Service / Training Manual Commercial Refrigeration Service, Inc. WWW.CorneliusParts.COM WWW.IceCubes.NET (866) 423-6253 (623) 869-8881 Date of Publication: November 26, 2001 Publication Number: TP00952 Revision: A www.cornelius.com IMI Cornelius Inc. Corporate Headquarters One Cornelius Place Anoka, MN 55303–6234 U.S.A.
TABLE OF CONTENTS Product Preview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 Preview Questions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Key Things to Know / Do . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 Model and Serial Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Xtreme Ice Machine . . . . . . . . . . . . . . . . . . . . .
Freeze Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Harvest Cycle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fan control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Calibration Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Leak Detection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . System Evacuation & Recharging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Self-Contained Products . . . . . . . . .
PRODUCT PREVIEW PREVIEW QUESTIONS Check your current knowledge by taking a few minutes to answer the following questions: 1. Does the ice machine need to be level? _____ Yes _____ No? 2. What is the recommended clearance for a air cooled machine? ________________________________________________________________________________ ____________________________ 3.
MODEL AND SERIAL LOCATION XTREME ICE MACHINE Condenser Discharge Air Deflector (as required)* Bin Adapter (as required)* Model/Serial Number Location FIGURE 1 *Bin adapters and condenser discharge air deflector may be equipped depending on your location or the size of the storage bin. Record the model number and the serial number of your ice equipment. These numbers are required when requesting information from your local dealer/distributor/service company.
SPECIFICATIONS The following table contains equipment specification information for the Xtreme Ice Machine. XAC Model 322/330 XWC 322/330 XAC 522/530 XWC 522/530 XRC 522/530 XAC 630 XWC 630 XRC 630 XAC 830 UNIT Volts Phase Hertz No. Wires 115 1 60 2+Ground MIN. CIRCUIT 230 1 60 2+Ground 20 Amps MAX. FUSE SIZE 20 Amps REFRIGERANT Type Weight (oz.) Weight (g) COMPRESSOR R404a 19 539 Amps Watts R404a 25 709 58.8 9.2 LRA RLA CONDENSER FAN MOTOR R404a 15 426 1.
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 determine 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.
INSTALLATION INSTRUCTIONS Installation and start up of the equipment should be performed by the distributor or the dealer’s professional staff. LOCATION OF EQUIPMENT For maximum performance the location should be away from heat sources such as ovens, direct sunlight, hot air discharge, etc. To reduce cost of maintenance and loss of efficiency, avoid placing air-cooled equipment in areas where grease, flour and other airborne contaminants are present. Allow a minimum of 6I (15.24 cm.
DISPENSER INSTALLATION 1. Order the proper cuber/dispenser adaptor kit. This package include gasket material, a hold-down bracket, and bin stat kit (contact service provider for more information). 2. RTV applications (See Figure 3). If the ice bin is full, new ice will not be able to drop. Instead it blocks the evaporator curtain open and no additional ice is made. This new ice may start to melt and the resulting liquid can leak out of the joint between the ice maker and bin.
PLUMBING CONNECTIONS 1. All plumbing lines and connections must conform to local and national plumbing codes. 2. Line shut-off valves must be located in supply water lines for cuber and condenser if product is water-cooled. Water supply to water-cooled condenser must include a stand-pipe to prevent “water hammer”. 3. Should your local water supply quality require the installation of a water filter system, consult your local distributor or dealer for proper size required. 4.
Preventative Maintenance Sequence The installation is not complete until you are sure the owner-operator understands the cuber operation and his or her responsibility of preventative maintenance. Does the owner-operator know: 1. Location of electrical disconnect switch and water shut-off valves? 2. How to start and/or shut down the product, clean and sanitize it? 3. Bin full operation and reset operation of high pressure cutout (water-cooled and remote products and 500 and 600 series (Air Cooled)? 4.
CLEANING PROCEDURES Approved ice machine cleaners by brand names: S Calgon Nickel Safe (green color only) NOTE: Failure to use approved products will void the warranty. CAUTION: Ice machine cleaners are acidic-based chemicals. Before beginning any cleaning of the cuber, the ice in the storage bin or dispenser must be removed. WARNING: When using any chemical, rubber gloves and eye protection should be worn. Cleaning Procedure if there is ice on the evaporator plate. 1. Turn the power switch on. 2.
