MARMON Cornelius WCC700R Installation guide

2019IceMakerTraining
Feb,2019
1••

••
Health & Safety topics
Before starting the presentation lets understand
safety:
• Physical Site / Location
• Safety exits for building
• Safe assembly area
• Electrical Hazards
• Voltage in Building
• Refrigeration
• We handle R404a refrigerant
• Gas Management / CO2
• Use this for fountain products
• Before installation please make sure you read
through the installation manual.

••
What Is Chunklet Ice?
• Also referred to as “Soft”, “Chewy”, or “Extruded” Ice.
• It is produced through continuous compression of ice
flakes… similar to a snowball.
• This process allows beverage to surround the ice and
cool faster and absorb into the ice.
• Nugget ice is also perfect for blended drinks.
ChunkletIce CubeIce
Funtochewandholdstheflavorofthe
drink.
HardtoChew
80%IceFraction 100%IceFraction
100%Usageofwater Waterre‐circulationoverevaporator
Lessercostofownership. Higher,whencomparedwithequivalent
Chunkletmodel

••
Cornelius Ice – Carbon Models
Designed based on our current 700#
unit, more reliable.
Easy to clean, plastic front panel
High-yield - Ideal for use in
demanding, high volume applications.
Durable Corrosion free stainless
steel cladding
Matches IDC Pro for modern, high-end
ice maker & dispense combination.

••
Location:
Make Sure proper air clearances for proper circulation –
front and side on air cooled.
12” clearance on air Intake to be maintained.
4” clearance minimum on air exhaust.
Ice-Maker should not be placed in direct sunlight or
in close proximity of any object generating additional heat
load on system.
MODEL REQUIREMENTS REQUIREMENTS
WCC700A 110-126V/60HZ/1PH 20Amp Stand alone circuit breaker
Notes:
Unit has to be plugged with individual circuit breaker of 20 Amps, no other equipment should be connected to this circuit.
Voltage is –5% / +10% with the compressor running.
Discuss 1.5 KVA Buck / Boost Transformer (+/- 16/32VAC). Explain wiring diagram and the fact that only one leg is being increased or
decreased.
Drain:
Overflow line is a 3/8” i.d. flexible tubing, plumb to local guidelines.
Installation Guide lines
Electrical requirements:

••
Installation Guide lines
Water supply:
•WaterInlet‐ Fittingisa1/4”(6.35mm)SAEmaleflarelocatedattherearoftheunit.
•Connectwatersupplywitha1/4”(6.35mm)orlargercopperorflexibletubing.Mainwaterlineshould
be3/8”.
•Unitmustbeinstalledwithonlypotablewater.
•Ashut‐offvalvewithaloopofadditionaltubingforserviceisrecommended.
•WaterPressure‐ Unlessotherwisespecified,theunitisdesignedtooperateonwaterpressures
between20P.S.I.(0.69Mpa)and90P.S.I.(0.62Mpa).50PSIistheidealincomingwaterpressure.
•Arecommendedwatersupplyiswithtemperaturesbetween50° F‐ 90° F(10° C‐ 32° C)withapressure
between20‐70p.s.i(0.138‐ 0.48Mpa).
•Forpressuresabove90P.S.I.(0.62Mpa)aregulatormustbeinstalled.Include50Psiwaterregulator.
•Thisequipmentmustbeinstalledwithadequatebackflowprotectiontocomplywithapplicablefederal
stateandlocalcodes.
•Filter– Filtrationshouldconsistofaprefilterandcarbonfilterstoremovetasteandodor.
•IMF(PhosphateFeeder)WaterFiltersandScaleinhibitorsarenottobeusedwiththeContinuous
FlowIce‐Maker,Taste&Odoronlyshouldbeused.
•TotaldissolvedsolidsinthewatershouldbewithinthebelowspecifiedlimitMINdissolvedsolids=270
PPM(TDS).Maxdissolvedsolids=500PPM(TDS).NOTE:WaterinletfortheIceMakershouldnotbe
withROFiltrationSystem.NOTE:Unitmustbeinstalledperlocalplumbingcode.

