Cornelius Enduro 200 User manual

Service Manual
SELF-CONTAINEDFLAKEDICEMAKER
Model:Series 200,525,725
(R404A Refrigerant)
IMPORTANT:
TOTHEINSTALLER.
Itistheresponsibilityof
theInstallertoensurethat
thewatersupplytothe
dispensing equipmentis
providedwith protection
againstbackflowby anair
gapas definedin
ANSI/ASMEA112.1.2-1979;
oranapprovedvacuum
breakerorothersuch
method as provedeffective
bytest.
Waterpipe connections
and fixtures directly
connectedtoapotable
watersupply shall be
sized, installed,and
maintainedaccording to
Federal, State,and Local
Codes.
PRINTEDIN U.S.A
IMI CORNELIUS INC; 1993--96Ó
IMICORNELIUSINC gOne CorneliusPlacegAnoka,MN55303-6234
Telephone [phone] Facsimile(612)422-3246
PartNo.166240010
November,1993
Revised:October,1996
THISDOCUMENTCONTAINSIMPORTANTINFORMATION
ThisManualmustbe read and understood beforeinstalling oroperating thisequipment

i166240010
TABLEOFCONTENTS
Page
INTRODUCTION1...........................................................
SPECIFICATIONS200 2.....................................................
SPECIFICATIONS525 3.....................................................
SPECIFICATIONS725 4.....................................................
INSTALLATIONINSTRUCTIONS5............................................
ADJUSTMENTPROCEDURE6...........................................
TYPICALWATER CIRCUIT7.............................................
TYPICALREFRIGERANTCIRCUIT8......................................
ELECTRICALCIRCUIT9.....................................................
CIRCUITDESCRIPTION9...............................................
ON--OFF SWITCH/CIRCUITBREAKER9.............................
BINTHERMOSTAT9...............................................
HIGHPRESSURECONTROL 9......................................
GEARMOTORSTARTRELAY 9.....................................
POWER RELAY/CONTACTOR9.....................................
FAN CYCLINGSWITCH 9...........................................
DELAY THERMOSTAT9............................................
COMPRESSORSTARTRELAY 10....................................
POTENTIALRELAYS 10.............................................
CAPACITORS-- GENERAL 10........................................
MAINTENANCE11...........................................................
SANITIZINGAND CLEANINGPROCEDURE12..............................
WATERTREATMENT12..................................................
WINTERSTORAGE13...................................................
CLEANINGTHECONDENSER(AIR COOLED)13...........................
SERVICEANALYSIS18.......................................................
UNITWILL NOTRUN 18..................................................
COMPRESSOR CYCLES INTERMITTENTLY.18.............................
MAKINGWETICE.18....................................................
UNITRUNS BUTMAKES NOICE.18.......................................
WATERLEAKS.19.......................................................
EXCESSIVE NOISE OR CHATTERING.19..................................
MACHINERUNSWITHFULL BINOFICE.19...............................
UNITOFF ON RESET.19.................................................
UNITGOES OFF ON RESET.19...........................................
UNITGOES OFF ON RESET.(CONT’D)20.................................
ILLUSTRATEDPARTSBREAKDOWN,SERIES 525--725 21......................
PARTSLIST22..............................................................
CABINETPARTSLIST23.....................................................
WARRANTY24..............................................................

i
i
166240010
TABLEOFCONTENTS(cont’d)
LISTOF FIGURES
Page
FIGURE1.200 SERIES SPECIFICATIONS2...............................
FIGURE2.525 SERIES SPECIFICATIONS3..............................
FIGURE3.725 SERIES SPECIFICATIONS4...............................
FIGURE4.WATERLEVELADJUSTMENTPROCEDURE6..................
FIGURE5.TYPICALWATER CIRCUIT7...................................
FIGURE6.TYPICALREFRIGERANTCIRCUIT8...........................
FIGURE7.WIRINGDIAGRAMAF-- 200--P-SC-R115 VOLTS60 HZ14.........
FIGURE8.WIRINGDIAGRAMAF-200-P-SC-50-R220 VOLTS50 HZ15.......
FIGURE9.WIRINGDIAGRAMAF525--SC-RAND AF725-SC-R
115 VOLTS60 HZ16......................................................
FIGURE10.WIRINGDIAGRAMAF/WF-525PSC-50-R220 VOLTS50 HZ17....
FIGURE11.PARTS BREAKDOWN21......................................
FIGURE12.CABINETPARTS BREAKDOWN23.............................
LISTOF TABLES
AF-200-P(S)-SCR PRODUCTION CHART2................................
AF-200-P-SC50RPRODUCTION CHART2.................................
AF-525-P(S)-SCR PRODUCTION CHART3................................
AF-525-P-SC50RPRODUCTION CHART3.................................
AF-725-P-SCR PRODUCTION CHART4...................................