PREP – CLEANING PROCEDURE Use ice machine cleaner on a coarse-surface cloth material (such as terry cloth) and wipe down the inside wall of the evaporator area, the water pan, the water curtain and the plastic water deflector. If the water distributor tube has heavy scale build-up, remove and soak it in full-strength nickel safe ice machine cleaner (or exchange the tube and clean the scaled tube at a later date) (See Figure 6). Water Restrictor INNER WATER DISTRIBUTOR WATER DIST.
SANITIZING THE WATER SYSTEM AND THE EVAPORATOR NOTE: To be performed only after cleaning the ice machine: 1. Turn the power switch to “OFF”. 2. Add 1/4 ounce (7.08 g) sodium hypochlorite solution (common liquid laundry bleach) to the water pan. You may also use a commercial sanitizer such as Calgon Ice Machine Sanitizer following the directions on the product label. 3. Turn the Cuber power switch “ON” allowing the compressor to start. Depress the clean button two times on the control board.
OPERATIONS UNIT SELECTION 1. The unit selection dip switches tell the microprocessor the correct water level difference for harvest and the number of proximity switch circuits to monitor. 2. The unit selection dip switches are a series of 3 switches that can be placed in either the ON or OFF position. 3. The following list shows the dip switch settings for each model: NOTE: The unit selection switches are preset at the factory to the correct model. Use the chart below if the control is replaced.
START UP SEQUENCE (PRIMARY) 1. Check all connections. 2. Water pan must be empty at the start of the initial fill cycle. 3. Turn on the main power switch, the red LED will flash 6 times then remains on for 4 seconds. NOTE: If there is a very large slab of ice on the evaporator you will need to push the manual harvest button to remove it. SECONDARY START UP 1. Compressor starts after ERROR LED extinguishes, and the green COMP LED turns on. 2. Compressor runs continuously after secondary start up sequence.
FIGURE 8 FREEZE CYCLE 1. Ten seconds after the fill valve turns off, the microprocessor records the water level. 2. Using the recorded high water level, the calibration level and the ice thickness level, the microprocessor calculates a harvest level. 3. The microprocessor monitors the water level until it reaches the harvest level. NOTE: As ice builds on the evaporator the water level in the water pan drops. This is called batch harvesting. HARVEST CYCLE 1.
ADJUSTING BRIDGE THICKNESS For optimum ice production and maximum cube separation, the ice connecting the individual cubes should be a minimum of 1/8I (.32cm.) thick (See Figure 9). When adjusting the ice thickness, the adjust Led is on the control board, it will be on for four seconds when it is at nominal voltage 2.4 to 2.5 VDC 2% (See Figure 8 for location of the J9 connector). BRIDGE 1/8I (0.32 cm.
WH COMPRESSOR GR COMPRESSOR RUN COMPRESSOR START CAPACITOR CAPACITOR CONTACTOR BK RD BR R RD 25 mfd 370V 60 HZ C S YL BK 72–88 mfd 250V 60 HZ EXTERNAL YL COMPRESSOR OVERLOAD WH UNIT OR 2 BR 5 SWITCH POTENTIAL BL 1 1 START RELAY WH 3 OFF ON MANUAL RESET HIGH PRESSURE CONTROL(W/C ONLY) WATER FILL WH BR CO 450 PSIG BL WH WATER DUMP BK VALVE BR WH YL CONDENSER (White Lead) Condenser Sensor See note 1 FAN MOTOR (A/C ONLY) ERROR DELAY CLEAN M BK BK WH Harvest RD
LED INDICATORS The LEDs are board circuit indicators. If the LED in the functional board circuit is complete, check component. Example: Contactor does not energize and LED is “ON”, board circuit is OK. Check contactor, coil, leads, & connections. Yellow: S Evaporator switch(s) (proximity) S Delay (located on the electrical box front).