••
Pictorial representation:

••
How Ice is Made:
•The Cornelius Chunklet Ice Maker creates Ice in a process called extrusion.
•Ice is frozen to an evaporator wall until it grows thick enough to harvest. At that point the ice is shaved from the
wall by an auger and carried upwards to the extruding head.
•The extruding head is a finned device that forms or compresses the ice into its familiar Chunklet shape. As ice is
compressed by the extruder head, whatever remaining water there is on the surface of the ice will be squeezed away
leaving a uniformly shaped chunk of ice.
•The ice made in this process is soft and chewable yet resists bridging in Ice Drink dispensers when properly setup.
Use of a bin stat set to a lower point, agitation time adjustments, restrictor plate adjustment and addition of a diverter
plate assure this.
Auger
Extruder head

••
Water System Overview
•Waterlevelinthereservoirshouldbesettothewaterlevellinewhile
operating.Lookingatthecenterpicturetakenotethatwithproperwaterlevel
settingthetopevaporatorcoilshouldbecoveredwithwater.
•Duringinstallationthefloatshouldbeverifiedfor:
•Properwaterlevel.
•Systemsafetyshutdown.
•Typicallywaterpressurewouldberegulatedifgreaterthan50psi.
•Makeprovisionsforplastictubingoverflowlinesaswell.

••
•Note that compression of the Ice takes
place at the top of the evaporator
assembly.
•The output shaft of GEARMOTOR
spins the auger with the extruding head
stationary, as the ice is driven up the
wall of the evaporator it compresses &
is extruded into the reservoir tray. The
upward movement of the ice pulls down
on the extruding head therefore the
thrust washers wear & need to be
replaced bi-annually.
Note: pictures from a WCC500
Extruder Assembly / Evaporator
Breakaway mounts – should the Ice Machine
not shut down these mounts are designed to
break & relieve auger pressure.
Extruder & Evaporator
The extruding oilite head bushing is replaceable. It is a special bushing that contains no lead
and needs to be pressed into the shaft. The thrust bearings will become worn and should be
replaced bi-annually or as needed.

••
•Bison gearbox with GE/other
reputed make motor (# 620067555)
•Manual overload (located on
opposite side of motor) trips at
approx. 2.4A.
•Motor cover to prevent
condensation penetration.
Gear Motor – over amp manual reset switch
Manual reset button –
underneath bottom
casing of motor.

••
Note: picture from a WCC500
Transmission holds +/- 1 pint of 80 /
90 gear lube.
Transmission – front end assembly
AUGER AND EXTRUDING HEAD REMOVAL
1. Disconnect unit from power supply.
2. Remove storage container cover and put aside.
3. Turn off water supply to icemaker.
4. After ice has been melted from head take hold of the auger nut and lift straight up to
disengage from icemaker.
5. When replacing the auger assembly, make certain that both the auger engages the
output shaft drive and the extruding head ribs engage the evaporator tube.
INSTALLATION AND SHAFT SEAL REPLACEMENT 700
1. Place shaft seal locator seat and shaft seal mount over gearmotor output shaft and
push down until shaft seal seat and shaft seal mount rest flush on top of gearmotor.
2. Place rubber coated ceramic seal (important: ceramic face up) over output shaft and
push down until seal nest in recess of shaft seal mount (lubricate rubber on ceramic
seal with rubber lubricant).
3. Place shaft seal with carbon face down (spring up) over output shaft and push
(gently) downward until seal rests on carbon face of the output shaft seal.
4. Place flat washer over output shaft and let rest on the output shaft seal. Push down on
the washer compressing the spring on the output shaft seal. While holding the seals
(down) in place slide the e-ring into the groove on the output shaft.

