MODULAR FLAKED ICE MAKER Service Manual MODELS: SERIES 750 (R404a), SERIES 1100 (R22), SERIES 2400 (R404a) Part No. 166240009 OCTOBER 1994 Revised October, 1996 THIS DOCUMENT CONTAINS IMPORTANT INFORMATION This Manual must be read and understood before installing or operating this equipment IMI CORNELIUS INC; 10/94 - 10/95 PRINTED IN U.S.
TABLE OF CONTENTS Page INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 SPECIFICATIONS 750 AND 1100 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 SPECIFICATIONS 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 INSTALLATION INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TABLE OF CONTENTS (cont’d) LIST OF FIGURES Page FIGURE 1. 750 AND 1100 SERIES SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . 2 FIGURE 2. SPECIFICATIONS FOR 2400 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . 4 FIGURE 3. WATER LEVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 FIGURE 4. TYPICAL WATER CIRCUIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 FIGURE 5. TYPICAL REFRIGERANT CIRCUIT . . . . . . . .
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 servicemen and users with information concerning installation, construction and maintenance of the ice making equipment. The problems of the serviceman and user have been given special attention in the development and engineering of our ice makers.
SPECIFICATIONS 750 AND 1100 SERIES 23 1/8-IN. 59-CM CHUTE OPENING 8 1/4-IN. 21-CM 23-IN. 58-CM 1 1/2-IN. 4-CM 1 3/4-IN. 4-CM 1 1/2-IN. 4-CM A 5-IN. 13-CM FRONT BOTTOM VIEW B C D E 11 1/2-IN. 29-CM 5 1/16-IN. 13-CM 26 1/4-IN. 67-CM 2-IN. 5-CM REAR VIEW A = POWER INLET B = WATER INLET C = CONDENSER (WATER IN) (WC ONLY) D = CONDENSER (WATER OUT) (WC ONLY) E = CHASSIS DRAIN 9-IN. 23-CM FIGURE 1.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁ ICE PRODUCTION CAPACITY (approximate) AIR TEMPERATURE 70°F/21°C 80°F/27°C 90°F/32°C RF-1100-P-MH PRODUCTION CHART WATER TEMPERATURE 50°F/10°C 60°F/16°C 1202 lbs/545 kgs 1119 lbs/508 kgs 70°F/21°C 988 lbs/448 kgs 750 1100 Compressor Electrical Rating 3/4 hp 2 hp Compressor Model
SPECIFICATIONS 2400 SERIES 17 1/2-IN. 44-CM OVERALL DIMENSIONS 23-9/16-IN. HIGH x 45-1/8-IN. WIDE x 27-5/16-IN. DEEP 60-CM 115-CM 69-CM 8-IN. 20-CM 15 1/8-IN. 38-CM 44-IN. 112-CM 14 1/4-IN. 36-CM 15 1/8-IN. 38-CM ELECTRICAL WATER OUT (W/C) AIR IN 44-IN. 112-CM NOTE: CONDENSER SIDE WATER IN (W/C) WATER INLET 23 1/2-IN. 60-CM 9 1/8-IN. 23-CM A B 8 3/4-IN. 22-CM 27-IN. 69-CM 9 1/8-IN. 23-CM ”A”- ALTERNATE ICE DROP AREA FOR TOP UNIT WHEN TWO ARE STACKED.
INSTALLATION INSTRUCTIONS You will get better service from the ice machine, longer life and greater convenience if you choose its location with care. Here are a few points to consider: 1. Select a location as close as possible to where you are going to use the 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.
14. Turn machine on and check for proper voltage and amp draw on the entire unit as well as components such as the gearmotor and fan motor. 15. Check refrigerant circuit and all plumbing connections for leaks, etc. 16. Check bin thermostat or mechanical shut–off for proper operations. In the mid–range the bin thermostat will open at 42° and has a 6° differential. REMOTE CONDENSER Remote condensers should be installed above the ice machine and in a level configuration.
WARNING: WATER LEVEL MUST BE MAINTAINED AT THE TOP OF THE EVAPORATOR. WATER LEVEL ill224 FIGURE 3. WATER LEVEL 1. Remove gearmotor and auger. 2. Adjust float valve to get water level to top seam of the evaporator. 3. Re–install auger. WATER LEVEL WILL RISE WHEN AUGER IS INSERTED BUT WHEN THE MACHINE IS TURNED BACK ON AND ICE STARTS BEING MADE, THE WATER LEVEL WILL GO BACK TO THE ORIGINAL SETTING. 4. Re–install gearmotor assembly and start machine.
