Cornelius XWC1230 User manual

Suction Line and Service Valve Assemblies Installation Instructions
© 2005-2014, Cornelius Inc. - 1 - Publication Number: 630460289INS
INSTALLATION INSTRUCTIONS
SUCTION LINE AND SERVICE VALVE ASSEMBLIES P/N 631500282
This kit applies to the XWC1230 Water Cooled Condenser X-Series Ice Maker
WORK OVERVIEW
1. Disconnect power. Shut off potable water and condenser water supplies.
2. Remove exterior panels. Recover refrigerant in system.
3. Disconnect electrical harnesses and remove structural panels.
4. Remove existing piping assemblies.
5. Place and braze new piping assemblies. Leak test unit.
6. Insulate critical components, replace structural panels, and reconnect electrical harnesses.
7. Turn on condenser water and potable water supply.
8. Evacuate system and recharge with refrigerant.
9. Run test unit.
10. Replace exterior panels.
Release Date: March 21, 2014 www.cornelius.com Revision: B

Suction Line and Service Valve Assemblies Installation Instructions
Publication Number: 630460289INS - 2 - © 2005-2014, Cornelius Inc.
LOOSE-SHIPPED PARTS
Item No. Part Number Description Qty.
1 630001159 Suction Line Heat Exchange Assembly 1
2 630001160 Service Valve and Bracket Assembly 1
3 630001178 Suction Line to LH Evaporator (Extension) 1
4 163506001 Wire Tie - 7” 3
5 630900972 Insulation Tape Kit - Expansion Valve Bulb 2
6 164005001 1/8” POP Rivet - Stainless 1
1
2
3
5

Suction Line and Service Valve Assemblies Installation Instructions
© 2005-2014, Cornelius Inc. - 3 - Publication Number: 630460289INS
GENERAL WORK GUIDELINES
• Read and understand all instructions before starting.
• Disconnect all electrical power from unit prior to beginning work.
• Shut off potable and condenser water supplies to unit prior to beginning work.
• Prepare work area so that no brazing material, dirt, metal shavings, or other objects/refuse will enter
the ice storage area.
• Save all screws, nuts, bolts, grommets, or other hardware.
• Work is to be performed by a trained, EPA certified refrigeration mechanic.
INSTRUCTIONS
1. DISCONNECT ALL ELECTRICAL POWER FROM UNIT.
2. SHUT OFF WATER SUPPLY - Potable (evaporator supply) AND Condenser supply.
3. Remove the front panel cover (a), top cover (b), and louvered side panel (c) (FIGURE 1).
4. Remove the evaporator splash panel (d) and control box cover (e) [not shown] (FIGURE 2).
5. The icemaker should be charged with 45 ounces of R-404A (HP-62). Regardless of the condition of
the refrigerant, it must be recovered (as defined in ARI Standard 740-91) from the system.
The refrigerant type and charge are indicated on the serial plate, located on the water pan
(f)(FIGURE 2).
USE ONLY RECOVERY EQUIPMENT DESIGNATED FOR USE WITH R-404A (HP-62)
REFRIGERANT.
Comply with all federal regulations concerning the handling of refrigerants.
WARNING: If the compressor has burned-out, there is a refrigerant leak, moisture is present, or
contaminates or other noncondensables are in the system, the refrigerant recovered from this
unit may NOT be reused in this product until it has been reclaimed to meet ARI Standard 700-88.
FIGURE 1 FIGURE 2
b
c
a
e
f
d

Suction Line and Service Valve Assemblies Installation Instructions
Publication Number: 630460289INS - 4 - © 2005-2014, Cornelius Inc.
6. Drain the evaporator water pans (a)(c) by
removing the connection tube behind the
metal evaporator support (b) (FIGURE 3).
The water MUST be drained from both
RIGHT and LEFT pan. Failure to do so will
cause the pressure transducer (which
controls the harvest cycle) to be set
improperly on start up.
DO NOT drain the water into the ice
storage area, unless the area is
completely free of ice.
Replace the connection tube and metal
support when the pans are completely
drained.
NOTE: The water pump motor must be
protected from water splash. DO NOT
introduce water into the motor housing.
Warranty on water pump is VOID if water
damaged.
FIGURE 3
7. Disconnect the electrical plug from the Water Fill Valve (d) and Water Dump Valve (e) (FIGURE 4).
8. Disconnect the Water Pump plug (f) and Transducer Pressure Hose (g) (FIGURE 5).
FIGURE 4 FIGURE 5
a
b
c
d
e
g
f

