be installed in
an indoor location wnich
temperatures should never exceed
100 degrees nor fall below 50 degrees.
(Temperatures above 100 degrees
will cut the ice making capacity below
an economical level
; temperatures below 50 .degrees will cause a
malfunction of thermostatic sensors.
'i
F
2.
is clean and which can be adequately ventilated; the air and water
3. The unit should be located where air circulation is not restricted.
The condenser
The unit should not be located near a kitchen grill.
grease vapors
will deposit grease on the condenser.
should
always be kept clean.
Air which contains
D. UNIT SET-UP
1.
2.
3.
Take off front panel of machine and remove hardware bag or service
manual envelope with the water strainer enclosed.
Mount the ice maker to the top
of the ice storage bin or adapter in
the proper position over the ice drop opening. The ice maker must
then be sealed both on the outside and the inside bottom edges with
an approved
N.S.F. mastic such as Dow Silastic #732, 734 or General
Electric
RTV #101, 102.
responsibility of the installer.
This is an
N.S.F. requirement and the
Remove shipping tape
from evaporator curtains.
4

1NSTALLATION 1NSTRUCTlONS CONT'D.
F.
G.
MAKE ELECTRICAL POWER SUPPLY CONNECTION
Requirements: 208-230/60hz. 1 ph. or 22OV 50ht. 1 ph. when used
REFER TO SERIAL PLATE FOR MINIMUM CIRCUIT AMPACITY AND MAXIMUM TIME
DELAY FUSE SIZE.
ALL WIRING MUST CONFORM TO NATIONAL AND LOCAL ELECTRICAL CODES.
MAKE PLUMBING CONNECTIONS
Water supply - (Install per ldcal codes)
The
water inlet connection to the unit is a 3/8" flare male connections
located
at the rear of the ice machine.
NOTE:
should be installed in the water inlet line between the water shuteoff valve
and the strainer.
If the water pressure exceeds 50 pounds, a water pressure recjulator'
Install
a reducer fitting on the shut-off valve to accomodate the water
strainer, which is supplied
with each ice machine and MUST be used.
the water strainer with the arrow in the proper direction of flow and with
the clean
out plug down,
Connect
either 3/8" or 1/2" copper tubing between the water inlet fitting of the
ice machine
and the water strainer.
Install
This is very important for cleaning.
For water cooled units, two water inlet connections are provided; one for
the ice making {evaporator) section which is located on the back of the
machine
and is a 3/8" flared connection. The other
is for the water cooled
condenser. The reason
for the separate water inlet connections is that some
installations use
a water tower for cooling the water used in the water-
cooled condenser
and some installations use treatedwater (filtered) for
the ice making inlet water connection.
(incoming)
to the 3/8" male flare connection on the back of the unit that
supplies water to the water regulating valve inside.
The setting
of the water regulating valve from the factory should be 120
pounds for R-12 units and 250 pounds for R-SO2 units.
out water lines before starting unit.
done at installation.
Be sure to install water line
NOTE:
Adjustments, if necessary, should be
Always flush
H. DRAINS
Provide a suitable trapped open drain as close as possible to the area where
the ice maker is
going to be installed.
1-1/4" trapped open drain.
cooled units, one
for the storage bin and one for the Dump Valve drain hose.
This may be an existing floor Or a
Two separate drain lines are required for air
An additional separate drain line will be required for water cooled units
from the outlet of the condenser coil to the drain.
lines
with a good fail to the open drain.
ALL PLUMBING MUST BE INSTALLED IN ACCORDANCE WITH LOCAL CODES.
NOTE:
AND
DRAIN LINE.
OF CARPETS OR HARDWOODS.
Run all gravity drain
Iff SOHE CASES IT HAY BE NECESSARY TO INSULATE THE WATER SUPPLY LINE
CONDENSATE DRIPPING TO THE FLOOR CAN CAUSE SERIOUS STAINING
'%
6