1166240010
INTRODUCTION
We havestrived to produce a qualityproduct. The design hasbeen keptsimplethusinsuring trouble--free op-
eration.
Thismanualhasbeen prepared to assistservicemen and userswithinformation concerning installation,
construction and maintenance of the icemaking equipment. The problemsof the serviceman and userhave
been given specialattention inthe developmentand engineering ofouricemakers.
If you encountera problemwhichisnotcovered inthismanual,pleasefeelfree towrite orcall.Wewill be
happyto assistyou in anywaywecan.
When writing,pleasestatethe modeland serialnumberof the machine.
Address all correspondenceto:
AProductofIMICorneliusInc.
OneCorneliusPlace
Anoka,MN55303--6234
Phone [phone]
FAX[phone]
PRINTED IN USA

2166240010
SPECIFICATIONS200
A
BC
REARVIEW
OFCABINET
ELECTRICAL
BOX AREA
AIR
FLOW
ON-OFF
SWITCH
A-1/4WATERINLETS
(S.A.E.MALEFLARE)
B-5/8O.D.TUBE (DRAIN)
C-1/2O.D.TUBE (DRAIN)
40-IN.
102-CM
34-IN.
86-CM
26-IN.
66-CM
6-IN.
15-CM
25-IN.
64-CM
24 7/8-IN.
63-CM
13 1/2-IN.
34-CM
26 1/2-IN.
67-CM
7-IN.
18-CM
4-IN.
10-CM
3/4-IN.
2-CM
7-IN.
18-CM
5-IN.
13-CM
19-IN.
48-CM
FIGURE1.200 SERIES SPECIFICATIONS
ICE PRODUCTION CAPACITY(approximate)
AF-200-P(S)-SCR PRODUCTION CHART
AIRTEMPERATUREWATERTEMPERATURE
50°F/10°C70°F/21°C80°F/27°C
50°F/10°C219 lbs/99 kgs188 lbs/85 kgs175 lbs/79 kgs
70°F/21°C208 lbs/95 kgs174 lbs/79 kgs166 lbs/75 kgs
90°F/27°C161 lbs/35 kgs130 lbs/59 kgs117 lbs/53 kgs
AF-200-P-SC50RPRODUCTION CHART
AIRTEMPERATUREWATERTEMPERATURE
50°F/10°C70°F/21°C80°F/27°C
50°F/10°C234 lbs/106 kgs206 lbs/94 kgs197 lbs/90 kgs
70°F/21°C213 lbs/97 kgs190 lbs/86 kgs180 lbs/82 kgs
90°F/27°C183 lbs/83 kgs164 lbs/75 kgs156 lbs/71 kgs
200
CompressorModelCopeland JS25CIE-IAA-203 (115V60HZ)
Copeland AS13CIE-1AZ-908 (220V50HZ)
CondenserAirCooled
RefrigerantCharge 8 oz.R-404a (115V60HZ)
7 oz.R-404a (220V50HZ)
RefrigerantControl(115V60HZ)AutomaticExpansion Valve(28-PSI)
RefrigerantControl(220V50HZ)AutomaticExpansion Valve(31-PSI)
InletWaterSupply1/4”SAE maleflare
Voltage 115V60HZor220V50HZ
GearmotorElectricalRating 1/8 hp
GearmotorAmp.Rating 2 amps(115V60 HZ)
1 amp(220V50HZ)
TotalAmp.Draw11.0Amps(115V60HZ)
4.0Amps(220V50HZ)
MaximumFuseSize 15 Amp(115V60HZ)
15 Amp(220V50HZ)