Curtain Open Yellow LED off Right evaporator curtain open. Yellow LED off Left evaporator curtain open. Prechill Mode Condenser Fan Green LED (on or off) Condenser fan cycles on and off depending upon condenser temperature. Compressor Green LED (on) Compressor contactor activeĆcompressor running. Right Curtain Yellow LED (on) Right evaporator curtain closed. Left Curtain Yellow LED (on) Left evaporator curtain closed (only if unit has two evaporators).
CLEAN CYCLE 1. The clean cycle can only be initiated during the 45 second hot gas cycle in Secondary Start Up. 2. The clean cycle starts when the CLEAN button is pressed twice (See Figure 12). Clean Button FIGURE 12 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 18. 19. 20. 21. 22. The hot gas valve opens. The microprocessor monitors the proximity switch circuits, waiting for all circuits to open. Once all circuits have opened, the hot gas valve closes.
SAFETY SAFETY FEATURES 1. 2. 3. 4. 5. 6. 7. Water Fill Time Out Maximum Freeze Time Out Harvest Time Out Bin Full Delay Low Condenser Temperature Delay High Condenser Temperature Open Condenser Thermistor FLASHING CODE FOR SELF DIAGNOSTICS Delay LED “Yellow” Error LED “Red” 1 High condenser Temperature Delay 1 High Condenser Temp.
MAXIMUM FREEZE TIME OUT 1. At the beginning of the prechill cycle, the microprocessor starts a timer. 2. If the timer reaches 50 minutes before a harvest cycle can be initiated, the machine enters a delay sequence. 3. After each delay, the machine restarts at the secondary start up. 4.
BIN FULL DELAY 1. During the harvest cycle if the microprocessor does not recognize all proximity switch circuits close 5 second after the last one opens, the machine enters a delay sequence. 2. The machine turns off all outputs except the bin full output. 3. The microprocessor monitors the proximity switch circuits waiting for all circuits to close. 4. After all circuits close, the machine continues with the dump cycle. LOW CONDENSER TEMPERATURE DELAY 1.
COMPONENT FUNCTION (CIRCUIT BOARD, ETC.) SENSORS Condenser sensor (WHITE) is a thermistor rated at 2618 ohms to 3032 ohms at 32_F (0_C). Condenser sensor signals the circuit board for fan cycling and also serves as the high temperature safety shut down. The red “DELAY LED” will flash on and off every second, during high temperature safety delay. The yellow “ERROR LED” will flash on and off every second, during high temperature safety error. Product is functionally shut down.
NOTE: The sensor controls the condenser fan cycling from 88/100 degree Fahrenheit. Thus any defects in the condenser circuit will effect the fan cycling rate. CONDENSER FAN CYCLING CONTROL The condenser fan on air-cooled cubers is cycled by the circuit board. The condenser sensor signals the circuit board when the condenser temperature reaches 100°F (38°C) the fan starts and continues to run until the temperature is reduced to 88°F (31°C).
WATER REGULATING VALVE The water regulating valve is used on water-cooled cubers only. The valve is installed in the condenser outlet water line. It’s function is to control the proper operating head pressure by regulating the amount of water flowing through the condenser. The valve is adjustable and factory set to maintain condenser discharge water temperature @ 108/112_F (42-44_C).
MOISTURE CONTAMINATION With the major changes in refrigerants in today’s marketplace and the use of hydroscopic oils the control of moisture and contaminates have become more critical to safeguard against than ever before in the history of mechanical refrigeration. Contaminates are also the most difficult of all problems to determine. A Meg-Ohm meter “Megger” can be a valuable tool to aid in the analysis of this problem.
COMPRESSOR & STARTING COMPONENT CHECK-OUT PROCEDURE When a compressor fails to start or run properly, it is normally the external electrical supply or the compressor start components that are defective – the overload protector, start and/or run capacitor, relay, circuit board, safety controls, etc. 1. Check voltage at compressor terminals. NO voltage will require checking the electrical circuit working back from the compressor to determine where the voltage supply is interrupted and correct as required.
Compressor 1. Using an ohm meter, check for continuity from compressor terminal C to R and C to S. If the compressor is hot, wait one (1) hour for compressor to cool and recheck. An open internal overload protector can cause a lack of continuity. If continuity cannot be measured through all windings, the compressor must be replaced. 2.