INSTALLATION INSTRUCTIONS CONT'D.
E. REMOTE CONDENSERS
Remote condensers should be
installed above the ice machine and 3n a level
configuration.
they are connected to the ice making unit by copper tubing
and line valves. The female
half of the line valve ismounted on the ice
making unit and
the remote condenser. The male half
i5 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 &it and the installer will mount them on the tubing he provides.
1.
NOTE:
STANDARD REFRIGERATION PRACTICES FOR VERTICAL LINES TO ASSURE POSITIVE
OIL RETURN
TO THE CUMPKESSOR. VERTICAL LIFT TO BE NO MORE THAN 15 FEET,
WHEN VERTICAL LINES ARE INVOLVED INTHE INSTALLATION, FOLLOW',
2. NOTE: WE DO NOT RECOMMEND TUBING HUNS OF MORE THAN 40 FEET.
3.
NOTE: THE SEALS FOR THE LINE VALVES
WILL BE FOUND INAN ENVELOPE
ON THE REMOTE CONDENSER. MAKE SURE THEY ARE USED.
4. NOTE: REMOVE CAP PLUGS
FROM ALL LINE VALVES BEFORE MAKING VALVE
CONNECTIONS WITH THE SEAL.
5.
NOTE: A LOW VOLTAGE ELECTRICAL CONTROL CIRCUIT MUST BE FIELD WIRED
BEWEEN
THE ICE MACHINE AND THE REMOTE CONDENSER RELAY. THOSE WIRES
SHOULD BE RUN WITH THE TUBING DURING INSTALLATION. REFER TO APPLICABLE
WIRING
DIAGRAMS.
6. 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 THROUGH 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 180 and 200 PSI for R-502 in the receiver in
cold ambient conditions to insure a good harvesting or defrosting of the ice
slabs on the evaporator. Because of this valve some liquid refrigerant wi 11
be held in the condenser.
NOTE:
TOTAL PRESSURE DROP OF 14 POUNDS OR MORE IS WATED BETWEEN THE ICE MAKING
UNIT, THROUGH THE TUBING TO THE REMOTE CONDENSER, THE CONDENSER AND THE
RETURN TUBING TO THE
ICE MAKING UNIT.
THE HEAD PRESSURE CONTROL VALVE WILL NOT OPERATE CORRECTLY WHEN A
The remote condenser requires a separate pow supply from the ice making
unit. Refer
to the remote condenser wiring diagram.
5

lNSTAlLATION INSTRUCTIONS CONT'D.
~~ I? * ~ I
yrs L* i
a
DRAIN CONIVECTION INSTALLATION INSTRUCTIONS
Taking care not to kink or
collapse vinyl
tubing at any
point, route tubes to any spen,
trapped or vented floor drain.
Run Wing to drain separately.
Dcr not tee any drain hoses
together.
Add drain cubing
required to reach floor drain.
I.
ADJUSTMENT OF WATER LEVEL IN RESERVOIR
With the water supply turned ON and the power supply OFF'adjust
float to maintain water level%" below the support web insidereservoir
(See Illustration Below)
-Adjust here
Water
level
Floa t ass emb 1
Reservoir drain cap
WAKNINC:
Ice bi;lkcr ~i11 noc opcracc properly when w;iCcr supply
tempcraturc
is below 50'F or above 100'1'.
pressure must not exceed SO PSI.
IJ;itcr supply
7

I N S,,,T A L L A T I 0 N I N S T R U C T I 0 N S C 0 N T ' D.
J. STARTING THE UNIT
After the ice cuber has been unpacked and leveled and all plumbing and
electrical connections have been made, start the unit and check for proper
opera
ti on.
A cuber has three separate circuits:
A. The water circuit
B. The refrigerant circuit
C. The electrical circuit
1.
Start checking the water circuit by making sure that there are no thread
or flare joint leaks, either outside the unit or in the compressor section.
Next check the water flow over-the evaporator and make sure that all boles
in the water distributor are open, and that there is no undue splash or
loss of water into the ice bin.
Also check to see
if the float valve is functioning properly and the
correct water level is being maintained. Re-adjust
if necessary.
2.
Check the refrigerant circuit by making sure that the condenser fan is
running.
(Feel the casing for vibration.)
(This
will be evident by air noise.)
Is the compressor running?
Is the evaporator getting cold?
3.
Check bin-harvest switch operation. (See proceedure in manual)
8

STACKING KIT. INSlALLATION INSTKUClIONS . I, ~”. ”-
. .C*Lt. --
‘4
1.
2.
3.
4.
5.
6.
8.
9.
10.
11.
12.
13.
14.
15.
16.
7.
5 - #857 screw 8/32 x 3/8
2 - #39449 tie strap
1 - #39450 ice slide diverter
1 - #39454 retainer shield assembly
1 - #39379 interface cable
PLEASE SEE ILLUSTRATIONS FOR REFERENCE FOR THE FOLLOWING INSTALL PROCEDURE
After the bottom unit of the stack has been positioned on the bin, the sealing
gasket supplied
with second unit must,be cemented to the base. Nearly any
adhesive can be used, however it should not be water soluble.
requirement
and the responsibility of the installer. This
is an N.S.F.
Remove the top and front panels from both units.
Mount the unit on top of the bottom one of the stack.
to stack more than one unit.)
Remove evaporator curtain cover.
N/A
(It is not recommended
Put the ice slide diverter through the top unit evaporator section and hook over
the
front edge of the top unit water reservoir.
Secure ice slide diverter
to the back wall of the lower unit with a provided
screw.
Insert the retainer shield
from the front of the lower unit evaporator section
and align the holes to the diverter and support bracket and secure with the
screws provided.
Remove electrical
box covers from both unit.
Remove lowest grommet from the left side of each electrical box .
Insert the interface cable through each hole and insert into the split grommets.
&&,the cable
will fall across the front of both machines with the front
covering the cable,
Reinstall gromnets
into electrical box.
Plug the interface cable end into the open middle left socket on each solid
state
board being careful to make sure of a good connection.
Replace electrical
box covers.
Plug the weld nut hole found to the right of the compressor with RTV sealant.
Remove the screws
from both sides of both units and insert the tie straps.
einstall
screws.
When reinstalling the front panels, take care in the positioning of the
interface cable.
9