3166240010
SPECIFICATIONS525
26 1/2-IN.
67-CM
ON-OFF
SWITCH
AIRIN
A
B
D
EC
REARVIEW
OFCABINET
A-3/8WATERINLET(S.A.E.MALEFLARE)
B-1/2O.D.TUBE (CONDENSATEDRAIN)
C-3/4N.P.T.BIN DRAIN
D-CONDENSERWATERIN(W/CONLY)
E-CONDENSERWATEROUT(W/CONLY)
ELECTRICAL
BOX AREA
26-IN.
66-CM
34-IN.
86-CM
40-IN.
102-CM
MIN.
6-IN.
15-CM
MIN.
14-IN.
36-CM
38 3/4-IN.
97-CM
24 3/4-IN.
63-CM
13 1/2-IN.
34-CM
2-IN.
5-CM
2 1/2-IN.
6-CM
3 1/2-IN.
9-CM
3 1/2-IN.
9-CM
5/8-IN.
2-CM
3 3/8-IN.
9-CM
4 5/8-IN.
12-CM
5 5/8-IN.
14-CM
19 1/2-IN.
50-CM
3 3/4-IN.
10-CM
26 3/8-IN.
67-CM
3 5/8-IN.
9-CM
FIGURE2.525 SERIES SPECIFICATIONS
ICE PRODUCTION CAPACITY(approximate)
AF-525-P(S)-SCR PRODUCTION CHART
AIRTEMPERATUREWATERTEMPERATURE
50°F/10°C70°F/21°C80°F/27°C
50°F/10°C654 lbs/297 kgs588 lbs/267 kgs552 lbs/251 kgs
70°F/21°C639 lbs/290 kgs563 lbs/256 kgs521 lbs/237 kgs
90°F/27°C562 lbs/255 kgs479 lbs/218 kgs448 lbs/204 kgs
AF-525-P-SC50RPRODUCTION CHART
AIRTEMPERATUREWATERTEMPERATURE
50°F/10°C70°F/21°C80°F/27°C
50°F/10°C629 lbs/286 kgs528 lbs/240 kgs494 lbs/225 kgs
70°F/21°C621 lbs/282 kgs525 lbs/239 kgs489 lbs/222 kgs
90°F/27°C493 lbs/224 kgs414 lbs/188 kgs387 lbs/176 kgs
525
CompressorModelCopeland RS43CIE-IAA-214 (115V60HZ)
Copeland RS43CIE-IAZ-214 (220V50HZ)
CondenserAirCooled
RefrigerantCharge 17 oz.R--404a
RefrigerantControlAutomaticExpansion Valve(34-PSI)
InletWaterSupply3/8”SAE MaleFlare
Voltage 115V60HZor220V50HZ
TotalAmpDraw15.5Amps(115V60HZ)
6.0Amps(220V50HZ)
GearmotorAmpDraw2Amps(115V60HZ)
1Amp(220V50HZ)
GearmotorElectricalRating 1/8 hp
MaximumFuseSize 20 Amp(115V60HZ)
15 Amp(220V50HZ)

4166240010
SPECIFICATIONS725
ON-OFF
SWITCH
AIRIN
A
B
D
EC
REARVIEW
OFCABINET
A-3/8WATERINLET(S.A.E.MALEFLARE)
B-1/2O.D.TUBE (CONDENSATEDRAIN)
C-3/4N.P.T.BIN DRAIN
D-CONDENSERWATERIN(W/CONLY)
E-CONDENSERWATEROUT(W/CONLY)
ELECTRICAL
BOX AREA
40-IN.
102-CM
MIN.
26-IN.
66-CM
34-IN.
86-CM
2 1/2-IN.
6-CM
2-IN.
5-CM
17 1/8-IN.
43-CM
30-IN.
76-CM
28 3/8-IN.
72-CM
16 3/8-IN.
42-CM
48-IN.
122-CM
6-IN.
15-CM
2 3/4-IN.
7-CM
2 3/8-IN.
6-CM
5/8-IN.
2-CM
3 1/4-IN.
8-CM
4 1/2-IN.
11-CM
5 5/8-IN.
14-CM
19 1/2-IN.
50-CM
5 1/32-IN.
13-CM
32 1/16-IN.
81-CM4-IN.
10-CM
FIGURE3.725 SERIES SPECIFICATIONS
ICE PRODUCTION CAPACITY(approximate)
AF-725-P-SCR PRODUCTION CHART
AIRTEMPERATUREWATERTEMPERATURE
50°F/10°C70°F/21°C80°F/27°C
50°F/10°C654 lbs/297 kgs588 lbs/267 kgs552 lbs/251 kgs
70°F/21°C639 lbs/290 kgs563 lbs/256 kgs521 lbs/237 kgs
90°F/27°C562 lbs/255 kgs479 lbs/218 kgs448 lbs/204 kgs
725
CompressorModelCopeland RS43CIE--IAA--214
CondenserAirCooled
RefrigerantCharge 17 oz.R--404a
RefrigerantControlAutomaticExpansion Valve(34-PSI)
InletWaterSupply3/8”SAE MaleFlare
Voltage 115V60HZ
TotalAmpDraw15.5Amps
GearmotorAmpDraw2Amps
GearmotorElectricalRating 1/8 hp
MaximumFuseSize 20 Amp

