Cornelius IAF1000 User manual

PRINTED IN U.S.A
IMI CORNELIUS INC; January 1997
THE HOTTEST MACHINES ON ICEt
Installation Instructions
“I” Series Flaker/Nugget Ice Machines
Model Number Description
IAF1000 / IAF650 Flaker/Nugget Modular Head Ice Maker Air Cooled
IWF1000 / IWF650 Flaker/Nugget Modular Head Ice Maker Water Cooled
IRF1000 / IRF650 Flaker/Nugget Modular Head Ice Maker Remote Cooled
Part No. 630460004
3/31/97
Revised 4/11/97
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment

i6304600003
TABLE OF CONTENTS
INTRODUCTION 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER AND ICE CIRCUIT 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
“I”SERIES FLAKER CLEANING
AND SANITIZING PROCEDURE 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER TREATMENT 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WINTER STORAGE 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE CONDENSER (AIR COOLED) 7. . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS REMOTE CONDENSERS 14. . . . . . . . . . . . . . . .
REMOTE CONDENSER LOCATION 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
HEAD PRESSURE CONTROL [HEADMASTER] 19. . . . . . . . . . . . . . . . . . . . .
REMOTE SYSTEM EVACUATION/RE-CHARGE 20. . . . . . . . . . . . . . . . . . . . .
FIGURE AND INSTALLATIONS
FIGURE 1. Bin Thermostat Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. Service Connections 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. instructions for converting flaked ice to nugget ice. 4. . . . . . . . . . . . . . . . . . .
FIGURE 4. water level 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. wiring diagram iaf1000 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6. wiring diagram iwf1000 and irf1000 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. wiring diagram iaf650 and iwf650 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

ii
6304600003
FIGURE 1. Bin Thermostat Installation 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 2. Service Connections 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 3. instructions for converting flaked ice to nugget ice. 4. . . . . . . . . . . . . . . . . . .
FIGURE 4. water level 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 5. wiring diagram iaf1000 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 6. wiring diagram iwf1000 and irf1000 9. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FIGURE 7. wiring diagram iaf650 and iwf650 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1630460004
INTRODUCTION
We have strived to produce a quality product. The design has been kept simple thus insuring trouble–free
operation.
This manual has been prepared to assist the Installer.
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 all correspondence to:
A Product of IMI Cornelius Inc.
One Cornelius Place
Anoka, MN 55303–1592
Phone [phone]
FAX [phone]
PRINTED IN USA

2
630460004
INSTALLATION INSTRUCTIONS
You will get better service from the ice machine, longer life and greater convenience if you choose its location
with care. Select a location as close as possible to where the highest volume of ice will used.
Here are a few points to consider:
1. Select a location as close as possible to where you are going to use the most ice.
2. Allow a minimum of 6”space at sides and rear of machine for ventilation.
3. A kitchen installation is not desirable as a rule. If a kitchen installation is necessary, locate the machine as
far away from the cooking area as possible. Grease laden air will form a greasy deposit on the condenser.
This reduces the ice making efficiency and necessitates thorough cleaning quite often.
4. If you install the unit in a storeroom, be sure the room is well ventilated.
NOTE: Do not install where the ambient and incoming water temperature will drop below 50°F or rise
to over 100°F.
WARNING: If water pressure exceeds 50 pounds, a water pressure regulator should be
installed in water inlet line between water shut–off valve and strainer. Minimum incoming
water pressure required is 22 pounds.
5. Uncrate the unit by cutting the lower band on the carton and lift the carton off the unit.
6. All “I”series flakers are supplied with bin sealing gasket material. Install the gasket around the bottom
outside edge of the unit by removing the protective paper and pressing in place.
7. Uncrate the ice storage bin and set in place. Connect a drain hose to the bin and level the bin. Install any
required bin adapter(s) at this time.
8. Carefully place the flaker on the bin. Be careful not to damage the flaker gasket material.
9. Remove the flaker front panel. Position the bin thermostat in place and install the hold down screws as
shown in Figure 1.
FIGURE 1. BIN THERMOSTAT INSTALLATION

