Cornelius CR-1200 User manual

12/1/94166240004
Revised: 3/4/96
THE HOTTEST MACHINES ON ICET
I" Series
Ice Cube Machine
SERVICE MANUAL & MAINTENANCE GUIDE
(Inc udes Insta ation Instructions)

i166240004
TABLE OF CONTENTS
Page
MODEL AND SERIAL LOCATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“I” SERIES CUBER 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERIAL NUMBER EXPLANATION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SPECIFICATIONS 3 – 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
GENERAL 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FREIGHT DAMAGE CLAIMS PROCEDURE 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF EQUIPMENT 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIPMENT SET-UP 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSER INSTALLATION 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
IACS/IWCS 227 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUMBING CONNECTIONS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION CHECK POINTS 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START-UP AND CHECK OUT 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OWNER -OPERATOR 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING PROCEDURES 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREP – CLEANING 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE WATER SYSTEM AND EVAPORATOR 16. . . . . . . . . . . . . . .
SANITIZING PROCEDURES 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUMP CYCLE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING BRIDGE THICKNESS 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOTAL ICE CAPACITY 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE PRODUCTION CHECK 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LED INDICATORS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CIRCUIT BOARD DIAGNOSTIC PROCEDURE 22. . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESTORING ICE THICKNESS POTENTIOMETER TO FACTORY SETTING 23. .
MAKING ADJUSTMENTS 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPONENT FUNCTION (CIRCUIT BOARD ETC.) 24. . . . . . . . . . . . . . . . . . . . . . . . . .
TEST PLUG 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
RESET OPERATION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATOR SWITCHES 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HARVEST SAFETY TERMINATION 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLTAGE CHECKS 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EVAPORATOR PROXIMITY SWITCH 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
VOLTAGE SELECTOR SWITCH 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STACKING CABLE 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSOR [THERMISTOR] DIAGNOSIS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SENSORS 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CONDENSER FAN CYCLING CONTROL 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
THERMOSTATIC EXPANSION VALVES 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STARVING TXV - PRODUCT SYMPTOMS 26. . . . . . . . . . . . . . . . . . . . . . . . . . .

ii
166240004
TABLE OF CONTENTS (cont’d)
Page
FLOODING TXV - PRODUCT SYMPTOMS 26. . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER REGULATING VALVE 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SERVICE STEM VALVES 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
MOISTURE CONTAMINATION 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR CONTACTOR 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR & STARTING COMPONENT CHECK-OUT PROCEDURE 28. . . .
RELAY 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
POTENTIAL –28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CURRENT –28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CAPACITORS 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LEAK DETECTION 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SYSTEM EVACUATION & RECHARGING 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SELF-CONTAINED PRODUCTS 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HIGH PRESSURE SAFETY SWITCH 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR RUN-ON 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUBER NOT OPERATING 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUBER NOT OPERATING, INDICATOR LIGHTS “OFF”, NO POWER
TO CIRCUIT BOARD 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUBER NOT OPERATING,
INDICATOR LIGHTS “OFF”, POWER TO THE CIRCUIT BOARD 51. . . . . . . . . . . .
COMPRESSOR DOES NOT RUN, CIRCUIT BOARD
INDICATOR LIGHTS “ON”51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
COMPRESSOR RUNS BUT DOES NOT COOL, CIRCUIT
BOARD INDICATOR LIGHTS “ON”52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUBER REMAINS IN THE FREEZE CYCLE 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CUBER REMAINS IN THE HARVEST CYCLE 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SUCTION LINE THERMISTOR OPEN (STARTS IN HARVEST) 52. . . . . . . . . . . . . .
PROXIMITY SWITCH LIGHT “OUT”52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PROXIMITY SWITCH LIGHT “ON”52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LONG FREEZE CYCLE WATER FLOW ASSOCIATED 53. . . . . . . . . . . . . . . . . . . . .
LONG FREEZE CYCLE GENERAL 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LONG HARVEST CYCLES 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ICE WEIGHT LIGHT AT TOP OF PLATE AND HEAVY AT THE BOTTOM 54. . . . .
SOFT WHITE ICE OR WATER PUMP NOT PUMPING 54. . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS REMOTE CONDENSERS 71. . . . . . . . . . . . . . . .
REMOTE CONDENSER LOCATION 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAD PRESSURE CONTROL [HEADMASTER] 77. . . . . . . . . . . . . . . . . . . . . . . . . . .
REMOTE SYSTEM EVACUATION/RE-CHARGE 78. . . . . . . . . . . . . . . . . . . . . . . . . . .
LIST OF FIGURES
LIST OF TABLES