5166240010
INSTALLATIONINSTRUCTIONS
You will getbetterservicefromthe icemachine,longerlife and greaterconvenienceifyou chooseitslocation
withcare.
Here areafewpointstoconsider:
1.Selectalocation as close aspossibletowhereyou are going to usethe ice.
2.Allowaminimumof6”space atsidesand rearofmachine forventilation.
3.Akitchen installation isnotdesirable asarule. If akitchen installation isnecessary,locatethe machine as
faraway
fromthe cooking area aspossible.Greaseladen airwill formgreasy depositson the condenser.Thisre-
ducesthe icemaking efficiency and necessitatesthorough cleaning quite often.
4. If you install the unitinastoreroom,be surethe roomiswell ventilated.
NOTE:Do notinstall wherethe ambientand incoming watertemperaturewill drop below50°F or rise to
over100°F.
NOTE:Ifwaterpressure exceeds50lbs., awaterpressureregulatorshould beinstalledinwaterinlet
linebetweenwatershut-off valve and strainer.Minimumincoming waterpressurerequiredis22lbs..
A.Uncratethe unitbyremoving the staplesornailsfromthe bottomof the carton and lift off.
B.Removethe boltsholding the skidtothe machine.
C. If legsare used,adjust the leveling legsof the storage bin until the unitisleveland all four (4)legsare
insolidcontactwiththe floor.Leveling is veryimportant to obtain properdraining.
D.Provideacoldwatersupplyline tothe area selected forthe installation of the unit. The incoming wa-
terline should haveashut--off valve provided ataconvenientlocation closetothe icemaker.The wa-
terstrainerprovided withthe unitshouldbeinstalled on the down--streamside of the shut--off valve.
The supplyline mustbe adequately sized tocompensateforthe lengthsof the incoming water run.
The machine isequipped witha3/8”maleflareconnection forthe incoming waterline.
NOTE:ALWAYS FLUSHOUTWATERLINES BEFORE STARTINGUNIT.
Watercooled unitshaveawater regulating valvethatisfactory set to operate at270 to 310 PSIG
head pressureforR404a (wateroutlet temp.approx.105F)This shouldbechecked at the timethe
unitisbeing installed.
Twowaterinletconnectionsare provided on watercooled units,one forthe icemaking (evaporator)
section, the otherisforthe watercooled condenser.Bothconnectionsare 3/8”maleflarefittings. In-
letwatertothe condenserwill go tothe water regulating valvefirst, then tothe condensercoil and out
the drain.
The reason forseparatewaterinletconnectionsisthatsomeinstallationsuse a watertowerforcooling
the waterused inthe watercooled condenserand someinstallationsusetreated waterforthe ice
making inletwater.
Aseparate drainwill be required forthe outletof the watercooled condenser.
E.Provideasuitabletrapped open drain as close aspossibletothe area wherethe icemakerisgoing to
be installed.Thismaybe an existing floorora11/4”trapped open drain.Connect the drainline to
the rearof the unitand run itwith a good fall tothe open drain.All plumbing mustbe installed accord-
ing tolocalcodes.The storage bin drainsbygravity,and thereforethe drainline mustmaintain a
gradualslope to an open drain and shouldbeinsulated.
NOTE:INSOMECASES ITMAYBENECESSARYTO INSULATETHEWATERSUPPLYLINEAND DRAIN
LINE.CONDENSATEDRIPPINGTOTHEFLOOR CAN CAUSE SERIOUS STAINING OFCARPETSOR
HARDWOODS.

6166240010
F.Connecta drain hosetothe condensate drainstub tube.
NOTE:All plumbing mustbedoneinaccordance with nationaland localcodes.
G.Connect the electricalsupplyline tothe unit.
NOTE:Make surethepropervoltage and numberofwires areprovided.See serialplateforthisin-
formation.
NOTE:All wiring mustconform to nationaland localcodes.
H.Turnonwatersupplyand observethe waterlevel in evaporatorsectionswhichshouldbenoless than
1/4”belowthe inclined discharge chute opening of the shell.
I. Turnmachine on and check forpropervoltage and amp drawon the entire unitaswell as components
such asthe gearmotorand fan motor.
J.Check refrigerantcircuitand all plumbing connectionsforleaks,etc.
K.Check binthermostatormechanicalshut--off forproperoperations. Inthe mid--range the binthermo-
statwill open at42° and hasa 6° differential.
ADJUSTMENTPROCEDURE
WARNING:WATERLEVELMUSTBEMAINTAINED AT THETOPOF THE EVAPORATOR.
WATERLEVEL
FIGURE4.WATERLEVELADJUSTMENTPROCEDURE
1.Remove gearmotorand auger.
2.Adjust floatvalveto getwaterleveltotop seamof the evaporator.
3.Re--install auger.WATERLEVELWILL RISE WHENAUGERISINSERTEDBUTWHENTHEMACHINE
ISTURNEDBACKONAND ICE STARTS BEINGMADE,THEWATERLEVELWILL GO BACKTOTHE
ORIGINALSETTING.
4.Re--install gearmotorassemblyand startmachine.