SYSTEM EVACUATION & RECHARGING Should service work ever be required on a product where the sealed refrigeration is opened for any reason, the refrigerant must be recovered, drier/filter replaced, evacuated and recharged. The old method of “purging” is NOT ACCEPTABLE. Always evacuate the system through both the high and low side service valves. Be certain both valves are completely open when evacuating and the drier/filter has been replaced.
REFRIGERANT DEFINITIONS (ASHRAE 3-1990) RECOVERY To remove refrigerant in any condition from a system and store it in an external container without necessarily testing or processing it in any way. RECYCLING To clean refrigerant for reuse by oil separation and single or multiple passes through devices, such as replaceable core filter-driers, which reduce moisture, acidity, and particulate matter. This term usually applies to procedures implemented at the field job site or at a local service shop.
TROUBLESHOOTING IMPORTANT: Only qualified personnel should service internal components or electrical wiring. Trouble Probable Cause Remedy CUBER NOT OPERATING A. Power switch in “OFF” position. A. Place switch in “ON” position. CUBER NOT OPERATING, INDICATOR LIGHTS “OFF”, NO POWER TO CIRCUIT BOARD A. Test power switch and leads. A. If defective, replace. CUBER NOT OPERATING, INDICATOR LIGHTS “OFF”, POWER TO THE CIRCUIT BOARD A. Magnet not in proximity switch field. A.
Trouble COMPRESSOR RUNS BUT DOES NOT COOL, CIRCUIT BOARD INDICATOR LIGHTS “ON” CUBER DOESN’T GO INTO FREEZE CYCLE CUBER REMAINS IN THE FREEZE CYCLE LONG FREEZE CYCLE GENERAL TP00952 Probable Cause Remedy A. Low charge. A. Leak check – Recharge. B. Hot gas solenoid leaking. B. Replace. C. Defective expansion valve. C. Replace. D. Inefficient compressor. D. Replace. E. Internal by-pass open, compressor noisy. E. Permit pressures to equalize. A. Ice bridge setting too low. A.
Trouble LONG HARVEST CYCLES SOFT WHITE ICE OR WATER PUMP NOT PUMPING November 26, 2001 Probable Cause Remedy A. Ice weight set too light. A. Adjust bridge per adjustment instructions. B. Unit not level. B. Level the unit. C. Water curtain movement restricted. C. Remove restriction. D. Low head pressure: ambient too low. D. Minimum ambient temperature 50_F (10_C). E. Low head pressure; water valve set too low (water cooled units only) or leaking during harvest. E.
Trouble LEAKING WATER PAN Probable Cause A. Damaged water pan. Remedy A. Replace water pan (see Kit Instructions, number below, for Water Pan Replacement). Model # 300 500/600/800/1000 1200 Pull tab toward you. Kit # 631500152 631500153 631500154 Turn pump clockwise and lift. FIGURE 15 NOTE: Remove pump tubing from the dump solenoid, after the pump has been lifted out of the reservoir, disconnect the distributor tubing at the tee fitting and lift pump out. ICE WILL NOT HARVEST A. Grid separation.
November 26, 2001 35 WATER DUMP VALVE HOT GAS SOLENOID VALVE S HIGH SIDE SERVICE VALVE MODELS XAC322, XAC330, XAC522, XAC530, XAC630, XAC830 REFRIGERATION AND WATER SYSTEMS WATER PUMP THERMOSTATIC EXPANSION VALVE EVAPORATOR LOW SIDE SERVICE VALVE COMPRESSOR HEAT EXCHANGER FAN MOTOR FAN BLADES AIR COOLED CONDENSER FILTER/DRIER ÄÄ ÄÄ ÄÄ FIGURE 16 TP00952
TP00952 36 WATER DUMP VALVE S HOT GAS SOLENOID VALVE Models XWC322, XWC330, XWC522, XWC530 , XWC630, XWC830 Refrigeration and Water Systems WATER PUMP HIGH SIDE SERVICE VALVE PRESSURE SWITCH COMPRESSOR LOW SIDE SERVICE VALVE HEAT EXCHANGER THERMOSTATIC EXPANSION VALVE EVAPORATOR WATER INLET WATER-COOLED CONDENSER WATER REGULATING VALVE FILTER/DRIER ÄÄ ÄÄ FIGURE 17 November 26, 2001
XTREME ICE – KITS BIN STAT KIT, P/N 630000408 Installation Instructions These Bin Stat kits apply to all “X” Series Ice makers. Item No. 1 2 3 4 5 Part No. 630000837 07578 630460162 630900895 620045454 or 620045455 or 620045456 or 620045457 Loose–Shipped Parts Name Thermostat Asy Screw TC 08–32 Installation Instruction, Thermostat Hex Nut 8–32 SS Keps Bin Stat Support Qty. 1 2 1 2 1 1. Disconnect power. 2. Remove front cover of the unit and the electrical box cover plate.