STACKING INSTRUCTIONS FOR STACKING KIT 29757 The Kit consists of: 1 – #26102 Sealer 2 – #261 1/4-20x5/8 screw 2 – #256 1/4” flat washer 2 – #239 1/4” Lock Washer 1 – #29758 Stacking Chute Extension 1. After uncrating machine to be stacked, remove front and rear panels. 2. Remove top and front panels of bottom machine. 3. Remove alternate chute opening cover from bottom machine. 4.
TYPICAL WATER CIRCUIT The supply water enters the float chamber through a small orifice. The water level rises and lifts the buoyant float with it. The float attached to the float arm seats a valve to shut off any further water supply. As water leaves the float chamber, the level drops along with the float and arm, causing the valve to open and admit more water. Thus the water level is maintained automatically as the machine operates.
TYPICAL REFRIGERANT CIRCUIT Heat always flows from hot to cold and therefore, the ”heat load” supplied to the evaporator section by water gives up its heat to the refrigerant which is at a temperature below the freezing point of water. This refrigerant now passes through the heat exchanger back to the compressor, as a low pressure vapor. This low pressure vapor is compressed in the compressor, as it leaves the compressor at a high pressure in vapor form it enters the top of the condenser.
ELECTRICAL CIRCUIT CIRCUIT DESCRIPTION As the manual on–off–circuit breaker switch is pushed to ”on”, an electrical circuit is completed to the gearmotor via the circuit breaker gearmotor overload, power relay / contactor, gearmotor delay thermostat and the bin thermostat. After the previous circuit has been completed the condenser fan motor will start as will the compressor (via the high pressure control and the compressor starting relay).
COMPRESSOR START RELAY This is a current type relay and contains a N.O. contact which is connected in series with the start winding of the compressor. The relay coil is electrically in series with the run winding. When power is applied, the compressor draws high current which sets up a magnetic field around the magnet coil which causes the relay to operate, closing the relay contact.
YL BL BL OUTLET BOX YL ON-OFF SWITCH CIRCUIT BREAKER RATED 2.
YL BL OUTLET BOX ON-OFF SWITCH CIRCUIT BREAKER RATED 1.
YL BL OUTLET BOX ON-OFF SWITCH CIRCUIT BREAKER RATED 1.
YL BL OUTLET BOX GW ON-OFF SWITCH CIRCUIT BREAKER RATED 1.
YL BL OUTLET BOX GR ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS BL RD BK BL RD BL YL BK GEAR MOTOR BL BIN THERMOSTAT START RELAY DELAY THERMOSTAT 3 BK 2 RD RD 4 BL GEAR MOTOR START CAPACITOR RD RD GEAR MOTOR M RD YL RD FAN MOTOR M BK RD CONTROL HIGH PRESSURE (W/C ONLY) BL RD BK RD BK BK RD BK RD BL COMPRESSOR M CONTACTOR AF/WF-1100-MH-3 3 PHASE 208/230 VOLTS 60 Hz FIGURE 10.
YL BL OUTLET BOX GW ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS BL RD BK BL LB YL BR BL BIN THERMOSTAT DELAY THERMOSTAT GEAR MOTOR START RELAY 3 BK 2 RD 4 RD BL GEAR MOTOR START CAPACITOR RD RD GEAR MOTOR M RD YL RD FAN MOTOR M BK RD CONTROL HIGH PRESSURE (W/C ONLY) LB COMPRESSOR BR COMPRESSOR RUN CAPACITOR RD RD YL YL R C RD BK BK RD CONTACTOR S BK RD OR BK 1 5 COMPRESSOR START RELAY AF/WF-1100-MH-50 240 VOLTS 50 Hz 166240009 COMPRESSOR START CAPACITOR FIGURE 11.
RD RD RD BK COMPRESSOR RUN CAPACITOR 35 MFD 370V RD COMPRESSOR RD COMPRESSOR START CAPACITOR 145-174 MFD 250V GW COMPRESSOR YL WH 5 C S BK RD YL MAIN ON-OFF SWITCH RD ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS YL YL BK YL 19 2 RD RD GEAR MOTOR DELAY THERMOSTAT BL BL RD BL BK 4 BK WH 2 COMPRESSOR START RELAY GEAR MOTOR START CAPACITOR YL OR BK ON-OFF SWITCH CIRCUIT BREAKER RATED 1.5 AMPS BIN THERMOSTAT LOW WATER BK PRESSURE SWITCH CI 20 CO 10 M COND.
MAINTENANCE THE FOLLOWING MAINTENANCE SHOULD BE PERFORMED AT LEAST EVERY SIX MONTHS ON FLAKED ICE MACHINES: 1. Check power supply with machine running for proper voltage. 2. Check water level in the float tank reservoir. Water level should be maintained at the top of the evaporator. Adjust if necessary. (See illustration and adjustment procedure) 3. Clean the air–cooled condenser coil with a stiff brush or vacuum cleaner (See procedure) CAUTION: CONDENSER COOLING FINS ARE SHARP, USE CARE WHEN CLEANING. 4.