7166240010
TYPICALWATER CIRCUIT
The supplywaterentersthe floatchamberthrough a small orifice.The waterlevelrisesand liftsthe buoyant
floatwithit. The floatattached tothe floatarmseatsavalvetoshutoff anyfurtherwatersupply.Aswater
leavesthe floatchamber, the leveldropsalong withthe floatand arm,causing the valveto open and admitmore
water.Thusthe waterlevel ismaintained automaticallyasthe machine operates.
Waternowflowsthrough a hoseconnected tothe floatchamberand entersthe opening of the evaporatorshell.
The waterlevel inthe shell will risetothe samelevelthatismaintained inthe floatchamber.The waterthatisin
immediatecontactwiththe centerpostevaporatorwill be reduced intemperature.Asaresult, freezing occurs
and iceformson the surface of the evaporator.
Asmorewaterisfrozen, the thickness of the iceincreasesuntil itexceedsthe distance allowed between the
evaporatorand auger.The auger rotatesataslowspeed towipe off the accumulated ice aswell ashelpit to
the surface.Afterthe icereachesthe surfaceitisdischarged through the top opening inthe shell.Anicechute
attached tothe shell conveys the icetothe storage binwhereitaccumulatesinthe insulated bin until itisused.
The icewill pileupto a pointwherethe binthermostat tubing islocated.When the icetouchesthisbrass tubing,
the unitwill shut--off and remain off until enough iceisused ormelted toreducethe pile.Anyicethatmeltswill
pass through the drain and drain hoseto an open drain.
OUT
ICE
EVAPORATOR
CHAMBER
FLOAT
CHAMBER
WATERIN
FIGURE5.TYPICALWATER CIRCUIT

8166240010
TYPICALREFRIGERANTCIRCUIT
Heatalways flowsfromhot tocold and therefore, the ”heatload”supplied tothe evaporatorsection bywater
givesup itsheat tothe refrigerantwhichisatatemperature belowthe freezing pointofwater.Thisrefrigerant
nowpassesthrough the heatexchangerback tothe compressor,asalowpressurevapor.
Thislowpressurevaporis compressed inthe compressor,asitleavesthe compressorata high pressureinva-
porformitentersthe top of the condenser.The condenserhasarapidflowofcoolairacross itwhichremoves
much of the heat fromthe hotrefrigerantvapor.
Asthe vapor,passing through the condenser,losesheatitcondensesback toaliquidsinceitis still underhigh
pressure and coolerthan when itentered the condenser.The liquidrefrigerant then passesthrough the drier/fil-
terstill underpressure and goesthrough the heatexchangerwherefurthercooling takesplace.Asthe refriger-
antleavesthe automaticexpansion valve, the pressure hasdropped,causing the refrigerant tovaporize and boil
off asitpicks up heatinthe evaporatorand sincethe pressureislow, the refrigerantwill be cold.
HEAT
EXCHANGER
EVAPORATOR
CONDENSERCOMPRESSOR
DRIER/FILTER
AXV
FIGURE6.TYPICALREFRIGERANTCIRCUIT

9166240010
ELECTRICALCIRCUIT
CIRCUITDESCRIPTION
Asthe manualon--off circuitbreakerswitchispushed to”on”,an electricalcircuitis completed tothe gearmotor
viathe circuitbreakergearmotoroverload,power relay/contactor,gearmotordelaythermostatand the binther-
mostat. Afterthe previous circuithasbeen completed the condenserfan motorwill startaswill the compressor
(viathe high pressurecontrol, the compressorstarting relayand lowambientcontrol).
ON--OFF SWITCH/CIRCUITBREAKER
This switchinterruptspowertothe entire unit. The switch hasacircuitbreakerincorporated intoits’ design.This
circuitbreakerwill trip outinthe event the gearmotordrawsto high ofamps. Insuch an event the powerisinter-
rupted tothe unit. Toreset the circuitbreakerand reestablish powertothe unit, pushthe switchtothe “off”posi-
tion and then back tothe “on”position.
BINTHERMOSTAT
Thisiselectricallyin”series”withthe icemaking system.when the binisfull, the contactopens, terminating
powertothe machine.
HIGH PRESSURE CONTROL
Switchcontactwill open at450 PSI forR404a breaking the circuit tothe compressor.This control ismanually
resetable.
GEARMOTOR STARTRELAY
Thisisacurrent type relaywhichmeansasthe gearmotor run winding comes”on”the line, the currentdrawini-
tiallyisrelativelyheavy through the relay coil (coil isinserieswithrun winding). It then actslike a normalrelay
and the N.O.startcontact”makes”,completingacircuit through the startcapacitortothe startwinding.Asthe
gearmotorpicks up speed, the amp drawthrough the relay coil dropsoff allowing the armaturetoreturntoits
normalposition (startcontact”opens”).Thisaction removesthe startwinding fromthe circuit.
POWER RELAY/CONTACTOR
Thisrelay controlsthe compressorpoweronly.
FAN CYCLINGSWITCH
The function of this switchistomaintaincondensing pressuresatasatisfactorylevelduring--lowambientcondi-
tions.The switch breaks the circuit tothe condenserfan motorat205 PSIand makesthe circuitat275 PSI.
DELAY THERMOSTAT
Thisthermostatkeepsthe gearmotor running until the suction line temperaturereaches45° afterthe full bin
switchterminatespowertothe power relay.