1166240004
12/1/94
Rev 3/4/96
MODEL AND SERIAL LOCATION
“I”SERIES CUBER
Condenser Discharge Air
Deflector (as required)*
Bin Adapter (as required)*
Model/Serial
Number Location
*Bin adapters and condenser discharge air deflector may be equipped depending on your location or the size of
the storage bin.
Record the model number and the serial number of your ice equipment. These numbers are required when re-
questing information from your local dealer/distributor/service company.
Model Number –Date Installed –
Serial Number –Purchased From -
SERIAL NUMBER EXPLANATION
AA 95 01 BC 0001
Number –4 digit number, 0001 –9999
Product Code –2 digit alpha
Month –2 digit numerical month designation
Year –2 digit year designation
Engineering Change Level –1 or 2 alpha designation

2
166240004 12/1/94
Rev 3/4/96
REMOTE CONDENSER SPECIFICATION
MODEL CR800 CR1200 CR1400
Volts 208/230 208/230 208/230
Phase 1 1 1
Hertz 60 60 60
Amps 1.0 1.0 1.0
Output, HP 1/6 1/6 1/6
Max. fuse size, Amps (HVAC circuit breaker
required) 20 20 20
ICE CUBER SPECIFICATION
MODEL IAC322/330
IAC227
IWC322/330
IWCS227 IAC522/530 IWC522/530
UNIT
Volts 115 115 115 115
Phase 1 1 1 1
Hertz 60 60 60 60
No. Wires 2+ground 2+ground 2+ground 2+ground
MIN. CIRCUIT
Amps 20 20 20 20
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 20 20 20 20
REFRIGERANT
Type R404A (HP62) R404A (HP62) R404A (HP62) R404A (HP 62)
Weight (oz) 17 15 26 23
Weight (g) 482 425 737 652
COMPRESSOR
Volts 115 115 115 115
Phase 1 1 1 1
Hertz 60 60 60 60
LRA 51 51 59 59
RLA 11.5 11.5 11.6 11.6
CONDENSER FAN MOTOR (Air-Cooled Systems only) of
AIR CIRCULATION FAN MOTOR (Water-Cooled and Remote Systems only)
Volts 115 115 115 115
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 1.7 0.38 1.75 0.38
Watts 50 6 50 6
WATER PUMP
Volts 115 115 115 115
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 0.88 0.88 0.76 0.88
HP 1/40 1/40 1/40 1/40

3166240004
12/1/94 Rev 3/4/96
SPECIFICATIONS –60 HZ
ICE CUBER SPECIFICATION
MODEL
IAC322E60
IAC330E60
IACS227E60
IWC322E60
IWC330E60
IWCS227E60
IAC522E60
IAC522E60L
IAC530E60
IAC530E60L
IWC522E60
IWC522E60L
IWC530E60
IWC530E60L
UNIT
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
No. Wires 2+ground 2+ground 2+ground 2+ground
MIN. CIRCUIT
Amps 15 15 15 15
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 15 15 15 15
REFRIGERANT
Type R404A(HP62) R404A(HP62) R404A(HP62) R404A(HP 62)
Weight (oz) 17 15 26 23
Weight (g) 482 425 737 652
COMPRESSOR
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
LRA 24.1 24.1 45 45
RLA 5.7 5.7 9.2 9.2
CONDENSER FAN MOTOR (Air-Cooled Systems only) or
AIR CIRCULATION FAN MOTOR (Water-Cooled and Remote Systems only)
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 0.89 0.36 0.89 .036
Watts 50 6 50 6
WATER PUMP
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 0.5 0.5 0.5 0.5
HP 1/30 1/30 1/30 1/30

4
166240004 12/1/94
Rev 3/4/96
SPECIFICATIONS –60 HZ
ICE CUBER SPECIFICATION
MODEL IAC630 IWC630 IRC630 IAC830 IWC830 IRC830
UNIT
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
No. Wires 2+ground 2+ground 2+ground 2+ground 2+ground 2+ground
MIN. CIRCUIT
Amps 20 20 20 20 20 20
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 20 20 20 20 20 20
REFRIGERANT
Type R404A(HP62) R404A(HP62) R404A(HP62) R404A(HP62) R404A(HP62) R404A(HP62)
Weight (oz) 43 35 170 55 33 170
Weight (g) 1219 992 4820 1559 936 4820
COMPRESSOR
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
LRA 69 69 69 61 61 61
RLA 8.8 8.8 8.8 12.5 12.5 12.5
CONDENSER FAN MOTOR (Air-Cooled Systems only) or
AIR CIRCULATION FAN MOTOR (Water-Cooled and Remote Systems only)
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
Amps Running 1.09 0.36 0.36 1.09 0.36 0.36
Watts 75 6 6 75 6 6
WATER PUMP
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
Amps Running 0.5 0.5 0.5 0.5 0.5 0.5
HP 1/30 1/30 1/30 1/30 1/30 1/30