ELECTRICAL BOX ASY TO CIRCUIT BOARD SCREW TC 08–32 THERMOSTAT KIT ASY 631500074 COIL TO CHASSIS BASE FIGURE 18 TP00952 38 November 26, 2001
(White Lead) Condenser Sensor See note 1 ERROR DELAY PRESSURE Transducer CLEAN Harvest RD Unit Selection Switch Bridge Thickness pot. Off 321 On Micro Processor (Manufacturing Date) 36430001 Off S3–1 S3–2 Adjust J9 Valve #8 #7 GR Dump On #6 GR Comp #4 WATER PUMP GR Pump #3 HOT GAS #2 NEUTRAL #1 POWER Bin Switches N S 4 LH Evap. Switch YL YL 3 YL 2 Plug Bin Thermostat on Top Two Pins of Stacking Cable Plug COMPRESSOR GR YL 5 FAN MOTOR (AIR COOLED) #5 RH Evap.
A DETAIL SCALE 1:2 BIN STAT SUPPORT INSERT COIL AROUND 8–32 HEX NUT BIN STAT SUPPORT CAPILLARY TUBE A SEE DETAIL BIN STAT SUPPORT FIGURE 20 TP00952 40 November 26, 2001
REMOTE CONDENSERS Installation Instructions 1/4-20 SCREW UNIT LEG BRACE LEG FIGURE 21 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 the following Figures): A. Assemble legs to base panel. Install leg supports on legs. B.
3. Remote condenser electrical hook-up: A. Connect remote condenser to a power source (208/230VAC, 60 HZ) separate from the cuber. An external 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! D. Never wire condenser into cuber section. The condenser is an independent electrical connection. E. Fan motor will not start until pressure rises to 205 PSIG [14.
REMOTE CONDENSER LOCATION 1. Physical Line-Set Length: 55 Ft. Maximum [16.764 meters] 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.
b. Insert measured drop (D) into formula and multiply by 6.6 to get a calculated drop (See Figure 26). 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.). COMBINATION OF DROP(S) WITH HORIZONTAL H D AIR FLOW FIGURE 26 c. Insert measured horizontal distance into formula. No calculation is necessary. (6 ft.) [1.828 meters]. d.
4. 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 condenser. 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. 5. Final Installation: A.
The normal flow pattern through the headmaster is from the condenser port to the receiver port. When this flow pattern is unable to maintain a receiver outlet pressure equal to or above the dome pressure setting of the valve, the dome pressure will force the valve portage to change closing the condenser port and opening the bypass port from the compressor discharge line. This allows the high pressure vapor from the discharge port to “buck” the receiver pressure back up.
MANIFOLD SET MANIFOLD SET OPEN OPEN OPEN LOW SIDE SERVICE VALVE RECEIVER OUTLET VALVE CLOSED CHARGING OPEN CYLINDER VACUUM PUMP OPEN CLOSED HIGH SIDE SERVICE VALVE OPEN MANIFOLD SET CLOSED CLOSED OPEN RECEIVER 2ND STAGE CHARGING COMPRESSOR OPERATING 1ST STAGE CHARGING EVACUATION RECEIVER OPEN ELECTRONIC SCALE CLOSED RECEIVER LOW SIDE CLOSED SERVICE VALVE RECEIVER OUTLET VALVE CLOSED VACUUM PUMP CLOSED HIGH SIDE SERVICE VALVE OPEN HIGH SIDE SERVICE VALVE LOW SIDE SERVICE VALVE R
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IMI CORNELIUS INC.