Suction Line and Service Valve Assemblies Installation Instructions
© 2005-2014, Cornelius Inc. - 5 - Publication Number: 630460289INS
9. Disconnect the plugs from the Hot Gas
Solenoid Valve (FIGURE 6).
Remove the compressor junction box
cover and disconnect all electrical leads
(FIGURE 7 and FIGURE 8).
Remove the ground wire from the screw
post on the chassis, by the compressor.
FIGURE 6
FIGURE 7 FIGURE 8
Yellow
Red
Black

Suction Line and Service Valve Assemblies Installation Instructions
Publication Number: 630460289INS - 6 - © 2005-2014, Cornelius Inc.
10. Disconnect and remove the leads from the junction box (FIGURE 9) for the:
A. Curtain Switches - 2 white low voltage plug harnesses (Control board)
B. High Pressure Cutout - 2 blue wires (Contactor and #5 pin on control board)
FIGURE 9
11. Remove the 2 screws connecting the
service valve bracket (c) to the control box
(FIGURE 10).
FIGURE 10
b
a
b
c

Installation Instructions Suction Line and Service Valve Assemblies
© 2005-2014, Cornelius Inc. - 7 - Publication Number: 630460289INS
12. Remove the 2 screws connecting the top support brace (a) to the evaporator bulkhead (FIGURE
11).
13. Drill out the rivet attaching the right side panel to the base (FIGURE 12). A 1/8”drill bit is
recommended.
FIGURE 11 FIGURE 12
14. Remove the 5 screws attaching the right side panel to the rear panel (FIGURE 13).
15. Lift and set aside the right side panel, control box, and support brace assembly (a).
16. Remove the 2 screws holding the 2 piping access covers (b) to the wrap panel (FIGURE 13).
FIGURE 13
a
aX5
b
b

Installation Instructions Suction Line and Service Valve Assemblies
Publication Number: 630460289INS - 8 - © 2005-2014, Cornelius Inc.
17. Remove the bulkhead seals at the front of
the evaporator assembly.
Remove the insulation from the evaporator
inlet and outlet lines (FIGURE 14).
Remove enough insulation to safely
disconnect these lines.
WARNING: All plastic, electrical, or sensing
components, assemblies, or harnesses must
be protected when heating the refrigeration
lines.
Failure to take appropriate actions may
result in damage to the unit.
THE REFRIGERANT IN THE SYSTEM
SHOULD BE RECOVERED AND THE
SYSTEM PURGED WITH NITROGEN PRIOR
TO ANY BRAZING OPERATIONS.
Failure to take appropriate actions may
cause damage to the unit and result in
personal injury or death.
FIGURE 14
18. If the refrigerant in the system has been
fully recovered, open the high side service
valve.
Attach a nitrogen feed (a) to the low side
service valve (5-10 psi) (FIGURE 14).
Open the low side service valve to purge
the system with nitrogen.
As power to the unit has been
disconnected, disassemble the hot gas
valve to allow nitrogen to flow through the
entire system (FIGURE 15).
19. Protecting the water pump and plastic
bulkhead from heat, remove the
evaporator piping at the bulkhead
(FIGURE 14).
FIGURE 15
Ring Seal
a

Installation Instructions Suction Line and Service Valve Assemblies
© 2005-2014, Cornelius Inc. - 9 - Publication Number: 630460289INS
20. Move the nitrogen feed to the high side
service valve.
21. Remove the suction line (a) from the water
cooled condenser (FIGURE 17).
DO NOT remove the water lines from the
condenser.
WARNING: DO NOT apply excessive heat to
the water side of the condenser. Protect in
the same manner as an expansion valve or
other heat sensitive equipment.
Remove the liquid line (b) from the water cooled
condenser, and the water control valve capillary
(c) from the suction line assembly.
FIGURE 16
22. At the rear of the unit, remove the suction
line (d) from the left evaporator. Do not
remove the line extension (e) (FIGURE
17).
FIGURE 17
a
b
c
d
e
fg

Installation Instructions Suction Line and Service Valve Assemblies
Publication Number: 630460289INS - 10 - © 2005-2014, Cornelius Inc.
Remove the liquid line (f) AND the extension (g)
from the left evaporator. LEAVE the elbow fitting
on the evaporator (FIGURE 18).
FIGURE 18
23. Move the nitrogen feed to the low side
service valve.
24. Remove the insulation from the suction
inlet (a) to allow safe removal of the line
from the compressor (FIGURE 19)
25. Remove the suction line inlet (a) and the
compressor discharge (b) from the
compressor.
26. Remove the service valve line (c) from the
compressor.
Remove and discard the service line and
suction line assembly.
FIGURE 19
Elbow
g
f
a
c
b