Cornelius IRC630 User manual

Installation Manual
I" Series
“REMOTE”
Ice Cube Machine
IMPORTANT:
TO THE INSTALLER.
It is the responsibility of
the Installer to ensure that
the water supply to the
dispensing equipment is
provided with protection
against backflow by an air
gap as defined in
ANSI/ASME A112.1.2-1979;
or an approved vacuum
breaker or other such
method as proved effective
by test.
Water pipe connections
and fixtures directly
connected to a potable
water supply shall be
sized, installed, and
maintained according to
Federal, State, and Local
Codes.
THIS DOCUMENT CONTAINS IMPORTANT INFORMATION
This Manual must be read and understood before installing or operating this equipment
CORNELIUS INC gOne Cornelius Place gAnoka, MN 55303-6234
Telephone [phone] Facsimile [phone]
 CORNELIUS INC; 1994–2014 PRINTED IN U.S.A
Part No. 166240001
Release Date: 10/31/1994
Revised: 05/6/2014
Revision: B

i166240001
TABLE OF CONTENTS
Page
GENERAL 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
FREIGHT DAMAGE CLAIMS PROCEDURE 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS REMOTE CONDENSERS 2. . . . . . . . . . . . . . . .
REMOTE CONDENSER LOCATION 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION INSTRUCTIONS 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LOCATION OF EQUIPMENT 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
EQUIPMENT SET-UP 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DISPENSER INSTALLATION 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PLUMBING CONNECTIONS 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ELECTRICAL 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
INSTALLATION CHECK POINTS 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
START-UP AND CHECK OUT 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OWNER -OPERATOR 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING PROCEDURES 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PREP – CLEANING 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
CLEANING THE WATER SYSTEM & EVAPORATOR 15. . . . . . . . . . . . . . . . . .
SANITIZING PROCEDURES 16. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
DUMP CYCLE 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WATER PAN LEVEL SETTINGS 17. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
STATUS INDICATOR 19. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ADJUSTING BRIDGE THICKNESS 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TOTAL ICE CAPACITY 20. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

i166240001
GENERAL
FREIGHT DAMAGE CLAIMS PROCEDURE
The deliverer of your equipment (freight company, distributor or dealer) is responsible for loss or damage of your
shipment. All claims must be filed with the deliverer of your equipment. Please follow the steps below to deter-
mine if your shipment is satisfactory or if a claim must be filed:
1. Check the number of products delivered against the number of products listed on the delivery receipt.
Should the totals not match, have the driver note all errors on both copies and both you and the driver sign
and date said notation.
2. Inspect all cartons for visible damage. Open and inspect as required before the driver leaves and have him
or her note any damage on the receipts. All damaged claims must be inspected within 15 days of delivery.
Notify your carrier immediately if concealed damage is found after delivery.
3. Should concealed damage be found when product is unpacked, retain the packing material and the product
and request an inspection from the deliverer.
4. All claims for loss or damage should be filed at once. Delays in filing will reduce the chance of achieving a
satisfactory resolution to the claim.

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166240001
INSTALLATION INSTRUCTIONS REMOTE CONDENSERS
UNIT 1/4-20 SCREW
LEG
BRACE
LEG
1. Follow the standard installation instructions supplied with cuber. Do not hook cuber into the power source
until the remote 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 equip-
ment’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 fasteners with tar or pitch to prevent entrance of moisture.
REMOTE CONDENSER
LEG
LEG SUPPORT
3. Remote condenser electrical hook-up:
A. Connect remote condenser to a power source (208/230VAC, 60 HZ) separate from the cuber. An ex-
ternal disconnect switch must be used.
B. Make sure the electrical connections follow all local and national codes.
C. DO NOT turn condenser on until cuber install and refrigerant line connections are complete!

iii 166240001
NOTE:
a. Never wire condenser into cuber section. The condenser is an independent electrical con-
nection.
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.
LIQUID
REFRIGERANT
LINE
DISCHARGE
LINE
CORRECT
4. Each condenser and cuber 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 me-
ters].
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 cuber and condenser.
6. Keep line set as short as possible. Place a 3 foot service loop behind cuber to allow for rear service should
it ever be required.
REMOTE CONDENSER LOCATION
1. Physical Line Set Length: 55 Ft. Maximum [16.764 meters]
NOTE: Installing an Cornelius remote cuber with other than an Cornelius remote condenser
and line set may be reason to void the cuber warranty.
NOTE: NOTE: Max. line set length for Cornelius cubers is 55 ft. - Do not confuse line
length with calculated line distance.