10166240010
COMPRESSOR STARTRELAY
Thisisacurrent type relayand containsaN.O.contactwhichis connected inserieswiththe startwinding of the
compressor.The relay coil iselectricallyinserieswiththe run winding.When powerisapplied, the compressor
drawshigh currentwhichsetsupamagneticfieldinthe magnetcoil whichcausesthe relayto operate,closing
the relay contact. Asthe compressorapproachesoperating speed, the current flowing through the coil de-
creases,permitting the relay contact to open, therebyopening the starting circuit.
POTENTIALRELAYS
The potentialrelayisused asacompressorstarting relay,The contactinthe potentialrelayisN.C.. The mag-
netcoil is connected across (parallel)the startwinding and isaffected byinduced voltage,generated bythe start
winding.Asthe compressorcomesup to design speed, the voltage across the relay coil increasesand atrun-
ning speed is sometimesasmuch as2 1/2timesthe supply voltage.This voltage setsupamagneticfield
whichcausesthe relayto operate.The starting relayis calibrated toremovethe startcapacitor (open the start-
ing circuit)atapproximately85%of the motordesign speed.
NOTE:BOTHTYPES OFRELAYS AREDESIGNEDTO OPERATEWITHINVERYNARROWLIMITSOF
VOLTAGEAND CURRENTDICTATED BYMOTOR DESIGN,THEREFORE,WHENMAKINGA REPLACE-
MENTOFA RELAYALWAYS PROVIDEAN EXACTREPLACEMENT,RECOMMENDED BYTHECOMPRES-
SORMANUFACTURER.
CAPACITORS -- GENERAL
An electricalcapacitorisa devicewhichstoresup electricalenergy.Capacitorsare used withsingle phasemo-
torsto provide starting torque and improverunning characteristics;byfeeding thisenergytothe startwinding in
step withthe run winding.
Any capacitorhasthree (3)essentialparts, two(2)ofwhich are usuallyfoil plates separated and insulated by
the third partcalled the dielectric.
Two generaltypesofcapacitorsare used with electricmotors.The electrolytic starting capacitorusuallyusesa
verythinfilmofoxide on the metallicplate asthe dielectric.The running capacitorusuallyisof the liquidfilled
type.

11 166240010
MAINTENANCE
THEFOLLOWINGMAINTENANCE SHOULD BE PERFORMED AT LEASTEVERY SIXMONTHSON
FLAKEDICEMACHINES:
1.Check powersupplywithmachine running forpropervoltage.
2.Check waterlevel inthe float tankreservoir.Waterlevelshouldbemaintained at the top of the evaporator.
Adjustifnecessary.(See illustration and adjustmentprocedure)
3.Clean the air--cooled condensercoil withastiff brush orvacuumcleaner (See procedure)
CAUTION:CONDENSER COOLINGFINSARE SHARP,USE CAREWHEN CLEANING.
4.Clean the icestorage bin and flushthe bin drain atleastonceamonth.
5. If awaterconditionerisinstalled inthe inletwaterline,change,replace,orclean the filter,strainerorcar-
tridge asrequired.
6. If heavy mineraldepositson the augerand evaporatorshell are encountered due to bad localwatercondi-
tions, followsanitizing and cleaning procedure.
7.Loosen hold--downcamlocks and remove gearmotorassembly.
8.Check thrustwasher;replaceifnoticeablyworn.
9.Lift outaugerand examine forwear.The corkscrewaugerguide bushing pressed intothe drive block
shouldbechecked forwear.Replaceifloose orifwornflatwith augerdrive block. If the Helixaugeron the
corkscrewauger round barbecomesflaton the inside morethan 1/8 ofan inch overalength of twoinches
ormoreitshouldbereplaced.
NOTE:HELIXAUGERSDOHAVE MACHINEDFLATRELIEFSURFACES.DON’TCONFUSE THEMWITH
WORN FLATAREAS.
Check the insertinthe bottomring of the Helixaugerand replaceifexcessivelyworn.
10.Check shell verticalstripsforwear.Replacethe shell ifexcessivewearis shown.
11.Check O--Ring,replaceifworn orcut.
12.Re--assemble,steps7through 11.
CAUTION:IN RE--ASSEMBLINGTHEAUGERGEARMOTOR,THEHOLD DOWN CLAMPS
MUSTBERIGHTAND SECURE. IN RE--INSTALLINGTHE EVAPORATORSHELL,BE
ABSOLUTELY SURETHAT THE”O”RINGISNOTPINCHEDOFF ASTHISWOULD CAUSE A
WATERLEAK AROUND THEBASE OF THE EVAPORATOR.LUBRICATETHE”O”RINGWITHFOOD
GRADELUBRICANTBEFORERE--ASSEMBLINGSHELL. IN RE--ASSEMBLINGTHEAUGER
GEARMOTOR,THEHOLD DOWN CLAMPS MUSTBERIGHTAND SECURE. IN RE--INSTALLINGTHE
EVAPORATORSHELL,BEABSOLUTELY SURETHAT THE”O”RINGISNOTPINCHEDOFF ASTHIS
WOULD CAUSE AWATERLEAK AROUND THEBASE OF THE EVAPORATOR.LUBRICATETHE”O”
RINGWITHFOODGRADELUBRICANTBEFORERE--ASSEMBLINGSHELL.
13.Check foralignmentoficechute.Makesurechute gasketisnotblocking path oficeflow.
14.Check binthermostatoperation. Inthe mid--range position the binthermostatwill open at42° and hasa 6°
differential.