3630460004
10. The incoming water for the ice making section requires a 3/8”copper tube. Connect this water tube to the
3/8”male flare fitting on the back of the unit. Make all drain connections. Drain tubes cannot be teed
together. See Figure 2 for location of all plumbing connections.
NOTE: For water cooled units, a separate 3/8”copper water line is required to be connected to the flare
fitting on the back of the unit marked condenser water in. A 3/8”flare connected line will have
to be provided from the fitting marked condenser water out to the drain.
A water regulating valve installed at the factory was set to maintain 290 to 310 PSI head pressure for R–404a
units. After 10 minutes of operation check the water temperature at condenser outlet and adjust to 100_F,
105_F if necessary.
11. Connect a drain hose to the condensate drain stub tube.
NOTE: All plumbing must be done in accordance with national and local codes.
22.00
1.25 5.25
5.25
4.50
22.60 27.83
FRONT SIDE ICE DROP
OPENING
ELECTRICAL SERVICE
OPENING(7/8-IN. DIA. HOLE) POTABLE WATER INLET
(3/8-IN. MALE FLARE)
CONDENSER
DRAIN
DUMP VALVE DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.) GEABOX/WTRPN DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.)
BOTTOM VIEW REAR VIEW
IAF 650
ill371
30.00
10.31 5.25
5.25
5.20
22.63 27.83
FRONT SIDE ICE DROP
OPENING
ELECTRICAL SERVICE
OPENING(7/8-IN. DIA. HOLE) POTABLE WATER INLET (3/8-IN. MALE FLARE)
CONDENSER
DRAIN
DUMP VALVE DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.) GEABOX/WTRPN DRAIN HOSE
(9/16-IN. I.D. BY 3/4-IN. O.D.)
BOTTOM VIEW REAR VIEW
IAF 1000
FIGURE 2. SERVICE CONNECTIONS
12. Bring the electrical supply (20 Amp.) into the unit at the rear of the cabinet and enters the unit control box.
The power and ground connections are completed to the leads in the control box. Strain relief connections
must be made at the cabinet and at the control box.
NOTE: Make sure the proper voltage and number of wires are provided. See serial plate for proper
configuration.
NOTE: All wiring must conform to national and local codes.

4
630460004
1. Remove the chute from the evaporator assembly
2. Remove item 1, .50-20 x 1.25 bolt; item 2, .50 lockwasher; item 3, ice paddle, and item 4,
flaker cutter head.
3. Install item 5, nugget ice cutter head, and re-install items 1, 2, & 3
4. Re-install chute. (RTV must be used around the base of the chute.)
3
4
5
1
2
FIGURE 3. INSTRUCTIONS FOR CONVERTING FLAKED ICE TO NUGGET ICE.

5630460004
WATER AND ICE CIRCUIT
The supply water enters the float chamber through a small orifice. The water level rises and lifts the float arm on
the float valve and seats the valve, shutting off the water supply when the water is at the desired level. As the
water leaves the float chamber, filling the evaporator, the float drops and allows additional water to enter refilling
the float chamber. Thus the water level is maintained automatically as the unit operates.
The water level in the evaporator shell will rise to the same level as the water in the float chamber. The water in
direct contact with the evaporator wall freezes and forms ice on the evaporator wall. As the freezing continues
the ice becomes thicker and exceeds the space between the evaporator wall and the auger. The auger rotating
at 8 RPM then chips off the ice and moves it to the surface of the shell. When the ice reaches the top surface of
the water in the shell it is pushed upward through the extruder opening into the cutter heads. From the cutter
head the ice enters the drop chute and falls into the storage bin. This action continues until the ice comes in
contact with the bin thermostat and the unit is shut down. The unit will remain off until the ice drops from the bin
thermostat through consumption or melting, at which time the unit will restart.
Water Level
Water Inlet Fitting
Water Pressure Switch
Strainer
Gear Motor
Float Valve
Water Dump Valve
Evaporator
FIGURE 4. WATER LEVEL