••
Auger Engagement
Install the extruder head as shown
in the picture.
When Auger is lowered into the evaporator,
rotate the auger to engage the motor drive
shaft.
Carefully rotate the extruder head until the
tabs on the extruder head drop into the slots
on evaporator

••
Wiring diagram WCC700A & Carbon units
All Units are equipped with Auger delay timer to
safeguard the equipment.
Auger delay time: After the refrigeration cycles shut down it helps the Auger to run 3 minutes so that it
can flush out the Ice in Barrel. This will help to reduce the initial Torque on the Next start up of unit.

••
Key Safety Controls
WCC Controls and Electrical
The WCC control circuit is a series circuit consisting of the following components:
1. Bin Control/s – Electrical power is run through the solid state bin control/s (one for the 700). This
circuit consists of a PC Board, thermistor, thermistor locating sleeve and drop tube to direct the ice drop
zone into the bin. The bin control is adjustable and is what stops ice production once ice backs up
partially in the drop tube/s.
2. Low Water Safety Switch – Located in the water float assembly this will stop ice production should the
water supply be interrupted, once water is restored ice production will resume if needed. This consists of
a magnet (attached to the float arm) and a reed switch (attached to the float assembly bracket).
3. Anti-freeze Relay – This relay is used in different ways depending on the model of icemaker but it too
will stop ice production. This relay is wired in with the evaporator gearmotor/s so that if a gearmotor
trips on internal overload power to the compressor is interrupted and ice production stops.
4. Manual Reset Overload – Each gearmotor has a manual reset switch underneath the outer casing,
should an over amperage situation occur this overload trips and stops ice production. The reset must be
manually reset and troubleshot as to the cause.
5. Contactor Coil – Runs the gearmotor and refrigeration systems.
6. Low Side Pressure Switch – Used only on remote refrigeration and typically used to sense start and stop
of ice production is also a safety, should the system be low on refrigerant or the drier be restricted ice
production will stop due to low suction pressure.

••
Bin stat/s – Solid State
Std. drop tube & extended drop
tube for Chunklet Ice shown below.
Reservoir tray with drop tube and solid stat
(stainless steel) probe tube shown below.

••
Bin Thermostat “Lowering Kit”
Picture of Kit – lowers Ice level +/- 4 inches
to reduce compacting and “snow coning”.
•Remove existing thermostat sensor from existing
stainless steel sensor sleeve (sensor to be reused).
•Remove existing s/s sensor sleeve from Dispense
tray cover.
•Insert Thermostat sensor into new (long) s/s
sensor sleeve until it extends thru the bottom, place
a small amount of silicone on the sensor and pull
up into the s/s sleeve until it is flush with the
bottom of the sleeve.
•Insert the new thermostat / stainless steel sleeve
assembly back into the Dispense tray cover and
seal with silicone.

••
Model Voltage NameplateAmps(A) RunningAmps(A)
WCC700ACarbon 115V/60Hz 20 11.0‐ 12.5
Ice Maker Amperage & refrigeration check
Evaporator Efficiency
The evaporator on the Cornelius/Wilshire icemaker can be tested for efficiency in three easy ways.
1. Simply observe the ice coming out of the extruder head during production. As the auger rotates, an ice chunklet should pop out of each
extruder slot on every rotation.
2. Frost pattern testing of the evaporator. Open up the icemaker so that the auger/extruding head can be removed (this may require waiting
until the evaporator has thawed out). Remove the assembly and allow the evaporator to fill with water. Start up the icemaker and allow it to
run for exactly one minute and forty-five seconds. Immediately shut the unit down, drain the evaporator or use a flashlight to look down into
the cylinder. A sleeve or spiral of ice should have formed inside the evaporator tube. This sleeve should extend the full length between the
refrigerant inlet and suction outlet lines. There should be no interruptions, gaps or holes in this pattern. There will not be any ice at either
end, which are beyond the refrigerant lines.
3. Weighing output. The 24-hour output of the icemaker may be determined by weighing its output of Ice for 15 minutes and multiplying that
figure by 96. This figure can also be used to calculate water usage. The weight of the melted ice (water) must be included in either of the
above calculations for accuracy. The icemaker should be run for at least 5 minutes before starting the test.
Superheat & Suction Temperature
Cornelius/Wilshire Chunklet icemakers run at a ~ 4 degree F superheat, for those reasons they are equipped with non-adjustable expansion
valves.
Suction temperature nominally runs at 8 – 12 degrees below zero, remote systems are apt to run at lower temperatures due to their
environment.