12166240010
SANITIZINGAND CLEANINGPROCEDURE
1.Turn unitoff atswitchin upper rear rightside panel.
2.Turnwateroff and removewaterhosefrombottomof floatchamberinside ofice bin and allowto drainfrom
the evaporatorviathe hose end;or
3.Removefloatchambercoverand while holding floatup to preventmorewaterfromentering the float
chamber,removewaterhosefromfloatchamberand proceed to drainthe floatchamberand evaporator.
4.Withwaterstill off, restorewaterhosetofloatchamberand add 1 oz.of”sanitizer”(see note below).Turn
wateron.
5.Removethe bin door, floatchambercover,icechutetrimcover, twothumbscrewsand chutetrimgasket.
6.Using soap,hotwater,and a non--metallicbristle brush orplastic scouring pad,scrub the partsremoved in
step 4 aswell asthe interiorof the ice bin,icechute, thermowell,doortracks,ice bintop,and around bin
opening.
NOTE:Use carewhencleaning around thermowell sensing tube; the small capillaryis easilybroken.
Rinse all partsincleanwater.
7. Ina5gallon bucket, mixasanitizing solution of1 oz.ofsanitizerto 1 gallon ofwarmwater (100° to 120° F).
8.Place all small,loose partsintothe sanitizing solution and allowthemtosoakfor10 minutes.
9.Usingaclean cloth and the sanitizing solution,wipe downthe interiorof the icechute, thermowell door
tracks,ice bintop,and around bin opening.Allowto airdry.
10.Reassemblethe floatchambercover,icechute gasketand cover,and bin door.
11.Turn unitswitch on and allowmachine tomakeiceforatleast1/2 hourthen discard all of the ice.DONOT
ALLOWICEWITHSANITIZERINIT TOBEUSED.
NOTE:APPROVEDSANITIZER:Household bleachsuchas Hi-Lex orClorox.
WATERTREATMENT
During the freezing process, the impuritiesinthe waterhaveatendency toberejected.
However, the more dissolved solidsinthe water, the moretroublesomethe freezing operation will be.Bicarbon-
atesinthe waterarethe most troublesome of the impurities.Theseimpuritieswill causescaling on the evapo-
rator,clogging of the floatvalvemechanismand otherpartsinthe watersystem. If the concentration ofimpuri-
tiesishigh,wetmushyicemaybe the result.
Partsof the icemaker, thatareincontactwiththe waterorice,may corrode if the waterishigh in acidity. In
some areas,watermayhavetobetreated in orderto overcomesome of the problemsthatarise because of the
mineralcontent.
IMICorneliushaswaterfilter/treatmentsystemsavailabletocontrol imputitiesfound inyourwatersupply.Con-
tactyourlocaldealerformoreinformation.

13 166240010
WINTERSTORAGE
If the unitistobestored in an area wherethe temperaturewill drop belowfreezing,itismostimportant thatall
waterlinesbe drained to prevent themfromfreezing and possiblerupture.
To blowout the waterline,disconnect the watersupplyat the cabinetinletand use airpressuretoforcethe wa-
terintothe water reservoirpan.This can then be removed fromthe waterpan.
WATER COOLED CONDENSER-- Toremovewaterfromcondenserunhookwatersupplyand attachcom-
pressed airhose.Startmachine.Ashead pressurereachesthe appropriatelevelopening the water regulating
valve, the compressed airwill forcethe waterout. Do notlet the machine operatelongerthan necessary.
CLEANINGTHECONDENSER(AIR COOLED)
In orderto produce at full capacity, the refrigeration condensermustbe keptclean.The frequency ofcleaning
will be determined by surrounding condition.Agood maintenance plan callsforan inspection atleasteverytwo
months.
Removethe unitcompartmentgrill at the front. Withavacuumcleaner,remove all accumulated dustand lint
thathasadhered tothe finned condenser.
CAUTION:CONDENSER COOLINGFINSARE SHARP.USE CAREWHEN CLEANING.