6
630460004
“I”SERIES FLAKER CLEANING
AND SANITIZING PROCEDURE
1. To eliminate water from entering the reservoir, block up the float located inside the reservoir, activate the
dump switch to the “ON”position and turn the power switch to “ON”. Allow the evaporator to drain. Turn the
power switch to the “OFF”position.
2. Remove the ice chute by removing the hold-down nuts at the base and the self-clamping bolt at the top. Lift
the chute clear of the evaporator assembly.
3. Return the float to it’s normal position. As the float chamber refills with water and fills the evaporator, add 3
oz. of Calgon Nickel-Safe ice machine cleaner to the float chamber. (Gravity will feed the cleaner to the
evaporator.)
NOTE: Do not remove the auger, extruder head, or other parts from the evaporator assembly.
4. Allow the cleaning solution to stand in the evaporator for 20 - 30 minutes. Block up the float and drain the
evaporator as in step 1.
5. Rinse/flush by carefully filling with warm water (100_F) and drain by following step 1 again. Repeat at least
3 times. During the final rinse/flush cycle, add 1 tablespoon of regular Baking Soda and allow it to stand for
10 - 15 minutes.
6. Drain the evaporator and rinse/flush one more time.
7. Install the ice chute and panels. (RTV must be used around the base of the chute.)
CAUTION: Should sanitizing be required, DO NOT use a mixture of household bleach and
water Chlorine will attack stainless steel. Use only a commercial ice machine sanitizer such
as Calgon Sanitizer for ice machines, following the directions on the container.
NOTE: When cleaning and/or sanitizing is complete return the machine back to an ice making cycle.
Discard the first 30 minutes of ice production. DO NOT allow any ice that has been in contact
with sanitizer to ever be used.

7630460004
WATER TREATMENT
During the freezing process, as water passes over the evaporator, the impurities in the water have a tendency
to be rejected and the plate will freeze only the pure water.
However, the more dissolved solids in the water, the more troublesome the freezing operation will be. Bicarbon-
ates in the water are the most troublesome of the impurities. These impurities will cause scaling on the evapo-
rator, clogging of the float valve mechanism and other parts in the water system. If the concentration of impuri-
ties is high, mushy ice may be the result.
Parts of the Flaker, that are in contact with the water or ice, may corrode if the water is high in acidity. In some
areas, water may have to be treated in order to overcome some of the problems that arise because of the min-
eral content.
IMI Cornelius has water filter/treatment systems available to control impurities found in most water supplies.
Contact your local dealer for more information.
WINTER STORAGE
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.
To blow out the water line, disconnect the water supply at the cabinet inlet and use air pressure to force the wa-
ter into the water reservoir pan, it can then be removed from the water pan.
WATER COOLED CONDENSER –To remove water from condenser unhook water supply and attach com-
pressed air hose. Start machine. As head pressure reaches the appropriate level opening the water regulating
valve, the compressed air will force the water out. Do not let the machine operate longer than necessary.
CLEANING THE CONDENSER (AIR COOLED)
In order to produce at full capacity, the refrigeration condenser must be kept clean. The frequency of cleaning
will be determined by surrounding condition. A good maintenance plan calls for an inspection at least every two
months.
With a vacuum cleaner, remove all accumulated dust and lint that has adhered to the finned condenser at the
rear of the unit. The use of a stiff bristle brush may be helpful.
CAUTION: CONDENSER COOLING FINS ARE SHARP. USE CARE WHEN CLEANING.

8
630460004
BK
YL
BL
BL
BR
BK
BL
145-174MFD 250V35MFD 370V
C.O. 10 PSIG
C.I. 20 PSIG
RD RD
BK
BL
BL
WH
WATER DUMP
VALVE
CO TROL
2
1 3
WATER DUMP
SWITCH
C.O. 450 PSIG
RD
BK
BKBK
FA MOTOR
FA SWITCH
CO 205
CI 275
BK
WH
1
3
BK
BL
CO TROL
LOW PRESSURE
START RELAY
RD
M
3
2
BK
4
GEAR MOTOR
CO DE SER
M
RD
GEAR
T/D
GW
RD
BK
BL
BK
THERMOSTAT
BI
RD
RATED 1.5 AMPS
CIRCUIT BREAKER
DELAY
THERMOSTAT
O -OFF SWITCH
START
CAPACITOR
OR
RD
CAPACITOR
RU
COMPRESSOR
YL
RD
COMPRESSOR
R
S
C
RD
YL
5
2
START RELAY
COMPRESSOR
COMPRESSOR
1
208/230 VOLTS 60 Hz
PRESSURE
HIGH
RD
BK
RD
BK
CO TACTOR
RD
FIGURE 5. WIRING DIAGRAM IAF1000