EX PAN S I 0 N
VALVE
-
EVAPORATOR I '$
W
ACCUM.
I I
u
CHECK
VALVE I
U
z RECEIVER
VALVES
'INE &
REMOTE
CONDENSER
11

ELECTRICAL CIRCUIT
SSN
An L.E.D. digit display mounted on the solid state control board will show
a status number 6,1,2,4,
&6 and a decimal point to indicate what is
happening
in the operation of the unit.
The electrical. sequence of operation you will see on the digit display for
a normal ice making cycle will be as follows:
The status number
0 will be shown telling you the unit is making ice.
solid state control
DELAYS the start of the water pump until the evaporator
temperatures reachesm. Approximately six minutes after the start
up
in the freeze cycle a decimal point will appear to the lower right of the "0"
to tell you that the evaporator sensor has been switched on. After the
evaporator temperature has pulled down low enough for the correct amount of
ice to be
on the evaporator, the decimal point will begin to flash and stay
flashing for approximately 20 seconds. If evaporator stays below the set+
point, the harvest cycle will start. A number "1'' on the digit display will
indicate that the machine
is in its harvest cycle with the hot gas valve
open. The water pump continues to operate and the water dump solenoid valve
is
now open. The water pump shuts off approximately 15 seconds later after
the water reservoir
is pumped out.
The
PLEASE NOTE:
fan motor will be cycled on
and off through the condenser sensor
and solid
state control board. The fan cycling pressures
in relation to the temperatures
sensed will be approximately
180# for cut out and 230# for cut in of the
fan motor.
During the freeze cycle
in low ambient condition the condenser
ADJUSTMENT
FOR ICE BRIDGE THICKNESS
An ice bridge connecting
all cubes is necessary for a proper harvest or
discharge of cubes from the evaporator.
To increase ice "bridge" thickness carefully turn adjustment screw counter
clockwise no more than one turn at
a time. -Wait and-checkthickness before
re-adjusting
.
HERE
n
fNCREASE
ClRCUlT
BOARD
12

I4
. 1 I- < ADJUSTM,EN,T AND CHECK-OUT
S W I T C H'E S
F 0 R--H-Tx-$*E S T '- B I~N*
.m
'1
B
0
EOCE Of
. EVAP W AT OR
PROXIM I TY
' SWlTCH
ACORN
HUTS
CHECKOUT PROCEUDRE
Turn on the ice machine and move the evaporator curtain(s)away from
the evaporator(s). The ice machine should then shutoff
in approximitly
8 seconds.(See detail A&B)
Slowly let the evaporator curtain(s) move back toward the evaporator(s)
until the bottom edge
of the curtain(s) is at least at the bent edge
of the water reservoir
or closer to the evaporator. With the curtain(s)
at that position, the machineshould start.(See detail
C)
ADJUSTMENT PROCEDURE
If adjustment is necessary,loosen acorn nutsand move proximity switch
closer to the curtain(s)and make sure the curtain
is properly mounted.
(See detail
A
1
Re-check per above proceedure.
13

430° Manual Rcsct
Control (W/C only)
Switch
High Pressure
pll-
I
I RCV-1 I
+
=+:; Optional -
7: Remote
-* '*Alarm Box
i
I I I 1 HornLioht Ouiet
ACAWC-700-MH
BL
I
208/230 VOLTS 60 HZ
The solid stote control OEL.4 YS the start of
the voter oumD until the evogorator
temperature reache:, 20 F.
4!!&%3
Uhite ond block connector blocks ore
'KEVED' ond HUST be inserted correctlu
on circuit boord-pm p$
14
PART HO 39149
fiRTUORK no. 50492
REV. H