14166240010
WH
YL
WH
BK
M
FAN MOTOR
BK
BK
COMPRESSOR
STARTCAPACITOR
145--174 MFD220 VAC
WH
BK
WH
BK
RATED2.0AMPS
CIRCUITBREAKER
ON--OFF SWITCH
BL
STARTCAPACITOR
GEAR MOTOR
64--77 MFD165 VAC
RD
RD
BK
4
3
2
WH
BK
STARTRELAY
GEAR MOTOR
FAN SWITCH
C.O.205 C.I. 275
GR
BK
BIN
BL
BL
HIGHPRESS CNTRL
C.O.450 PSIG
MANUALRESET
THERMOSTAT
2
1
3
YL5
RD
R
S
C
COMPRESSOR
1
BK
BK
OVERLOAD
COMPRESSOR
BK
BL
BK
CONTACTOR
Artwork 50922
AF--200--P--SC--R
PartNo.161909061
WH
115 VOLTS60 Hz
COMPRESSOR
STARTRELAY
YL
M
GEAR
MOTOR
BK
FIGURE7.WIRINGDIAGRAMAF-- 200--P-SC-R115 VOLTS60 HZ

15 166240010
RD
YL
RD
FAN MOTOR
BK
M
GN/Y
RD
BK
BK
COMPRESSOR
STARTCAPACITOR
50--60 MFD330 VAC
RD
RD
BK
RATED1.5AMPS
CIRCUITBREAKER
ON--OFF SWITCH
BL
STARTCAPACITOR
GEAR MOTOR
21--25 MFD
220/250 VAC
RD RD
BL
3
4
2
BL
STARTRELAY
GEAR MOTOR
FAN SWITCH
C.O.205 C.I. 275
BR
LBGN/Y
BIN
BL
BL
HIGHPRESS CNTRL
C.O.450 PSIG
MANUALRESET
THERMOSTAT
2
M
RD
1S
YL
R
C
BK S
COMPRESSOR
GN/Y
1
BK
RD
OVERLOAD
COMPRESSOR
BL
BK
LB
RDBR
BL
CONTACTOR
Artwork 50929
AF--200--P--SC--50--R
PartNo.161909064
RD
BK
220 VOLTS50 Hz
COMPRESSOR
STARTRELAY
BL
M
GEAR
MOTOR
BK
GN/Y
FIGURE8.WIRINGDIAGRAMAF-200-P-SC-50-R220 VOLTS50 HZ

16166240010
YL
WH
YL
M
YL
BK
WH
BL
BK M
OR
COMPRESSOR
START
CAPACITOR
243--292 MFD
115 VAC
BK
WH
BK
RATED2.0AMPS
CIRCUITBREAKER
ON--OFF SWITCH
4START
GEAR MOTOR
CAPACITOR
BL
RD
WIRENUT
RD
BK
BK
2
3
BK
BLTHERMOSTAT
DELAY
BL
RD STARTRELAY
GEAR MOTOR
FAN SWITCH
C.I. 275 C.O.205
WH
GW
BL
BIN
BL
RD
CONTROL
THERMOSTAT
R
YL
S
COMPRESSOR
C
1
52
1
BK
BL
BK
OVERLOAD
COMPRESSOR
POTENTIAL
STARTRELAY
RD
BLBL
Rev.B
Artwork 50923
AF525--SC--R
PartNo.161909062
HIGHPRESSURE
C.O.450 PSI
CONTACTOR
AF725--SC--R
BK
115 VOLTS60 Hz
CONDENSORFAN
GEAR
MOTOR
RD
FIGURE9.WIRINGDIAGRAMAF525--SC-R AND AF725-SC-R115 VOLTS60 HZ

17 166240010
YL
MOTOR
M
GEAR
YL
BK
RD
GW
M
FAN MOTOR
L
BL
COMPRESSOR
43--52 MFD330 V
STARTCAPACITOR
RD
M
S
GW
BR
LBRD
ON--OFF SWITCH
CIRCUITBREAKER
RATED1.5AMPS
START
BL
BL
4CAPACITOR
GEAR MOTOR
RDRD
BK
3
2
BK
BLTHERMOSTAT
DELAY
BK
RD
STARTRELAY
GEAR MOTOR
FAN SWITCH
BK
GW
BIN
RD
YL
BL
CONTROL
THERMOSTAT
RD
R
C
YL
GW
S
1
COMPRESSOR
BK
RD
RD
CONTACTOR
COMPRESSOR
OVERLOAD
BL
BK
RD
Artwork 50925
Rev.A
AF/WF--525PSC--50--R
PartNo.161909063
HIGHPRESSURE
220 VOLTS50 Hz
COMPRESSOR
STARTRELAY
WIRENUT
FIGURE10.WIRINGDIAGRAMAF/WF-525PSC-50-R220 VOLTS50 HZ