9630460004
GW
RD
BK
RD
BK
RD
BK BL
BL
RD
BL
RD
BK
BK
BK
BL
BK
BK BK
WH
RD
RD RD
YL YL
BK
BK
RD RD
RD
RD
BL
BL
RD
BK
RD BR
OR
BK
YL
BK BK WH
Crankcase Heater
(IRF Only)
ON-OFF Switch
Circuit Breaker
Rated 1.5 Amps
Control
Low Pressure
CI 20 PSIG
CO 10 PSIG
Bin
Thermostat
Delay
Thermostat
Gear Motor
Start Relay
T/D
Cooling Fan
Motor
Water Dump
Valve
Control
High Pressure
CO 450 PSIG
Water Dump
Switch
Contactor
Liquid Line
Solenoid
(IRF Only)
Compressor
Start Relay
Compressor
CR
S
Compressor Run
Capacitor
35MFD 370 V
Compressor Start
Capacitor
145-174MFD 250 V
123
M
M
BL
FIGURE 6. WIRING DIAGRAM IWF1000 AND IRF1000

10
630460004
CONTACTOR
HIGH
PRESSURE
1
COMPRESSOR
COMPRESSOR
START RELAY 2
5
CS
R
COMPRESSOR
COMPRESSOR
RUN
CAPACITOR CAPACITOR
START
ON–OFF SWITCH
THERMOSTAT
DELAY
CIRCUIT BREAKER
RATED 2.0 AMPS
BIN
THERMOSTAT
21
11
T/D
GEAR
M
GEAR MOTOR
4
2
3
22i
12k
START RELAY
LOW PRESSURE
CONTROL
31
C.O. 450 PSIG
SWITCH
WATER DUMP
1
2
CONTROL
VALVE
WATER DUMP
C.I. 20 PSIG
C.O. 10 PSIG
30MFD 440V
YL
BK
M
FAN MOTOR
COOLING
IWF ONLY
M
LOW AMBIENT
SWITCH (A/C ONLY)
CI275 C0205
(A/C ONLY)
CONDENSOR FAN MOTOR
BK
BK
WH
YL
RD RD
YL
OR
WH
BK BL
BK
GW
WH
BK WH
BL
BK
WH
BR
WH
BL
BL
BK
RD
RD
BL
BR
BL
WH
BK
WH
BK
WH
BL
BKBKBK
BL
BK
WH
BK
3
FIGURE 7. WIRING DIAGRAM IAF650 AND IWF650

11 630460004
“I”Series “Remote”
Ice Machine
Remote Condenser Specifications
Model CR800
Volts 230
Phase 1
Hertz 60
Amps 1.0
Output, HP 1/6
Max, fuse size, Amps (HVAC circuit breaker
required) 20

12
630460004

13 630460004
BK
CAPACITOR
RED
2 mfd 440 VAC
BK
GR
208/230 VOLTS 60 HZ
BK
GR
FAN CYCLING
SWITCH
RD
M
FAN MOTOR
CONDENSER
CR800, CR1200, & CR1400 REMOTE CONDENSERS
HEAT SHRINK TAPE
HEAT SHRINK
TAPE
HEAT SHRINK TAPE
COLORED
BAND

14
630460004
InstallationInstructions Remote Condensers
1. Follow the standard installation instructions supplied with
flaker. Do not hook flaker into the power source until the re-
mote condenser and line set installation is complete.
2. Assembly of remote condenser (see drawing):
a. Assemble legs to base panel.
Install leg supports on legs.
b. Locate the remote condenser in a well–ventilated area
on the roof away from other refrigeration equipment’s
condenser discharge air flow.
c. Use the mounting holes provided to secure the remote
condenser to the roof. Seal over heads of bolts or fasten-
ers with tar or pitch to prevent entrance of moisture.
3. Remote condenser electrical hook-up:
a. Connect remote condenser to a power source
(208/230VAC, 60 HZ) separate from the flaker. An exter-
nal disconnect switch must be used.
b. Make sure the electrical connections follow all local and
national codes.
c. DO NOT turn condenser on until flaker install and re-
frigerant line connections are complete!
a. Never wire condenser into flaker section. The con-
denser is an independent electrical connection.
b. Fan motor will not start until pressure rises to 205
PSIG [14.07 Bars] closing fan cycling switch.
c. The condenser fan may cycle off during the harvest
cycle –this would be normal.
Note: Installing an IMI Cornelius remote flaker with other
than an IMI Cornelius remote condenser and line set
may be reason to void the warranty.
UNIT 1/4-20 SCREW
LEG
BRACE
LEG
REMOTE CONDENSER
LEG
LEG SUPPORT