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166240001
The ice machine compressor must have the proper oil return. 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 return 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 THEN EVAP. MAX. 35
B –LINE LENGTH 15’: EXAMPLE B - LINE LENGTH 35’: EXAMPLE
C - (DROP) CONDENSER LOWER THAN EVAP. 15’: MAX.
A
B
B
C
Maximum Line Set Distance Formula
3. Measured rise x 1.7=Calculated (Rise 35 ft. Max.) [10.66 meters]
4. Measured drop x 6..6=Calculated (Drop 15ft. Max.) [4.57 meters]
5. Measured Horizontal Distance= actual measurement.
6. Total Calculated distance (A+B+C)=Total Calculated Distance (100 ft. Max.) [30.48 meters]
Examples:
a. Insert measured rise (R) into 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).

v166240001
H
R
AIR
FLOW
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 (8ft. x 6.6 = 52.8 ft.)
D
H
AIR
FLOW
COMBIATION OF DROP(S)
WITH HORIZONTAL
c. Insert measured horizontal distance into formula. No calculation is necessary. (6 ft.) [1.828 meters].
R
H
D
AIR
FLOW
COMBIATION OF RISE AND
DROP(S)WITH HORIZONTAL
d. Add the calculated rise, calculated drop, and horizontal distance together to get the total calculated dis-
tance (25.5 + 52.8 + 6) equals 84.3 ft. [25.694 meters]. If 100 ft. [30.48 meters] total calculated distance
is exceeded, the condenser must be moved to a new location which permits proper equipment opera-
tion..
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.
7. Lengthening Or Reducing The Line Set Lengths
In most cases, by routing the line set properly, shortening will not be necessary (refer to illustration). How-
ever when shortening or lengthening is required, do so before connecting the line set to the ice machine or
the remote condenser. This prevents the loss of refrigerant from the ice machine or the condenser.
The quick connect fittings on the line sets are equipped with Schrader Valves. Use these valves to recover
any vapor charge from the line set. When lengthening or shortening lines, apply good refrigeration practic-
es and insulate new tubing. Do not change the tube sizes. Evacuate the lines and place approximately 5
oz. of vapor refrigerant charge in each line.

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166240001
INTERMEDIATE
SEAL
PARENT
METAL
SEAL
SCHRADER
VA LV E
8. Connection of Line Set
A. Remove the plastic caps from the line set, the condenser, and the ice machine.
B. Apply refrigeration oil to the threads on the quick connect couplers before connecting them to the con-
denser.
C. Carefully thread the female fitting onto the condenser or ice machine by hand.
D. Using the proper size wrench, tighten the couplings until they bottom out. Turn an additional 1/4 turn
to ensure proper brass-to-brass seating.
E. Check all fittings for leaks.
9. Final Installation:
A. Remove grill from the right hand side panel of cuber.
B. Turn service port on receiver tank to open position releasing refrigerant to the balance of the system.
C. Leak check line set connections at cuber and condenser.
D. Replace grill.
E. Connect cuber to power source.
F. Make sure electrical connections follow all local and national codes.
10. Start Up:
A. Use standard procedures from cuber installation instructions.
B. After the cuber is running, check the remote condenser and verify that the condenser fan is running.
CAUTION: Once the refrigerant lines are connected, the seal is broken in the fittings. If the
line are removed or loosened from the cuber or remote condenser, the refrigerant charge
will be discharges to the atmosphere. DISCHARGING TO THE ATMOSPHERE IS IN
VIOLATION OF THE CLEAN AIR ACT OF JULY, 1992.

vii 166240001
ICE CUBER SPECIFICATION –60 HERTZ
MODEL IRC630 IRC830 IRC1030
IRC1030L IRC1230
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 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(HP62)
Weight (oz) 170 170 210 210
Weight (g) 4820 4820 5954 5954
COMPRESSOR
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
LRA 69 61 82 96
RLA 8.8 12.5 13.0 13.5
CONDENSER FAN MOTOR (AIR COOLED SYSTEMS ONLY
AIR CIRCULATION FAN MOTOR (WATER-COOLED & REMOTE SYSTEMS ONLY)
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 0.36 0.36 0.36 0.36
Watts 6 6 6W 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

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166240001
ICE CUBER SPECIFICATION –60 HERTZ
MODEL IRC1448 IRC1448-3PH IRC2448 IRC2448-3PH
UNIT
Volts 230 230 230 230
Phase 1 3 1 3
Hertz 60 60 60 60
No. Wires 2+ground 3+ground 2+ground 3+ground
MIN. CIRCUIT
Amps 25 25 30 25
MAX FUSE SIZE (HVAC CIRCUIT BREAKER REQUIRED)
Amps 25 25 30 25
REFRIGERANT
Type R404a(HP 62) R404a(HP 62) R404a(HP 62) R404a(HP 62)
Weight (oz) 250 250 320 320
Weight (g) 7088 7088 9072 9072
COMPRESSOR
Volts 230 230 230 230
Phase 1 3 1 3
Hertz 60 60 60 60
LRA 95.6 82 125 90
RLA 23.9 10 20 13
CONDENSER FAN MOTOR (AIR COOLED SYSTEMS ONLY
AIR CIRCULATION FAN MOTOR (WATER-COOLED & REMOTE SYSTEMS ONLY)
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 0.36 0.36
Watts 6 6W
WATER PUMP
Volts 230 230 230 230
Phase 1 1 1 1
Hertz 60 60 60 60
Amps Running 0.5 0.5 0.77 0.77
HP 1/30 1/30 1/50 1/50