SANITIZING AND CLEANING PROCEDURE 1. Turn switch to ”OFF” to stop unit. 2. Remove top cabinet panel. CAUTION: Hazardous moving parts. Do not operate unit with panel removed. 3. Mix sanitizing solution by using 0.5-ounces of household liquid bleach (such as Hi-Lex or Chlorox) to one gallon of potable water. This mixture must not exceed 200-ppm of chlorine. 4. Turn water ”OFF”. Remove water hose from float chamber and allow all water to drain from the float chamber and evaporator.
WATER TREATMENT During the freezing process, as water passes under the freezing plate, 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. Bicarbonates in the water are the most troublesome of the impurities.
TROUBLESHOOTING Trouble UNIT WILL NOT RUN COMPRESSOR CYCLES INTERMITTENTLY. Probable Cause Remedy A. On–off switch in ”off” position. A. Turn switch to ”on”. B. Defective on–off switch. B. Check and replace. C. Blown fuse. C. Replace fuse and check for cause of blown fuse. D. Thermostat set too warm for ambient. D. Adjust colder. E. Power relay contacts corroded. E. Check and clean. F. Defective thermostat. F. Check and replace. G. Loose electrical connection. G.
Trouble MAKING WET ICE. Probable Cause Remedy A. Surrounding air temperature too high. A. Correct or move unit B. High water level in float reservoir. B. Lower water level, see step 2, page 5 C. Dirty condenser. C. Clean condenser D. Faulty compressor. D. Check and replace E. Refrigerant leak. E. Check and repair F. ”O” ring leaking at bottom of evaporator shell. F. Check and replace *NOTE: Special care must be used with R404a (HP62) charged systems using (POE) Polyolester oil.
Trouble UNIT OFF OR TRIPS CIRCUIT BREAKER. Probable Cause Remedy A. Ice jams up in evaporator shell. A. Clean inside surface of evaporator shell. B. Bin thermostat will not shut–off machine. Set too cold. B. Check and adjust or replace . C. Auger motor has worn bearings. C. Check and replace. D. Ice chute out of alignment, restricted ice flow out of evaporator section. D. Re–align. E. Ice chute center separator bent restricting ice flow out of evaporator section . E.
Trouble Probable Cause L. UNIT GOES OFF OR TRIPS CIRCUIT BREAKER. (CONT’D) Plugged expansion valve, or L. capillary tube causing low back pressure. Check back pressure, replace valve or capillary tube. Evacuate and re–charge system, replace drier–strainer. M. Slight leak, causing low back pressure. M. Check back pressure, find gas leak, repair leak, evacuate system, add drier and recharge. N. Loose hold–down assy. N. Check and tighten or replace. O.
PARTS LIST FOR 750 AND 1100 SERIES ILL. NO .
45 49 47 5 25 7 9 29 24 30 4 12 3 11 21 2 19 8 28 6 43 1 23 22 27 20 26 16 15 14 13 31 33 32 34 41 35 42 18 39 36 37 46 38 17 44 51 40 48 10 50 ill227 166240009 FIGURE 13.
1 2 3 4 5 6 7 9 8 13 14 12 10 11 FIGURE 14. REMOTE CONDENSER ILLUSTRATED PARTS BREAKDOWN FOR 1100 SERIES ILL. NO. PART NO.
PARTS LIST 2400 SERIES ITEM NO DESCRIPTION PART NO. 1 Condenser A/C 161870011 2 Fan mounting bracket 164820021 3 Fan motor 4 Fan blade 5 Drier 6 Masonite Pad 7 Hold–down 27185 27183 166184002 26124 163277003 8 Evaporator 42597 9 Evaporator O–Ring 03120 10 Auger 11 Shell L.H. 162966001 21078 12 Shell R.H.
41 24 43 15 36 42 25 35 33 28 37 16 38 38 27 35 33 28 36 14 11 44 34 37 10 26 12 14 32 10 21 23 39 13 19 29 18 32 30 29 31 20 40 17 8 3 5 4 9 20 6 7 22 13 8 7 6 5 2 1 FIGURE 15.
CORNELIUS LIMITED COMMERCIAL WARRANTY PLAN TO THE ORIGINAL OWNER OF A CORNELIUS COMMERCIAL FLAKE ICEMAKER This warranty applies to Icemakers installed within the United States, Canada, Mexico and Puerto Rico only. For warranty information outside the U.S., Canada, Mexico and Puerto Rico, contact your nearest IMI Cornelius Sales Office. PARTS WARRANTY PERIOD IMI CORNELIUS INC.
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IMI CORNELIUS INC.