15 630460004
4. Each condenser and flaker is connected with two (2) *pre-
charged lines.
a. The pre-charged lines are ordered separately from the
condenser to suit each individual application.
b. The pre-charged line lengths are 20 feet [6.096 meters],
35 feet [10.66 meters] and 55 feet [16.76 meters].
Note: *(Pre-charged is defined as a vapor holding charge –
not a portion of the system charge.)
5. Installation of line kits (see drawing). Remove the tubing
from the carton. Carefully uncoil the lines so the tubing
doesn’t become kinked, and route lines to flaker and con-
denser.
6. Keep line-set as short as possible. Place a 3-foot service
loop behind flaker to allow for rear service should it ever be
required.
LIQUID
REFRIGERANT
LINE
DISCHARGE
LINE
CORRECT

16
630460004
Remote Condenser Location
1. Physical Line-Set Length: 55 Ft. Maximum [16.764 me-
ters]
The ice machine compressor must have the proper oil re-
turn. Line-set rises, drop, or horizontal runs greater than the
maximum distance allowed will exceed the compressor start-
up and pumping design limits, and will result in poor oil re-
turn to the compressor.
Line-Set Rise: 35 Ft. Maximum [10.66 meters]
Line-Set Drop: 15 Ft. Maximum [4.57 meters]
2. Calculated Line-Set Distance: 100 Ft. [30.48 meters]
To prevent the combination of rises, drops and horizontal
runs exceeding the compressor start-up and pumping design
limit, the following calculations should be made:
A - (RISE) CONDENSER HIGHER THAN EVAP.
MAX. 35 FT.
B - LINE LENGTH 15 FT.: EXAMPLE B - LINE LENGTH 35 FT.: EXAMPLE
C - (DROP) CONDENSER LOWER THAN EVAP. 15 FT.: MAX.
A
B
B
C
NOTE: MAX. LINE-SET
LENGTH FOR IMI CORNELIUS
FLAKERS IS 55 FT.
DO NOT CONFUSE LINE
LENGTH WITH CALCULATED
LINE DISTANCE.

17 630460004
Maximum Line-Set Distance Formula
a. Measured rise x 1.7= Calculated
Rise 35 ft. Max) [10.66 meters]
b. Measured drop x 6.6= Calculated
Drop 15 ft. Max) [4.57 meters]
c. Measured Horizontal Distance = actual measurement.
d. Total Calculated Distance (A+B+C)=Total
Calculated Distance (100 ft. Max.) [30.48 meters]
EXAMPLES:
a. Insert measured rise (R) into the formula and multiply
it by 1.7 to get a calculated rise.
example: A condenser located 15 ft. [4.572 meters]
above the ice machine has a 25.5 ft. [8.874 meters]
calculated total (15 ft. x 1.7 = 25.5).
b. Insert measured drop (D) into formula and multiply by
6.6 to get a calculated drop.
example: A condenser located 8 ft. [2.438 meters]
below the ice machine has a 52.8 ft. [16.093 meters]
calculated total (8 ft. x 6.6 = 52.8 ft.).
c. Insert measured horizontal distance into formula. No
calculation is necessary. (6 ft.) [1.828 meters].
d. Add the calculated rise, calculated drop, and hori-
zontal distance together to get the total calculated
distance (25.5 + 52.8 + 6) equals 84.3 ft. [25.694 me-
ters]. If 100 ft. [30.48 meters] total calculated dis-
tance is exceeded, the condenser must be moved to
a new location which permits proper equipment op-
eration.
Caution If a line-set rise is followed by a line-set drop, a second
line-set rise cannot be made.
Or
If a line-set drop is followed by a line-set rise, a second
line-set drop cannot be made.
3. Lengthening or Reducing the Line-Set Lengths
In most cases, by routing the line-set properly, shortening
H
R
D
H
R
H
D
AIR
FLOW
AIR
FLOW
AIR
FLOW
COMBINATION OF
DROP(S)
WITH HORIZONTAL
COMBINATION OF RISE AND
DROP(S)WITH HORIZONTAL