AD
rankcase Heater Compressor
Comoressor I
Outlet Box
1
-
Pump
Water
*
BL -
I I -rAlarm Box ,
RCV-1
Rev. E II
ORRD 4))) # :p
To stacked Unit*DC2 I Control
DCZ
if required I
Horn Light Ouiet
Switch
I
Switch 432=yDC4 rUH I I
RC-700-MH
The solid state control DELAYS the start of
e
the voter pump until the evogorotor
temperature reoches 20 F,
Uhitr and block connrctor blocks ore
'KEYED' ond RUST be inserted correctlu
on circui t board-- D
PRRT NO. 39362
f3ATUORK NO. 50498
REV. H
15

r RD I
Compressor Compressor I
RD
ON 430" Manual Reset
High Pressure
Control (W/C only)
YYY
@
BL
Water
Pump
II.
Sensors I I,
6
Fan motor
( A/C only)'
I
Dump
+
\- -
-5 -, . Optional
G! Remote
Horn light Quiet
Switch 1
230 VOLTS SO HZ
ACtiWC-7OO-MH
The aolid atate control DELA Ys the Btort of
the voter DumD until the evagorator
temperoture
reachea 20 F.
l4!Eis
Uhite ond block connector blocks ore
'KEYED" ond RUST be inserted correct lu
on circuit board.
16
PART fl0. 39341
RRTUORK NO. 5049'7
REU. C

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
SANITIZING AND CLEANING PROCEDURE
Remove front panel to gain access to the on-off-clean switch.
Push
switch to "cleann and allow the ice on the evaporator to
release or melt away.
Remove
all ice from storage bin.
Mix a sanitizing solution of 1/4 02. "Calgon Ice Machine
Sanitizer"
to one gallon of water, Using a non-metallic
bristle brush scrub the following:
a.
b.
Inside surfaces of ice bin including top and door.
Inside surfaces of the icemaker to include evaporator
section in the ice machine including the top, front panel
and evaporator splash curtain, c
c, Make sure splash curtain is correctly positioned.
Add 2 oz. of "Calgon Nickel-Safe Ice Machine Cleaner"
directly into
water reservoir.
45 minutes.
Circulate for approximately
Remove cap from reservoir
drain and allow cleaner to drain
away. Replace cap.
Fill reservoir with clean fresh water, circulate for
approximately
1 minute,
allow water to drain away.
Remove cap from reservoir drain and
Repeat three times.
Flush all waste water from ice storage bin with clean fresh
water .
Push switch from ncleann to
"on" position.
Replace front panel.
Adj us t here
Water level
Floar assembly
Reservoir drain cap
\
17

WATER TREATMENT
Automatic ice-making machines can quit working for any number of reasons,
mechanical
, electrical or faulty refrigeration, but water problems foul them
up faster than almost anything else. While ice machines vary in design, you
can apply these water treatment tips to all of them.
1.
START WITH THE WATER
The mlneral content of water varies in different areas and as the
chart shows, high hardness and alkalinity counts combine to form
insoluble calcium carbonate or lime scale.
If this condition is
constant, the intake water must be treated constantly to pre’vent
scale formation in the ice machine.
2. PREVENT LIME SCALE FORMATION d
We recomnend the installation of a Calgon Microment Feeder on the
incoming water line.
with a capacity of 400-450 lbs. per day. Fill the feeder with 6R
Micromet, the slowly soluble poly-phosphate which lasts six months
before renewing the
8-02. charge.
No.
X-8B Feeder is recommended for ice machines
Constant treatment with
6R Micromet will control lime scale and
prevent minerals from sticking to the freezing surfaces in ice
machines.
ice cubes, efficient, automatic production.
Result
- smooth movement of ice slabs, good harvest of
3.
REMOVE OBJECTIONABLE TASTE OR ODOR
If the bad taste or odor is traceable to the water source, install a
Calgon Fine Carbon Filter to the incoming water line. The No.
1-1/28
Fine Carbon Filter is ideal for machines making up to 500 pounds of
ice per day and will remove bad taste, odors, and problems caused
by chlorine in the water supply.
cause odor problems and these growths can be removed by the use of
liquid ice machine cleaner.
In some instances, slime growths may
4. SERVICE REGULARLY
A service program to clean the ice machine at regular intervals and
check on filter and feeder charges is important.
will assure adequate water treatment, reduce emergency calls and aid
in the trouble-free performance of automatic ice making machines.
In the long run,
it
18

I
1 I.
WIN,TER S?QRAG,E
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.
I
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.
CLEANING THE CONDENSER
In order to produce at full capacity, the refrigeration condenser must be
kept clean. The frequency of cleaning will be determined by surrounding
condition.
every
two months.
Remove
the lower front panel of the machine. With a vacuum cleaner, remove
all accumulated dust and lint that has adhered
to the finned condenser.
A good maintenance plan calls for an inspection at least
#
CAUTION: CONDENSER COOLING FINS ARE SHARP. USE CARE WHEN CLEANING.
1.
If the condenser is being cleaned from the back of the machine, remove
all accumulated dust, dirt etc., that has adhered
to the finned
surface
with a vacuum cleaner.
2. If the unit is being cleaned from the front, remove lower panel, turn
the power switch off and blow through the finned surface of the
condenser past the fan blade to remove accumulated dust, etc.
%%4
19