5166240004
12/1/94 Rev 3/4/96
SPECIFICATIONS –60 HZ
ICE CUBER SPECIFICATION
MODEL IAC1030
IAC1030L
IWC1030
IWC1030L
IRC1030
IRC1030L
UNIT
Volts 230 230 230
Phase 1 1 1
Hertz 60 60 60
No. Wires 2+Ground 2+Ground 2+Ground
MIN. CIRCUIT
Amps 20 20 20
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 20 20 20
REFRIGERANT
Type R404a(HP62) R404a(HP62) R404a(HP62)
Weight (oz) 60 42 210
Weight (g) 1701 1191 5954
COMPRESSOR
Volts 230 230 230
Phase 1 1 1
Hertz 60 60 60
LRA 82 82 82
RLA 13.0 13.0 13.0
CONDENSER FAN MOTOR (Air-Cooled Systems only) or
AIR CIRCULATION FAN MOTOR (Water-Cooled and Remote Systems only)
Volts 230 230 230
Phase 1 1 1
Hertz 60 60 60
Amps Running 0.892 0.36 0.36
Watts 50W2 6W 6W
WATER PUMP
Volts 230 230 230
Phase 1 1 1
Hertz 60 60 60
Amps Running 0.5 0.5 0.5
HP 1/30 1/30 1/30

6
166240004 12/1/94
Rev 3/4/96
SPECIFICATIONS –60 HZ
ICE CUBER SPECIFICATION
MODEL IAC1230 IWC1230 IRC1230 IAC1448 IWC1448 IRC1448
UNIT
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
No. Wires 2+ground 2+ground 2+ground 2+ground 2+ground 2+ground
MIN. CIRCUIT
Amps 20 20 20 25 25 25
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 20 20 20 25 25 25
REFRIGERANT
Type R404A(HP62) R404A(HP62) R404A(HP62) R404A(HP 62) R404A(HP 62) R404A(HP 62)
Weight (oz) 49 45 210 92 44 250
Weight (g) 1389 1276 5954 2608 1247 7088
COMPRESSOR
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
LRA 96 96 96 95.6 95.6 95.6
RLA 13.5 13.5 13.5 23.9 23.9 23.9
CONDENSER FAN MOTOR (Air-Cooled Systems only) or
AIR CIRCULATION FAN MOTOR (Water-Cooled and Remote Systems only)
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
Amps Running 0.89 X 2 0.36 0.36 0.4 0.36 0.36
Watts 50 W X 2 6 W 6 W 1/15 HP 6 W 6 W
WATER PUMP
Volts 230 230 230 230 230 230
Phase 1 1 1 1 1 1
Hertz 60 60 60 60 60 60
Amps Running 0.5 0.5 0.5 0.5 0.5 0.5
HP 1/30 1/30 1/30 1/30 1/30 1/30

7166240004
12/1/94 Rev 3/4/96
SPECIFICATIONS –50 HZ
MODEL
IAC322E50
IAC330E50
IACS277E50
IWC322E50
IWC330E50
IWCS227E50
IAC522E50
IAC522E50L
IAC530E50
IAC530E50L
IWC522E50
IWC522E50L
IWC530E50
IWC530E50L
UNIT
Volts 220 220 220 220
Phase 1 1 1 1
Hertz 50 50 50 50
No. Wires 2+ground 2+ground 2+ground 2+ground
MIN. CIRCUIT
Amps 15 15 15 15
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 15 15 15 15
REFRIGERANT
Type R404A(HP62) R404A(HP62) R404A(HP62) R404A(HP 62)
Weight (oz) 17 15 26 23
Weight (g) 482 425 737 652
COMPRESSOR
Volts 220 220 220 220
Phase 1 1 1 1
Hertz 50 50 50 50
LRA 26 26 33 33
RLA 5.3 5.3 8.2 8.2
CONDENSER FAN MOTOR (Air-Cooled Systems only) or
AIR CIRCULATION FAN MOTOR (Water-Cooled and Remote Systems only)
Volts 220 220 220 220
Phase 1 1 1 1
Hertz 50 50 50 50
Amps Running 0.75 0.3 0.75 0.3
Watts 50 6 50 6
WATER PUMP
Volts 220 220 220 220
Phase 1 1 1 1
Hertz 50 50 50 50
Amps Running 0.5 0.5 0.5 0.5
HP 1/30 1/30 1/30 1/30