••
Preventative Maintenance Procedures
EvaporatorSquealing
•Squealingnoisescomingfromtheevaporatorareaccompaniedbylowproduction.Thesenoisesarecausedbya“rotationalfreeze”. A
rotationalfreezeisusuallycausedbymineralbuildupontheevaporatorwalls.Thesedepositsarenotalwaysvisible,especiallywhenthe
evaporatoriswet.Theproductionoficedependsontheicefreezingtothewalloftheevaporatorandbeingshavedoffbytheauger.
•Theevaporatorwallisbeltsandedtocreatescratchesfromtoptobottom.Thesescratchesgivetheicesomethingtoholdonto,preventing
itfromrotatingwiththeauger.Ifthegroovesbecomefilledwithmineraldeposits,theicewillnothaveanygripontheevaporatorand
begintorotate,insteadofbeingshavedandpushedupward.Thesquealingnoiseiscausedbytheicecontinuingtoexpandasitrotates.
•Icestickingtogetherinthebinisalmostalwaystheresultofwaterchemistry.Highconcentratesofmineralsinthewater,chlorine,and
salinityareusuallyfoundtobethecause.Filtersthatarespeciallydesignedforcubedicemakersusuallycontainchemicalscalled
phosphates.Thesephosphateswillpreventmineralsfromfreezingintotheicecubesasthebindwiththeimpurities,thiswillallowthe
purestwatertofreezefirstandthemineralladenwatertobedumpedduringtheharvestcycle.TheWCCChunkletuse100%oftheir
water,ifphosphatefeedersareusedthemineralshavenochoicebuttofillthebinwiththeChunklet– shouldnotuse.Oncethereit
behaveslikesaltcausingtheicetobreakdownandpotentiallysticktogether,thiscanresultindamagedagitatorbladesoralargeblockof
ice(snowcone)mayformduetoclumpingtogether.Thereforeforphosphatefeedersandscaleinhibitorsshouldnotbeusedwith
Chunkletice.

••
Preventative Maintenance Procedures
ICEMAKERCLEANINGANDSANITIZINGPROCEDURES
•WARNING:Donotuseanyoftheicemadeduringcleaningoperations.Cleanandsanitizeicestorageareawhencleaningicemaker.
•Turnmachineoff.
•Shutoffwatersupply.
•Removeicefromstoragebin.
•Mixapprovedcleaner(2gallonsasdirected).Recommendedcleaner:Nu‐Calgonliquidicemachinecleaner.Mixture:3‐1/3ouncesper
gallonofwater.
•Cleanermustbesafeforstainlesssteel.NOEXCEPTIONS.
•Cleanauger/diverterassemblyandicetransition/droptubeinasinkusingcleanermixtureandreinstallinicemaker.Usingcleaner,
wipedownthedispensetray.
•Turnmachineonandaddcleanersolutiontowaterlevelcontroluntil2gallonshavebeenused.
•Turnonwatersupplyandrunmachinefor15minutes.
•Turnoffmachineandremoveallice.
•Sanitizeusinghouseholdliquidbleach(50ppmchlorine).Mixture:1fluidouncepergallonroomtemperaturewater.2minute
exposuretime.
•Sanitizeauger/diverterassemblyandicetransition/droptubeinasinkusingsanitizingsolutionandreinstallinicemaker.Using
sanitizer,wipedownthedispensetray.
•Fillicemakerwithsanitizerbyslowlypouringsolutionintowaterfeedreservoiruntilfull.Solutionwilldrainthroughoverflowtube.Do
notrunmachine.Allowtoairdry.
•Ificemakerisusedinconjunctionwithicedispenserorstoragebin,followmanufacturer’srecommendedcleaninginstructions at this
time.